SSANGYONG KORANDO 1997 Service Repair Manual

FRONT AXLE 3A-9
SSANGYONG MY2002
5. With part time transfer case.
5-1.Remove the cover mounting bolts and pull off
the cover.
Installation Notice
5-2. Remove the snap ring of the drive shaft and pull
off the hub body.
Notice: For assembly, adjust the clearance
between the snap ring and hub not to exceed
0.2 mm (Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0
mm).
6. With full time transfer case
6-1. Detach the hub cap with screw driver and remove
the snap ring on drive shaft.
Installation Notice 5-3.Remove the screws and pull off the locking hub
washer.
Installation Notice
Notice: For assembly, adjust the clearance
between the snap ring and hub not to exceed 0.2
mm (Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0 mm).
KAA3A110
KAA3A120
KAA3A130
KAA3A140
Tightening Torque50 - 60 Nm
(37 - 44 lb-ft)
Tightening Torque2 - 4 Nm
(18 - 35 lb-in)
Tightening Torque 15 Nm (11 lb-ft)

SSAMGYONG MY2002
3A-10 FRONT AXLE
8. Remove the hub and disk assembly. 6-2.Unscrew the bolts and remove hub flange.
Installation Notice
Before installation, apply loctite on the mating
surface.
7. Remove the hub nut with special tool.
KAA3A150
KAA3A160
KAA3A170
KAA3A180
9. Remove the disk brake dust shield.
Installation Notice
Tightening Torque70 - 90 Nm
(52 - 66 lb-ft)
Tightening Torque 15 Nm (11 lb-ft)
Tightening Torque4 - 6 Nm
(35 - 53 lb-in)

FRONT AXLE 3A-11
SSANGYONG MY2002
10. Remove the cotter pin and slotted nut and then
remove the steering knuckle arm and tie-rod.
Installation Notice
11. Remove the cotter pin and nut from the steering
knuckle arm and upper arm ball joint connection.
Installation Notice
12. Remove the cotter pin and nut from the steering
knuckle arm and lower and lower arm boll joint
connection.
Installation Notice
13. Carefully remove the knuckle arm.Replace the cotter pin with new one.
Replace the cotter pin with new one.
KAA3A190
KAA3A200
KAA3A210
Tightening Torque 40 Nm (30 lb-ft)
Tightening Torque115 Nm (85 lb-ft)
Tightening Torque150 Nm (111 lb-ft)
14. Remove the drive shaft mounting bolts and
remove the drive shaft.
Installation Notice
Observe the tighening torque and sequence.
15. Installation should follow the removal precedure
in the reverse order.
KAA3A220
Tightening Torque4.6 - 60 kgfm

SSAMGYONG MY2002
3A-12 FRONT AXLE
1 Axle Mounting Bracket
2 Breather Hose
3 Bolt (Rear)
4 Nut ......................... 95 - 142 Nm (70 - 105 lb-ft)
5 Cross Member
6 Bolt (Front)
7 Bushing
8 Spacer
FRONT AXLE ASSEMBLY
9 Bushing
10 Nut ......................... 95 - 142 Nm (70 - 105 lb-ft)
11 Front Axle Assembly
12 Nut .............................. 70 - 80 Nm(52 - 59 lb-ft)
13 Bolt
14 Inner Axle Shaft (LH)
15 Inner Axle Shaft (RH) Preceding Work : Removal of the front axle drive shaft
Removla of the steering gear box
KAA3A230

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

SSAMGYONG MY2002
3A-14 FRONT AXLE
Tightening Torque118 Nm (87 lb-ft)
7. Remove the front axle housing mounting nuts from
the crossmember.
Installation Notice
KAA3A280
KAA3A300
KAA3A290
9. Support the front axle housing with front axle sup-
port DW340-080.
Tightening Torque 78 Nm (58 lb-f t ) 8. Remove the lower ball joint using the ball joint re-
mover 661 589 13 33 00.
Installation Notice
10. Remove the front axle mounting bracket nuts.
Installation Notice
KAA3A310
Tightening Torque9.5 - 14.2 kgfm

FRONT AXLE 3A-15
SSANGYONG MY2002
11. Lowering the jack carefully, remove the front axle
assembly.
12. Installation should follow the removal procedure
in the reverse order.
KAA3A320

SSAMGYONG MY2002
3A-16 FRONT AXLE
UNIT REPAIR
AXLE HOUSING
Preceding Work : Removal of the axle housing
KAA3A330

FRONT AXLE 3A-17
SSANGYONG MY2002
1 Front Axle Housing Mounting Bracket
2 Inner Shaft (Left)
3 Bolt............................ 55 - 65 Nm (41 - 48 lb-ft)
4 Oil Seal................................................................
........Replace, Apply Grease to the Sealing Rib
5 Snap Ring
6 Bearing
7 Snap Ring
8 Oil Drain Plug............ 28 - 41 Nm (21 - 30 lb-ft)
9 Front Axle Housing
10 Breather Nipple
11 Inner Shaft (Right)
12 Pinion Lock Nut .. 240 - 310 Nm (177 - 229 lb-ft)
13 Washer
14 Companion Flange
15 Oil Seal................................................................
........Replace, Apply Grease to the Sealing Rib
16 Bearing
17 Shim
18 Bearing Baffle
19 Shim20 Bearing
21 Oil Slinger
22 Drive Pinion
23 Oil Filler Plug............ 28 - 41 Nm (21 - 30 lb-ft)
24 Bolt............................ 39 - 46 Nm (29 - 34 lb-ft)
25 Axle Housing Cover.............................................
.....Apply Liquid Gasket to the Contact Surface
26 Ring Gear
27 Bearing
28 Shim
29 Shaft Lock Pin
30 Differential Case
31 Bolt............................ 75 - 90 Nm (55 - 66 lb-ft)
32 Bolt............................ 48 - 69 Nm (35 - 51 lb-ft)
33 Washer
34 Bearing Cap
35 Thrust Washer
36 Side Gear
37 Differential Shaft
38 Differential Pinion
39 Thrust Washer

SSAMGYONG MY2002
3A-18 FRONT AXLE


Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall
the drain plug.
Installation Notice
2. Unscrew the axle housing and housing mounting
bracket bolts and remove the bracket and inner
shaft assembly.
3. Remove the bearing fixing snap ring of the inner
shaft and pull out the bearing. Separate the inner
shaft and the mounting bracket.
4. Remove the axle housing cover.
Notice: Clean the cover and housing contact
surfaces.
KAA3A340
KAA3A360
KAA3A350
KAA3A370
Tightening Torque2.8 - 4.2 kgfm