wheel alignment SSANGYONG KORANDO 1997 Service Owner's Manual

WHEEL ALIGNMENT 2B-9
SSANGYONG MY2002
Application
Camber
Caster
King Pin Inclination
Toe-in (No load)Rear
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-
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SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS
Front
0° ± 30′
2°30′ ± 30′
12°30′
0 - 4 mm
54
Front Toe Adjusting NutN

m ApplicationLb-In
FASTENER TIGHTENING SPECIFICATIONS
Lb-Ft
73
-

FRONT SUSPENSION 2C-7
SSANGYONG MY2002
TORSION BAR
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the height control bolt.
Notice:
Install the torsion bar and adjust the distance
be tween the end of the height control blot and
piece end of the bolt to be 50 - 55 mm (1.97 -
2.17 inch). Adjust the vehicle height.
KAA2C110
KAA2C120
KAA2C130
3. Remove the torsion bar fixing nuts and bolts and
then withdraw the torsion bar.
Installation Notice
Check and adjust the wheel alignment.
4. Installation should follow the removal procedure
in the reverse order.
LOWER CONTROL ARM
Tools Required
661 589 13 33 00 Ball Joint Remover
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E,
Tires and Wheels.
3. Remove the torsion bar. Refer to “Torsion Bar” in
this section.
4. Remove the front shock absorber lower mounting
bolt and nut.
Installation Notice
Tightening Torque 70 Nm (52 lb-ft)
Tightening
TorqueM10
M1250 Nm (37 lb-ft)
70 Nm (52 lb-ft)

FRONT SUSPENSION 2C-9
SSANGYONG MY2002
4. Remove the upper ball joint using the ball joint
remover 661 589 13 33 00.
Installation Notice
KAA2C170
KAA2C180
KAA2C130
KAA2C160
5. Remove the fulcrum pin mounting bolts and nuts
and remove the upper control arm.
Removal Notice
Tightening Torque115 Nm (85 lb-ft)
FRONT SHOCK ABSORBER
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E,
Tires and Wheels.
3. Remove the front shock absorber lower mounting
bolt and nut.
Removal Notice
4. Remove the front shock absorber upper mounting
nut.
Notice:
The distance between the nut end and the screw
end is 6 - 9 mm (0.24 - 0.35 inch).
5. Installation should follow the removal procedure
in the reverse order.
Tightening Torque130 Nm (96 lb-ft)
Tightening Torque 70 Nm (52 lb-ft)
Be careful not to damage or lose the adjusting
shims.
Check and adjust the wheel alignment.
6. Installation should follow the removal procedure
in the reverse order.

HYDRAULIC BRAKES 4A-3
SSANGYONG MY2002
DIAGNOSTIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy,
or covered with loose dirt which can cause tires not to
grip the road unequally. Testing also will be inaccurate
on a crowned roadway because the wheels tend to
bounce.
Test the brakes at different vehicle speeds with both
light-and heavy-pedal pressure; however, avoid locking
the brakes and sliding the tires. Locked brakes and
slid-ing tires do not indicate brake efficiency since
heavily braked but turning wheels will stop the vehicle
in less distance than locked brakes. More tire-to-road
friction is present with a heavily braked, turning tire
than with a sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:
•Tires having unequal contact and grip of the road
will cause unequal braking. Tires must be equally
inflated, and the tread pattern of the right and the
left tires must be approximately equal.
Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.
Misalignment of the wheels, particularly conditions
of excessive camber and caster, will cause the
brakes to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and
the shift lever in NEUTRAL. If the pedal gradually falls
away with the constant pressure, the hydraulic system
may be leaking. Perform a visual check to confirm any
suspected leaks.
Check the master cylinder fluid level. While a slight
drop in the reservoir level results from normal lining
wear, an abnormally low level indicates a leak in the
system. The hydraulic system may be leaking either
internally or externally. Refer to the procedure below
to check the master cylinder. The system may appear
to pass this test while still having a slight leak. If the
fluid level is normal, check the vacuum booster pushrod
length. If an incorrect pushrod length is found, adjust
or replace the rod.Check the master cylinder using the following proce
dure:
Check for a cracked master cylinder casting or a
brake fluid leak around the master cylinder. Leaks
are indicated only if there is at least one drop of
fluid. A damp condition is not abnormal.
Check for a binding pedal linkage and for an
incorrect pushrod length. If both of these parts are
in satisfactory condition, disassemble the master
cylinder and check for an elongated or swollen
primary cylinder or piston seals. If swollen seals
are found, substandard or contaminated brake fluid
should be suspected. If contaminated brake fluid
is found, all the components should be
disassembled and cleaned, and all the rubber
components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, the rubber parts have
deteriorated.
If deterioration of the rubber is evident, disassemble
all the hydraulic parts and wash the parts with alcohol.
Dry these parts with compressed air before reassembly
to keep the alcohol out of the system. Replace all the
rubber parts in the system, including the hoses. When
working on the brake mechanisms, check for fluid on
the linings. If excessive fluid is found, replace the
linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush
the master cylinder with brake fluid, refill the master
cylinder, and bleed the system.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of
the outer cover, and for leaks or blisters. Inspect the
hoses for proper routing and mounting. A brake hose
that rubs on a suspension component will wear and
eventually fail. A light and a mirror may be needed for
an adequate inspection. If any of the above conditions
are observed on the brake hose, adjust or replace the
hose as necessary.

SSANGYONG MY2002
5B-4 MANUAL TRANSMISSION
DIAGNOSTIC INFORMATION AND PROCEDURES
Control lever assembly broken or dam-
aged.
Damaged offset lever, shift fork, selector
place or selector arm.
Clutch not releasing.
Improper or low transmission oil.
Shift or shift rail binding.
Binding of sliding synchronizers or gears.
If reverse only, faulty backup switch.
Worn or damaged flywheel pilot bushing.
Engine idle speed too high.
Damaged or faulty clutch.
Pilot bearing between input shaft and
output shaft binding.
Damaged synchronizer.
Bell housing misaligned.
Damaged gear(s).
Worn or damaged flywheel pilot bushing.
Loosened transmission or flywheel
housing bolts, improper alignment.
Synchronizer damaged or excessively
worn.
Blocking ring damaged, worn index slots
or friction surfaces worn or damaged.
Excessive countershaft end play.
Worn or damaged fork due to loosened
shaft, rail or shifting fork.
Fork or offset lever loose on shaft or rail.
Worn or damaged forks, offset lever,
shaft or rail.Replace control lever and housing assem-
bly.
Remove extension, adapter or case
cover. Check or replace damaged parts.
Adjust or replace clutch.
Add or replace with specified oil.
Remove extension, adapter or case
cover. Check or replace damaged parts.
Remove extension, adapter or case
cover. Check synchronizers and gears
and replace damaged parts.
Check or replace backup switch.
Replace pilot bushing.
Adjust idle speed to specified speed.
Adjust or replace clutch.
Replace or check roller bearings.
Check or replace synchronizer parts.
Align bell housing and bore.
Check or replace gear(s).
Replace pilot bushing.
Tighten bolts to specified value. Realign
if necessary.
Check or replace synchronizer parts.
Check or replace blocking ring.
Check worn or damaged parts. Adjust
shim thickness using roller bearings if
necessary.
Check for wear or damaged. Replace
worn or damaged parts.
Replace extension, adapter or case
cover. Check or replace loose parts on
shaft or rail. Replace roll pin(s).
Remove extension, adapter or case
cover. Check for wear or damaged.
Replace damaged parts. Check Applicatio
Will not shift
(control lever moves)
Hard shift or control
lever will not move into
gear
Gears crash when
shifting
Transmission jumps
out
Transmission locked in
one gear
Action

MANUAL TRANSMISSION 5B-5
SSANGYONG MY2002
Check worn or damaged synchronizer
parts and replace if necessary.
Check worn or damaged gears and
replace if necessary.
Add or drain and replace with proper oil.
Tighten as specified.
Realign correctly.
Check bearings, bearing rollers and parts
for wear or damage. Replace if neces-
sary.
Check for worn or damaged
gears(including speedometer gear).
Replace if necessary.
Clean all exposed surfaces, then check
for leaks.
Clean or replace vent or breather.
Check oil level.
Tighten as specified.
Clean leaking surfaces. Reapply sealant.
Replace oil seal.
Action
Worn or damaged synchronizer.
Worn or damaged gears.
Improper or low transmission oil.
Loose bolts or other attaching parts.
Improper flywheel housing to engine
crankshaft alignment.
Noisy transmission bearing.
Noisy gears.
Leakage from transmission.
Vent or breather clogged.
Too much oil.
Loose bolts at sealing faces.
Improperly applied sealant.
Worn or damaged oil seal.Check Applicatio
Transmission locked in
one gear
Transmission noise
Transmission leakage

SSANGYONG MY2002
5B-22 MANUAL TRANSMISSION
62 - 93 Nm
(45 - 69 lb-ft)
21 - 35 Nm
(15 - 26 lb-ft)
Check the housing face alignment.
- Place the dial indicator on the housing face.
- By rotating the crankshaft one revolution,
record the dial indicator reading.
Notice: If the reading is greater than 0.010 inch,
insert the shim between the engine and clutch
housing and adjust the alignment.
5. Check the following parts :
Pressure plate spring assembly
Disc
Flywheel
Input shaft pilot bearing
Notice: Replace the excessively worn parts.
6. Lubricate the clutch release bearing bore, fork
pivot head during assembly.
Installation Procedure
1. Install the transmission to the vehicle. At this time,
seat correctly the input shaft of the transmission
on the pilot bearing of the flywheel.
2. Tighten the transmission mounting bolts as the
specified torque on the vehicle.
Installation Notice
YAD5B390
YAD5B400
YAD5B410
YAD5B420
Tightening Torque77 - 87 Nm
(57 - 64 lb-ft)
3. Install the cross member and tighten as the
specified torque by supporting the suitable jack.
Installation Notice
Tightening
TorqueLeft/Right
Center

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

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-13
SSANGYONG MY2002
KAA6C150
UNIT REPAIR
RACK AND PINION
Disassembly and Assembly Procedure
1. Remove the rack and pinion assembly from the
vehicle. Refer to “Rack and Pinion Assembly” in
this section.
2. Remove the valve and pinion assembly from the
rack and pinion steering assembly. Refer to “Valve
and Pinion” in this section.
3. Remove the rack bearing assembly from the rack
and pinion steering assembly. Refer to “Rack
Bearing” in this section.
4. Mark the threads on the inner tie rod to aid in
repositioning the adjusting nut.
5. Loosen the adjusting nut and remove the outer tie
rod nut and the adjusting nut.
Installation Notice:
When installing the outer tie rod nut, the mark
on the inner tie rod and adjusting nut should
line up.
After installation, perform a front toe adjustment.
Refer to Section 2B, Wheel Alignment.
KAA6C160
KAA6C170
6. Remove the dust boot retaining clamps and
remove the dust boot.
7. Push back the retainer holding the connection be-
tween the inner tie rod and the power steering gear
rack.