manual transmission SSANGYONG NEW ACTYON SPORTS 2013 Service Manual

14-72412-02
1. OVERVIEW
The low emission vehicle is being sold increasingly in the market as a countermeasure for complying
with the environment regulations such as a special act on Seoul metropolitan air quality improvement
and for reducing the PM (Particulate Material) from the diesel-powered vehicle. For the CDPF system,
the DOC (two-way catalytic converter or catalytic combustion system) fitted to the conventional diesel
engine has the high purification rate for HC or CO but not have a high reduction rate for the PM. For this
reason, a necessity has been raised in order to consider a countermeasure to reduce the PM since the
existing DOC can't meet the regulation, which is getting tighter.
This results in a development of the CDPF (Catalyst & Diesel Particulate Filter) that is combination of the
existing DOC (Diesel Oxydation Catalyst) and DPF (Diesel Particulate Filter). While the DOC converts
the CO and HC into the CO2 and H2O - unharmful to human body - using a oxidation reaction, the DPF
collects the PF (Particulate Material) for regeneration of it. However, each of these devices can only
reduce a part of the exhaust gas. This evoked the necessity of the CDPF with both features. The DOC
capacity is more on the manual transmission than the automatic transmission.
DPF(Diesel Particulate Filter) ▶DOC(Diesel Oxidation Catalyst) ▶
It is called as a oxidation catalyst, which purifies CO and HC in exhaust gas. The three-way catalyst is
used for the gasoline vehicle. But, the diesel engine oxidates CO and HC excepting NOx into H2O and
CO2 in order to purify the exhaust gas since the exhaust gas has a rich oxygen at all times.
It consists of mainly the aluminum and titanium and there is a porous thin film, which emits the exhaust
gas but does not emit the PM in it. It emits the exhaust gas generated during combustion and filters the
PM which is a byproduct of combustion to burn it when a certain amount of it is collected in the filter.
When a certain amount of the PM builds up, exposure to high exhaust gas causes carbon, the
fundamental ingredient in PM, to burn and release into the atmosphere in form of CO2.

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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.

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1. OVERVIEW AND CHARACTERISTICS OF MANUAL
TRANSMISSION
1) System Components
Inside
Front View
(1) Features
All gears use the helical type and high strength materials. 1.
The helical type gear prevents the axial gear missing and provides less noise. -
The semi-remote control type gear shift mechanism is used to prevent incorrect shifting.
To improve the shifting performance, 3-piece triple cone is used for 1/2 shift. 2.
3.
The synchronizing devices are installed in 1/2, 3/4, 5/R gears. To prevent the double engagement,
the independent interlock devices are installed. 4.TSM54/52 transmission uses the inertia lock type key to make smooth gear engagement and to
provide silent gear engagement. -
The clutch release system is available to use CSC (Concentric Slave Cylinder) or Fork type according
to the vehicle model. 5.

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2. SPECIFICATIONS AND TIGHTENING TORQUE OF
MANUAL TRANSMISSION
1) Specifications

03-6
Inside N Switch
1. MANUAL TRANSMISSION SYSTEM
1) Neutral Switch
Outside N Switch
N (Neutral) Switch
0.5 mm
0.5 mm

03-8
Variant Coding Options
(2) Detects the position of the shifting lever for the HDC operation
among ABS functions.
The HDC function operates only if the M/T shift lever is in forward or reverse position. Please refer to the
ABS section for the specific information related to the HDC.
Variant Coding Related to N Switch ▶
The N switch transmits information to the ECU through the CAN communication while New Rexton is
connected to the ECU through wires. Thus, if you set the variant coding in the engine ECU, you must do
it differently, and you must set the variant coding differently according to the vehicle category and
specification as below.
Neutral Signal Input None / Wire / CANWire /
Actyon & Kyron models with
manual transmission
New Rexton model with manual
transmission Manufactured after
04.09.15
BODY IN: after 154600
Automatic transmission & Rodius
model with automatic transmission
before 2006

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Operation ▶
Description Mode Conditions
Driving
mode2H 2 Wheel drive
(rear wheel)Rear-wheel drive mode. This is used under
normal or high-speed driving conditions on
public roads or highways.
4H 4 Wheel drive
(high speed)This is used under sandy, muddy or snow-
covered road conditions
4L 4 Wheel drive
(low speed)This is used for maximum traction.
When cornering with low speed in 4WD
condition, there could be tire dragging, some
mechanical shocks and resistances in
vehicle’s drive train. These are normal
conditions due to internal resistance in the drive
train when the 4WD system is properly working
Mode change2H←4H2 Wheel drive
↔4 Wheel driveShifting is possible while driving at the speed of
70 km/h or less
2H,
4H↔4L2 Wheel drive,
4 Wheel drive (high
speed)
↔4 Wheel drive
(low speed)For Automatic Transmission:
For Manual Transmission:
Stop the vehicle on level ground and
move the gear selector lever into the
“N” position. Turn the switch to the
desired position. ·
Stop the vehicle on level ground and
move the gear selector lever into the
“N” position. Then turn the switch to
the desired position while depressing the
clutch pedal. ·
To make the mode change easily, stop the
vehicle on level ground and turn the mode
switch to the desired position and move the
shift lever to "N"-"R"-"N" while depressing
the brake pedal.

09-10
This section describes the noise phenomena occurred possibly in the brake system operation.
Distinguish between the information given below and the actual problems and then, inspect the vehicle
and take appropriate measures.
Noise symptoms and Causes -
Symptom 1. If depressing the brake pedal when the engine is cold, "screeching" sound always
occurs and, after driving for a while, the sound disappears..
This usually occurs in the morning. When the temperature goes down, the dew condensation
phenomenon sets moisture on the brake disc as the window frost forms. Due to this moisture, the iron
within the brake disc and pad oxidizes, forming undetectable micro-rusts on the disc surface. When
starting the engine under this condition, noise may sound due to the friction of micro-rusts. When
operating the brake several times, the disc temperature goes up and the micro-rusts come off and the
noise goes away. Depending on the driving conditions, noise gets louder when slightly depressing the
brake pedal and oppositely, noise is smaller when deeply depressing the brake pedal. This is simply a
physical phenomenon, called "morning effect" in professional terms, and does not imply any problems
with the brake system.
Symptom 2. Slip or screech after the brake pad replacement.
This usually occurs when the bed-in is not made between the disc and the pad's friction material. The
bed-in is a state that the brake system normally works and gives no noise out, when, after about 300 km
city driving, the contact area of the pad friction material is enlarged and the disk is in complete contact
with the pad's friction material. Therefore, for some time after the brake disk/pad replacement, the brake
system poorly operates or noise (abnormal sound) occurs due to the partial contact.
Symptom 3. "Groaning" sound occurs in the automatic transmission vehicle when slightly taking the foot
off the brake pedal to slowly start after waiting for the signal, or slightly depressing the brake pedal.
This is the noise "Creep groan" that occurs when, in both the automatic and manual transmission,
slightly releasing the brake pedal in the neutral gear at downhill roads.
It frequently occurs at the low braking power and low speed, through the following process. When
operating the brake system at low speed and low pressure, adhesion and slip repeatedly take place
between the brake disk and the friction material, and this makes the braking power inconstant, instantly
increasing or decreasing, and gives out the brake noise.
It is also a physical phenomenon and has no relation with the brake performance.BRAKE OPERATION AND NOISE ▶

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5. A/C INPUT/OUTPUT DIAGRAM
Below diagram shows the input/output mapping between the components of FATC A/C and A/C
controller briefly.
▶ A/C compressor control by engine ECU
In case of current vehicle models, the system turns ON or OFF the compressor switch according to the
refrigerant pressure, ambient temperature and condenser temperature to protect the A/C circuits.
However, for the vehicles equipped with DI engine, the engine ECU turns off the A/C compressor unde
r
below conditions, including those above.
Coolant temperature: 20℃ or less
Coolant temperature: 115℃ or more
For approx. 4 sec. after starting the engine
Engine speed: 650 rpm or less
Engine speed: 4,500 rpm or more
During abrupt acceleration for the vehicle equipped with manual transmission 1.
2.
3.
4.
5.
6.