1998 SSANGYONG MUSSO torque

5A-80 AUTOMATIC TRANSMISSION
6. Switch off the engine and raise the vehicle on the hoist, if applicable, ensuring that the vehicle is level.
7. Three minutes after the engine has stopped, but no longer than one hour, remove the filler pump, The correct
level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATF to the correct level.
8. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle.
9. Tighten the transmission filler plug to specification.
Checking, Adding Fluid and Filling - Drained or Dry Transmission
To set the correct fluid level proceed as follows.
1. Set the transmission selector to Park and switch the engine off.
2. Raise the vehicle on a hoist (or leave over a service pit).
3. Clean all dirt from around the service fill plug prior to removing the plug, Remove the oil service fill plug. Clean the
fill plug and check that there is no damage to the ‘O’ ring. Install the filler pump into the filler hole.
4. Lower the vehicle with the filler pump still connected and partially fill the transmission. This typically requires
approximately :
a. If the transmission torque converter is empty:
9.0 litres - 4WD
9.0 litres - RWD
b. If the transmission torque converter is full:
4.5 litres - 4WD
4.5 litres - RWD
5. Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.
6. Then add an additional 0.5 litres of ATF.
7. Switch off the engine and raise the vehicle on the hoist. Remove the filler pump and replace the filler plug. The
plug shall be tightened to specification.
8. The vehicle is then to be driven between 3.5 and 4.5 kilometers at light throttle so that the engine does not
exceed 2500 rpm. This should result in the transmission temperature being in the range 50 to 60°C.
9. With the engine idling, cycle the transmission selector through all gear positions with the brake applied.
10. Stop the engine. Raise the vehicle on the hoist, if applicable ensuring the vehicle is level.
11. Three minutes after the engine has stopped, but no longer than one hour, remove the filler plug. The correct
level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATP to the correct level.
12. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle. Tighten the
transmission Filler plug to specification.
ELECTRONIC ADJUSTMENTS
Idle Speed Adjustment
Carry out the adjustments to the idle speed as detailed in the workshop manual.
Throttle Position Calibration
Should the throttle position data stored in the TCU be lost or be out of specification, as indicated by a diagnostic
trouble message, it may be re-established by the following procedure.
lCheck that the hot engine idle speed is within specification.
lAllow the engine to idle in ‘Drive’ for 60 seconds with the air conditioner (if fitted) turned off. The closed throttle
reference point in the TCU has now been set.
Switch the engine off but leave the ignition on. Hold the accelerator pedal on the floor for 60 seconds. The wide open
throttle reference point in the TCU has now been set.

5A-82 AUTOMATIC TRANSMISSION
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Tightening Torque 70 - 80 Nm
5. Remove the rear propeller shaft .
Installation Notice
REMOVAL & INSTALLATION OF
TRANSMISSION
1. Disconnect the negative battery cable.
2. Disconnect the connectors from transfer case.
3. Disconnect the speedometer connector from transfer
case.
4. Disconnect the inhibitor and Sear position sensor
connector.
6. Unscrew the eight bolts and two nuts, and remove the
cross member.

AUTOMATIC TRANSMISSION 5A-83
Tightening Torque 70 - 80 Nm
11. Remove the two pipes for oil cooler.
Installation Notice
Tightening Torque24.5 - 34.3 Nm
12. Remove the service hall cover on torque converter.
13. Put the alignment mark for installation, and unscrew the
six mounting bolts for torque converter from drive plate
through the service hole (arrow) by rotating the engine
and remove the torque converter.
Installation Notice
Tightening Torque 42 Nm
7. Remove the rear propeller shaft.
Installation Notice
8. Unscrew the five bolts and remove the transfer case.
9. Disconnect the 10-Pins Plug connector from transmission.
10. Separate the locking clip on shift lever and remove the
shift rod.
Notice
Removal and installation performed when the shift
procedure should be lever is in “D” range.
Screw the six bolts mounting the torque converter through
the service hole by using a mirror and rotating the engine.

5A-84 AUTOMATIC TRANSMISSION
Tightening Torque 55 - 65 Nm
14. Remover the starter.
15. Unscrew the eight transmission housing bolts and remove
the transmission assembly.
Installation Notice
Be careful not to drop the torque converter while removing
the transmission.
16. Installation should follow the removal procedure in the
reverse order.

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.

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.

5A-100 AUTOMATIC TRANSMISSION
Planet Carrier Assembly and Centre Support
To assemble the planet carrier assembly and centre support,
proceed as follows.
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 the tolerance stated in
section 9.2.
2. Install the one way clutch (OWC) retainer to the planet
carrier with the inner edge pointing downwards. Inspect
the OWC race and the sprag assembly for wear or damage.
Replace if necessary.
3. Install the outer race in the drum. Press the race to the
bottom of the drum and install the retaining circlip. Ensure
the circlip is firmly seated in its groove.
Refer to figure 8.21.
4. Install the OWC into the outer race with the lip edge
uppermost. Lubricate the sprags with automatic
transmission fluid. Refer to figure 8.20.
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-clockwise direction only.
Refer to figure 8.21.
Figure 8.20 - Planet Carrier Assembly and
Centre Support
6. Lubricate the No.9 needle thrust bearing and the thrust
washer with petroleum jelly and fit them to the rear face of
the planet carrier. Refer to figure 8.19.
7. Install the planet assembly and the centre support into the
case, and align the centre support mounting bolt holes.
8. Install the centre support bolts finger tight.
9. Install the circlip retainer ensuring that the circlip is
completely seated in the groove of the case.
10. Remove the centre support bolts and apply Loctite 222 or
equivalent to the threads. Install the bolts and torque to
specifications.

AUTOMATIC TRANSMISSION 5A-101
Extension Housing Assembly
To assemble the extension housing assembly, proceed as
follows.
1. Check the condition of the extension housing roller bearing.
Replace if necessary (RWD models). Install the new bearing
from rear of extension housing. Press on the branded face
of bearing only.
2. Install a new seal to the extension housing or adaptor
housing. Refer to figure 8.21.
Notice
Do not use petroleum jelly to hold the gasket in position.
3. Position a new gasket onto the extension housing or adaptor
housing.
Notice
See section 8.3.17 for the procedure to assemble the output
flange assembly - RWD models.
4. Install the extension housing (RWD) or adaptor housing
(4WD) and torque the bolts to specification.
Front Servo Assembly
NOTICE
Ensure that the front servo snap ring is installed correctly.
Orient the circlip with the gap at the bottom, near the pan rail.
Refer to figure 8.22.
To assemble the front servo assembly (refer to figure 8.22),
proceed as follows.
1. Lubricate the cover ‘O’ ring with automatic transmission fluid
and fit to the cover.
2. Lubricate the piston ‘O’ rings with automatic transmission
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.
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.
Figure 8.21 - Extension Housing
Figure 8.22 - Front Servo and Band