2003 SSANGYONG MUSSO Service Manual

5A-94 AUTOMATIC TRANSMISSION
ASSEMBLY PROCEDURE The transmission is assembled in modular fashion and details of assembly for each module are given under the appropriatesubject. 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 Torxbit 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 notfitted, 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 seatedin its groove.
4. Install the rear servo lever and pivot pin.
Notice The lever must pivot freely on its pin.

AUTOMATIC TRANSMISSION 5A-95
Notice
Care must be taken when applying sealant to ensure that it is
not applied between the pin and the lever.
5. Assemble the park rod lever, complete with the return springand pivot pin, applying a small amount of sealant to the
outer end of the pivot pin.Notice That the lever must pivot freely on its pin and the spring must return the park rod lever to its correct location.
6. Secure the pivot pin with the circlip. Notice The pawl must pivot freely on its pin.
7. Install the parking pawl pivot pin and spring.
8. Connect the park rod to the manual valve detent lever.Ensure the spring and cam collar is firmly installed on the rod.

5A-96 AUTOMATIC TRANSMISSION9. 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 andterminal in the pump mounting flange at the front of the case. The solenoid 7 wire is routed under the park rodand cross shaft in the case.

AUTOMATIC TRANSMISSION 5A-97
20. Install the ten pin connector in the case engaging the tangson the connector in the notches in case.
4WD MODELS ONLY
21. Route the portion of the wiring loom coming out of the case down between the inhibitor switch and the case.
Position the ten pin plug on the wiring loom bracket .

5A-98 AUTOMATIC TRANSMISSION Rear Band Assembly
To assemble the rear band assembly proceed as follows:
1. Check the rear band for any cracks or damage along thelining and metal backing.
2. Install the reaction anchor strut into the main case, without shims.Notice
If fitting a new band, soak the new band in automatic
transmission fluid (or a minimum of five minutes prior to
assembly.
3. Carefully install the rear band into the transmission case and ensure that it is properly fitted in the case.
4. Position the apply strut on the rear band then engage the apply strut in the servo lever.
5. Install the cam plate and tighten the screws to specification.
Figure 8.19 - Thrust Bearing and Washer Locations Figure 8.18 - Rear Servo and Band

AUTOMATIC TRANSMISSION 5A-99
Output Shaft and Gear Assembly
To assemble the output shaft and gear assembly (refer to (figure 8.19), proceed as follows:
1. Check that the output shaft bush is not won or damaged.Replace if necessary.
2. Check for damage to parking pawl teeth on the ring gear. Replace if necessary.
3. Check that the sealing ring grooves have not been damaged.
4. Lubricate the sealing rings with automatic transmission fluid.
5. Assemble the sealing rings to the output shaft with the scat cut uppermost.
6. If previously dismantled, assemble the ring gear to the output shaft and secure with circlip. Ensure that the circlip is firmly seated in its groove.
7. Fit the thrust bearing assembly No. 10 onto the output shaft using petroleum jelly.
8. Carefully install the output shaft assembly in the case to prevent damage to the sealing rings.
Rear Servo Assembly
To assemble the rear servo assembly (refer to figure 8.18), proceed as follows.
1. Check the servo piston ‘O’ rings and gasket for any damage.
2. Lubricate the servo piston ‘O’ rings with automatic
transmission fluid, and fit the ‘O’ rings to the piston grooves.
3. Assemble the piston to the cover, ensuring t h a t ‘O’ ring
compression is adequate but not excessive.
4. Align the spring on the piston spigot, then position the rear servo rod into the spigot.NoticeDo not use petroleum jelly on the gasket.
5. Assemble the gasket to the cover and fit the assembly to the case.
6. Apply Loctite 567 sealant to the bolts. Install the bolts and tighten to specification.

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 andCentre 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