FR 6SPEED AT PRACTICE

SsangYong Motor Company

Housing

Fluid Level Set1. Start the E/G in P(park)2. TCU => Oil Temp => Range 50~60 ℃(82~140℉)3. Turn the E/G OFF => Level Check - Converter empty : 9.0 L - Converter full : 4.0 L4. Oil Fluid Specification :

FUCH TITAN ATF 3292(~2009: CATEX PED 1712)

Remove the Converter housing.

Tool : 12mm, 12angle socket * 9EATorque : 45Nm

* Coat the Locktite to the Housing bolts. * Install the Housing parallely to the TM.

Remove the oil pan Tool : 10mm socket * 9EA Torque : 5Nm

Check the oil color ＊Black : Band Burnt ＊Steal Dust : Planet Gear ＊Brass Dust : Oil Cooler

Notice : Do not install over torque as this will fluid leakage (Seal Damaged)

Remove each of the Oil filter retaining clip from the Valve body.

* Keep the Retaining clip banding position.

Remove the Filter.

＊Check the Seal-ring ;

Not good condition => Slip.

Remove the Input Speed Sensor(EMM).

Tool : Torx 20

* EMM

(Embedded Memory Module)

: contains TM specific

characterisation information.

Front

Rear

Short

Long

Front

Rear

Seal-ring

Locktite

Inplut Speed Sensor(EMM)

Detecting hole

Magnetic

Oil check plug

DSI NO

SYMC NO

DSI 6 speed - Housing 2

Housing

Disconnect the Wiring.

Remove the Valve body

Tool : Torx30 * 12EA ( L : 30mm-10, 50mm-2 )

Torque : 11Nm

Remove the Parking Rod

Tool : Torx40 - 2EA Torque : 20Nm

Remove the Wiring from the TM housing.

Remove the Pump ASSY. Tool : 8mm 12angle socket

* 8EA (L=75mm) Torque : 30Nm

* Shim : t=0.127(0578-037077) t=0.245(0578-037078) t=0.197(0578-037079)

* Shim Retainer : 0578-040052 (t=0.55mm)

Shift valve rod

O-ring

Substitution Pullers

* SST : W9936 0011C (SYMC P/N) 0555 336257 ( D'SI P/N)

* Free load : - About 8~10 kgf · cm - It's deferent as temp, oil condition…etc * End play ≒ 0(①), 0.25~0.30mm(②)

Parking Rod

Locktite

On-off SolConnectors

Variable BleedSol Connectors

RR SpeedSensor

connector

OldNew Shim

Oil TempSensor

①

②

DSI 6 speed - Housing 3

Housing

Remove the Pump gasket.

Installation * Install the Guide pin and than

intall the Gasket. * Adjust the Housing and

Gasket shape.

Remove the SPG(Single Planetary Gear).

Coat the Grease slightly and than install the Bearing to the Carrier gear. (Only installation procedure)

* Bearing size :Inner : Φ=33.2mmOuter : Φ=51mm t = 3.8mm

Coat the Grease slightly and than install the Bearing to the C1 clutch pack. (Only installation procedure) * Bearing size :

Inner : Φ=33.2mmOuter : Φ=51mm t = 3.8mm

Remove the C1 clutch pack.

Coat the Grease slightly and than install the Bearing to the C2 clutch pack. (Only installation procedure) * Bearing size :

Inner : Φ=33.2mmOuter : Φ=51mm t = 3.8mm

Remove the C2 clutch pack.

* Check the center of Front speed sensordetecting plate.

Housing side Gasket side

11

≒ 1mm

≒ 3mm

Housing

Inside Outside

Inside Outside

Inside Outside

C2 Clutch Pack

Installation

C1 Clutch Pack

DSI 6 speed - Housing 4

Housing

Remove the Bearing and cap to the C3 clutch pack.

* Bearing size :Inner : Φ=33.2mmOuter : Φ=51mm t = 3.8mm

Remove the C3 clutch pack.* Bearing size : Φ = mm

Install the Bearing. (Only installation procedure)

Slope the TM housing because installation procedure correctly. (Only installation procedure)

Remove the Front band.

* Push Rod Travel : - 3.0mm

Remove the Front band retainner.

Remove the Front Band Piston.

OuterInner

① ③33.522.447.743.35

Inside Outside

C3 clutch pack

①

②

③

① Bearing face :C3 direction

③ Bearing face :C3 direction

② Hollow Shaft

Adjustment Shim

Snap Ring

Front BandPiston

Θ

DSI 6 speed - Housing 5

Housing

Install the Front Band Piston and compress the Band Piston and thaninstall the Snap ring. (Only installation procedure)

* Protect the Housing face with clothe.

Remove the Snap ring to the Housing.

Unscrew the Bolts and than remove the DPG(Double Planetery Gear). Tool : Torx 50 - 2EA

Torque : 45Nm * Installation procedure 1. Install the DPG as slightly turn the Rear shaft. 2. Align the DPG bolt hole and Housing hole. 3. Install the Bolts not complitly. 4. Install the Snap ring and than Screw the Bolt tightly.

Coat the Grease slightly and than install the Thrust washer and bearing. (Only installation procedure)

* Bearing size :Inner : Φ=35mmOuter : Φ=55mm

Remove the Rear band.

＊Piston travel : 3.75mm 3.75mm ↑ => Some time not working reverse.

Remove the Rear Band Piston. Tool : 8mm 12 angle socket * 6EA Torque : 30Nm

Remove the Output Shaft Gear

* Bearing size :Inner : Φ=52.4mmOuter : Φ=72mm

Snap Ring

DPG(one way clutch)

Bearing directionBearing

Rear Break Band

Adjust shim

Rear direction

Output Speed Sensor

(O)(×)

Φ ≒ 15mm

Locktite Rear Band Piston

DSI 6 speed - Housing 6

Housing

Remove the Adaptor Housing. Tool : 8mm socket - 10EA

(L=100mm-4. 35mm-6) Torque : 30Nm

Remove the Rear speed sensor from the Housing.Tool : 8mm soket

* Air gap : 0.35 ~1.5mm(A-B=C)

Remove the Parking pawl and Lever pivot.

* Shifting Eelements

S1 S2 S3 S4 S5 S6 S7 S8 S9 S10

on 1 0 1 TC

on 1 0 0-1 TC

on on 1 0 1 0-1 TC

on on 1 0 1 0-1 TC

0 0 0-1 TC

on on 0 1 1 0-1 TC

on on 0 1 1 0-1 TC

on on 1 1 1 0-1 TC

on

B2 OWC

2.143

1st

2nd

Mode

M1 on

Ratio

3.536

Operating Components

C1 C2 C3 B1

5th

6th

Reverse

1.478

1.156

0.866

4th

3rd

0.677

3.084

on on

on

on on

on

3.536 on

on on

on on

on

on

Shift On/Off Sol. Variable Sol.

on

Steel GasketLocktite

AdaptorHousing

Detection

Out putSpeed Sensor

Parking Pawl Lever Pivot

C2 Clutch

B2 inner B2 outer

B1 inner B1 Damper B1 Outer C1 ClutchC3 Clutch/Lubrication

From Oil cooler out

Filterto

Pump

Front Rear

To OilCooler

IN

Output Shaft(Parking Gear)

A B

C

DSI 6 speed - Housing 7

DPG(Double Planetery Gear)

1. Remove the Needle Bearing. 2. Remove the Thrust Washer. 3. Installation process

Φ=35mm Φ=55mm * Risen face bearing direction. * Check the Rotation

direction.

3. Separate the Center Support.

4. Remove the One Way Clutch.

* Risen face upper direction

8. Remove the O-ring. 5. Remove the Snap Ring.

7. Remove the OWC Retainer. 6. Remove the OWC Outer Race.

* Risen face Upper direction.

(O)(×)

Installation

DPG( Double Planetery Gear)

Disassembly

Assembly

DSI 6 speed - DPG8

Clutch Packs

No

Clutch

* Disk / Plate : C1 = C2 = C3 ( Interchang ability).

* Install the Last plate(t=4.5) as sharp face opposite of Disc.

* Specified clearance : ≒ {(D*0.2)+0.2} mm ± 20％ (Normal condition, Adjust Shim Plate is selective.).

14

* Subscripts :

P : Plate, D : Disc, AS : Adjustment Shim, WS : Wave Spring,

CP : Cover type Plate(Plate + Spline)

139 10 11 12

-

-

-

- -

CP

-

-

4.5 -

AS

1.8 2 1.8 2 AS 2 4.5 -

1.8 2 1.8 22 1.8 2 1.8

1.8 2 AS 21.8 2 1.8 2

t = mm

- 1.8 2

- 1.8 2

- 1.8 2

-

D

-

1.8

- -

1 2 3 4 5 6 7 8

P

P D P D P D P D P

P D P D

P D P

ws P D P D P D

P D P DP D P DC1

C2

C3

-

ws

t = mm

t = mm

C1 Clutch Line

C2 Clutch Line

C3 Clutch Line

C1 Clutch Pack

C3 clutch pack

C2 Clutch Pack

DSI 6 speed - Clutch Pack9

PumpRemove the Pump front Housing, Driving and Driven Gear.

Tool : Torx40 - 5EA Torque : 30Nm

Remove the Rear Cover and Gasket. Tool : Torx30 - 7EA Torque : 11Nm

Remove the Retainer Pin and than remove the Valves.* Pin size :

L = 22.6 mmΦ = 2 mm

Instalation * Carefully install the Valve Caps because of the O-ring damage. * Coat the ATF Oil at the at the each component.

FIG.

Size of Components (mm)

Valve

component

CRV

Retainer Pin

Length Dia(Φ)

9 1

CSV

PRV

CLRV

RRV

CBV

Cap Inside(Φ)Thick(Φ)Dia(Φ)Length

Spring

11.5(inner)

7.2(outer)

10(inner)

4.6(outer)

11.5(inner)

-

40

59

53

29.4

46.2

9 0.5

9.4

9.4

6

1

1.25

0.7

110.8

6 -

-

6.4

Ball Dia

22.6 2

ATF Coating

CRV : Convertor Regulator Valve

CSV : Convertor Shift Valve

PRV : Primary Regulator Valve

RRV : Release limit Regulator Valve

CLRV :Cooler Lubrication controlRegulator Valve

Cooler Bypass Valve(Ball: In, Spring: out)

Fluid Pump

DSI 6 Speed - Pump10

Valve BodyRemove the Valve Housing Bolts.

Tool : Torx30 - 28EA Torque : 11Nm

Remove the Lower Housing, Gasket Plate and then remove the Gasket plate from the Lower Housing.

Remove the Plastic Balls, Exhaust Valves and Filters.

Remove the RFSV.* Spring size : mm

Dia(Φ)

Thick(Φ)

9

0.8

-

Length 40

Components

9 1.8

136

QTYSpring

Length Dia(Φ) Thick(Φ)13 5 0.4

Ball(Φ)

Plastic Ball(white) Plastic Ball(brown) Exhaust Valve 16.4

86.5 - - -

Exhaust Blow off Valve(Spring : in, Ball: out)

Exhaust Valve

FilterB1 Quick

Release ValveExhaust Valve

Exhaust Valve

Exhaust Valve

Exhaust Valve

Filter

Filter

B2 Supply Ball /REV Supply Ball

RFSV

Lower Valve Body

Reverse LHM Valve /Reverse Lockout Valve

DSI 6 speed - Valve Body11

Valve Body

Remove the VBSs(Variable Bleeding Solenoids). Tool : Torx20 - 6EA Torque : 8Nm

Remove the Solenoid Retainer and On/Off Solenoids.

* S1 : C1 apply and release. * S2 : C2 apply and release. * S3 : Torque converter apply and release. * S4 : B1 apply and release.

1. Electric test

2. Vacuum testInspect the Variable Bleeding Solenoids vacuum condition with the Vacuum tester. * Nomal state : Keep the Gage indigator at a fixed vacuum. * Poor state : The vacuum Gage indigator go down.

Resistance4.2Ω22.1ΩSift SV

VBS

Variable Bleeding Solenoid(Nomally Low)-S7

Variable Bleeding Solenoid(Nomally High)-S5

VBS(N/H)-S9

Detent Spring

VBS(N/H)-S10

Suction Port

VBS(N/L)-S8

VBS(N/H)-S6

CBS

B2S

B2R

C2R

S2(on/off)C2S

S3(on/off)CNV

S4(on/off)B1S

S1(on/off)CIS

B1RC1R

Manual Valve

SSV

Upper Valve Body

VBSNomally Hight

VBSNomally Low

DSI 6 speed - Valve Body12

Valve Body

Size of Spring mm

Thick(Φ) 0.8 1.3 0.8

C3S SSV OthersLength 30 54 40Dia(Φ) 6 99.3

C1S :C1 Shift Valve

C1RC1 Regulator Valve

B1RB1 Regulator Valve

B1SB1 Shift Valve

CNVConverter Supply Valve

C2SC2 Shift Valve

C2RC2 Regulator Valve

SSVSolenoid Supply Valve

MANManual Valve

B2RC3/ B2 Regulator Valve

B2SB2 Shift Valve

Filter

Filter

C3SC3 Shift Valve

S1

S2

S3

S4

Upper Valve Body Valves

DSI 6 speed - Valve Body13

DSI 6speed Transmission

NO

1

3

4

QTY REMARKTOOL NO DESCRIPTION APPLICATION

1

W9936 0011C

Pump Puller

For removal of oil pump.

1

W9931 0010B

TransmissionBench Cradle

For transmission support when removal andinstallation of overhaul.

Dimesion of DSI 6speed TM Supportor

1W9936 0031C

Clutch SpringCompressor

For compressing the spring when removal ofclutch snap ring.

400mm

280mm

60mm

20mm

☞ Procedure for Rear Speed Sensor Replacement

Oil

FUCHS ATF 3353 SHELL ATF 3353

CASTROL TQ95

CALTEX PED 1712 ATF FUCHS TITAN ATF 3292

0.866 0.677 3.0843.536 2.143 1.478 1.156

- - 2.4292.742 1.508 1.000 0.709

0.831 - 3.1673.595 2.186 1.405 1.000

5th 6th R

☞ Lock up Control

1st 2nd 3rd 4th

Gear RatioLock-up

Gear

DSI 6speed(M78)

All

Model Name

3~MB 5speed(W5A400)

ION 4speed(M74)

3~

1. Trasfer Case 2. Oil / Oil Pan 3. RR Adaptor Housign

5. RR Sensor 4. RR Sensor Connector