SsangYong Rexton. Service manual - part 542

AUTOMATIC TRANSMISSION  5A-39

SSANGYONG  Y200

3. Park the vehicle on a hoist, inspection pit or similar

raised level surface. The vehicle must be control
level to obtain a correct fluid level measurement.

4. Place a fluid container below the fluid filler plug.

5. Clean all dirt from around the fluid filler plug.

Remove the fluid filler plug. Clean the filler plug
and check that there is no damage to the ‘O’ ring.

•

If fluid drains through the filler hole the transmis-
sion may have been overfilled. When the fluid
stops draining the fluid level is correct. Install
the fluid filler plug and tighten it to 33 N•m (24
lb-ft).

•

If fluid does not drain through the filler hole, the
transmission fluid level may be low. Install the
filler pump into the filler hole. Lower the vehicle
with the filler pump still connected and partially
fill the fluid through the filler hole.

Start the vehicle in P (Park) with the parking
brake and the brake applied. With the engine
idling, move the gear shift. control lever through
the gear ranges, pausing a few seconds in each
range and adding the fluid until gear application
is felt.

Return the gear shift lever to P (Park).

Turn the engine OFF and raise the vehicle. When
the three minutes passed after the engine
stopped, remove the filler pump.

Check if the fluid level is aligned with the bottom
of the filler hole. If not, add a small quantity of
fluid to the correct level. Install the fluid filler
plug and tighten it to 33 N•m (24 lb-ft).

•

If fluid does not drain through the filler hole al-
t h o u g h   a d d i n g   a   t o t a l   o f   1 . 5   l i t e r s ,   t h e
transmission should be inspected for fluid leaks
and any leaks should be fixed before setting
the transmission fluid level.

6. When the fluid level checking procedure is com-

pleted, wipe any fluid around the filler plug with a
rag or shop towel.

Fluid Level Set After Service

1. Depending on the service procedure performed,

add the following amounts of fluid through the filler
plug hole prior to adjusting the fluid level:

Converter empty

8.0 liters  (8.5 quarts)

Converter full

3.8 liters  (4.0 quarts)

2. Follow steps 1 through 4 of the Fluid Level

Diagnosis Procedure.

3. Clean all dirt from around the fluid filler plug.

Remove the fluid filler plug. Clean the filler plug
and check that there is no damage to the ‘O’ ring.

4. Lower the vehicle with the filler pump still connected

and start the vehicle in P (Park) with the parking
brake and the brake applied. With the engine idling,
move the gear shift control lever through the gear

ranges, pausing a few seconds in each range and
adding the fluid until gear application is felt.

Then add an additional 0.5 litres of fluid. Return
the gear shift lever to P (Park). Turn the engine OFF
and raise the vehicle. Install the fluid filler plug and
tighten it to 33 N•m (24 lb-ft).

5. Drive the vehicle at 3.5 to 4.5 kilometers with light

throttle so that the engine does not exceed 2500
rpm.

This should result in the transmission temperature
being in the range 50 - 60 °C (82 - 140 °F). With the
brake applied, move the shift lever through the gear
ranges, pausing a few seconds in each range at
the engine idling.

6. Return the gear shift lever to P (Park).

Turn the en-gine OFF and raise the vehicle on the
hoist, if applicable, ensuring the vehicle is level.
When the three minutes passed after the engine
stopped, remove the filler plug.

Check if the fluid level is aligned with the bottom of
the filler hole. If not, add a small quantity of fluid to
the correct level. Install the fluid filler plug and
tighten it to 33 N•m (24 lb-ft).

7. Wipe any fluid around the filler plug with a rag or

shop towel.

FLUID LEAK DIAGNOSIS AND
REPAIR

The cause of most external leaks can generally be lo-
cated and repaired with the transmission in the vehicle.

Methods for Locating Leaks

General Method

1. Verify that the leak is transmission fluid.

2. Thoroughly clean the suspected leak area.

3. Drive the vehicle for approximately 25 km (15 miles)

or until the transmission reaches normal operating
temperature (88 °C, 190 °F).

4. Park the vehicle over clean paper or cardboard.

5. Turn the engine OFF and look for fluid spots on the

paper.

6. Make the necessary repairs to correct the leak.

Powder Method

1. Thoroughly clean the suspected leak area.

2. Apply an aerosol type powder (foot powder) to the

suspected leak area.

3. Drive the vehicle for approximately 25 km (15 miles)

or until the transmission reaches normal operating
temperature (88 °C, 190 °F).

4. Turn the engine OFF.

5. Inspect the suspected leak area and trace the leak

path through the powder to find the source of the
leak.

5A-40  AUTOMATIC TRANSMISSION

SSANGYONG  Y200

6. Make the necessary repairs.

Dye and Black Light Method

1. A d d   d y e   t o   t h e   t r a n s m i s s i o n   t h r o u g h   t h e

transmission  fluid filler plug. Follow the
manufacturer’s recommen-dation for the amount of
dye to be used.

2. Use the black light to find the fluid leak.

3. Make the necessary repairs.

Repairing the Fluid Leak

Once the leak point is found the source of the leak
must be determined. The following list describes the
potential causes for the leak:

•

Fasteners are not torqued to specification.

•

Fastener threads and fastener holes are dirty or
corroded.

•

Gaskets, seals or sleeves are misaligned, damaged
or worn.

•

Damaged, warped or scratched seal bore or gasket
surface.

•

Loose or worn bearing causing excess seal or sleeve
wear.

•

Case or component porosity.

•

Fluid level is too high.

•

Plugged vent or damaged vent tube.

•

Water or coolant in fluid.

•

Fluid drain back holes plugged.

ELECTRICAL / GARAGE SHIFT
TEST

This preliminary test should be performed before a hoist
or road test to make sure electronic control inputs are
connected and operating. If the inputs are not checked
before operating the transmission, a simple electrical
c o n d i t i o n   c o u l d   b e   m i s d i a g n o s e d   a s   a   m a j o r
transmission condition.

A scan tool provides valuable information and must
be  used on the automatic transmission for accurate
diagnosis.

1. Move gear shift control lever to P (Park) and set

the parking brake.

2. Connect scan tool to Data Link Connector (DLC)

terminal.

3. Start engine.

4. Turn the scan tool ON.

5. Verify that the appropriate signals are present.

These signals may include:

•

ENGINE SPEED

•

VEHICLE SPEED

•

THROTTLE POSITION

•

ACCEL. PEDAL POSITION

•

TRANSMISSION GEAR STATE

•

GEAR SHIFT LEVER POSITION

•

TRANSMISSION FLUID TEMPERATURE

•

CLOSED THROTTLE POSITION LEARN

•

OPEN THROTTLE POSITION LEARNT

•

CLOSED ACCEL. PEDAL POSITION LEARNT

•

OPEN ACCEL. PEDAL POSITION LEARNT

•

A/C COMPRESSOR STATUS

•

KICKDOWN SWITCH STATUS

•

4WD STATUS

•

MODE SWITCH

•

THROTTLE POSITION VOLTAGE

•

GEAR SHIFT LEVER POSITION VOLTAGE

•

TRANS. FLUID TEMPERATURE VOLTAGE

•

A/C SWITCH

•

KICKDOWN SWITCH VOLTAGE

•

4WD LAMP LOW VOLTAGE

•

4WD LAMP HIGH VOLTAGE

•

MODE SWITCH VOLTAGE

•

BATTERY VOLTAGE

6. Monitor the A/C COMPRESSOR STATUS signal

while pushing the A/C switch.

•

The A/C COMPRESSOR STATUS should come
ON when the A/C switch is pressed, and turn
OFF when the A/C switch is repushed.

7. Monitor the GEAR SHIFT LEVER POSITION signal

and move the gear shift control lever through all
the ranges.

•

Verify that the GEAR SHIFT LEVER POSITION
value matches the gear range indicated on the
instrument panel or console.

•

Gear selections should be immediate and not
harsh.

8. Move gear shift control lever to neutral and monitor

the THROTTLE POSITION signal while increasing
and decreasing engine speed with the accelerator
pedal.

•

THROTTLE POSITION should increase with en-
gine speed.

ROAD TEST PROCEDURE

•

Perform the road test using a scan tool.

•

This test should be performed when traffic and road
conditions permit.

•

Observe all traffic regulations.

AUTOMATIC TRANSMISSION  5A-41

SSANGYONG  Y200

ELECTRONIC ADJUSTMENTS

Idle Speed Adjustments

Carry out the adjustments to the idle speed as detailed
in the workshop manual.

Vehicle Coding

The vehicle coding is integrated as part of the
diagnostic  software. A scan tool has the function to
code the ve-hicle through the K-line.

Throttle Clearing

The leant throttle clearing routine uses the mode switch
and gear lever. Carry out the following steps to
complete the automated throttle clearing procedure:

1. Switch ignition 'ON' with handbrake applied and

engine 'OFF'.

2. Select the selector lever to 1st gear and 'WINTER'

mode.

3. Move the selector lever to 2nd gear and 'ECONO'

or 'POWER' mode.

4. Move the selector lever to 3rd gear and 'WINTER'

mode.

Throttle Position Calibration

Should the throttle position data stored in the TCU be
lost or be out of specification, as indicated by a
diagnostic trouble message, it may be re-established
by the following procedure.

•

Check that the hot engine idle speed is within
specfication.

•

Allow the engine to idle in 'Drive' for 60 seconds
with the air conditioner (if fitted) turned off. The
closed throttle reference point in the TCU has now
been set.

•

Switch the engine off but leave the ignition on. Hold
the accelerator pedal on the floor for 60 seconds.
The wide open throttle reference point in the TCU
has now been set.

5A-42  AUTOMATIC TRANSMISSION

SSANGYONG  Y200

SYMPTOM DIAGNOSIS

DRIVE FAULTS

Condition

No Drive in D

Possible Causes

•

Insufficient auto transmission
fluid.

•

Blocked feed in C1/C2 cylinder.

•

‘Z’ link displaced.

•

Primary Regulator Valve (PRV)
jammed open.

•

Overdrive shaft or input shaft
seal rings failed.

•

3-4 or 1-2 One Way Clutch
(OWC) installed backwards or
failed.

•

C2 piston broken or cracked.

•

Rear band or servo faulty.

•

Failure in C3, C3 hub or C1/C2
cylinder.

•

Damaged input shaft sealing rings.

•

Jammed Primary Regulator
Valve (PRV).

•

Damaged/broken pump gears.

•

Dislodged output shaft snap ring.

Action

•

Check the fluid level. Top up as

necessary.

•

Inspect and clean C1/C2 feed.

•

Reinstall/renew the ‘z’ link.

•

Remove, clean and re-install the

PRV.

•

Inspect and replace as necessary.

•

Inspect and replace as necessary.

•

Inspect and replace as necessary.

•

Check servo adjustment or

replace rear band as necessary.

•

Check for failure in C3, C3 hub

or C1/C2 cylinder. Repair as
necessary.

•

Inspect and replace as necessary.

•

Inspect and clean PRV.

•

Inspect and replace pump

gears as necessary.

•

Inspect and repair as necessary.

No Drive in Reverse

No engine braking in Manual 1

Engine braking in Manual 1 is OK

No drive in Drive and Reverse