2003 SSANGYONG MUSSO parking brake

PARKING BRAKE 4G-3
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE PARKING BRAKE Removal & Installation Procedure
1. Disconnect the parking brake indicator switch connector.
2. Disconnect the right and left cable from equalizer whileparking brake lever is released.
3. Unscrew 8 bolts and remove the parking brake lever assembly. Installation Notice Notice
Tighten the bolts with sequence number while the lever is pulled up 4 to 6 notches.
Tightening Torque 8 - 18 Nm
4. Unscrew the frame and lower arm side cable mounting bracket bolts. Installation Notice
Tightening Torque 8 - 18 Nm

4G-4 PARKING BRAKE
5. Remove the retainer with a screwdriver and disconnect thebrake cable.
6. Installation should follow the removal procedure in the reverse order.

5A-42 AUTOMATIC TRANSMISSIONPOWER TRAIN SYSTEM
The Power Train System consists of: A torque converter with single face lock-up clutch
Four multi-plate clutch assemblies
Two brake bands
Two one-way clutches
Planetary gearset
Parking mechanism
A conventional six pinion Ravigneaux compound planetary gearset is used with overdrive (fourth gear) being obtained
by driving the carrier.
The cross-sectional arrangement is very modular in nature. Four main sub-assemblies are installed within the case
to complete the build. These sub-assemblies are: Gearset-sprag-centre support
C1 -C2-C3-C4 clutch sub-assembly
Pump assembly
Valve body assembly
One, or a combination of selective washers are used between the input shaft flange and the number 4 bearing to
control the transmission end float. This arrangement allows for extensive subassembly testing and simplistic finalassembly during production.
A general description of the operation of the Power Train System is detailed below. Refer to table 4.1 and figure 4.1.
First gear is engaged by applying the C2 clutch and locking the 1-2 One Way Clutch (1-2 OWC). The 1-2 shift is
accomplished by applying the B1 band and overrunning the 1-2 OWC. The 2-3 shift is accomplished by applying the
C1 clutch and releasing the B1 band. The 3-4 shift is accomplished by re-applying the B1 band and overrunning the
3-4 OWC. Reverse gear is engaged by applying the C3 clutch and the B2 band.
The C4 clutch is applied in the Manual 1,2 and 3 ranges to provide engine braking. In addition, the C4 clutch is also
applied in the Drive range for second and third gears to eliminate objectionable freewheel coasting. The B2 band is
also applied in the Manual 1 range to accomplish the low-overrun shift.
Both the front and rear servos are dual area designs to allow accurate friction element matching without the need for
secondary regulator valves. All the friction elements have been designed to provide low shift energies and high static
capacities when used with the new low static co-efficient transmission fluids. Non-asbestos friction materials are used throughout.
Gear
First
Second ThirdFourth
Reverse
Manual 1 Gear
Ratio 2.741 1.508 1.0000.7082.4282.741 C1
XX C2
X X XX X C3
X C4
X X B1
X X X B2
X X 1-2
OWC X 3-4
OWC X XX LU
CLUTCH
X*X
ELEMENTS ENGAGED
* For Certain Vehicle Applications, Refer to the Owner's Manual.
Table 4.1 - Engaged Elements vs Gear Ratios

AUTOMATIC TRANSMISSION 5A-79
ADJUSTMENTS
HYDRAULIC SYSTEM
The procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a
defect symptom, indicates that there is a fault in the hydraulic system.
When making adjustments to the transmission, select the appropriate procedures from the following preliminary checks. Conduct a transmission fluid test procedure, refer to section 7.2.
Check the manual linkage adjustment (refer to the vehicle workshop manual).
Check engine idle speed (refer to Section 7.3).
Conduct a stall test (it is outside the scope of this publication to detail this procedure)
conduct a road test (it is outside the scope of this publication to detail this procedure).
TRANSMISSION FLUID TEST PROCEDURE
Checking Transmission Fluid Level
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in
gearshift loss or delay if driven when the vehicle is cold.
The vehicle is first checked for transmission diagnostic messages (refer to section 6). If the vehicle has a speedo fault
it is possible for the oil level to be low.
The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of
drive. One symptom of low oil level is a momentary loss of drive when driving the vehicle around a comer. Also when
the transmission fluid level is low, a loss of drive may occur when the transmission oil temperature is low.
If there is no loss of drive when the vehicle is driven warm and a speedo fault is registered, then fluid should be addedto the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (A TF) or other approved
fluids. The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded. Do not underfill the transmission. Incorrect tilling may cause damage to the transmission. The fluid level setting
procedure is detailed below. Notice
When a transmission is at operating temperature hot transmission fluid may come out of the case if the fill plug is
removed. 9 the transmission is at operating temperature allow two hours for cooling prior to removing the plug.
1. If the vehicle is at operating temperature allow the vehicle to cool down for two, but no greater than four hours before adding transmission fluid (this will allow the transmission to be within the correct temperaturerange).
While hot the ATF level is higher and removing the plug may result in oil being expelled from the filler hole. This
will result in the level being low.
2. The transmission selector is to be in Park. Switch the engine off.
3. Raise the vehicle on a hoist (or leave over a service pit).
4. Clean all dirt from around the service fill plug prior to removing the plug. Remove the oil service fill plug. Clean the fill plug and check that there is no damage to the ‘O’ ring.
Install the filler pump into the filler hole.
5. Lower the vehicle with the filler pump still connected and partially fill the transmission.
Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.

5A-80 AUTOMATIC TRANSMISSION6. Switch off the engine and raise the vehicle on the hoist, if applicable, ensuring that the vehicle is level.
7. Three minutes after the engine has stopped, but no longer than one hour, remove the filler pump, The correct level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATF to the correct level.
8. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle.
9. Tighten the transmission filler plug to specification.
Checking, Adding Fluid and Filling - Drained or Dry Transmission
To set the correct fluid level proceed as follows. 1. Set the transmission selector to Park and switch the engine off.
2. Raise the vehicle on a hoist (or leave over a service pit).
3. Clean all dirt from around the service fill plug prior to removing the plug, Remove the oil service fill plug. Clean the fill plug and check that there is no damage to the ‘O’ ring. Install the filler pump into the filler hole.
4. Lower the vehicle with the filler pump still connected and partially fill the transmission. This typically requires approximately :
a. If the transmission torque converter is empty:
9.0 litres - 4WD9.0 litres - RWD
b. If the transmission torque converter is full: 4.5 litres - 4WD4.5 litres - RWD
5. Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission gear selector through all positions, adding ATF until gear application is felt.
6. Then add an additional 0.5 litres of ATF.
7. Switch off the engine and raise the vehicle on the hoist. Remove the filler pump and replace the filler plug. The plug shall be tightened to specification.
8. The vehicle is then to be driven between 3.5 and 4.5 kilometers at light throttle so that the engine does not exceed 2500 rpm. This should result in the transmission temperature being in the range 50 to 60 °C.
9. With the engine idling, cycle the transmission selector through all gear positions with the brake applied.
10. Stop the engine. Raise the vehicle on the hoist, if applicable ensuring the vehicle is level.
11. Three minutes after the engine has stopped, but no longer than one hour, remove the filler plug. The correct level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATP to the correct level.
12. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle. Tighten the transmission Filler plug to specification.
ELECTRONIC ADJUSTMENTS Idle Speed Adjustment
Carry out the adjustments to the idle speed as detailed in the workshop manual.
Throttle Position Calibration
Should the throttle position data stored in the TCU be lost or be out of specification, as indicated by a diagnostic
trouble message, it may be re-established by the following procedure. Check that the hot engine idle speed is within specification.
Allow the engine to idle in ‘Drive ’ for 60 seconds with the air conditioner (if fitted) turned off. The closed throttle
reference point in the TCU has now been set.
Switch the engine off but leave the ignition on. Hold the accelerator pedal on the floor for 60 seconds. The wide open
throttle reference point in the TCU has now been set.

9A-10 BODY WIRING SYSTEM94 Seat Belt Switch (Driver)
95 Seat Belt Switch (Dirver)
96 Parking Brake Switch
97 Rear Cigarette Lighter
9 8 OVPR ................................................................. Gasoline E/G
99 LH Side Repeater ............................................... Rear Fog Lamp
100 Engine Wiring Connector
101 Engine Joint Connector
102 Engine Joint Connector ......................................Gasoline E/G
103 ECS Engine Wiring Connector ...........................Diesel E/G & Gasoline E/G with HFM ECU
104 ABD Engine Wiring Connector ...........................ABD 5.0
105 ABD Engine Wiring Connector ...........................ABD 5.0
105-1 ABS Engine Wiring Connector ............................ABS 5.0
106 Canister Purge Solenoid Valve ...........................Gasoline E/G with MSE ECU
106-1 Canister Purge Solenoid Valve ...........................E20 & E23 Gasoline E/G with FHM ECU
107 Econo/Standard Solenoid Valve .........................Gasoline E/G with Automatic Transmission
108 CO Potentio Meter .............................................. Gasoline E/G with HFM ECU & CO Potentio Meter
109 Front Wiper Motor 11 0 O 2 Sensor
........................................................... E20 or E23 Gasoline E/G
111 RH Side Repeater
112 Engine Wiring Connector
113 Vertical Sensor
114 Lateral Sensor
115 Diagnosis
11 6 Joint Box ............................................................. Gasoline E/G (E32)
117 Canister Purge Solenoid Valve ...........................E32 Gasoline E/G with HFM ECU
118 Led Antenna ...................................................... Rolling code type Immobilizer
119 E-key Connector ................................................ Gasoline E/G with Rolling Code Type Immobilizer
120 Receiver Unit ...................................................... Gasoline E/G with Rolling Code Type Immobilizer
121 Receiver Unit ...................................................... Gasoline E/G with Rolling Code Type Immobilizer
122 Receiver Antenna .............................................. Gasoline E/G with Rolling Code Type Immobilizer
123 Receiver Connector ........................................... Gasoline E/G with Rolling Code Type Immobilizer
124 ICU Connector .................................................... Gasoline E/G with Rolling Code Type Immobilizer
125 ICU ..................................................................... Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
126 CAN Line ............................................................ Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
127 TOD ................................................................... Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
128 TOD ................................................................... Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
129 Transfer Case Speed Sensor .............................Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
130 Engine Main Wiring Connector ...........................Gasoline E/G with MSE ECU
131 Remote Engine Start .......................................... Diesel E/G with A/T & Black Out Lamp
132 Remote Engine Start .......................................... Diesel E/G with A/T & Black Out Lamp
133 TCU .................................................................... Diesel E/G with BTRE A/T
134 TCU .................................................................... Diesel E/G with BTRE A/T
135 Ground 5 ............................................................ Diesel E/G
136 Start Protection Relay .........................................Diesel E/G with Rolling Code Type Immobilizer
137 EGR control unit ................................................. Diesel E/G
1 3 8 ICU 1 .................................................................. Diesel E/G with Rolling Code Type Immobilizer
1 3 9 ICU 2 .................................................................. Diesel E/G with Rolling Code Type Immobilizer
140 Injection Pump Valve Extension ..........................Diesel E/G with Rolling Code Type Immobilizer
141 Injection Pump Valve Extension ..........................Diesel E/G with Rolling Code Type Immobilizer
142 EGR Solenoid .................................................... Diesel E/G
143 ICU led ................................................................ Diesel E/G with Rolling Code Type Immobilizer
144 Immobilizer Solenoid Valve ..................................Diesel E/G with Crypto Type Immobilizer
147 Immobilizer Unit ................................................... Diesel E/G with Crypto Type Immobilizer

9U-10 CONTROL UNITS AND SYSTEMMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
STICS STICS, electonic control warning device, controls 16 functions and contains the self diagnostic function detecting any malfunctions in the sensors and load. Removal & Installation Procedure
1. Disconnector the battery negative cable.
2. Unscrew 4screw from center console box.
3. Remove the center console box and disconnect 3 STICS connectors.
4. Unscrew 3 fastening bolts and remove the STICS unit.
5. Installation should follow the removal procedure in the reverse order.
1 STICS Unit
2 STICS Connector 3 STICS Unit Fastening Bolt
4 Parking Brake Lever

CONTROL UNITS AND SYSTEM 9U-3
FUNCTION DESCRIPTION
STICS Operating Functions
NO.Application Deseription
1 Wiper INT sensing vehicle speed By operating INT time control volume, variable time will be changed within 1.5 - 20 seconds.
2 Washer relating wiper Wiper begins to operate within 0.6 - 1 sec when the washer switch is ON and it operates 3 times after the washer switch is OFF while the IGN2 switch in ON.
3 Dimming room lamp
When room lamp is coupled with door, it turns on if door is opened. After closing the door it maintains 2 seconds of lightingand dims off whithin 3 seconds.
4 Time delayed power window control Power window can be operated within 30 seconds after turning
the IGN1 switch from ON to OFF. If driver ’s/passenger ’s door is
opened within the 30 seconds, time will be prolonged for more 30 seconds from that moment.
5 Rear defogger timer The rear defogger will be operated for 12 min. by turning ON the defogger switch while engine is running.
Defogger will be stopped by pushing the switch again.
The defogger will be operated 6 min, if push ON the switch within10 min. after 12 min. of operation.
6
Seat belt warning The warning lamp will be turned on for about 6 sec. with an intermittent chime bell when the IGN. switch is ON unlessfastening the seat belt.
7 Parking brake warning
The indicator lamp will flash if drive while the parking brake is applied.
8 Tail lamp lighting warning When the driver ’s door is opened while the tail lamp is still ON,
the buzzer operates intermittently. In this condition, the door will be automatically unlocked when it locked.
9 Door ajar warning
The indicator lamp will be blinking when the door is not closed completely and driving.
10 IGN key reminder
The chime will be operated intermittently if the driver ’s door is
opened while the IGN key is still remaining in the ignition switch. In this condition, the door will be automatically unlocked when itlocked.
11 Central door lock All doors will be locked/unlocked by locking/unlocking the driver ’s or passenger ’s door.