parking brake SSANGYONG MUSSO 2003 User Guide

3D-8 REAR DRIVE AXLE
Tightening Torque 50 - 65 Nm
6. Remove the plug from the axle shaft flange and remove theinner shaft mounting nuts. Installation Notice
7. Remove the axle shaft, parking brake lining and back plate assembly.
8. Installation should follow the removal precedure in the reverse order.

REAR DRIVE AXLE 3D-9
AXLE Removal & Installation Procedure
1. Lift up the vehicle and support the frame safely.
2. Remove the axle shaft.
Tightening Torque 150 - 180 Nm
3. Remove the propeller shaft from the rear axle input shaft.
Installation Notice Notice Place alignment marks before removal.
Tightening Torque 81 - 89 Nm
4. Disconnect the parking brake cable and brake hose.
5. Remove the lower arm mounting nuts and remove the lower arm from the axle housing. Installation Notice

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-2Increasing 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 thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless 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
Specification PBR Brake
4.3 : 1
132 mm
23.81 mm
5.0 : 1
60.4 mm

40.5 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 Fluid MANDO Brake
4.3 : 1
138 mm
25.4 mm
5.6 : 1
60 mm
Solid Disc
38.2 mm
10.0 mm 10.4 mm
Application

HYDRAULIC BRAKES 4A-3
Check
Air in Brake system Fluid LeakingExcessive Clearance Between Push Rod and M/cylinder Parking Brake is not Fully Released Incorrect Adjustment of Parking BrakeWeak Return Spring of Brake PedalIncorrect Pedal FreeplayBroken Rear Drum Brake Shoe Return Spring Lack of Lubrication
Damaged Master Cylinder Check Valve or Piston Return Spring Action
Bleeding
RepairAdjust
Repair Adjust
Replace
Repair
Replace
lubricate Replace
INCREASING PEDAL STROKE (PEDAL GOES TO FLOOR)
OR BRAKE DRAGGING
Check
Insufficient Clearance Between Push Rod and Master Cylinder Worn Brake Lining Oil or Grease on Lining Binding Parking Brake CableFaulty Auto AdjusterExcessive Lever Stroke Action
Adjust
Replace Replace ReplaceReplace
Adjust or Check Cable
POOR BRAKING OF PARKING BRAKE

SECTION 4G
PARKING BRAKE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4G-1General Specifications . . . . . . . . . . . . . . . . . . 4G-1
Fastener Tightening Specifications . . . . . . . . . 4G-1
Component Locator . . . . . . . . . . . . . . . . . . . 4G-2 TABLE OF CONTENTS
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
Maintenance and Repair . . . . . . . . . . . . . . . 4G-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4G-3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-3
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 thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Parking Brake Lever Bolt Cable Mounting Bracket Bolt
N 

 m
8 - 18 8 - 18
FASTENER TIGHTENING SPECIFICATIONS
Application
Type
Operating Type
Description
Mechanically Operated Rear Wheel Expansion Manual

4G-2 PARKING BRAKE
COMPONENT LOCATOR
PARKING BRAKE
1 Parking Brake Lever
2 Praking Brake Lamp Switch
3 Bolt
4 Bolt ........................................................ 8-18 Nm
5 Front Parking Brake Cable
6 Equalizer 7 Nut
8 Bolt
........................................................ 8-18 Nm
9 Rear Parking Brake Cable
10 Brake Drum (if Equipped with Rear Drum Brake) 11 Brake Disc (if Equipped with Rear Disc Brake)

PARKING BRAKE 4G-3
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE PARKING BRAKE Removal & Installation Procedure
1. Disconnect the parking brake indicator switch connector.
2. Disconnect the right and left cable from equalizer whileparking brake lever is released.
3. Unscrew 8 bolts and remove the parking brake lever assembly. Installation Notice Notice
Tighten the bolts with sequence number while the lever is pulled up 4 to 6 notches.
Tightening Torque 8 - 18 Nm
4. Unscrew the frame and lower arm side cable mounting bracket bolts. Installation Notice
Tightening Torque 8 - 18 Nm

4G-4 PARKING BRAKE
5. Remove the retainer with a screwdriver and disconnect thebrake cable.
6. Installation should follow the removal procedure in the reverse order.

5A-42 AUTOMATIC TRANSMISSIONPOWER TRAIN SYSTEM
The Power Train System consists of: A torque converter with single face lock-up clutch
Four multi-plate clutch assemblies
Two brake bands
Two one-way clutches
Planetary gearset
Parking mechanism
A conventional six pinion Ravigneaux compound planetary gearset is used with overdrive (fourth gear) being obtained
by driving the carrier.
The cross-sectional arrangement is very modular in nature. Four main sub-assemblies are installed within the case
to complete the build. These sub-assemblies are: Gearset-sprag-centre support
C1 -C2-C3-C4 clutch sub-assembly
Pump assembly
Valve body assembly
One, or a combination of selective washers are used between the input shaft flange and the number 4 bearing to
control the transmission end float. This arrangement allows for extensive subassembly testing and simplistic finalassembly during production.
A general description of the operation of the Power Train System is detailed below. Refer to table 4.1 and figure 4.1.
First gear is engaged by applying the C2 clutch and locking the 1-2 One Way Clutch (1-2 OWC). The 1-2 shift is
accomplished by applying the B1 band and overrunning the 1-2 OWC. The 2-3 shift is accomplished by applying the
C1 clutch and releasing the B1 band. The 3-4 shift is accomplished by re-applying the B1 band and overrunning the
3-4 OWC. Reverse gear is engaged by applying the C3 clutch and the B2 band.
The C4 clutch is applied in the Manual 1,2 and 3 ranges to provide engine braking. In addition, the C4 clutch is also
applied in the Drive range for second and third gears to eliminate objectionable freewheel coasting. The B2 band is
also applied in the Manual 1 range to accomplish the low-overrun shift.
Both the front and rear servos are dual area designs to allow accurate friction element matching without the need for
secondary regulator valves. All the friction elements have been designed to provide low shift energies and high static
capacities when used with the new low static co-efficient transmission fluids. Non-asbestos friction materials are used throughout.
Gear
First
Second ThirdFourth
Reverse
Manual 1 Gear
Ratio 2.741 1.508 1.0000.7082.4282.741 C1
XX C2
X X XX X C3
X C4
X X B1
X X X B2
X X 1-2
OWC X 3-4
OWC X XX LU
CLUTCH
X*X
ELEMENTS ENGAGED
* For Certain Vehicle Applications, Refer to the Owner's Manual.
Table 4.1 - Engaged Elements vs Gear Ratios

AUTOMATIC TRANSMISSION 5A-79
ADJUSTMENTS
HYDRAULIC SYSTEM
The procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a
defect symptom, indicates that there is a fault in the hydraulic system.
When making adjustments to the transmission, select the appropriate procedures from the following preliminary checks. Conduct a transmission fluid test procedure, refer to section 7.2.
Check the manual linkage adjustment (refer to the vehicle workshop manual).
Check engine idle speed (refer to Section 7.3).
Conduct a stall test (it is outside the scope of this publication to detail this procedure)
conduct a road test (it is outside the scope of this publication to detail this procedure).
TRANSMISSION FLUID TEST PROCEDURE
Checking Transmission Fluid Level
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in
gearshift loss or delay if driven when the vehicle is cold.
The vehicle is first checked for transmission diagnostic messages (refer to section 6). If the vehicle has a speedo fault
it is possible for the oil level to be low.
The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of
drive. One symptom of low oil level is a momentary loss of drive when driving the vehicle around a comer. Also when
the transmission fluid level is low, a loss of drive may occur when the transmission oil temperature is low.
If there is no loss of drive when the vehicle is driven warm and a speedo fault is registered, then fluid should be addedto the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (A TF) or other approved
fluids. The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded. Do not underfill the transmission. Incorrect tilling may cause damage to the transmission. The fluid level setting
procedure is detailed below. Notice
When a transmission is at operating temperature hot transmission fluid may come out of the case if the fill plug is
removed. 9 the transmission is at operating temperature allow two hours for cooling prior to removing the plug.
1. If the vehicle is at operating temperature allow the vehicle to cool down for two, but no greater than four hours before adding transmission fluid (this will allow the transmission to be within the correct temperaturerange).
While hot the ATF level is higher and removing the plug may result in oil being expelled from the filler hole. This
will result in the level being low.
2. The transmission selector is to be in Park. Switch the engine off.
3. Raise the vehicle on a hoist (or leave over a service pit).
4. Clean all dirt from around the service fill plug prior to removing the plug. Remove the oil service fill plug. Clean the fill plug and check that there is no damage to the ‘O’ ring.
Install the filler pump into the filler hole.
5. Lower the vehicle with the filler pump still connected and partially fill the transmission.
Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.