brakes SSANGYONG MUSSO 2003 User Guide

4A-8 HYDRAULIC BRAKES
For Hydraulic Unit Replacement
1. Add oil after hydraulic unit replacement.
2. Run the engine and depress the pedal several times tobuild pressure and then keep the pedal fully depressed.
3. Loosen hydraulic pipe screws at the hydraulic unit 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 from the wheels if pressure building is not enough by pressing the pedal only after above air bleeding.

HYDRAULIC BRAKES 4A-9
BRAKE PEDAL1 Clevis Pin
2 Brake Pedal
3 Stop Lamp Switch
4 Pad
5 Nut ....................................................... 21-35 Nm
6 Yoke Pin
7 Fulcrum Pin
8 Return Spring
9 Pedal Mounting Bracket
10 Washer 11 Nut ....................................................... 16-32 Nm
12 Bolt ........................................................ 8-18 Nm
13 Stopper Bolt .............................................. Adjust
14 Rubber Pad ........................................... Replace

4A-10 HYDRAULIC BRAKES
Removal & Installation Procedure
1. Remove the stop lamp switch connector.
2. Remove the clevis pin and disconnect the brake boosterpush rod. Notice
Install in the upper hole (1), in case of Mando brake and
in the below hole (2), incase of PBR brake.
Install the snap pin fully in the hole of clevis pin.
Apply the grease around the hole of clevis pin.
3. Loosen the nut (4EA) and bolt (2EA) and remove the brake pedal.
4. Installation should follow the removal procedure in reverse order.
Tightening Torque 8 - 18 Nm

HYDRAULIC BRAKES 4A-11
Adjustment Procedure
1. Pedal HeightNotice If pedal height is not in specified value, loosen the stop lamp nut (B) and adjust the pedal height.
2. Pedal Stroke
Height (A) 150 mm (From the carpet)
Notice If pedal stroke is not in specified value, loosen the stop bolt and lock nut (F) and adjust the pedal stroke.
3. Free Play
Stroke (C) Mando : 138 mm
PBR : 132mm
Notice
To adjust, depress the brake pedal several times until there is no more vacuum left in the vacuum line.
To adjust, loosen the lock nut (D) of the push rod and turn the rod.
Free Play (E) 1 - 4 mm
Inspection Procedure
1. Inspect the wear of bushing.
2. Inspect the warp and bend of brake pedal.
3. Inspect the return spring of brake pedal.
4. Inspect the conductivity when connecting the tester to the stop lamp switch connector.

4A-12 HYDRAULIC BRAKES
LCRV (LOAD CONSCIOUS REDUCING VALVE)1 Brake Tube (from the master cylinder)
2 Brake Tube (from the rear brake)
3 LCRV Bracket
4 Bolt ........................................................... 12 Nm
5 LCRV Assembly
6 Connecting Link
7 Spring Washer
8 Nut ....................................................... 14-18 Nm

HYDRAULIC BRAKES 4A-13
Construction LCRV consists of sensing part and hydraulic control part.
1. Sensing PartIt detects the changes of vehicle height caused by vehicle load. It consists of load sensing spring and control leverwhich change according to vehicle load.
2. Hydraulic Control Part It consists of valve stem devices which controls hydraulicpressure according to load detected by sensing part.
Trouble Shooting Poor Braking Possible Cause
Air in Brake System Poor Adjustment of Sensor SpringDamaged Sensor SpringFluid Leaking from LCRV Remedy
Bleeding Adjust
Replace Replace
Possible Cause
Poor Adjustment of Sensor Spring Internal Fluid Leaking of LCRV Remedy
Adjust
Replace
Abnormal Locking

4A-14 HYDRAULIC BRAKES
LCRV SETTING METHOD
1. LCRV setting should be performed with unladen vehiclecondition.
2. Install the connecting rod (a) to the No.1 hole.
Tightening Torque 14 - 18 Nm
3. Adjust the clearance “X” to be 0 mm and tighten the bolt (c) using the lock nut (b).
Tightening Torque 14 - 18 Nm
4. Remove the connecting rod (a) from the No.1 hole and reinstall it to the No. 2 hole.
5. Place alignment marks between the lock nut (b) and adjusting screw (c) after the valve setting.

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 & NutCaliper Bolt
N 

 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 tires7 Front Disc Assembly
8 Brake Pad
9 Brake Hose and Nut ............................. 25-35 Nm
10 Gasket ................................................... Replace
11 Washer
12 Bolt .................................................... 85-105 Nm

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