Daewoo Korando. Manual - part 264

AUTOMATIC TRANSMISSION  5A-99

Output Shaft and Gear Assembly

To assemble the output shaft and gear assembly (refer to
(figure 8.19), proceed as follows:

1. Check that the output shaft bush is not won 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 scat

cut uppermost.

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. Fit the thrust bearing assembly No. 10 onto the output shaft

using petroleum jelly.

8. Carefully install the output shaft assembly in the case to

prevent damage to the sealing rings.

Rear Servo Assembly

To assemble the rear servo assembly (refer to figure 8.18),
proceed as follows.

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.

Notice

Do not use petroleum jelly on the gasket.

5. Assemble the gasket to the cover and fit the assembly to

the case.

6. Apply Loctite 567 sealant to the bolts. Install the bolts and

tighten to specification.

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 and

Centre 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-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