Page 1265 of 2053

5A-170 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
7. Lift the separator plate and gaskets from the upper
valve body.
8. Remove the five nylon check balls exposed in the
valve body.
9. Remove the retaining plate, plug, spring and re-
verse lockout valve.
10. Remove the filter (1.3) and the large nylon check
ball (2) from the lower valve body.
11. Remove the retaining plates and pins from the 1 -
2, 2 - 3, 3 - 4, BAR and CAR valves. The pins can
be removed with a magnet.
Notice: Once the pins are removed, the plates are
loose in the valve body and will drop out when the
valve body is turned over.
12. Remove the 1 - 2, 2 - 3 and 3 - 4 shift valves.
13. Depress the 4 - 3 sequence valve plug and
remove the retaining plate.
Notice: The plug is preloaded by the spring and
may unexpectedly fall out of the valve body.
14. Remove the plug, spring and valve
15. Depress the solenoid 5 valve. Remove the
retaining in and remove the valve, damper guide
and spring.
Notice: The valve is preloaded by the spring and
may unexpectedly fall out of the valve body.
16. Depress the line pressure release valve, remove
the retaining pin, disc (if fitted), spring and valve.
17. Drive out the retaining pin and remove the spring
and ball check valve adjacent to the BAR valve.
KAA5A840
KAA5A850
KAA5A860
KAA5A870
Page 1266 of 2053

AUTOMATIC TRANSMISSION 5A-171
SSANGYONG MY2002
ASSEMBLY PROCEDURE
Transmission
Tools Required
0555-336256Transmission Bench Cradle
0555-336258 C r o s s Shaft Pin Remover/Installer
(Detent Lever)
0555-336262Cross Shaft Seal Installer
0555-336263Cross Shaft bullet
0555-336265 C r o s s Shaft Pin Remover/Installer
(Inhibitor Switch)
Notice:
The transmission is assembled in modular fashion
and details of assembly for each module are given
under the appropriate subject.
Technicians overhauling these transmissions will
also require a selection of good quality Torx bit
sockets, in particular numbers 30, 40 and 50, and
an 8 mm, 10 mm and 12 mm double hex socket.
Ensure that the B1R circlip is fitted to the case. (If
this is not fitted, the valve will peen its way into
and through the separator plate)
Ensure that the ’E’clip is fitted to the cross shaft.
Ensure that all aspects of the parking mechanism
are working.
3. Assemble the B1R valve and spring, and secure
with the circlip. Ensure that the circlip is completely
seated in its groove. 1. Turn the transmission case upside down on the
bench and mount it to the transmission bench cradle
0555-336256.
2. Install all fittings, plugs and the breather, applying
a sealant where applicable, Tighten the fittings to
specifications. Ensurethatthebreatheris clear,
andcheckthat the lube fitting in the rear of the case
is fittedand clear of obstruction.
KAA5A500
KAA5A880
Page 1267 of 2053

5A-172 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
4. Install the rear servo lever and pivot pin.
Notice: The lever must pivot freely on its pin.
5. Assemble the park rod lever, complete with the
return spring and pivot pin, applying a small
amount of sealant to the outer end of the pivot
pin.
Notice: Care must be taken when applying sealant
to ensure that it is not applied between the pin and
the lever.
6. Secure the pivot pin with the circlip.
Notice: The lever must pivot freely on its pin and
the spring must return the park rod lever to its correct
location.
7. Install the parking pawl pivot pin and spring.
Notice: The pawl must pivot freely on its pin.
8. Connect the park rod to the manual valve detent
lever. Ensure the spring and cam collar is firmly
installed on the rod.
9. Check that the cam collar slides freely on the rod.
10. Insert the cross shaft into the case, from the side
opposite to the inhibitor switch, then install the
antirattle spring on the shaft.
KAA5A890
KAA5A640
KAA5A900
KAA5A910
Page 1268 of 2053

AUTOMATIC TRANSMISSION 5A-173
SSANGYONG MY2002
11. Poition the manual valve detent lever, aligning it
with the cross-shaft bore in the case.
12. Push the shaft through the detent lever until it
starts in the detent lever side of the case.
16. Install the new cross shaft seals using cross shaft
seal installer 0555-336262 (1) and cross shaft
bullet 0555-336263 (2).
17. Install the inhibitor switch on the case. Torque the
bolts as per specifications. Press the pin into the
shaft until the tool bottoms using cross shaft pin
installer/ remover (inhibitor switch) 0555-336265.
Installation Notice
18. Thoroughly check the terminal wiring loom for
condition and continuity. 13. Install the detent lever drive pin in the shaft using
cross shaft pin remover/installer (detent lever)
0555-336258 with the adaptor over the pin.
14. Press the pin into the shaft until the tool bottoms.
15. Remove the tool and fit the spring retaining circlip
to the shaft.
KAA5A920
KAA5A600
KAA5A930
KAA5A580
Tightening Torque4 - 6 Nm
(35 - 53 lb-in)
Page 1269 of 2053

5A-174 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
19. Position the wiring loom and locate the solenoid 7
contact and terminal in the pump mounting flange
at the front of the case. The solenoid 7 wire is
routed under the park rod and cross shaft in the
case.
20. Install the 10 pin connector in the case engaging
the tangs on the connector in the notches in case.
Output Shaft and Gear Assembly
1. Check that the output shaft bush is not worn or
damaged. Replace if necessary.
2. Check for damage to parking pawl teeth on the
ring gear. Replace if necessary.
3. Check that the sealing ring grooves have not been
damaged.
4. Lubricate the sealing rings with automatic
transmission fluid.
5. Assemble the sealing rings to the output shaft
with the scarf cut uppermost.
6. If previously dismantled, assemble the ring gear
to the output shaft and secure with circlip. Ensure
that the circlip is firmly seated in its groove.
7. Install the No. 10 needle bearing assembly onto
the output shaft using petroleum jelly.
8. Carefully install the output shaft assembly in the
case to prevent damage to the sealing rings.
KAA5A940
KAA5A610
KAA5A970
KAA5A980
Page 1270 of 2053

AUTOMATIC TRANSMISSION 5A-175
SSANGYONG MY2002
Rear Band Assembly
1. Check the rear band for any cracks or damage
along the lining and metal backing.
2. Install the reaction anchor strut into the main case,
without shims.
3. Carefully install the rear band into the transmission
case and ensure that it is properly fitted in the
case.
Notice: If fitting a new band, soak the new band in
automatic transmission fluid for a minimum of five
minutes prior to assembly.
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.
Installation Notice
Rear Servo Assembly
1. Check the servo piston ‘O’ rings and gasket for
any damage.
2. Lubricate the servo piston ‘O’ rings with
automatic transmission fluid, and fit the ‘O’ rings
to the piston grooves.
3. Assemble the piston to the cover, ensuring that
‘O’ ring compression is adequate but not
excessive.
4. Align the spring on the piston spigot, then position
the rear servo rod into the spigot.
5. Assemble the gasket to the cover and fit the
assembly to the case.
Notice: Do not use petroleum jelly on the gasket.
6. Apply additional Loctite 202 or equivalent as
required to the rear servo to case bolts. Install
the bolts and tighten to specification.
Installation Notice
KAA5A950
KAA5A960
KAA5A630
KAA5A990
Tightening Torque30 - 35 Nm
(22 - 26 lb-ft)
Tightening Torque16 - 22 Nm
(12 - 16 lb-ft)
Page 1271 of 2053

5A-176 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Planet Carrier Assembly and Centre Support
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
0.10 mm - 0.50 mm.
2. Install the One Way Clutch (OWC) retainer (1) to
the planet carrier with the inner edge pointing down-
wards. Inspect the OWC race and the sprag
assemblies for wear or damage. Replace if
necessary.
3. Install the outer (3) race in the drum. Press the
race to the bottom of the drum and install the
retaining circlip (2). Ensure the circlip is firmly
seated in its groove.
4. Install the OWC (1) into the outer race with the lip
edge uppermost. Lubricate the sprags with auto-
matic transmission fluid.
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-clock-wise direction only.
6. Lubricate the No. 9 needle bearing and washer
with petroleum jelly and fit them to the rear face
of the planet carrier.
7. In s t a l l th e
KAA5A0A0
KAA5A760
KAA5A750
KAA5A560
Tightening Torque20 - 27 Nm
(15 - 20 lb-ft)
Page 1272 of 2053

AUTOMATIC TRANSMISSION 5A-177
SSANGYONG MY2002
Adaptor Housing Assembly
1. Install a new seal to the adaptor housing.
2. Position a new gasket onto the adaptor housing.
Notice: Do not use petroleum jelly to hold the gasket
in position.
3. Apply additional Loctite 202 or equivalent as required
to the adapter housing bolts. Install the adaptor
housing and torque the bolts to specification.
Installation Notice
Front Servo Assembly
1. Lubricate the cover ‘O’ ring with automatic
transmission fluid and fit to the cover.
2. Lubricatethepiston‘O’ rings with automatic trans-
mission 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.
KAA5A0C0
KAA5A520 KAA5A0B0
Tightening Torque30 - 35 Nm
(22 - 26 lb-ft)
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.
Notice: Ensure that the front servo snap ring is
installed correctly. Orient the circlip with the gap at
the bottom, near the pan rail.
KAA5A0D0