automatic transmission SSANGYONG MUSSO 2003 Owner's Manual

1D2-2 M161 ENGINE COOLINGFASTENER TIGHTENING SPECIFICATIONS
N

 m
30
22.5 - 27.5
9 - 11
9 - 11
9 - 11
40.5 - 49.5
3 - 73 - 7
Application
Coolant Drain PlugEngine Hanger Bracket and Coolant OutletPort Bolt Thermostat Cover Bracket Bolt Oil Cooler Pipe Line BoltCooling Fan BoltViscous Clutch Bolt
Automatic Transmission Oil Cooling Hose Bolt Cooling Fan Shroud Bolt

M161 ENGINE COOLING 1D2-15
REMOVAL AND INSTALLATION OF RADIATOR Preceding Work : Removal of cooling fan shroud
1 Inlet Hose
2 Hose (to Engine)
3 Hose (to 3-way Connector)
4 Make-up Hose (to Coolant Reservoir)
5 3-way Connector
6 Automatic Transmission Oil Cooling Hose (A/T Equippend Vehicle) 7 Bolt (M6 X 20, 4 pieces)
...........................3-7 Nm
8 Insulator
9 Radiator Bracket
10 Radiator

1D2-16 M161 ENGINE COOLING Removal & Installation Procedure1. Drain coolant from the radiator.
2. Remove the coolant thermo connector from the radiator.
3. Remove the each coolant hoses.
Tightening Torque 14 Nm
4. Remove the automatic transmission oil cooling hose.
Installation Notice
5. Unscrew the bolts from radiator bracket and remove the bracket and insulator. Installation Notice
Tightening Torque 3 - 7 Nm
6. Remove the radiator upper mounting bolts and then remove the bracket and insulator.
7. Remove the radiator.
8. Check the radiator pin for crack, damage, leakage and bending and replace if necessary.
9. Installation should follow the removal procedure in the reverse order.
10. Berform the cooling system leakage test.

SECTION 5A
AUTOMATIC TRANSMISSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
Model Part Numbers and Applications . . . . . . 5A-2
Model Specifications . . . . . . . . . . . . . . . . . . . . 5A-2
Clutch Pack Details . . . . . . . . . . . . . . . . . . . . . 5A-3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5A-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5A-4
Schematic and Routing Diagrams . . . . . . . . 5A-5
TCU Circuit (Diesel) . . . . . . . . . . . . . . . . . . . . 5A-5
TCU Circuit (Gasoline) . . . . . . . . . . . . . . . . . . 5A-6
Shift Pattern Diagram . . . . . . . . . . . . . . . . . 5A-7
661LA Normal Mode . . . . . . . . . . . . . . . . . . . . 5A-7
661LA Power Mode . . . . . . . . . . . . . . . . . . . . 5A-8
662LA Normal Mode . . . . . . . . . . . . . . . . . . . . 5A-9
662LA Power Mode . . . . . . . . . . . . . . . . . . . 5A-10
662LA Low Mode . . . . . . . . . . . . . . . . . . . . . 5A-11
E32 Power Mode . . . . . . . . . . . . . . . . . . . . . 5A-12
E32 Normal Mode . . . . . . . . . . . . . . . . . . . . . 5A-13
E32 Low Mode . . . . . . . . . . . . . . . . . . . . . . . 5A-14
E23 Power Mode . . . . . . . . . . . . . . . . . . . . . 5A-15
E23 Normal Mode . . . . . . . . . . . . . . . . . . . . . 5A-16
E23 Low Mode . . . . . . . . . . . . . . . . . . . . . . . 5A-17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . 5A-18
Operator Interfaces . . . . . . . . . . . . . . . . . . 5A-20
Gear Select Lever Operation . . . . . . . . . . . . 5A-20
Driving Mode Selector . . . . . . . . . . . . . . . . . 5A-21
Control Systems . . . . . . . . . . . . . . . . . . . . . 5A-22
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-22
Electronic Control System . . . . . . . . . . . . . . . 5A-22
Hydraulic Control System . . . . . . . . . . . . . . . 5A-31
Power Train System . . . . . . . . . . . . . . . . . . 5A-42
Torque Converter . . . . . . . . . . . . . . . . . . . . . 5A-43
Clutch Packs . . . . . . . . . . . . . . . . . . . . . . . . . 5A-44Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-45
One Way Clutches . . . . . . . . . . . . . . . . . . . .
5A-45
Planetary Gear Set . . . . . . . . . . . . . . . . . . . . 5A-45
Parking Mechanism . . . . . . . . . . . . . . . . . . . 5A-46
Power Flows . . . . . . . . . . . . . . . . . . . . . . . . 5A-47
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-47
Power Flow - Park and Neutral . . . . . . . . . . . 5A-48
Power Flow - Reverse . . . . . . . . . . . . . . . . . . 5A-49
Power Flow - Manual 1 . . . . . . . . . . . . . . . . . 5A-50
Power Flow - Drive 1 . . . . . . . . . . . . . . . . . . . 5A-51
Power Flow - Drive 2 and Manual 2 . . . . . . . 5A-52
Power Flow - Drive 3 and Manual 3 . . . . . . . 5A-54
Power Flow - Drive 3 Lock Up and Manual
3 Lock Up . . . . . . . . . . . . . . . . 5A-56
Power Flow - Drive 4 (Overdrive) . . . . . . . . . 5A-57
Power Flow - Drive 4 Lock Up . . . . . . . . . . . . 5A-59
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-60
Diagnostic System . . . . . . . . . . . . . . . . . . . . 5A-60
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . 5A-69
Self Diagnosis Test . . . . . . . . . . . . . . . . . . 5A-75
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 5A-79
Hydraulic System . . . . . . . . . . . . . . . . . . . . . 5A-79
Transmission Fluid Test Procedure . . . . . . . . 5A-79
Electronic Adjustments . . . . . . . . . . . . . . . . . 5A-80
Maintenance and Repair . . . . . . . . . . . . . . 5A-82
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5A-82
Removal and Installation of Transmission . . . 5A-82
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5A-85
Rebuild Warnings . . . . . . . . . . . . . . . . . . . . . 5A-85
Disassembly Procedure . . . . . . . . . . . . . . . . 5A-85
Assembly Procedure . . . . . . . . . . . . . . . . . . . 5A-94
Front and Rear Band Adjustment . . . . . . . . 5A-128

5A-2 AUTOMATIC TRANSMISSIONSPECIFICATIONS
MODEL PART NUMBERS AND APPLICATIONS
Transmission
0574-000001 (9) 0574-000002 (8)
0574-000004 (10) 0574-000005 (7) Torque Converter
179K160K160K179KEngine Version661LAE32
662LA(Turbo) E23
MODEL SPECIFICATIONS
Application
Torque Converter Mean diameter of fluid circuit Maximum torque multiplication Stall speed (rpm)0574-000001 (D23LA)0574-000002 (E32)0574-000004 (D29LA) 0574-000005 (E23) 0574-0000200574-000021
Gear Ratios First Second ThirdFourthReverse
Lubricant
TypeCapacityDry SystemService Refill
Gear Train End Float Gear Set Pinion End FloatDescriprtion
260
2.0 : 1
2100 - 2250 2050 - 22502100 - 2200 1800 - 2100
2.741 : 1 1.508 : 11.000 : 10.708 : 12.429 : 1
Castrol TQ95 or other approved fluid 9.0 Litres (approx)4.5 Litres (approx)0.50 - 0.65 mm0.10 - 0.50 mm
DWMC P/NO
36100-05420 (1)36100-05430 (1)36100-05410 (1)36100-05440 (1)

AUTOMATIC TRANSMISSION 5A-3
CLUTCH PACK DETAILS
C1Composition Steel
C2
Composition Steel
C3
CompositionSteel
C4 CompositionSteel
0574-000002
5
5(2)
5
4(2)
4
4(2)
3
4(1)0574-000001, 0574-000004, 0574-000005
4
6(2)
4
5(2)
3
5(2)
3
4(1)
Note : Numbers in brackets indicate number of selective thickness steel plates required to achieve specifed
clutch pack clearance

5A-4 AUTOMATIC TRANSMISSIONSPECIAL TOOLS
SPECIAL TOOLS TABLE
Part Number
0555 - 332083 0555 - 3360460555 - 3362560555 - 3362570555 - 336258 0555 - 336259 0555 - 3362600555 - 3362610555 - 3362620555 - 336263 0555 - 336264 0555 - 3362650555 - 3362660555 - 3362670555 - 336268 0555 - 336269 0555 - 3362700555 - 332895Description
Solenoid / Thermistor, Electronic Tester
Solenoid, Bench Tester
Transmission Bench Cradle Pump Puller
Pin Remover / Installer Tool (Cross Shaft / Detent Lever)Clutch Spring CompressorClutch Pack Clearance Kit
Seal Removal Tool (Cross - Shaft) Oil Seal Dolly (Cross - Shaft)Assembly BulletSeal CompressorPin Press Seal Dolly
Alignment ToolPump Seal DollyEnd Float AdaptorEnd Float Shaft
Locknut Crimping Tool (W-Car Only)

AUTOMATIC TRANSMISSION 5A-5
SCHEMATIC AND ROUTING DIAGRAMS
TCU CIRCUIT (4WD-DIESEL)

5A-6 AUTOMATIC TRANSMISSION
TCU CIRCUIT (4WD-GASOLINE)

AUTOMATIC TRANSMISSION 5A-7
SHIFT PATTERN DIAGRAM
661LA NORMAL MODE