SSANGYONG KORANDO 1997 Service Repair Manual

POWER STEERING GEAR 6C-3
SSANGYONG MY2002
COMPONENT LOCATOR
KAA6C010
1 Intermediate Shaft
2 Lower Pinch Bolt
3 Boot
4 Outer Tie Rod
5 Return Line Pipe6 Rack and Pinion Assembly
7 Rack and Pinion Assembly Mounting Bolt
8 Castle Nut
9 Cotter Pin
10 Pressure Line Pipe

SSANGYONG MY2002
6C-4 POWER STEERING GEAR
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER STEERING RACK AND PINION GEAR
Hissing Noise
Check the intermediate shaft joints for looseness.
Check the power steering hose for contact with other
components.ChecksActionTighten the intermediate shaft joints.
Be sure the power steering hose is correctly fitted into
the hose clips.
Loss of Coolant
Check the power steering hose for contact with the
body.
Check the steering gear for insufficient lubrication.
Check the steering gear mounting for improper
installation.
Check the outer tie rods for improper installation.ChecksActionBe sure the power steering hose is correctly fitted into
the hose clips.
Lubricate the steering gear.
Tighten the steering gear mounting bracket nuts and
bolts.
Tighten the outer tie rod joints. Replace the outer tie rods.
Loss of Coolant
Check the steering wheel for contact with the turn
signal housing.
Check the intermediate shaft joints for binding or
looseness.
Check the power steering pump flow control valve for
sticking and improper alignment.
Check the wheel alignment.
Check the wheel bearings for wear or damage.
Check the intermediate shaft joints for improper
installation.
Check the outer tie rods and the ball joints for binding
or looseness.
Check the steering gear adjustments.
Check the steering column shaft seal for rubbing on
the shaft.
Check the steering shaft bearings for binding.ChecksActionAdjust the turn signal housing.
Replace the intermediate shaft.
Replace the power steering pump.
Align the wheels.
Replace the wheel bearings.
Adjust the intermediate shaft between the steering gear
and the steering column. Replace the intermediate shaft.
Tighten the tie rods and the ball joints. Replace the tie
rods and the ball joints.
Perform a straight-ahead check.
Replace the dash seal.
Replace the stub shaft bearings.
Check the power steering pump for internal leaks.
Check the hoses for damage or restricted flow.
Check the power steering fluid level.
Check the power steering pump flow control valve for
sticking and improper operation.ChecksActionReplace the power steering pump.
Replace the power steering hoses and/or pipes.
Fill the power steering fluid reservoir.
Replace the power steering pump.
Momentary Increase in Effort When Turning the Wheel Quickly

POWER STEERING GEAR 6C-5
SSANGYONG MY2002
Check the power steering pump for insufficient pres-
sure.
Check the power steering pump flow control valve for
sticking and improper operation.
Check the power steering pump serpentine belt for
slippage.
Check for air contamination in the power steering
system.ChecksActionReplace the power steering pump.
Replace the power steering pump.
Tighten the power steering serpentine belt.
Bleed the power steering system
Steering Surges or Jerks When Turning with Engine Running
Check for air contamination in the power steering
system.
Check the power steering pump serpentine belt for
looseness.ChecksActionBleed the power steering system.
Tighten the power steering serpentine belt.
Steering Vibrates During Low Speed or Static Steering
Excessive Wheel Kickback or Loose Steering
Check for air contamination in the power steering
system.
Check the wheel bearings for wear or damage.
Check the steering gear mounting for improper instal-
lation.
Check the intermediate shaft joints for improper
Installation.
Check the outer tie rods and the ball joints for
looseness.ChecksActionBleed the power steering system.
Replace the wheel bearings.
Tighten the steering gear mounting bracket nuts and
bolts.
Adjust the intermediate shaft between the steering
gear and the steering column. Replace the intermedi-
ate shaft.
Tighten the tie rods and the ball joints. Replace the tie
rods and the ball joints.
Hard Steering or Lack of Assist (Especially During Parking)
Check the intermediate shaft joints for improper
installation.
Check the power steering pump flow control valve for
sticking and improper installation.
Check the power steering pump for insufficient pressure.
Check the power steering pump for internal leaks.
Check for a loose or a worn intermediate shaft.
Check the power steering pump serpentine belt tension.ChecksActionAdjust the intermediate shaft between the steering gear
and the steering column. Replace the coupling flange.
Replace the power steering pump.
Replace the power steering pump.
Replace the power steering pump.
Tighten the intermediate shaft. Replace the intermedi-
ate shaft, as needed.
Tighten the power steering serpentine belt.

SSANGYONG MY2002
6C-6 POWER STEERING GEAR
POWER STEERING RACK AND
PINION GEAR BENCH TESTING
Removal and Installation Procedure
Notice: Pressure checks or pressure and flow checks
may also be conducted using this setup.
1. Disconnect and remove the power steering gear.
Refer to “Rack and Pinion Assembly” in this
section.
2. Place the power steering gear on a bench next to
the vehicle.
3. Disconnect the pressure line at the point where the
hose connects to the pipe. Extend this line to reach
the power steering gear on the bench.
4. Disconnect the return line from the power steering
fluid reservoir. Extend this line to reach the power
steering gear on the bench.
5. Connect the power steering pipes to the power
steering gear.
6. Start the engine and allow it to idle for 10 seconds.
7. Check the power steering fluid level. Refer to
Section 6A, Power Steering System.
8. Start the engine and turn the rack and pinion stub
shaft a full turn in each direction. Hold the shaft
against each stop for 5 seconds.
9. Inspect for possible leak points. Refer to Section
6A, Power Steering System.
Installation Procedure
1. Stop the engine.
2. Disconnect the power steering pipes from the power
steering gear.
KAA6C020
3. Remove the extensions and reconnect the pressure
and return lines.
4. Install and connect the power steering gear. Refer
to “Rack and Pinion Assembly” in this section.
5. Start the engine and allow it to idle for 10 seconds.
6. Check the power steering fluid level. Refer to
Section 6A, Power Steering System.
STRAIGHT-AHEAD CHECK
After all the necessary operations on the steering gear
are completed (removing and installing, disassembling
and assembling), check the exact straight-ahead posi-
tion of the steering in each case.
With the vehicle on the floor, place the steering wheel
in the straight-ahead position. Mark the centerline of
both tires on the floor. Turn the steering wheel all the
way to the right and mark the new centerline of both
tires on the floor.

POWER STEERING GEAR 6C-7
SSANGYONG MY2002
Yes
Go to Step 2
Go to Step 3
Go to Step 5
Go to Step 2
Go to Step 3
System OK
Go to Step 6No
-
Go to Step 4
Go to Step 6
-
-
Go to Step 7
- Value
-
-
-
-
-
Inner angle :
33°39′
Outer angle :
31°54′
-Step
1
2
3
4
5
6
7Action
Place the steering wheel in the straight-ahead position.
Is the wheel in the correct position?
Is the lower intermediate shaft pinch bolt lying parallel to
the steering gear?
Is the steering wheel off center by more than 5 degrees?
The pinion is displaced on the rack. The steering pinion
position must be corrected.
Is the repair complete?
Remove steering wheel and center on the spindle
splines.
Is the repair complete?
Turn the steering wheel all the way to the right.
Measure the inner and the outer angles of the tire
centerline compared to the straight-ahead centerline.
Are the angle within specifications?
The rack assembly was not assembled correctly.
Repair as needed.
Is the repair complete?
Straight-Ahead Check Table

SSANGYONG MY2002
6C-8 POWER STEERING GEAR
KAA6C040
KAA6C030
ON-VEHICLE SERVICE
RACK AND PINION ASSEMBLY
Tools Required
661 589 13 33 00 Ball Joint Remover
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheels. Refer to Section 2E, Tires
and Wheels.
3. Remove the intermediate shaft. Refer to
“Intermediate shaft” in this section.
4. Disconnect the return line pipe from the power
steering gear outlet. Place a drain pan under the
steering gear to catch the power steering fluid.
Installation Notice
REPAIR INSTRUCTIONS
Tightening Torque 17 Nm (13 lb-ft)
5. Disconnect the pressure line pipe from the power
steering gear inlet.
Installation Notice
Tightening Torque 17 Nm (13 lb-ft)

POWER STEERING GEAR 6C-9
SSANGYONG MY2002
KAA6C140
KAA6C050
KAA6C050
6. Remove the outer tie rod nuts and disconnect the
tie rod ends from the knuckle using the ball joint
remover 661 589 13 33 00.
Installation Notice
7. Remove the rack and pinion assembly mounting
bolts and remove therackand pinion assembly.
Installation Notice
Tightening Torque 40 Nm (30 lb-ft)
After installing the rack and pinion assembly,
bleed the power steering system. Refer to
Section 6A, Power Steering System.
OUTER TIE ROD
Tools Required
661589 13 33 00 BallJointRemover
Removal and Installation Procedure
1. Remove the wheel. Refer to Section 2E, Tires and
wheels.
2. Mark the threads on the inner tie rod to aid in
repositioning the adjusting nut.
3. Remove the outer tie rod nut and disconnect the
outer tie rod from the knuckle using the ball joint
remover 661 589 13 33 00.
Installation Notice
Tightening Torque 78 Nm (58 lb-ft)
Tightening Torque 40 Nm (30 lb-ft)

SSANGYONG MY2002
6C-10 POWER STEERING GEAR
KAA6C090
KAA6C100
KAA6C110
KAA6C080
4. Loosen the outer tie rod adjusting nut and remove
the outer tie rod by twisting it off the inner tie rod.
Installation Notice:
After Installation, perform a front toe adjustment.
Refer to Section 2B, Wheel Alignment.
DUST BOOT
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the wheel. Refer to Section 2E, Tires and
wheels.
3. Remove the outer tie rod. Refer to “Outer Tie Rod”
in this section.
4. Remove the dust boot retaining clamps.
5. Remove the dust boot.
Installation Notice:
After Installation, perform a front toe adjustment.
Refer to Section 2B, Wheel Alignment.
INTERMEDIATE SHAFT
Removal and Installation Procedure
1. Turn the steering wheel until it is horizontal. This
is the straight-ahead position. Make a mark on
the stub shaft housing that lines up with a mark
on the intermediate shaft lower universal joint.
Installation Notice:
When attaching the lower universal joint, the
marks on the intermediate shaft and on the stub
shaft should line up

POWER STEERING GEAR 6C-11
SSANGYONG MY2002
KAA6C120
KAA6C130
2. Remove the lower pinch bolt from the universal
joint on the intermediate shaft.
Installation Notice
Tightening Torque 27 Nm (20 lb-ft)
3. Make a mark on the steering column shaft that
lines up with a mark on the intermediate shaft
upper universal joint.
Installation Notice:
When attaching the upper universal joint, the
marks on the intermediate shaft and steering
column shaft should line up
4. Remove the upper pinch bolt from the universal
joint on the intermediate shaft.
Installation Notice
5. Remove the intermediate shaft.
Tightening Torque 27 Nm (20 lb-ft)
HYDRAULIC CYLINDER LINES
Removal and Installation Procedure
1. Siphon the power steering fluid from the power
steering fluid reservoir.
2. Disconnect the power steering gear hydraulic
cylinder pipes from the power steering gear at the
valve end. Replace the O-ring seals as needed.
Installation Notice
Tightening Torque 14 Nm (10 lb-ft)

SSANGYONG MY2002
6C-12 POWER STEERING GEAR
KAA6C140
3. Raise and suitably support the vehicle.
4. Disconnect the power steering gear hydraulic
cylinder pipes from the power steering gear at the
cylinder end.
5. Remove the steering gear hydraulic cylinder pipes
from the vehicle.
Installation Notice
Tightening Torque 61 Nm (44 lb-ft)
When adding power steering fluid or making a
complete change, always use DEXRON. - II pow-
er steering fluid. Failure to use the proper fluid
will cause hose and seal damage and fluid
leaks.
Fill the reservoir with power steering fluid.
Inspect for leaks. If there are leaks, correct the
cause of the leaks and bleed the system. Refer
to “Bleeding the Power Steering System” in this
section.