Transmision Automatica Rexton (Manual de Taller) PDF

AUTOMATIC TRANSMISSION 5A-159
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
TRANSMISSION
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the connectors from transfer case.
3. Disconnect the speedometer connector from
transfer case.
4. Disconnect the inhibitor connector, gear position
sensor connector and transmission case connector.
YAD5A080
5. Remove the rear propeller shaft bolts.

Installation Notice
Tightening Torque 70-80 N•m (52-59 lb-ft)
YAD5A090
6. Remove the cross member bolts and nuts.

Installation Notice
YAD5A100
SSANGYONG Y200
5A-160 AUTOMATIC TRANSMISSION
7. Remove the front propeller shaft bolts from transfer

case.
Installation Notice
YAD5A110
8. Remove the transfer case-to-transmission housing

bolts and remove the transfer case.
Installation Notice
Tightening Torque 44 N•m (33 lb-ft)
9. Disconnect the 10-Pins Plug connector from trans-

mission.
YAD5A120
10. Separate the locking clip on shift lever and remove

the shift rod.
Notice: Removal and installation performed when
the shift procedure should be lever is in ’D’ range.
YAD5A130
11. Remove the oil cooler pipes.

Installation Notice
YAD5A140
SSANGYONG Y200
12. Remove the service hole cover in the engine block.

13. Put the alignment mark for installation, and remove
the six mounting bolts for torque converter from
drive plate through the service hole by rotating
the engine and remove the torque converter.
Installation Notice
• Screw the six bolts mounting the torque converter

through the service hole by using a mirror and
rotating the engine.
14. Remover the starter. Refer to Section 1E, Engine
KAA5A2N0
Electrical.
15. Remove the extension housing to case bolts and

remove the transmission assembly.
Installation Notice
• Be careful not to drop the torque converter while

removing the transmission.
16. Installation should follow the removal procedure
in the reverse order.
YAD5A150
SSANGYONG Y200
UNIT REPAIR
REBUILD WARNINGS
Prior to rebuilding a transmission system, the following warnings are to be noted.
• Ensure that, before replacing a transmission the cooler lines are flushed out to remove any debris. This can be
done by applying compressed air to the rear cooler line forcing oil and any contaminants out of the front cooler
line.
• The cooler flow should be checked after the transmission has been fitted. With the front cooler line connected
and the rear line run into a suitable container, measure the flow over 15 seconds with the vehicle idling in park.
• The flow rate should exceed 1 liter in 15 seconds.
• Be wary of any situation where water enters the transmission. This may result in fluid foaming and leaking
through the breather.
• Ensure that both earth straps (one at the battery terminal and one on the vehicle body) are connected in the
vehicle before connecting the positive side of the battery.
• Follow the throttle position calibration procedure in this manual if the engine control module/ transmission
control module (ECM/TCM) is swapped.
KAA5A710
SSANGYONG Y200
DISASSEMBLY PROCEDURE
Transmission
Tools Required
0555-336256 Transmission Bench Cradle
0555-336257 Pump Puller
Notice:
• Remove the inhibitor switch before washing the

transmission in solvent or hot wash.
• It is assumed that the transmission fluid has been
drained when the transmission was removed from
the vehicle and that the ’special tools’ quoted are
available.
• The transmission is dismantled in a modular fashion,
and the details of disassembly for each module are
given under the appropriate subject. Refer to
Special Tools Table in this chapter for details of all
special tools required when performing
disassembly procedures.
• Technicians overhauling these transmissions will
also require a selection of good quality Torx bit
sockets, in particular numbers 30, 40 and 50, and
an 8mm, 10mm and 12 mm double hex socket.
1. Remove the converter and the converter housing.

2. Mount the transmission on the transmission bench
cradle 0555-336256.
3. Remove the oil pan and the oil pan seal.
KAA5A500
4. Remove each end of the filter retaining clip from

the valve body and remove the filter.
5. Disconnect the wires from each solenoid and ground
and lay the wiring to one side.
6. Remove the valve body securing screws and
remove the valve body from the case.
KAA5A510
SSANGYONG Y200
7. Remove the front servo cover circlip.

8. Remove the front servo cover, piston and spring.
Notice: The plastic servo block is retained by the
piston return spring only.
9. Remove the adaptor housing bolts and adaptor

housing.
KAA5A520
10. Remove the pump to case bolts using a multi-hex

8 mm spanner.
11. Using the pump puller 0555-336257, remove the
pump and pump cover.
KAA5A530
12. Remove the input shaft, forward clutch cylinder,

and the overdrive shaft as an assembly,
withdrawing them through the front of the case.
13. Remove the C3 clutch cylinder and sun gears.
KAA5A540
14. Remove the front band struts. Remove the front

band.
KAA5A550
SSANGYONG Y200
15. Remove the two centre support retaining bolts

using a T50 Torx bit.
16. Remove the centre support retaining circlip.
Notice: Do not hammer the output shaft to remove
the centre support as this will cause permanent
damage to the thrust bearing surfaces.
17. Remove the centre support, 1-2 one way clutch,

and planetary gear set as an assembly.
18. Remove the parking rod cam plate using a T40
Torx bit.
KAA5A560
19. Remove the rear band struts and remove the band.
Notice: Vise the both end of rear band using the
plier and lean forward about 15 degrees
20. Remove the output shaft assembly.
KAA5A570
Transmission Case
Tools Required
0555-336258 Cross Shaft Pin Remover/Installer
(Detent Lever)
0555-336261 Cross Shaft Seal Remover
(Inhibitor Switch)
1. Remove the pin from the side of cross shaft
inhibitor switch using cross shaft pin remover/
installer (inhibitor switch) 0555-336265.
2. Remove the inhibitor switch bolts and inhibitor
KAA5A580 switch from the case.
3. Remove the cross shaft seals with cross shaft seal

remover 0555-336261.
4. Remove the circlip from the cross shaft. Pull the
shaft to release the drive pin from the selector
quadrant.
KAA5A590
SSANGYONG Y200
5. Using cross shaft pin remover/installer (detent le-

ver) 0555-336258, press the pin from the cross
shaft and withdraw the shaft from the case.
6. Remove the cross shaft pin and spring.
7. Remove the manual valve lever and the park rod.
KAA5A600
8. Depress the tangs and withdraw the 10 pin

connector into the case. Remove the wiring loom
assembly.
KAA5A610
9. Detach the No.7 solenoid wire from the front of

the case.
10. Remove the parking pawl pivot pin and the pawl
and spring from the case.
11. Remove the shaft and the rear servo lever.
KAA5A620
12. Remove the rear servo cover and piston assembly.

13. Remove the B1R circlip, valve and spring.
14. Remove both band adjustment shims.
15. Inspect the output shaft bushing in the case and
replace if necessary.
16. Inspect cooler line fittings and replace as
necessary.
17. Inspect the case for damage.
KAA5A630
SSANGYONG Y200
18. To remove the park rod lever: Remove the circlip

from the inner end of the pivot shaft and tap the
outer end of the shaft until it moves free from the
case, then using a wide shallow tapered drift as a
wedge, drive the pin out from the inside of the
case and remove the lever and spring.
Notice: Do not remove the park rod lever unless
absolutely necessary.
KAA5A640
Forward Clutch Cylinder

Tools Required
0555-336259 Clutch Spring Compressor
1. Place the assembly in a horizontal position.
KAA5A650
2. Remove the No. 4 needle bearing (2) and adjust-

ment shims (1) from the input shaft.
3. Remove the circlip from the front of the clutch cylin-
der 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.
KAA5A660
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 No. 5 needle bearing from the C4 hub.
8. Removethe C2 clutch plates.
KAA5A670
SSANGYONG Y200
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, and the hubs may be
separated by rotating one hub clockwise and
withdrawing it from the other.
10. Remove the thrust block from the C4 clutch
cylinder hub.
KAA5A680
11. Mount the clutch cylinder on clutch spring

compressor 0555-336259 with the C2/C4 end
uppermost and compress the piston return spring.
Remove the spring retaining circlip. Release the
tool and remove the circlip, keeper and spring.
Notice: Make sure that the spring keeper is not
caught in the circlip groove, and that all the spring
pressure is released, before removing the tool.
12. Invert the clutch cylinder on the compressor tool

and removethe C1 clutch piston return spring in
asimilar manner.
KAA5A690
13. To remove the clutch pistons from the clutch

cylinder, apply air pressure to the apply ports in
the bore of the cylinder.
KAA5A700
C3 Clutch Cylinder
Tools Required
1. Remove the forward sun gear, No.7 needle bearing
(2) thrust washer (1) and lipped thrust washer (3)
from the C3 clutch cylinder.
2. Remove the thrust plate (4), No.6 needle bearing
(5), thrust plate (6) and nylon thrust plate (7) from
the clutch cylinder hub.
3. Remove the clutch plate retaining circlip and re-
move the clutch plates.
KAA5A720
SSANGYONG Y200
4. Mount the clutch assembly on clutch spring com-

pressor 0555-336259 and compress the piston re-
turn spring.
5. Remove the circlip and release the spring.
6. Remove the tool, circlip, keeper and spring.
Notice: Make sure that the spring keeper has not
been caught in the circlip groove, and that all spring
pressure has been released, before removing the tool.
KAA5A730
7. Remove the sealing rings from the C3 clutch

cylinder.
8. To remove the clutch piston from the clutch cylinder,
apply air pressure to the port between the iron
sealing rings on the bearing journals of the cylinder.
9. Remove the reverse sun gear and C3 washer from
the cylinder.
KAA5A740
Planet Carrier Assembly and Centre

Support
1. Remove the No. 9 (2) needle bearing and washer
(1) from the output shaft and the planet carrier.
2. Separate the centre support from the planet carrier
by rotating it anti-clockwise.
KAA5A750
3. Lift the one way clutch (1) from the planet carrier
(5).
4. Remove the circlip (2) retaining the one way clutch
outer race (3) in the planet carrier and remove the
race.
5. Remove the one way clutch retainer (4) from the
planet carrier.
KAA5A760
SSANGYONG Y200
Pump
Notice: The following valves are housed in the pump
cover:
• Solenoid 7
• Converter clutch control valve
• Converter clutch regulator valve
• Primary regulator valve
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 with T30 Torx bit. Note that the long screw
holds the pump body to the pump body cover.
Notice: Do not strike the converter support tube to
loosen the pump body.
KAA5A770
4. Separate the pump body from the pump cover.

5. Remove the cover plate, gasket and seal from the
cover.
KAA5A780
6. Remove the ball check valve and one spring from

the pump cover.
KAA5A790
SSANGYONG Y200
7. Depress the plug inward and remove the retaining

pin for each of the three valves.
Notice: Some of the valves and plugs are preloaded
by springs and may unexpectedly fall out of the
cover when the pins are removed.
8. Remove the four valves, plugs and springs.
KAA5A800
9. Remove the pump gears from the pump body.

10. Remove the lip seal from the front of the pump
body.
KAA5A810
Valve Body
1. Remove the manual valve detent spring and retain-
er plate using a T40 Torx bit.
2. Slide the manual valve out of the lower valve body.
Notice: Be aware that the manual valve will fall out
of the valve body.
3. Take note of the angular relationship of the

solenoid terminals to the valve body and remove
the solenoids 1, 2, 3, 4, 5, 6 and valve assemblies.
Notice: Take care that the bracket is not separated
KAA5A820
from the solenoid.
4. Place the valve body assembly on the bench with

the upper body uppermost.
5. Remove the 24 clamping screws with a No. 30
Torx bit. Separate the upper and lower valve
bodies by lifting the upper body and the separator
plate togeth-er.
6. Turn the upper body over and place it on the bench
with the separator plate uppermost.
KAA5A830
SSANGYONG Y200
7. Lift the separator plate and gaskets from the upper

valve body.
8. Remove the five nylon check balls exposed in the
valve body.
9. Remove the retaining plate, plug, spring and re-
verse lockout valve.
KAA5A840
10. Remove the filter (1) and the large nylon check
ball (2) from the lower valve body.
11. Remove the retaining plates and pins from the 1-
2, 2-3, 3-4, BAR and CAR valves. The pins can
be removed with a magnet.
Notice: Once the pins are removed, the plates are
loose in the valve body and will drop out when the
valve body is turned over.
12. Remove the 1-2, 2-3 and 3-4 shift valves.
KAA5A85A
13. Depress the 4-3 sequence valve plug and remove

the retaining plate.
Notice: The plug is preloaded by the spring and
may unexpectedly fall out of the valve body.
14. Remove the plug, spring and valve
KAA5A860
15. Depress the solenoid 5 valve. Remove the

retaining in and remove the valve, damper guide
and spring.
Notice: The valve is preloaded by the spring and
may unexpectedly fall out of the valve body.
16. Depress the line pressure release valve, remove

the retaining pin, disc (if fitted), spring and valve.
17. Drive out the retaining pin and remove the spring
and ball check valve adjacent to the BAR valve.
KAA5A870
SSANGYONG Y200
ASSEMBLY PROCEDURE
Transmission
Tools Required
0555-336256 Transmission Bench Cradle
(Detent Lever)
0555-336262 Cross Shaft Seal Installer
0555-336263 Cross Shaft bullet
(Inhibitor Switch)
Notice:
• The transmission is assembled in modular fashion

and details of assembly for each module are given
under the appropriate subject.
• Technicians overhauling these transmissions will
also require a selection of good quality Torx bit
sockets, in particular numbers 30, 40 and 50, and
an 8 mm, 10 mm and 12 mm double hex socket.
• Ensure that the B1R circlip is fitted to the case. (If
this is not fitted, the valve will peen its way into
and through the separator plate)
• Ensure that the ’E’clip is fitted to the cross shaft.
• Ensure that all aspects of the parking mechanism
are working.
1. Turn the transmission case upside down on the

bench and mount it to the transmission bench cradle
0555-336256.
2. Install all fittings, plugs and the breather, applying
a sealant where applicable, Tighten the fittings to
specifications. Ensurethatthebreatheris clear,
andcheckthat the lube fitting in the rear of the case
is fittedand clear of obstruction.
KAA5A500
3. Assemble the B1R valve and spring, and secure

with the circlip. Ensure that the circlip is completely
seated in its groove.
KAA5A880
SSANGYONG Y200
4. Install the rear servo lever and pivot pin.

Notice: The lever must pivot freely on its pin.
KAA5A890
5. Assemble the park rod lever, complete with the

return spring and pivot pin, applying a small
amount of sealant to the outer end of the pivot
pin.
Notice: Care must be taken when applying sealant
to ensure that it is not applied between the pin and
the lever.
6. Secure the pivot pin with the circlip.

Notice: The lever must pivot freely on its pin and
the spring must return the park rod lever to its correct
location.
KAA5A640
7. Install the parking pawl pivot pin and spring.

Notice: The pawl must pivot freely on its pin.
KAA5A900
8. Connect the park rod to the manual valve detent

lever. Ensure the spring and cam collar is firmly
installed on the rod.
9. Check that the cam collar slides freely on the rod.
10. Insert the cross shaft into the case, from the side
opposite to the inhibitor switch, then install the
antirattle spring on the shaft.
KAA5A910
SSANGYONG Y200
11. Poition the manual valve detent lever, aligning it

with the cross-shaft bore in the case.
12. Push the shaft through the detent lever until it starts
in the detent lever side of the case.
KAA5A920
13. Install the detent lever drive pin in the shaft using
cross shaft pin remover/installer (detent lever)
0555-336258 with the adaptor over the pin.
14. Press the pin into the shaft until the tool bottoms.
15. Remove the tool and fit the spring retaining circlip
to the shaft.
KAA5A600
16. Install the new cross shaft seals using cross shaft
seal installer 0555-336262 (1) and cross shaft
bullet 0555-336263 (2).
KAA5A930
17. Install the inhibitor switch on the case. Torque the

bolts as per specifications. Press the pin into the
shaft until the tool bottoms using cross shaft pin
installer/ remover (inhibitor switch) 0555-336265.
Installation Notice
Tightening Torque 4-6 N•m (35-53 lb-in)
18. Thoroughly check the terminal wiring loom for

condition and continuity.
KAA5A580
SSANGYONG Y200
19. Position the wiring loom and locate the solenoid 7

contact and terminal in the pump mounting flange
at the front of the case. The solenoid 7 wire is
routed under the park rod and cross shaft in the
case.
KAA5A940
20. Install the 10 pin connector in the case engaging

the tangs on the connector in the notches in case.
KAA5A610
Output Shaft and Gear Assembly

1. Check that the output shaft bush is not worn or
damaged. Replace if necessary.
2. Check for damage to parking pawl teeth on the
ring gear. Replace if necessary.
3. Check that the sealing ring grooves have not been
damaged.
4. Lubricate the sealing rings with automatic
transmission fluid.
5. Assemble the sealing rings to the output shaft with
the scarf cut uppermost.
KAA5A970
6. If previously dismantled, assemble the ring gear

to the output shaft and secure with circlip. Ensure
that the circlip is firmly seated in its groove.
7. Install the No. 10 needle bearing assembly onto
the output shaft using petroleum jelly.
8. Carefully install the output shaft assembly in the
case to prevent damage to the sealing rings.
KAA5A980
SSANGYONG Y200
Rear Band Assembly

1. Check the rear band for any cracks or damage along
the lining and metal backing.
2. Install the reaction anchor strut into the main case,
without shims.
3. Carefully install the rear band into the transmission
case and ensure that it is properly fitted in the case.
Notice: If fitting a new band, soak the new band in
automatic transmission fluid for a minimum of five
minutes prior to assembly.
KAA5A950
4. Position the apply strut on the rear band then

engage the apply strut in the servo lever.
5. Install the cam plate and tighten the screws to
specification.
Installation Notice
KAA5A960
Rear Servo Assembly

1. Check the servo piston ‘O’ rings and gasket for
any damage.
2. Lubricate the servo piston ‘O’ rings with automatic
transmission fluid, and fit the ‘O’ rings to the piston
grooves.
3. Assemble the piston to the cover, ensuring that ‘O’
ring compression is adequate but not excessive.
4. Align the spring on the piston spigot, then position
the rear servo rod into the spigot.
KAA5A630
5. Assemble the gasket to the cover and fit the assem-

bly to the case.
Notice: Do not use petroleum jelly on the gasket.
6. Apply additional Loctite 202 or equivalent as

required to the rear servo to case bolts. Install the
bolts and tighten to specification.
Installation Notice
KAA5A990
SSANGYONG Y200
Planet Carrier Assembly and Centre Support

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
0.10 mm - 0.50 mm.
KAA5A0A0
2. Install the One Way Clutch (OWC) retainer (1) to

the planet carrier with the inner edge pointing down-
wards. Inspect the OWC race and the sprag
assemblies for wear or damage. Replace if
necessary.
3. Install the outer (3) race in the drum. Press the
race to the bottom of the drum and install the
retaining circlip (2). Ensure the circlip is firmly
seated in its groove.
4. Install the OWC (1) into the outer race with the lip
edge uppermost. Lubricate the sprags with auto-
matic transmission fluid.
KAA5A760
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-clock-wise direction only.
6. Lubricate the No. 9 needle bearing and washer
with petroleum jelly and fit them to the rear face
of the planet carrier.
KAA5A750
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.
Installation Notice
KAA5A560
SSANGYONG Y200
Adaptor Housing Assembly

1. Install a new seal to the adaptor housing.
2. Position a new gasket onto the adaptor housing.
Notice: Do not use petroleum jelly to hold the gasket
in position.

required to the adapter housing bolts. Install the
adaptor housing and torque the bolts to
specification.
Installation Notice
KAA5A0B0 Tightening Torque 30-35 N•m (22-26 lb-ft)
Front Servo Assembly

1. Lubricate the cover ‘O’ ring with automatic
transmission fluid and fit to the cover.
2. Lubricatethepiston‘O’ rings with automatic trans-
mission 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.
KAA5A0C0
5. Install the front servo block and spring into the case.
6. Install the front servo assembly into the case.
KAA5A520
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.
Notice: Ensure that the front servo snap ring is
installed correctly. Orient the circlip with the gap at
the bottom, near the pan rail.
KAA5A0D0
SSANGYONG Y200
Front Band Assembly

1. Install the reaction anchor strut to the case.
2. Check the band for all cracks or damage along its
lining and metal backing.
3. Position the strut retainers on the band.
KAA5A0E0
4. Install the front band into the transmission case,

ensuring that it is properly seated in place.
Notice: If fitting a new band, soak the band in
automatic transmission fluid for a minimum of 5
5. Position the reaction strut in its retaining clip and

engage it with the band and anchor strut.
6. Position the apply strut in its retaining clip and
engage it with the band and the servo piston rod.
KAA5A550
C2/C4 Clutch Assembly

Tools Required
0555-336260 Clutch Pack Clearance Kit
Notice:
• Check pistons for cracks.

• Do not mix the clutch piston return springs.
• Ensure that the snap rings are fitted correctly.
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 (ATF)
4. Fit the small ‘O’ ring onto the inner groove, and
the large ‘O’ ring onto the outer groove of the piston.
Notice: ‘O’ rings must not be twisted in the grooves.
KAA5A0F0
SSANGYONG Y200
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
KAA5A0G0
on the outside of the cylinder, until the outer
diameter of the C2 piston enters the inner diameter
of the cylinder.
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.
KAA5A690 14. Lubricate the ‘O’ rings with ATF and fit them to
their respective grooves.
Notice: ‘O’ rings must not be twisted in the
grooves.
SSANGYONG Y200
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.
KAA5A0H0
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
KAA5A0I0
• Steel plate
• Wave washer
SSANGYONG Y200
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.
KAA5A0J0
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.
KAA5A0K0 Notice: The clutch pack clearance must be taken
before the elements are soaked in ATF.
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)
KAA5A0L0 • Steel plate (selective)
• Friction disc
• Friction disc
SSANGYONG Y200
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.
KAA5A0M0 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.
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.
KAA5A0N0
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.
KAA5A0O0
SSANGYONG Y200
C3 Clutch and Reverse Sun Gear Assembly

Tools Required
1. Check the orifices in the cylinder are clear of ob-
structions.
2. Check the C3 cylinder bush outside diameter and
the centre support inside diameter are in good con-
dition and not damaged. Coat the sealing rings
with automatic transmission fluid and fit into the
C3 cylinder grooves.
3. Check the reverse sun gear splines, grooves and

thrust face for condition. Coat the ‘O’ ring with
automatic transmission fluid and fit it to the groove
of the reverse sun gear.
4. Lubricate the C3 washer with petroleum jelly and
fit to the inner face of the reverse sun gear.
5. Install the reverse sun gear in the C3 cylinder, en-
suring that the ‘O’ ring compression is adequate
but not excessive.
Notice: ‘O’ rings must not be twisted in the
grooves.
KAA5A0P0
6. Coat the C3 piston ‘O’ rings with automatic trans-

mission fluid and fit the small ‘O’ ring onto the
inner ring and the large ‘O’ ring onto the outer
ring of the C3 piston.
7. Check that the bleed orifices of the piston are
clean and clear of obstructions.
8. Install the C3 piston in the cylinder until the outside
diameter of the piston enters the inside diameter
of the cylinder.
Notice: Take care not to cut the ‘O’ ring.
KAA5A0Q0
9. Assemble the spring and spring retainer on the

piston. 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 the
groove, and remove the tool.
10. Fit the C3 wave plate to the C3 piston face,
ensuring that one crest of the wave plate of the
C3 piston face is aligned over one of the piston
orifices.
KAA5A730
SSANGYONG Y200
11. Assemble the clutch plates and discs into the

cylinder in the following sequence :
• Steel plate
• Friction disc
• Steel plate
• Steel plate (0574-000013, `014, `015, `016, `019,
`022), or Friction disc (0574-000012, `017)
• Friction disc
• Friction disc
KAA5A0R0
12. Align and fit the pressure plate with the
counterbore facing away from the clutch plates.
13. Install the circlip.

14. Check the C3 clutch clearance using 0555-336260
clutch pack clearance kit in the following manner
(weight only).
a. Place the weight on the pressure plate and
measure the distance from the end of the
cylinder to the top of the pressure plate.
b. Record this figure.
c. Remove the weight.
d. Lift the pressure plate up against the circlip
and measure the distance from the end of the
cylinder to the top of the pressure plate.
KAA5A0S0
e. Record this figure.
f. Subtract the second reading from the first read-
ing to obtain the clutch pack clearance.
SSANGYONG Y200
Notice: With the clutch pack supporting a weight

of 2kg, the clearance between the snap ring and
the top of the pressure plate is to be between 1.07
- 1.45 mm.
15. If new friction plates are being fitted, remove the

clutch pack and soak the friction elements in auto-
matic transmission fluid for a minimum of five min-
utes prior to reassembly.
Notice: The clutch pack clearance must be taken
before the elements are soaked in automatic
transmission fluid.
KAA5A0TA
Forward Sun Gear and C3 Clutch Pack

Assembly
1. Fit the No.7 needle bearing assembly over the for-
ward sun gear, ensuring that the thrust washer is
between the bearing and the sun gear.
2. Lubricate the lipped thrust plate with petroleum
jelly and fit the thrust plate onto the reverse sun
gear.
KAA5A0U0
3. Align and fit the C3 clutch assembly over the for-

ward sun gear.
KAA5A0V0
4. Lubricate the No.6 needle bearing with petroleum

jelly and fit it to the thrust plate. Ensure the lugs
on the outside diameter of the bearing fit in the
thrust plate counterbore.
5. Align and fit the plastic thrust washer to the thrust
plate with petroleum jelly.
6. Install the assembly over the forward sun gear
shaft against the No. 6 needle bearing.
7. Place the assembly to one side.
KAA5A0W0
SSANGYONG Y200
C1 Clutch Overdrive Shaft and Input Shaft

Assembly
Tools Required
Notice:
• Ensure that the snap rings are fitted correctly.
• Check pistons for cracks, especially the C1 piston.
• Do not mix clutch piston return springs.
• If the C1/C2 clutch packs separate from the C3
clutch pack, make sure the No. 6 bearing doesn’t
drop out of the bearing retainer.
1. Check the overdrive shaft grooves for any defect.

2. Coat the sealing rings, large and small, with petro-
leum jelly and fit them to the overdrive shaft. The
sealing rings may be held in place with a small
amount of petroleum jelly.
KAA5A0X0
3. Assemble the clutch plate and disc into the cylinder

in the following sequence:
• Steel plate
• Friction disc
• Steel plate
• Friction disc
• Steel plate
• Steel plate ( 0574-000013, `014, `015, `016, `019,
`022), or friction disc (0574-000012 & `017)
• Friction disc
KAA5A0Y0
• Friction disc
SSANGYONG Y200
4. Check the clutch pack clearance using 0555-

336260 clutch pack clearance kit.
5. Use selective plates to achieve the correct specifi-
cation.
Notice: With the clutch pack supporting a 2 kg
weight, the dimension from the input shaft locating
stop to the friction disc must be 0.70 - 0.90 mm.
6. If new friction plates are being fitted, remove the

clutch pack and soak the friction elements in auto-
matic transmission fluid for a minimum of five
KAA5A0Z0 Notice: The clutch pack clearance must be taken
before elements are soaked in automatic
transmission fluid.
7. Check the fit of the C1 clutch hub on the overdrive

shaft. If it is loose, the hub and shaft assembly
must be replaced.
8. Coat the small nylon thrust spacer with petroleum
jelly and install it over the overdrive shaft.
9. Carefully fit the overdrive shaft into the C1 cylinder
so as not to damage the sealing ring.
10. Fit the small bronze C1 hub thrust washer in place
with petroleum jelly.
11. Check the input shaft for any defect. Fit the input
shaft into the cylinder and secure it with the circlip,
ensuring that the circlip is completely seated in
KAA5A660 the groove.
12. Coat the sealing rings with petroleum jelly and fit
onto the input shaft.
KAA5A1A0
SSANGYONG Y200
13. Assemble the C1/C2/C4 clutch assembly to the

C3 clutch and sun gear assembly.
14. Install this assembly in the transmission case.
KAA5A1B0
Pump Cover and Converter Support

Notice:
• Do not wash the nose of solenoids in solvent.
• Ensure that the correct ‘O’ ring is fitted for the
application.
• Be careful not to damage the needle bearings on
the assembly. Avoid any axial impact loads during
assembly.
• Check the transmission end float. This will help to
detect any missing parts or incorrect assembly.
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.
KAA5A1C0
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.
KAA5A810
SSANGYONG Y200
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.
KAA5A1D0
9. Assemble the primary regulator valve, spring and

plunger to the pump cover, ensuring that the
regulator valve slides freely, then fit the regulator
valve plug and ‘O’ ring.
10. Install the retaining pin.
KAA5A1E0
11. Install the converter clutch regulator valve, plug,

spring and ‘O’ ring.
KAA5A1F0
KAA5A1GO
KAA5A1G0
SSANGYONG Y200
13. Install the converter clutch control valve, spring,

plug, and ‘O’ ring.
KAA5A1H0
15. Install the converter release check ball and spring.

16. Install the gasket on the pump cover.
KAA5A1J0
17. Install the cover plate, solenoid 7 with the retainer

and the solenoid wiring retainer to the pump cover,
ensuring that the periphery of the cover plate is
flush with the periphery of the pump cover.
18. Tighten the screws to specification in the order.
(1-5)
Installation Notice
19. Tighten the solenoid 7 screw.

Installation Notice
KAA5A1K0
• Check that neither the wiring nor the connector

protrudes excessively, in order that at
assembly neither the wiring and the connector
contacts or rubs on the input shaft or the C1/
C2 clutch cylinder.
SSANGYONG Y200
20. Assemble the pump to the pump cover.

21. Tighten all bolts and the crescent screw finger
tight, ensuring that the pump is flush against the
pump cover. Tighten the bolts and the screw to
specification in the order. (A-F)
Installation Notice
Tightening Bolt (A-E) : 24-27 N•m (18-20 lb-ft)

Torque Screw (F) : 13-16 N•m (10-12 lb-ft)
22. Install the pump to transmission case gasket onto
the case.
23. Fit the ‘O’ ring to the pump cover outer diameter.
KAA5A1L0
24. Install the pump and cover assembly over the

input shaft being careful not to damage the sealing
rings. Apply additional Loctite 202 or equivalent
as required to the pump cover to case bolts. Install
and tighten bolts to specification.
Installation Notice
KAA5A1M0
25. Check that the transmission end float is 0.50 -

0.65 mm. If the unshimmed end float clearance is
greater than specification, shims are to be placed
between the No. 4 bearing and the input shaft
bearing surface. If the end float clearance is less
than 0.5 mm then the transmission has been
assembled incorrectly or the parts are out of
specification.
26. Perform the following steps to check the end float :
a. Attach a dial indicator to the front of the trans-
mission case with the stylus resting on the end
of the input shaft.
KAA5A1N0 b. Apply a force of approximately 250 N or 25 kg
to the input shaft.
c. Zero the dial indicator.
d. Place a small lever behind the forward clutch
cylinder and lever the cylinder forward.
e. The measurement recorded on the dial indicator
is the transmission end float or clearance be-
tween the No.4 bearing and the converter sup-
port tube.
27. On completion of this procedure, adjust the front
and rear bands to specifications. Refer to “Front
and Rear Band Adjustment” in this section.
SSANGYONG Y200
Valve Body
Notice:
• Do not wash the nose of solenoids in solvent.
• Be aware of ball positions in the upper valve body.
• Be aware of 1-2 and 3-4 shift valve positions, they
can be swapped.
• Check the 4-3 sequence valve and spring
orientation.
• Check that the 12 mm ball is in the lower body.
• Check the line pressure relief valve for swarf, and
be aware of replacing the shims.
• When servicing the transmission, ensure that the
solenoid 5 damper spring is not broken.
• Locate the detent spring central to the detent lever.
• Wash the upper and lower valve bodies thoroughly
with cleansing solvent and blow dry.
• Check the valve body cavities, ports and holes for
damage or obstructions.
• The orifices in the valve body are for stability and
safeguard. Do not drill them larger.
• Thoroughly wash all loose components.
• Check that all valves slide freely in their location.
1. Install the detent lever locating pin

2. Install the Band Apply Regulator (BAR) valve,
springs, plunger and retaining pin.
KAA5A1O0
3. Install the line pressure relief valve, tapered end

first, spring and disc. Secure with the retaining pin.
KAA5A1P0
SSANGYONG Y200
4. Install the solenoid 5 damper guide and spring,

piston and retaining pin.
KAA5A870
5. Install the 4-3 sequence valve, spring, plug and

retaining plate.
KAA5A860
6. Install the 1-2 shift valve, plug and retaining pin.
KAA5A1Q0
7. Install the 2-3 shift valve and retaining pin.
KAA5A1R0
SSANGYONG Y200
8. Install the 3-4 shift valve and retaining pin.
KAA5A1S0
9. Install the Clutch Apply Regulator (CAR) valve,

springs, plunger and retaining pin.
KAA5A1T0
10. Install the solenoid supply valve, spring and

retaining plate.
Notice: This aluminum valve is easily damaged.
11. Install solenoid 6 plunger, spring and retaining pin.
KAA5A1U0
12. Position the third feed ball (large nylon) in the valve
body and install the solenoid 6 filter.
13. Check the separator plate for burrs and damage.
Repair or replace the separator plate as
necessary.
14. Check the upper and lower valve body gaskets
for damage. Replace the gaskets as necessary.
15. Install the lower valve body gasket on the lower
valve body.
KAA5A850
SSANGYONG Y200
16. Install the reverse lockout valve, spring, plug and

retaining plate. Ensure that the valve is correctly
oriented.
KAA5A1V0
17. Position the five nylon ball checks in the upper

valve body.
18. Fit the upper valve body gasket. Install the separa-
tor plate over the upper valve body.
KAA5A840
19. Holding the separator plate to the upper valve

body to prevent the check balls from falling out,
install the upper valve body on the lower valve
body. Install all screws finger tight then tighten
the screws to specification in the prescribed
sequence.
Installation Notice
20. Install solenoids 1, 2, 3, 4 and 6. Ensure the

solenoid is firmly secured by the retainer and that
the screw is tightened to specification.
KAA5A830
Installation Notice
• The wiring loom ground wire eyelet terminal is

secured beneath the solenoid 1 retainer.
SSANGYONG Y200
21. Install solenoid 5. Ensure that the solenoid is

pushed firmly into the valve body by the retainer
and that the screw is tightened to specification.
Installation Notice
KAA5A1W0
22. Install the detent spring assembly (spring, support

plate and screw), ensuring that the screw is tight-
ened to specification. Check the spring for wear
or damage.
Installation Notice
KAA5A1X0
23. Install the manual shift valve.

Notice: Be aware that the manual valve will fall out
of the valve body.
KAA5A1Y0
24. Align the valve body assembly on the transmission

case and 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.
Installation Notice
KAA5A1Z0
SSANGYONG Y200
25. Check the alignment of the detent roller and the

manual lever quadrant.
26. 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
Notice: All hardware must be correctly installed and
torqued to specification.
KAA5A2A0
Oil Filter and Pan Assembly

Notice:
• Replace the filter whenever rebuilding a
transmission where a significant amount of
mechanical damage has occurred.
• 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.
• Ensure that the internal line pressure plus in the
valve body is fitted.
KAA5A510
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.
3. Secure the oil filter assembly with the retainer.
4. Check that the magnet is located in the dimple in
the corner of the oil pan.
5. Assemble the gasket on the pan lip. The gasket
must be free of any distortion when installed.
KAA5A2B0
SSANGYONG Y200
6. Fit the oil pan assembly to the transmission case

and tighten the securing bolts to specification and
sequence Do not over torque.
Installation Notice
KAA5A2C0
Torque Converter and Housing Assembly

1. Locate the torque converter housing on the trans-
mission main case.
required to the converter housing to case bolts.
Install and tighten bolts to specification.
Installation Notice
• All the hardware must be correctly installed and

torqued to specification.
KAA5A2D0 3. Fit the converter ensuring that the tangs are
engaged in the pump gear. Ensure that the tangs
do not contact the pump seal.
Output Flange Assembly (2WD Mode)

1. Position the transmission detent lever into the park
position and lock the output shaft.
2. Clear the threads on the output shaft and apply
Loctite 243 or equivalent as required to threads.
3. Install the flange, ‘O’ ring and torque the nut to
specification.
Installation Notice
KAC5A040
KAC5A040
SSANGYONG Y200
FRONT AND REAR BAND ADJUSTMENT

Front Band Setting Procedure
KAA5A2E0
1. Measure the projection of the front servo push rod 2. Fit the selected shim(s) to the shank of the anchor
from the transmission case dimension ’A’. strut as follows:
a. Apply air at 650/700 kPa to the front servo apply a. Inspect the shim(s) for damage, wear or corro-
area (B1 outer) sion. Replace as necessary.
b. Measure the travel of the push rod and subtract b. The shim(s) are to be installed between the case
3 mm to find the shim size required. abutment face and the anchor strut flange.
c. Release the air. c. The shim(s) are to be fitted by hand and under
no circumstances to be hammered or forced.
Notice: A minimum of one shim is required at all times
- minimum shim size is 1 mm. The thickness of d. Shim(s) are to be pressed on by hand until an
available shims are listed in the table below. audible click is heard. The click indicates that
the shim is clipped home correctly.
Thickness(mm) Part Number 3. Re-check that the push rod travel. (3mm ±0.25mm)
0.95/1.05 0574-037017
1.15/1.25 0574-037018
1.44/1.56 0574-037019
1.73/1.87 0574-037020
1.93/2.07 0574-037021
2.12/2.28 0574-037022
2.42/2.58 0574-037023
2.61/2.79 0574-037024
SSANGYONG Y200
Rear Band Setting Procedure
KAA5A2F0
1. Measure distance‘A’ from the rear servo piston to 2. Fit the selected shim(s) to the shank of the anchor
the inner face of the transmission case using vernier strut as follows.
calipers. a. Inspect the shim(s) for damage, wear or
a. Apply air at 650/700 kPa to the rear servo apply corrosion and replace as necessary. The shim(s)
area (B2 outer) are to be installed between the case abutment
b. Measure the travel of the piston, subtract 3.75 face and the anchor strut flange.
mm and divide the remainder by 2.5 to find shim b. The shim(s) are to be fitted by hand and under
size. no circumstances to be hammered or forced
c. Release the air. c. The shim(s) are to be pressed on by hand until
an audible click is heard. The click indicates
Notice: A minimum of one shim is required at all times
that the shim is clipped home correctly.
- minimum shim size is 1 mm. The thickness of
available shims are listed in the table below. 3. Re-check that the piston travel.
(3.75 mm ± 0.625 mm)
Thickness(mm) Part Number
0.0.95/1.05 0574-037017
1.15/1.25 0574-037018
1.44/1.56 0574-037019
1.73/1.87 0574-037020
1.93/2.07 0574-037021
2.12/2.28 0574-037022
2.42/2.58 0574-037023
2.61/2.79 0574-037024
SSANGYONG Y200
KAA5A2G0
SSANGYONG Y200
GEAR SHIFT CONTROL LEVER

Disassembly and Assembly Procedure
2. Remove the gear shift control lever assembly.
Refer to Section 9G, interior Trim.
3. Remove the gear shift control lever knob.
4. Separate the upper and middle housing from the
gear shift control lever assembly by unlocking the
lock.
5. Remove the upper housing.
KAA5A5P0
6. Disconnect the P position lamp by turning it from
the middle housing.
7. Remove the P position switches assembly bolts.

8. Remove the middle housing with the mode selector
switch wiring harness from the gear shift control
lever assembly.
9. Separate the P position switches assembly with
the P position lamp wiring harness from the gear
shift control lever assembly.
Notice: Adjust the brake transmission shift interlock
ease the operation well.
KAA5A5Q0
10. Remove the clips supporting the springs and

bushes from the pin of the pin of the gear shift
control lever.
11. Remover the spring and bushes from the pin of
the gear shift control lever.
12. Remove the gear shift control lever by pushing
the pin.
13. Installation should follow the removal procedure
in the reverse order.
KAA5A5R0
SSANGYONG Y200
KICKDOWN SWITCH
1. Separate the Kickdown Switch from the Kickdown
Switch bracket by pushing the lock.
2. Disconnect the Kickdown Switch connector.
3. Installation should follow the removal procedure in
the reverse order.
KAA5A5S0
TRANSMISSION CONTROL
MODULE
Removal and Installation Procedure
2. Push the driver's seat and disconnect the
transmission control module connector.
YAD5A160
3. Removal the TCM mounting bolts and TCM.

Installation Notice
YAD5A170
4. Installation should follow the removal procedure in

the reverse order.
YAD5A180
SSANGYONG Y200
SPECIFICATIONS
GENERAL SPECIFICATION
Model Part Numbers And Applications
SYMC P/NO Transmission Engine Version Torque Converter

36100-05442 0574-000013 E23 179K
36100-05432 0574-000012 E32 150K
36100-05412 0574-000014 662LA 150K
Model Specifications
Application Descriprtion
Torque Converter
Mean Diameter of Fluid Circuit Description 260 mm (10.2 in.)
Maximum Torque Multiplication 2.0 : 1
Gear Ratios
First 2.741 : 1
Second 1.508 : 1
Third 1.000 : 1
Fourth 0.708 : 1
Reverse 2.429 : 1
Lubricant
Type Castrol TQ95
Capacity
Dry System 9.0 Liters (approx.)
Service Refill 4.5 Liters (approx.)
Gear Train End Float 0.50 - 0.65 mm (0.020 - 0.026 in.)
Gear Set Pinion End Float 0.10 - 0.50 mm (0.004 - 0.020 in.)
Clutch Pack Details
0574-000012 0574-000013 (14)

C1
Composition 5 4
Steel 5 6
C2
Composition 5 4
Steel 4 5
C3
Composition 4 3
Steel 4 5
C4
Composition 3 3
Steel 4 4
SSANGYONG Y200
Model Part Numbers and Applications

E23 Gasoline Engine
THROTTLE SHIFT (km/h)
MODE
OPENING 1/2 2/3 3/4 4/3 3/2 2/1 UNL3 LCK3 UNL4 LCK4
0% 10.1 19.3 36.4 20.8 8.9 9.2 50.7 79.1 71.7 79.1
16 % 10.1 19.3 36.4 20.8 8.9 9.2 50.7 79.1 71.7 79.1
31 % 13.9 30.9 47.0 28.4 12.4 9.2 50.7 79.1 71.7 79.1
49 % 22.3 46.1 70.5 41.8 18.9 9.3 50.7 90.3 74.2 90.3
NORMAL
50 % 22.8 46.4 71.7 42 19.2 9.3 50.7 58.1 75.4 91.5
MODE
58 % 27.2 53.2 89.0 52.7 24.7 10.9 59.4 66.8 81.6 100.2
64 % 30.9 59.4 94.0 60 28.4 12.1 66.8 74.2 86.6 106.4
71 % 34.1 66.5 103.3 69.3 32.6 18.6 71.7 76.7 95.8 115.0
100 % (WOT) 47.4 91.9 147.2 98.9 45.5 34.6 81.6 95.1 134.3 147.2
Kidkdowm 47.9 94.0 149.6 139.7 86.9 45.4 90.7 95.5 147.2 149.6
0% 11.9 22.8 42.0 20.8 8.9 9.2 73.0 75.4 73.0 75.4
16 % 11.9 22.8 42.0 20.8 8.9 9.2 73.0 75.4 73.0 75.4
31 % 22.5 42.0 70.0 33.4 17.3 9.2 73.0 79.1 73.0 79.1
POWER 49 % 27.2 56.9 87.2 42.0 24.7 9.2 73.6 94.0 73.6 94.0
MODE 50 % 30.7 64.3 96.5 49.5 29.7 10.4 76.2 103.9 76.2 103.9
58 % 35.1 73.2 110.8 60.6 37.8 15.1 81.6 110.8 81.6 110.8
64 % 37.6 77.4 116.3 68 42.5 18.1 86.6 116.3 87.8 116.3
71 % 40.1 81.1 121.2 77.7 47.7 20.8 86.6 121.2 97.7 121.2
100 % (WOT) 47.4 91.9 147.2 115.0 66.7 33.0 86.6 136.0 142.2 147.2
Kickdown 47.9 94.0 149.6 139.7 86.9 45.4 90.7 95.5 147.2 149.6
SSANGYONG Y200
E32 Gasoline Engine

MODE
0% 11.7 20.2 39.5 24.6 10.2 10.5 37.4 81.9 73.1 81.9
15 % 11.7 22.8 39.5 24.6 10.2 10.5 37.4 81.9 73.1 81.9
25 % 13.3 30.4 67.3 32.2 14.6 10.5 37.4 81.9 73.1 81.9
32% 16.8 36.6 76.0 38.0 19.7 11.0 39.5 83.4 73.1 83.4
NORMAL
35 % 18.6 40.1 80.4 40.9 21.9 11.7 40.9 62.9 74.6 86.3
MODE
45 % 24.0 49.7 93.6 52.6 27.8 13.9 46.8 70.2 81.9 93.6
55 % 31.9 66.1 114.1 70.2 32.2 17.3 54.1 79.0 102.4 114.1
70 % 42.1 85.4 146.2 90.7 39.5 21.9 64.3 93.6 128.7 146.2
100 % (WOT) 56.7 110.0 170.4 119.9 46.8 26 93.6 114.1 152.1 170.4
Kidkdowm 57.0 110.6 175.5 163.8 104.7 50.3 116.4 119.3 166.7 175.5
0% 12.3 24.6 40.9 24.6 10.2 10.5 76.0 81.9 76.0 81.9
15 % 14.0 27.8 43.9 29.2 10.2 10.5 76.0 81.9 76.0 81.9
25 % 23.4 43.9 65.8 39.5 17.5 11.0 76.0 81.9 76.0 81.9
32 % 24.6 49.1 76.6 46.1 24.9 11.6 81.9 90.7 81.9 90.7
POWER
35 % 26.3 52.6 81.9 51.2 27.8 12.0 84.8 96.5 84.8 96.5
MODE
45 % 32.2 65.8 105.3 67.3 37.3 15.4 102.4 117.0 102.4 117.0
55 % 38.6 76.9 125.8 87.7 51.2 21.4 111.1 125.8 114.1 125.8
70 % 46.7 90.8 146.2 113.3 66.5 28.7 111.1 146.2 128.7 146.2
100 % (WOT) 56.7 110.0 170.4 148.4 89.9 42.4 111.1 170.4 152.1 170.4
Kickdown 57.0 110.6 175.5 163.8 104.7 50.3 116.4 119.3 166.7 175.5
SSANGYONG Y200
662LA Diesel Engine

MODE
0% 11.4 20.4 35.4 26.7 9.3 9.5 47.6 76.2 72.1 76.2
25 % 11.4 20.4 35.4 27.2 9.3 9.5 47.6 76.2 72.1 76.2
40 % 12.2 25.4 40.8 29.9 13.6 9.5 47.6 76.2 72.1 76.2
60 % 14.7 36.5 61.8 38.1 21.8 9.5 47.6 76.2 72.1 76.2
NORMAL
61 % 14.7 36.7 62.0 38.4 22.0 9.5 47.6 50.3 72.1 76.2
MODE
70 % 16.6 40.0 70.7 43.5 25.9 12.2 47.6 51.7 72.1 77.0
75 % 18.2 43.3 76.2 49.0 28.6 13.6 47.6 54.4 72.1 81.6
80 % 21.8 51.7 84.4 54.4 31.3 15.0 49.0 57.7 75.1 89.0
100 % (WOT) 28.6 62.6 104.5 69.4 38.1 19.6 57.1 62.6 92.5 104.5
Kidkdowm 34.8 68.0 110.2 100.7 63.9 31.3 61.2 68.0 100.7 110.2
0% 11.7 21.8 38.1 26.7 9.3 9.5 61.2 76.2 72.1 76.2
25 % 11.7 21.8 38.1 31.3 9.3 9.5 61.2 76.2 72.1 76.2
40 % 14.1 27.5 43.5 32.7 16.3 10.2 61.2 76.2 72.1 76.2
60 % 21.8 44.6 69.4 47.6 27.2 12.8 61.2 76.2 72.1 76.2
POWER
61 % 28.0 57.1 88.7 54.4 35.4 14.4 61.2 88.7 72.1 88.7
MODE
70 % 29.9 59.9 93.9 61.2 40.8 15.8 61.2 93.9 72.1 93.9
75 % 31.3 61.8 96.6 65.3 46.3 17.4 61.2 96.6 75.1 96.6
80 % 32.7 64.8 100.4 70.7 50.3 20.4 61.2 100.4 81.6 100.4
100 % (WOT) 34.0 67.8 105.3 83.0 54.4 23.1 61.2 105.3 92.5 105.3
Kickdown 34.8 68.0 110.2 100.7 63.9 31.3 61.2 68.0 100.7 110.2
SSANGYONG Y200
FASTENER TIGHTENING SPECIFICATIONS

Application N•m Lb-Ft Lb-Ft ı-
-ı-ı-ı-
Adaptor Housing to Case Bolts 30 - 35 22 - 26
Cam Plate to Case (Parking Pawl) Screws 16 - 22 12 - 16
Centre Support to Case Bolts 20 - 27 15 - 20
Detent Spring Screw 20 - 22 15 - 16
Extension Housing to Case Bolts 54 - 68 40 - 50
Front Propeller Shaft Bolts 70 - 80 52 - 59
Inhibitor Switch to Case Bolts 4-6 -
Oil Cooler Pipes 40 - 45 29 - 33
Oil Pan to Case Bolts 4-6 -
On/Off Solenoid Retainer Screws 8 - 12 -
Output Flange Nuts 35 26
Pump Cover Plate to Crescent Screw 13 - 16 10 - 12
Pump Cover Plate to Pump Cover Screws 13 - 16 10 - 12
Pump Cover to Case Bolts 24 - 34 18 - 25
Pump to Pump Cover Bolts 24 - 27 18 - 20
Rear Propeller Shaft Bolts 70 - 80 52 - 59
Rear Servo Cover to Case Bolts 30 - 35 22 - 26
TCM Mounting Bolt 10 -
Torque Converter Housing to Case Bolts 54 - 68 40 - 50
Torque Converter Mounting Bolts 42 31
Transfer Case to Transmission Housing Bolts 35 - 60 26 - 44
Transmission Filler Plug 30 - 35 22 - 26
Upper Valve Body to Lower Valve Body Screws 11 - 16 8 - 12
Valve Body To Case Bolts 8 - 13 -
Variable Pressure Solenoid (S5) Retainer Screw 8 - 12 -
SSANGYONG Y200
TCM WIRING DIAGRAM (GASOLINE ENGINE-1 OF 2)

SCHEMATIC AND ROUTING DIAGRAMS
YAD5A210
SSANGYONG Y200
TCM WIRING DIAGRAM (GASOLINE ENGINE-2 OF 2) YAD5A220
SSANGYONG Y200
TCM WIRING DIAGRAM (DIESEL ENGINE-1 OF 2)
YAD5A230
SSANGYONG Y200
TCM WIRING DIAGRAM (DIESEL ENGINE-2 OF 2) YAD5A240
SSANGYONG Y200
CONNECTOR END VIEW
KAA5A5O0
SSANGYONG Y200
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE
0555 - 336256
0555 - 336257
Transmission Bench
Pump Puller
Cradle
KAA5A2P0 KAA5A2Q0
0555 - 336259
Clutch Spring
Compressor
KAA5A2R0 KAA5A2S0
0555 - 336260 0555 - 336261

Clutch Pack Clearance Cross Shaft Seal
Kit Remover
KAA5A2T0 KAA5A2U0
0555 - 336262
0555 - 336263
Cross Shaft Seal
Cross Shaft Bullet
Installer
KAA5A2V0 KAA5A2W0
SSANGYONG Y200
SPECIAL TOOLS TABLE (Cont'd)
0555 - 336265
0555 - 336266
Cross Shaft Pin
Adaptor Housing Seal
Remover / Installer
Installer
(Inhibitor Switch)
KAA5A2X0 KAA5A2Y0
0555 - 336267 0555 - 336268

Pump Alignment Tool Pump Seal Installer
KAA5A2Z0 KAA5A3A0
0555 - 336269 0555 - 336270

End Float Measuring End Float Measuring
Adaptor Shaft
KAA5A3B0 KAA5A3C0
0555 - 336302 0555 - 336045

Output Shaft Bullet Solenoid Bench Tester
KAA5A3D0 KAC5A050
SSANGYONG Y200
SPECIAL TOOLS TABLE (Cont'd)
0555 - 332083
Solenoid /Thermistor
Electronic Tester
KAC5A060
SSANGYONG Y200

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AUTOMATIC TRANSMISSION 5A-159

5. Remove the rear propeller shaft bolts.

6. Remove the cross member bolts and nuts.

7. Remove the front propeller shaft bolts from transfer

8. Remove the transfer case-to-transmission housing

Tightening Torque 44 N•m (33 lb-ft)

9. Disconnect the 10-Pins Plug connector from trans-

10. Separate the locking clip on shift lever and remove

11. Remove the oil cooler pipes.

12. Remove the service hole cover in the engine block.

• Screw the six bolts mounting the torque converter

15. Remove the extension housing to case bolts and

Tightening Torque 55-65 N•m (41-48 lb-ft)

• Be careful not to drop the torque converter while

• Remove the inhibitor switch before washing the

1. Remove the converter and the converter housing.

4. Remove each end of the filter retaining clip from

7. Remove the front servo cover circlip.

9. Remove the adaptor housing bolts and adaptor

10. Remove the pump to case bolts using a multi-hex

12. Remove the input shaft, forward clutch cylinder,

14. Remove the front band struts. Remove the front

15. Remove the two centre support retaining bolts

17. Remove the centre support, 1-2 one way clutch,

20. Remove the output shaft assembly.

3. Remove the cross shaft seals with cross shaft seal

5. Using cross shaft pin remover/installer (detent le-

8. Depress the tangs and withdraw the 10 pin

9. Detach the No.7 solenoid wire from the front of

12. Remove the rear servo cover and piston assembly.

18. To remove the park rod lever: Remove the circlip

Forward Clutch Cylinder

2. Remove the No. 4 needle bearing (2) and adjust-

6. Remove the circlip retaining the C3 clutch hub in

9. Invert the clutch cylinder and remove the C4 clutch

11. Mount the clutch cylinder on clutch spring

12. Invert the clutch cylinder on the compressor tool

13. To remove the clutch pistons from the clutch

4. Mount the clutch assembly on clutch spring com-

7. Remove the sealing rings from the C3 clutch

Planet Carrier Assembly and Centre

1. Remove the wiring loom retainer plate and remove

4. Separate the pump body from the pump cover.

6. Remove the ball check valve and one spring from

7. Depress the plug inward and remove the retaining

8. Remove the four valves, plugs and springs.

9. Remove the pump gears from the pump body.

3. Take note of the angular relationship of the

4. Place the valve body assembly on the bench with

7. Lift the separator plate and gaskets from the upper

12. Remove the 1-2, 2-3 and 3-4 shift valves.

13. Depress the 4-3 sequence valve plug and remove

14. Remove the plug, spring and valve

15. Depress the solenoid 5 valve. Remove the

16. Depress the line pressure release valve, remove

• The transmission is assembled in modular fashion

1. Turn the transmission case upside down on the

3. Assemble the B1R valve and spring, and secure

4. Install the rear servo lever and pivot pin.