SSANGYONG MUSSO 1998 Workshop Repair Manual

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

MASTER CYLINDER 4B-3
Removal & Installation Procedure
1. Remove the oil level sensor connector.
2. Remove the tube from the master cylinder.
Installation Notice
Notice
lBe careful not to drop the oil when removing the tube.
lIf the oil is dropped, promptly sweep up.
3. Remove the booster vacuum hose.
Notice
lConnect fully to the end of vacuum hose when installing.
4. Loosen the nut of master cylinder.
Installation Notice
5. Remove the clevis pin and disconnect the pedal and brake
booster push rod.
Notice
lInstall in the upper hole when PBR brake.
lConnect the snap pin in the hole of clevis pin fully.
lApply the grease around the hole of clevis pin.
Tightening Torque 14 - 22 Nm
Tightening Torque 15 - 19 Nm

4B-4 MASTER CYLINDER
6. Loosen the nut of booster and remove the booster from the
dash panel.
Installation Notice
Tightening Torque 8 - 18 Nm
7. Installation should follow the removal procedure in the
reverse order.
8. Add the fluid and bleed.
9. If necessary, adjust the pedal height, pedal stroke and free
play.

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

POWER BOOSTER 4C-3
Removal & Installation Procedure
1. Remove the oil level sensor connector.
2. Remove the tube from the master cylinder.
Installation Notice
Notice
lBe careful not to drop the oil when removing the tube.
lIf the oil is dropped, promptly sweep up.
3. Remove the booster vacuum hose.
Notice
lConnect fully to the end of vacuum hose when installing.
4. Loosen the nut of master cylinder.
Installation Notice
5. Remove the clevis pin and disconnect the pedal and brake
booster push rod.
Notice
lInstall in the upper hole when PBR brake.
lConnect the snap pin in the hole of clevis pin fully.
lApply the grease around the hole of clevis pin.
Tightening Torque 14 - 22 Nm
Tightening Torque 15 - 19 Nm

4C-4 POWER BOOSTER
6. Loosen the nut of booster and remove the booster from the
dash panel.
Installation Notice
Tightening Torque 8 - 18 Nm
7. Installation should follow the removal procedure in the
reverse order.
8. Add the fluid and bleed.
9. If necessary, adjust the pedal height, pedal stroke and free
play.

POWER BOOSTER 4C-5
PEDAL STROKE INSPECTION
1. Start the engine and stop it after one or two minutes.
Depress the brake pedal several times.
If the pedal goes down furthest the first time, but gradually
rises after the second or third time, brake booster is normal.
If there is no change in pedal stroke, the brake booster is
abnormal.
2. Depress the brake pedal several times with engine stopped,
and depress the brake pedal and start the engine. If the
pedal goes down slightly, the booster is normal.
3. Depress the brake pedal with engine running, and stop it
with the pedal depressed. If there is no change in pedal
height during 30 sec., the booster is normal.

SECTION 4D
FRONT DISC BRAKES
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4D-1
Fastener Tightening Specifications . . . . . . . . . 4D-1
Maintenance and Repair . . . . . . . . . . . . . . . 4D-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4D-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Caliper Mounting Bolt
Brake Hose Bolt & Nut
Caliper BoltN
· ·· ·
·m
85 - 105
25 - 35
22 - 34
Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-2
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5
Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-5

4D-2 FRONT DISC BRAKES
1 Eye-Hose Bolt......................................25-35 Nm
2 Gasket ................................................... Replace
3 Brake Hose
4 Brake Caliper
5 Bolt........................................................... 20 Nm
6 Washer
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
FRONT DISC BRAKE
Preceding Work : Removal of wheels and tires
7 Front Disc Assembly
8 Brake Pad
9 Brake Hose and Nut.............................25-35 Nm
10 Gasket ................................................... Replace
11 Washer
1 2 Bolt....................................................85-105 Nm