2003 SSANGYONG MUSSO Service Manual

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Valve Bodies Notice1. Do not wash the nose of solenoids in solvent.
2. Be aware of ball positions in the upper valve body.
3. Be aware of 1-2 and 3-4 shift valve positions, they can be swapped.
4. Check the 4-3 sequence valve and spring orientation.
5. Check that the 12 mm ball is in the lower body.
6. Do not mix up the low first blow-off and the torque converter blow-off ball springs.
7. Check the line pressure relief valve for swarf, and be aware of replacing the shims.
8. The orifices in the valve body are for stability and safeguard; do not drill them any larger.
9. When servicing the transmission, ensure that the solenoid 5 damper spring is not broken.
10. Locate the detent spring central to the detent lever.
To assemble the valve bodies, proceed as follows. 1. Wash the upper and lower valve bodies (refer to figures 8.47 and 8.48) thoroughly with cleansing solvent and blow
dry.
2. Check the valve body cavities, ports and holes for damage or obstructions.
3. Install the detent lever locating pin.
4. Thoroughly wash all loose components.
5. Check that all valves slide freely in their location.
Figure 8.47 - Lower Valve Body
Figure8.48 - Upper Valve Body Showing Check Ball Locations

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6. Install the lo-1st spring, ball check valve and roll pin. Referto figure 8.49.
7. Install the solenoid 5 damper guide spring, piston and retaining pin. Refer to figure 8.49.
Figure 8.49 - Solenoid 5 and Damper, Lo-1st Check Valve Assemblies
Figure 8.50 - 1-2 Shift Valve
8. Install the 1-2 shift valve, plug and retaining pin. Refer to
figure 8.50.

5A-120 AUTOMATIC TRANSMISSION9. Install the 3-4 shift valve and retaining pin. Refer to figure 8.51.
Figure 8.51 - 3-4 Shift Valve
10. Install the 2-3 shift valve and retaining pin. Refer to figure 8.52.
Figure 8.52 - Solenoid 2 and 2-3 Shift Valve
11. Install the 4-3 sequence valve, spring, plug and retainingplate. Refer to figure 8.53.
Figure 8.53 - 4-3 Sequence Valve

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12. Install the band apply regulator (BAR) valve (refer to figure8.54), springs, plunger and retainer pin.
Figure 8.54 - Band Apply Regulator Valve and Solenoid 4
13. Install the clutch apply regulator (CAR) valve (refer to figure8.55), springs, plunger and retainer pin.
Figure 8.55 - Clutch Apply Regulator Valve and solenoid 3
14. Install the solenoid supply valve, spring and retainer plate.Refer to figure 8.56. NoticeThis aluminum valve is easily damaged.
Figure 8.56 - Solenoid Supply Valve and Solenoid 6

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15. Install solenoid 6 plunger, spring and retaining pin.
16. Position the third feed ball (large nylon) in the valve bodyand install the solenoid 5 filter and the solenoid 6 filter.
Refer to figures 8.5 and 8.56.
17. Check the separator plate for burrs and damage. Repair or replace the separator plate as necessary.
18. Check the upper and lower valve body gaskets for damage. Replace the gaskets as necessary.
19. Install the lower valve body gasket on the lower valve body.
20. Install the reverse lockout valve, spring, plug and retainer plate. Ensure that the valve is correctly oriented. Refer to figure 8.57.
Figure 8.57 - Reverse Lockout Valve
21. Position the five nylon ball checks in the upper valve body.Refer to figure 8.48.
22. Fit the upper valve body gasket. Install the separator plate over the upper valve body.

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23. Holding the separator plate to the upper valve body toprevent the check balls from falling out, install the upper
valve body on the lower valve body. Install all screws finger tight then tighten the screws to specification in the
prescribed sequence. Refer to figure 8.58.
24. Install solenoids 1,2,3,4 and 6. Ensure the solenoid is firmly secured by the retainer and that the screw is tightened to specification.
25. Install solenoid 5. Ensure that the solenoid is pushed firmly into the valve body by the retainer. NoticeThe wiring loom ground wire eyelet terminal is secured
beneath the solenoid retainer.
26. Install the line pressure relief valve, tapered end first, (refer to figure 8.59), and the spring and disc. Secure with theretaining pin.
Figure 8.58 - Tightening Sequence Upper to Lower Valve Body
Figure 8.59 - Line Pressure Relief Valve

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27. Install the line pressure plug and tighten to specification.Refer to figure 8.62.
28. Install the detent spring assembly (spring, support plate and screw), ensuring that the screw is tightened to
specification. Check the spring for wear or damage.
29. Install the manual shift valve. Refer to figure 8.60. Notice Be aware that the manual valve will fall out of the valve
body.
Figure 8.62 - Wiring Installation
Figure 8.60 - Manual Shift Valve

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30. Align the valve body assembly on the transmission caseand install the manual valve lever to manual valve link. Fit
the long end of the link to the manual valve first. Install the
securing bolts and tighten to specification in the specified
sequence. Refer to figure 8.61.
31. Check the alignment of the detent roller and the manual lever quadrant.
32. Connect the solenoid wiring as detailed below: Solenoid 1 - red
Solenoid 2 - bIue
Solenoid 3 - yellow
Solenoid 4 - orange
Solenoid 5 - green
Solenoid 6 - violet (Refer to figure 8.62.)
Notice All hardware must be correctly installed and torqued to specification.
Figure 8.61 - Tightening Sequence Valve Body to Case