SSANGYONG NEW ACTYON SPORTS 2012 Service Manual

01-73680-01
2WD Automatic Transmission ▶
Torque converter
Oil cooler outletOil cooler return
Inhibiter switch Flange for
propeller shaft
Connector plug
Flange for
propeller shaft

01-8
4WD
2WD
3) Sectional Diagram
Fluid pumpClutch pack
Double planetary
gear-set
Torque converter Valve body
Fluid pumpSingle planetary
gear-set
Clutch pack
Torque converter Valve body
Single planetary
gear-setDouble planetary
gear-set

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3. TIGHTENING TORQUE
Description Size x Numbers Tightening torque
Transfer case housing M12 x 32 54 ~ 68
Etension housing M12 x 32 54 ~ 68
Oil pan M6 x 16 4 ~ 6
Valve body to transmission housing M6 x 26 8 ~ 13
Valve body to transmission housing M6 x 45 8 ~ 13
Center support to transmission housing M10 x 34 20 ~ 27
Output shaft locking nut M24 x 15 100 ~ 110
Pump cover to oil pump M8 x 55 24 ~ 27
Pump cover to transmission housing M8 x 40 24 ~ 34
Pump cover to transmission housing M8 x 58 24 ~ 34
Upper valve body to lower valve body M6 x 30 15 ~ 17
Detent spring M8 x 16 20 ~ 25
Variable bleed solenoid and speed sensor
M4 x 12 2.8 ~ 3.2
Transmission oil level plug 30 ~ 35
Front cooling lines to transmission cooler
25 ~ 35
Rear cooling lines to transmission cooler
25 ~ 35
Drive plate to torque converter
40 ~ 42
Gear select lever to shaft rod
14 ~ 20

01-10
4. SHIFT PATTERN DIAGRAM

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1. OVERVIEW
The six speed automatic (M78) transmission
is available in two variants: four wheel drive
and two wheel drive.
The transmission has the following features:
Six Forward Speeds
One reverse gear
A torque converter with an integral converter lock-up clutch
Electronic shift and pressure controls
A single planetary gear-set
A double planetary gear-set
Two hydraulically controlled brake bands
Three multi-plate clutches
All hydraulic functions are directed by electronic solenoids to control: -
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Engagement feel
Shift feel
Shift scheduling
Modulated torque converter clutch applications ·
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The transmission contains fully synthetic automatic transmission fluid (ATF) and is filled for life;
therefore it does not require periodic servicing.
Engine power reaches the transmission via a torque converter with integral converter lock-up
clutch.
The six forward gears and one reverse gear are obtained from a single planetary set, followed by
a double planetary set. This type of gear-set arrangement is commonly known as Lepelletier type
gear-set.
The automatic transmission is electronically controlled. The control system is comprised of the
following elements:
External transmission control unit (TCU)
Internal embedded memory module (EMM)
Input and output speed sensors
Valve body unit comprised of four on/off solenoid valves and six variable bleed solenoids
Torque converter -
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01-12
2. FEATURES
Early Downshifts with Hard Braking and Skip Shifts ▶
When heavy braking is detected, the transmission downshifts early and skips gears to provide
increased engine braking to provide gear selection for tip-in.
Gear Hold on Uphill/Downhill ▶
If the accelerator pedal is released when travelling uphill, upshifts are prevented to reduce
busyness on grades. If the accelerator pedal is released when travelling downhill, upshifts are
prevented to enhance engine braking.
Soft Engagement when Shifting to “D” and “R” Position ▶
A soft engagement feature avoids harsh take up of drive when selecting Drive or Reverse. This is
achieved by limiting engine speed and engine torque which results in a rapid, but progressive
engagement of either Drive or Reverse when moving from the Park or Neutral positions. There is
no drive engagement prevention strategy implemented on the transmission system as there is
sufficient engine strategy to protect the system. However, reverse gear engagement is prevented
until engine speed is less than 1400 rpm and the accelerator pedal position is less than 12% and
vehicle speed is less than 10 km/h.
Converter Clutch Lock-Up In All Gears ▶
The transmission features converter clutch lock-up in all gears. This feature provides improved
fuel economy and vehicle performance. It also improves transmission cooling efficiency when
towing heavy loads at low speeds, e.g. in city driving or hill terrain.
Embeded Memory Module (EMM) ▶
The embedded memory module (EMM) is
matched to the transmission's valve bodies
during transmission assembly to ensure
refined shift quality. The EMM is integrated
into the input speed sensor which is mounted
on the valve body in the transmission. The
EMM is used to store data such as valve body
calibration data and valve body serial number.
Upon installation, the TCU will download the
data from the EMM and utilise this data in the
operation of the transmission.
1) Features

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2) Cooling System
The transmission cooling system ensures rapid warm-up and constant operating temperature
resulting in reduced fuel consumption and refined shift quality.
It also includes a cooler by-pass within the hydraulic system to allow sufficient cooling and
lubrication to the transmission drivetrain in the event of a blockage in the transmission cooler.
Gear Shift ▶
Coastdown ▶
Torque Demand ▶ Transmission gear change is controlled by the TCU. The TCU receives inputs from various engine
and vehicle sensors to select shift schedules and to control the shift feel and torque converter
clutch (TCC) operation at each gear change
Coastdown downshifts occur at 0% accelerator pedal when the vehicle is coasting down to a
stop. To reduce the shift shock and to improve the shift feeling during downshift, TCU
electronically controls the transmission.
Torque demand downshifts occur (automatically) when the driver demand for torque is greater
than the engine can provide at that gear ratio. If applied, the transmission will disengage the TCC
to provide added acceleration.
3) Shift Strategy

01-14
3. MODE DESCRIPTIONS
1) Functions
Tip Switch in “M” Position (Manual Gear
Shift) (5)
The shiftable gear can be adjusted by
moving this switch to forward and
rearward when the gear select lever is in
“M” position. 5.Shift Lock Release Button Hole when Locked in the "P" Position (1)
If you cannot move the gear select lever from the "P" position, try to move the lever while
pushing down here with a sharp object such as a ballpoint pen. For your safety, turn off
the engine and depress the brake pedal before the attempt. 1.
Gear Position (4)
P :
R :
N :
D : 4.Mode Switch (3)
W :
S : 3.Selection of Manual/Automatic Shift Function (M↔D) (2)
D :
M : 2.
Automatic shift according to the driving condition
Manual shift
Winter mode (Start off the vehicle in 2nd gear)
Standard mode (Use the standard mode in normal driving conditions.)
Park
Reverse
Neutral
Drive

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2) Mode “M” (Manual Shift Mode)
This allows the driver to define the highest possible gear by selecting "+" or "-" on the gear
selector when the lever is in the "M" position. When the lever is first moved to the manual "M"
position the transmission will select the lowest possible gear.
When maximum engine rpm is reached the transmission will upshift automatically regardless of
the driver selected limit. 4WD models with low range will not automatically upshift when low range
is selected.
1st gear position ▶
2nd gear position ▶
3st gear position ▶
4th gear position ▶
5th gear position ▶
6th gear position ▶Use on a rugged road, mountain path and steep hill. Engine braking effect on steep hill is
available. -
Use on a long and gentle slope. 2-1 automatic kickdown shift is available. Engine braking
effect is available. -
Use on a long and gentle slope. 3-2 and 2-1 automatic kickdown shift is available.
Engine braking effect is available. -
Use on a long and gentle slope. 4-3, 4-2 and 4-1 automatic kickdown shift is available. -
5-4 and 5-3 automatic kickdown shift is available. -
6-5 and 6-4 automatic kickdown shift is available. -
Kickdown Function
If you need to accelerate rapidly, depress the accelerator pedal completely to the floor.
Then, a one- or two-lever gear will automatically be engaged. This is called the Kickdown
function.

01-16
4. LIMP HOME MODE
In case of transmission malfunction ▶
If a serious fault occurs in the automatic transmission, the TCU enters the limp home
mode to secure safe driving and protect the automatic transmission.
As power is no longer supplied to the solenoid, the current basic function (P, R, N, D) is
maintained and the 4th gear can be maintained only by the operation of the hydraulic
system without electrical operation.
The ECU communicates with other electric modules with CAN. If a serious fault occurs, the
transmission automatically enters the limp home mode for service.
The TCU monitors all factors which can affect to the performance of the transmission and
diagnose the system according to OBD II regulation. 1.
2.
3.
4.
In case of overheated transmission ▶
The TCU enters the limp home mode when the batter voltage drops below 8 V.
If the transmission is overheated, the shift pattern is changed to the hot mode to cool the
transmission more efficiently.
While the transmission is overheated, the selector lever symbol and engine temperature
warning lamp on the instrument cluster blink until the transmission is cooled down to the
normal operation temperature. If the transmission is excessively overheated, the gear
cannot be shifted but remains in the neutral position. 1.
2.
3.
Towing the vehicle with A/T ▶
The best way to transport the vehicle is to load it to a truck and transport it, especially if the
vehicle is 4WD.
If towing the vehicle with the propeller shaft connected, the transmission or oil pump of
transfer case may malfunction, resulting in internal damage due to poor lubrication. -