SSANGYONG MUSSO 1998 Workshop Repair Manual

REAR DRIVE AXLE 3D-3
Checks
Worn or Damaged Tooth of Pinion or Side Gear
Worn Pinion Shaft
Excessive Backlash of Pinion Gear and Side Gear
Excessive End-play of Rear Axle Shaft
Incorrect Contact of Side Gear and Differential Case
Axle Housing Crack
Bent or Poor Installation of Drive Pinion Oil Seal
Damaged or Torn Drive Pinion Oil Seal
Loosened Bearing Collar
Worn or Damaged Universal Joint
Worn or Damaged Axle Shaft BearingChecks
Excessive Oil
Faulty Seal of Carrier Contact Surface
Axle Housing Crack
Worn or Damaged Oil SealChecks
Lack of Oil
Low Viscosity of Oil
Insufficient Oil
Excessive Backlash of Ring Gear
Worn or Damaged Tooth of Ring and Pinion Gear
Worn or Damaged Drive Pinion Bearing
Bent Axle Housing
Bent Differential Case
Worn Pinion Shaft
Incorrect Drive Pinion Preload
Incorrect Contact of Ring Gear and Pinion
DIAGNOSIS
NOISE (DURING STRAIGHT DRIVING)
Action
Replenish
Replace
Replace
Adjust
Replace
Replace
Replace
Replace
Replace
Adjust
Retightening
OIL LEAKAGE
Action
Adjust
Repair
Replace
Replace
NOISE (DURING TURNING)
Action
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
Replace
Replace
Replace
Replace
HEATING
Checks
Lack of Oil
Insufficient Backlash of Gears
Excessive Preload of BearingAction
Replenish
Adjust
Adjust

3D-4 REAR DRIVE AXLE
VIBRATION
Checks
Faulty Connection of Sliding Joint
Bent Propeller Shaft
Symmetry of Universal Joint Snap Ring
Loosened Yoke BoltsAction
Adjust
Replace
Adjust
Tighten
NOISE
Checks
Worn or Damaged Universal Joint Bearing
Fallen Off Universal Joint Snap Ring
Loosened Yoke Connection
Worn Sliding Joint Spline
Insufficient GreaseAction
Replace
Adjust or Replace
Tighten
Replace
Apply as Necessary

REAR DRIVE AXLE 3D-5
1 Spring Seat
2 Coil Spring
3 Lateral Rod
4 Shock Absorber5 Upper Arm
6 Lower Arm
7 Connecting Link
8 Stabilizer Bar
COMPONENT LOCATOR

3D-6 REAR DRIVE AXLE
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
AXLE SHAFT
1 Brake Disc
2 Dust Plug
3 Rear Axle Shaft
4 Nut .......................................................50-65 Nm
5 Washer
6 Parking Brake Cable7 Parking Brake Lining and Back Plate Assembly
8 Caliper Assembly
9 Gasket
1 0 Bolt....................................................85-100 Nm
11 Rear Axle Housing

REAR DRIVE AXLE 3D-7
Removal & Installation Procedure
1. Remove the tire.
Installation Notice
2. Release the parking brake.Steel Wheel
Aluminum Wheel
Tightening Torque
3. Remove the bolts and the brake caliper.
Installation Notice
Be careful not to damage the brake hose.
Tightening Torque 85 - 100 Nm
4. Remove the brake disc.
Notice
To remove the disc, install the bolts (M8 x 1.25) into the
service hole and uniformly tighten the bolts.
5. Disconnect the parking brake cable.
80 - 120 Nm
110 - 130 Nm

3D-8 REAR DRIVE AXLE
Tightening Torque 50 - 65 Nm
6. Remove the plug from the axle shaft flange and remove the
inner shaft mounting nuts.
Installation Notice
7. Remove the axle shaft, parking brake lining and back plate
assembly.
8. Installation should follow the removal precedure in the
reverse order.

REAR DRIVE AXLE 3D-9
AXLE
Removal & Installation Procedure
1. Lift up the vehicle and support the frame safely.
2. Remove the axle shaft.
Tightening Torque 150 - 180 Nm 3. Remove the propeller shaft from the rear axle input shaft.
Installation Notice
Notice
Place alignment marks before removal.
Tightening Torque 81 - 89 Nm
4. Disconnect the parking brake cable and brake hose.
5. Remove the lower arm mounting nuts and remove the lower
arm from the axle housing.
Installation Notice

3D-10 REAR DRIVE AXLE
6. Separate the lower shock absorber from the axle housing.
Installation Notice
7. Remove the upper arm mounting nuts and remove the
upper arm form the axle housing.
Installation Notice
Tightening Torque 50 - 65 Nm
8. Remove the stabilizer bar.
Installation Notice
Tightening Torque 150 - 180 Nm
9. Remove the lateral rod mounting nuts and remove the
lateral rod from the axle housing.
Installation Notice
Tightening Torque 30 - 45 Nm
10. Lowering the axle housing slowly, remove the coil springs
and spring seats.
11. Installation should follow the removal precedure in the
reverse order.
Tightening Torque 150 - 180 Nm

REAR DRIVE AXLE 3D-11
UNIT REPAIR
AXLE HOUSING
Preceding Work : Removal of the axle shaft
Removal of the axle housing
1 Drive Pinion Lock Nut......................240-310 Nm
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
1 3 Shim
14 Bearing
15 Drive Pinion
16 Bearing Cap1 7 Bolt....................................................87-124 Nm
18 Bearing
1 9 Shim
20 Ring Gear
21 Shaft Lock Pin
22 Differential Case
23 Ring Gear Mounting Bolt......................75-90 Nm
24 Thrust Washer
25 Differential Pinion
26 Thrust Washer
27 Side Gear
28 Differential Shaft
29 Housing Cover
3 0 Bolt......................................................38-46 Nm
31 Oil Filler Plug.......................................28-42 Nm

3D-12 REAR DRIVE AXLE
Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall the drain
plug.
2. Remove the axle housing cover.
Notice
Clean the cover and housing contact surface.
3. Remove 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.
4. Disassemble the parts of the differential carrier assembly.
Tightening Torque 28 - 42Nm