SsangYong Rexton. Service manual - part 552

AUTOMATIC TRANSMISSION  5A-183

SSANGYONG  Y200

24. Reassemble the sleeve and clutch pack into the

cylinder. Observe the alignment of the wave
washer to the hole in the cylinder.

25. Install the C2 clutch plates in the cylinder in the

following sequence:

•

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

21. Holding the cylinder horizontal, install the sleeve

and clutch plate assembly into the cylinder, with
the crest of one wave of the washer in line with
one of the holes in the outside of the cylinder,
until the sleeve contacts the C2 wave washer.

22. Check the C4 clutch pack clearance using 0555-

336260 clutch pack clearance kit.

Notice: With the C2 wave spring compressed, and
the clutch Pack supporting a 2 kg weight, the
dimension from the underside of the C2 pressure plate
to the selective steel is to be between 1.4 - 1.8 mm. If
the clutch is to be gauged from the top of the pressure
plate, then the dimension is to be the actual thickness
of the pressure plate plus 1.4 - 1.8 mm.

23. Use selective plates to achieve the correct

specification. If new friction plates are being
fitted, remove the clutch pack and soak the friction
plates in ATF for a minimum of 5 minutes prior to
reassembly.

Notice:  The clutch pack clearance must be taken
before the elements are soaked in ATF.

KAA5A0J0

KAA5A0K0

KAA5A0L0

5A-184  AUTOMATIC TRANSMISSION

SSANGYONG  Y200

KAA5A0M0

KAA5A0N0

KAA5A0O0

26. Check the clutch pack clearance using only the

weight from 0555-336260 clutch pack clearance
kit.

Notice:  With the clutch pack supporting a 2
kgweight, the dimension from the C3 clutch hub
locating step to the friction plate is to be between
0.80 - 1.05 mm.

27. Use selective plates to achieve the correct

specifica-tion. If new friction plates are being fitted,
remove the clutch pack and soak the friction
plates in ATF for a minimum of 5 minutes prior to
reassembly.

Notice: The clutch pack clearance must be taken
before the elements are soaked in ATF.

28. Lubricate and fit the 3-4 OWC and end caps to

the C2 hub.

32. Apply petroleum jelly to the No. 5 needle bearing

and fit it to the C4 hub.

33. Remove the C2 clutch plates from the clutch cylin-

der.

34. Fit the thrust plate over the cylinder inner  hub.

35. Engage the C2/C4 clutch hub assembly in the C4

clutch plates.

36. Install the C2 clutch plates.

37. Install the C3 hub and secure it with the circlip,

ensuring that the circlip is firmly seated in its
groove.

29. Align the tangs and fit the nylon thrust washer

onto the C4 hub.

30. Align and fit the C4 hub to the C2 clutch and the

OWC assembly.

31. Check the rotation of the C2 hub. While holding

the C4 hub, the C2 hub should rotate in the
clockwise direction and lockup in the anti-
clockwise direction when viewed from the C2 hub.

AUTOMATIC TRANSMISSION  5A-185

SSANGYONG  Y200

KAA5A0P0

KAA5A0Q0

KAA5A730

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 con-
dition 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, en-

suring that the ‘O’ ring compression is adequate
but not excessive.

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

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.

5A-186  AUTOMATIC TRANSMISSION

SSANGYONG  Y200

KAA5A0R0

KAA5A0S0

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.