SsangYong Rexton. Manual - part 551

AUTOMATIC TRANSMISSION  5A-179

SSANGYONG  Y200

KAA5A0B0

KAA5A0C0

KAA5A520

KAA5A0D0

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.

3. Apply additional Loctite 202 or equivalent as

required to the adapter housing bolts. Install the
a d a p t o r   h o u s i n g   a n d   t o r q u e   t h e   b o l t s   t o
specification.

Installation Notice

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.

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.

Notice: Ensure that the front servo snap ring is
installed correctly. Orient the circlip with the gap at
the bottom, near the pan rail.

Tightening Torque

30-35 N•m (22-26 lb-ft)

5A-180  AUTOMATIC TRANSMISSION

SSANGYONG  Y200

KAA5A0E0

KAA5A550

KAA5A0F0

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.

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
minutes prior to assembly.

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.

C2/C4 Clutch Assembly

Tools Required

0555-336259

Clutch Spring Compressor

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.

AUTOMATIC TRANSMISSION  5A-181

SSANGYONG  Y200

KAA5A0G0

KAA5A690

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.

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.

5A-182  AUTOMATIC TRANSMISSION

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.

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

KAA5A0H0

KAA5A0I0