maintenance SSANGYONG MUSSO 2003 Repair Manual

4E-2 REAR DISC BRAKES
1 Rear Brake Disc Assembly
2 Brake Pad
3 Brake Caliper
4 Gasket ................................................... Replace
5 Bolt........................................................... 20 Nm
6 Gasket ................................................... Replace MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
REAR DISC BRAKE Preceding Work : Removal of wheels and tires7 Brake Hose
8 Gasket ................................................... Replace
9 Eye-hose Bolt ...................................... 15-18 Nm
10 Washer
11 Bolt .................................................... 85-105 Nm

FrontRear
Front Rear
SECTION 4F
ANTILOCK BRAKE SYSTEM
TABLE OF CONTENTS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Model
ECUNumber of Pins
Operating TemperatureMotor Operating CurrentSolenoid Coil Resistance External Resistance Air Gap
Number of teeth Description
ABS 5.3 31
-40 ~ +120 °C
Below MAX 40A
1.28K - 1.92K
0.35 - 1.60 mm 0.15 - 1.20 mm 52 52 ABS/ABD 5.3
83
-40 ~ +85 °C
Below MAX 45A
8.04 - 9.04 except AV,
HSV 4.04 - 4.54
1.28K - 1.92K
0.35 - 1.60 mm 0.15 - 1.20 mm
52 52
Hydraulic System
Wheel Speed Sensor Impulse Ring
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4F-1
General Specifications . . . . . . . . . . . . . . . . . . 4F-1
Schematic and Routing Diagrams . . . . . . . . 4F-2 ABS 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-2
ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-3
ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-4
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-5
Component Locator . . . . . . . . . . . . . . . . . . . 4F-6 ABS, ABS/ABD . . . . . . . . . . . . . . . . . . . . . . . . 4F-6
ABD System Description . . . . . . . . . . . . . . . 4F-7 Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . 4F-11
Defect Codes . . . . . . . . . . . . . . . . . . . . . . . . 4F-13
Maintenance and Repair . . . . . . . . . . . . . . 4F-19
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 4F-19
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . 4F-19
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . 4F-21 ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-21
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . 4F-24

ANTILOCK BRAKE SYSTEM 4F-19
MAINTENANCE AND REPAIRON-VEHICLE SERVICE
WHEEL SPEED SENSOR
1 Bolt
2 Front Wheel Speed Sensor
3 Knuckle 4 Bolt
5 Rear Wheel Speed Sensor
6 Rear Axle

SECTION 4G
PARKING BRAKE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4G-1General Specifications . . . . . . . . . . . . . . . . . . 4G-1
Fastener Tightening Specifications . . . . . . . . . 4G-1
Component Locator . . . . . . . . . . . . . . . . . . . 4G-2 TABLE OF CONTENTS
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
Maintenance and Repair . . . . . . . . . . . . . . . 4G-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4G-3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-3
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Parking Brake Lever Bolt Cable Mounting Bracket Bolt
N 

 m
8 - 18 8 - 18
FASTENER TIGHTENING SPECIFICATIONS
Application
Type
Operating Type
Description
Mechanically Operated Rear Wheel Expansion Manual

PARKING BRAKE 4G-3
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE PARKING BRAKE Removal & Installation Procedure
1. Disconnect the parking brake indicator switch connector.
2. Disconnect the right and left cable from equalizer whileparking brake lever is released.
3. Unscrew 8 bolts and remove the parking brake lever assembly. Installation Notice Notice
Tighten the bolts with sequence number while the lever is pulled up 4 to 6 notches.
Tightening Torque 8 - 18 Nm
4. Unscrew the frame and lower arm side cable mounting bracket bolts. Installation Notice
Tightening Torque 8 - 18 Nm

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-82 AUTOMATIC TRANSMISSIONMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Tightening Torque 70 - 80 Nm
5. Remove the rear propeller shaft .
Installation Notice
REMOVAL & INSTALLATION OF TRANSMISSION
1. Disconnect the negative battery cable.
2. Disconnect the connectors from transfer case.
3. Disconnect the speedometer connector from transfer case.
4. Disconnect the inhibitor and Sear position sensor connector.
6. Unscrew the eight bolts and two nuts, and remove the cross member.

Model
Type Gear Ratio Oil Weight (Dry)SECTION 5B
MANUAL TRANSMISSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5B-1 General Specifications . . . . . . . . . . . . . . . . . . 5B-1
Fastener Tightening Specifications . . . . . . . . . 5B-2
External View . . . . . . . . . . . . . . . . . . . . . . . . 5B-3 Gear T rain . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3
Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5 Will not Shift (Control Lever Moves) . . . . . . . . 5B-5 Hard Shift or Control Lever Will not Move Into
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5
Gears Crash When Shifting . . . . . . . . . . . . . . 5B-5
Transmission Jumps Out . . . . . . . . . . . . . . . . . 5B-6
Transmission Locked in One Gear . . . . . . . . . 5B-6
Transmission Noise . . . . . . . . . . . . . . . . . . . . . 5B-6
Transmission Leakage . . . . . . . . . . . . . . . . . . 5B-7Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . .
5B-8
Component Locator . . . . . . . . . . . . . . . . . . . 5B-9
Maintenance and Repair . . . . . . . . . . . . . . 5B-11
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5B-11 Shift Control Cable . . . . . . . . . . . . . . . . . . . . 5B-11
Transmission . . . . . . . . . . . . . . . . . . . . . . . . 5B-14
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17 Major Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17
Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-27
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-32
Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . 5B-34
Extension Housing . . . . . . . . . . . . . . . . . . . . 5B-35
Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-36
Inspection of Components . . . . . . . . . . . . . . 5B-40
Pre-Installation Checks . . . . . . . . . . . . . . . . . 5B-45
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Description
T5WC
Floor Change
3.97 : 1 2.34 : 11.46 : 11.00 : 10.85 :1
3.71 : 1
ATF DEXRON II / III 3.4 L
Check : Every 15,000km, Replace : Every 50,000km
33kg
1st
2nd 3rd
4th 5th
Reverse
Specification
Capacity(litre)
Change Interval
Notice Add LUBRIZOL (280cc) in oil after overhauling.

MANUAL TRANSMISSION 5B-11
MAINTENANCE AND REPAIRON-VEHICLE SERVICE
SHIFT CONTROL CABLE
1 Shift Lever Assembly
2 Bolt ...................................................... 20-30 Nm
3 Select Cable
4 Shift Cable
5 Snap Pin
6 Snap Pin
7 Transmission
8 Shift Cable 9 Select Cable
10 Clip 11 Clip
12 Snap Pin
13 Snap Pin
14 Protector
15 Washer

Type Clutch Pedal Clutch Disc Clutch Master Cylinder Clutch Release Cylinder Clutch FluidDescription
Hydraulic
Suspended 158 mm
5 - 10 mm
Single Dry Diaphragm
9.85 - 10.2 mm 9.2 mm
19.8 mm
15.87 mm
14.0 mm
17.46 mm
SAE J1703 / DOT3
SECTION 5C
CLUTCH
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 General Specifications . . . . . . . . . . . . . . . . . . 5C-1
Fastener Tightening Specifications . . . . . . . . . 5C-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4
Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4
Clutch Chatters When Starting . . . . . . . . . . . . 5C-4
Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5
SPECIFICATIONS
GENERAL SPECIFICATIONS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Application
Type Max. Pedal StrokePedal Free Play
TypeThickness of Disc Stroke Inner DiameterStrokeInner DiameterFree
With Load
Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Component Locator . . . . . . . . . . . . . . . . . . . 5C-6 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7
Maintenance and Repair . . . . . . . . . . . . . . . 5C-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8
Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8
Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17