FR 6SPEED AT PRACTICE

SsangYong Motor

Company

Housing
Oil check plug

DSI NO

SYMC NO

Fluid Level Set

1. 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 L
4. Oil Fluid Specification :
FUCH TITAN ATF 3292(~2009: CATEX PED 1712)

Remove the Converter housing.

Tool
: 12mm, 12angle socket * 9EA
Torque : 45Nm
* Coat the Locktite to the Housing bolts.
* Install the Housing parallely to the TM.
Locktite
Remove the oil pan
Tool
: 10mm socket * 9EA
Torque : 5Nm
Check the oil color
Black : Band Burnt
Steal Dust : Planet Gear
Magnetic
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. Rear
Rear
Long
Front
Short
* Keep the Retaining clip banding position.

Front

Remove the Filter.

Check the Seal-ring ;

Not good condition => Slip.

Seal-ring

Remove the Input Speed Sensor(EMM).

Tool
: Torx 20
* EMM
(Embedded Memory Module)
Inplut Speed Sensor
: contains TM specific
(EMM)
characterisation information.

Detecting hole

DSI 6 speed - Housing

Housing
Disconnect the Wiring.

Variable Bleed
Sol Connectors

On-off Sol
Connectors

RR Speed
Sensor
connector

Oil Temp
Sensor

Remove the Valve body

Tool : Torx30 * 12EA ( L : 30mm-10, 50mm-2 )
Torque : 11Nm

Shift valve rod

Remove the Parking Rod
Tool : Torx40 - 2EA
Torque : 20Nm

Parking Rod

Remove the Wiring from the TM housing.

O-ring

Remove the Pump ASSY.

Tool : 8mm 12angle socket
* 8EA (L=75mm)
Torque : 30Nm

Locktite

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 conditionetc
* End play 0(), 0.25~0.30mm()
* Shim :

New

Old

t=0.127(0578-037077)
t=0.245(0578-037078)
t=0.197(0578-037079)
* Shim Retainer : 0578-040052 (t=0.55mm)

Shim

DSI 6 speed - Housing

Housing
1

Remove the Pump gasket.

1
Installation
* Install the Guide pin and than
intall the Gasket.
* Adjust the Housing and
Gasket shape.

Housing side

Gasket side

Remove the SPG(Single Planetary Gear).

Housing
1mm
3mm
Installation
Coat the Grease slightly and than install the Bearing to the Carrier gear.
(Only installation procedure)
* Bearing size :
Inner : =33.2mm
Outer : =51mm
t = 3.8mm

Inside

Outside

Coat the Grease slightly and than install the Bearing to the
C1 clutch pack.
(Only installation procedure)
* Bearing size :
Inner : =33.2mm
Outer : =51mm
Inside
Outside
t = 3.8mm
Remove the C1 clutch pack.

C1 Clutch Pack

Coat the Grease slightly and than install the Bearing to the
C2 clutch pack.
(Only installation procedure)
* Bearing size :
Inner : =33.2mm
Inside
Outside
Outer : =51mm
t = 3.8mm
Remove the C2 clutch pack.

* Check the center of Front speed sensor

detecting plate.
C2 Clutch Pack

DSI 6 speed - Housing

Housing
Remove the Bearing and cap to the C3 clutch pack.
* Bearing size :
Inner : =33.2mm
Outer : =51mm
t = 3.8mm

Inside

Outside

Remove the C3 clutch pack.

* Bearing size : = mm

C3 clutch pack
Inner 22.4 33.5
Outer 43.35 47.7

Hollow Shaft

Bearing face :
C3 direction

Bearing face :
C3 direction

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

Adjustment Shim
Remove the Front band retainner.

Snap Ring
Remove the Front Band Piston.

Front Band
Piston

DSI 6 speed - Housing

Housing
Install the Front Band Piston and compress the Band Piston and than
install the Snap ring.
(Only installation procedure)
15mm
* Protect the Housing face with clothe.

Remove the Snap ring to the Housing.

Snap Ring
Unscrew the Bolts and than remove the DPG(Double Planetery Gear).
Tool : Torx 50 - 2EA
Torque : 45Nm
* Installation procedure
()
(O)
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.
DPG
4. Install the Snap ring and than Screw the Bolt tightly.
(one way clutch)
Coat the Grease slightly and than install the Thrust washer and bearing.
(Only installation procedure)
* Bearing size :
Inner : =35mm
Outer : =55mm

Bearing

Bearing direction

Remove the Rear band.

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

Adjust shim
Rear Break Band

Remove the Rear Band Piston.

Tool : 8mm 12 angle socket * 6EA
Torque : 30Nm

Locktite

Rear Band Piston

Remove the Output Shaft Gear

Output Speed Sensor

* Bearing size :
Inner : =52.4mm
Outer : =72mm
Rear direction

DSI 6 speed - Housing

Housing
Remove the Adaptor Housing.
Tool : 8mm socket - 10EA
(L=100mm-4. 35mm-6)
Torque : 30Nm
Adaptor
Housing

Locktite

Steel Gasket

Remove the Rear speed sensor from the Housing.

Tool
: 8mm soket
Out put
Speed Sensor A B
C

Output Shaft
(Parking Gear)
Detection
* Air gap : 0.35 ~1.5mm(A-B=C)

Remove the Parking pawl and Lever pivot.

Parking Pawl
C3 Clutch/
Lubrication

B1 inner

B1 Damper

B1 Outer

Lever Pivot

C1 Clutch
Filter
to
Pump

C2 Clutch

To Oil
Cooler
IN

Rear

Front
B2 inner

From Oil cooler out

B2 outer

* Shifting Eelements
Mode

Ratio

Operating Components
C1

C2

M1

3.536

on

1st

3.536

on

2nd

2.143

on

3rd

1.478

on

4th

1.156

on

5th

0.866

on

6th

0.677

on

Reverse

3.084

C3

B1

Shift On/Off Sol.

B2

OWC

on
on
on

S1

S2

S3

S5

S6

S7

on

on

on

on

on

on

S4

on

on

on
on

on
on

on

on

on

Variable Sol.

on

on
on

S8

S9 S10
TC
0-1 TC

0-1 TC

0-1 TC

0-1 TC

0-1 TC

1
1

0-1 TC
0-1 TC

DSI 6 speed - Housing

DPG(Double Planetery Gear)

1. Remove the Needle Bearing.

2. Remove the Thrust Washer.

3. Installation process

()
=35mm
=55mm

* Risen face bearing direction.

(O)

* Check the Rotation

direction.

Disassembly
3. Separate the Center Support.

Assembly

4. Remove the One Way Clutch.

DPG( Double Planetery Gear)

* Risen face upper

direction

8. Remove the O-ring.

5. Remove the Snap Ring.

Installation

7. Remove the OWC Retainer.

6. Remove the OWC Outer Race.

* Risen face Upper direction.

DSI 6 speed - DPG

Clutch Packs
C1 Clutch Line

C1 Clutch Pack

C2 Clutch Line

C2 Clutch Pack

C3 Clutch Line

C3 clutch pack

* Subscripts :
P : Plate,
D : Disc,
AS : Adjustment Shim,
CP : Cover type Plate(Plate + Spline)

WS : Wave Spring,

No

10

11

12

13

14

C1

t = mm

1.8

1.8

1.8

1.8

AS

4.5

C2

ws

CP

t = mm

1.8

1.8

1.8

1.8

1.8

AS

1.8

C3

ws

t = mm

1.8

1.8

1.8

AS

4.5

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.).

DSI 6 speed - Clutch Pack

Pump
Remove 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 mm
= 2 mm
Instalation
ATF Coating
* Carefully install the Valve Caps because of the O-ring damage.
* Coat the ATF Oil at the at the each component.

Fluid Pump
PRV : Primary Regulator Valve
Cooler Bypass Valve
(Ball: In, Spring: out)
CRV : Convertor Regulator Valve

CLRV :
Cooler Lubrication control
Regulator Valve

CSV : Convertor Shift Valve

RRV : Release limit Regulator Valve

Size of Components
component
Valve

Cap Inside()

(mm)
Spring

Retainer Pin

Length

Dia()

Thick()
1

CRV

11.5(inner)

40

CSV

7.2(outer)

59

9.4

PRV

10(inner)

53

9.4

1.25

CLRV

4.6(outer)

29.4

0.7

RRV
CBV

11.5(inner)
-

46.2
9

10.8
6

1
0.5

Length

Dia()

22.6

Ball Dia

6.4

FIG.

10

DSI 6 Speed - Pump

Valve Body
Remove 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.

Spring
Components
QTY
Length Dia()
Plastic Ball(white)
13
5
1
Plastic Ball(brown)
3
Exhaust Valve
16.4
6
9
Remove the RFSV.
* Spring size : mm
Length
40
Dia()
9
Thick()
0.8

Thick()
0.4
1.8

Ball
()
8
6.5
-

Reverse LHM Valve /

Reverse Lockout Valve

Lower Valve Body

Exhaust Valve

Filter

B1 Quick
Release Valve

Exhaust Valve
Exhaust Valve

Exhaust Blow off Valve

(Spring : in, Ball: out)

Filter

Exhaust Valve
B2 Supply Ball /
REV Supply Ball
Exhaust Valve

RFSV

11

Filter

DSI 6 speed - Valve Body

Valve Body

Detent Spring

Upper Valve Body

B2S
CBS

B2R

Manual Valve
Variable Bleeding Solenoid
(Nomally Low)-S7

SSV
VBS(N/H)-S9

VBS(N/H)-S6

Suction Port
C2R
Variable Bleeding Solenoid
(Nomally High)-S5

VBS(N/H)-S10

S3(on/off)
C1R
B1R
CNV
VBS(N/L)-S8
S4(on/off)
S1(on/off)
B1S
CIS

S2(on/off)
C2S

Remove the VBSs(Variable Bleeding Solenoids).

Tool : Torx20 - 6EA
Torque : 8Nm
VBS
Nomally Hight

VBS
Nomally Low

Remove the Solenoid Retainer and On/Off Solenoids.

*
*
*
*

S1
S2
S3
S4

:
:
:
:

C1 apply and release.

C2 apply and release.
Torque converter apply and release.
B1 apply and release.

1. Electric test
VBS
Sift SV

Resistance
4.2
22.1

2. Vacuum test
Inspect 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.

12

DSI 6 speed - Valve Body

Valve Body

Upper Valve Body Valves

C1S :
C1 Shift Valve
MAN
Manual Valve

SSV
Solenoid Supply Valve

S1

Filter
C1R
C1 Regulator Valve

B1R
B1 Regulator Valve

C3S
C3 Shift Valve

B1S
B1 Shift Valve

B2S
B2 Shift Valve

CNV
Converter Supply Valve

B2R
C3/ B2 Regulator Valve
Size of Spring
C3S
Length
30
Dia()
6
Thick()
0.8

SSV
54
9.3
1.3

C2S
C2 Shift Valve
mm
Others
40
9
0.8

S4

S3

S2

Filter
C2R
C2 Regulator Valve

13

DSI 6 speed - Valve Body

DSI 6speed Transmission

NO

TOOL NO

W9931 0010B

DESCRIPTION
Transmission
Bench Cradle

APPLICATION

QTY

For transmission support when removal and

installation of overhaul.
1

For removal of oil pump.

Pump Puller
3

W9936 0011C

W9936 0031C

Clutch Spring
Compressor

For compressing the spring when removal of

clutch snap ring.
1

Dimesion of DSI 6speed TM Supportor

400mm

60mm
280mm

20mm

REMARK

 Procedure for Rear Speed Sensor Replacement

1. Trasfer Case

2. Oil / Oil Pan

3. RR Adaptor Housign

5. RR Sensor

4. RR Sensor Connector

Lock up Control

Model Name

Lock-up
Gear

Gear Ratio
Oil
1st

2nd

3rd

4th

5th

6th

MB 5speed
(W5A400)

3~

3.595 2.186 1.405 1.000 0.831

3.167 SHELL ATF 3353

ION 4speed
(M74)

3~

2.742 1.508 1.000 0.709

2.429 CASTROL TQ95

DSI 6speed
(M78)

All

3.536 2.143 1.478 1.156 0.866 0.677 3.084 FUCHS TITAN ATF 3292

FUCHS ATF 3353

CALTEX PED 1712 ATF