2003 SSANGYONG MUSSO check transmission fluid

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

5A-102 AUTOMATIC TRANSMISSION Front Band Assembly
To assemble the front band assembly, proceed as follows.1. Install the reaction anchor strut to the case.
2. Check the band for ally cracks or damage along its lining and metal backing.
3. Position the strut retainers on the band (refer to figure 8.23).NOTICE
If fitting a new band, soak the band in automatic
transmission fluid for a minimum of 5 minutes prior to
assembly.
4. Install the front band into the transmission case, ensuring that it is properly seated in place.
5. Position the reaction strut in its retaining clip and engage it with the band and anchor strut.
Position the apply strut in its retaining clip and engage it
with the band and the servo piston rod.
C2/C4 Clutch Assembly Notice
1. Check pistons for cracks.
2. Do not mix the clutch piston return springs.
3. Ensure that the snap rings are fitted correctly.
To assemble the C2/C4 clutch assembly (refer to figure 8.24), proceed as follows. 1. Check the feed orifices in the cylinder bore are clear of obstructions.
2. Check the C2 piston bleed orifices are clear of obstructions.
3. Lubricate the ‘O’ rings with automatic transmission fluid.
Notice
‘O’ rings must not be twisted in the grooves.
4. Fit the small ‘O’ ring onto the inner groove, and the large
‘O’ ring onto the outer groove of the piston.
5. Check the C4 piston bleed orifices are clear of obstructions.
6. Lubricate the ‘O’ rings with automatic transmission fluid.
7. Fit the small ‘O’ rings onto the inner groove and the large
‘O’ rings onto the outer groove of the pis ton.
8. Position the clutch cylinder with the C2/C4 cavity facing upwards.
9. Fit the C4 piston into the C2 piston with the bleed orifices in alignment.
10. Install the C2/C4 piston assembly into the cylinder, with the piston bleed orifices aligned with the holes on the outside
of the cylinder, until the outer diameter of the C2 piston
enters the inner diameter of the cylinder.
Figure 8.23 - Front Band Strut Installation
Figure 8.24 - Typical C2/C4 Clutch Assembly

AUTOMATIC TRANSMISSION 5A-103
11. Assemble the piston return spring to the piston, and fit thespring retainer over the spring. NoticeThe wire diameter of this spring is 4.3 mm.
12. Using special tool No. 0555-331899, compress the spring sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then remove the tool.
13. Check the C1 piston check valves are not damaged and are free to move, and that the cylinder feed orifices areclear of obstructions.
14. Lubricate the ’0’rings with automatic transmission fluid and
fit them to their respective grooves. Notice
‘O’ rings must not be twisted in the grooves.
15. Position the cylinder with the C1 cavity upwards. Install the piston into the cylinder until the outer diameter of the piston
enters the inner diameter of the cylinder.
16. Install the spring and spring retainer onto the piston. Notice The wire diameter of this spring is 5.26 mm.
17. Using special tool No. 0555-331899, compress the spring sufficiently to enable the installation of the retaining circlip
ensuring that the circlip is firmly seated in its groove, then remove the tool.
18. Install the C2 wave washer into the cylinder with the crest of one wave covering one of the bleed orifices in the C2 piston.
19. Measure and record the thickness of the flange of the C2 sleeve. Refer to figure 8.25.
20. Install the C4 clutch plates and wave washer into the C2 actuating sleeve, with the rounded edge of the steel plates
down, in the following sequence:
Steel plate (selective)
Friction disc
Steel plate
Friction disc
Steel plate
Friction disc
Steel plate
Wave washer

AUTOMATIC TRANSMISSION 5A-105
21. Holding the cylinder horizontal, install the sleeve and clutchplate assembly into the cylinder, with the crest of one wave
of the washer In line with one of the holes in the outside of
the cylinder, until the sleeve contacts the C2 wave washer.
22. Check the C4 clutch pack clearance using special tool No. 0555-331900. Refer to figure 8.25. NoticeWith the C2 wave spring compressed, and the clutch Pack supporting a 2 k9 weight, the dimension from the undersideof the C2 pressure plate to the selective steel is to bebetween 1.4- 1.8 mm. If the clutch is to be gauged from the top of the pressure plate, then the dimension is to be the actual thickness of the pressure plate plus 1.4-1.8 mm.
23. Use selective plates to achieve the correct specification. If new friction plates are being fitted, remove the clutch packand 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 Automatic Transmission Fluid
(ATF).
24. Reassemble the sleeve and clutch pack into the cylinder. Observe the alignment of the wave washer to the hole in
the cylinder.
25. Install the C2 clutch plates in the cylinder in the following sequence:
Friction disc
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

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

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