SSANGYONG KORANDO 1997 Service Repair Manual

FRONT AXLE 3A-19
SSANGYONG MY2002
5. Unscrew the bearing cap bolts and remove the
bearing caps. Pull out the differential carrier
assembly.
Notice:
Place alignment marks on the bearing cap not
to change the caps before removal. When
pulling out the differential carrier assembly, be
careful not to damage the axle housing.
When adding fluid or making a complete fuid
change, always use front axle housing.
7. Disassemble the parts of the differential carrier
assembly.
8. Remove the drive pinion lock nut. Disassemble
the parts of the drive pinion.
KAA3A380
KAA3A410
KAA3A390
KAA3A400
6. Pull out the differential assembly using the
differential assembly remover/installer DW340-
090-01 and front differental assembly/installer
DW340-090-02.

SSAMGYONG MY2002
3A-20 FRONT AXLE
2. Assemble the parts of the drive pinion.
3. Assemble the parts of the differential carrier.
4. Measure backlash of the side gear and pinion.
Assembly Procedure
1. Clean the all parts and check the followings :
Check the ring gear and 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.
KAA3A420
KAA3A430
KAA3A660
KAA3A420
Tightening Torque
of the Lock Nut240 - 310 Nm
(177 - 229 lb-ft)
Tightening Torque
of the Ring Gear Bolts75 - 90 Nm
(55 - 66 lb-ft)
Standard 0.025 mm

FRONT AXLE 3A-21
SSANGYONG MY2002
5. Install the differential carrier assembly into the axle
housing.
Notice: Be careful not to change the caps. Be
sure to keep the original position of the caps.
6. Measure backlash of the drive pinion and ring
gear.
Tightening Torque of
the Bearing Cap Bolts4.8 - 6.9 kgfm
KAA3A670
KAA3A360
KAA3A440
KAA3A680
7. Install the axle housing cover.
8. Assemble the parts of the front axle shaft and
housing mounting bracket.
Notice: Apply grease to the oil seal rib.
Specified Value 0.165 mm
Tightening Torque3.9 - 4.6 kgfm

SSAMGYONG MY2002
3A-22 FRONT AXLE
1. Heel contact
2. Toe contact
3. Face contact
4. Flank contactAdjust backlash
(Drecrease backlash)
Select proper shim(s) to
move the drive pinion
toward the ring gear
(toward toe)
Adjust backlash
(Increase backlash)
Select proper shim(s) to
move the drive pinion
against the ring gear
(toward heel)
Adjust backlash
(Increase pinion shim)
Move the drive pinion
toward the ring gear
(toward center of ring
gear)
Adjust backlash
(Decrease pinion shim)
Move the ring gear toward
the drive pinion (toward
ring gear center line) Excessive backlash (little)
Noise can be occurred
Insufficient backlash (little)
Tooth can be damaged
or broken under heavy
load
Excessive backlash (much)
Drive pinion shaft is
apart from the ring gear
Noise can be occurred
Insufficient backlash (much)
Gear contacts on the
low flank
Gear can be damaged
or worn
Noise can be occurred
Inspection of Ring Gear Tooth Contact
Pattern
Normal Contact
Apply gear-marking compound (Prussian blue / red
lead) on the ring gear teeth. Rotate the ring gear and
check the tooth contact pattern.
KAA3A450
Abnormal Contact
Tooth contact pattern Possible cause Remedy
KAA3A460
KAA3A470
KAA3A480KAA3A500
KAA3A510
KAA3A520
KAA3A490KAA3A530

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.

FRONT AXLE 3A-25
SSANGYONG MY2002
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
661 589 13 33 00
Ball Joint Remover
661 589 18 33 00
Axle Bearing Puller
Plate
KAA3A590
KAA3A600
KAA3A610
J-8059
Snap Ring PlierDW340-080
Front Axle Support
DW340-090-02
Front Differential
Assembly
Remover/Installer
KAA3A630
KAA3A640
KAA3A650
DW340-100
Front Axle Bearing
Remover
DW340-090-01
Differential Assembly
Remover/Installer
KAA3A620

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-2 PROPELLER SHAFT
COMPONENT LOCATOR
KAA3C010
1 Front Propeller Shaft
2 Bolt
3 Nut
4 Washer
5 Bolt6 Rear Propeller Shaft
7 Bolt
8 Nut
9 Washer
10 Bolt

PROPELLER SHAFT 3C-3
SSANGYONG MY2002
PROPELLER SHAFT
Inspection Procedure
1. Visually check the propeller shaft.
2. Using a dial indicator, measure propeller shaft
runout by turning the shaft. If runout exceeds limit,
replace the propeller shaft or correct it.
Adjustment Notice
DIAGNOSTIC INFORMATION AND PROCEDURES
KAA3C020
Specification 0.4 mm (0.016 inch)
3. Measure the universal joint starting torque.
Adjustment Notice
Specification 0.54 N•m (4.78 lb-in)
KAA3C030
4. Measure the spider outer diameter.
Adjustment Notice
Specification 16.668 mm (0.656 inch)
KAA3C040
4. Measure the spider outer diameter.
Adjustment Notice
Specification 0.064 mm (0.0025 inch)
KAA3C050