SsangYong Musso. Manual - part 481

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 piston.

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 the

spring retainer over the spring.

Notice

The 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 are
clear 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

5A-104  AUTOMATIC TRANSMISSION

Figure 8.25 - C4 Clutch Pack Clearance