torque SSANGYONG KORANDO 1997 Service Repair Manual

SSANGYONG MY2002
3D-10 REAR AXLE
KAA3D140
KAA3D150
KAA3D130
2. Tighten the flange fixing bolts and washers with
the retainer plate.
Installation Notice
3. Assemble the plastic plug n the rear axle flange
and install the dust shield.
Installation Notice
4. Install the brake disc and caliper assembly.
Installation Notice
5. Install the parking brake cable and tire.
Tightening torque 85 - 105 N•m
KAA3D120
Installation
Clean the detached axle shaft, check the damage or
wear.
1. After checking the spline & shaft of rear axle shaft,
assemble the shaft into the rear axle housing.
Tightening Torque50 - 65 Nm
(37 - 48 lb-ft)
Tightening Torque4 - 8 Nm
(35 - 71 lb-in)

SSANGYONG MY2002
3D-12 REAR AXLE










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7. Remove the axle shaft.
KAA3D200
KAA3D210
KAA3D230
KAA3D220
Tightening Torque50 - 65 Nm
(37 - 48 lb-ft)
Installation
1. Check the rear axle shaft.
2. Insert the rear axle shaft into the axle housing and
tighten the fixing nuts of axle shaft flange.
Installation Notice
3. Connect the brake cable and install the brake
drum.
4. Install the tire and test the braking force.

SSANGYONG MY2002
3D-16 REAR AXLE
KAA3D360
KAA3D370
KAA3D390
KAA3D380
2. Install the lateral rod in axle hosing.
Notice: Do not tighten the nuts completely.
Installation Notice
3. Install the shock absorber in axle housing.
Installation Notice
Tightening Torque30 - 45 Nm
(22 - 33 lb-ft)
Tightening Torque150 - 180 Nm
Tightening Torque70 - 80 Nm
(52 - 59 lb-ft) 4. Install the stabilizer bar and upper/lower arm in
axle housing
Installation Notice
5. Install the propeller shaft of rear axle side and
tighten above the fixing bolts/nuts.
Installation Notice
6. Install the brake cable, air bleeder hose, oil pipe,
LCRV unit in rear axle assembly with assembled
completely.
Installation Notice
7. Bleeding the air in brake, install the tire.30 - 45 Nm
(22 - 33 lb-ft)
150 - 180 Nm
(111 - 133 lb-ft)
150 - 180 Nm
(111 - 133 lb-ft)
Stabilizer bar cap bolt
Upper arm nut
Lower arm nut
12 - 23 Nm
(9 - 17 lb-ft)
6 - 8 Nm
(53 - 71 lb-in)
15 - 19 Nm
(11 - 14 lb-ft)LCRV Mounting Bolt
Air Breather Hose Bolt
Brake Oil Pipe (M10)

SSANGYONG MY2002
3D-20 REAR AXLE


DIFFERENTIAL GEAR ASSEMBLY
Disassembly
1. Remove the drain plug and drain oil. Reinstall the
drain plug.
Installation Notice
KAA3D450
KAA3D470
KAA3D460
KAA3D480
Tightening Torque28 - 42 Nm
(21 - 31 lb-ft)
2. Remove the axle housing cover.
Notice: Clean the cover and housing contact
surface.
3. Remove the bearing cap bolts and remove the
bearing cap. Pull out the differential carrier
assembly.
Notice: Do alignment marks on the bearing cap
not to change the caps before removal. When pulling
out, be careful to damage the axle housing.
4. Disassemble the parts of differential carrier
assembly.

REAR AXLE 3D-23
SSANGYONG MY2002
Assembly
1. Clean all parts and check the followings.
Check the ring gear, drive pinion for wear and
damage. If damaged, replace it as a set.
Check the bearing for sticks, wear, noise and
turning resistance.
Check the side gear, pinion, pinion shaft and
thrust washer for wear and damage.
Check the differential carrier for crack and wear
(bearing contact surface). Check the gear case
for crack.
KAA3D590
KAA3D600
KAA3D620
KAA3D610
2. Assemble the drive pinion assembly to the axle
housing and then tighten the pinion lock nut.
Installation Notice
Tightening torque 240 - 310 Nm
Tightening Torque75 - 90 Nm
(55 - 66 lb-ft) 3. Assemble the differential carrier assembly. Align
the ring gear to the mark of differential carrier,
tighten the fixing bolts.
Installation Notice
4. Measure the backlash of side gear and pinion gear.
Specified value 0 - 0.5 mm

SSANGYONG MY2002
3D-24 REAR AXLE
KAA3D630
KAA3D640
KAA3D650
5. Install the differential carrier assembly into the axle
housing. Set up the bearing cap and then tighten
the cap bolts.
Installation Notice
Notice: Be careful not to change the caps. Be sure
to keep the original position of the caps.
Tightening Torque48 - 69 Nm
(35 - 51 lb-ft)
6. Measure the backlash of drive pinion and ring
gear.
Specified value 0.13 - 0.20 mm
7. Install the axle housing cover. Tighten the fixing
bolts.
Installation Notice
Tightening Torque39 - 46 Nm
(29 - 34 lb-ft)

SSAMGYONG MY2002
4A-8 HYDRAULIC BRAKES
YAD4A170
YAD4A180
LCRV (LOAD CONSCIOUS
REDUCING VALVE)
LCRV consists of sensing part and hydraulic control
part.
1. Sensing Part
It detects the changes of vehicle height caused
by vehicle load. It consists of load sensing spring
and control lever which change according to
vehicle load.
2. Hydraulic Control Part
It consists of valve stem devices which controls
hydraulic pressure according to load detected by
sensing part.
YAD4A190
4. Place alignment marks between the lock nut (b)
and adjusting screw (c) after the valve setting.
5. LCRV setting should be performed with unloaded
vehicle condition.
Setting Method
1. Install the connecting rod (a) to the No.1 hole.
2. Adjust the clearance “X” to be 0mm and tighten
the bolt (c) using the lock nut (b).
Installation Notice
Tightening Torque14 - 18 Nm
(10 - 13 lb-ft)
3. Remove the connecting rod (a) from the No.1 hole
and reinstall it to the No.2 hole.
Installation Notice
Tightening Torque14 - 18 Nm
(10 - 13 lb-ft)

HYDRAULIC BRAKES 4A-11
SSANGYONG MY2002
KAA4A040
KAA4A020
KAA4A040
KAA4A050
3. Disconnect the brake line at the front of the master
cylinder.
4. Allow the brake fluid to fill the master cylinder until
it begins to flow from the port.
5. Reconnect the brake line at the front of the master
cylinder.
6. Slowly push and hold the brake pedal.
7. While the brake pedal is pushed down, loosen the
brake fitting at the front of the master cylinder to
purge the air from the cylinder.
8. Slightly tighten the brake fitting. Then release the
brake pedal slowly. Wait 15 seconds before continu-
ing with the next step.
9. Repeat Steps 6-8 until all of the air is removed
from the master cylinder bore.
10. Tighten the brake line fitting.
Installation Notice
11. After the air has been bled at the front connection,
bleed the master cylinder at the rear connection
using the same sequence as with the top
connection.
Installation Notice
Tightening Torque 22 Nm (16 lb-ft)
Tightening Torque 17 Nm (13 lb-ft)

SSAMGYONG MY2002
4A-12 HYDRAULIC BRAKES
13. Slowly push and hold the brake pedal. Avoid rapid
pumping of the brake pedal.
14. While the brake pedal is pushed down, loosen the
bleeder valve to purge the air from the caliper.
15. After the air bubbles have escaped into the
container of brake fluid, slightly tighten the rear
bleeder valve.
16. Slowly release the brake pedal. Wait 15 seconds
before proceeding with the next step.
Notice: Keep brake fluid away from painted
surfaces because brake fluid will damage the paint
finish.
17. Repeat Steps 13 - 16 until all of the air is removed.
You will know all of the air is removed when no
bubbles appear in the container when the bleeder
valve is loosened. Keep the master cylinder reser
voir at least one-half full during the bleeding
operation.
18. Tighten the front bleeder valve.
Installation Notice 12. Attach a transparent tube over the rear bleeder
valve at the right rear caliper. Allow the tube to
hang submerged in the brake fluid in a transparent
container. (After the right rear caliper is bled in
the following steps, use this procedure at the left
front, the left rear and the right front bleeder valves.)
19. Bleed the remaining calipers in the following order
: left rear, right front, and left front. Use the
procedure in Steps 12 - 17.
20. After all calipers have been bled, check the brake
pedal for sponginess. If the brake pedal is not firm,
repeat the entire bleeding procedure to correct this
condition.
Tightening Torque 10 Nm (89 lb-ft)
KAA4A060
KAA4A070

HYDRAULIC BRAKES 4A-13
SSANGYONG MY2002
Tightening Torque 17 Nm (13 lb-ft)
FRONT BRAKE HOSE
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Disconnect the brake line from the brake hose sup
port bracket on the front frame on each side of the
vehicle and remove the retainer.
Installation Notice
KAA4A080
KAA4A090
KAA4A100
KAA4A110
3. Remove the brake hose from the brake hose
support bracket on the upper control arm.
4. Remove the front brake hose-to-front caliper
assembly bolt.
5. Remove the ring seals and the disc brake hose.
Installation Notice
Tightening Torque 30 Nm (22 lb-ft)
Bleed the brake system. Refer to “Manual
Bleeding the Brakes” in this section.
Check the brake system for leaks.
6. Installation should follow the removal procedure
in the reverse order.
REAR BRAKE HOSE
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Disconnect the brake line from the disc brake hose
at the rear axle bracket on each side of the vehicle.
Installation Notice
Tightening Torque 17 Nm (13 lb-ft)