SSANGYONG MUSSO 2003 Service Manual

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

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9. Assemble the primary regulator valve and plunger (referto figure 8.36) to the pump cover, ensuring that the
regulator valve slides freely, then fit the regulator valve plug and ‘O’ ring.
10. Install the retaining pin.
11. Install the converter clutch regulator valve (refer to figure 8.37), plug, and ‘O’ ring.
Figure 8.36 - Primary Regulator Valve
Figure 8.37 - Converter Clutch Regulator Valve

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13. Install the converter clutch control valve (refer to figure8.38), spring, plug, and ‘O’ ring.
14. Install the retaining pin. Refer to figure 8.39.
Figure 8.39 - Valve Retaining Plugs and Pins
Figure 8.38 - Converter Clutch Control Valve
12. Install the retaining pin. Refer to figure 8.39.

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15. Install the C1 bias valve spring, valve, plug and ‘O’ ring.
Refer to figure 8.40.
16. Install the retaining pin. Refer to figure 8.39.
17. Install the converter release check ball and spring and the feed ball. Refer to figures 8.41, 8.42 and 8.43. Figure 8.40 - C1 Bias Valve
Figure 8.41 - Converter Relief Ball and Spring Figure 8.42 - Peed Ball
Figure 8.42 - Feed Ball

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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

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25. Check that the transmission end float is set to the tolerancestated in section 9.2. Refer to figure 8.46. If the unshimmed
end float clearance is greater than specification, shims
are to be placed between the No. 4 bearing and the input
shaft bearing surface. Refer to figure 8.19. If the end float
clearance is less than 0.5 mm then the transmission has
been assembled incorrectly or the parts are out of specification.
26. Perform the following steps to check the end float : a. Attach a dial indicator to the front of the transmissioncase with the stylus resting on the end of the input shaft.
b. Apply a force of approximately 250 newtons or 25 kg to the input shaft.
c. Zero the dial indicator.
d. Place a small lever behind the forward clutch cylinder and lever the cylinder forward.
e. The measurement recorded on the dial indicator is the transmission end float or clearance between the No.4
bearing and the converter support tube.
27. On completion of this procedure, adjust the front and rear bands to specifications detailed in section 8.4.
Figure 8.46 - Gear Train End Float Check

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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

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6. Install the lo-1st spring, ball check valve and roll pin. Referto figure 8.49.
7. Install the solenoid 5 damper guide spring, piston and retaining pin. Refer to figure 8.49.
Figure 8.49 - Solenoid 5 and Damper, Lo-1st Check Valve Assemblies
Figure 8.50 - 1-2 Shift Valve
8. Install the 1-2 shift valve, plug and retaining pin. Refer to
figure 8.50.

5A-120 AUTOMATIC TRANSMISSION9. Install the 3-4 shift valve and retaining pin. Refer to figure 8.51.
Figure 8.51 - 3-4 Shift Valve
10. Install the 2-3 shift valve and retaining pin. Refer to figure 8.52.
Figure 8.52 - Solenoid 2 and 2-3 Shift Valve
11. Install the 4-3 sequence valve, spring, plug and retainingplate. Refer to figure 8.53.
Figure 8.53 - 4-3 Sequence Valve

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12. Install the band apply regulator (BAR) valve (refer to figure8.54), springs, plunger and retainer pin.
Figure 8.54 - Band Apply Regulator Valve and Solenoid 4
13. Install the clutch apply regulator (CAR) valve (refer to figure8.55), springs, plunger and retainer pin.
Figure 8.55 - Clutch Apply Regulator Valve and solenoid 3
14. Install the solenoid supply valve, spring and retainer plate.Refer to figure 8.56. NoticeThis aluminum valve is easily damaged.
Figure 8.56 - Solenoid Supply Valve and Solenoid 6