SSANGYONG MUSSO 2003 Service Manual

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 housingmounting bracket. NoticeApply 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 pattern Possible CauseRemedy
1. Heel Contact
2. Toe Contact
3. Face Contact
4. Flank ContactInsufficient backlash (little)

Tooth can be damaged or broken under heavy load
Excessive backlash (much)
Drive pinion shaft is apart from the ring gear
Noise can be occurred
Insufficient backlash (much)
Gear contacts on the low flank
Gear can be damaged orworn
Noise can be occurred Adjust backlash(Decrease backlash)

Select proper shim(s) to move the drive pinion toward the ring gear (toward toe)
Adjust backlash(Increase backlash)
Select proper shim(s) 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 (little)

Noise can be occurred

Diesel Gasoline (M161) Gasoline (M162)
Diesel Gasoline
Application
Joint Type Number of Spider Front FrontRear Front Rear
Front (Full-Time)
Front (Part-Time)Rear Front Rear
SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 General Specifications . . . . . . . . . . . . . . . . . . 3C-1
Component Locator . . . . . . . . . . . . . . . . . . . 3C-2 M/T & A/T (Part-time T/C) . . . . . . . . . . . . . . . . 3C-2 Maintenance and Repair . . . . . . . . . . . . . . . 3C-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . .
3C-3
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description
Single or Single & Double Cardan Single Cardan
Constant Velocity(CV) & Double Carden Single Cardan
3 22
CV Joint : 1, Double Spiders : 1 2
Diesel Gasoline
Shaft Dimensions (L×O.D ×I.D)
When CompressedFully FrontRearFrontRear Front Rear- --M/T & MB A/T
BTRA A/T (2p-Type) TONGIL KSC-
576
×59.5 ×63.5
973 ×
63.5 ×659.5
583.5 ×
44.7×50.8
973 ×
63.5 ×459.5
380.8 ×
63.5×59.5
591.5 ×
63.5×59.5
601.6 ×
50.8×44.7
579.6 ×
50.8×44.7
776.8 ×
63.5×59.5

3C-2 PROPELLER SHAFT
1 Flange Yoke
2 Cross and Bearing Assembly (with Snap Ring)
3 Cross and Bearing Assembly (with Snap Ring)
4 Slip Yoke Assembly
5 Grease Nipple
6 Dust Cap
7 Oil Seal
8 Split Washer
9 Slip Tube Shaft
10 Tube
Notice Only the length of shaft is different and the components of front/rear shaft are the same.(The deadener is inserted to the inside of tube of rear shaft, both ends) COMPONENT LOCATOR
M/T & A/T (PART-TIME T/C)
1. Gasolin : E32 - Fromt Propeller Shaft
2. Diesel/Gasolin : E23,20 - Fromt Propeller Shaft
: A/T + Full - Time T/C
3. Gasolin - Rear Propeller Shaft
Diesel - Fromt & Rear Propeller Shaft
: M/T & A/T + FPart - Time T/C
11 Tube Yoke
12 Flange Yoke
13 Diesel : Cross and Bearing Assembly (with Snap Ring)
Gasoline : CV Joint (DOJ)
14 Diesel : Double Cardan
Gasoline : Stub Shaft
15 Tube
16 Cross and Bearing Assembly (with Snap Ring)
17 Center Couping Yoke
18 Boots Band

PROPELLER SHAFT 3C-3
1 Front Axle
2 Bolt...................................................... 70-80 Nm
3 Front Propeller Shaft (661LA/662LA)
4 Front Propeller Shaft (E32)
5 Bolt ...................................................... 81-89 Nm
6 Transfer Case MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
PROPELLER SHAFT7 Bolt ...................................................... 81-89 Nm
8 Rear Propeller Shaft
9 Bolt ...................................................... 70-80 Nm
10 Rear Axle
11 Front Propeller Shaft (E20/E23)

3C-4 PROPELLER SHAFT
Removal Procedure
1. Place alignment marks and remove the propeller shaft.
2. Place alignment marks before removing the spider.
3. Using a snap ring pliers, remove the snap ring.
GasolineDiesel

PROPELLER SHAFT 3C-5
5. If difficult to remove, clamp the yoke side in a vise and tapoff the needle bearing, using a proper tool.
6. Disassemble the universal joint parts. As axles move up and down, universal joints allow drive angles to change without binding propeller shaft.
1 Grease Nipple
2 Flange Yoke
3 Spider4 Seal
5 Needle Roller Bearing
6 Snap Ring
4. Slightly tapping the yoke shoulder using a brass hammer,
remove the bearing. Remove the remaining bearings in the
same way.

3C-6 PROPELLER SHAFT
3. Clearance between the spider and bearing.
4. Propeller shaft runout Using a dial indicator, measure propeller shaft runout by turning the shaft. If runout exceeds limit, replace thepropeller shaft or correct it using a press.
Standard
0.03 - 0.098 mm Limit
0.25 mm
Inspection Procedure
1. Visual check.
Check the disassembled parts for wear or crack.
Replace them if necessary.
2. Spider outer diameter (mm).
Standard 16.668 Limit
16.647
Limit 0.4 mm

PROPELLER SHAFT 3C-7
Installation Procedure Clean the disassembled parts and replace them if damaged.
1. Align the alignment marks of the yoke and assemble thespider, bearing and snap ring.
2. Apply grease to the inner of the bearing cap of the needle roller bearing and assemble the needle roller.
Grease EP #2
6. Possible cause of vibration.
Drift away of balance weights.
Excessive runout of the propeller shaft.
Using normal bolts.
Excessive wear of the universal joint.
Sticks in sleeve joint.
Drive angle changes in universal joints or cross causes vibration and can be detected around 60~100 km/h.
5. Universal joint starting torque.
Starting Torque 3 - 8 kg

cm

3C-8 PROPELLER SHAFT
3. Install the bearing cap to the yoke and insert the spider.Install the opposite side cap by tapping with a plastic
hammer. Adjust clearance of the spider pin to be within 0.1 mm and install the snap ring.
4. Align the alignment marks and install the front and rear propeller shaft. Tighten the nuts to the specified torque.
GasolineDiesel