SsangYong Rexton. Manual — part 547
AUTOMATIC TRANSMISSION 5A-163
SSANGYONG Y200
KAA5A500
KAA5A510
DISASSEMBLY PROCEDURE
Transmission
Tools Required
0555-336256 Transmission Bench Cradle
0555-336257 Pump Puller
Notice:
•
Remove the inhibitor switch before washing the
transmission in solvent or hot wash.
•
It is assumed that the transmission fluid has been
drained when the transmission was removed from
the vehicle and that the ’special tools’ quoted are
available.
•
The transmission is dismantled in a modular fashion,
and the details of disassembly for each module are
given under the appropriate subject. Refer to
Special Tools Table in this chapter for details of all
special
t o o l s r e q u i r e d w h e n p e r f o r m i n g
disassembly procedures.
•
Technicians overhauling these transmissions will
also require a selection of good quality Torx bit
sockets, in particular numbers 30, 40 and 50, and
an 8mm, 10mm and 12 mm double hex socket.
1. Remove the converter and the converter housing.
2. Mount the transmission on the transmission bench
cradle 0555-336256.
3. Remove the oil pan and the oil pan seal.
4. Remove each end of the filter retaining clip from
the valve body and remove the filter.
5. Disconnect the wires from each solenoid and ground
and lay the wiring to one side.
6. Remove the valve body securing screws and
remove the valve body from the case.
5A-164 AUTOMATIC TRANSMISSION
SSANGYONG Y200
7. Remove the front servo cover circlip.
8. Remove the front servo cover, piston and spring.
Notice: The plastic servo block is retained by the
piston return spring only.
9. Remove the adaptor housing bolts and adaptor
housing.
10. Remove the pump to case bolts using a multi-hex
8 mm spanner.
11. Using the pump puller 0555-336257, remove the
pump and pump cover.
12. Remove the input shaft, forward clutch cylinder,
a n d t h e o v e r d r i v e s h a f t a s a n a s s e m b l y ,
withdrawing them through the front of the case.
13. Remove the C3 clutch cylinder and sun gears.
14. Remove the front band struts. Remove the front
band.
KAA5A520
KAA5A550
KAA5A530
KAA5A540
AUTOMATIC TRANSMISSION 5A-165
SSANGYONG Y200
15. Remove the two centre support retaining bolts
using a T50 Torx bit.
16. Remove the centre support retaining circlip.
Notice: Do not hammer the output shaft to remove
the centre support as this will cause permanent
damage to the thrust bearing surfaces.
17. Remove the centre support, 1-2 one way clutch,
and planetary gear set as an assembly.
18. Remove the parking rod cam plate using a T40
Torx bit.
19. Remove the rear band struts and remove the band.
Notice: Vise the both end of rear band using the
plier and lean forward about 15 degrees
20. Remove the output shaft assembly.
Transmission Case
Tools Required
0555-336258
Cross Shaft Pin Remover/Installer
(Detent Lever)
0555-336261
Cross Shaft Seal Remover
0555-336265
Cross Shaft Pin Remover/Installer
(Inhibitor Switch)
1. Remove the pin from the side of cross shaft
inhibitor switch using cross shaft pin remover/
installer (inhibitor switch) 0555-336265.
2. Remove the inhibitor switch bolts and inhibitor
switch from the case.
3. Remove the cross shaft seals with cross shaft seal
remover 0555-336261.
4. Remove the circlip from the cross shaft. Pull the
shaft to release the drive pin from the selector
quadrant.
KAA5A560
KAA5A570
KAA5A580
KAA5A590
5A-166 AUTOMATIC TRANSMISSION
SSANGYONG Y200
KAA5A610
KAA5A620
KAA5A630
KAA5A600
5. Using cross shaft pin remover/installer (detent le-
ver) 0555-336258, press the pin from the cross
shaft and withdraw the shaft from the case.
6. Remove the cross shaft pin and spring.
7. Remove the manual valve lever and the park rod.
8. Depress the tangs and withdraw the 10 pin
connector into the case. Remove the wiring loom
assembly.
9. Detach the No.7 solenoid wire from the front of
the case.
10. Remove the parking pawl pivot pin and the pawl
and spring from the case.
11. Remove the shaft and the rear servo lever.
12. Remove the rear servo cover and piston assembly.
13. Remove the B1R circlip, valve and spring.
14. Remove both band adjustment shims.
15. Inspect the output shaft bushing in the case and
replace if necessary.
16. Inspect cooler line fittings and replace as
necessary.
17. Inspect the case for damage.
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