2003 SSANGYONG MUSSO clock

5A-54 AUTOMATIC TRANSMISSION POWER FLOW - DRIVE 3 AND MANUAL 3
In Drive 3 and Manual 3, transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows : The C2 clutch is engaged to drive the forward sun gear.
The C1 clutch is engaged to drive the planet carrier.
The forward sun gear and the planet carrier are driven clockwise at the same speed therefore there is no
relative motion between the sun gear and the pinions.
The ring gear and output shaft are driven in a clockwise or forward direction at input shaft speed.
The C4 clutch is applied to bypass the 3-4 OWC and provide engine braking on overrun.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoid S1 is switched Off. S2 is switched Off.
With S1 and S2 switched Off, the 2-3 and 3-4 shift valves are held in the third gear position by line 500
pressure.
The 1-2 shift valve is held in the third gear position by S1-S2 oil pressure.
2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply regulator valve. and to the 2-3 shift
valve.
The band apply regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ratio) to the
band apply feed (BAF) circuit.
Band apply feed oil is directed to:
- The outer apply area of the front servo
- The 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear
- The 3-4 shift valve for use when the transmission is shifted into fourth gear
2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit.
3rd oil from the 2-3 shift valve is directed to the clutch apply regulator valve, and to the 4-3 Sequence Valve.
The clutch apply regulator valve supplies oil (regulated to line 500 pressure multiplied by the valve ratio) to the
clutch apply feed (CAF) circuit.
The CAF oil is directed to:
- The C1 clutch- The C1 bias valve- The 4-3 sequence valve
At the 4-3 sequence valve the CAF oil becomes band 1 release feed (B1R-F) oil, and is directed through the
3-4 shift valve to the spring end of the 4-3 sequence valve, and to the release side of the front servo piston to hold band 1 off.
Drive (line pressure) is routed through the 3-4 shift valve to apply the C4 clutch.
Refer to figure 5.6 and table 5.7.
Table 5.7 - Engaged Elements - Drive 3 and Manual 3
Gear State
Drive 3 and Manual 3 C1
X C2
X C3
- C4
X B1
- B2
- 1-2
OWC - 3-4
OWC X LU
CLUTCH -
ELEMENTS ENGAGED

AUTOMATIC TRANSMISSION 5A-57
POWER FLOW - DRIVE 4 (OVERDRIVE)
In Drive 4 (Overdrive), transmission drive is via the input shaft to the forward clutch cylinder. The elements of the transmission function as follows :
The C1 clutch is applied to drive the planet carrier clockwise.
The B1 band is applied to hold the reverse sun gear stationary.
As the planet carrier tuns, the long pinion ‘walks ’ around the stationary reverse sun gear and rotates around its
axis driving the internal ring gear and output shaft in a clockwise or forward direction at a speed faster than the input shaft i.e. in overdrive ratio.
The forward sun gear is also driven faster than the input shaft and overruns the 3-4 OWC.
The C2 clutch is engaged to reduce the speed differential across the 3-4 OWC.
Control
To maintain this arrangement in the steady state solenoids and valves are activated as follows: Solenoid S1 is switched On. S2 is switched Off.
With S1 switched On the 3-4 shift valve is held in the fourth gear position by line 500 pressure on the small end
of the valve.
With S2 switched Off the 2-3 shift valve is held in the fourth gear position by line 500 pressure on the large end of the valve.
The 1-2 shift valve is held in the fourth gear position by S2 oil pressure.
2nd oil (line pressure) from the 1-2 shift valve is directed to the band apply regulator valve, and to the 2-3 shift
valve.
The band apply regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ratio) to the
band apply feed (BAF) circuit.
Band apply feed oil is directed to: - the outer apply area of the front servo- the inner apply area of the front servo piston via the 3-4 shift valve
- the 1-2 shift valve to provide an exhaust port when the transmission is shifted to first gear
2nd oil at the 2-3 shift valve is directed to the 3rd oil circuit.
3rd oil from the 2-3 shift valve is directed to the clutch apply regulator valve, and to the 4-3 Sequence Valve.
The clutch apply regulator valve supplies oil (regulated to line 500 pressure multiplied by the valve ratio) to the
clutch apply feed (CAF) circuit.
The CAF oil is directed to:- the C1 clutch- the C1 bias valve- the 4-3 sequence valve
Drive oil (line pressure) from the manual valve engages the C2 clutch
Refer to figure 5.8 and table 5.9.
Table 5.9 - Engaged Elements - Drive 4 (Overdrive)
Gear State
Drive 4 (Overdrive) C1
X C2
X C3
- C4
- B1
X B2
- 1-2
OWC - 3-4
OWC X LU
CLUTCH -
ELEMENTS ENGAGED

AUTOMATIC TRANSMISSION 5A-89
Forward Clutch Cylinder
To remove the forward clutch cylinder, refer to figure 8.4,
proceed as follows.
1. Place the assembly in a horizontal position.
2. Remove the thrust bearing and adjustment shims from the input shaft.
3. Remove the circlip from the front of the clutch cylinder and remove the input shaft.
4. Remove the overdrive shaft and the C1 clutch hub assembly from the clutch cylinder.
5. Remove the C1 clutch plates from the cylinder.
6. Remove the circlip retaining the C3 clutch hub in the rear of the clutch cylinder and remove the hub.
7. Remove the C2/C4 clutch hub assembly and remove the thrust bearing from the C4 hub.
8. Remove the C2 clutch plates.
9. Invert the clutch cylinder and remove the C4 clutch sleeve, clutch plates and the two wave washers. The 3-4 one way
clutch is located between the C2 and C4 clutch hubs, andthe hubs may be separated by rotating one hub clockwise
and withdrawing it from the other.
Figure 8.4 - Forward Clutch Cylinder Assembly

5A-92 AUTOMATIC TRANSMISSION
Planet Carrier and Centre Support
To remove the planet carrier and centre support, proceed as follows.1. Separate the planet carrier and centre support from the output shaft. Remove the thrust bearings from the output
shaft and the planet carrier.
2. Separate the centre support from the planet carrier by rotating it anti-clockwise.
3. Lift the one way clutch from the planet carrier.
4. Remove the circlip retaining the one way clutch outer race in the planet carrier and remove the race.
5. Remove the one way clutch retainer from the planet carrier.
Pump
Note that the following valves are housed in the pump cover:
Solenoid 7
C1 bias valve
Converter clutch control valve
Converter clutch regulator valve
Primary regulator valve
To remove the pump, proceed as follows. 1. Remove the wiring loom retainer plate and remove solenoid 7 with a T30 Torx bit.
2. Remove the five washer head bolts from the cover plate using a multi-point 8 mm socket.
3. Remove the five Torx head screws from the cover plate (Torx bit No. 30). Note that the odd screw holds the pump
body to the pump body cover. Notice
Do not strike the converter support tube to loosen the
pump body.
4. Separate the pump body from the pump cover.
5. Lift the cover plate from the cover.
6. Remove the two ball check valves and one spring from the pump cover.Notice
Some of the valves and plugs are preloaded by springs
and may unexpectedly fall out of the cover when the pinsare removed.
7. Depress the plug inward and remove the retaining pin for each of the four valves.
8. Remove the four valves, plugs and springs.
9. Remove the pump gears from the pump body.
10. Remove the lip seal from the front of the pump body.

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.

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.

5D1-34 TRANSFER CASE (PART TIME 4408)
External Electric Shift
1. Align the motor with shift shaft and position the motorassembly onto the cover.
2. Install the motor to the shift shaft and contact cover androtate the motor clockwise direction to check correctengagement.
6 Bolt
7 Washer
8 Bolt
9 Sensor and Harness Bracket
10 Sensor Assembly
14 Speed Sensor
12 O-ring
13 Motor Assembly
2 5 Cover
13 Motor Assembly
103 Shift Shaft
3. Insert the 0-ring on the speed sensor speed sensor
assembly to the cover.
4. Install the bracket to the motor assembly and tighten 3bolts.
Tightening Torque 8 -11 Nm

TRANSFER CASE (TOD) 5D2-13
Speed Sensor/Clutch Coil and Motor Connector Speed senso /clutch coil and shift motor connector locate upper backside transfer case (upper part of shift motor).
- Shift motor connector : Black
- Speed sensor and clutch coil connector : White
Shift Mtor Connector Speed Sensor/Clutch Coil ConnectorRear View for Connector
Pin A B
CD
EF
G Function
Position 4Motor (Counter-Clockwise)Position 3Position 2 Position 1 Position RetumMotor (Clockwise) Pin
HI
J
K L
M N Function
Clutch Coil (EMC) Front Speed ReturnFront SpeedFront Speed Sensor Supply Rear Speed Sensor Supply Rear SpeedRear Speed Return
Rear View for Connector