SsangYong Rexton. Service manual — part 549
AUTOMATIC TRANSMISSION 5A-171
SSANGYONG Y200
KAA5A800
KAA5A810
KAA5A820
KAA5A830
7. Depress the plug inward and remove the retaining
pin for each of the three valves.
Notice: Some of the valves and plugs are preloaded
by springs and may unexpectedly fall out of the
cover when the pins are removed.
8. Remove the four valves, plugs and springs.
9. Remove the pump gears from the pump body.
10. Remove the lip seal from the front of the pump
body.
Valve Body
1. Remove the manual valve detent spring and retain-
er plate using a T40 Torx bit.
2. Slide the manual valve out of the lower valve body.
Notice: Be aware that the manual valve will fall out
of the valve body.
3. Take note of the angular relationship of the
solenoid terminals to the valve body and remove
the solenoids 1, 2, 3, 4, 5, 6 and valve assemblies.
Notice: Take care that the bracket is not separated
from the solenoid.
4. Place the valve body assembly on the bench with
the upper body uppermost.
5. Remove the 24 clamping screws with a No. 30
Torx bit. Separate the upper and lower valve
bodies by lifting the upper body and the separator
plate togeth-er.
6. Turn the upper body over and place it on the bench
with the separator plate uppermost.
5A-172 AUTOMATIC TRANSMISSION
SSANGYONG Y200
7. Lift the separator plate and gaskets from the upper
valve body.
8. Remove the five nylon check balls exposed in the
valve body.
9. Remove the retaining plate, plug, spring and re-
verse lockout valve.
10. Remove the filter (1) and the large nylon check
ball (2) from the lower valve body.
11. Remove the retaining plates and pins from the 1-
2, 2-3, 3-4, BAR and CAR valves. The pins can
be removed with a magnet.
Notice: Once the pins are removed, the plates are
loose in the valve body and will drop out when the
valve body is turned over.
12. Remove the 1-2, 2-3 and 3-4 shift valves.
13. Depress the 4-3 sequence valve plug and remove
the retaining plate.
Notice: The plug is preloaded by the spring and
may unexpectedly fall out of the valve body.
14. Remove the plug, spring and valve
15. Depress the solenoid 5 valve. Remove the
retaining in and remove the valve, damper guide
and spring.
Notice: The valve is preloaded by the spring and
may unexpectedly fall out of the valve body.
16. Depress the line pressure release valve, remove
the retaining pin, disc (if fitted), spring and valve.
17. Drive out the retaining pin and remove the spring
and ball check valve adjacent to the BAR valve.
KAA5A840
KAA5A85A
KAA5A860
KAA5A870
AUTOMATIC TRANSMISSION 5A-173
SSANGYONG Y200
ASSEMBLY PROCEDURE
Transmission
Tools Required
0555-336256
Transmission Bench Cradle
0555-336258
Cross Shaft Pin Remover/Installer
(Detent Lever)
0555-336262
Cross Shaft Seal Installer
0555-336263
Cross Shaft bullet
0555-336265
Cross Shaft Pin Remover/Installer
(Inhibitor Switch)
Notice:
•
The transmission is assembled in modular fashion
and details of assembly for each module are given
under the appropriate subject.
•
Technicians overhauling these transmissions will
also require a selection of good quality Torx bit
sockets, in particular numbers 30, 40 and 50, and
an 8 mm, 10 mm and 12 mm double hex socket.
•
Ensure that the B1R circlip is fitted to the case. (If
this is not fitted, the valve will peen its way into
and through the separator plate)
•
Ensure that the ’E’clip is fitted to the cross shaft.
•
Ensure that all aspects of the parking mechanism
are working.
3. Assemble the B1R valve and spring, and secure
with the circlip. Ensure that the circlip is completely
seated in its groove.
1. Turn the transmission case upside down on the
bench and mount it to the transmission bench cradle
0555-336256.
2. Install all fittings, plugs and the breather, applying
a sealant where applicable, Tighten the fittings to
specifications. Ensurethatthebreatheris clear,
andcheckthat the lube fitting in the rear of the case
is fittedand clear of obstruction.
KAA5A500
KAA5A880
5A-174 AUTOMATIC TRANSMISSION
SSANGYONG Y200
KAA5A890
KAA5A640
KAA5A900
4. Install the rear servo lever and pivot pin.
Notice: The lever must pivot freely on its pin.
5. Assemble the park rod lever, complete with the
return spring and pivot pin, applying a small
amount of sealant to the outer end of the pivot
pin.
Notice: Care must be taken when applying sealant
to ensure that it is not applied between the pin and
the lever.
6. Secure the pivot pin with the circlip.
Notice: The lever must pivot freely on its pin and
the spring must return the park rod lever to its correct
location.
7. Install the parking pawl pivot pin and spring.
Notice: The pawl must pivot freely on its pin.
8. Connect the park rod to the manual valve detent
lever. Ensure the spring and cam collar is firmly
installed on the rod.
9. Check that the cam collar slides freely on the rod.
10. Insert the cross shaft into the case, from the side
opposite to the inhibitor switch, then install the
antirattle spring on the shaft.
KAA5A910
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