SsangYong Korando II (1996-2006 year). Manual - part 319

AUTOMATIC TRANSMISSION  5A-179

SSANGYONG  MY2002

5. Check the C4 piston bleed orifices are clear of

obstructions.

6. Lubricate the ‘O’ rings with ATF.

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.

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11. Assemble the piston return spring to the piston,

and fit the spring retainer over the spring.

12. Using 0555-336259 clutch spring compressor,

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.

Notice: The wire diameter of this spring is 4.3 mm.

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 ‘O’ rings with ATF and fit them to

their respective grooves.

Notice: ‘O’ rings must not be twisted in the
grooves.

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5A-180  AUTOMATIC TRANSMISSION

SSANGYONG  MY2002

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.

17. Using 0555-336259 clutch spring compressor,

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.

Notice: The wire diameter of this spring is 5.26 mm.

18. Install the C2 wave washer into the cylinder with

the crest of one wave covering one of the bleed
orifices inthe C2 piston.

19. Measure and record the thickness of the flange of

the C2 sleeve.

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

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AUTOMATIC TRANSMISSION  5A-181

SSANGYONG  MY2002

21. Holding the cylinder horizontal, install the sleeve

and clutch plate 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 0555-

336260 clutch pack clearance kit.

Notice: With the C2 wave spring compressed, and
the clutch Pack supporting a 2 kg weight, the
dimension from the underside of the C2 pressure plate
to the selective steel is to be between 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 pack and soak the friction plates
in ATF for a minimum of 5 minutes prior to reassembly.

Notice: The clutch pack clearance must be taken
before the elements are soaked in ATF.

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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 (0574-000013, `014, `015, `016,

`019, `022), or Friction disc (0574-000012 & `017)

•

Steel plate (selective)

•

Friction disc

•

Steel plate (selective)

•

Friction disc

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5A-182  AUTOMATIC TRANSMISSION

SSANGYONG  MY2002

26. Check the clutch pack clearance using only the

weight from 0555-336260 clutch pack clearance
kit.

Notice:  With the clutch pack supporting a 2
kgweight, 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

specifica-tion. 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.

Notice: The 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.

32. Apply petroleum jelly to the No. 5 needle bearing

and fit it to the C4 hub.

33. Remove the C2 clutch plates from the clutch cylin-

der.

34. Fit the thrust plate over the cylinder inner  hub.

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.

29. Align the tangs and fit the nylon thrust washer

onto the C4 hub.

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.

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