DC 5 A/T PRACTICE

Tae-Man Chang
International A/S Team
Phone : (Korea)- 31 - 610 - 1437
Fax : (Korea) - 31 - 610 - 3748
E-mail : jidle21@smotor.com

SSangYong Motor Company

OVERVIEW

00: E2.3(CM)
04: E2.8(CM)
05: E3.2(CM)/2.3

STRUCTURE
1 3 5 7 8 9
2 4 6 10

17 15 13 11
18 16 14 12

1. Torque converter 7. B3 (Disc brake) 13. F2 (Freewheel)

2. Oil pump 8. C3 (Disc clutch) 14. Center planetary gear set
3. Input shaft 9. B2 (Disc brake) 15. Electric control unit( valve body)
4. B1 (Disc brake) 10. Output shaft 16. F1 (Freewheel)
5. C1 (Disc clutch) 11. Parking lock gear 17. Stator shaft
6. C2 (Disc clutch) 12. Intermediate shaft 18. Converter lockup clutch
2page MB5 practice.xls
 COMPONENTS

Shifting elements
Gear C1 C2 C3 B1 B2 B3 F1 F2
1 O3) O3) O O O
2 O O3) O O
3 O O O
4 O O O
5 O O O3) O
P/N1) O O 1) Selector program switch : "S" mode.
P/N2) O O 2) Selector program switch : "W" mode
1) 3)
R O O O O 3) Overrun.
R2) O O O

3page MB5 practice.xls

 Remove the Torque converter.

Explanation :
＊Specified installation height(A) : Below 6.5 mm
＊P/NO : A210 250 0502
＊Diameter : 270 mm
＊Lockup Clutch disc : 2 EA
Installation ＊Engine : E23/E28/E32/D27DT

Unscrew the Bolt and Remove the Guide bush(7mm).

Tool : 7 mm - 1 EA
Torque : 4 Nm

Explanation :
＊The quality of the O-ring rubber Guide bush
was improved.(P/N : 2035400053)
＊Capillarity in tube(surface tension) : Cohesion - Adhesion

2 1 NO Color Connection NO Color Connection

6 5 4 3 1 Gr n3 SIG 8 R 2-3 SOL GND
10 9 8 7
2 Br M/P GND 9 Or 3-4 SOL GND
3 W n2 SIG 10 Bw S/P GND
13 12 11
4 V Oil Temp REF(6v) 11 L Lock-up GND
6 G SOL REF(13v) 12 Gb n2,n3,Temp GND
7 Wb n2,n3 REF(7v) 13 Y 1-2,4-5 SOL GND
Guide bush Connector

Unscrew the Oil pan bolt and remove the Oil pan.
Tool : Torx30 - 6 EA
Torque : 8 Nm

Magnetic filter

Old New

Remove the Oil filter

Notice :
＊Installation :
Align the Oil filter projection
and Valve body hole.
Oil filter Valve body

Unscrew the Bolt and remove the Valve body.

Tool : Torx30 - 10 EA
Torque : 8 Nm

4page MB5 practice.xls

Remove the Rear extension housing.
Tool : Torx45 - 12 EA
Torque : 32 Nm

Explanation :
＊Use the tool above 75mm length.

Unscrew the Coller nut with special tool and remove Output shaft flange.
Tool : 30mm(12 angle long socket)
Torque : 200 Nm

Notice :
＊Bend the Collar nut to lock it during
installation.
Installation

Remove the Rear oil seal ring.

Explanation :
SST NO : 140 589 12 1500

Installation

Remove the Snap ring with snap ring pliers and remove the Washer.

Remove the Ball bearing(Skip this procedure ).

Explanation : Formal procedure of DC

＊Install the Flare clamping pliers.
＊Install the Puller onto inner bearing race.
＊Rotate the Clamping pliers counterclockwise(arrow direction) to tighten.
＊Remove the ball bearing from Puller collect chuck with spanner.
＊SST NO : Puller 001 589 50 3300, Collet chuck 140 589 06 3400

Unscrew the Socket bolts.

Tool : Torx45 - 17 EA
Torque : 20 Nm

Notice :
＊Installation :
- Apply Loctite to the Bolts from T/C housing to T/M(15EA).
- No loctite to the Bolts from T/M to T/C housing(2EA).

5page MB5 practice.xls

 Remove the T/M honsing from T/C housing with Rubber hammer.

Explanation : Installation
＊Instal the two Guide bolt and then remove the
Housing to make the removal process saftly.
＊Instal the two Guide bolt and then slightly turn
the Housing to left and right direction to make Installation
the instllation process easier.

Remove the C3 clutch.

Remove the C2 clutch.

Explanation : Installation
＊T/C housing ~ the end of C2 clutch.
: ≒ 84mm
≒ 84mm

Remove the C1 clutch.

Explanation : Installation
o × ＊T/C housing ~ the end of C1 clutch. ≒ 40mm
: ≒ 40mm

Remove the Bolts on B1 and Remove the Bolts in converter housing

and then remove the B1.
Tool : Torx45 - 7 EA : Torx30 - 11 EA
Torque : 16 Nm : 8 Nm

Explanation :
＊Instal the two Guide bolts on the opposite
side of B1 and tap the Bolts with rubber
hammer to remove it from converter housing.
＊Instal the two Guide bolt and then to make
the Gasket instllation process saftly..
＊Apply the Sealant on the socket bolts
and tighten them.

6page MB5 practice.xls

 Remove the Oil pump.

Explanation :
＊Instal the two Guide bolts on the opposite
side of pump housing and tap with rubber
hammer to make removal/installation
process safty.

Shaft Axial Clearance Adjust

＊Measure the clearance between the ball bearing and the parking
b
lock gear.

① Place the measuring bridge on top of transmission housing

and measure the distance fron the parking lock gear to the c
measuring bridge(a). a
② Measuri the distance from measuring bridge to the ball bearing
groove on mating surface with gauge(b).
③ Adjust the axial play with adjusting shim (c).
④ Install the shim.
⑤ Insert the ball bearing into rear part of transmission housing.
⑥ Measure the clearance between ball bearing(2) and snap ring(1).
⑦ Install the appropriate size of snap ring(2).

＊ Axial play ( specitied value) : 0.3 ~ 0.5 mm

＊ Select a proper thickness of shim : 0.2, 0.3, 0.4, 0.5 mm
＊ Measuring bridge (SST) NO : 126 589 04 3100
＊ Select a proper thickness of snap ring : 2.0, 2.1, 2.2 mm

7page MB5 practice.xls

 COMPONENTS MP S/V
Plug connector
SP S/V
n3 Cap
1-2,4-5
n2
S/V
3-4 S/V
Cap
Electric kit
Lockup

2-3 S/V Float

Start lock-out

Oil temp Shift plate

Valve body

Start lock-out SW, Oil temp sensor

It's actuated by a cam rail,which is
located on the Latching plate.

＊SW open(P,N) : ENG starting.

＊SW close(R,D) : Oil checking.
＊Oil temp Volt(Semi conductor type)
℃ V ℃ V
-10 1.260 50 1.685
0 1.33O 80 1.900
10 1.400 100 2.040
30 1.545 120 2.180

Float function
This is the function that closes the opening between oil chamber and planetary gear set chamber, so that
the gear set does not splash in oil if oil level rises. Reduction of power losses and prevention of fluid loss
from the transmission at high fluid level.

n2,n3 speed sensor

n3 detects the speed of the front sun gear and
n2 detects the speed of front planetary carrier.
If the speed sensor is defective,the TM is
operats emergency driving mode.
Gear n2 n3
1/5/R(S mode) o -
2 o o
3 o o
4 o o
R(W mode) o o

8 page valve body

 Remove the solenoid cap.

Explanation : Valve body part NO

＊New : 2112700006 (Old : 1402700606)
1. Without solenoid cap
2. Electric kit fixed firmly.
3. Lockup control valve spring tension changed. ( noise, vibration)

Unscrew the bolts on solenoid valve and remove the leaf spring.
1
Tool : Torx30 - 3 EA
Torque : 8 Nm

2 1

Remove the Solenoid valves.

a b
Explanation :
＊MP S/V ↔ SP S/V : Interchange ability. a b
( Duty control type)
＊Each Up/down shift S/V : Interchange ability.
(On / off control tapy)
c ＊Lockup S/V : 3rd,4th,5th operating. c
( Dudy control tapy)

1. Electric test Measuring error : 10％

Solenoid Valve Resistance Operating distance Working Current
Up/down S/V 4Ω 0.2 mm 1.5 ~ 2.0 A
MP,SP S/V 5Ω 0.6 mm 0 ~ 1.0 A
Lockup S/V 2.5 Ω 0.2 mm 1.5 ~ 2.0 A

2. Vacuum test
Inspect the each solenoid vlaves vacuum condition with Vacuum tester.
＊Nomal state : Keep the Gauge at a fixed vacuum.
＊Poor state : The vacuum go down rapidly.

MP,SP Up/dwwn Lockup

Vacuum tester

3. External inspection
＊Inspect the O-ring condition.
＊Inspect the each solenoid valves contact surface.

a
9 page valve body
 a Remove the Electric kit from valve body.

b a : fixing point b : fixing point

Unscrew the bolts on valve body and remove the Shifting housing.
Tool : Torx30 - 29 EA
Torque : 8 Nm

MP/SP filter

Suportor(SST)

4
1
5
2
6
3
7
1. 2-3 overlap control valve
2. Lubricating pressure control valve
8
3. Operating pressure control valve
4. Selector valve
5. 3-4 holding pressure shift valve
6. 3-4 command valve
Upper Section
7. 3-4 shift pressure shift valve
8. 3-4 overlap control valve

Valve movement
Explanation :
＊Check the Vlave movement before remving.
＊Remove the Shift plate center bolts and install the SST and then remove
the side bolts.(SST NO : 111589015900 ) : Tightening torque 4Nm(T20)
＊Clean the Housing with Solvent thinner and Air gun and then coat the Oil. Installation
＊Installation : Use the Guide tools and install the Shift bolts.

10 page valve body

 Remove the Leaf spring and then remove the Sealing plate.
Tool : Torx30
Torque : 8 Nm
Sealing plate

Location of Balls Plastic ball

Explanation :
＊Before installation, check the Balls
and the others correct position.

＊Steel balls - 8 EA
(Effect of plug) Steel ball
＊Plastic balls - 4 EA Steel ball
(Effect of shift valve)
＊Filter - 2 EA
(Effect of second filter)
＊Check valve - 1 EA
＊Dowel pin - 1 EA
Filter Dowel pin Filter Check valve

Lower Section 8

1 9

10
2
11
3

4
12
5
13
6

14

15
7
16

1. Shift plate 6. 2-3 holding pressure shift valve

2. TC lockup clutch control valve
(Spring tension improvement,2005)
3. Regulating valve(Lubricating pressure)
4. 2-3 shift pressure shift valve
5. 2-3 command valve
7. Shift valve B2
8. Shift plate
9. 1-2/4-5 command valve
10. 1-2/4-5 holding pressure shift valve
11. 1-2/4-5 shift pressure shift valve
12. Shift plate
13. 1-2/4-5 overlap valve
14. shift pressure control valve
15. Regulating pressure control valve
16. Shift valve pressure control valve

11 page valve body

 HOUSING COMPONENTS

Brake B3 Snap ring

Brake B2 Parking lock gear Conponents of selector lever

B2 COMPONENTS
13 15

14

2 10

1
5 3 11
4
6
9 8 7

1. Disc carrier B2 6. Sealing ring in piston guide ring 11. O-ring

2. Sealing ring 7. Return spring 12. Disc and steel plate
3. Sealing ring 8. Spring plate 13. Snap ring
4. Piston in B2 9. Snap ring 14. Cushion plate
5. Sealing ring in piston guide ring 10. Piston guide in B2,B3

Install the transmission housing assembly on the fixture stand.

Explanation :

12 page Housing
 Remove the Snap ring and B3 disc pack from Housing.

6
2 3 6 4 5

Cushion spring

3 5 Fig 1
Explanation :
＊Sectional drawing of B3
1. Husing 1
2. Snap ring 5. Steel plate 2
3. Steel plate 6. Cushion spring
4. Disc plate 7. Piston
7
L. Clearance 6
4
＊Measurement Procedure
1. Soak new discs into ATF for one hour before installation.
2. Install the B3 discs with the order as shown in Fig 1. Fig 2
3. Determine the clearance(L) at three points between
Snap ring(2) and Steel plate(3) with feeler gauge. 2
4. Adjust the clearance with proper snap rings if needed.

- Specified clearance(L) : 1.0 ~ 1.4 mm 3

- Thickness of B3 snap ring : 3.2, 3.5, 3.8, 4.1, 4.4, 4.7mm

Remove the fixing bolts for B2 from Housing.

Tool : Torx45 - 2 EA
Torque : 16 Nm

Remove the B2 from Housing.

Explanation :
＊Installation :
Align the B2 carrier slot center and
Bolts center and then install the B2
slot as Housing slot.
Installation

13 page Housing
 2 7 6 5 4
3

＊Sectional drawing of B2 1 3 4 7 Fig 1

1. Disc carrier 6. Steel plate
2. Snap ring 7. Cushion spring
3. Steel plate 8. Piston
4. Disc plate L. Clearance 2
5. Steel plate
8
＊Measurement Procedure(Formal of DC)
5 6
1. Soak new discs into ATF for one hour before installation.
2. Install the B2 discs with the order as shown in Fig 1.
3. Install the compressor on Steel plate(3) and apply the 1200N of Fig 2
force to the disc pack. This force is applied on the marking ring point
(small arrow in Fig 2). Do not apply excessive force. SST
4. Determine the clearance(L) at three points between Snap ring(2)
and Steel plate(3) with feeler gauge.
- The snapring(2) should be contacted to top of the external disc
carrier(1) during installation.
5. Adjust the clearance with proper snap rings if needed.
＊Specified clearance(L) : 1.5 mm ± 20％ (Normal condition)
NO Clearance(L)
3 1.9 ~ 2.3 mm
4 2.0 ~ 2.5 mm
5 2.0 ~ 2.4 mm
＊Thickness of B2 snap ring : 2.9, 3.3, 3.5, 3.8 mm

1
2 3

SST
a b

C d
a b 4

Piston components

c Shaft b d c d

Explanation :
＊SST NO : 140 589 13 4300(1) 2
＊Installation : Align the Piston hole and Spring plate projection(2).

14 page Housing
 Remove the Parking lock gear.

Remove the range lever bracket.

Tool : Sockte 13mm
Torque : 25 Nm

1 2 Remove the Range selector lever rod.

Tool : Torx 30
Torque : 6 Nm

Range lever rod

Remove the Detent plate ASSY.

Detent plate ASSY

Remove the Snap ring and Parking lock pawl ASSY.

1

2 3

Snap ring Parking lick pawl ASSY

1 2 Remove the Snap ring and parking lock guide.

Parking lock guide

15 page Housing
 B1 COMPONENTS

4 5 6
3
2

1. Disc brake B1 4. Snap ring 7. snap ring

2. Piston 5. Cushion spring
3. Return spring 6. Disc and steel plate

2 3 7 4 5 4 5

＊Sectional drawing of B1 7 6 5 3 Fig 1

1. External disc carrier 6. Exteranl disc 1

2. Snapring 7. Cushion spring

3. Steel plate(4.0mm) 8. Return spring
2
4. Inner disc 9. Piston
5. Outer disc L. Clearance

＊Measurement Procedure(Formal of DC)

1. Soak new discs into ATF for one hour before installation.
9 8 4
2. Install the B1 discs with the order as shown in Fig 1.
3. Install the compressor on Steel plate(3) and apply
the 1200N of force to the disc pack. This force is applied Fig 2
on the marking ring point(small arrow in Fig 2). SST
Do not apply excessive force.
4. Determine the clearance(L) at three points between
Snap ring(2) and Steel plate(3) with feeler gauge.
- The snapring(2) should be contacted to top of the
external disc carrier(1) during installation.
5. Adjust the clearance with proper snap rings if needed.

＊Specified clearance(L) : 1.8 mm ± 20％ (Normal condition)

NO Single friction Dual friction
2 2.2 ~ 2.6 mm 2.3 ~ 2.7 mm
3 2.4 ~ 2.8 mm 2.7 ~ 3.1 mm
4 2.6 ~ 3.0 mm 3.0 ~ 3.4 mm

＊Thickness of B1 snap ring : 2.6, 2.9, 3.2, 3.5, 3.8, 4.1 mm

16 page B1
Install the SST and remove the Snap ring.

Explanation :
SST NO : 140 589 13 4300

SST Snap ring

Remove the Return spring.

Remove the B1 piston.

17 page B1
 C1 COMPONENTS

5
4
2
1 3
9
10

A 1 8

1. Sealing ring indisc carrier 5. Spring plate 9. Snap ring

2. Piston 6. Snap ring 10. One-way clutch F1
3. Sealing ring in piston 7. Desc and steel plate A. Oil gallery in clutch C1
4. Return spring 8. Snap ring

2 3 7 4 5 4 5

＊Sectional drawing of B1 6 5 3
1
1. External disc carrier 6. Exteranl disc
2. Snapring 7. Cushion spring
3. Steel plate(4.0mm) 8. Piston 2
4. Inner disc L. Clearance
5. Outer disc

＊Specified clearance(L) : 1.9 mm ± 20％ (Normal condition)

NO Single friction Dual friction 8 7 4
3 2.4 ~ 2.8 mm 2.7 ~ 3.1 mm
4 2.6 ~ 3.0 mm 3.0 ~ 3.4 mm
5 2.8 ~ 3.2 mm 3.3 ~ 3.7 mm
6 2.9 ~ 3.3 mm 3.6 ~ 4.0 mm
＊Thickness of B1 snap ring : 2.6, 2.9, 3.2, 3.5, 3.8, 4.1 mm

Install the SST and remove the Snap ring.

SST Snap ring

18 page C1
Remove the spring plate.

Spring plate

Remove the return spring.

Return spring

Remove the C1 piston.

C1 piston

Rimove the snap ring and one-way clutch upper cap.

Remove the One-way clutch.

Explanation :
＊Install in the one-way clutch an arrowhead
for down direction.

Remove the one-way clutch lower cap.

Cap

19 page C1
 C2 COMPONENTS

11
10
9
7 6
8
5
4

1
3
13 2

12

1. Front planetary gear set 6. Piston 11. Snap ring

2. Gear wheel 7. Inner sealing ring in piston 12. Disc and steel plate
3. Snap ring 8. Outer sealing in piston 13. Snap ring
4. Thrust bearing 9. Return spring
5. Clutch C2 and input shaft 10. Spring plate

Remove the thrust bearing.

Thrust

Remove the snap ring.

Remove the Gear wheel.

Gear wheel

20 page C2
 Remove the C2 clutch shaft ASSY.

2 3 4 6 4 5 6
7

＊Sectional drawing of C2 6 5 3 1
1. External disc carrier 6. Exteranl disc
2. Snapring 7. Cushion spring
3. Steel plate(4.0mm) 8. Piston
4. Friction disc L. Clearance
2
5. External disc

＊Specified clearance(L) : 1.55 mm ± 20％ (Normal condition)

NO Dual friction 8 7 4
3 2.3 ~ 2.7 mm
4 2.4 ~ 2.8 mm
5 2.5 ~ 2.9 mm
6 2.7 ~ 3.1 mm
＊Thickness of C2 snap ring : 2.3, 2.6, 2.9, 3.2, 3.5, 3.8 mm

Remove the C2 piston.

Remove the Thrust bearing.

Thrust bearing

Unscrew the Bolts and remove the Front planetary gear.

Tool : Torx30 - 4 EA
Torque : 10 Nm

Front planetary gear

21 page C2
 C3 COMPONENTS

1
2
3
4
5

Rear gear set /

center output shaft 14
12

10 13
11
17
18
16 15

B
8 A 9

Rear one-way clutch / hollow

shaft

26
24 25
23
21 22
19

20

1. Clutch C3 11. Thrust washer 21. Snap ring

2. Sealing ring 12. Thrust needle bearing 22. One-way clutch
3. Piston 13. Shim 23, Inner disc carrier/sun gear
4. Disc spring 14. Snap ring 24. Thrust needle bearing
5. Snap ring 15. Rear gear set 25. Shim
6. Disc pack 16. Thrust washer 26. Snap ring
7. Snap ring 17. Clutch C3 A. Oil outlet port C3
8. Center gear set 18. Rear hollow shaft B. Oil inlet port C3
9. Needle bearing 19. Hollow shaft
10. Teflon ring 20. O-ring

22 page C3
 Remove the Snap ring and Shim.
??????

Shim washer

Remove the Thrust needle bearing and Thrust washer.

Needle bearing Thrust washer

Remove the Output shaft in center gear set.

Output shaft

Remove the C3 clutch pack.

Clutch pack

One - way clutch

2 3 4 5 7 4 5 4 5

＊Sectional drawing of C3 1 3 5 6 7
1. External disc carrier 6. Exteranl disc
2. Snapring 7. Cushion spring
3. Steel plate 8. Piston 2
4. Friction disc L. Clearance
5. External disc
4 8
＊Specified clearance(L) : 1.6 mm ± 20％ (Normal condition)
NO Single friction (2WD,CM) Dual friction (4WD)
3 2.3 ~ 2.7 mm 2.3 ~ 2.7 mm
4 2.4 ~ 2.8 mm 2.4 ~ 2.8 mm
5 2.5 ~ 2.9 mm 2.5 ~ 2.9 mm
＊Thickness of C3 snap ring : 2.0, 2.3, 2.6, 2.9, 3.2, 3.5 mm

23 page C3
 1 2 3

Return spring

Snap ring
SST
4

C3 piston

C3 piston

1 3
o × 2

Snap ring
Hollow shaft

Rear One-way clutch

5 4

Explanation :
Install the one-way clutch
projection for Right direction. One - way Snap ring

1
2 3

Snap ring Ring gear

Rear gear set

24 page C3
Circlip thikness / part number

25 page C3
Fixing Plate Assembly Stand
 Shift Rod Adjustment

DD P
P

DD PP

1. Range lever D. "D" range

2. Shift rod P. "P" range
3. Selector lever

Adjustment procedure
1. Disengage the shift rod from range lever and place the range lever at "D" position.
2. Place the selector lever at "D" position.
3. Insert the shift into range lever and tighten nut.

Notice
Lock the selector lever so that it will not move.

4. Check it the indication lamp in meter indicates correct gear position while moving
the selector to "P", "R", "N", and "D" position.
5. Check it the engine can be started at selector lever "P" or "N" position.
80

25

Special Tool
How to remove the oil cap pin.

Explanation :
Cap pin is very weak, sometimes to be broken pin head.

Take the groove for your fingers damaged and then

take out the cap quickly and strong.

a
Explanation :
a : Locker
b : Pin

Put into the small driver between the Loker and pin.
And then push the pin with the sharp tool.