2003 SSANGYONG MUSSO automatic transmission

5A-106 AUTOMATIC TRANSMISSION
29. Align the tangs and fit the nylon thrust washer onto theC4 hub. Refer to figure 8.27.
30. Align and fit the C4 hub to the C2 clutch and the OWC assembly.
31. Check the rotation of the C2 hub. While holding the C4 hub, the C2 hub should rotate in the clockwise
direction and lockup in the anti-clockwise direction when
viewed from the C2 hub. Refer to figure 8.27.
Figure 8.27 - C2 - Hub Rotation
32. Apply petroleum jelly to the No. 5 thrust bearing and fitit to the C4 hub. Refer to figure 8.19.
33. Remove the C2 clutch plates from the clutch cylinder.
34. Fit the thrust plate over the cylinder inner hub. Refer to figures 8.24 and 8.19.
35. Engage the C2/C4 clutch hub assembly in the C4 clutch plates.
36. Install the C2 clutch plates.
37. Install the C3 hub and secure it with the circlip, ensuring that the circlip is firmly seated in its groove.Refer to figure 8.32. Figure 8.26 - Typical C2 Clutch Pack Clearance
26. Check the clutch pack clearance using only the weight
from tool No.0555-331900. Refer to figure 8.26.NoticeWith the clutch pack supporting a 2 kg weight, the dimension from the C3 clutch hub locating step to the friction plate is to be between 0.80-1.05 mm.
27. Use selective plates to achieve the correct specification. If new friction plates are being fitted, remove the clutch
pack and soak the friction plates in ATF for a minimum
of 5 minutes prior to reassembly. NoticeThe clutch pack clearance must be taken before the
elements are soaked in ATF.
28. Lubricate and fit the 3-4 OWC and end caps to the C2 hub.

AUTOMATIC TRANSMISSION 5A-107
C3 Clutch and Reverse Sun Gear Assembly
To assemble the C3 clutch and reverse sun gear assembly (refer to figure 8.28), proceed as follows.1. Check the orifices in the cylinder are clear of obstructions.
2. Check the C3 cylinder bush outside diameter and the centre support inside diameter are in good condition and
not damaged. Coat the sealing rings with automatic
transmission fluid and fit into the C3 cylinder grooves.
3. Check the reverse sun gear splines, grooves and thrust face for condition. Coat the ‘O’ ring with automatic
transmission fluid and fit it to the groove of the reverse
sun gear.
4. Install the reverse sun gear in the C3 cylinder, ensuring that the ‘O’ ring compression is adequate but not
excessive. Notice
‘O’ rings must not be twisted in the grooves.
5. Coat the C3 piston ‘O’ rings with automatic transmission
fluid and fat the small ‘O’ ring onto the in ner ring and the
large ‘O’ ring onto the outer ring of the C3 piston.
6. Check that the bleed orifices of the piston are clean and clear of obstructions.
7. Install the C3 piston in the cylinder until the outside diameter of the piston enters the inside diameter of the
cylinder. Notice
Take care not to cut the ‘O’ ring.
8. Assemble the spring and spring retainer on the piston. Using tool No. 0555-331899 compress the spring
sufficiently to enable the installation of the retaining circlip,
ensuring that the circlip is firmly seated in the groove, andremove the tool.
9. Fit the C3 wave plate to the C3 piston face, ensuring that one crest of the wave plate of the C3 piston face is aligned
over one of the piston orifices.
10. Assemble the clutch plates and discs into the cylinder in the following sequence :
Steel plate
Friction disc
Steel plate
Steel plate - 0574-000001, 0574-000003, 0574-000004,0574-000005,0574-000020,
0574-000021, or friction disc -0574-000002
Steel plate (selective)
Friction disc
Steel plate (selective)
Friction disc
11. Align and fit the pressure plate with the counterbore facing away from the clutch plates. Figure 8.28 - C3 Clutch and Reverse Sun Gear

5A-108 AUTOMATIC TRANSMISSION
12. Install the circlip.
13. Check the C3 clutch clearance (refer to figure 8.29) usingspecial tool No.0555-331900 in the following manner (weight only).
a. Place the weight on the pressure plate and measure
the distance from the end of the cylinder to the top of the pressure plate.
b. Record this figure.
c. Remove the weight.
d. Lift the pressure plate up against the circlip and measure the distance from the end ofthe cylinder to the top of the pressure plate.
e. Record this figure.
f. Subtract the second reading from the first reading to obtain the clutch pack clearance.
NoticeWith the clutch pack supporting a weight of 2 kg, the clearance between the snap ring and the top of the pressure plate is to be between 1.20-1.45 mm.
14. If new friction plates are being fitted, remove the clutch pack and soak the friction elements in automatic
transmission fluid for a minimum of five minutes prior to
reassembly. NoticeThe clutch pack clearance must be taken before the elements are soaked in automatic transmission fluid. Figure 8.29 - Typical C3 Clutch Assembly
Clearance

AUTOMATIC TRANSMISSION 5A-109
Forward Sun Gear and C3 Clutch Pack Assembly
To assemble the forward sun gear and C3 clutch pack assembly
(Refer to figure 8.30), proceed as follows:
1. Fit the No. 7 needle thrust bearing assembly over the forwardsun gear, ensuring that the thrust washer is between the
bearing and the sun gear.
2. Lubricate the thrust plate with petroleum jelly and fit the thrust plate onto the reverse sun gear. Refer to figure 8.33.
3. Align and fit the C3 clutch assembly over the forward sun gear.
4. Lubricate the No. 6 needle thrust bearing with petroleum jelly and fit it to the thrust plate. Ensure the lugs on the outside diameter of the bearing fit in the thrust plate
counterbore. Refer to figure 8.19.
5. Align and fit the plastic thrust washer to the thrust plate with petroleum jelly.
Refer to to figures 8.19.
6. Install the assembly over the forward sun gear shaft against the No.6 thrust bearing.
Refer to figure 8.19.
7. Place the assembly to one side.
Figure 8.30 - Typical forward Sun Gear add C3 Clutch Assembly

5A-110 AUTOMATIC TRANSMISSION C1 Clutch Overdrive Shaft and Input Shaft Assembly Notice
1. Ensure that the snap rings are fitted correctly.
2. Check pistons for cracks, especially the C1 piston.
3. Do not mix clutch piston return springs.
4. If the C1/C2 clutch packs separate from the C3 clutch pack,make sure the No. 6 bearing doesn ’t drop out of the bearing
retainer.
To assemble the C1 clutch overdrive shaft and input shaft
assembly, proceed as follows:
1. Check the overdrive shaft grooves for any defect.
2. Coat the sealing rings, large and small, with petroleum jelly and fit them to the overdrive shaft. The sealing rings may
be held in place with a small amount of petroleum jelly.
3. Assemble the clutch plate and disc into the cylinder in the following sequence:
steel plate
friction disc
steel plate
friction disc
steel plate
steel plate - 0574-GOOGOl, 0574-000003, 0574-000004, 0574-000005, 0574-000020,
0574-000021, or friction disc -0574-000002
steel plate (selective)
friction disc
steel plate (selective)
friction disc
4. Check the clutch pack clearance using special tool No.0555- 331900. Refer to figure 8.31.Use selective plates to achieve the correct specification.NoticeThe clutch pack supporting a 2 kg weight, the dimension from the input shaft locating stop to the friction disc mustbe 0.70-0.90 mm.
5. If new friction plates are being fitted, remove the clutch pack and soak the friction elements in automatic transmission
fluid for a minimum of five minutes prior to assembly. NoticeThe clutch pack clearance must be taken before elements are soaked in automatic transmission fluid.
6. Check the fit of the C1 clutch hub on the overdrive shaft. If it is loose, the hub and shaft assembly must be replaced. Figure 8.31 - Typical C1 Clutch Assembly
Clearance

AUTOMATIC TRANSMISSION 5A-111
7. Coat the small nylon thrust spacer with petroleum jelly andinstall it over the overdrive shaft. Refer to figure 8.19.
8. Carefully fit the overdrive shaft into the C1 cylinder so as not to damage the sealing ring.
9. Fit the small bronze C1 hub thrust washer in place with petroleum jelly. Refer to figure 8.19.
10. Check the input shaft for any defect. Fit the input shaft into the cylinder and secure it with the circlip, ensuring
that the circlip is completely seated in the groove.
11. Coat the sealing rings with petroleum jelly and fit onto the input shaft.
12. Assemble the C1/C2/C4 clutch assembly to the C3 clutch and sun gear assembly. Refer to figures 8.32 and 8.33.
13. Install this assembly in the transmission case.

5A-112 AUTOMATIC TRANSMISSION
Pump Cover and Converter Support Notice
1. Do not wash the nose of solenoids in solvent.
2. Ensure that the correct ‘O’ ring is fitted for the application.
3. Do not mix up the low first blow-off and the torque converter blow-off ball springs.
4. Be careful not to damage the needle bearings on the assembly. Avoid any axial impact loads during assembly.
5. Check the transmission end float. This will help to detect any missing parts or incorrect assembly.NoticeFigure 8.35 shows the orientation of the cross- sections for figures 8.36 to 8.42.
To assemble the pump cover and converter support (refer to figures 8.34 and 8.35), proceed as follows.
1. Check the pump body for any damage, chips or irregularity. Check that the bush is firmly staked in the drive gear.
2. Install the seal flush with the front face of the pump body.
3. Lubricate the pump bush, and the drive and driven gears, with automatic transmission fluid.
4. Install the pump driven gear and the pump drive gear into the pump body.
5. Using a straight edge and thickness gauge, check that the clearance between pump face and gears is 0.04 - 0.018
mm.
6. Lubricate the pump body ‘O’ ring with automatic transmission
fluid and fit it to the pump body. Put the pump body to one side.
7. Ensure that the pump cover cavities, ports and holes are clean and free of any obstruction.
8. Lubricate all loose parts with automatic transmission fluid prior to assembly. Figure 8.34 - Pump, Cover and Converter
Support
Figure 8.35 - Pump Cover Assembly

AUTOMATIC TRANSMISSION 5A-113
9. Assemble the primary regulator valve and plunger (referto figure 8.36) to the pump cover, ensuring that the
regulator valve slides freely, then fit the regulator valve plug and ‘O’ ring.
10. Install the retaining pin.
11. Install the converter clutch regulator valve (refer to figure 8.37), plug, and ‘O’ ring.
Figure 8.36 - Primary Regulator Valve
Figure 8.37 - Converter Clutch Regulator Valve