1998 SSANGYONG MUSSO transmission

AUTOMATIC TRANSMISSION 5A-91
C3 Clutch Cylinder
To remove the C3 clutch cylinder, proceed as follows:
1. Remove the forward sun gear and thrust bearing from the
C3 clutch cylinder.
2. Remove the nylon thrust bearing, bearing support, needle
thrust bearing and thrust block from the clutch cylinder hub.
3. Mount the clutch assembly on tool No.0555-331899 and
compress the piston return spring.
Remove the circlip and release the spring.
Notice
Make sure that the spring keeper has not been caught in
the circlip groove, and that all spring pressure has been
released, before removing the tool.
4. Remove the tool, circlip, keeper and spring.
5. Remove the sealing rings from the C3 clutch cylinder.
6. Remove the clutch plate retaining circlip and remove the
clutch plates.
7. To remove the clutch piston from the clutch cylinder, apply
air pressure to the port between the iron sealing rings on
the bearing journals of the cylinder.
8. Remove the reverse sun gear from the cylinder.

5A-92 AUTOMATIC TRANSMISSION
Planet Carrier and Centre Support
To remove the planet carrier and centre support, proceed as
follows.
1. Separate the planet carrier and centre support from the
output shaft. Remove the thrust bearings from the output
shaft and the planet carrier.
2. Separate the centre support from the planet carrier by
rotating it anti-clockwise.
3. Lift the one way clutch from the planet carrier.
4. Remove the circlip retaining the one way clutch outer race
in the planet carrier and remove the race.
5. Remove the one way clutch retainer from the planet carrier.
Pump
Note that the following valves are housed in the pump cover:
lSolenoid 7
lC1 bias valve
lConverter clutch control valve
lConverter clutch regulator valve
lPrimary regulator valve
To remove the pump, proceed as follows.
1. Remove the wiring loom retainer plate and remove
solenoid 7 with a T30 Torx bit.
2. Remove the five washer head bolts from the cover plate
using a multi-point 8 mm socket.
3. Remove the five Torx head screws from the cover plate
(Torx bit No. 30). Note that the odd screw holds the pump
body to the pump body cover.
Notice
Do not strike the converter support tube to loosen the
pump body.
4. Separate the pump body from the pump cover.
5. Lift the cover plate from the cover.
6. Remove the two ball check valves and one spring from
the pump cover.
Notice
Some of the valves and plugs are preloaded by springs
and may unexpectedly fall out of the cover when the pins
are removed.
7. Depress the plug inward and remove the retaining pin for
each of the four valves.
8. Remove the four valves, plugs and springs.
9. Remove the pump gears from the pump body.
10. Remove the lip seal from the front of the pump body.

AUTOMATIC TRANSMISSION 5A-93
Valve Body
To disassemble the valve body, proceed as follows.
1. Remove the detent spring and retainer plate using a T40 Torx bit.
Notice
Be aware that the manual valve will fall out of the valve body.
2. Take note of the angular relationship of the solenoid terminals
to the valve body, then slide the manual valve out of the lower
valve body.
3. Remove the solenoid and valve assembly as follows:
lsolenoid 1
lsolenoid 2
lsolenoid 3
lsolenoid 4
lsolenoid 5
lsolenoid 6
4. Place the valve body assembly on the bench with the upper
body uppermost.
5. Remove the 24 clamping screws with a No. 30 Ton bit. Separate
the upper and lower valve bodies by lifting the upper body and
the separator plate together.
6. Upper body over and place it on the bench with the separator
plate uppermost.
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 retainer plate, plug, spring and reverse lockout
valve.
10. Remove the two filters (and the large nylon check ball) from the
lower valve body.
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.
11. Remove the keeper plates and pins from the 1-2,2-3,3-4, BAR
and CAR valves. The pins can be removed with a magnet.
12. Remove the 1-2,2-3 and 3-4 shift valves.
Notice
The plug is preloaded by the spring and may unexpectedly fall
out of the valve body.
13. Depress the 4-3 sequence valve plug and remove the keeper
plate.
14. Remove the plug, valve and spring.
15. Depress the solenoid 5 valve. Remove the keeper pin and
remove the valve 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 keeper
pin, disc (if fitted), spring and valve.
17. Drive out the roll pin and remove the spring and ball check valve
adjacent to the BAR valve.

5A-94 AUTOMATIC TRANSMISSION
ASSEMBLY PROCEDURE
The transmission is assembled in modular fashion and details
of assembly for each module are given under the appropriate
subject. Refer to table 8.1 (at the end of Section 8.3) for the
torque specifications to be applied, and to table 9.10 in section
9.6 for details of all special tools required, when performing
assembly procedures. 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.
Transmission
Notice
1. 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.)
2. Ensure that the ‘E’ clip is fitted to the cross shaft.
3. Ensure that all aspects of the parking mechanism are
working.
To assemble the transmission, proceed as follows:
1. Turn the transmission case upside down on the bench and
mount it to the transmission cradle No.0555-331895.
2. Install all fittings, plugs and the breather, applying a sealant
where applicable, Tighten the fittings to specifications.
Ensure that the breather is clear, and check that the lube
fitting in the rear of the case is fitted and clear of obstruction.
3. Assemble the B1R valve and spring, and secure with the
irclip. Refer to Ensure that the circlip is completely seated
in its groove.
4. Install the rear servo lever and pivot pin.
Notice
The lever must pivot freely on its pin.

AUTOMATIC TRANSMISSION 5A-95
Notice
Care must be taken when applying sealant to ensure that it is
not applied between the pin and the lever.
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
That the lever must pivot freely on its pin and the spring
must return the park rod lever to its correct location.
6. Secure the pivot pin with the circlip.
Notice
The pawl must pivot freely on its pin.
7. Install the parking pawl pivot pin and spring.
8. Connect the park rod to the manual valve detent lever.
Ensure the spring and cam collar is firmly installed on the
rod.

5A-96 AUTOMATIC TRANSMISSION
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 anti-rattle spring on
the shaft.
11. Position 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.
13. Install the detent lever drive pin in the shaft using tool No.
0555-331897 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.
16. Install the new cross shaft seals using tool No. 0555-
331894.
17. Install the inhibitor switch on the case. Torque the screws
as per specifications. Press the pin into the shaft until the
tool bottoms (4WD models) using tool No.0555-332942.
18. Thoroughly check the terminal wiring loom for condition
and continuity.
19. Position the 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.

AUTOMATIC TRANSMISSION 5A-97
20. Install the ten pin connector in the case engaging the tangs
on the connector in the notches in case.
4WD MODELS ONLY
21. Route the portion of the wiring loom coming out of the
case down between the inhibitor switch and the case.
Position the ten pin plug on the wiring loom bracket .

5A-98 AUTOMATIC TRANSMISSION
Rear Band Assembly
To assemble the rear band assembly proceed as follows:
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.
Notice
If fitting a new band, soak the new band in automatic
transmission fluid (or a minimum of five minutes prior to
assembly.
3. Carefully install the rear band into the transmission case
and ensure that it is properly fitted in the case.
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.
Figure 8.19 - Thrust Bearing and Washer LocationsFigure 8.18 - Rear Servo and Band