1997 SSANGYONG KORANDO clearance automatic

5A-178 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
4. Install the front band into the transmission case,
ensuring that it is properly seated in place.
Notice: If fitting a new band, soak the band in
automatic transmission fluid for a minimum of 5
minutes prior to assembly.
5. Position the reaction strut in its retaining clip and
engage it with the band and anchor strut.
6. Position the apply strut in its retaining clip and
engage it with the band and the servo piston rod.
C2/C4 Clutch Assembly
Tools Required
0555-336259Clutch Spring Compressor
0555-336260Clutch Pack Clearance Kit
Notice:
Check pistons for cracks.
Do not mix the clutch piston return springs.
Ensure that the snap rings are fitted correctly.
1. Check the feed orifices in the cylinder bore are clear
of obstructions.
2. Check the C2 piston bleed orifices are clear of
obstructions.
3. Lubricate the ‘O’ rings with Automatic Transmission
Fluid (ATF)
4. Fit the small ‘O’ ring onto the inner groove, and
the large ‘O’ ring onto the outer groove of the
piston.
Notice: ‘O’ rings must not be twisted in the grooves.
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KAA5A550
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Front Band Assembly
1. Install the reaction anchor strut to the case.
2. Check the band for all cracks or damage along its
lining and metal backing.
3. Position the strut retainers on the band.

AUTOMATIC TRANSMISSION 5A-181
SSANGYONG MY2002
21. Holding the cylinder horizontal, install the sleeve
and clutch plate assembly into the cylinder, with
the crest of one wave of the washer in line with
one of the holes in the outside of the cylinder,
until the sleeve contacts the C2 wave washer.
22. Check the C4 clutch pack clearance using 0555-
336260 clutch pack clearance kit.
Notice: With the C2 wave spring compressed, and
the clutch Pack supporting a 2 kg weight, the
dimension from the underside of the C2 pressure plate
to the selective steel is to be between 1.4 - 1.8 mm. If
the clutch is to be gauged from the top of the pressure
plate, then the dimension is to be the actual thickness
of the pressure plate plus 1.4 - 1.8 mm.
23. Use selective plates to achieve the correct
specification. If new friction plates are being fitted,
remove the clutch pack and soak the friction plates
in ATF for a minimum of 5 minutes prior to reassembly.
Notice: The clutch pack clearance must be taken
before the elements are soaked in ATF.
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24. Reassemble the sleeve and clutch pack into the
cylinder. Observe the alignment of the wave
washer to the hole in the cylinder.
25. Install the C2 clutch plates in the cylinder in the
following sequence:
Friction disc
Steel plate
Friction disc
Steel plate
Steel plate (0574-000013, `014, `015, `016,
`019, `022), or Friction disc (0574-000012 & `017)
Steel plate (selective)
Friction disc
Steel plate (selective)
Friction disc
KAA5A0L0

5A-182 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
26. Check the clutch pack clearance using only the
weight from 0555-336260 clutch pack clearance
kit.
Notice: With the clutch pack supporting a 2
kgweight, the dimension from the C3 clutch hub
locating step to the friction plate is to be between
0.80 - 1.05 mm.
27. Use selective plates to achieve the correct
specifica-tion. If new friction plates are being
fitted, remove the clutch pack and soak the friction
plates in ATF for a minimum of 5 minutes prior to
reassembly.
Notice: The clutch pack clearance must be taken
before the elements are soaked in ATF.
28. Lubricate and fit the 3-4 OWC and end caps to
the C2 hub.
32. Apply petroleum jelly to the No. 5 needle bearing
and fit it to the C4 hub.
33. Remove the C2 clutch plates from the clutch cylin-
der.
34. Fit the thrust plate over the cylinder inner hub.
35. Engage the C2/C4 clutch hub assembly in the C4
clutch plates.
36. Install the C2 clutch plates.
37. Install the C3 hub and secure it with the circlip,
ensuring that the circlip is firmly seated in its
groove. 29. Align the tangs and fit the nylon thrust washer
onto the C4 hub.
30. Align and fit the C4 hub to the C2 clutch and the
OWC assembly.
31. Check the rotation of the C2 hub. While holding
the C4 hub, the C2 hub should rotate in the
clockwise direction and lockup in the anti-
clockwise direction when viewed from the C2 hub.
KAA5A0M0
KAA5A0N0
KAA5A0O0

AUTOMATIC TRANSMISSION 5A-183
SSANGYONG MY2002
C3 Clutch and Reverse Sun Gear Assembly
Tools Required
0555-336259Clutch Spring Compressor
0555-336260Clutch Pack Clearance Kit
1. Check the orifices in the cylinder are clear of ob-
structions.
2. Check the C3 cylinder bush outside diameter and
the centre support inside diameter are in good
condition and not damaged. Coat the sealing rings
with automatic transmission fluid and fit into the
C3 cylinder grooves.
3. Check the reverse sun gear splines, grooves and
thrust face for condition. Coat the ‘O’ ring with
automatic transmission fluid and fit it to the groove
of the reverse sun gear.
4. Lubricate the C3 washer with petroleum jelly and
fit to the inner face of the reverse sun gear.
5. Install the reverse sun gear in the C3 cylinder,
ensuring that the ‘O’ ring compression is
adequate but not excessive.
Notice: ‘O’ rings must not be twisted in the
grooves.
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6. Coat the C3 piston ‘O’ rings with automatic trans-
mission fluid and fit the small ‘O’ ring onto the
inner ring and the large ‘O’ ring onto the outer
ring of the C3 piston.
7. Check that the bleed orifices of the piston are
clean and clear of obstructions.
8. Install the C3 piston in the cylinder until the
outside diameter of the piston enters the inside
diameter of the cylinder.
Notice: Take care not to cut the ‘O’ ring.
9. Assemble the spring and spring retainer on the
piston. Using 0555-336259 clutch spring
compressor compress the spring sufficiently to
enable the installation of the retaining circlip,
ensuring that the circlip is firmly seated in the
groove, and remove the tool.
10. Fit the C3 wave plate to the C3 piston face,
ensuring that one crest of the wave plate of the
C3 piston face is aligned over one of the piston
orifices.
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KAA5A730

5A-184 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
11. Assemble the clutch plates and discs into the
cylinder in the following sequence :
Steel plate
Friction disc
Steel plate
Steel plate (0574-000013, `014, `015, `016, `019,
`022), or Friction disc (0574-000012, `017)
Steel plate (selective)
Friction disc
Steel plate (selective)
Friction disc
12. Align and fit the pressure plate with the
counterbore facing away from the clutch plates.
13. Install the circlip.
14. Check the C3 clutch clearance using 0555-336260
clutch pack clearance kit in the following manner
(weight only).
a. Place the weight on the pressure plate and
measure the distance from the end of the
cylinder to the top of the pressure plate.
b. Record this figure.
c. Remove the weight.
d. Lift the pressure plate up against the circlip
and measure the distance from the end of the
cylinder to the top of the pressure plate.
e. Record this figure.
f. Subtract the second reading from the first read-
ing to obtain the clutch pack clearance.KAA5A0R0
KAA5A0S0

AUTOMATIC TRANSMISSION 5A-185
SSANGYONG MY2002
Notice: With the clutch pack supporting a weight
of 2kg, the clearance between the snap ring and
the top of the pressure plate is to be between 1.07
- 1.45 mm.
15. If new friction plates are being fitted, remove the
clutch pack and soak the friction elements in auto-
matic transmission fluid for a minimum of five min-
utes prior to reassembly.
Notice: The clutch pack clearance must be taken
before the elements are soaked in automatic
transmission fluid.
Forward Sun Gear and C3 Clutch Pack
Assembly
1. Fit the No. 7 needle bearing assembly over the
for-ward sun gear, ensuring that the thrust washer
is between the bearing and the sun gear.
2. Lubricate the lipped thrust plate with petroleum
jelly and fit the thrust plate onto the reverse sun
gear.
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3. Align and fit the C3 clutch assembly over the for-
ward sun gear.
4. Lubricate the No. 6 needle bearing with petroleum
jelly and fit it to the thrust plate. Ensure the lugs
on the outside diameter of the bearing fit in the
thrust plate counterbore.
5. Align and fit the plastic thrust washer to the thrust
plate with petroleum jelly.
6. Install the assembly over the forward sun gear
shaft against the No. 6 needle bearing.
7. Place the assembly to one side.
KAA5A0W0KAA5A0V0

5A-186 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
KAA5A0X0
C1 Clutch Overdrive Shaft and Input Shaft
Assembly
Tools Required
0555-336260Clutch Pack Clearance Kit
Notice:
Ensure that the snap rings are fitted correctly.
Check pistons for cracks, especially the C1 piston.
Do not mix clutch piston return springs.
If the C1/C2 clutch packs separate from the C3
clutch pack, make sure the No. 6 bearing doesn’t
drop out of the bearing retainer.
1. Check the overdrive shaft grooves for any defect.
2. Coat the sealing rings, large and small, with petro-
leum jelly and fit them to the overdrive shaft. The
sealing rings may be held in place with a small
amount of petroleum jelly.
3. Assemble the clutch plate and disc into the cylinder
in the following sequence:
Steel plate
Friction disc
Steel plate
Friction disc
Steel plate
Steel plate ( 0574-000013, `014, `015, `016, `019,
`022), or friction disc (0574-000012 & `017)
Steel plate (selective)
Friction disc
Steel plate (selective)
Friction disc
4. Check the clutch pack clearance using 0555-
336260 clutch pack clearance kit.
5. Use selective plates to achieve the correct
specification.
Notice: With the clutch pack supporting a 2 kg
weight, the dimension from the input shaft locating
stop to the friction disc must be 0.70 - 0.90 mm.
6. If new friction plates are being fitted, remove the
clutch pack and soak the friction elements in auto-
matic transmission fluid for a minimum of five
minutes prior to assembly.
Notice: The clutch pack clearance must be taken
before elements are soaked in automatic
transmission fluid.
KAA5A0X0
KAA5A0Y0
KAA5A0Z0

5A-188 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Pump Cover and Converter Support
Notice:
Do not wash the nose of solenoids in solvent.
Ensure that the correct ‘O’ ring is fitted for the
application.
Be careful not to damage the needle bearings on
the assembly. Avoid any axial impact loads during
assembly.
Check the transmission end float. This will help to
detect any missing parts or incorrect assembly.
1. Check the pump body for any damage, chips or
irregularity. Check that the bush is firmly staked
in the drive gear.
2. Install the seal flush with the front face of the
pump body.
3. Lubricate the pump bush, and the drive and driven
gears, with automatic transmission fluid.
4. Install the pump driven gear and the pump drive
gear into the pump body.
5. Using a straight edge and thickness gauge, check
that the clearance between pump face and gears
is 0.04 - 0.018 mm.
6. Lubricate the pump body ‘O’ ring with automatic
transmission fluid and fit it to the pump body. Put
the pump body to one side.
7. Ensure that the pump cover cavities, ports and
holes are clean and free of any obstruction.
8. Lubricate all loose parts with automatic
transmission fluid prior to assembly.
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KAA5A810
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