solenoid SSANGYONG MUSSO 2003 Workshop Manual

AUTOMATIC TRANSMISSION 5A-77
Action
Check cable for open / short.
Check connection of other connectors.
Check voltage between terminal 4 and 11 of TCU.
- Standard value : when the A/C compressor is ON : 12V
when the A/C compressor is OFF : 0V
Check cable for open / short,
Check connection of other connectors.
Check voltage between terminal 1 and 12 of TCU.
- Standard value : when the kick down switch is ON : 12V
when the kick down switch is OFF : 0V
Fully depress accelerator pedal for 5 seconds(ignition key is ON).
Release accelerator pedal.
Depress brake pedal and start the engine in ‘P’ position.
Depress brake pedal and idle the engine for 5 seconds in ‘D’
position.
Shift into ‘D’ position and determine fault code for throttle initial-
ization.
Complete the initialization.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 34 of TCU(when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors,
Check resistance between terminal 1 and 40 of TCU (when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 41 of TCU (when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 33 of TCU (when theconnector is disconnected),
- Standard value : 26 - 30
Possible Cause
Air conditioner switch
Kick down switch Pedal
Vehicle ID
VPS offset
Throttle position sensor
initialization
Solenoid 1 Solenoid 2Solenoid 3Solenoid 4
Symptom
P1710 P1712P1713 P1714P1715P1716 P1733 P1734P1735 P1736

5A-78 AUTOMATIC TRANSMISSION
Action
Check solenoid.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 36 and 44 of TCU (when the connector is disconnected).
- Standard value : 3.6 - 4.2
Check solenoid.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 39 of TCU (when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 42 of TCU (when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for short.
Check connection of other connectors,
Check solenoid.
Check cable for short.
Check connection of other connectors.
Check solenoid.
Check cable for short.
Check connection of other connectors.
Check solenoid.
Check cable for short.
Check connection of other connectors.
Check solenoid.
Check cable for short.
Check connection of other connectors.
Check solenoid.
Check cable for short.
Check connection of other connectors,
Check solenoid.
Check cable for short.
Check connection of other connectors.
Check solenoid.
Possible Cause
Solenoid 5 Solenoid 6Solenoid 7
Short of solenoid 1 Short of solenoid 2Short of solenoid 3 Short of solenoid 4 Short of solenoid 5 Short of solenoid 6 Short of solenoid 7
Symptom
P1737 P1738P1739 P1741 P1742 P1743 P1744 P1745P1746 P1747

5A-86 AUTOMATIC TRANSMISSION
9. Remove the pump to case bolts using a multi-hex 8 mmspanner.
10. Using the pump puller No. 0555-332941, remove the pump.
11. Remove the input shaft, forward clutch cylinder, and the overdrive shaft as an assembly, withdrawing them through the front of the case.
12. Remove the C3 clutch cylinder and sun gears.
13. Remove the fronts band struts. Remove the front band.
14. Remove the two centre support retaining bolts using a T50 Torx bit.
15. Remove the centre support retaining circlip. Notice
Do not hammer the output shaft to remove the centre
support as this will cause permanent damage to the thrust bearing surfaces.
16. Remove the centre support, 1-2 one way clutch, planetary gear set and output shaft as an assembly.
17. Remove the parking rod cam plate. (T40 Torx bit).
18. Remove the rear band struts and remove the band. 4. Detach each end of the filter retaining clip from the valve
body and remove the filter.
5. Detach the wires from each solenoid and lay the wiring to one side.
6. Remove the valve body securing screws and remove the valve body from the case.
7. Remove the front servo cover circlip. Remove the cover and piston.Notice
The plastic servo block is retained by the piston return
spring only.
8. Where fitted, remove the flange yoke, and then remove the extension housing (RWD model).
Remove the adaptor housing (4WD model).

5A-88 AUTOMATIC TRANSMISSION
8. Detach the No.7 solenoid wire from the front of the case.
9. Remove the parking pawl pivot pin and the pawl and springfrom the case.
10. Remove the shaft and the rear servo lever.
11. Remove the rear servo cover and piston assembly.
12. Remove the B1R circlip, valve and spring.
13. Remove both band adjustment shims.
14. Inspect the output shaft bushing in the case and replace if necessary.
15. Inspect cooler line fittings and replace as necessary.
16. Inspect the case for damage.
17. To remove the park rod lever: Remove the circlip from the inner end of the pivot shaft and tap the outer end of the
shaft until it moves free from the case, then using a wide
shallow tapered drift as a wedge, drive the pin out fromthe inside of the case and remove the lever and spring. NoticeDo not remove the park rod lever unless absolutely
necessary.

5A-92 AUTOMATIC TRANSMISSION
Planet Carrier and Centre Support
To remove the planet carrier and centre support, proceed as follows.1. Separate the planet carrier and centre support from the output shaft. Remove the thrust bearings from the output
shaft and the planet carrier.
2. Separate the centre support from the planet carrier by rotating it anti-clockwise.
3. Lift the one way clutch from the planet carrier.
4. Remove the circlip retaining the one way clutch outer race in the planet carrier and remove the race.
5. Remove the one way clutch retainer from the planet carrier.
Pump
Note that the following valves are housed in the pump cover:
Solenoid 7
C1 bias valve
Converter clutch control valve
Converter clutch regulator valve
Primary regulator valve
To remove the pump, proceed as follows. 1. Remove the wiring loom retainer plate and remove solenoid 7 with a T30 Torx bit.
2. Remove the five washer head bolts from the cover plate using a multi-point 8 mm socket.
3. Remove the five Torx head screws from the cover plate (Torx bit No. 30). Note that the odd screw holds the pump
body to the pump body cover. Notice
Do not strike the converter support tube to loosen the
pump body.
4. Separate the pump body from the pump cover.
5. Lift the cover plate from the cover.
6. Remove the two ball check valves and one spring from the pump cover.Notice
Some of the valves and plugs are preloaded by springs
and may unexpectedly fall out of the cover when the pinsare removed.
7. Depress the plug inward and remove the retaining pin for each of the four valves.
8. Remove the four valves, plugs and springs.
9. Remove the pump gears from the pump body.
10. Remove the lip seal from the front of the pump body.

AUTOMATIC TRANSMISSION 5A-93
Valve Body
To disassemble the valve body, proceed as follows.1. Remove the detent spring and retainer plate using a T40 Torx bit.
Notice
Be aware that the manual valve will fall out of the valve body.
2. Take note of the angular relationship of the solenoid terminals to the valve body, then slide the manual valve out of the lower
valve body.
3. Remove the solenoid and valve assembly as follows: solenoid 1
solenoid 2
solenoid 3
solenoid 4
solenoid 5
solenoid 6
4. Place the valve body assembly on the bench with the upper body uppermost.
5. Remove the 24 clamping screws with a No. 30 Ton bit. Separate the upper and lower valve bodies by lifting the upper body and
the separator plate together.
6. Upper body over and place it on the bench with the separator plate uppermost.
7. Lift the separator plate and gaskets from the upper valve body.
8. Remove the five nylon check balls exposed in the valve body.
9. Remove the retainer plate, plug, spring and reverse lockout valve.
10. Remove the two filters (and the large nylon check ball) from the lower valve body. Notice Once the pins are removed, the plates are loose in the valve
body and will drop out when the valve body is turned over.
11. Remove the keeper plates and pins from the 1-2,2-3,3-4, BAR and CAR valves. The pins can be removed with a magnet.
12. Remove the 1-2,2-3 and 3-4 shift valves. Notice The plug is preloaded by the spring and may unexpectedly fall
out of the valve body.
13. Depress the 4-3 sequence valve plug and remove the keeper plate.
14. Remove the plug, valve and spring.
15. Depress the solenoid 5 valve. Remove the keeper pin and remove the valve and spring. Notice The valve is preloaded by the spring and may unexpectedly fall
out of the valve body.
16. Depress the line pressure release valve, remove the keeper pin, disc (if fitted), spring and valve.
17. Drive out the roll pin and remove the spring and ball check valve adjacent to the BAR valve.

5A-96 AUTOMATIC TRANSMISSION9. Check that the cam collar slides freely on the rod.
10. Insert the cross shaft into the case, from the side opposite to the inhibitor switch, then install the anti-rattle spring on the shaft.
11. Position the manual valve detent lever, aligning it with the cross-shaft bore in the case.
12. Push the shaft through the detent lever until it starts in the detent lever side of the case.
13. Install the detent lever drive pin in the shaft using tool No. 0555-331897 with the adaptor over the pin.
14. Press the pin into the shaft until the tool bottoms.
15. Remove the tool and fit the spring retaining circlip to the shaft.
16. Install the new cross shaft seals using tool No. 0555-
331894.
17. Install the inhibitor switch on the case. Torque the screws as per specifications. Press the pin into the shaft until the
tool bottoms (4WD models) using tool No.0555-332942.
18. Thoroughly check the terminal wiring loom for condition and continuity.
19. Position the loom and locate the solenoid 7 contact andterminal in the pump mounting flange at the front of the case. The solenoid 7 wire is routed under the park rodand cross shaft in the case.

5A-112 AUTOMATIC TRANSMISSION
Pump Cover and Converter Support Notice
1. Do not wash the nose of solenoids in solvent.
2. Ensure that the correct ‘O’ ring is fitted for the application.
3. Do not mix up the low first blow-off and the torque converter blow-off ball springs.
4. Be careful not to damage the needle bearings on the assembly. Avoid any axial impact loads during assembly.
5. Check the transmission end float. This will help to detect any missing parts or incorrect assembly.NoticeFigure 8.35 shows the orientation of the cross- sections for figures 8.36 to 8.42.
To assemble the pump cover and converter support (refer to figures 8.34 and 8.35), proceed as follows.
1. Check the pump body for any damage, chips or irregularity. Check that the bush is firmly staked in the drive gear.
2. Install the seal flush with the front face of the pump body.
3. Lubricate the pump bush, and the drive and driven gears, with automatic transmission fluid.
4. Install the pump driven gear and the pump drive gear into the pump body.
5. Using a straight edge and thickness gauge, check that the clearance between pump face and gears is 0.04 - 0.018
mm.
6. Lubricate the pump body ‘O’ ring with automatic transmission
fluid and fit it to the pump body. Put the pump body to one side.
7. Ensure that the pump cover cavities, ports and holes are clean and free of any obstruction.
8. Lubricate all loose parts with automatic transmission fluid prior to assembly. Figure 8.34 - Pump, Cover and Converter
Support
Figure 8.35 - Pump Cover Assembly

5A-116 AUTOMATIC TRANSMISSION
18. Install the gasket on the pump cover.
19. Install the cover plate, solenoid 7 with the retainer and thesolenoid wiring retainer to the pump cover, ensuring that
the periphery of the cover plate is flush with the periphery
of the pump cover. Refer to figure 8.34.
Tighten the screws to specification in the order (1-5), shown in figure 8.44.
24. Install the pump and cover assembly over the input shaft being careful not to damage the sealing rings. Tighten the
pump cover to case bolts to specification. Refer to figure 8.45.
20. Tighten the solenoid 7 screw. Refer to figure 8.39.
Notice Check that neither the wiring nor the connector protrudes
excessively, in order that at assembly neither the wiringand the connector contacts or rubs on the input shaft or
the C1/C2 clutch cylinder.
21. Assemble the pump to the pump cover.
Tighten all bolts and the crescent screw finger tight,
ensuring that the pump is flush against the pump cover.
Tighten the bolts and the screw to specification in the order
(A - F), shown in figure 8.44.
22. Install the pump to transmission case gasket onto the case.
23. Fit the ‘O’ ring to the pump cover outer diameter.Figure 8.44 - Pump Bolt Tightening Sequence
Figure 8.45 - Tightening Sequence Pump to
Case

5A-118 AUTOMATIC TRANSMISSION
Valve Bodies Notice1. Do not wash the nose of solenoids in solvent.
2. Be aware of ball positions in the upper valve body.
3. Be aware of 1-2 and 3-4 shift valve positions, they can be swapped.
4. Check the 4-3 sequence valve and spring orientation.
5. Check that the 12 mm ball is in the lower body.
6. Do not mix up the low first blow-off and the torque converter blow-off ball springs.
7. Check the line pressure relief valve for swarf, and be aware of replacing the shims.
8. The orifices in the valve body are for stability and safeguard; do not drill them any larger.
9. When servicing the transmission, ensure that the solenoid 5 damper spring is not broken.
10. Locate the detent spring central to the detent lever.
To assemble the valve bodies, proceed as follows. 1. Wash the upper and lower valve bodies (refer to figures 8.47 and 8.48) thoroughly with cleansing solvent and blow
dry.
2. Check the valve body cavities, ports and holes for damage or obstructions.
3. Install the detent lever locating pin.
4. Thoroughly wash all loose components.
5. Check that all valves slide freely in their location.
Figure 8.47 - Lower Valve Body
Figure8.48 - Upper Valve Body Showing Check Ball Locations