SSANGYONG KORANDO 1997 Service Repair Manual

REAR AXLE 3D-17
SSANGYONG MY2002










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2. Measure the run-out of shaft.
KAA3D400
KAA3D410
KAA3D430
Inspection
1. Check the shaft spline for the wear and damage.
KAA3D420
Specified value Within 1.0 mm
3. Measure the run-out of shaft flange.
Specified value Within 0.13 mm
4. Install the axle shaft and measure the clearance
of shaft direction.
Specified value Within 0.38 mm

SSANGYONG MY2002
3D-18 REAR AXLE
UNIT REPAIR
AXLE ASSEMBLY
KAA3D440

REAR AXLE 3D-19
SSANGYONG MY2002
1 Drive Pinion Lock Nut
...........................240 - 310 Nm (177 - 229 lb-ft)
2 Washer
3 Companion Flange
4 Pinion Oil Seal
5 Bearing Slinger
6 Bearing
7 Shim
8 Shim
9 Bearing Cup
10 Breather Nipple
11 Rear Axle Housing
12 Oil Drain Plug............ 28 - 42 Nm (21 - 31 lb-ft)
13 Shim
14 Bearing
15 Drive Pinion
16 Bearing Cap17 Bolt......................... 87 - 124 Nm (64 - 94 lb-ft)
18 Bearing
19 Shim
20 Ring Gear
21 Shaft Lock Pin
22 Differential Case
23 Ring Gear Mounting Bolt
.................................. 75 - 90 Nm (55 - 66 lb-ft)
24 Thrust Washer
25 Differential Pinion
26 Thrust Washer
27 Side Gear
28 Differential Shaft
29 Housing Cover
30 Bolt............................ 38 - 46 Nm (28 - 34 lb-ft)
31 Oil Filler Plug............ 28 - 42 Nm (21 - 31 lb-ft)

SSANGYONG MY2002
3D-20 REAR AXLE


DIFFERENTIAL GEAR ASSEMBLY
Disassembly
1. Remove the drain plug and drain oil. Reinstall the
drain plug.
Installation Notice
KAA3D450
KAA3D470
KAA3D460
KAA3D480
Tightening Torque28 - 42 Nm
(21 - 31 lb-ft)
2. Remove the axle housing cover.
Notice: Clean the cover and housing contact
surface.
3. Remove the bearing cap bolts and remove the
bearing cap. Pull out the differential carrier
assembly.
Notice: Do alignment marks on the bearing cap
not to change the caps before removal. When pulling
out, be careful to damage the axle housing.
4. Disassemble the parts of differential carrier
assembly.

REAR AXLE 3D-21
SSANGYONG MY2002
5. Remove the drive pinion lock nut. Disassemble
the parts of drive pinion
KAA3D490

SSANGYONG MY2002
3D-22 REAR AXLE
Adjust backlash
(Drecrease backlash)
Select proper shin to
move the drive pinion
toward the ring gear
(toward toe)
Adjust backlash
(Increase backlash)
Select proper shim to
move the drive pinion
against the ring gear
(toward heel)
Adjust backlash
(Increase pinion shim)
Move the drive pinion
toward the ring gear
(toward center of ring
gear)
Adjust backlash
(Decrease pinion shim)
Move the ring gear
toward the drive pinion
(toward ring gear
center line) Excessive backlash
Noise can be occurred
Insufficient backlash
Tooth can be damaged
or broken under heavy
load
Excessive backlash
Drive pinion shaft is
apart from the ring gear
Noise can be occurred
Insufficient backlash
Gear contacts on the
low flank
Gear can be damaged
or worn
Noise can be occurred
Inspection of Ring Gear Tooth Contact
Pattern
1. Normal Contact
Apply gear-marking compound (prussian blue/red
lead) on the ring rear teeth. Rotate the ring gear
and check the to the contact pattern.
KAA3D500
Tooth contact pattern Possible cause Remedy
KAA3D510
KAA3D530
KAA3D550KAA3D520
KAA3D540
KAA3D560
KAA3D570KAA3D580
2. Abnormal contact
1. Heel contact
2. Toe contact
3. Face contact
4. Flank contact

REAR AXLE 3D-23
SSANGYONG MY2002
Assembly
1. Clean all parts and check the followings.
Check the ring gear, drive pinion for wear and
damage. If damaged, replace it as a set.
Check the bearing for sticks, wear, noise and
turning resistance.
Check the side gear, pinion, pinion shaft and
thrust washer for wear and damage.
Check the differential carrier for crack and wear
(bearing contact surface). Check the gear case
for crack.
KAA3D590
KAA3D600
KAA3D620
KAA3D610
2. Assemble the drive pinion assembly to the axle
housing and then tighten the pinion lock nut.
Installation Notice
Tightening torque 240 - 310 Nm
Tightening Torque75 - 90 Nm
(55 - 66 lb-ft) 3. Assemble the differential carrier assembly. Align
the ring gear to the mark of differential carrier,
tighten the fixing bolts.
Installation Notice
4. Measure the backlash of side gear and pinion gear.
Specified value 0 - 0.5 mm

SSANGYONG MY2002
3D-24 REAR AXLE
KAA3D630
KAA3D640
KAA3D650
5. Install the differential carrier assembly into the axle
housing. Set up the bearing cap and then tighten
the cap bolts.
Installation Notice
Notice: Be careful not to change the caps. Be sure
to keep the original position of the caps.
Tightening Torque48 - 69 Nm
(35 - 51 lb-ft)
6. Measure the backlash of drive pinion and ring
gear.
Specified value 0.13 - 0.20 mm
7. Install the axle housing cover. Tighten the fixing
bolts.
Installation Notice
Tightening Torque39 - 46 Nm
(29 - 34 lb-ft)

REAR AXLE 3D-25
SSANGYONG MY2002
KAA3D670
KAA3D660
DRIVE SHAFT
Tools Required
661 589 15 33 00 Rear Hub Bearing Installer
661589 18 33 00 Axle Bearing Puller Plate
661 589 18 33 01 Rear Axle Bearing Remover
661 589 18 33 02 Rear Axle Oil Seal Remover
Disassembly Procedure
1. Remove the rear drive shaft from the vehicle. Refer
to “Rear Drive Shaft” in this section.
2. Remove the toothed ring using the axle bearing
puller plate 661 589 18 33 00 and rear axle bearing
remover 661 589 18 33 01 by press.
3. Remove the rear drive shaft oil seal bearing using
the axle bearing puller plate 661 589 18 33 00 and
rear axle oil seal remover 661 589 18 33 02 by
press.
4. Remove the rear disc brake rotor shield.
3. Install the retainer drive shaft bearing using the
rear hub bearing installer 661 589 15 33 00 by press.
4. Install the rear drive shaft. Refer to “Rear Drive
Shaft” in this section.
KAA3D690
KAA3D680
Assembly Procedure
1. Install the rear disc brake rotor shield.
2. Install the rear drive shaft bearing oil seal using
the rear hub bearing installer 661 589 15 33 00 by
press.

SSANGYONG MY2002
3D-26 REAR AXLE
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
661 589 13 33 00
Ball Joint Remover
661 589 18 33 00
Axle Bearing Puller
Plate
KAA3D700
KAA3D710
KAA3D720
661 589 18 33 02
Rear Axle Oil Seal
Remover
661 589 15 33 00
Rear Hub Bearing
Installer
661 589 18 33 01
Rear Axle Bearing
Remover
KAA3D740
KAA3D750
KAA3D760
J-8059
Snap Ring Plier
DW340-090-01
Differential Assembly
Remover/InstallerDW340-090-03
Rear Differential
Assembly
Remover/Installer
KAA3D730KAA3D770