2003 SSANGYONG MUSSO torque

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-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

5A-118 AUTOMATIC TRANSMISSION
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

AUTOMATIC TRANSMISSION 5A-125
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

5A-126 AUTOMATIC TRANSMISSION
Oil Filter and Pan Assembly Notice
1. Replace the filter whenever rebuilding a transmission where a significant amount of mechanical damage hasoccurred.
2. To aid the assembly of the pan gasket, use a small amount of Vaseline at the pan/gasket interface. This ensures that the gasket remains on the pan ridge. Do not over torque pan bolts as this may distort the pan and cause leaks.
3. Ensure that the internal line pressure plus in the valve body is fitted.
To assemble the oil filter and pan assembly (refer to figures 8.63 and 8.64), proceed as follows.
1. Lubricate the oil filter sealing ring with automatic transmission fluid.
2. Carefully assemble the oil filter to the valve body. The spigot must not lean on one side while being fitted. Refer to figure 8.63.
3. Secure the oil falter assembly with the retainer.
4. Check that the magnet is located in the dimple in the comer of the oil pan.
5. Assemble the gasket on the pan lip. The gasket must be free of any distortion when installed.
6. Fit the oil pan assembly to the transmission case and tighten the securing bolts to specification and sequence (refer to figure 8.65). Do not over torque.

AUTOMATIC TRANSMISSION 5A-127
Torque Converter and Housing Assembly
To assemble the torque converter and housing assembly, proceed as follows.
1. Locate the torque converter housing on the transmissionmain case.
2. Install and tighten the securing bolts to specification. NoticeAll the hardware must be correctly installed and torqued to specification.
3. Fit the converter ensuring that the tangs are engaged in the pump gear. Ensure that the tangs do not contact thepump seal.
Figure 8.1 - Torque Specifications
Torque Specifications
Torque converter housing to case Extension housing to case Rear servo coverPan to caseInhibitor switch to caseCooler connectors
Transmission filler plug Output flange lock nut (RWD models)Centre support to caseCam plate to case (parking pawl)
Valve body to case Upper valve body to lower valve bodyON/OFF solenoid retainers
Variable pressure solenoid retainerLine pressure plug Detent spring Pump cover to casePump cover plate to pump coverPump to pump adaptorPump cover plate to crescent Adaptor to case N

m
54 - 68 54 - 6825 - 35 4 - 6
2.3 - 3.4 30 - 3530 - 35
100 - 110
20 - 27 16 - 228 - 13
11 - 16 8 - 12 8 - 12
4 - 7
20 - 2224 - 3413 - 1624 - 27 13 - 16 25 - 35

MANUAL TRANSMISSION 5B-15
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug from the transmission housing anddrain the oil. Reinstall the drain plug.Installation Notice
Tightening Torque 25 Nm
4. Disconnect the back-up switch connector.
5. Remove the breather hose.
6. Remove the speedometer connector and other wiring harnesses and connectors.