Page 1289 of 2053
5A-194 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
8. Install the 3 - 4 shift valve and retaining pin.
9. Install the Clutch Apply Regulator (CAR) valve,
springs, plunger and retaining pin.
10. Install the solenoid supply valve, spring and
retaining plate.
Notice: This aluminum valve is easily damaged.
11. Install solenoid 6 plunger, spring and retaining
pin.
12. Position the third feed ball (large nylon) in the valve
body and install the solenoid 6 filter.
13. Check the separator plate for burrs and damage.
Repair or replace the separator plate as
necessary.
14. Check the upper and lower valve body gaskets
for damage. Replace the gaskets as necessary.
15. Install the lower valve body gasket on the lower
valve body.
KAA5A1S0
KAA5A1T0
KAA5A1U0
KAA5A850
Page 1290 of 2053
AUTOMATIC TRANSMISSION 5A-195
SSANGYONG MY2002
19. Holding the separator plate to the upper valve
body to prevent the check balls from falling out,
install the upper valve body on the lower valve
body. Install all screws finger tight then tighten
the screws to specification in the prescribed
sequence.
Installation Notice
The wiring loom ground wire eyelet terminal is
secured beneath the solenoid 1 retainer. 16. Install the reverse lockout valve, spring, plug and
retaining plate. Ensure that the valve is correctly
oriented.
17. Position the five nylon ball checks in the upper
valve body.
18. Fit the upper valve body gasket. Install the
separator plate over the upper valve body.
KAA5A830 KAA5A840 KAA5A1V0
Tightening Torque11 - 16 Nm
(8 - 12 lb-ft)
20. Install solenoids 1, 2, 3, 4 and 6. Ensure the
solenoid is firmly secured by the retainer and that
the screw is tightened to specification.
Installation Notice
8 - 12 Nm
(71 - 106 lb-in)
Page 1291 of 2053
5A-196 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
21. Install solenoid 5. Ensure that the solenoid is
pushed firmly into the valve body by the retainer
and that the screw is tightened to specification.
Installation Notice
22. Install the detent spring assembly (spring, support
plate and screw), ensuring that the screw is tight-
ened to specification. Check the spring for wear
or damage.
Installation Notice
23. Install the manual shift valve.
Notice: Be aware that the manual valve will fall out
of the valve body.
24. Align the valve body assembly on the
transmission case and install the manual valve
lever to manual valve link. Fit the long end of the
link to the manual valve first. Install the securing
bolts and tighten to specification in the specified
sequence.
Installation Notice
KAA5A1Y0 KAA5A1X0
KAA5A1Z0 KAA5A1W0
Tightening Torque8 - 12 Nm
(71 - 106 lb-in)
Tightening Torque20 - 22 Nm
(15 - 16 lb-ft)
Tightening Torque8 - 13 Nm
(71 - 115 lb-in)
Page 1292 of 2053

AUTOMATIC TRANSMISSION 5A-197
SSANGYONG MY2002
2. Carefully assemble the oil filter to the valve body.
The spigot must not lean on one side while being
fitted.
3. Secure the oil filter assembly with the retainer.
4. Check that the magnet is located in the dimple in
the corner of the oil pan.
5. Assemble the gasket on the pan lip. The gasket
must be free of any distortion when installed. 25. Check the alignment of the detent roller and the
manual lever quadrant.
26. Connect the solenoid wiring as detailed below:
Solenoid 1 - red
Solenoid 2 - bIue
Solenoid 3 - yellow
Solenoid 4 - orange
Solenoid 5 - green
Solenoid 6 - violet
Notice: All hardware must be correctly installed and
torqued to specification.
Oil Filter and Pan Assembly
Notice:
Replace the filter whenever rebuilding a
transmission where a significant amount of
mechanical damage has occurred.
To aid the assembly of the pan gasket, use a small
amount of Vaseline at the pan/gasket interface. This
ensures that the gasket remains on the pan ridge.
Do not over torque pan bolts as this may distort
the pan and cause leaks.
Ensure that the internal line pressure plus in the
valve body is fitted.
1. Lubricate the oil filter sealing ring with automatic
transmission fluid.
KAA5A2B0 KAA5A2A0
KAA5A510
Page 1293 of 2053

5A-198 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Torque Converter and Housing Assembly
1. Locate the torque converter housing on the trans-
mission main case.
2. Apply additional Loctite 202 or equivalent as
required to the converter housing to case bolts.
Install and tighten bolts to specification.
Installation Notice
All the hardware must be correctly installed and
torqued to specification.
3. Fit the converter ensuring that the tangs are
engaged in the pump gear. Ensure that the tangs
do not contact the pump seal.
Output Flange Assembly (2WD Mode)
1. Position the transmission detent lever into the park
position and lock the output shaft.
2. Clear the threads on the output shaft and apply
Loctite 243 or equivalent as required to threads.
3. Install the flange, ‘O’ ring and torque the nut to
specification.
Installation Notice
6. Fit the oil pan assembly to the transmission case
and tighten the securing bolts to specification and
sequence. Do not over torque.
Installation Notice
KAA5A2C0
KAA5A2D0
KAA5A040
Tightening Torque4 - 6 Nm
(35 - 53 lb-in)
Tightening Torque54 - 68 Nm
(40 - 50 lb-ft)
Tightening Torque 35 Nm (26 lb-ft)
Page 1294 of 2053

AUTOMATIC TRANSMISSION 5A-199
SSANGYONG MY2002
1. Measure the projection of the front servo push rod
from the transmission case dimension ‘A’.
a. Apply air at 650/700 kPa to the front servo apply
area (B1 outer)
b. Measure the travel of the push rod and subtract
3 mm to find the shim size required.
c. Release the air.
Notice: A minimum of one shim is required at all times
- minimum shim size is 1 mm. The thickness of
available shims are listed in the table below.
FRONT AND REAR BAND ADJUSTMENT
Front Band Setting Procedure
2. Fit the selected shim(s) to the shank of the anchor
strut as follows:
a. Inspect the shim(s) for damage, wear or corro-
sion. Replace as necessary.
b . The shim(s) are to be installed between the case
abutment face and the anchor strut flange.
c. The shim(s) are to be fitted by hand and under
no circumstances to be hammered or forced.
d. Shim(s) are to be pressed on by hand until an
audible click is heard. The click indicates that
the shim is clipped home correctly.
3. Re-check that the push rod travel. (3 mm ± 0.25
mm)
KAA5A2E0
Thickness (mm)Part Number
0.95/1.050574-037017
1.15/1.250574-037018
1.44/1.560574-037019
1.73/1.870574-037020
1.93/2.070574-037021
2.12/2.280574-037022
2.42/2.580574-037023
2.61/2.790574-037024
Page 1295 of 2053

5A-200 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
1. Measure distance‘A’ from the rear servo piston to
the inner face of the transmission case using vernier
calipers.
a. Apply air at 650/700 kPa to the rear servo apply
area (B2 outer)
b. Measure the travel of the piston, subtract 3.75
mm and divide the remainder by 2.5 to find shim
size.
c. Release the air.
Notice: A minimum of one shim is required at all times
- minimum shim size is 1 mm. The thickness of
available shims are listed in the table below.
Rear Band Setting Procedure
2. Fit the selected shim(s) to the shank of the anchor
strut as follows.
a. Inspect the shim(s) for damage, wear or
corrosion and replace as necessary. The shim(s)
are to be installed between the case abutment
face and the anchor strut flange.
b. The shim(s) are to be fitted by hand and under
no circumstances to be hammered or forced
c. The shim(s) are to be pressed on by hand until
an audible click is heard. The click indicates
that the shim is clipped home correctly.
3. Re-check that the piston travel.
(3.75 mm ± 0.625 mm)
KAA5A2F0
Thickness (mm)Part Number
0.0.95/1.050574-037017
1.15/1.25 0574-037018
1.44/1.56 0574-037019
1.73/1.87 0574-037020
1.93/2.07 0574-037021
2.12/2.28 0574-037022
2.42/2.58 0574-037023
2.61/2.79 0574-037024
Page 1296 of 2053
AUTOMATIC TRANSMISSION 5A-201
SSANGYONG MY2002
KAA5A2G0