SSANGYONG Rexton 2004 Bedienungsanleitung

CHASSIS

SERVICE MANUAL

PYUNGTAEK, KOREA

DRIVING SYSTEM

SERVICE

MANUAL (vol. 2 of 2)

SECTION INDEX

AXLE & PROPELLER SHAFT 4

PYUNGTAEK, KOREA

SSANGYONG MOTOR CO., LTD.

REXTON

FOREWORD

This manual includes procedure for maintenance,

adjustment, service operation and removal and

installation of components.

All information, illustrations and specifications

contained in this manual are based on the latest

product information available at the time of manual

approval.

The right is reserved to make changes at any time

without notice.

VOLUME 2 OF 2

WHEEL & SHAFT 5

STEERING SYSTEM 6

SUSPENSION SYSTEM 7

BRAKE SYSTEM 8

ELECTRIC SYSTEM 9

HVAC SYSTEM 10

BODY 11

RESTRAINT SYSTEM 12

CHASSIS

DRIVING SYSTEM...........................SECTION 03

AXLE & PROPELLER SHAFT ........SECTION 04

WHEEL & SHAFT ............................SECTION 05

STEERING SYSTEM .......................SECTION 06

SUSPENSION SYSTEM..................SECTION 07

BRAKE SYSTEM.............................SECTION 08

ELECTRIC SYSTEM........................SECTION 09

HVAC SYSTEM................................SECTION 10

BODY................................................ SECTION 11

RESTRAINT SYSTEM .....................SECTION 12

CONTENTS

DRIVING SYSTEM

SECTION 3

DC 5-SPEED AUTOMATIC TRANSMISSION............. 3A1

BTRA 4 AUTO TRANSMISSION................................. 3A2

TSM54/52 MANUAL TRANSMISSION ......................... 3B

CLUTCH ......................................................................... 3C

PART TIME..................................................................... 3D

TOD ................................................................................ 3E

CONTENTS

3A1-1

CHANGEDBY

EFFECTIVE DATE

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DC 5-SPEED AUTOMATIC TRANSMISSION

REXTONSM - 2004.4

DC 5-SPEED AUTOMATIC

TRANSMISSION

´Ü¿ø 00SECTION 3A1

Table of Contents

GENERAL INFORMATION...................3A1-3

Overview ..........................................3A1-3

Characteristics .................................3A1-4

Structure ..........................................3A1-5

Performance curve and general

characteristics..................................3A1-6

Specifications...................................3A1-7

Power flow ........................................3A1-9

FUNCTIONAND DESCRIPTION ........3A1-17

Selector lever.................................3A1-17

Torque converter ...........................3A1-18

Lockup clutch.................................3A1-20

Planetary gear set .........................3A1-22

Multiple-disc clutch ........................3A1-23

Freewheel ......................................3A1-24

Sensors and controls.....................3A1-25

OTHER FUNCTIONS..........................3A1-47

Circuit diagram...............................3A1-50

TROUBLE CODEAND DIAGNOSIS ..3A1-52

Trouble diagnosis with scanner.....3A1-52

HYDRAULIC SYSTEM .......................3A1-61

Structure of valve body..................3A1-61

Hydraulic circuit..............................3A1-62

Hydraulic circuit when starting engine

.......................................................3A1-67

Structure of electro-hydraulic control

module (shift plate) ........................3A1-73

REMOVALAND INSTALLATION

(DC 5-SPEEDA/T) ..............................3A1-76

Components locationor..................3A1-76

DISASSEMBLYAND REASSEMBLY

(DC 5-SPEEDA/T) ..............................3A1-83

Components...................................3A1-83

Components assembly ..................3A1-84

Disassembly and reassembly ........3A1-86

SPECIALTOOLSANDEQUIPMENT .3A1-106

3A1-3

CHANGEDBY

EFFECTIVE DATE

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DC 5-SPEED AUTOMATIC TRANSMISSION

REXTONSM - 2004.4

Y220_3A1001

DC 5-Speed Automatic Transmission

DCAG 5-speedautomatic transmission is anelectronically controlled5-speed transmission witha lockup clutch in the

torqueconverter.

The ratios for the gears are realized by three planetary gear sets. The 5th gear isdesigned with a step-up ratioof 0.83

as an overdrive. The selector lever is controlled by electronically and mechanically. The gears are shifted by the corre-

sponding combination of three hydraulically actuated multiple-disc brakes, three hydraulically actuated multiple-disc

clutches and two mechanical one-way clutches.

This electronically controlled automatic transmission adjusts the operating pressure to provide proper shifting inrelation

to engine power. This function improves shiftingquality significantly.And, the driver can select “S” (Standard) mode or

“W” (Winter) modeaccording tothe driving conditions.

This automatic transmission provides two gears even during reverse driving. The internal sensors and controls are

connected to TCU by cylindrical 13-pin connector.

* DCAG 5-speed automatic transmission offers the following advantages:

1. Improvedshiftingquality

2. More gears

3. Extended working life and reliability

4. Reducedfuelconsumption

2WD 4WD

OVERVIEW

GENERAL INFORMATION

DC Part Number

DC Variant Number

Serial Number

Automatic Transmission Assembly

Transmission Type

Automatic Transmission for

Passenger Car

Engine Code

Number

34: D27DT (2WD)

61: D27DT (4WD)

62: E3.2 Engine (4WD)

3A1-4

CHANGEDBY

EFFECTIVE DATE

AFFECTEDVIN

DC 5-SPEEDAUTOMATIC TRANSMISSION

REXTONSM - 2004.4

Engine torque Torque

converter Automatic

transmission Final drive

gear Output

torque

Multiple disc

clutch Multiple disc

brake

Torque

converter

lockup

clutch

Flywheel

Characteristic Function and Description

CHARACTERISTICS

Slope recognition

(down hill, up hill)

Engine torque limitation

Engine torque decrease

Engine rpm limitation

ESP Operation

ABS Operation

Fast-off function

Altitude recognition

Oil temperature

Hydraulic pressure is pro-

duced in emergency driv-

ing mode

Adaptation

Recognize it according to engine RPM and accelerator

pedal position

During 1st gear driving or reverse driving with full throttle

condition

Delay of ignition timing to reduce torque at all shifting

moments

Limit engine rpm until the gears are fully engaged when

shifting from “P” or “N” to “D”

When the ESP is controlling the engine torque, shifting is

not available and vehicle starts off with 2nd gear.

Not any effect to brake control

Does not up shift when accelerator pedal is abruptly re-

leased

As altitude increases (atmospheric pressure

reduces) engine torque decreases. Up shift while

additionally depressing the accelerator pedal

(adjusting shift diagram)

If transmission oil temperature is too low, the shifting point

gets delayed in full throttle and kick down

When starting the engine with cycling the ignition

switch (“OFF” and “ON”) due to transmission trouble,

the selector lever should be placed in “P” position. If

starting the engine with selector lever “N” position,

the lever should be moved into “P” position. Because,

the hydraulic pressure can be produced in selector

lever “P” position.

Function to optimize the shifting quality.

Effect

Delay up shift

Prevent automatic transmis-

sion from overheating

Improve shift quality

Prevent shift shock

Cannot use kick-down func-

tion and shift at maximum rpm

To get an engine brake effect

during cornering

Improves driving performance

and increases torque

Improvesdriving performance

The hydraulic pressure flows

withdirect operation modevia

“R” and “D” valve to operate

“R” and “forward 2nd” gear.

To exclude play and wear

3A1-5

CHANGEDBY

EFFECTIVE DATE

AFFECTEDVIN

DC 5-SPEED AUTOMATIC TRANSMISSION

REXTONSM - 2004.4

Y220_3A1002

STRUCTURE

Y220_3A1002A

Basic structure of DC 5-speed automatic transmission

1. Torque converter

2. Oil pump

3. Input shaft

4. Disc brake B1

5. Disc clutch C1

6. Disc clutch C2

7. Disc brake B3

8. Disc clutch C3

9. Disc brake B2

10. Output shaft

11. Parking lock gear

12. Intermediate shaft

13. Freewheel F2

14. Center planetary gear set

15. Electric control unit (valve body)

16. Freewheel F1

17. Stator shaft

18. Converter lockup clutch

3A1-6

CHANGEDBY

EFFECTIVE DATE

AFFECTEDVIN

DC 5-SPEEDAUTOMATIC TRANSMISSION

REXTONSM - 2004.4

Standard mode

Pedal value (%)

Vehicle speed (kph)

Y220_3A1004

Y220_3A1003

PERFORMANCECURVEAND GENERALCHARACTERISTICS

Note

1. Based on DI Engine + A/T equipped vehicle

specifications

• Gear ratio

1st gear: 3.595

2nd gear: 2.185

3rd gear: 1.405

4th gear: 1.000

5th gear: 0.831

2. WINTER Mode: Standard Mode

3. Allowable shifting point:

Upshift

Downshift

Lockup (sleeping)

Unlock (open)

FAST OFF

Dynamic shift range

4. FAST OFF

• When abruptly releasing the accelerator pedal, the

transmission remains at 4th gear other than 4

→→

→

shift (when slowly releasing the accelerator pedal,

the transmission is shifted to 5th gear).

5. Dynamic shift range

• When operating the accelerator pedal, the 4

→→

→

shift is completed by kick-down signal after

completion of 4

→→

→

4 shift.

• When promptly operating the accelerator pedal, the

→→

→

3 shift is done in shaded arae.

Pedal value (%)

Vehicle speed (kph)

Lockup mode (open/sleeping)

Pedal value (%)

Vehicle speed (kph)

4-LOW mode

5th gear sleeping

4th gear sleeping

3rd gear sleeping

4th gear open

3rd gear open

5th gear open

Rev. 1st gear: 3.167

Rev. 2nd gear: 1.926

Axle ratio: 3.31

3A1-7

CHANGEDBY

EFFECTIVE DATE

AFFECTEDVIN

DC 5-SPEED AUTOMATIC TRANSMISSION

REXTONSM - 2004.4

SPECIFICATIONS

2WD (4WD)

Fuchs ATF 3353

or Shell ATF 3353

approx. 8

Mechanical

Electrical

Brake switch (signal)

→TGS lever

CAN →TGS lever

Lever position

CAN

0.5 ~ 2.5 kΩ

20 kΩ

EGS 52

3.8 ± 0.2 Ω

0.2 mm

1.5 ~ 2 A

5.0 ± 0.2 Ω

0.6 mm

0 ~ 1 A

2.5 ± 0.2 Ω

0.2 mm

1.5 ~ 2.0 A

3rd to 5th gears

HALL type

6 V

ON (D, R position )

OFF (P, N position)

W5A580(400)

580 Nm

78 kg

270 mm

Yes

3.595

2.186

1.405

1.000

0.831

3.167/1.926

Item

Input torque

Weight (including ATF)

Diameter (Torque converter)

Lockup function

Gear ratios

Driving type

Fluid specification

Fluid capacity

Selector lever position

Parking lock system

Reverse lock system

Selected lever indication

Oil temperature sensor

TCU

Shift solenoid valve

(25°C)

M/P, S/P solenoid valve

(23°C)

Lockup solenoid valve

(25°C)

RPM sensor

Start lockout switch

1st

2nd

3rd

4th

5th

Reverse: S mode / W mode

P.R.N.D

D+/D-

P.R.N.D

4, 3, 2, 1

Resistance: R, D

Resistance: P, N

Resistance

Operating distance

Operating current

Resistance

Operating distance

Operating current

Resistance

Operating distance

Operating current

Operating range

Resistance

Operating voltage

Switch contact

W5A330(300)

330 Nm

78 kg

270 mm

Yes

3.951

2.423

1.486

1.000

0.833

3.147/1.93

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