washer fluid SSANGYONG MUSSO 2003 Service Manual

0B-12 GENERAL INFORMATIONOWNER INSPECTIONS AND SERVICES
WHILE OPERATING THE VEHICLE Horn Operation Blow the horn occasionally to make sure it works. Check all the button locations. Brake System Operation Be alert for abnormal sounds, increased brake pedal travel or repeated puling to one side when braking. Also, if the brake warning light goes on, or flashes, something may be wrong with part of the brake system. Exhaust System Operation Be alert to any changes in the sound of the system or the smell of the fumes. These are signs that the system may be leaking or overheating. Have the system
inspected and repaired immediately. Tires, Wheels and Alignment Operation Be alert to any vibration of the steering wheel or the seats at normal highway speeds. This may mean a wheelneeds to be balanced. Also, a pull right or left on a straight, level road may show the need for a tire pressure adjustment or a wheel alignment. Steering System Operation Be alert to changes in the steering action. An inspection is needed when the steering wheel is hard to turn or
has too much free play, or is unusual sounds are noticedwhen turning or parking. Headlight Aim
Take note of the light pattern occasionally. Adjust the headlights if the beams seem improperly aimed.
AT EACH FUEL FILL A fluid loss in any (except windshield washer) system may indicate a problem. Have the system inspected and
repaired immediately. Engine Oil Level
Check the oil level and add oil if necessary. The best time to check the engine oil level is when the oil is warm.
1. After stopping the engine, wait a few minutes for the oil to drain back to the oil pan.
2. Pull out the oil level indicator (dip stick).
3. Wipe it clean, and push the oil level indicator back down all the way.
4. Pull out the oil level indicator and look at the oil level on it. 5. Add oil, if needed, to keep the oil level above the
lower mark. Avoid overfilling the engine, since this may cause engine damage.
6. Push the indicator all the way back down into the engine after taking the reading.
If you check the oil level when the oil is cold, do not runthe engine first. The cold oil will not drain back to the pan fast enough to give a true oil level reading. Engine Coolant Level and Condition Check the coolant level in the coolant reservoir tank
and add coolant if necessary. Inspect the coolant. Replace dirty or rusty coolant.
Windshield Washer Fluid Level
Check the washer fluid level in the reservoir. Add fluid if
necessary.
AT LEAST TWICE A MONTH Tire And Wheel Inspection and Pressure Check Check the tire for abnormal wear or damage. Also check for damaged wheels. Check the tire pressure when the tires are cold ( check the spare also, unless it is astowaway). Maintain the recommended pressures. Refer
to “Tire and Wheel” is in section 0B.
AT LEAST MONTHLY Light Operation Check the operation of the license plate light, the headlights (including the high beams), the parking lights,the fog lights, the taillight, the brake lights, the turn
signals, the backup lights and the hazard warning flasher. Fluid Leak Check Periodically inspect the surface beneath the vehicle for
water, oil, fuel or other fluids, after the vehicle has been
parked for a while. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, find the cause and correct it at once.
AT LEAST TWICE A YEAR Power Steering System Reservoir Level Check the power steering fluid level. Keep the power steering fluid at the proper level. Refer to Section 6A,
Power Steering System. Brake Master Cylinder Reservoir Level Check the fluid and keep it at the proper level. A low fluid level can indicate worn disc brake pads which mayneed to be serviced. Check the breather hole in the reservoir cover to be free from dirt and check for an open passage.

GENERAL INFORMATION 0B-15
GENERAL DESCRIPTION
AND SYSTEM OPERATION
GENERAL REPAIR INSTRUCTIONS
If a floor jack is used, the following precautions are recommended.
Park the vehicle on level ground, “ block” the front or rear wheels, set the jack against the frame, raise the vehicle and support it with chassis stands and then perform the service operation.
Before performing the service operation, disconnectthe negative battery cable in order to reduce the chance of cable damaged and burning due to short- cir cuiting.
Use a cover on the body, the seats and the floor to protect them against damage and contamination.
Handle brake fluid and antifreeze solution with care as they can cause paint damage.
The use of proper tools, and the recommended essential and available tools where specified, are important for efficient and reliable performance of the service repairs.
Use genuine DAEWOO parts.
Discard used cotter pins, gaskets, O-rings, oil seals, lock washers and self-locking nuts. Prepare new ones for installation. Normal function of these parts cannot be maintained if these parts are reused.
Keep the disassembled parts neatly in groups to
facilitate proper and smooth reassembly.
Keep attaching bolts and nuts separated, as they vary in hardness and design depending on theposition of the installation.
Clean the parts before inspection or reassembly.
Also clean the oil parts, etc. Use compressed air tomake certain they are free of restrictions.
Lubricate rotating and sliding faces of parts with oil or grease before installation.
When necessary, use a sealer on gaskets to prevent leakage.
Carefully observe all specifications for bolt and nut torques.
When service operation is completed, make a final check to be sure service was done properly and theproblem was corrected.

5A-42 AUTOMATIC TRANSMISSIONPOWER TRAIN SYSTEM
The Power Train System consists of: A torque converter with single face lock-up clutch
Four multi-plate clutch assemblies
Two brake bands
Two one-way clutches
Planetary gearset
Parking mechanism
A conventional six pinion Ravigneaux compound planetary gearset is used with overdrive (fourth gear) being obtained
by driving the carrier.
The cross-sectional arrangement is very modular in nature. Four main sub-assemblies are installed within the case
to complete the build. These sub-assemblies are: Gearset-sprag-centre support
C1 -C2-C3-C4 clutch sub-assembly
Pump assembly
Valve body assembly
One, or a combination of selective washers are used between the input shaft flange and the number 4 bearing to
control the transmission end float. This arrangement allows for extensive subassembly testing and simplistic finalassembly during production.
A general description of the operation of the Power Train System is detailed below. Refer to table 4.1 and figure 4.1.
First gear is engaged by applying the C2 clutch and locking the 1-2 One Way Clutch (1-2 OWC). The 1-2 shift is
accomplished by applying the B1 band and overrunning the 1-2 OWC. The 2-3 shift is accomplished by applying the
C1 clutch and releasing the B1 band. The 3-4 shift is accomplished by re-applying the B1 band and overrunning the
3-4 OWC. Reverse gear is engaged by applying the C3 clutch and the B2 band.
The C4 clutch is applied in the Manual 1,2 and 3 ranges to provide engine braking. In addition, the C4 clutch is also
applied in the Drive range for second and third gears to eliminate objectionable freewheel coasting. The B2 band is
also applied in the Manual 1 range to accomplish the low-overrun shift.
Both the front and rear servos are dual area designs to allow accurate friction element matching without the need for
secondary regulator valves. All the friction elements have been designed to provide low shift energies and high static
capacities when used with the new low static co-efficient transmission fluids. Non-asbestos friction materials are used throughout.
Gear
First
Second ThirdFourth
Reverse
Manual 1 Gear
Ratio 2.741 1.508 1.0000.7082.4282.741 C1
XX C2
X X XX X C3
X C4
X X B1
X X X B2
X X 1-2
OWC X 3-4
OWC X XX LU
CLUTCH
X*X
ELEMENTS ENGAGED
* For Certain Vehicle Applications, Refer to the Owner's Manual.
Table 4.1 - Engaged Elements vs Gear Ratios

5A-98 AUTOMATIC TRANSMISSION Rear Band Assembly
To assemble the rear band assembly proceed as follows:
1. Check the rear band for any cracks or damage along thelining and metal backing.
2. Install the reaction anchor strut into the main case, without shims.Notice
If fitting a new band, soak the new band in automatic
transmission fluid (or a minimum of five minutes prior to
assembly.
3. Carefully install the rear band into the transmission case and ensure that it is properly fitted in the case.
4. Position the apply strut on the rear band then engage the apply strut in the servo lever.
5. Install the cam plate and tighten the screws to specification.
Figure 8.19 - Thrust Bearing and Washer Locations Figure 8.18 - Rear Servo and Band

5A-100 AUTOMATIC TRANSMISSION Planet Carrier Assembly and Centre Support
To assemble the planet carrier assembly and centre support, proceed as follows.1. Check the carrier and planet assembly for any damage or irregularity and ensure that all pinions rotate freely and
that the pinion end float is within the tolerance stated in section 9.2.
2. Install the one way clutch (OWC) retainer to the planet carrier with the inner edge pointing downwards. Inspect
the OWC race and the sprag assembly for wear or damage.
Replace if necessary.
3. Install the outer race in the drum. Press the race to the bottom of the drum and install the retaining circlip. Ensure
the circlip is firmly seated in its groove. Refer to figure 8.21.
4. Install the OWC into the outer race with the lip edge uppermost. Lubricate the sprags with automatic
transmission fluid. Refer to figure 8.20.
5. Check that the plugs are fitted to the centre support, then assemble the centre support into the OWC, ensuring that
the support will rotate in an anti-clockwise direction only.Refer to figure 8.21.
Figure 8.20 - Planet Carrier Assembly andCentre Support
6. Lubricate the No.9 needle thrust bearing and the thrust
washer with petroleum jelly and fit them to the rear face of
the planet carrier. Refer to figure 8.19.
7. Install the planet assembly and the centre support into the case, and align the centre support mounting bolt holes.
8. Install the centre support bolts finger tight.
9. Install the circlip retainer ensuring that the circlip is completely seated in the groove of the case.
10. Remove the centre support bolts and apply Loctite 222 or equivalent to the threads. Install the bolts and torque to specifications.

AUTOMATIC TRANSMISSION 5A-101
Extension Housing Assembly
To assemble the extension housing assembly, proceed as follows.
1. Check the condition of the extension housing roller bearing.Replace if necessary (RWD models). Install the new bearing
from rear of extension housing. Press on the branded face
of bearing only.
2. Install a new seal to the extension housing or adaptor housing. Refer to figure 8.21. Notice
Do not use petroleum jelly to hold the gasket in position.
3. Position a new gasket onto the extension housing or adaptor housing.Notice
See section 8.3.17 for the procedure to assemble the output
flange assembly - RWD models.
4. Install the extension housing (RWD) or adaptor housing (4WD) and torque the bolts to specification.
Front Servo Assembly NOTICE
Ensure that the front servo snap ring is installed correctly.
Orient the circlip with the gap at the bottom, near the pan rail.Refer to figure 8.22.
To assemble the front servo assembly (refer to figure 8.22), proceed as follows.
1. Lubricate the cover ‘O’ ring with automatic transmission fluid
and fit to the cover.
2. Lubricate the piston ‘O’ rings with automatic transmission
fluid and fit to the piston.
3. Assemble the piston, push rod, spring, belleville washer, seat and retaining ring.
4. Fit the piston push rod assembly into the front servo cover.
5. Install the front servo block and spring into the case.
6. Install the front servo assembly into the case.
7. Compress the servo cover and fit the servo cover retaining circlip, aligning the gap with the pan rail, and ensuring that
it is completely seated in its groove.
Figure 8.21 - Extension Housing
Figure 8.22 - Front Servo and Band

AUTOMATIC TRANSMISSION 5A-103
11. Assemble the piston return spring to the piston, and fit thespring retainer over the spring. NoticeThe wire diameter of this spring is 4.3 mm.
12. Using special tool No. 0555-331899, compress the spring sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then remove the tool.
13. Check the C1 piston check valves are not damaged and are free to move, and that the cylinder feed orifices areclear of obstructions.
14. Lubricate the ’0’rings with automatic transmission fluid and
fit them to their respective grooves. Notice
‘O’ rings must not be twisted in the grooves.
15. Position the cylinder with the C1 cavity upwards. Install the piston into the cylinder until the outer diameter of the piston
enters the inner diameter of the cylinder.
16. Install the spring and spring retainer onto the piston. Notice The wire diameter of this spring is 5.26 mm.
17. Using special tool No. 0555-331899, compress the spring sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then remove the tool.
18. Install the C2 wave washer into the cylinder with the crest of one wave covering one of the bleed orifices in the C2 piston.
19. Measure and record the thickness of the flange of the C2 sleeve. Refer to figure 8.25.
20. Install the C4 clutch plates and wave washer into the C2 actuating sleeve, with the rounded edge of the steel plates
down, in the following sequence:
Steel plate (selective)
Friction disc
Steel plate
Friction disc
Steel plate
Friction disc
Steel plate
Wave washer

AUTOMATIC TRANSMISSION 5A-105
21. Holding the cylinder horizontal, install the sleeve and clutchplate assembly into the cylinder, with the crest of one wave
of the washer In line with one of the holes in the outside of
the cylinder, until the sleeve contacts the C2 wave washer.
22. Check the C4 clutch pack clearance using special tool No. 0555-331900. Refer to figure 8.25. NoticeWith the C2 wave spring compressed, and the clutch Pack supporting a 2 k9 weight, the dimension from the undersideof the C2 pressure plate to the selective steel is to bebetween 1.4- 1.8 mm. If the clutch is to be gauged from the top of the pressure plate, then the dimension is to be the actual thickness of the pressure plate plus 1.4-1.8 mm.
23. Use selective plates to achieve the correct specification. If new friction plates are being fitted, remove the clutch packand soak the friction plates in ATF for a minimum of 5
minutes prior to reassembly. NoticeThe clutch pack clearance must be taken before the
elements are soaked in Automatic Transmission Fluid
(ATF).
24. Reassemble the sleeve and clutch pack into the cylinder. Observe the alignment of the wave washer to the hole in
the cylinder.
25. Install the C2 clutch plates in the cylinder in the following sequence:
Friction disc
Steel plate
Friction disc
Steel plate
Steel plate - 0574-000001, 0574-000003, 0574-000004, 0574-000005, 0574-000020,
0574-000021, or friction disc -0574-000002
Steel plate (selective)
Friction disc
Steel plate (selective)
Friction disc

TRANSFER CASE (TOD) 5D2-47
Assembly Procedure Assembly
Before assembly, lubricate all parts with Automatic Transmission Fluid or equivalent.
1. If removed, drive the bearing into the front output case bore.Drive the bearing in staight, making sure it is not cocked in the bore. Install the internal snap ring that retains the bearing to the front case.
2. If removed, install the front yoke to flange seal in the front case bore.
3. If removed, install the yoke to flange seal into the mounting adapter bore.
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Thrust Washer
8 Bearing
9 External Snap Ring
10 Internal Snap Ring
4. If the input shaft needle bearing and bushing were removed,
install a new bearing and bushing as detailed in the following steps: Press a new needle bearing, then a new bushing in the input shaft as follows:
a. Position the input shaft on Axle Bearing/Seal Plate or equivalent, and Pinion Bearing Cone Replacer as a
spacer.
b. Press a new needle bearing into the end of the input shaft until it seats in the input shaft.
c. Press in a new bushing.
5. The recessed face of the sun gear and the snap ring groove on the bearing outer race should be toward the rear of thetransfer case. The stepped face of the thrust washer shouldface toward the bearing.
Slide the sun gear, thr ust plate and thrust washer into
position on the input shaft. Press the bearing over the input shaft. Install the external snap ring to the input shaft.

TRANSFER CASE (TOD) 5D2-53
40. Install the rear case flange on the output shaft. Install therubber seal, output shaft yoke washer and nut. Tighten the nut.
Tightening Torque 137 - 196 Nm
41. Install the drainplug and tighten.
42. Fill the transfer case with 1.4 liters of Automatic Transmission Fluid or equivalent. NoticeFluid level should be just below the filler plug hole.
Tightening Torque 19 - 30 Nm
Tightening Torque 19 - 30 Nm
43. Install the fill pulg and tighten.
44. Install the transfer case as outlined in removal and
Installation, transfer case in the section. NoticeMake sure proper drain and fill plugs are installed if case is replaced.