SSANGYONG KORANDO 1997 Service Repair Manual

FRONT SUSPENSION 2C-3
SSANGYONG MY2002
DIAGNOSTIC INFORMATION AND PROCEDURES
BALL JOINT INSPECTION
Ball Joint Inspection
1. Raise the front of the vehicle to allow the front
suspension to hang free.
2. Grasp the tire at the top and the bottom.
3. Move the top of the tire in an in-and-out motion.
4. Look for any horizontal movement of the knuckle
relative to the control arm.
5. Ball joints must be replaced under the following
conditions:
•The joint is loose.
The ball seal is cut.
The ball stud is disconnected from the knuckle.
The ball stud is loose at the knuckle.
The ball stud can be twisted in its socket with
finger pressure.
Ball Stud Inspection
Make sure to check the tightness of the ball stud in the
knuckle boss during each inspection of the ball joint.
One way to inspect the ball stud for wear is to shake
the wheel and feel for movement of the stud end at the
knuckle boss.
Another way to inspect the ball stud for wear is to check
the fastener torque at the pinch nut. A loose nut can
indicate a stressed stud orahole in theknuckle boss.
Worn of damaged ball joints and knuckles must be re-
placed.

SSANGYONG MY2002
2C-4 FRONT SUSPENSION
REPAIR INSTRUCTIONS
KAA2C020
ON-VEHICE SERVICE
FRONT HUB BEARING ASSEMBLY
Tools Required
DW340-050Sliding Hammer
DW340-060Front Hub Cap Remover/Installer
DW340-070Front Hub Flange Remover
661 589 01 07 00 Front Hub Adjusting Nut Remover/
nstaller
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 caliper assembly. Refer to Section
4D, Front Disc Brakes.
4. Remove the hub cap with front hub cap remover/
Installer DW340-060 and sliding hammer DW340-
050.
KAA2C030
5. Remove the hub flange bolts.
Installation Notice
Tightening Torque 55 Nm (41 lb-ft)
6. Remove the snap ring and hub flange with front
hub flange remover DW340-070 and sliding
hammer DW340-050.
Notice:
When installing, coat the hub flange surface with
Loctitte.

FRONT SUSPENSION 2C-5
SSANGYONG MY2002
7. Remove the hub adjust locking washer.
KAA2C040
KAA2C050
KAA2C060
KAA2C070
8. Remove the hub adjusting nut with front hub adjust-
ing nutremover/installer 661589 01 07 00.
Installation Notice
Tightening Torque 15 Nm (11 lb-ft)
When installing, adjust the clearance between
the hub adjusting nut and hub not to exceed
0.2 mm (0.008 inch) using the shim.
9. Remove the hub bearing assembly.
10. Installation should follow the removal procedure
in the reverse order.
FRONT STABILIZER
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the lower cover.
Installation Notice
Tightening Torque 35 Nm (26 lb-ft)

SSANGYONG MY2002
2C-6 FRONT SUSPENSION
3. Remove the front stabilizer-to-stabilizer link nuts.
Installation Notice
KAA2C080
KAA2C090
KAA2C080
KAA2C100
4. Remove the front stabilizer mounting bolts.
Installation Notice
Tightening Torque 70 Nm (52 lb-ft)
5. Installation should follow the removal procedure
in the reverse order.
STABILIZER LINK
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the front stabilizer-to-stabilizer link nuts.
Installation Notice
3. Remove the stabilizer link-to-lower control arm
nuts.
4. Remove the stabilizer link.
Installation Notice
Tightening Torque 19 Nm (14 lb-ft)
Tightening Torque 38 Nm (28 lb-ft)
Tightening Torque 70 Nm (52 lb-ft)
The distance between the end of the nut and
the end of the stabilizer link should be 10 - 12
mm (0.39 - 0.47 inch) at the connection of the
stabilizer link and lower control arm.
5. Installation should follow the removal procedure
in the reverse order.

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)

SSANGYONG MY2002
2C-8 FRONT SUSPENSION
5. Remove the stabilizer link-to-lower control arm nut.
Installation Notice
KAA2C100
KAA2C140
KAA2C150
KAA2C160
6. Remove the lower ball joint using the ball joint
remover 661 589 13 33 00.
Installation Notice
Tightening Torque 19 Nm (14 lb-ft)
7. Remove the lower control arm mounting bolts.
Installation Notice
UPPER CONTROL ARM
Tools Required
661589 13 33 00 BallJointRemover
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 upper mounting nut.
Notice:
The distance between the nut end and the screw
end is 6 - 9 mm (0.24 - 0.35 inch).
Tightening Torque150 Nm (111 lb-ft)
Tightening Torque120 Nm (89 lb-ft)
The distance between the end of the nut and
the end of the stabilizer link should be 10 - 12
mm (0.39 - 0.47 inch) at the connection of the
stabilizer link and lower control arm.
8. Installation should follow the removal procedure
in the reverse order.

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.

SSANGYONG MY2002
2C-10 FRONT SUSPENSION
LOWER BALL JOINT
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 knuckle assembly. Refer to “Knuckle
Assembly” in this section.
4. Remove the lower ball joint.
Installation Notice
KAA2C190
KAA2C2005. Installation should follow the removal procedure
in the reverse order.
UPPER BALL JOINT
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 knuckle assembly. Refer to “Knuckle
Assembly” in this section.
4. Remove the upper ball joint.
Installation Notice
5. Installation should follow the removal procedure
in the reverse order.
Tightening Torque 70 Nm (52 lb-ft)
Tightening Torque130 Nm (96 lb-ft)

FRONT SUSPENSION 2C-11
SSANGYONG MY2002
KNUCKLE ASSEMBLY
Tools Required
661589 13 33 00 BallJointRemover
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 caliper assembly. Refer to Section
4D, Front Disc Brakes.
4. Remove the front hub bearing assembly. Refer to
“ Front hub bearing assembl y ” in this section.
KAA2C060
KAA2C210
KAA2C220
5. Remove the splash shield mounting bolts.
Installation Notice
6. Remove the front wheel speed sensor.
Installation Notice
KAA2C230
7. 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
Tightening Torque 6 Nm (53 lb-in)
Tightening Torque 5 Nm (33 lb-in)
Tightening Torque 40 Nm (30 lb-ft)

SSANGYONG MY2002
2C-12 FRONT SUSPENSION
9. Remove the upper ball joint using the ball joint re-
mover 661 589 13 33 00.
Installation Notice
KAA2C170
KAA2C070
CROSSMEMBER
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the lower cover.
Installation Notice 8. Remove the lower ball joint using the ball joint re-
mover 661 589 13 33 00.
Installation Notice
KAA2C140
KAA2C240
3. Remove the front axle housing mounting nuts from
the crossmember.
Installation Notice
Tightening Torque150 Nm (111 lb-ft)
10. Remove the knuckle assembly.
11. Installation should follow the removal procedure
in the reverse order.
Tightening Torque115 Nm (85 lb-ft)
Tightening Torque 35 Nm (26 lb-ft)
Tightening Torque118 Nm (87 lb-ft)