1998 SSANGYONG MUSSO manual transmission

5A-70 AUTOMATIC TRANSMISSION
Action
Inspect S1. Repair or replace as necessary.
Check for 12 Volts applied to S1 at all times or
for wiring fault.
Inspect S1. Repair or replace as necessary.
Check for 12 Volts applied to S1 at all times or
for wiring fault.
Inspect S2. Repair or replace as necessary.
Check for open circuit or wiring fault.
Inspect S2. Repair or replace as necessary.
Check for open circuit or wiring fault.
Inspect and adjust as necessary.
Inspect and repair as necessary.
Inspect and replace or refit as necessary.
Inspect ‘O’ ring. Refit or replace as necessary.
Inspect the 2-3 shift valve. Repair or replace
as necessary.
Inspect C1 clutch. Repair or replace as neces-
sary.
Inspect ball. Refit or replace as necessary.
Inspect C4. Repair C4 or replace C4 wave plate
as necessary.
Inspect rear band adjustment. Adjust as nec-
essary.
Inspect ball- Refit or replace as necessary.
Inspect’0’ring. Refit or replace as necessary.
Inspect C4 and C4 wave plate. Repair or re-
place as necessary.
Inspect inhibitor switch.
Repair or replace as necessary.
Inspect the 1-2 shift valve.
Repair or replace as necessary
Inspect inhibitor switch.
Repair or replace as necessary.
Inspect the 2-3 shift valve.
Repair or replace as necessary. Possible Cause
S1 always OFF.
S1 always ON.
S2 always OFF.
S2 always ON.
B1 failed.
Loose band adjustment.
Front servo piston or seal failed.
S1/S2 ball misplaced,
Smaller’0’ring on front servo piston failed
or missing.
2-3 shift valve jammed.
C1 clutch failed or slipping in 3rd and 4th.
(Gives 1st in 3rd and 2nd in 4th.)
Over-run clutch (OC)/low ball misplaced.
C4 failed or C4 wave plate broken.
Rear band slipping when hot.
Reverse/Low-1st ball misplaced.
Rear servo inner ‘O’ ring missing.
C4 failed or C4 wave plate broken.
Inhibitor switch faulty.
1-2 shift valve jammed.
Inhibitor switch fault, 1-2 only.
2-3 shift valve jammed.Symptom
2-3 shift only
(no 4th or 1st)
1-4 shift only
1-3-4 (Delayed
1-2shift)
4-3 shift only
1-2-Neutral
(1st over run)
1-3 shift only
1-3-4 only
1-2-1 only
No manual 4-3,3-2
or 2-1
No manual 1st
1st gear only or
2nd,3rd, and 4th
only
1st and 2nd only
or 1st, 3rd and 4th
only

5A-72 AUTOMATIC TRANSMISSION
Action
Drain and fill with specified ATF.
Check that S5 is fitted correctly, or replace S5.
Inspect band apply and clutch apply regulator
springs. Refit or replace as necessary.
Inspect the ball. Refit or replace as necessary.
Inspect C4 clutch. Replace or repair as neces-
sary.
Check the alignment. ]Realign as necessary.
Inspect wave plate. Replace as necessary.
Inspect S5 and replace as necessary.
Inspect the damper spring and replace as nec-
essary.
Replace spring as necessary.
Check the clearance and adjust as necessary.
Inspect C4. Repair or replace as necessary.
Inspect piston. Repair or replace as necessary.
Inspect and adjust band as necessary.
Replace the plug.
Replace the spring.
Replace the spring/plug.
Refit the ball.
Inspect the clutch. Repair the clutch as neces-
sary.
Inspect and clean C1 feed.
Replace the piston.
Inspect and replace the sealing rings and/or
shaft as necessary.
Inspect and replace the ball.
Inspect and replace the sealing rings and/or
shaft as necessary.
Inspect and repair the C1 clutch as necessary.
Refit the valve.
Replace the ball. Possible Cause
Incorrect auto transmission fluid (ATF).
S5 faulty won, or incorrectly fitted.
Band apply and clutch apply regulator
springs misplaced.
Over-run clutch (OC)/Low-1st ball
misplaced.
C4 clutch worn or burnt.
C4 wave plate not lined up with the holes
in the piston.
C4 wave plate failed.
S5 worn.
S5 damper spring broken.
Front servo belleville spring broken.
Incorrect C4 pack clearance.
Damaged C4 clutch.
Cracked C2 piston (leaking into C4).
Incorrect band adjustment
Front servo plastic plug missing
B1R spring broken.
B1R spring/plug left out.
C1/B1R ball misplaced.
C1 clutch damaged.
Restriction in C1 feed.
C1 piston check ball jammed.
Overdrive or input shaft sealing rings dam-
aged.
C1/B1R ball misplaced.
Overdrive or input shaft sealing rings dam-
aged.
C1 clutch damaged.
4-3 sequence valve in backwards.
Low-1st check ball misplaced.Symptom
All Shifts Firm
Manual 4-3-2-1 is
soft delayed or
missing
Firm 1-2 Hot
4th Tied up
Tied up on 2-3
Flare on 2-3
Slips in 4th
Flare on 4-3, Flare
on 3-2
Firm Manual low
shift-high line
press.

5A-74 AUTOMATIC TRANSMISSION
Action
Inspect, repair C2 and adjust the linkage as neces-
sary.
Repair C2. Inspect, repair or replace S6 as neces-
sary.
Repair C2. Inspect, replace the sealing rings and/
or shaft as necessary.
Repair C2. Inspect, repair or replace the C2 piston
as necessary.
Inspect C4 and repair as necessary.
Inspect and adjust the C4 pack clearance as nec-
essary.
Repair C4. Inspect and replace the wave plate as
necessary.
Repair C4. Inspect and realign the wave plate as
necessary.
Repair C4. Inspect and realign the sealing rings
and/or shaft as necessary.
Repair C4. Inspect and refit the OWC as neces-
sary.
Repair C4. Inspect and replace the C2 piston as
necessary.
Repair C4. Inspect and refit the ball as necessary.
Inspect and repair B1 and replace the spring as
necessary.
Replace sealing ring.
Repair B1. Refit the ball as necessary.
Inspect and repair C1 and replace the spring.
Repair C1. Inspect and replace the sealing tongs
and/or shaft as necessary.
Repair C1. Inspect and replace the C1 piston as
necessary.
Repair C1. Inspect and refit the capsule as neces-
sary.
Repair C1. Inspect and refit the valve as neces-
sary.
Repair C1. Inspect and replace the ball as neces-
sary.
Inspect and adjust the band as necessary.
Inspect and refit the ball as necessary.
Inspect and replace the ‘O’ ring as necessary.
Inspect and refit the valve as necessary.
Inspect and replace the ‘O’ ring as necessary.
Inspect and refit the valve as necessary.
Possible Cause
T-bar linkage out of adjustment.
56 foiled - stuck low.
Overdrive/output shaft sealing rings damaged.
C2 piston cracked.
Incorrect C4 pack clearance.
C4 wave plate broken.
C4 wave plate not lined up properly.
Overdrive or output shaft sealing rings dam-
aged.
3-4 one way clutch (OWC) in backwards.
C2 piston cracked.
Over-run clutch (OC)/low-1st ball misplaced.
B1R spring broken.
Input shaft sealing ring cut.
C1/B1R ball misplaced.
B1R spring left out.
Overdrive or input shaft sealing rings damaged.
C1 piston cracked.
Ball capsule jammed.
4-3 sequence valve in backwards.
Clutch apply feed (CAF)/B1R ball left out.
Rear band incorrectly adjusted or damaged.
Reverse-low/first ball misplaced.
Input shaft ‘O’ ring missing or damaged.
Converter clutch regulator valve in backwards.
Input shaft ‘O’ ring missing or damaged.
C1 bias valve in backwards.
Symptom
C2 burnt
C4 burnt
B1 burnt
C1 burnt
Slips in reverse -
no manual 1st
Firm converter
lock or unlock
No lock up at light
throttle
Table 6.2.4 - After Teardown Faults

AUTOMATIC TRANSMISSION 5A-79
ADJUSTMENTS
HYDRAULIC SYSTEM
The procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a
defect symptom, indicates that there is a fault in the hydraulic system.
When making adjustments to the transmission, select the appropriate procedures from the following preliminary
checks.
lConduct a transmission fluid test procedure, refer to section 7.2.
lCheck the manual linkage adjustment (refer to the vehicle workshop manual).
lCheck engine idle speed (refer to Section 7.3).
lConduct a stall test (it is outside the scope of this publication to detail this procedure)
lconduct a road test (it is outside the scope of this publication to detail this procedure).
TRANSMISSION FLUID TEST PROCEDURE
Checking Transmission Fluid Level
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in
gearshift loss or delay if driven when the vehicle is cold.
The vehicle is first checked for transmission diagnostic messages (refer to section 6). If the vehicle has a speedo fault
it is possible for the oil level to be low.
The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of
drive. One symptom of low oil level is a momentary loss of drive when driving the vehicle around a comer. Also when
the transmission fluid level is low, a loss of drive may occur when the transmission oil temperature is low.
If there is no loss of drive when the vehicle is driven warm and a speedo fault is registered, then fluid should be added
to the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (ATF) or other approved
fluids. The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded.
Do not underfill the transmission. Incorrect tilling may cause damage to the transmission. The fluid level setting
procedure is detailed below.
Notice
When a transmission is at operating temperature hot transmission fluid may come out of the case if the fill plug is
removed. 9 the transmission is at operating temperature allow two hours for cooling prior to removing the plug.
1. If the vehicle is at operating temperature allow the vehicle to cool down for two, but no greater than four hours
before adding transmission fluid (this will allow the transmission to be within the correct temperature
range).
While hot the ATF level is higher and removing the plug may result in oil being expelled from the filler hole. This
will result in the level being low.
2. The transmission selector is to be in Park.
Switch the engine off.
3. Raise the vehicle on a hoist (or leave over a service pit).
4. 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.
5. Lower the vehicle with the filler pump still connected and partially fill the transmission.
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.

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.

AUTOMATIC TRANSMISSION 5A-85
UNIT REPAIR
REBUILD WARNINGS
Prior to rebuilding a transmission system, the following warnings
are to be noted.
lEnsure that, before replacing a transmission the cooler
lines are flushed out to remove any debris. This can be
done by applying compressed air to the rear cooler line
forcing oil and any contaminants out of the front cooler
line.
lThe cooler flow should be checked after the transmission
has been fitted. With the front cooler line connected
and the rear line run into a suitable container, measure
the flow over 15 seconds with the vehicle idling in park.
lThe flow rate should exceed 1 liter in 15 seconds.
lBe wary of any situation where water enters the
transmission. This may result in fluid foaming and leaking
through the breather.
lEnsure that both earth straps (one at the batted terminal
and one on the vehicle body) are connected in the
vehicle before connecting the positive side of the
battery.
lFollow the throttle position calibration procedure in
section 7 of this manual if the powertrain control module
transmission control unit (PCM/TCU) is swapped.
DISASSEMBLY PROCEDURE
Transmission
Notice
Remove the inhibitor switch before washing the transmission
in solvent or hot wash.
It is assumed that the transmission fluid has been drained
when the transmission was removed from the
vehicle and that the ‘special tools’ quoted are available.
The transmission is dismantled in a modular fashion, and the
details of disassembly for each module are given under the
appropriate subject. Refer to table 9.10 in section 9.6 for details
of all special tools required when performing disassembly
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.
To disassemble the transmission, proceed as follows:
1. Remove the converter and the converter housing.
2. Mount the transmission on the bench cradle
No.0555-331895.
3. Remove the sump and the sump seal.

AUTOMATIC TRANSMISSION 5A-87
Transmission Case
To teardown the transmission case, proceed as follows:
1. Remove the pin from the cross shaft inhibitor switch side
(4WD models) using tool No.0555-332942.
2. Remove the inhibitor switch from the case.
Remove the cross shaft seals with special tool No.0555-
331893.
3. Remove the circlip from the cross-shaft. Pull the shaft to
release the drive pin from the selector quadrant.
4. Using tool No. 0555-331897, press the pin from the cross-
shaft and withdraw the shaft from the case. Retrieve the
spring and pin
5. Remove the manual valve lever and the park rod.
6. Remove the 10 pin plug from the wiring loom bracket
adjacent to the inhibitor switch(RWD models),
7. Depress the tangs and withdraw the 10 pin connector from
the case. Remove the loom assembly.

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.