2003 SSANGYONG MUSSO Service Manual

5A-70 AUTOMATIC TRANSMISSION
Action
Inspect S1. Repair or replace as necessary.
Check for 12 Volts applied to S1 at all times orfor 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 nec essary.
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 necessaryInspect 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 only1-3-4 (Delayed1-2shift)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 4thonly 1st and 2nd only or 1st, 3rd and 4th
only

AUTOMATIC TRANSMISSION 5A-71
Table 6.2.2 - Faulty Shift Patterns
Action
Inspect inhibitor switch. Repair or replace as
necessary.
Inspect the 3-4 shift valve. Repair or replace
as necessary.
Inspect the release valve. Repair or replace as
necessary.
Inspect S3 or S2. Repair or replace as neces-
sary.
Inspect the regulator valve. Repair or replace
as necessary.
Inspect the ball. Refit or replace as necessary.
Inspect the sealing rings. Refit or replace as
necessary.Inspect the ‘O’ rings. Refit or replace as neces-
sary.
Inspect the bleed ball. Refit or replace as nec-
essary.
Inspect S1 or S4. Repair or replace as neces-
sary.
Inspect the release valve. Repair or replace as
necessary.
Inspect the band. Adjust as necessary. Inspect the ‘O’ rings. Refit or replace as neces-
sary.
Inspect S5. Repair or replace as necessary.
Inspect the regulator valve. Repair or replace
as necessary.
Possible Cause
Inhibitor switch fault, 1-2-3 only. 3-4 shift valve jammed. Jammed band 1 release valve. Faulty S3 or S2 solenoid. Faulty clutch apply regulator valve.Missing or damaged clutch apply feed ball. Damaged input shaft sealing rings. Damaged C1 piston ‘O’ rings.
Damaged or dislodged C1 piston bleed ball. Faulty S1 or S4 solenoid.
Jammed band 1 release valve. Incorrect front band adjustment. Damaged front servo piston ‘O’ rings.
Faulty or damaged variable pressuresolenoid (S5). Faulty band apply regulator valve.Symptom
1st,2nd and 4th
only or 1st,2nd,
and 3rd (tied up in3rd) Harsh 2-3 shift Harsh 3-4 shift

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 regulatorsprings 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 2-3Flare on 2-3 Slips in 4th Flare on 4-3, Flare on 3-2Firm Manual low
shift-high line press.

AUTOMATIC TRANSMISSION 5A-73
Table 6.2.3 - Shift Quality Faults
Action
Check the resistance. Replace the inhibitor
switch as necessary.
Inspect and replace the sensor as necessary.
Inspect and adjust the band as necessary.Inspect and replace the ’0’rings as necessary.
Inspect, repair or replace S5 as necessary.
Inspect, repair or replace S1 or S4 as neces-
sary.
Inspect, repair or replace the BAR as neces-
sary.
Inspect and repair as necessary.
Inspect and clean CCCV.
Inspect, repair or replace as necessary.
Possible Cause
Faulty inhibitor switch.
Faulty throttle position sensor. Incorrect front band adjustment.Damaged front servo piston ’0’rings.
Faulty or damaged variable pressure so- lenoid (S5). Faulty S1 or S4 solenoid. Faulty band apply regulator valve (BAR). Misassembled front servo return spring. Jammed converter clutch control valve(CCCV).Faulty solenoid 7.Symptom
Harsh 1-2 shift stalls when Drive
or Reverse selected Shudder
on Rolldown

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 unlockNo lock up at lightthrottle
Table 6.2.4 - After Teardown Faults

AUTOMATIC TRANSMISSION 5A-75
SELF DIAGNOSIS TEST
1. Turn the ignition switch to “OFF ” position.
2. Connect the scanner harness connector to the engine compartment diagnosis socket.
3. Turn the ignition switch to “ON ” position.
4. Select “Electronics control vehicle diagnosis ” from the
function selection display and press “Enter ”.
5. Select “Musso(98 face lift) ” from the vehicle model selection
model selection display and press “Enter ”.
6. Select “Transmission control unit(TCU) ” from the control
system selection and press “Enter ”.
7. Select “Self-diagnosis ” from diagnosis items.
Notice
Check sensor output value displays if necessary.
8. Determine the fault code and check the detective Items. NoticeRefer to sefadf3fnosfs list.

5A-76 AUTOMATIC TRANSMISSION
Action
Check cable for open / short.
Check connection of other connectors.
Check voltage between terminal 27 and 29 of TCU,
- Standard value : 0.2 - 4.7V
Check TPS.
Check cable for open / short.
Check connection of other connectors.
Check engine speed sensor.
Check resistance between terminal 8 and 24 of TCU (when the connector is disconnected).
- Standard value : 1 .9 - 0.2 k
Check cable for open / short.
Check connection of other connectors.
Check vehicle speed sensor.
Check cable for open / short.
Check connection of other connectors.
Check engine speed sensor.
Check inhibitor switch resistance between terminal 34 and 37 of TCU(when the connector is disconnected).
- Standard value : 1st gear - 4 - 4.4 k
2nd gear - 4,8 - 2.2 k
3rd gear - 3 - 3.4 k
D gear - 4.5 - 4.g k
N gear - 6.8 - 7.2 k
R gear - 10.8 -11.2 k
P gear - 18.6 - 19 k
Check voltage between terminal 31 and 37 of TCU.
- Standard value : 0-5V(P,R,N,D,L)
Check cable for open / short.
Check connection of other connectors.
Check mode switch.
Check condition between terminal 1 and 13 of TCU.
Winter mode :12V, Normal mode : Open status, Power mode : 0V
Check cable for open / short.
Check connection of other connectors.
Check voltage between terminal 32 and 38 of TCU.
- Standard value : 0-5V
Check oil temperature sensor.
Check cable for open / short.
Check connection of other connectors.
Check battery condition.
Check alternator.
Possible Cause
Throttle position sensor
Engine RPM
Vehicle speed Shift lever
W, E, P mode switch T/M oil temperature Battery voltage
Symptom
P1702 P1703 P1704 P4705 P1706 P1707P1708
Self-diagnosis List

AUTOMATIC TRANSMISSION 5A-77
Action
Check cable for open / short.
Check connection of other connectors.
Check voltage between terminal 4 and 11 of TCU.
- Standard value : when the A/C compressor is ON : 12V
when the A/C compressor is OFF : 0V
Check cable for open / short,
Check connection of other connectors.
Check voltage between terminal 1 and 12 of TCU.
- Standard value : when the kick down switch is ON : 12V
when the kick down switch is OFF : 0V
Fully depress accelerator pedal for 5 seconds(ignition key is ON).
Release accelerator pedal.
Depress brake pedal and start the engine in ‘P’ position.
Depress brake pedal and idle the engine for 5 seconds in ‘D’
position.
Shift into ‘D’ position and determine fault code for throttle initial-
ization.
Complete the initialization.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 34 of TCU(when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors,
Check resistance between terminal 1 and 40 of TCU (when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 41 of TCU (when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 33 of TCU (when theconnector is disconnected),
- Standard value : 26 - 30
Possible Cause
Air conditioner switch
Kick down switch Pedal
Vehicle ID
VPS offset
Throttle position sensor
initialization
Solenoid 1 Solenoid 2Solenoid 3Solenoid 4
Symptom
P1710 P1712P1713 P1714P1715P1716 P1733 P1734P1735 P1736