SSANGYONG KORANDO 1997 Service Repair Manual

REAR BRAKES 4E-11
SSANGYONG MY2002
YAD4C110
DISC BRAKE
1 Rear brake disc assembly
2 Brake pad
3 Brake caliper
4 Gasket...................................................Replace
5 Bolt........................................... 20 Nm (15 lb-ft)6 Gasket...................................................Replace
7 Brake hose
8 Gasket...................................................Replace
9 Hose bolt........................................... 8 - 18 Nm

SSANGYONG MY2002
4E-12 REAR BRAKES
ON-VEHICLE SERVICE
DISC BRAKE ASSEMBLY
Removal Procedure
1. Remove the rear wheel.
Notice:
Park the vehicle on the flat ground and fix the
vehicle not to move it.
Release the parking brake.
Position the transmission in NEUTRAL.
2. Remove the brake hose from the rear brake
caliper.
Notice: Be carefully to prevent the brake fluid loss
and contamination.
3. Remove the caliper cylinder mounting bolt and
remove the disc pad and the cylinder.
YAD4C130
YAD4C140
RERAIR INSTRUCTIONS
4. Remove the caliper mounting bolt and remove the
caliper assembly.
YAD4C150

REAR BRAKES 4E-13
SSANGYONG MY2002
5. Disconnect the parking brake cable from the
parking brake lever.
6. Remove the brake disc.
7. Using the rubber hammer, hit to separate the
parking brake lining lightly and move the lining
upward.
Inspection
1. Clean the dissembled parts and visually check
the followings;
Wear, rust and damage on the cylinder and
piston
Damage, crack on the caliper body and
damage, wear on the guide pin
Pad uneven wear and oil contamination
Boot’s damage and tear
YAD4C160
YAD4C170
YAD4C180
YAD4C190

SSANGYONG MY2002
4E-14 REAR BRAKES
2. Inspect the brake pad thickness.
Pad Thickness
10 mmMax wear Limit
2 mm
Notice: If the thickness of both pads is not same,
replace both pads at the same time.
3. Inspect the disc thickness.
Pad Thickness
10.4 mmMax wear Limit
8.5 mm
4. Inspect the disc plate’s scratch and deformation.
Brake Pad
1. Remove the cylinder mounting bolt (lower) at the
brake caliper.
2. Raise and fix the caliper assembly at the proper
position not to cause any damage in the hoses or
others.
YAD4C200
YAD4C210
3. Remove the brake pad and replace the new pad.
YAD4C220

REAR BRAKES 4E-15
SSANGYONG MY2002
4. Install the caliper cylinder assembly and tighten
the retaining bolt.
Installation Procedure
1. Install the brake lining between the backing plate
and the flange.
Installation Notice
Tightening Torque4 - 8 Nm
(35 - 71 lb-in)
Notice: Apply a certain amount of grease on the
parking brake lining surface.
2. Install the brake disc and connect the parking
brake cable to the lever.
3. Install the caliper to the brake disc.
Installation Notice
Tightening Torque4 - 8 Nm
(35 - 71 lb-in)
YAD4C230
YAD4C240
YAD4C250
YAD4C260

SSANGYONG MY2002
4E-16 REAR BRAKES
4. Install the brake hose.
Notice: The washer should be replaced new part.
5. Tighten the air bleeder screw.
Installation Notice
Tightening Torque7 - 13 Nm
(62 - 115 lb-in)
6. Bleed the brake system after replacement.
YAD4C270

REAR BRAKES 4E-17
SSANGYONG MY2002










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DRUM BRAKE ASSEMBLY
1. Remove the tires
Notice:
Park the vehicle on the flat ground and fix the
vehicle not to move it.
Position the transmission in NEUTRAL.
2. Disconnect the brake pipe from the rear brake.
Notice: Be carefully to prevent the brake fluid loss
and contamination.
3. Insert the bolt (M8) to the service hole of the brake
drum and remove the brake drum.
4. Remove the service hole plug of the axle shaft.
YAD4C290
YAD4C300
YAD4C310
5. Remove the return spring.
(1) Disconnect the upper return spring.
(2) Disconnect the lower return spring.
(3) Disconnect the lever spring.
(4) Disconnect the adjuster lever from the adjuster.
YAD4C320

SSANGYONG MY2002
4E-18 REAR BRAKES
6. Rotate the lining shoe hold down-washer in the
plug hole of the axle shaft flange and disconnect
the pin and the spring.
7. Disconnect the parking cable from the parking
lever.
YAD4C330
YAD4C340
YAD4C350
8. Disconnect the brake lining and adjuster lever.
YAD4C360

REAR BRAKES 4E-19
SSANGYONG MY2002
9. Remove the wheel cylinder mounting bolt and
remove the wheel cylinder.
Inspection
1. Measure the inside diameter of the brake drum
and replace as needed.
I.D.
φ 254 mmWear Limitφ 255.5 mm
Notice: Measure two more position.
2. Inspect the surface between the lining and brake.
Mark the brake drum inside using chalk and scrub
the shoe & lining assembly. If there is excessive
contact problem, replace the shoe & lining
assembly or the brake drum.
Notice: Clean any chalk mark after inspection
complete.
YAD4C370
YAD4C380
YAD4C390
Installation Procedure
1. Install the wheel cylinder to the backing plate.
Installation Notice
Tightening Torque8 - 12 Nm
(71 - 106 lb-in)
YAD4C400

SSANGYONG MY2002
4E-20 REAR BRAKES
2. Install both brake linings between the wheel
cylinder and the bottom anchor plate. And then
install adjuster and each return spring.
3. Connect the parking cable.
4. The outside diameter of the lining set to
φ 253.08
-
φ 253.50 mm by rotating the adjuster screw.
YAD4C410
YAD4C420
YAD4C430
5. Install the plate and drum to the axle shaft
sequently.
6. Check that the brake drum is rotated properly by
hand.
Notice: Adjust the adjuster screw as needed.
YAD4C440