section 2c SSANGYONG KORANDO 1997 Service Manual PDF

SECTION 3A
FRONT AXLE
TABLE OF CONTENTS
Specifications.......................................................3A-2
General Specifications.........................................3A-2
Fastener Tightening Specifications.......................3A-2
Component Locator.............................................3A-3
Front Axle Assembly ...........................................3A-3
Auto-Locking Hub................................................3A-4
Maintnance and Repair........................................3A-5
On-Vehicle Service.................................................3A-5
Vacuum Line........................................................3A-5Steering Knuckle and Drive Shaft.........................3A-7
Front Axle Assembly .........................................3A-12
Unit Repair.......................................................... 3A-16
Axle Housing.....................................................3A-16
Outer Joint Seal.................................................3A-23
Inner Tripot Seal................................................3A-24
Special Tools and Equipment............................ 3A-25
Special Tools Table............................................3A-25

FRONT AXLE 3A-13
SSANGYONG MY2002
Tools Required
DW340-80Front Axle Support
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the lower cover.
Installation Notice
KAA3A240
KAA3A260
KAA3A250
5. Remove the front drive shaft-to-front axle
assemblybolts.
Installation Notice
Tightening Torque4.5 - 6.0 kgfm 3. Remove the rack and pinion assembly. Refer to
Section 6C, Power Steering Gear.
4. Remove the front axle bleeder hose.
Tightening Torque 35 Nm (26 lb-ft)
KAA3A270
6. Remove the front propeller shaft-to-front axle bolts.
Removal Notice
Make alignment marks on the front propeller
shaft and front axle housing.
Installation Notice
Tightening Torque7.0 - 8.5 kgfm

FRONT AXLE 3A-23
SSANGYONG MY2002
KAA3A550
KAA3A540
OUTER JOINT SEAL
Tools Required
J-8059Snap Ring Plier
Disassembly and Assembly Procedure
1. Remove the front drive shaft from the vehicle.
Refer to “Front Drive Shaft” in this section.
2. Remove the large seal retaining clamp.
3. Remove the small seal retaining clamp.
4. Degrease the joint.
Installation Notice:
Fill the joint seal with 135 to 155 g (4.76 to 5.46
ounces) of the recommended grease. Repack
the joint with 135 to 155 g (4.76 to 5.46 ounces)
of the recommended grease.
5. Spread the snap ring using the snap ring plier J-
8059 and remove the outer joint from the front drive
shaft.
Caution: Do not disassembly the outer joint
assembly. Parts are match fit and cannot be
serviced separately. Improper reassembly will
adversely affect both performance and safety.
6. Remove the seal from the joint assembly.

SSAMGYONG MY2002
3A-24 FRONT AXLE
KAA3A580
KAA3A570
4. Degrease the tripot assembly.
Installation Notice
Fill the tripot housing with 185 to 205 g (6.53 to
7.23 ounces) of the recommended grease.
Repack the tripot with 185 to 205 g (6.53 to
7.23 ounces) of the recommended grease.
5. Remove the shaft retaining ring using the snap
ring plier J-8059.
6. Remove the tripot and the tripot joint retaining ring
from the front drive shaft.
7. Remove the tripot joint seal from the front drive
shaft.
KAA3A560
INNER TRIPOT SEAL
Tools Required
J-8059 Snap Ring Plier
Disassembly and Assembly Procedure
1. Remove the front drive shaft from the vehicle.
Refer to “Front Drive Shaft” in this section.
2. Remove the large seal retaining clamp.
3. Remove the small seal retaining clamp.

SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
Components Locator............................................3C-2
Diagnostic Information and Procedures...............3C-3
Propeller Shaft.....................................................3C-3
Repair Instructions................................................3C-4
On-Vehicle Service.................................................3C-4
Front Propeller Shaft............................................3C-4Rear Propeller Shaft.............................................3C-4
Unit Repair............................................................3C-6
Propeller Shaft.....................................................3C-6
Specifications.......................................................3C-7
Fastener Tightening Specifications.......................3C-7

SSANGYONG MY2002
3C-6 PROPELLER SHAFT
UNIT REPAIR
PROPELLER SHAFT
Removal and Installation Procedure
1. Remove the front propeller shaft. Refer to “Front
Propeller Shaft” in this section.
2. Place alignment marks before removing the spider.
KAA3C100
KAA3C120
KAA3C110
KAA3C130
3. Using a snap ring pliers, remove the snap ring.
4. Slightly tapping the yoke shoulder using a brass
hammer, remove the bearing. Remove the
remaining bearings in the same way.
5. Disassemble the universal joint parts.
Installation Notice:
Clean the disassembled parts and replace them
if damaged.
Apply grease to the inner of the bearing cap of
the needle roller bearing and assemble the needle
roller.
GreaseEP#2

SECTION 3D
REAR AXLE
TABLE OF CONTENTS
General Description and Operation.................3D-2
Specifications...................................................3D-2
Fastener Tightening Specifications..................3D-2
Diagnostic Information and Procedures........3D-3
Component Locator .........................................3D-4
Rear Axle Assembly .........................................3D-4
Cross Sectional View........................................3D-5
Rear Axle Shaft Assembly...............................3D-6
Maintenance and Repair..................................3D-8
On-Vehicle Service ..............................................3D-8Axle Shaft Assembly (With Disc Brake)..........3D-8
Axle Shaft Assembly (With Drum Brake)...... 3D-11
Rear Axle Housing .......................................... 3D-13
Unit Repair....................................................... 3D-18
Axle Assembly............................................... 3D-18
Differential Gear Assembly............................ 3D-20
Drive Shaft...................................................... 3D-25
Special Tools and Equipment....................... 3D-26
Special Tools Table........................................ 3D-26

REAR AXLE 3D-5
SSANGYONG MY2002
CROSS SECTIONAL VIEW
KAA3D020
1 Rear Axle Shaft Assembly
2 Bracket Assembly
3 Hub Oil Seal
4 Bolt
5 Axle Shaft Tube6 Coil Spring Seat (Lower)
7 Caliper Assembly
8 Input Shaft/Flange
9 Rod Mounting Bracket
10 Wheel Speed Sensor

REAR AXLE 3D-25
SSANGYONG MY2002
KAA3D670
KAA3D660
DRIVE SHAFT
Tools Required
661 589 15 33 00 Rear Hub Bearing Installer
661589 18 33 00 Axle Bearing Puller Plate
661 589 18 33 01 Rear Axle Bearing Remover
661 589 18 33 02 Rear Axle Oil Seal Remover
Disassembly Procedure
1. Remove the rear drive shaft from the vehicle. Refer
to “Rear Drive Shaft” in this section.
2. Remove the toothed ring using the axle bearing
puller plate 661 589 18 33 00 and rear axle bearing
remover 661 589 18 33 01 by press.
3. Remove the rear drive shaft oil seal bearing using
the axle bearing puller plate 661 589 18 33 00 and
rear axle oil seal remover 661 589 18 33 02 by
press.
4. Remove the rear disc brake rotor shield.
3. Install the retainer drive shaft bearing using the
rear hub bearing installer 661 589 15 33 00 by press.
4. Install the rear drive shaft. Refer to “Rear Drive
Shaft” in this section.
KAA3D690
KAA3D680
Assembly Procedure
1. Install the rear disc brake rotor shield.
2. Install the rear drive shaft bearing oil seal using
the rear hub bearing installer 661 589 15 33 00 by
press.

SECTION 4A
HYDRAULIC BRAKES
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when
a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this
cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK
unless otherwise noted.
TABLE OF CONTENTS
Description and Operation...................................4A-2
General Description.............................................4A-2
Diagnostic Information and Procedures..............4A-3
Brake System Testing ..........................................4A-3
Brake Hose Inspection.........................................4A-3
Brake Warning Lamp Circuit Description..............4A-4
Brake Warning Lamp Diagnosis...........................4A-5
LCRV (Load Conscious Reducing Valve)..............4A-8
Repair Instructions..............................................4A-10On-Vehicle Service...............................................4A-10
Manual Bleeding The Brakes.............................4A-10
Front Brake Hose...............................................4A-13
Rear Brake Hose...............................................4A-13
Stoplamp Switch................................................4A-14
Brake Pedal.......................................................4A-14
Specifications.....................................................4A-15
General Specification .........................................4A-15
Fastener Tightening Specifications.....................4A-16