1998 SSANGYONG MUSSO automatic transmission

AUTOMATIC TRANSMISSION 5A-127
Torque Converter and Housing Assembly
To assemble the torque converter and housing assembly,
proceed as follows.
1. Locate the torque converter housing on the transmission
main case.
2. Install and tighten the securing bolts to specification.
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.
Figure 8.1 - Torque Specifications
Torque Specifications
Torque converter housing to case
Extension housing to case
Rear servo cover
Pan to case
Inhibitor switch to case
Cooler connectors
Transmission filler plug
Output flange lock nut (RWD models)
Centre support to case
Cam plate to case (parking pawl)
Valve body to case
Upper valve body to lower valve body
ON/OFF solenoid retainers
Variable pressure solenoid retainer
Line pressure plug
Detent spring
Pump cover to case
Pump cover plate to pump cover
Pump to pump adaptor
Pump cover plate to crescent
Adaptor to caseNlm
54 - 68
54 - 68
25 - 35
4 - 6
2.3 - 3.4
30 - 35
30 - 35
100 - 110
20 - 27
16 - 22
8 - 13
11 - 16
8 - 12
8 - 12
4 - 7
20 - 22
24 - 34
13 - 16
24 - 27
13 - 16
25 - 35

5A-128 AUTOMATIC TRANSMISSION
FRONT AND REAR BAND ADJUSTMENT
Front Band Setting Procedure
To set the front band, proceed as follows.
1. Measure the projection of the front servo push rod from the transmission case. Refer to figure 8.66, dimension A.
a. Apply air at 650/700 kPa to the front servo apply area (B1 outer). (Refer to figure 8.67.)
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 thicknesses of available shims
are listed in table 8.2.
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. Replace as necessary.
b. The shim(s) are to be installed between the case abutment face and the anchor strut flange. Refer to figure
8.66.
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 is 3 mm ± 0.25 mm.
Figure 8.66 - Front Band Settings

AUTOMATIC TRANSMISSION 5A-129
Figure 8.68 - Rear Band Settings
Rear Band Setting Procedure
To set the rear band, proceed as follows.
1. Measure distance ‘A’ from the rear servo piston to the inner face of the transmission case using vernier calipers.
Refer to figure 8.68.
a. Apply air at 650/700 kPa to the rear servo apply area (B2 outer). Refer to figure 8.67.
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 table 8.2.
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. Refer to figure 8.68.
c. The shim(s) are to be fitted by hand and under no circumstances to be hammered or forced.
d. The shim(5) 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 is 3.75 mm ± 0.625 mm.

5A-130 AUTOMATIC TRANSMISSION
Table 8.2 - Thickness of Available Shims
Thickness
0.95/1.05
1.15/1.25
1.44/1.56
1.73/1.87Part Number
0574-037017
0574-037018
0574-037019
0574-037020Thickness
1.93/2.07
2.12/2.28
2.42/2.58
2.61/2.79Part Number
0574-037021
0574-037022
0574-037023
0574-037024
Figure 8.68 - Thickness of Available Shims

TRANSFER CASE (TOD) 5D2-5
Definitions
Rear Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in
response to a rotating 30 tooth wheel coupled to the rear propshaft inside the
Transfer Case. Each rotation of the rear propshaft will result in 30 speed sensor
pulse.
Front Speed SensorA Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in
response to a rotating 30 tooth wheel coupled to the front propshaft inside the
Transfer Case. Each rotation of the front propshaft will result in 30 speed sensor
pulse.
EMC An Electromagnetic clutch used to control the amount of torque applied to the
front propshaft.
TOD
TMTorque on DemandTM.
Duty Cycle Duty Cycle is the time the EMC is on divided by the period in which it is being
modulated.
Touch-off A minimum amount of duty cycle applied to the EMC.
Front OverrunA condition where the front propshaft is turning at a rate which is faster than the
rear propshaft.
Rear Overrun A condition where the rear propshaft is turning at a rate which is faster than the
front propshaft.
High RangeThe highest (numerically lowest = 1 :1) gear ratio between the input and outputs
of the Transfer Case.
Low RangeThe lowest (numerically highest = 2.48:1) gear ratio between the input and outputs
of the Transfer Case.
4H/4L Switch A switch which selects the desired gear ratio.
Shift Motor Electric motor which changes the Transfer Case range.
Position Encoder A set of 4 Gray code switches which provide feedback to the TCCU indicating the
position of the Shift Motor.
Clutch Interlock Switch A switch on vehicles equipped with a manual transmission which indicates that
the clutch pedal is depressed.
Neutral Safety Switch A switch on vehicles equipped with an automatic transmission which indicates
that the transmission is in neutral.
Shift Inhibit Speed The vehicle speed above which Transfer Case shifts are disallowed. Vehicle speed
is indicated by propshaft speed measurement.

TRANSFER CASE (TOD) 5D2-19
Classification
Engine Type
Transmission/Vehicle Type
Axle Ratio
Tire Size
Coding Required
1. Replacement of TOD control unit.
2. Adjustment by input error.
3. Change of tire specification.
Items
Gasoline Engine (E32)
661 Diesel Engine
661LA Diesel Turbo Engine
662 Diesel Engine
662LA Diesel Turbo Engine
Manual Transmission
Automatic Transmission
MUSSO
KORANDO
3.73
4.55
4.89
5.38
5.86
P215
P235
P255
P275
Coding Method
1. Check and record engine type, axle ratio and tire size.
2. Ignition “OFF”.
3. Connect SCANNER with diagnosis connector in engine
room.
4. Ignition “ON”.
5. Read the current memorized specification in TOD control
unit.
6. Compare memorized specification with the checked record.
If not matched, perform a coding.
7. Read again memorized coding specification in TOD control
unit for confirmation of coding.
8. Check coding specification whether it matches with vehicle
or not. If not, perform a coding again.
Coding items

TRANSFER CASE (TOD) 5D2-47
Assembly Procedure
Assembly
Before assembly, lubricate all parts with Automatic Transmission
Fluid or equivalent.
1. If removed, drive the bearing into the front output case bore.
Drive the bearing in staight, making sure it is not cocked in
the bore. Install the internal snap ring that retains the bearing
to the front case.
2. If removed, install the front yoke to flange seal in the front
case bore.
3. If removed, install the yoke to flange seal into the mounting
adapter bore.
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Thrust Washer
8 Bearing
9 External Snap Ring
10 Internal Snap Ring
4. If the input shaft needle bearing and bushing were removed,
install a new bearing and bushing as detailed in the following
steps:
Press a new needle bearing, then a new bushing in the
input shaft as follows:
a. Position the input shaft on Axle Bearing/Seal Plate or
equivalent, and Pinion Bearing Cone Replacer as a
spacer.
b. Press a new needle bearing into the end of the input
shaft until it seats in the input shaft.
c. Press in a new bushing.
5. The recessed face of the sun gear and the snap ring groove
on the bearing outer race should be toward the rear of the
transfer case. The stepped face of the thrust washer should
face toward the bearing.
Slide the sun gear, thrust plate and thrust washer into
position on the input shaft. Press the bearing over the input
shaft. Install the external snap ring to the input shaft.

5D2-48 TRANSFER CASE (TOD)
6. Install the front planet to the sun gear and input shaft.
Install the internal snap ring to the planetary carrier.
7. Place the tanged snap ring in the case. Expand snap ring
with snap ring pliers and install planetary carrier assembly.
Check installation by holding the case and carefully tapping
the face of the input shaft against a wooden block to make
sure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket sealant on the surface of the front case.
9. Install the high-low shift fork and high-low collar as an
assembly into the front planet.
Notice
Make sure that the nylon wear pads are installed on the
shift fork and snapped securely into place.
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Body
10. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
lDo not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump
rotates freely.
lDo not remove the plastic insert from the bore of the
new pump. Discard it after it slides out during pump
installation to the rear output shaft.
lWhile turning the output shaft, prime the pump through
the oil filter pickup tube or housing inlet hole with clean
Automatic Transmission Fluid or equivalent.
11. Inspect the outside surfaces and bore of the oil pump. If
there is no discoloration in the pump housing, gear or cover,
and the pump bore and the lube holes of the output shaft
show evidence of oil, the pump is working.