change wheel SSANGYONG MUSSO 2003 User Guide

REAR DISC BRAKES 4E-3
Tightening Torque 15 - 18 Nm
Tightening Torque 85 - 105 Nm
Removal & Installation Procedure
1. Remove the eye-hose bolt and disconnect the hose.
Installation Notice
2. Unscrew the mounting bolts and remove the brake caliper assembly. Installation Notice
3. Pull out the brake pads. Replace pads if necessary. Notice Always change the all pads on one wheel at a time.
4. Installation should follow the removal precedure in the reverse order.
5. Bleed the air from the system.

4E-4 REAR DISC BRAKES
Standard10.4 mm Wear Limit
9.3 mm
UNIT REPAIR REAR DISC BRAKE Inspection Procedure
1. Clean all components and visually check the followings. Check the cylinder and piston for wear, rust or damage.
Check the caliper body and guide pin for wear, damage
or crank.
Check the pads for uneven wear or oiliness.
Check the boots for damage or tear.
Standard
40.5 mm
38.2 mm Wear Limit
41.5 mm
39.2 mm
2. Measure caliper housing inner diameter.
3. Measure pad thickness.
Standard
9.5 mm Wear Limit
2.0 mm
Notice Always change the all pads on one wheel at a time.
4. Measure rotor disc thickness.
5. Check the rotor disc for score or runout.
Item
With PBR
With MANDO

5D2-4 TRANSFER CASE (TOD)FUNCTION DESCRIPTION
TOD System Select Mode (4H and 4L) 4H is the mode when drive normally of which gear ratio is 1:1 and 4L mode distributes power to front and rear wheels 50:50 of which gear ratio is 2.48:1.
TOD System Function (select 4H mode) TOD system controls clutch mechanism to comply with rotation in front and rear propeller shaft and if its difference exceeds the permissible range, corresponding power is distributed into front wheel through EMC (Electro-MagneticClutch). Hall effect sensor signals speed on front and rear propeller shafts going through with TOD control unit.
Transfercase clutch coil is activated by variable current on exceeding difference of speed in front and rear propeller shafts.
Function of 4L Mode When select 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts. Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1:1 to 2.48:1 by planetarygear set.
Shift Motor It locates backside transfer case, which drives rotary helical cam. When mode select switch changes to 4L, shift fork is on position for 2.48:1 by rotation of helical cam.
Transfer Case
TOD transfer case distributes power into front and rear axle by operation of 4H/4L switch and shift motor. Shifting 4H to 4L, is performed towards reducing HI-LO collar by means for connection HI-LO shift fork with
output shaft in order to join with planetary gear. Torque transmits input shaft then sun gear rotating front planetary
gear. Front planetary gear join with output shaft and drives LO position.

TRANSFER CASE (TOD) 5D2-5
Definitions
Rear Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal inresponse to a rotating 30 tooth wheel coupled to the rear propshaft inside the
Transfer Case. Each rotation of the rear propshaft will result in 30 speed sensor pulse.
Front Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in response to a rotating 30 tooth wheel coupled to the front propshaft inside the
Transfer Case. Each rotation of the front propshaft will result in 30 speed sensor pulse.
EMC An Electromagnetic clutch used to control the amount of torque applied to the front propshaft.
TOD TM
Torque on DemandTM
.
Duty Cycle Duty Cycle is the time the EMC is on divided by the period in which it is being modulated.
Touch-off A minimum amount of duty cycle applied to the EMC.
Front OverrunA condition where the front propshaft is turning at a rate which is faster than the rear propshaft.
Rear Overrun A condition where the rear propshaft is turning at a rate which is faster than the
front propshaft.
High Range The highest (numerically lowest = 1 :1) gear ratio between the input and outputsof the Transfer Case.
Low Range The lowest (numerically highest = 2.48:1) gear ratio between the input and outputs
of the Transfer Case.
4H/4L Switch A switch which selects the desired gear ratio.
Shift Motor Electric motor which changes the Transfer Case range.
Position Encoder A set of 4 Gray code switches which provide feedback to the TCCU indicating theposition of the Shift Motor.
Clutch Interlock Switch A switch on vehicles equipped with a manual transmission which indicates that the clutch pedal is depressed.
Neutral Safety Switch A switch on vehicles equipped with an automatic transmission which indicatesthat the transmission is in neutral.
Shift Inhibit Speed The vehicle speed above which Transfer Case shifts are disallowed. Vehicle speedis indicated by propshaft speed measurement.

Application
Steering Wheel Steering Gear Box Oil Pump Steering Column
Minmum Turning Radius Oil SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
General Specifications . . . . . . . . . . . . . . . . . . 6A-1
Fastener Tightening Specifications . . . . . . . . . 6A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Hard Steering . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Steering Pulls to One Side . . . . . . . . . . . . . . . 6A-2
Excessive Wheel Play . . . . . . . . . . . . . . . . . . . 6A-2
Poor Return of Steering Wheel . . . . . . . . . . . . 6A-2
Steering Wheel Shimmy . . . . . . . . . . . . . . . . . 6A-3
SPECIFICATIONS
GENERAL SPECIFICATIONS Abnormal Noise From Steering System . . . . . 6A-3
Component Locator . . . . . . . . . . . . . . . . . . . 6A-4
Steering System . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Maintenance and Repair . . . . . . . . . . . . . . . 6A-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 6A-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Oil Pump Pressure Check . . . . . . . . . . . . . . . . 6A-6
Bleeding of Power Steering System . . . . . . . . 6A-6
Steering Gear Box . . . . . . . . . . . . . . . . . . . . . 6A-7
Number of Spoke Outer Diameter
Type Gear Ratio Inner Steering AngleOuter Steering Angle
TypeMaximum Pressure
Upper Tilting Angle
Lower Tilting Angle
Type Capacity Change Interval
Description
4
396 mm
Rack and Pinion

33°37'
31°50' Vane
75-82 kg/cm 2
4.646° 6.969°
5.25m
ATF DEXRON II
1 L
Every 24,000 km
FASTENER TIGHTENING SPECIFICATIONS
Application
Steering Shaft Bolt Pressure Hose BoltReturn Pipe Nut Slotted Nut Steering Gearbox Bolt
N m
30 - 40 12 - 1812 - 1835 - 45 35 - 45

6A-6 POWER STEERING SYSTEM
OIL PUMP PRESSURE CHECK Oil Pump Pressure Check
1. Disconnect the pressure hose from the oil pump connect apressure gauge between the oil pump and pressure hose
2. Bleed the system . Start the engine and turn the steering wheel form lock several times until oil temperature is up to
50°C
3. Run the engine at 1,000 rpm.
4. Close the pressure gauge valve and check oil pressure.
NoticeDo not keep the valve closed for more than 10 seconds.
5. Remove the pressure gauge and connect the pressure hose.
6. Do bleeding procedure. BLEEDING OF POWER STEERING SYSTEM Bleeding of Power Steering System
1. Disconnect the fuel line. Using a starter motor, crank the engine and turn the steering wheel from lock to lock 5 or 6 times. Notice Do bleeding with engine cranking. If bleed with idling, there can be a air contact with oil.
2. Connect the fuel feed line and start the engine at idle speed.
3. Turn the steering wheel from lock to lock until there is no more air in oil reservoir.
4. Connect the oil level is within specification.
5. By turning the steering wheel left to right, check the oil level change. Notice
If oil is not changes more than 5mm, do bleeding again.
If oil level rises suddenly when stopped engine, again.
Relief Pressure
75 - 82 kg/cm2