SsangYong Korando II (1996-2006 year). Manual - part 320

AUTOMATIC TRANSMISSION  5A-183

SSANGYONG  MY2002

C3 Clutch and Reverse Sun Gear Assembly

Tools Required

0555-336259 Clutch Spring Compressor

0555-336260 Clutch Pack Clearance Kit

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
condition 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,

e n s u r i n g   t h a t   t h e   ‘ O ’   r i n g   c o m p r e s s i o n   i s
adequate but not excessive.

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

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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.

9. Assemble the spring and spring retainer on the

p i s t o n .   U s i n g   0 5 5 5 - 3 3 6 2 5 9   c l u t c h   s p r i n g
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.

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5A-184  AUTOMATIC TRANSMISSION

SSANGYONG  MY2002

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)

•

Steel plate (selective)

•

Friction disc

•

Steel plate (selective)

•

Friction disc

12. A l i g n   a n d   f i t   t h e   p r e s s u r e   p l a t e   w i t h   t h e

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.

e. Record this figure.

f. Subtract the second reading from the first read-

ing to obtain the clutch pack clearance.

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AUTOMATIC TRANSMISSION  5A-185

SSANGYONG  MY2002

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.

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.

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3. Align and fit the C3 clutch assembly over the for-

ward sun gear.

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.

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5A-186  AUTOMATIC TRANSMISSION

SSANGYONG  MY2002

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C1 Clutch Overdrive Shaft and Input Shaft
Assembly

Tools Required

0555-336260 Clutch Pack Clearance Kit

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.

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)

•

Steel plate (selective)

•

Friction disc

•

Steel plate (selective)

•

Friction disc

4. Check the clutch pack clearance using 0555-

336260 clutch pack clearance kit.

5. Use selective plates to achieve the correct

specification.

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
minutes prior to assembly.

Notice: The clutch pack clearance must be taken
before elements are soaked in automatic
transmission fluid.

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