brakes SSANGYONG MUSSO 2003 Owner's Manual

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. Check the cylinder and piston for wear, rust or damage.
Check the caliper body and guide pin for wear, damage
or crank.
Check the pads for uneven wear or oiliness.
Check the boots for damage or tear.
2. Measure caliper housing inner diameter.
Item
With PBR
With MANDO Wear Limit

61.4 mm
61.0 mm
Standard
10 mm Wear Limit
2.0 mm
Standard
60.4 mm
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 mm Wear 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 HoseCaliper Bolt
N 

 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 tires7 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
Standard10.4 mm Wear Limit
9.3 mm
UNIT REPAIR REAR DISC BRAKE Inspection Procedure
1. Clean all components and visually check the followings. Check the cylinder and piston for wear, rust or damage.
Check the caliper body and guide pin for wear, damage
or crank.
Check the pads for uneven wear or oiliness.
Check the boots for damage or tear.
Standard
40.5 mm
38.2 mm Wear Limit
41.5 mm
39.2 mm
2. Measure caliper housing inner diameter.
3. Measure pad thickness.
Standard
9.5 mm Wear 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

ANTILOCK BRAKE SYSTEM 4F-7
ABD SYSTEM DESCRIPTION
General: The Automatic Brake Differential Lock (ABD) is a traction system by means of brake intervention only, available in a low speed range (< 60kph). It workes on µ-split roads with sidewise different friction coefficients.
The spinning driven wheel is braked and the drive torque can be transferred to the wheel on the high- µ side.
During ABD active, the ABD information lamp is blinking.The temperature of the brakes is calculated by a mathematical model and ABD is switched passive if the calculated temperature is greater than a threshold value(500 °C).
ABD is permitted again, when the calculated temperature is less than 350 °C.
Control Algorithm: The input signals for the control algorithm are the filteredwheel speed signals from the ABS speed processing. With the speed difference of the driven wheels, the control deviation is calculated. If the control deviation exceeds a certain threshold value,
the wheel with the greater slip is braked actively. The threshold value depends on the vehicle speed:It is reduced with increasing vehicle speed down to a constant value.
Pressure Modulation: Depending on the control deviation and the wheel acceleration of the spinning wheel, pressure increase, hold and decrease are made.
The pressure modulation is done with the conventional control with the valves. ASV, USV, EV and AV according the the following table:
Speed Range: ABD is available in the speed range 60 kph.
Above 60 kph vehicle speed, ABD is passive. It is possible to initiate ABD operation up to a vehicle speed of 55kph.
Increase Open
Open
Open
ASV Decrease
Hold
Closed
Closed
Closed
Closed
Closed
Open
Open
Closed
Closed
USV
EVAV
Speed difference driven wheels [kph]
18
6 12 60ABD operation
Vehicle speed[kph]

4F-8 ANTILOCK BRAKE SYSTEM
Temperature Model:ABD operation is a high thermal load for the brakes.
To avoid any damages at the brakes, the disk temperature is calculated with a mathematical model for each driven
wheel separately. After ignition on, the calculation starts with 30 °C and then three different phases are evaluated
separately and added: ABD operation, braking and coling phase.If the temperature is highter than 500 °C, ABD is disabled for this wheel.
It is permitted again, if the model has calculated down the 350 °C.
Lamp Concepts: The system is equipped with an ABD information lamp, which is blinking during ABD operation.The activation of the EBD, ABS warning lamp and the ABD info lampo is summarized in the following table:
IgnitionON ABS
Operation ABD
Operation System failure
(EBD,ABS or ABD are
not distinguished) ABD passive due
to temperature
model
ABS warning lamp
ABD info lamp
EBD warning lamp 2s on for lamp
check
2s on for lamp check
2s on for lamp check OFF
EBD operation / OFFOFF
OFF
Dlinking
(Flashing)
OFF ON
OFF ON OFF OFF OFF

5-156 ELECTRICAL WIRING DIAGRAMS
31. STICS
1) POWER SUPPLY, GROUND, CHIME BELL, BUZZER, WARNING LAMP (PARK'GBRAKE, SEAT BELT) CIRCUIT Main - Engine Main - Engine Main Main MainMain
C101 (21Pin, Colorless)C103 (21Pin, White)
S201 (Black) S202 (Gray) G202 G205
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Behind The Cluster Behind The ClusterBeside The STICS Beside The TCCU
C101
W/H MAIN
CLUSTER
112
29 38
28
13 2021
39 434842
C103
W/H MAIN
KEY REMINDER SWITH
REKES CHIME
BELL
BUZZER MULTI-FUNCTIONSWITCH
SEAT BELT SWITCH
12312
123456123C1 C2
C3 C4
B1 B2 B3 B4
B5 B6 B7 B8 B9B10
A1 A2 A3 A4 A5 A6
A7 A8 A9A10 A11 A12 A13 A14
1234
B
F24
10AEf8
60AEf2
80A
F17
10AC103
1
G202
1
5
7 6
SIG
ILL
3 21
YL Y
RY
BrW
Rekes "4"
Illunination Relay
"S"
1
B+ 31
Multifunction
Switch"B6"
SIG2 27
11
Chime
Bell 2 1
L
RY12
Buzzer
3 1
YL
Stics
RY
1 2
S201 LW LW
29
IGN1
F22
10A
LB GY
17
BrB
16
Park'g Brake
Warning
Lamp Seat Belt
WariningLamp
18
Cluster
71 0
S202
Key
Reminder Swtich
5 B R
R
R
C101
5
Rekes"3"
SIG30
YG
5V
5VSIG28
5V
GY
Park'g
BrakeSwitch
G205
SIG22
5V
LW
Seat Belt Switch
B
2
1
Close
Open
30 BAT+
15 IGN 1
31 GND
BZ1
2