brake SSANGYONG MUSSO 2003 Owner's Guide

FRONT DRIVE AXLE 3A-11
8. Remove the hub and disk assembly.
9. Remove the disk brake dust shield.Installation Notice
Tightening Torque 4 - 6 Nm
6-2.Unscrew the bolts and remove hub flange. Installation Notice
Tightening Torque 70 - 90 Nm
Before installation, apply loctite on the mating surface.
7. Remove the hub nut with special tool.
Tightening Torque 15 Nm

3D-6 REAR DRIVE AXLEMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
AXLE SHAFT
1 Brake Disc
2 Dust Plug
3 Rear Axle Shaft
4 Nut ....................................................... 50-65 Nm
5 Washer
6 Parking Brake Cable
7 Parking Brake Lining and Back Plate Assembly
8 Caliper Assembly
9 Gasket
10 Bolt .................................................... 85-100 Nm
11 Rear Axle Housing

REAR DRIVE AXLE 3D-7
Removal & Installation Procedure
1. Remove the tire.Installation Notice
2. Release the parking brake. Steel Wheel
Aluminum Wheel
Tightening Torque
3. Remove the bolts and the brake caliper.
Installation Notice Be careful not to damage the brake hose.
Tightening Torque 85 - 100 Nm
4. Remove the brake disc. Notice
To remove the disc, install the bolts (M8 x 1.25) into the service hole and uniformly tighten the bolts.
5. Disconnect the parking brake cable.
80 - 120 Nm
110 - 130 Nm

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

4A-2 HYDRAULIC BRAKESCheck
Dirty or Lack of Fluid Air in Brake SystemFaulty Brake Booster Poor Contact of Pad or Lining Oil or Grease on PadFaulty Auto AdjusterOver Heated Rotor Due to Dragging Pad or LiningClogging Brake Line
Faulty Proportioning Valve Check
Incorrect Tire Pressure Between Left and Right Poor Contact of Pad or LiningOil or Grease is Applied to Pad or LiningBent or Uneven Wear of DrumIncorrectly Mounted Wheel Cylinder Faulty Auto Adjuster Action
Repair
Retighten Replace Replace
RepairRepair
Lubricate
Retighten
Check
Incorrectly Mounted Back Plate or CaliperLoosened Bolt of Back Plate or CaliperCrack or Uneven Wear of Brake Drum or DiscPad or Lining Sticking to Contact Surface Excessive Clearance Between Caliper and Pad Uneven Contact of PadLack of LubricationLoosened Suspension DIGNOSIS
NOISE OR VEHICLE VIBRATION WHEN APPLIED BRAKE
PULLS TO ONE SIDE WHEN BRAKING
Action Adjust
Repair
Replace Replace
Repair
Replace
Action
Replenish or Replace(Check eventual leakage) Bleeding
Replace
Repair
Replace Replace RepairRepair
Repair
POOR BRAKING
( If low cut-in : Adjust ) ( If Leakage : Replace )

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

4A-4 HYDRAULIC BRAKES
COMPONENT LOCATOR
ABS
1 Actuation Assembly (Booster+TMC)
2 ABS Control Unit
3 Master Cylinder 2nd Tube (Secondary)
4 Master Cylinder 1st Tube (Primary)
5 Front Tube (LH)
6 Front Tube (RH) 7 Brake Hose
8 Rear Tube
9 Bolt
...................................................... 25-35 Nm
10 2-way Connector 11 3-way Connector

HYDRAULIC BRAKES 4A-5
ABS / ABD1 Actuation Assembly (Booster+TMC)
2 Master Cylinder 1st Tube (Primary)
3 Master Cylinder 2nd Tube (Secondary)
4 Hydraulic Modulator
5 Front Tube (LH) 6 Front Tube (RH)
7 Rear Tube (RH)
8 Rear Tube (LH)
9 2-way Connector