maintenance SSANGYONG MUSSO 1998 Workshop Workshop Manual

Diesel
Gasoline
(M161)
Gasoline
(M162) Diesel
GasolineApplication
Joint Type
Number of Spider
FrontFront
Rear
Front
Rear
Front (Full-Time)
Front (Part-Time)
Rear
Front
Rear
SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3C-1
General Specifications . . . . . . . . . . . . . . . . . . 3C-1
Component Locator . . . . . . . . . . . . . . . . . . . 3C-2
M/T & A/T (Part-time T/C) . . . . . . . . . . . . . . . . 3C-2
Maintenance and Repair . . . . . . . . . . . . . . . 3C-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 3C-3
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description
Single or Single & Double Cardan
Single Cardan
Constant Velocity(CV) & Double Carden
Single Cardan
3
2
2
CV Joint : 1, Double Spiders : 1
2
Diesel
Gasoline
Shaft Dimensions
(L´O.D´I.D)
When Compressed
FullyFront
Rear
Front
Rear
Front
Rear-
-
-
M/T & MB A/T
BTRA A/T (2p-Type)
TONGIL
KSC
-576´f59.5´f63.5
973´
f63.5´f659.5
583.5´
f44.7´f50.8
973´
f63.5´f459.5
380.8´
f63.5´f59.5
591.5´
f63.5´f59.5
601.6´
f50.8´f44.7
579.6´
f50.8´f44.7
776.8´
f63.5´f59.5

PROPELLER SHAFT 3C-3
1 Front Axle
2 Bolt......................................................70-80 Nm
3 Front Propeller Shaft (661LA/662LA)
4 Front Propeller Shaft (E32)
5 Bolt......................................................81-89 Nm
6 Transfer Case
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
PROPELLER SHAFT
7 Bolt......................................................81-89 Nm
8 Rear Propeller Shaft
9 Bolt......................................................70-80 Nm
10 Rear Axle
11 Front Propeller Shaft (E20/E23)

SECTION 3D
REAR DRIVE AXLE
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3D-1
General Specifications . . . . . . . . . . . . . . . . . . 3D-1
Fastener Tightening Specifications . . . . . . . . . 3D-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3
Noise (During Straight Driving) . . . . . . . . . . . . 3D-3
Oil Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3
Noise (During Turning) . . . . . . . . . . . . . . . . . . 3D-3
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-4Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-4
Component Locator . . . . . . . . . . . . . . . . . . . 3D-5
Maintenance and Repair . . . . . . . . . . . . . . . 3D-6
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 3D-6
Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-6
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3D-11
Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3D-11
LSD (Limited Slip Diffrential) . . . . . . . . . . . . . 3D-16
SPECIFICATIONS
GENERAL SPECIFICATIONS
Axle Shaft Type
Axle Housing Type
Differential
Reduction Ratio
Type
Gear
M/T
M/T
A/T (MB)
M/T
A/T (BTRA)
M/T
A/T (BTRA)
Description
Semi - floating
Salibury (Build-up)
Conventional Type
Hypoid Gear
4.55
4.55
3.73
4.55
5.38
4.27
4.89Application
661NA
662NA
661LA
662LA

3D-6 REAR DRIVE AXLE
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
AXLE SHAFT
1 Brake Disc
2 Dust Plug
3 Rear Axle Shaft
4 Nut .......................................................50-65 Nm
5 Washer
6 Parking Brake Cable7 Parking Brake Lining and Back Plate Assembly
8 Caliper Assembly
9 Gasket
1 0 Bolt....................................................85-100 Nm
11 Rear Axle Housing

SECTION 4A
HYDRAULIC BRAKES
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
General Specifications . . . . . . . . . . . . . . . . . . 4A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Noise or Vehicle Vibration When Applied
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Pulls to One Side When Braking . . . . . . . . . . . 4A-2
Poor Braking . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Increasing Pedal Stroke (Pedal Goes to
Floor) or Brake Dragging . . . . . . . . . . . . . . . 4A-3
Poor Braking of Parking Brake . . . . . . . . . . . . 4A-3
TABLE OF CONTENTS
Component Locator . . . . . . . . . . . . . . . . . . . 4A-4
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4
ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Non-ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Maintenance and Repair . . . . . . . . . . . . . . . 4A-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4A-7
Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . 4A-7
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
LCRV (Load Conscious Reducing Valve) . . . 4A-12
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this
cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK
unless otherwise noted.
Type
Pedal Ratio
Pedal Stroke
Pedal Freeplay
Type
Inner Diameter
Type
Ratio
Type
I.D. of Caliper Cylinder
Thickness of Brake Pad
Thickness of Disc Plate
Type
I.D. of Caliper Cylinder
Thickness of Brake Pad
Thickness of Disc Plate
Type
Operation
SpecificationPBR Brake
4.3 : 1
132 mm
f23.81 mm
5.0 : 1
f60.4 mm
¬
f40.5 mm
9.5 mm
¬ Suspended
1 - 4 mm
Tandem Type with Lever Sensor
Vacuum Booster Type
Ventilated Disc
10 mm
24 mm
Rear Wheel Internal Expansion Type
Mechanical
SAE J1703, DOT3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Brake Pedal
Master Cylinder
Brake Booster
Front Brake
Rear Brake
Parking Brake
Brake FluidMANDO Brake
4.3 : 1
138 mm
f25.4 mm
5.6 : 1
f60 mm
Solid Disc
f38.2 mm
10.0 mm
10.4 mm
Application

HYDRAULIC BRAKES 4A-7
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BLEEDING THE BRAKES
For Master Cylinder Replacement
1. Add oil after master cylinder replacement.
2. Run the engine and depress the brake pedal several times
to build pressure and then keep the pedal fully depressed.
3. Loosen the screws of primary and secondary pipe at the
master cylinder outlets to bleed air.
4. Repeat above step No.3 several times until there are no
more air bubbles.
5. Bleed air in the system at the hydraulic unit outlet pipe and
wheel if pressure building is not enough by depressing the
pedal only after above air bleeding.
For Caliper and Brake Hose Replacement
1. Check the oil level from the oil reservoir and refill if necessary.
2. Run the engine and depress the pedal several times to
build pressure and then keep the pedal fully depressed.
3. Connect a vinyl tube to the caliper breather and prepare a
container to coentain brake oil.
4. Loosen the breather screw until there are no more bubbles.
5. Bleed air in the system at four (4) wheels in order as shown
in right figure if pressure building is not enough by depressing
the pedal after above air bleeding.
Tightening Torque
9 - 14 Nm
Item
Front Bleeder Screw
Rear Bleeder Screw
Notice
lDo not reuse the bled brake fluid.
lAlways bleed the air after replacing brake fluid or
master cylinder, caliper, brake hose and pipe.
lAlways operate in normal order.

SECTION 4B
MASTER CYLINDER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Fastener Tightening Specifications . . . . . . . . . 4B-1
Maintenance and Repair . . . . . . . . . . . . . . . 4B-2
TABLE OF CONTENTS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Master Cylinder Nut
Booster NutN
· ·· ·
·m
14 - 22
8 - 18
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4B-2
Booster & Brake Master Cylinder . . . . . . . . . . 4B-2

4B-2 MASTER CYLINDER
1 Nut .......................................................14-22 Nm
2 Washer
3 Master Cylinder Assembly
4 Oil Level Sensor
5 Check Valve
6 Booster
7 Clevis Pin
8 Snap Pin9 Seal
10 Spacer
11 Nut .........................................................8-18 Nm
12 Front Tube (LH)
13 Front Tube (RH)
14 Rear Tube
15 1st Tube (Primary)
16 2nd Tube (Secondary)
MANDO
PBR
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER

SECTION 4C
POWER BOOSTER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
General Specifications . . . . . . . . . . . . . . . . . . 4C-1
Maintenance and Repair . . . . . . . . . . . . . . . 4C-2
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Type
RatioN
· ·· ·
·m
Vacuum Assisted
5.6 : 1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4C-2
Booster & Brake Master Cylinder . . . . . . . . . . 4C-2
Pedal Stroke Inspection . . . . . . . . . . . . . . . . . 4C-5

4C-2 POWER BOOSTER
1 Nut .......................................................14-22 Nm
2 Washer
3 Master Cylinder Assembly
4 Oil Level Sensor
5 Check Valve
6 Booster
7 Clevis Pin
8 Snap Pin
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER
9 Seal
10 Spacer
11 Nut .........................................................8-18 Nm
12 Front Tube (LH)
13 Front Tube (RH)
14 Rear Tube
15 1st Tube (Primary)
16 2nd Tube (Secondary)
MANDO
PBR