SSANGYONG MUSSO 1998 Workshop Repair Manual

FRONT DISC BRAKES 4D-3
Removal & Installation Procedure
1. MANDO Brake
Tightening Torque 25 - 35 Nm
2. PBR Brake
Remove the eye-hose bolt and disconnect the hose.
Installation Notice
Tightening Torque 15 - 18 Nm
3. Remove the wheel speed sensor (for ABS vehicies).
Installation Notice
Tightening Torque 6 - 8 Nm
4. Remove the mounting bolts and then caliper assembly.
Installation Notice
Tightening Torque 85 - 105 Nm
Remove the hose mounting nut and disconnect the hose.
Installation Notice

4D-4 FRONT DISC BRAKES
5. Pull out the brake pads. Replace pads if necessary.
Notice
Always change the all pads on one wheel at a time.
6. Installation should follow the removal procedure in the
reverse order.
7. Bleed the air from the system.

FRONT DISC BRAKES 4D-5
4. Measure rotor disc thickness.
UNIT REPAIR
FRONT DISC BRAKE
Inspection Procedure
1. Clean all components and visually check the followings.
lCheck the cylinder and piston for wear, rust or damage.
lCheck the caliper body and guide pin for wear, damage
or crank.
lCheck the pads for uneven wear or oiliness.
lCheck the boots for damage or tear.
2. Measure caliper housing inner diameter.
Item
With PBR
With MANDOWear Limit
f 61.4 mm
f 61.0 mm
Standard
10 mmWear Limit
2.0 mm
Standard
f 60.4 mm
f 60.0 mm
3. Measure pad thickness.
Notice
Always change the all pads on one wheel at a time.
5. Check the rotor disc for score or runout.
Standard
24 mmWear Limit
22 mm

SECTION 4E
REAR DISC BRAKES
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4E-1
Fastener Tightening Specifications . . . . . . . . . 4E-1
Maintenance and Repair . . . . . . . . . . . . . . . 4E-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4E-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Caliper Mounting Bolt
Brake Hose
Caliper BoltN
· ·· ·
·m
85 - 105
15 - 18
20
Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-2
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-4
Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-4

4E-2 REAR DISC BRAKES
1 Rear Brake Disc Assembly
2 Brake Pad
3 Brake Caliper
4 Gasket ................................................... Replace
5 Bolt........................................................... 20 Nm
6 Gasket ................................................... Replace
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
REAR DISC BRAKE
Preceding Work : Removal of wheels and tires
7 Brake Hose
8 Gasket ................................................... Replace
9 Eye-hose Bolt......................................15-18 Nm
10 Washer
11 Bolt....................................................85-105 Nm

REAR DISC BRAKES 4E-3
Tightening Torque 15 - 18 Nm
Tightening Torque 85 - 105 Nm
Removal & Installation Procedure
1. Remove the eye-hose bolt and disconnect the hose.
Installation Notice
2. Unscrew the mounting bolts and remove the brake caliper
assembly.
Installation Notice
3. Pull out the brake pads. Replace pads if necessary.
Notice
Always change the all pads on one wheel at a time.
4. Installation should follow the removal precedure in the
reverse order.
5. Bleed the air from the system.

4E-4 REAR DISC BRAKES
Standard
10.4 mmWear Limit
9.3 mm
UNIT REPAIR
REAR DISC BRAKE
Inspection Procedure
1. Clean all components and visually check the followings.
lCheck the cylinder and piston for wear, rust or damage.
lCheck the caliper body and guide pin for wear, damage
or crank.
lCheck the pads for uneven wear or oiliness.
lCheck the boots for damage or tear.
Standard
f40.5 mm
f38.2 mmWear Limit
f41.5 mm
f39.2 mm
2. Measure caliper housing inner diameter.
3. Measure pad thickness.
Standard
9.5 mmWear Limit
2.0 mm
Notice
Always change the all pads on one wheel at a time.
4. Measure rotor disc thickness.
5. Check the rotor disc for score or runout.
Item
With PBR
With MANDO

Front
Rear
Front
Rear
SECTION 4F
ANTILOCK BRAKE SYSTEM
TABLE OF CONTENTS
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.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Model
ECUNumber of Pins
Operating Temperature
Motor Operating Current
Solenoid Coil Resistance
External Resistance
Air Gap
Number of teethDescription
ABS 5.3
31
-40 ~ +120°C
Below MAX 40A
1.28KW - 1.92KW
0.35 - 1.60 mm
0.15 - 1.20 mm
52
52ABS/ABD 5.3
83
-40 ~ +85°C
Below MAX 45A
8.04 - 9.04W except AV,
HSV 4.04 - 4.54W
1.28KW - 1.92KW
0.35 - 1.60 mm
0.15 - 1.20 mm
52
52 Hydraulic System
Wheel Speed Sensor
Impulse Ring
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4F-1
General Specifications . . . . . . . . . . . . . . . . . . 4F-1
Schematic and Routing Diagrams . . . . . . . . 4F-2
ABS 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-2
ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-3
ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-4
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-5
Component Locator . . . . . . . . . . . . . . . . . . . 4F-6
ABS, ABS/ABD . . . . . . . . . . . . . . . . . . . . . . . . 4F-6
ABD System Description . . . . . . . . . . . . . . . 4F-7Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . 4F-11
Defect Codes . . . . . . . . . . . . . . . . . . . . . . . . 4F-13
Maintenance and Repair . . . . . . . . . . . . . . 4F-19
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 4F-19
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . 4F-19
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . 4F-21
ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-21
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . 4F-24

4F-2 ANTILOCK BRAKE SYSTEM
ABS 5.0
SCHEMATIC AND ROUTING DIAGRAMS
5.0W
5.0W
30A
30A ENG

ANTILOCK BRAKE SYSTEM 4F-3
ABS/ABD 5.0
ABD ACTIVE