FF 6-SPEED AT TM PRACTICE

SSANGYONG MOTOR COMPANY

 10 7 4
STRUCTURE & COMPONENTS 6 5

1. Lockup Clutch
2. Torque Converter 3
3. One Way Clutch(Torque Converter)
4. Front SPG(Single Planetary Gear)
- FSG(Front Sun Gear) : 36 Teeth
- PP(Planetary Pinion) : 16 Teeth
1
- RG(Ring Gear) Internal : 69 Teeth
5. C3 Clutch 2
6. B1 Brake Band
7. C2 Clutch 9 8
8. OWC(One Way Clutch)
9. B2 Brake Disc
10. C1 Clutch 11
11. DPG(Ravigneaux Type-Ring Gear) Set
- FSG(Forward Sun Gear) : 34 Teeth
- RSG(Reverse Sun Gear) : 26 Teeth
- LPP(Lont Planetary Pinion) : 18 Teeth
12
- SPP(Short Planetary Pinion) : 21 Teeth
13
- RG(Ring Gear) : 71 Teeth
- Driveven Gear : 40 Teeth
12. Intermeadiate(counter) Shaft
- Driven Contact Gear : 39 Teeth
- Diff Contact Gear : 21 Teeth
13. Differential Gear Set
- Differential Gear : 64 Teeth

9
10 7 6 B1 5

B2 8 1
OWC C3
C1 2
C2
(71)
(69)
(18)
(16)
(21) (26)
(36)
(34)
3

11

Intermeadiate Ratio
39/40 = 0.976

(40)
Axle Ratio
64/21 = 3.047

12
(39) (21)
13

(64)

() : Teeth Number

-2- FF 6AT Practice

 S5, S6, S9 : Nomal High S7, S8, S10 : Nomal Low
Shifting Elements TC LU : Torque Converter Lock Up LHM : Limp Home Mode
Operating Component On/ Off Sol VBS Sol (A)
Gear Ratio
C1 C2 C3 B1 B2 OWC TC LU 1 2 3 4 5 6 7 8 9 10
P N/A ON ON ON 1
Rev 3.178 ON ON ON ON ON 1 1 1 0-1
R LHM 3.178 ON ON
N N/A ON ON ON 1
M1 4.156 ON ON ON 1 0 0-1
1st 4.156 ON ON ON 1 0-1
1st Locked 4.156 ON ON ON ON ON 1 0-1
2nd 2.375 ON ON ON ON 1 0 1 0-1
2nd Locked 2.375 ON ON ON ON ON ON 1 1 1.1
3rd 1.522 ON ON ON ON 1 0 1 0-1
3rd Locked 1.522 ON ON ON ON ON 1 0 1 0-1 1.1
4th 1.144 ON ON 0 0 0-1
4th Locked 1.144 ON ON ON ON 0 0 0-1 1.1
4th LHM 1.144 ON ON
5th 0.859 ON ON ON ON 0 1 1 0-1
5th Locked 0.859 ON ON ON ON ON 0 1 1 0-1 1.1
6th 0.676 ON ON ON ON 0 1 1 0-1
6th Locked 0.676 ON ON ON ON ON 0 1 1 0-1 1.1

Remove the Torque Converter.

* Torque Converter to Drive Plate Bolts:

Tool : 13mm Socket * 6ea h
Torque : 40~42 Nm
* Housing ↔ T/C Distance :
h ≒ 12 mm
Torque Converter

Fluid Level Set

Filler Plug 1. Interval : 60,000km
25~30Nm 2. TCU => Oil Temp => Range 50~60 ℃(82~140℉)
3. Turn the E/G OFF => Level Check
- Converter empty : 7.5 L
- Converter full : ≒ 2.5 L
Drain Plug 4. Oil Fluid Specification : 10,000km Interval(SYMC)
Fuchs FES 209-3292 ATF(P/No. 0578-244023)

Remove the Oil Pan.

Tool : E8 Socket * 15ea
Torque : 7~9 Nm

Check the oil color

＊Black : Disc & Band Burnt
＊Steal Dust : Planet Gear Oil Pan
Notice : Do not install over torque as this will fluid leakage(Seal Damaged).

Remove the Detent Spring.

Tool : Torx 40
Torque : 20 Nm

Detent Spring

-3- FF 6AT Practice

 Remove the Valve Body Bolts and then remove the Shift Valve Rod and
Manual Valve.
Tool : Torx 30 * 9ea( L : 70, 30mm)
Torque : 11 Nm

Z Link /
Manual Valve

Remove Connector(①) and Speed Sensor(②) from the Housing and then
remove the Valve Body.
① Tool : Torx 30 (L : 20mm)
Torque : 11 Nm

Out-put In-put
Driven C1 Housing
② Gear
EMM Speed Sensor
Valve Body
Remove the Front Housing Bolts.
Tool : 8 mm 12angle Socket * 20ea
Torque : 30 Nm

Locktite(?)

Remove the Front Housing from Rear Housing.

* Installation
- Carefully install(Seal Damage)
- Sealant : ???
- Use the Guide Pin. Front Housing & Seal

Remove the O - Ring.

* If O-ring doesn't removal befor Pump Housing removal,

it is damaged to the Pump Housing Shaft.

O-Ring

Check the End-play. (Only for installation procedure)

End Play ≒ 0.25 ~ 0.30 mm

* Refered to Adjustment Procedure.

Remove the Oil Filter and then remove the Pump Housing form the TM Case.
Tool : 8 mm 12angle Socket * 9ea
Torque : 30 Nm

Oil Filter Mounting

Tool : Torx 30 - 4ea Pump Assy
Torque : 11 Nm

-4- FF 6AT Practice

 Remove the Magnetic and Oil Filter.

Oil Filter Magnetic & Filter

Magnetic

Remove the C2, C3, Front SPG Set.

h ≒ 2 mm

C2, C3, SPG Set

Remove the B1 Band,

B1 Band

Remove the B1 Supportor and Piston Assy.

Tool : Hexa 8mm, Torx 30 - 4ea
Torque : 90, 11 Nm
Locktite(?)

B1 Supportor & Piston Assy

Remove the Differential Assy and then remove the Oil Seal.
* Installation
: Install the Diff Assy and then install the Oil Seal.

Diff Assy
Oil Seal

Remove the Parking Pawl Pivot,

Tool : Torx 30
Torque : 7~9 Nm

* 7KPH ↑ : Ratcheting. Parking Pawl Pivot

Remove the Counter Gear Assy.

Count Gear Assy

-5- FF 6AT Practice

Remove the Center Support with the Sliding Puller.
Tool : 8 mm 12angle Socket * 7ea
Torque : 30 Nm

B1 Band Supportor Center Support

Remove the Snap Ring and then Remove Rear Planetary Gear Assy.

Snap Ring RR Assy

Install the One Way Clutch.(Installation Procedure)

O ×
- Align the Two OWC Gear Slots
and Housing Tabs.
Installation OWC

Install the B2 Clutch Pack. (Installation Procedure)

* installation
1. Align the Two Disc Plate Slots and Housing
Tabs.
2. P+D+P+D+P+D+P+D+P+D+WS Housing Plate
3. P : Plate, D : Disc, WS : Wave Spring

Install the Rear Planetary Gear Assy.(Installation Procedure)

Rear Planetary Gear

Install the Oil Seal at the C1 Shaft.(Installation Procedure)

* Remove the Oil Seal befor the Hollow Shaft

removal(Seal Damaged).

Oil Seal

Install the Rear Planetary Gear Assy.(Installation Procedure)

* Uper and Lower Plastic Insulator. ≒ 1 mm

* Bearing size(Between FSG and RSG) :
Inner : Φ ≒ 40mm
Outer : Φ ≒ 54.5mm

-6- FF 6AT Practice

Install the Reverse Sun Hollow Shaft Gear.(Installation Procedure)

Reverse Sun Gear

Install the Bearing in the C1 Clutch Housing.(Installation Procedure)

* Bearing size :
Inner : Φ ≒ 33.2mm
Outer : Φ ≒ 51mm
Inside Outside

Remove the Snap Ring.

Snap Ring

Remove the B2 Return Spring.

- Install the Spring Letter Mark "W"

to Counter Gear Direction.
Installation Return Spring

Remove the B2 Piston.

Installation B2 Piston

Remove the Bearings.

* Bearing size :
Inner : Φ ≒ 58mm
Outer : Φ ≒ 78mm
Outside Inside

Remove OD(Over Drive) Supportor Assy.

Tool : Torx 20
Torque : 7~9 Nm

OD Supportor

-7- FF 6AT Practice

 Seal

Count Shaft
Diff Seal

Diff Shaft Race Shim

Bearing Race &

Rear Housing Case Front Housing Case Shim(Front)

Bearing Size : mm

Rear Bearing Front Bearing

Class
Count Diff Cout Diff

a ≒ 35 ≒ 57 ≒ 48 ≒ 57

b ≒ 57.7 ≒ 83.5 ≒ 83.5 ≒ 83.5

c ≒ 72 ≒ 97 ≒ 97 ≒ 97
a
b
c
33207J 08/08 08/08 08/08
Marking
D0828-1617-05 382A ZXY 382A ZXY 382A ZXY

Suction Line CA( Converter Apply)

To Cooler From Cooler C2 Lube(C2, C3, SPG… Upper Side)

CR
(Converter Release)

B1

Out-put
Speed Sensor
(Driven Gear)
C1 C3 B2 Valve Body
In-put Supportor
Speed Sensor
(C1 Housing)

Lube(C1, B1, DPG..Lower side)

-8- FF 6AT Practice

 Input Shaft Hole
1 : Converter Release Port

2 : C2 Pressure Port

3 : Lubrication Port

1
2

Over Drive Shaft Hole

1. Lubrication Port
: C2 and C3 Dam

2. C2 Dam Supply
: Connected to item 1
1
3. C3 Dam Supply
: Connected to item 1

4. C3 Piston Supply 2
6
5. Lubrication
: Rear Gearset 3
4 7
6. C2 Piston Supply

7. C3 Piston Supply
: Same as item 4 5 8
8. Lubrication
: Rear Gearset(Same as item 5) 9

9. Lubrication
: Gearset Bearing

-9- FF 6AT Practice

1. Remove the Snap Ring. 2. Remove the Cover Plate. 3. Remove the FRT SPG.

4. Remove the Needle Bearing

Φ ≒ 35mm
Φ ≒ 55mm

5. Remove the Input Shaft.

Washer and
Adjustment Shim

6. Remove the Needle Bearing.

C2, C3, SPG Set Φ ≒ 33mm, Φ ≒ 51mm

Inside

Installation Outside

9. Remove the Needle Bearing. 8. Remove the C2 Clutch Pack. 7. Remove the C3 Clutch Set.

Φ ≒ 44.5mm
Φ ≒ 63mm

- 10 - FF 6AT Clutchs
 ① ⑫ ① ⑬

C1 C2

① ⑪

C3

① ⑪ ⑬
⑫

B2 OWC Snap Ring

* Subscripts :
P : Plate, D : Disc, AS : Adjustment Shim(1.8, 2.2, 2.4, 2.8mm) WS : Wave Spring,
CP : Cover type Plate, SR : Snap Ring, SC : Specified Clearance
No
1 2 3 4 5 6 7 8 9 10 11 12 13 SC
Class

C1 P D P D P D P D P D P SR
1.5
t = mm 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 2.0 1.8 3.5 1.5

C2 WS P D P D P D P D P D P SR
0.8
t = mm 1.0 2.5 1.8 1.8 1.8 1,8 1.8 1.8 1.8 1.8 1.8 3.5 1.5

C3 WS P D P D P D P D CP SR
?
t = mm 1.0 2.5 1.8 1.8 1.8 2.2 1.8 2.2 1.8 3.0 1.5

B2 P D P D P D P D P D WS OWC SR
?
t = mm 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 2.2 1.8 1.2 1.5

* Specified Clearance : ≒ {(D*0.2)+0.2} mm ± 20％ (Normal condition, Adjust Shim Plate is selective.).
* Disc Size : C1 ≠ C2 ≠ C3 ≠ B2
* Without C1 Wave Spring : 4th ↑ Operating, Torque ↓

- 11 - FF 6AT Clutchs
OUTER OVER VIEW (EMM)
MAN
Manual Valve
SSV
Solenoid
Supply
B1B(×)
B1 Boostor
B2S
B2 Shift
B1R
B1 Regulator
C1R
S3 CSV C1 Regulator
Counter EMM
Supply C2B
C2 Booster
S4 B1S
B1 Shift C2R
C2 Regulator
S1 C1S
C1 Shift

S2 C2S
C2 Shift

INNER OVER VIEW (VBS)

RFSV
Reverse /
LHM Valve

PRV
Primary RRV
Regulator Reverse
Regulator
CRV
Convertor
Regulator CLRV
Cooler
Lubrication
Regulator
C3S CSIHFTV
C3 Shift Converter
Shift Valve S7 VBS(N/L)
B2C3R
B2, C3 S10 VBS(N/L)
Regulator

S5 VBS(N/H)
S9 VBS(N/H)

S6 VBS(N/H) S8 VBS(N/L)

FF 6AT Vave Body 12

 ② ①
INNER SECTION (VBS)
① CLRV : Cooler Lubrication Regulator Valve

② RRV : Reverse Regulator Valve

③ RFSV : Reverse LHM Shift Valve

④ PRV : Primary Regulator Valve

④ ⑤ ⑥ ⑦

⑤ CRV : Convertor Regulator ③

⑥ CSHIFTV : Converter Shift Valve

⑦ VBS : Variable Bleeding Solenoid

Nomally Nomally
Hight Low
② ①
* Valve Body Bolt Length
* Solenoid Resistance
VBS 4.2 Ω 70mm - 19ea
Sift SV 22.1 Ω 30mm - 6ea
33mm - EMM

* Size of Components mm
Component Spring
Cap Inside(Φ) Spool Total Length
Valve Length Dia(Φ) Thick(Φ)
CLRV 15(O-Ring Type) 29 6 0.7 44.6
RRV 14 42 10.8 1 55
RFSV 6.3 40 9 0.7 38.8
PRV Plate 53 9.4 1.2 71
CRV Plate 40 9 0.7 47.6
C3HFTV 15(O-Ring Type) 48 9.4 1 78.5

Fig.

FF 6AT Vave Body 13

OUTER SECTION (EMM) ④ ⑤

① C2R : C2 Regulator

② C2B : C2 Booster

③ C1R : C1 Regulator

① ② ③ ⑧

⑦
⑥

④ B1R : B1 Regulator

⑤ B1B(×) : B1 Boostor(No Application) ⑦

⑥

⑥ EX : Exhaust Valve ⑦ Filter

⑥ ⑦ ④ ⑤
⑧ EBOV :Exhaust Blow Off Valve ⑨ B2RSB : B2, REV Supply Ball
(White Color) (Brown Color)

Size of Components mm
Component Spring
Cap Inside(Φ) Spool Total Length
Valve Length Dia(Φ) Thick(Φ)
C2R 15(O-Ring Type) 40 9 0.7 71.4
C2B 6.3 52.6 9.4 1.2 54.4
C1R 15 (O-Ring Type) 40 9 0.7 60
B1R 15 (O-Ring Type) 40 9 0.7 60
B1B _ _ _ _ _
EBOV _ 12 5.7 0.3 8(Φ)-Ball
B2RSB _ _ _ _ 6.4(Φ)-Ball

Fig.

FF 6AT Vave Body 14

 ⑦ ⑥ ⑤ ④ ③ ② ①
MID SECTION (ON/OFF SOL)
① MAN : Manual Valve

② SSV : Solenoid Supply Valve

③ B2S : B2 Shift

④ S3 CSV : Counter Supply Valve

⑪ ⑧ ⑨ ⑪
⑤ S4 B1S : B1 Shift
⑥ S1 C1S : C1 Shift
⑦ S2 C2S : C2 Shift

⑩
⑬

⑧ B2C3R : B2, C3 Regulator

⑨ C3S : C3 Shift

⑩ EX : Exhaust Valve ⑪ Filter ⑫ CBV : Cooler Bypass Valve ⑬ B1 Quick Release Valve
(Brown Color) (Brown Color)

Size of Components mm
Component Spring
Cap Inside(Φ) Spool Total Length
Valve Length Dia(Φ) Thick(Φ)
MAN _ _ _ _ 132.7
SSV 6.3 52.6 9.4 1.2 54.4
B2S 15 (O-Ring Type) 40 9 0.7 52
S3 CSV
S4 B1S
On Off Sol 40 9 0.7 47.6
S1 C1S
S2 C2S
B2C3R 15 (O-Ring Type) 40 9 0.7 60
C3S 15 (O-Ring Type) 29 6 0.7 59.7
CBV _ 11 6 0.5 6.4(Φ)-Ball

FF 6AT Vave Body 15

 Process of End Play Measurement
1. Measure End play with Dial Gage.
2. Adjust the Shim(Input Shaft)

End Play ≒ 0.25 ~ 0.30 mm

Input Shaft

0.127(0511-037097)
Bearing Shim 0.254(0511-037098)
0.198(0511-037099)
C2, C3, SPG Set Washer

Process of Spacer Selection

1. Measure Clearance "Hs" and "Hr".
Hs : TM Housing surface ↔ Shaft Front Case Bearing Seat
Hr : TM Housing surface ↔ Shaft Rear Bearing Race Hr

2. Select the specified Spacer.

3. Install the selected Spacer and Bearing Race

Spacer Thickness = (Hs - Hr) + (Spec)

* Specified Range of Clearance

Count Shaft : 0.27 ~ 0.32T
Diff Shaft : 0.35 ~ 0.40T
T : Tight, mm

Hs
ex) If, Hs = Hr
Diff Spacer Thickness = 0.40 ~ 0.45 mm (Whitout Press)

* Specs are considered Bearing size, Load, Rotation friction…etc.

Process of Specified Clearance

1. Measure Clearance between the Snap Ring and Plate.
2. Select the specified Spacer(Plate).

* Specified Range of Clearance(DSI Spec)

C1 : 1.08~1.38
C2 : 0.7 ~1.0
C3 : 0.6~0.9
B1 : 3.0~3.5
B2 : 1.0~1.6
E/F : 0.3~0.5

FF 6AT Adjustment