lock SSANGYONG MUSSO 1998 Workshop Owners Manual

3A-6 FRONT DRIVE AXLE
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
VACUUM LINE
1 Vacuum Auto-locking Hub Assembly
2 Bolt......................................................50-60 Nm
3 Cam Washer
4 Auto-locking Hub Cap
5 Retainer Ring
6 Shim
7 Locking Hub
8 Band
9 Hose (L : 400)
10 T-connector
11 Hose (L : 250, white)12 Check Valve
13 Hose (L :100, green)
14 Auto Locking Hub Solenoid Valve
1 5 Bolt
16 Hose (L :100, green)
17 T-connector
18 Hose (L : 720, yellow)
19 Hose (L :2, 360 , red)
20 Corrugated Tube
2 1 Clip
2 2 Clip

FRONT DRIVE AXLE 3A-7
Removal & Installation Procedure
1. Be careful not to change the valve when connecting the
check valve and each hose.
2. Adjust the clearance between the retainer ring (5) and
locking hub (7) using the shim(6).
Notice
Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0 mm
NormalMax. 0.2 mm
3. Tighten the auto locking hub cap bolt to the specified torque
and order.
Tightening Torque 50 - 60 Nm

FRONT DRIVE AXLE 3A-9
Removal & Installation Procedure
1. Remove the tire.
Installation Notice
Steel Wheel
Aluminum WheelTightening Torque80 - 120 Nm
110 - 130 Nm
2. Remove the autolocking hub vacuum hose.
3. With ABS
Remove the wheel speed sensor from the steering knuckle.
Installation Notice
4. Remove the mounting bolts and pull off the caliper assembly.
Installation Notice
Tightening Torque 6 - 8 Nm
Hose Bolt
Mounting BoltTightening Torque25 - 35 Nm
85 - 105 Nm
Notice
Be careful not to damage the brake hose.

3A-10 FRONT DRIVE AXLE
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).
Tightening Torque 50 - 60 Nm
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
Tightening Torque 2 - 4 Nm 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).
Tightening Torque 15 Nm

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

FRONT DRIVE AXLE 3A-19
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.
6. Disassemble the parts of the differential carrier assembly.
7. Remove the drive pinion lock nut. Disassemble the parts of
the drive pinion.
Assembly Procedure
1. Clean the all parts and check the followings :
lCheck the ring gear and drive pinion for wear and
damage. If damaged, replace it as a set.
lCheck the bearing for sticks, wear, noise and turning
resistance.
lCheck the side gear, pinion, pinion shaft and thrust
washer for wear and damage.
lCheck the differential carrier for crack and wear (bearing
contact surface). Check the gear case for crack.

3A-20 FRONT DRIVE 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.
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.
Tightening Torque of the
Lock Nut240 - 310 Nm
Tightening Torque of the
Ring Gear Bolts75 - 90 Nm
Standard 0 - 0.05 mm
Tightening Torque of the
Bearing Cap Bolts48 - 69 Nm

3D-2 REAR DRIVE AXLE
FASTENER TIGHTENING SPECIFICATIONS
Application
Inner Bracket Mounting Nut
Propeller Shaft to Rear Axle Input Shaft
Lower Arm Mounting Nut
Lower Shock Absorber to Axle Housing
Upper Arm Mounting Nut
Stabilizer Bar Mounting Bolt
Lateral Rod Mounting Nut
Drive Pinion Lock Nut
Oil Drain Plug
Ring Gear Mounting Bolt
Oil Filler PlugN
· ·· ·
·m
50 - 65
70 - 80
150 - 180
50 - 65
150 - 180
30 - 45
150 - 180
240 - 310
28 - 42
75 - 90
28 - 42
4.55
4.55
4.55
4.27
5.86
3.73
3.73
4.89
1.9 L
SEA 80W/90, API GL - 5 M/T
A/T (MB)
M/T
A/T (MB)
A/T (BTRA)
M/T
A/T (MB)
A/T (BTRA)
Oil Capacity
Oil Specification
ApplicationDescription
GENERAL SPECIFICATIONS(CONT'D)
E20
E23
E32 Reduction Ratio

REAR DRIVE AXLE 3D-11
UNIT REPAIR
AXLE HOUSING
Preceding Work : Removal of the axle shaft
Removal of the axle housing
1 Drive Pinion Lock Nut......................240-310 Nm
2 Washer
3 Companion Flange
4 Pinion Oil Seal
5 Bearing Slinger
6 Bearing
7 Shim
8 Shim
9 Bearing Cup
10 Breather Nipple
11 Rear Axle Housing
12 Oil Drain Plug.......................................28-42 Nm
1 3 Shim
14 Bearing
15 Drive Pinion
16 Bearing Cap1 7 Bolt....................................................87-124 Nm
18 Bearing
1 9 Shim
20 Ring Gear
21 Shaft Lock Pin
22 Differential Case
23 Ring Gear Mounting Bolt......................75-90 Nm
24 Thrust Washer
25 Differential Pinion
26 Thrust Washer
27 Side Gear
28 Differential Shaft
29 Housing Cover
3 0 Bolt......................................................38-46 Nm
31 Oil Filler Plug.......................................28-42 Nm

REAR DRIVE AXLE 3D-13
5. Remove the drive pinion lock nut. Disassemble the parts of
the drive pinion.
Assembly Procedure
1. Clean the all parts and check the followings.
lCheck the ring gear and drive pinion for wear or damage.
If damaged, replace it as set.
lCheck the bearing for sticks, wear, noise or turning
resistance.
lCheck the side gear, pinion, pinion shaft and thrust
washer for wear or damage.
lCheck the differential carrier for crack or wear (bearing
contact surface). Check the gear case for crack.
2. Assemble the parts of the drive pinion.
3. Assemble the parts of the differential carrier.
Tightening Torque of The
Pinion Lock Nut240 - 310 Nm
Tightening Torque of The
Ring Gear Bolts75 - 90 Nm