SSANGYONG MUSSO 1998 Workshop Repair Manual

FRONT DRIVE AXLE 3A-13
14. Remove the drive shaft mounting bolts and remove the
drive shaft.
Installation Notice
Tightening Torque 45 - 60 Nm
15. Installation should follow the removal precedure in the
reverse order. Observe the tighening torque and sequence.

3A-14 FRONT DRIVE AXLE
1 Axle Mounting Bracket
2 Breather Hose
3 Bolt (Rear)
4 Nut .....................................................95-142 Nm
5 Cross Member
6 Bolt (Front)
7 Bushing
8 Spacer
FRONT AXLE
9 Bushing
10 Nut .....................................................95-142 Nm
11 Front Axle Assembly
12 Nut .......................................................70-80 Nm
1 3 Bolt
14 Inner Axle Shaft (LH)
15 Inner Axle Shaft (RH) Preceding Work : Removal of the front axle drive shaft
Removla of the steering gear box

FRONT DRIVE AXLE 3A-15
Removal & Installation Procedure
1. Remove the propeller shaft from the front axle input shaft.
Notice
Before removal, place the alignment marks.
Installation Notice
2. Remove the breather hose.
3. Remove the axle housing mounting nuts (1) from the cross
member.
Installation Notice
Tightening Torque 70 - 80 Nm
4. Remove the cross member mounting nuts (2) from the frame
and remove the cross member.
Installation Notice
Tightening Torque 95 - 142 Nm
5. Support the axle housing on a suitable jack, Remove the
axle housing mounting bracket nuts.
Installation Notice
Tightening Torque 62 - 93 Nm
Tightening Torque 95 - 142 Nm
6. Lowering the jack carefully, remove the axle housing
assembly.
7. Installation should follow the removal precedure in the
reverse order.

3A-16 FRONT DRIVE AXLE
UNIT REPAIR
AXLE HOUSING
Preceding Work : Removal of the axle housing

FRONT DRIVE AXLE 3A-17
1 Front Axle Housing Mounting Bracket
2 Inner Shaft (Left)
3 Bolt......................................................55-65 Nm
4 Oil Seal.................................................. Replace
Apply Grease to the Sealing Rib
5 Snap Ring
6 Bearing
7 Snap Ring
8 Oil Drain Plug.......................................28-41 Nm
9 Front Axle Housing
10 Breather Nipple
11 Inner Shaft (Right)
12 Pinion Lock Nut................................240-310 Nm
13 Washer
14 Companion Flange
15 Oil Seal.................................................. Replace
Apply Grease to the Sealing Rib
16 Bearing
1 7 Shim
18 Bearing Baffle
1 9 Shim20 Bearing
21 Oil Slinger
22 Drive Pinion
23 Oil Filler Plug.......................................28-41 Nm
2 4 Bolt......................................................39-46 Nm
25 Axle Housing Cover..............Apply Liquid Gasket
to the Contact Surface
26 Ring Gear
27 Bearing
2 8 Shim
29 Shaft Lock Pin
30 Differential Case
3 1 Bolt......................................................75-90 Nm
3 2 Bolt......................................................48-69 Nm
33 Washer
34 Bearing Cap
35 Thrust Washer
36 Side Gear
37 Differential Shaft
38 Differential Pinion
39 Thrust Washer

3A-18 FRONT DRIVE AXLE
Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall the drain
plug.
Installation Notice
Tightening Torque 28 - 41 Nm
2. Unscrew the axle housing and housing mounting bracket
bolts and remove the bracket and inner shaft assembly.
3. Remove the bearing fixing snap ring of the inner shaft and
pull out the bearing. Separate the inner shaft and the
mounting bracket.
4. Remove the axle housing cover.
Notice
Clean the cover and housing contact surfaces.

FRONT DRIVE AXLE 3A-19
5. Unscrew the bearing cap bolts and remove the bearing caps.
Pull out the differential carrier assembly.
Notice
Place alignment marks on the bearing cap not to change
the caps before removal. When pulling out the differential
carrier assembly, be careful not to damage the axle housing.
6. Disassemble the parts of the differential carrier assembly.
7. Remove the drive pinion lock nut. Disassemble the parts of
the drive pinion.
Assembly Procedure
1. Clean the all parts and check the followings :
lCheck the ring gear and drive pinion for wear and
damage. If damaged, replace it as a set.
lCheck the bearing for sticks, wear, noise and turning
resistance.
lCheck the side gear, pinion, pinion shaft and thrust
washer for wear and damage.
lCheck the differential carrier for crack and wear (bearing
contact surface). Check the gear case for crack.

3A-20 FRONT DRIVE AXLE
2. Assemble the parts of the drive pinion.
3. Assemble the parts of the differential carrier.
4. Measure backlash of the side gear and pinion.
5. Install the differential carrier assembly into the axle housing.
Notice
Be careful not to change the caps. Be sure to keep the
original position of the caps.
Tightening Torque of the
Lock Nut240 - 310 Nm
Tightening Torque of the
Ring Gear Bolts75 - 90 Nm
Standard 0 - 0.05 mm
Tightening Torque of the
Bearing Cap Bolts48 - 69 Nm

FRONT DRIVE AXLE 3A-21
6. Measure backlash of the drive pinion and ring gear.
7. Install the axle housing cover.
8. Assemble the parts of the front axle shaft and housing
mounting bracket.
Notice
Apply grease to the oil seal rib.
9. Align the axle shaft and differential carrier spline and insert
the axle shaft. Assemble the axle housing mounting bracket
to the axle housing.
Specified Value 0.13 - 0.20 mm
Tightening Torque 39 - 46 Nm
Tightening Torque 55 - 65 Nm

3A-22 FRONT DRIVE AXLE
Inspection of Ring Gear Tooth Contact Pattern
Normal Contact
Apply gear-marking compound (prussian blue / red lead) on
the ring gear teeth. Rotate the ring gear and check the tooth
contact pattern.
Abnormal Contact
Tooth Contact patternPossible CauseRemedy
1. Heel Contact
2. Toe Contact
3. Face Contact
4. Flank ContactInsufficient backlash (little)
lTooth can be damaged
or broken under heavy
load
Excessive backlash (much)
lDrive pinion shaft is apart
from the ring gear
lNoise can be occurred
Insufficient backlash (much)
lGear contacts on the low
flank
lGear can be damaged or
worn
lNoise can be occurredAdjust backlash(Decrease backlash)
lSelect proper shim(s) to move the
drive pinion toward the ring gear
(toward toe)
Adjust backlash(Increase backlash)
lSelect proper shim(s) to move the
drive pinion against the ring gear
(toward heel)
Adjust backlash(Increase pinion shim)
lMove the drive pinion toward the ring
gear (toward center of ring gear)
Adjust backlash(Decrease pinion shim)
lMove the ring gear toward the drive
pinion (toward ring gear center line) Excessive backlash (little)
lNoise can be occurred