engine oil SSANGYONG MUSSO 2003 Service Manual

AUTOMATIC TRANSMISSION 5A-69
MECHANICAL TESTS
In Vehicle Transmission Checks
Carry out the following tests before removing the transmission. See Checking Transmission Fluid Level, Section 7.2.1.
Check that the transmission oil is not burnt (colour and smell are correct).
Ensure that the transmission is not in limp home mode (LHM).
Check that the battery terminals and the earth connections are not corroded or loose.
Check the engine stall speed is within the handbook value.
Check that the cooler flow is not restricted.
Check that all electrical plug connections are tight.
Carry out a road test to confirm the symptoms, if necessary.
Inspect the oil, ensure that there are no metal or other contaminants in the oil pan.
Diagnosing Oil Leaks
Determine the source of oil leaks by firstly cleaning down the affected area, then driving the vehicle. Inspect the seals to confirm the source of the leak. To determine the source of a rear servo oil leak, raise the vehicle on a hoist, then carry out a reverse stall.
To determine the source of a front servo leak, raise the vehicle on a hoist, then run the vehicle in second gear.
Troubleshooting Charts The troubleshooting charts are set out as follows: Table 6.2.1 Drive Faults,
Table 6.2.2 Faulty Shift Patterns.
Table 6.2.3 Shift Quality Faults.
Table 6.2.4 After Teardown Faults.
Table 6.2.1 - Drive Faults
Action
Check the fluid level. Top up as necessary. Inspect and clean C1/C2 feed. Reinstall/renew the ‘z’ link.
Remove, clean and re-install the PRV.
Inspect and replace as necessary.
Inspect and replace as necessary.
Inspect and replace as necessary.
Check servo adjustment or replace rear band
as necessary.
Check for failure in C3, C3 hub or C1/C2 cylin-
der. Repair as necessary.
Inspect and clean PRV.
Inspect and replace pump gears as necessary.
Inspect and repair as necessary.
Possible Cause
Insufficient auto transmission fluid.
Blocked feed in C1/C2 cylinder.
‘Z’ link displaced.
Primal regulator valve (PRV) jammed open.Overdrive shaft or input shaft seal ringsfailed. 3-4 or 1-2 one way clutch (OWC) installed backwards or failed.C2 piston broken or cracked.
Rear band or servo faulty.
Failure in C3, C3 hub or C1/C2 cylinder.Jammed primary regulator valve (PRV). Damaged/broken pump gears. Dislodged output shaft snap ring.Symptom
No Drive in D No Drive in ReverseNo engine braking
in Manual 1 Engine braking in Manual 1 is OKNo drive in Driveand Reverse

5A-76 AUTOMATIC TRANSMISSION
Action
Check cable for open / short.
Check connection of other connectors.
Check voltage between terminal 27 and 29 of TCU,
- Standard value : 0.2 - 4.7V
Check TPS.
Check cable for open / short.
Check connection of other connectors.
Check engine speed sensor.
Check resistance between terminal 8 and 24 of TCU (when the connector is disconnected).
- Standard value : 1 .9 - 0.2 k
Check cable for open / short.
Check connection of other connectors.
Check vehicle speed sensor.
Check cable for open / short.
Check connection of other connectors.
Check engine speed sensor.
Check inhibitor switch resistance between terminal 34 and 37 of TCU(when the connector is disconnected).
- Standard value : 1st gear - 4 - 4.4 k
2nd gear - 4,8 - 2.2 k
3rd gear - 3 - 3.4 k
D gear - 4.5 - 4.g k
N gear - 6.8 - 7.2 k
R gear - 10.8 -11.2 k
P gear - 18.6 - 19 k
Check voltage between terminal 31 and 37 of TCU.
- Standard value : 0-5V(P,R,N,D,L)
Check cable for open / short.
Check connection of other connectors.
Check mode switch.
Check condition between terminal 1 and 13 of TCU.
Winter mode :12V, Normal mode : Open status, Power mode : 0V
Check cable for open / short.
Check connection of other connectors.
Check voltage between terminal 32 and 38 of TCU.
- Standard value : 0-5V
Check oil temperature sensor.
Check cable for open / short.
Check connection of other connectors.
Check battery condition.
Check alternator.
Possible Cause
Throttle position sensor
Engine RPM
Vehicle speed Shift lever
W, E, P mode switch T/M oil temperature Battery voltage
Symptom
P1702 P1703 P1704 P4705 P1706 P1707P1708
Self-diagnosis List

AUTOMATIC TRANSMISSION 5A-79
ADJUSTMENTS
HYDRAULIC SYSTEM
The procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a
defect symptom, indicates that there is a fault in the hydraulic system.
When making adjustments to the transmission, select the appropriate procedures from the following preliminary checks. Conduct a transmission fluid test procedure, refer to section 7.2.
Check the manual linkage adjustment (refer to the vehicle workshop manual).
Check engine idle speed (refer to Section 7.3).
Conduct a stall test (it is outside the scope of this publication to detail this procedure)
conduct a road test (it is outside the scope of this publication to detail this procedure).
TRANSMISSION FLUID TEST PROCEDURE
Checking Transmission Fluid Level
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in
gearshift loss or delay if driven when the vehicle is cold.
The vehicle is first checked for transmission diagnostic messages (refer to section 6). If the vehicle has a speedo fault
it is possible for the oil level to be low.
The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of
drive. One symptom of low oil level is a momentary loss of drive when driving the vehicle around a comer. Also when
the transmission fluid level is low, a loss of drive may occur when the transmission oil temperature is low.
If there is no loss of drive when the vehicle is driven warm and a speedo fault is registered, then fluid should be addedto the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (A TF) or other approved
fluids. The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded. Do not underfill the transmission. Incorrect tilling may cause damage to the transmission. The fluid level setting
procedure is detailed below. Notice
When a transmission is at operating temperature hot transmission fluid may come out of the case if the fill plug is
removed. 9 the transmission is at operating temperature allow two hours for cooling prior to removing the plug.
1. If the vehicle is at operating temperature allow the vehicle to cool down for two, but no greater than four hours before adding transmission fluid (this will allow the transmission to be within the correct temperaturerange).
While hot the ATF level is higher and removing the plug may result in oil being expelled from the filler hole. This
will result in the level being low.
2. The transmission selector is to be in Park. Switch the engine off.
3. Raise the vehicle on a hoist (or leave over a service pit).
4. Clean all dirt from around the service fill plug prior to removing the plug. Remove the oil service fill plug. Clean the fill plug and check that there is no damage to the ‘O’ ring.
Install the filler pump into the filler hole.
5. Lower the vehicle with the filler pump still connected and partially fill the transmission.
Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.

5A-80 AUTOMATIC TRANSMISSION6. Switch off the engine and raise the vehicle on the hoist, if applicable, ensuring that the vehicle is level.
7. Three minutes after the engine has stopped, but no longer than one hour, remove the filler pump, The correct level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATF to the correct level.
8. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle.
9. Tighten the transmission filler plug to specification.
Checking, Adding Fluid and Filling - Drained or Dry Transmission
To set the correct fluid level proceed as follows. 1. Set the transmission selector to Park and switch the engine off.
2. Raise the vehicle on a hoist (or leave over a service pit).
3. Clean all dirt from around the service fill plug prior to removing the plug, Remove the oil service fill plug. Clean the fill plug and check that there is no damage to the ‘O’ ring. Install the filler pump into the filler hole.
4. Lower the vehicle with the filler pump still connected and partially fill the transmission. This typically requires approximately :
a. If the transmission torque converter is empty:
9.0 litres - 4WD9.0 litres - RWD
b. If the transmission torque converter is full: 4.5 litres - 4WD4.5 litres - RWD
5. Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission gear selector through all positions, adding ATF until gear application is felt.
6. Then add an additional 0.5 litres of ATF.
7. Switch off the engine and raise the vehicle on the hoist. Remove the filler pump and replace the filler plug. The plug shall be tightened to specification.
8. The vehicle is then to be driven between 3.5 and 4.5 kilometers at light throttle so that the engine does not exceed 2500 rpm. This should result in the transmission temperature being in the range 50 to 60 °C.
9. With the engine idling, cycle the transmission selector through all gear positions with the brake applied.
10. Stop the engine. Raise the vehicle on the hoist, if applicable ensuring the vehicle is level.
11. Three minutes after the engine has stopped, but no longer than one hour, remove the filler plug. The correct level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATP to the correct level.
12. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle. Tighten the transmission Filler plug to specification.
ELECTRONIC ADJUSTMENTS Idle Speed Adjustment
Carry out the adjustments to the idle speed as detailed in the workshop manual.
Throttle Position Calibration
Should the throttle position data stored in the TCU be lost or be out of specification, as indicated by a diagnostic
trouble message, it may be re-established by the following procedure. Check that the hot engine idle speed is within specification.
Allow the engine to idle in ‘Drive ’ for 60 seconds with the air conditioner (if fitted) turned off. The closed throttle
reference point in the TCU has now been set.
Switch the engine off but leave the ignition on. Hold the accelerator pedal on the floor for 60 seconds. The wide open
throttle reference point in the TCU has now been set.

AUTOMATIC TRANSMISSION 5A-83
Tightening Torque 70 - 80 Nm
11. Remove the two pipes for oil cooler. Installation Notice
Tightening Torque 24.5 - 34.3 Nm
12. Remove the service hall cover on torque converter.
13. Put the alignment mark for installation, and unscrew the six mounting bolts for torque converter from drive plate through the service hole (arrow) by rotating the engine
and remove the torque converter. Installation Notice
Tightening Torque 42 Nm
7. Remove the rear propeller shaft.
Installation Notice
8. Unscrew the five bolts and remove the transfer case.
9. Disconnect the 10-Pins Plug connector from transmission.
10. Separate the locking clip on shift lever and remove the shift rod.Notice Removal and installation performed when the shift procedure should be lever is in “D” range.
Screw the six bolts mounting the torque converter through the service hole by using a mirror and rotating the engine.

MANUAL TRANSMISSION 5B-5
Check
Clutch not releasing. Improper or low transmission oil. Shift or shift rail binding. Binding of sliding synchronizers or gears.
If reverse only, faulty backup switch. Worn or damaged flywheel pilot bushing. Check
Control lever assembly broken or damaged.
Damaged offset lever, shift fork, selector place or selector arm. DIAGNOSIS
WILL NOT SHIFT(CONTROL LEVER MOVES)
Action
Replace control lever and housing assembly.
Remove extension, adapter or case cover. Check or replace damaged parts.
HARD SHIFT OR CONTROL LEVER WILL NOT MOVE INTO GEAR
Action
Adjust or replace clutch. Add or replace with specified oil.
Remove extension, adapter or case cover. Check or replace damaged parts.
Remove extension, adapter or case cover. Check synchronizers and gears and replace damaged parts. Check or replace backup switch. Replace pilot bushing.
GEARS CRASH WHEN SHIFTING
Check
Engine idle speed too high. Damaged or faulty clutch.Pilot bearing between input shaft and output shaft binding.
Damaged synchronizer. Bell housing misaligned. Damaged gear(s).Worn or damaged flywheel pilot bushing. Action
Adjust idle speed to specified speed.Adjust or replace clutch.Replace or check roller bearings.Check or replace synchronizer parts. Align bell housing and bore. Check or replace gear(s).Replace pilot bushing.

5B-6 MANUAL TRANSMISSIONCheck
Loosened transmission or flywheel housing bolts,
improper alignment.Synchronizer damaged or excessively worn. Blocking ring damaged, worn index slots or friction surfaces worn or damaged.
Excessive countershaft end play. Worn or damaged fork due to loosened shaft, rail or shifting fork. TRANSMISSION JUMPS OUT
Action
Tighten bolts to specified value. Realign if necessary. Check or replace synchronizer parts.
Check or replace blocking ring.Check worn or damaged parts. Adjust shim thickness
using roller bearings if necessary.Check for wear or damaged. Replace worn or damaged parts.
Check
Fork or offset lever loose on shaft or rail.
Worn or damaged forks, offset lever, shaft or rail.
Worn or damaged synchronizer. Worn or damaged gears. TRANSMISSION LOCKED IN ONE GEARAction
Replace extension, adapter or case cover. Check or replace loose parts on shaft or rail. Replace roll pin(s).
Remove extension, adapter or case cover. Check forwear or damaged. Replace damaged parts.Check worn or damaged synchronizer parts and
replace if necessary.
Check worn or damaged gears and replace if neces-
sary.
Check
Improper or low transmission oil. Loose bolts or other attaching parts.Improper flywheel housing to engine crankshaftalignment.Noisy transmission bearing. Noisy gears. TRANSMISSION NOISEAction
Add or drain and replace with proper oil.
Tighten as specified.
Realign correctly. Check bearings, bearing rollers and parts for wear or damage.
Replace if necessary.Check for worn or damaged gears(including speedometer gear).
Replace if necessary.

5C-4 CLUTCHChecks
Oily Facing Hard or Faulty Facing
Burnt Torsion Spring Faulty Pressure Plate Bent Clutch Diaphragm SpringHard or Bent FlywheelEngine Mounts Loose or Burnt Lever Action
Adjust Pedal Freeplay
Repair Release Cylinder Repair or Replace
Repair as Necessary Replace
Checks
Excessive Clutch Pedal Free play Faulty Clutch Release Cylinder Worn Disc, Excessive Run-out, Damaged LiningDirty or Burred Splines on Input Shaft or Clutch DiscDamaged Clutch Pressure Plate Checks
Vibration or Excessive Run-out of DiscRust or Wear of Disc Spline Oily Facing Damaged Diaphragm SpringExcessive Clutch Pedal Free play DIAGNOSIS
CLUTCH SLIPS
Checks
Excessive Wear of Facing Hard or Oily FacingDamaged Pressure Plate or FlywheelDamaged or Burnt Diaphragm SpringClutch Pedal Free play Insufficient Faulty Operation of Clutch Pedal Worn or Damaged Clutch Disc Action
Replace
Repair or Replace ReplaceReplaceAdjust
Repair or Replace Replace
POOR DISENGAGEMENT
Action
Replace
Repair or Replace Repair or Replace Replace
Adjust
HARD TO SHIFT OR WILL NOT SHIFT
CLUTCH CHATTERS WHEN STARTING
Action
Repair or Replace
Replace Replace Replace Replace
Repair or Replace
Tighten or Replace

TRANSFER CASE (TOD) 5D2-35
Removal & Installation Procedure1. Disconnect (-) cable from battery.
2. Lift on vehicle and make sure on safety. NoticeBe careful for catalytic converter due to high temperature after driving or engine running.
3. Prepare a vessel to drain transfer case and manual transmission oil.
4. Release drain plug and drain transfer case and manual transmission oil. If planar damper is installed, unscrew 4 bolts and remove
the planar damper. NoticeOil drain should be along with whole transfer case
disassembly and assembly.
5. Disconnect transmission extension wiring connector back
side transfer case. Notice
When disconnect connector, make sure on direction of locking tab towards inside.
6. Disconnect shift motor/clutch coil connect (Black 7 pin) connector upper backside.
7. Disconnect front and rear speed sensor connector (white 7 pin).
8. Disconnect speedometer sensor connector right upper side.
9. Disconnect breather tube front upper side transfer case (upper connecting point of transfer case and front propeller).
10. Prepare hydraulic jack and support transfer case assembly.

6A-6 POWER STEERING SYSTEM
OIL PUMP PRESSURE CHECK Oil Pump Pressure Check
1. Disconnect the pressure hose from the oil pump connect apressure gauge between the oil pump and pressure hose
2. Bleed the system . Start the engine and turn the steering wheel form lock several times until oil temperature is up to
50°C
3. Run the engine at 1,000 rpm.
4. Close the pressure gauge valve and check oil pressure.
NoticeDo not keep the valve closed for more than 10 seconds.
5. Remove the pressure gauge and connect the pressure hose.
6. Do bleeding procedure. BLEEDING OF POWER STEERING SYSTEM Bleeding of Power Steering System
1. Disconnect the fuel line. Using a starter motor, crank the engine and turn the steering wheel from lock to lock 5 or 6 times. Notice Do bleeding with engine cranking. If bleed with idling, there can be a air contact with oil.
2. Connect the fuel feed line and start the engine at idle speed.
3. Turn the steering wheel from lock to lock until there is no more air in oil reservoir.
4. Connect the oil level is within specification.
5. By turning the steering wheel left to right, check the oil level change. Notice
If oil is not changes more than 5mm, do bleeding again.
If oil level rises suddenly when stopped engine, again.
Relief Pressure
75 - 82 kg/cm2