SsangYong Rexton. Service manual - part 553

AUTOMATIC TRANSMISSION  5A-187

SSANGYONG  Y200

KAA5A0TA

KAA5A0U0

KAA5A0V0

KAA5A0W0

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.

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.

5A-188  AUTOMATIC TRANSMISSION

SSANGYONG  Y200

KAA5A0X0

KAA5A0Y0

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

AUTOMATIC TRANSMISSION  5A-189

SSANGYONG  Y200

KAA5A660

KAA5A1A0

KAA5A0Z0

7. Check the fit of the C1 clutch hub on the overdrive

shaft. If it is loose, the hub and shaft assembly
must be replaced.

8. Coat the small nylon thrust spacer with petroleum

jelly and install it over the overdrive shaft.

9. Carefully fit the overdrive shaft into the C1 cylinder

so as not to damage the sealing ring.

10. Fit the small bronze C1 hub thrust washer in place

with petroleum jelly.

11. Check the input shaft for any defect. Fit the input

shaft into the cylinder and secure it with the circlip,
ensuring that the circlip is completely seated in
the groove.

12. Coat the sealing rings with petroleum jelly and fit

onto the input shaft.

4. Check the clutch pack clearance using 0555-

336260 clutch pack clearance kit.

5. Use selective plates to achieve the correct specifi-

cation.

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.

5A-190  AUTOMATIC TRANSMISSION

SSANGYONG  Y200

Pump Cover and Converter Support

Notice:

•

Do not wash the nose of solenoids in solvent.

•

Ensure that the correct ‘O’ ring is fitted for the
application.

•

Be careful not to damage the needle bearings on
the assembly. Avoid any axial impact loads during
assembly.

•

Check the transmission end float. This will help to
detect any missing parts or incorrect assembly.

1. Check the pump body for any damage, chips or

irregularity. Check that the bush is firmly staked
in the drive gear.

2. Install the seal flush with the front face of the

pump body.

3. Lubricate the pump bush, and the drive and driven

gears, with automatic transmission fluid.

4. Install the pump driven gear and the pump drive

gear into the pump body.

5. Using a straight edge and thickness gauge, check

that the clearance between pump face and gears
is 0.04 - 0.018 mm.

6. Lubricate the pump body ‘O’ ring with automatic

transmission fluid and fit it to the pump body. Put
the pump body to one side.

KAA5A1C0

KAA5A810

KAA5A1B0

13. Assemble the C1/C2/C4 clutch assembly to the

C3 clutch and sun gear assembly.

14. Install this assembly in the transmission case.