2003 SSANGYONG MUSSO Service Manual

4G-2 PARKING BRAKE
COMPONENT LOCATOR
PARKING BRAKE
1 Parking Brake Lever
2 Praking Brake Lamp Switch
3 Bolt
4 Bolt ........................................................ 8-18 Nm
5 Front Parking Brake Cable
6 Equalizer 7 Nut
8 Bolt
........................................................ 8-18 Nm
9 Rear Parking Brake Cable
10 Brake Drum (if Equipped with Rear Drum Brake) 11 Brake Disc (if Equipped with Rear Disc Brake)

PARKING BRAKE 4G-3
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE PARKING BRAKE Removal & Installation Procedure
1. Disconnect the parking brake indicator switch connector.
2. Disconnect the right and left cable from equalizer whileparking brake lever is released.
3. Unscrew 8 bolts and remove the parking brake lever assembly. Installation Notice Notice
Tighten the bolts with sequence number while the lever is pulled up 4 to 6 notches.
Tightening Torque 8 - 18 Nm
4. Unscrew the frame and lower arm side cable mounting bracket bolts. Installation Notice
Tightening Torque 8 - 18 Nm

4G-4 PARKING BRAKE
5. Remove the retainer with a screwdriver and disconnect thebrake cable.
6. Installation should follow the removal procedure in the reverse order.

SECTION 5A
AUTOMATIC TRANSMISSION
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5A-2
Model Part Numbers and Applications . . . . . . 5A-2
Model Specifications . . . . . . . . . . . . . . . . . . . . 5A-2
Clutch Pack Details . . . . . . . . . . . . . . . . . . . . . 5A-3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5A-4
Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5A-4
Schematic and Routing Diagrams . . . . . . . . 5A-5
TCU Circuit (Diesel) . . . . . . . . . . . . . . . . . . . . 5A-5
TCU Circuit (Gasoline) . . . . . . . . . . . . . . . . . . 5A-6
Shift Pattern Diagram . . . . . . . . . . . . . . . . . 5A-7
661LA Normal Mode . . . . . . . . . . . . . . . . . . . . 5A-7
661LA Power Mode . . . . . . . . . . . . . . . . . . . . 5A-8
662LA Normal Mode . . . . . . . . . . . . . . . . . . . . 5A-9
662LA Power Mode . . . . . . . . . . . . . . . . . . . 5A-10
662LA Low Mode . . . . . . . . . . . . . . . . . . . . . 5A-11
E32 Power Mode . . . . . . . . . . . . . . . . . . . . . 5A-12
E32 Normal Mode . . . . . . . . . . . . . . . . . . . . . 5A-13
E32 Low Mode . . . . . . . . . . . . . . . . . . . . . . . 5A-14
E23 Power Mode . . . . . . . . . . . . . . . . . . . . . 5A-15
E23 Normal Mode . . . . . . . . . . . . . . . . . . . . . 5A-16
E23 Low Mode . . . . . . . . . . . . . . . . . . . . . . . 5A-17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . 5A-18
Operator Interfaces . . . . . . . . . . . . . . . . . . 5A-20
Gear Select Lever Operation . . . . . . . . . . . . 5A-20
Driving Mode Selector . . . . . . . . . . . . . . . . . 5A-21
Control Systems . . . . . . . . . . . . . . . . . . . . . 5A-22
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-22
Electronic Control System . . . . . . . . . . . . . . . 5A-22
Hydraulic Control System . . . . . . . . . . . . . . . 5A-31
Power Train System . . . . . . . . . . . . . . . . . . 5A-42
Torque Converter . . . . . . . . . . . . . . . . . . . . . 5A-43
Clutch Packs . . . . . . . . . . . . . . . . . . . . . . . . . 5A-44Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-45
One Way Clutches . . . . . . . . . . . . . . . . . . . .
5A-45
Planetary Gear Set . . . . . . . . . . . . . . . . . . . . 5A-45
Parking Mechanism . . . . . . . . . . . . . . . . . . . 5A-46
Power Flows . . . . . . . . . . . . . . . . . . . . . . . . 5A-47
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-47
Power Flow - Park and Neutral . . . . . . . . . . . 5A-48
Power Flow - Reverse . . . . . . . . . . . . . . . . . . 5A-49
Power Flow - Manual 1 . . . . . . . . . . . . . . . . . 5A-50
Power Flow - Drive 1 . . . . . . . . . . . . . . . . . . . 5A-51
Power Flow - Drive 2 and Manual 2 . . . . . . . 5A-52
Power Flow - Drive 3 and Manual 3 . . . . . . . 5A-54
Power Flow - Drive 3 Lock Up and Manual
3 Lock Up . . . . . . . . . . . . . . . . 5A-56
Power Flow - Drive 4 (Overdrive) . . . . . . . . . 5A-57
Power Flow - Drive 4 Lock Up . . . . . . . . . . . . 5A-59
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-60
Diagnostic System . . . . . . . . . . . . . . . . . . . . 5A-60
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . 5A-69
Self Diagnosis Test . . . . . . . . . . . . . . . . . . 5A-75
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 5A-79
Hydraulic System . . . . . . . . . . . . . . . . . . . . . 5A-79
Transmission Fluid Test Procedure . . . . . . . . 5A-79
Electronic Adjustments . . . . . . . . . . . . . . . . . 5A-80
Maintenance and Repair . . . . . . . . . . . . . . 5A-82
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5A-82
Removal and Installation of Transmission . . . 5A-82
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5A-85
Rebuild Warnings . . . . . . . . . . . . . . . . . . . . . 5A-85
Disassembly Procedure . . . . . . . . . . . . . . . . 5A-85
Assembly Procedure . . . . . . . . . . . . . . . . . . . 5A-94
Front and Rear Band Adjustment . . . . . . . . 5A-128

5A-2 AUTOMATIC TRANSMISSIONSPECIFICATIONS
MODEL PART NUMBERS AND APPLICATIONS
Transmission
0574-000001 (9) 0574-000002 (8)
0574-000004 (10) 0574-000005 (7) Torque Converter
179K160K160K179KEngine Version661LAE32
662LA(Turbo) E23
MODEL SPECIFICATIONS
Application
Torque Converter Mean diameter of fluid circuit Maximum torque multiplication Stall speed (rpm)0574-000001 (D23LA)0574-000002 (E32)0574-000004 (D29LA) 0574-000005 (E23) 0574-0000200574-000021
Gear Ratios First Second ThirdFourthReverse
Lubricant
TypeCapacityDry SystemService Refill
Gear Train End Float Gear Set Pinion End FloatDescriprtion
260
2.0 : 1
2100 - 2250 2050 - 22502100 - 2200 1800 - 2100
2.741 : 1 1.508 : 11.000 : 10.708 : 12.429 : 1
Castrol TQ95 or other approved fluid 9.0 Litres (approx)4.5 Litres (approx)0.50 - 0.65 mm0.10 - 0.50 mm
DWMC P/NO
36100-05420 (1)36100-05430 (1)36100-05410 (1)36100-05440 (1)

AUTOMATIC TRANSMISSION 5A-3
CLUTCH PACK DETAILS
C1Composition Steel
C2
Composition Steel
C3
CompositionSteel
C4 CompositionSteel
0574-000002
5
5(2)
5
4(2)
4
4(2)
3
4(1)0574-000001, 0574-000004, 0574-000005
4
6(2)
4
5(2)
3
5(2)
3
4(1)
Note : Numbers in brackets indicate number of selective thickness steel plates required to achieve specifed
clutch pack clearance

5A-4 AUTOMATIC TRANSMISSIONSPECIAL TOOLS
SPECIAL TOOLS TABLE
Part Number
0555 - 332083 0555 - 3360460555 - 3362560555 - 3362570555 - 336258 0555 - 336259 0555 - 3362600555 - 3362610555 - 3362620555 - 336263 0555 - 336264 0555 - 3362650555 - 3362660555 - 3362670555 - 336268 0555 - 336269 0555 - 3362700555 - 332895Description
Solenoid / Thermistor, Electronic Tester
Solenoid, Bench Tester
Transmission Bench Cradle Pump Puller
Pin Remover / Installer Tool (Cross Shaft / Detent Lever)Clutch Spring CompressorClutch Pack Clearance Kit
Seal Removal Tool (Cross - Shaft) Oil Seal Dolly (Cross - Shaft)Assembly BulletSeal CompressorPin Press Seal Dolly
Alignment ToolPump Seal DollyEnd Float AdaptorEnd Float Shaft
Locknut Crimping Tool (W-Car Only)

AUTOMATIC TRANSMISSION 5A-5
SCHEMATIC AND ROUTING DIAGRAMS
TCU CIRCUIT (4WD-DIESEL)