1997 SSANGYONG KORANDO Service Repair Manual

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Page 1129 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual AUTOMATIC TRANSMISSION 5A-35
SSANGYONG MY2002
Power Flow - Drive 4 (Overdrive)
In Drive 4 (Overdrive), transmission drive is via the
input shaft to the forward clutch cylinder.
The elements of the t

AUTOMATIC TRANSMISSION 5A-35
SSANGYONG MY2002
Power Flow - Drive 4 (Overdrive)
In Drive 4 (Overdrive), transmission drive is via the
input shaft to the forward clutch cylinder.
The elements of the transmission function as follows;
The C1 clutch is applied to drive the planet carrier
clockwise.
The B1 band is applied to hold the reverse sun gear
stationary.
As the planet carrier tuns, the long pinion walks
around the stationary reverse sun gear and rotates
around its axis driving the internal ring gear and
output shaft in a clockwise or forward direction at a
speed faster than the input shaft i.e. in overdrive
ratio.
The forward sun gear is also driven faster than the
input shaft and overruns the 3-4 OWC.
The C2 clutch is engaged to reduce the speed differ-
ential across the 3-4 OWC.
Control
To maintain this arrangement in the steady state sole-
noids and valves are activated as follows;
Solenoid S1 is switched ON. S2 is switched OFF.
With S1 switched ON, the 3-4 shift valve is held in
the fourth gear position by line 500 pressure on the
small end of the valve.
With S2 switched OFF, the 2-3 shift valve is held in
the fourth gear position by line 500 pressure on the
large end of the valve.
The 1-2 shift valve is held in the fourth gear position
by S2 oil pressure.
2nd oil (line pressure) from the 1-2 shift valve is di-
rected to the band apply feed regulator valve, and
to the 2-3 shift valve.
The band apply feed regulator valve supplies 2nd
oil (regulated to line pressure multiplied by the valve
ra-tio) to the Band Apply Feed (BAF) circuit.
Band apply feed oil is directed to;
- the outer apply area of the front servo
- the inner apply area of the front servo piston via
the 3-4 shift valve
- the 1-2 shift valve to provide an exhaust port
when the transmission is shifted to first gear
2nd oil at the 2-3 shift valve is directed to the 3rd
oil circuit.
3rd oil from the 2-3 shift valve is directed to the
clutch apply regulator valve, and to the 4-3
sequence valve.
The clutch apply regulator valve supplies oil (regu-
lated to line 500 pressure multiplied by the valve
ratio) to the Clutch Apply Feed (CAF) circuit.
The CAF oil is directed to;
- the C1 clutch
- the 4-3 sequence valve
Drive oil (line pressure) from the manual valve en-
gages the C2 clutch.
Gear State
Drive 4 Overdrive
C1
XC2
XC3
-C4
-B1
XB2
-1-2
OWC
-3-4
OWC
-LU
CLUTCH
- ELEMENTS ENGAGED
KAA5A460

Page 1130 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual 5A-36 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
DRIVE 4 LOCK UP
KAA5A47A

Page 1131 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual AUTOMATIC TRANSMISSION 5A-37
SSANGYONG MY2002
Power Flow - Drive 4 Lock Up
In Drive 4 Lock Up, transmission drive is the same as
for Drive 4 but with the application of the converter
lock up clutch

Page 1132 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual 5A-38 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
DIAGNOSIS
BASIC KNOWLEDGE REQUIRED
You must be familliar with some basic electronics to
use this section of the Service Manual. They will help
you to fo

5A-38 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
DIAGNOSIS
BASIC KNOWLEDGE REQUIRED
You must be familliar with some basic electronics to
use this section of the Service Manual. They will help
you to follow diagnostic procedures.
Notice: Lack of the basic knowledge of this transmis-
sion when performing diagnostic procedures could re-
sult in incorrect diagnostic performance or damage to
transmission components. Do not, under any circum-
stances, attempt to diagnose a transmission problem
without this basic knowledge.
Notice: If a wire is probed with a sharp instrument
and not properly sealed afterward, the wire will corrode
and an open circuit will result.
Diagnostic test probes are now available that allow
you to probe individual wires without leaving the wire
open to the environment. These probe devices are
inexpensive and easy to install, and they permanently
seal the wire from corrosion.
Special Tools
You should be able to use a Digital Volt Meter (DVM),
a circuit tester, jumper wires or leads and a line
pressure gauge set. The functional check procedure
is designed to verify the correct operation of electronic
components in the transmission. This will eliminate the
unnecessary removal of transmission components.
FUNCTIONAL CHECK
PROCEDURE
Begin with the Functional Check Procedure which pro-
vides a general outline of how to diagnose automatic
transmission. The following functional check procedure
will indicate the proper path of diagnosing the transmis-
sion by describing the basic checks and then referenc-
ing the locations of the specific checks.
Check the fluid level according to the Fluid Level
Service Procedure.
Check the transmission fluid leak.
Check if the transmission fluid is not burnt by smell.
Notice: The specific fluid used in this transmission
turns brown during normal operation. Brown fluid
does not indicate a transmission fault.
Ensure that the transmission is not in Limp Home
Mode (LHM).
Check the battery terminals and the earth connec-
tions for corrosion or looseness.
Check that the cooler flow is not restricted.
Check all electrical plug connections for tightness.
Use on-board diagnostic tool or a scan tool to see
if any transmission trouble codes have been set.
DIAGNOSTIC INFORMATION AND PROCEDURES
Refer to the appropriate “Diagnostic Trouble Code
(DTC)” information and repair the vehicle as
directed. After repairing the vehicle, perform the
road test and verify that the code has not set again.
Perform the Electrical/Garage Shift Tests.
Perform the Road Test Procedure in this section.
Inspect the oil and check for metal or other contami-
nants in the oil pan.
TRANSMISSION FLUID LEVEL
SERVICE PROCEDURE
This procedure is to be used when checking a concern
with the fluid level in a vehicle. A low fluid level will
result in slipping and loss of drive/ reverse or delay on
engagement of drive/ reverse when the vehicle is cold.
The vehicle is first checked for transmission diagnostic
messages on the scan tool. If the oil level is low, it is
possible to register a vehicle speed signal fault.
The vehicle is to be test driven to determine if there is
an abnormal delay when selecting drive or reverse, or
loss of drive. One symptom of low fluid level is a
momentary loss of drive when driving the vehicle around
a corner. Also when the transmission fluid level is low,
a loss of drive may occur when the transmission fluid
temperature is low.
If there is no loss of drive when the vehicle is driven
warm and a vehicle speed signal fault is registered,
then fluid should be added to the transmission.
When adding or changing transmission fluid use only
Castrol TQ 95 automatic transmission fluid. The use of
incorrect fluid will cause the performance and durability
of the transmission to be severely degraded.
Fluid Level Diagnosis procedure
1. If the vehicle is at operating temperature allow the
vehicle to cool down for two hours, but no greater
than four hours. Or if the vehicle is at cool status,
start the engine and allow the engine to idle for
approximately 5 minutes or, if possible, drive the
vehicle for a few kilometers. This will allow the
transmission to be within the correct temperature
range. Transmission fluid level should be checked
at temperature 50 - 60 °C (82 - 140 °F).
Caution: Removal of the fluid filler plug when
the transmission fluid is hot may cause injury if
fluid drains from the filler hole.
2. With the brake pedal pressed, move the gear shift
control lever through the gear ranges, pausing a
few seconds in each range. Return the gear shift
control lever to P (Park). Turn the engine OFF.
3. Park the vehicle on a hoist, inspection pit or similar
raised level surface. The vehicle must be control
level to obtain a correct fluid level measurement.

Page 1133 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual AUTOMATIC TRANSMISSION 5A-39
SSANGYONG MY2002
4. Place a fluid container below the fluid filler plug.
5. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the fil

AUTOMATIC TRANSMISSION 5A-39
SSANGYONG MY2002
4. Place a fluid container below the fluid filler plug.
5. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug
and check that there is no damage to the ‘O’ ring.
If fluid drains through the filler hole the transmis-
sion may have been overfilled. When the fluid
stops draining the fluid level is correct. Install
the fluid filler plug and tighten it to 33 Nm (24
lb-ft).
If fluid does not drain through the filler hole, the
transmission fluid level may be low. Install the
filler pump into the filler hole. Lower the vehicle
with the filler pump still connected and partially
fill the fluid through the filler hole.
Start the vehicle in P (Park) with the parking
brake and the brake applied. With the engine
idling, move the gear shift. control lever through
the gear ranges, pausing a few seconds in each
range and adding the fluid until gear application
is felt.
Return the gear shift lever to P (Park).
Turn the engine OFF and raise the vehicle. When
the three minutes passed after the engine
stopped, remove the filler pump.
Check if the fluid level is aligned with the bottom
of the filler hole. If not, add a small quantity of
fluid to the correct level. Install the fluid filler
plug and tighten it to 33 Nm (24 lb-ft).
If fluid does not drain through the filler hole al-
though adding a total of 1.5 liters, the transmission
should be inspected for fluid leaks and any leaks
should be fixed before setting the transmission
fluid level.
6. When the fluid level checking procedure is com-
pleted, wipe any fluid around the filler plug with a
rag or shop towel.
Fluid Level Set After Service
1. Depending on the service procedure performed,
add the following amounts of fluid through the filler
plug hole prior to adjusting the fluid level:
Converter empty 8.0 liters (8.5 quarts)
Converter full 3.8 liters (4.0 quarts)
2. Follow steps 1 through 4 of the Fluid Level Diagnosis
Procedure.
3. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug
and check that there is no damage to the ‘O’ ring.
4. Lower the vehicle with the filler pump still connected
and start the vehicle in P (Park) with the parking
brake and the brake applied. With the engine idling,
move the gear shift control lever through the gear
ranges, pausing a few seconds in each range and
adding the fluid until gear application is felt.Then add an additional 0.5 litres of fluid. Return
the gear shift lever to P (Park). Turn the engine OFF
and raise the vehicle. Install the fluid filler plug and
tighten it to 33 Nm (24 lb-ft).
5. Drive the vehicle at 3.5 to 4.5 kilometers with light
throttle so that the engine does not exceed 2500
rpm.
This should result in the transmission temperature
being in the range 50 - 60 °C (82 - 140 °F). With the
brake applied, move the shift lever through the gear
ranges, pausing a few seconds in each range at
the engine idling.
6. Return the gear shift lever to P (Park).
Turn the en-gine OFF and raise the vehicle on the
hoist, if applicable, ensuring the vehicle is level.
When the three minutes passed after the engine
stopped, remove the filler plug.
Check if the fluid level is aligned with the bottom of
the filler hole. If not, add a small quantity of fluid to
the correct level. Install the fluid filler plug and
tighten it to 33 Nm (24 lb-ft).
7. Wipe any fluid around the filler plug with a rag or
shop towel.
FLUID LEAK DIAGNOSIS AND
REPAIR
The cause of most external leaks can generally be lo-
cated and repaired with the transmission in the vehicle.
Methods for Locating Leaks
General Method
1. Verify that the leak is transmission fluid.
2. Thoroughly clean the suspected leak area.
3. Drive the vehicle for approximately 25 km (15 miles)
or until the transmission reaches normal operating
temperature (88 °C, 190 °F).
4. Park the vehicle over clean paper or cardboard.
5. Turn the engine OFF and look for fluid spots on the
paper.
6. Make the necessary repairs to correct the leak.
Powder Method
1. Thoroughly clean the suspected leak area.
2. Apply an aerosol type powder (foot powder) to the
suspected leak area.
3. Drive the vehicle for approximately 25 km (15 miles)
or until the transmission reaches normal operating
temperature (88 °C, 190 °F).
4. Turn the engine OFF.
5. Inspect the suspected leak area and trace the leak
path through the powder to find the source of the
leak.
6. Make the necessary repairs.

Page 1134 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual 5A-40 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Dye and Black Light Method
1. Add dye to the transmission through the transmission
fluid filler plug. Follow the manufacturer’s recommen-
dation for t

5A-40 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Dye and Black Light Method
1. Add dye to the transmission through the transmission
fluid filler plug. Follow the manufacturer’s recommen-
dation for the amount of dye to be used.
2. Use the black light to find the fluid leak.
3. Make the necessary repairs.
Repairing the Fluid Leak
Once the leak point is found the source of the leak
must be determined. The following list describes the
potential causes for the leak:
Fasteners are not torqued to specification.
Fastener threads and fastener holes are dirty or
corroded.
Gaskets, seals or sleeves are misaligned, damaged
or worn.
Damaged, warped or scratched seal bore or gasket
surface.
Loose or worn bearing causing excess seal or sleeve
wear.
Case or component porosity.
Fluid level is too high.
Plugged vent or damaged vent tube.
Water or coolant in fluid.
Fluid drain back holes plugged.
ELECTRICAL / GARAGE SHIFT
TEST
This preliminary test should be performed before a hoist
or road test to make sure electronic control inputs are
connected and operating. If the inputs are not checked
before operating the transmission, a simple electrical
condition could be misdiagnosed as a major
transmission condition.
A scan tool provides valuable information and must
be used on the automatic transmission for accurate
diagnosis.
1. Move gear shift control lever to P (Park) and set
the parking brake.
2. Connect scan tool to Data Link Connector (DLC)
terminal.
3. Start engine.
4. Turn the scan tool ON.
5. Verify that the appropriate signals are present.
These signals may include:
ENGINE SPEED
VEHICLE SPEED
THROTTLE POSITION
ACCEL. PEDAL POSITION
TRANSMISSION GEAR STATE
GEAR SHIFT LEVER POSITION
TRANSMISSION FLUID TEMPERATURE
CLOSED THROTTLE POSITION LEARN
OPEN THROTTLE POSITION LEARNT
CLOSED ACCEL. PEDAL POSITION LEARNT
OPEN ACCEL. PEDAL POSITION LEARNT
A/C COMPRESSOR STATUS
KICKDOWN SWITCH STATUS
4WD STATUS
MODE SWITCH
THROTTLE POSITION VOLTAGE
GEAR SHIFT LEVER POSITION VOLTAGE
TRANS. FLUID TEMPERATURE VOLTAGE
A/C SWITCH
KICKDOWN SWITCH VOLTAGE
4WD LAMP LOW VOLTAGE
4WD LAMP HIGH VOLTAGE
MODE SWITCH VOLTAGE
BATTERY VOLTAGE
6. Monitor the A/C COMPRESSOR STATUS signal
while pushing the A/C switch.
The A/C COMPRESSOR STATUS should come
ON when the A/C switch is pressed, and turn
OFF when the A/C switch is repushed.
7. Monitor the GEAR SHIFT LEVER POSITION signal
and move the gear shift control lever through all
the ranges.
Verify that the GEAR SHIFT LEVER POSITION
value matches the gear range indicated on the
instrument panel or console.
Gear selections should be immediate and not
harsh.
8. Move gear shift control lever to neutral and monitor
the THROTTLE POSITION signal while increasing
and decreasing engine speed with the accelerator
pedal.
THROTTLE POSITION should increase with en-
gine speed.
ROAD TEST PROCEDURE
Perform the road test using a scan tool.
This test should be performed when traffic and road
conditions permit.
Observe all traffic regulations.
ELECTRONIC ADJUSTMENTS
Idle Speed Adjustments
Carry out the adjustments to the idle speed as detailed
in the workshop manual.
Vehicle Coding
The vehicle coding is integrated as part of the
diagnostic software. A scan tool has the function to
code the ve-hicle through the K-line.

Page 1135 of 2053

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SSANGYONG KORANDO 1997 Service Repair Manual AUTOMATIC TRANSMISSION 5A-41
SSANGYONG MY2002
SYMPTOM DIAGNOSIS
DRIVE FAULTS
Condition
No Drive in DPossible Causes
Insufficient auto transmission
fluid.
Blocked feed in C1/C2 cylinder.
‘Z’ l

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