SsangYong Rexton. Service manual - part 546

AUTOMATIC TRANSMISSION  5A-159

SSANGYONG  Y200

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.

REPAIR INSTRUCTIONS

5. Remove the rear propeller shaft bolts.

Installation Notice

YAD5A080

YAD5A090

YAD5A100

6. Remove the cross member bolts and nuts.

Installation Notice

Tightening Torque

70-80 N•m (52-59 lb-ft)

Tightening Torque

70-80 N•m (52-59 lb-ft)

5A-160  AUTOMATIC TRANSMISSION

SSANGYONG  Y200

YAD5A120

YAD5A130

YAD5A140

8. Remove the transfer case-to-transmission housing

bolts and remove the transfer case.

Installation Notice

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.

11. Remove the oil cooler pipes.

Installation Notice

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

mission.

YAD5A110

7. Remove the front propeller shaft bolts from transfer

case.

Installation Notice

Tightening Torque

44 N•m (33 lb-ft)

Tightening Torque

70-80 N•m (52-59 lb-ft)

Tightening Torque

25-35 N•m (18-26 lb-ft)

AUTOMATIC TRANSMISSION  5A-161

SSANGYONG  Y200

KAA5A2N0

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

Electrical.

Tightening Torque

42 N•m (31 lb-ft)

YAD5A150

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.

Tightening Torque

55-65 N•m (41-48 lb-ft)

5A-162  AUTOMATIC TRANSMISSION

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