SSANGYONG MUSSO 2003 Service Manual

M/T M/TA/T (MB)M/TA/T (BTRA) M/T A/T (BTRA)M/TA/T (MB)M/T A/T (MB) A/T (BTRA)M/TA/T (MB)A/T (BTRA)
SECTION 3A
FRONT DRIVE AXLE
TABLE OF CONTENTSSPECIFICATIONS
GENERAL SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . .
3A-1
General Specifications . . . . . . . . . . . . . . . . . . 3A-1
Fastener Tightening Specifications . . . . . . . . . 3A-2
Component Locator . . . . . . . . . . . . . . . . . . . 3A-3
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-3
Auto-Locking Hub . . . . . . . . . . . . . . . . . . . . . . 3A-4
Vacuum Circuit . . . . . . . . . . . . . . . . . . . . . . . . 3A-5Maintenance and Repair . . . . . . . . . . . . . . .
3A-6
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 3A-6
Vacuum Line . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-6
Steering Knuckle and Drive Shaft . . . . . . . . . . 3A-8
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-14
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16
Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16
Application
Drive Shaft Type
Axle Housing Type
Differential TypeDifferential Gear
CV Joint
Build - up
Conventional
Hypoid Gear 4.56 4.56 3.734.565.384.27 4.89 4.894.554.554.55 5.86 3.733.734.89
1.4 L
SAE 80W/90, API GL - 5
Description
661NA 662NA 661LA662LA E20 E23 E32
Reduction Ratio Oil Capacity Oil Specification

3A-2 FRONT DRIVE AXLEFASTENER TIGHTENING SPECIFICATIONS
Steering Knuckle and Drive Shaft
Application
Drive Shaft to Front Axle Inner Shaft Wheel Speed Sensor Drive Shaft Cover Bolt
Locking Hub Washer ScrewHub Flange BoltHub Nut N
m
25 - 35
85 - 105 50 - 60 2 - 4
70 - 90
15

FRONT DRIVE AXLE 3A-3
1 Drive Shaft
2 Axle Housing Mounting Bolt
3 Axle Housing
4 Cross MemberCOMPONENT LOCATOR
FRONT AXLE5 Brake Disc
6 Hub-Wheel
7 Locking Hub

3A-4 FRONT DRIVE AXLE AUTO-LOCKING HUB
1 Cap
2 Filter
3 Vacuum Diaphragm
4 Diaphragm Retainer
5 Piston
6 Bolt (M10)
7 Lock Washer
8 O-ring
9 Retaining Ring
10 Clutch Ring 11 Body
12 Return Spring
13 Bearing
14 O-ring
15 Retaining Ring
16 Inner Drive Gear
17 Oil Seal
18 Oil Seal Race
19 Axle Retaining Ring

FRONT DRIVE AXLE 3A-5
VACUUM CIRCUIT
1 Engine
2 Vacuum Pump
3 3-way Connector
4 T-connector
5 Check Valve 6 Auto locking Hub Solenoid Valve
7 T-connector Hose
8 Hub Hose (left)
9 Hub Hose (right)

3A-6 FRONT DRIVE AXLEMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
VACUUM LINE
1 Vacuum Auto-locking Hub Assembly
2 Bolt ...................................................... 50-60 Nm
3 Cam Washer
4 Auto-locking Hub Cap
5 Retainer Ring
6 Shim
7 Locking Hub
8 Band
9 Hose (L : 400)
10 T-connector 11 Hose (L : 250, white)
12 Check V alve
13 Hose (L :100, green)
14 Auto Locking Hub Solenoid Valve
15 Bolt
16 Hose (L :100, green)
17 T-connector
18 Hose (L : 720, yellow)
19 Hose (L :2, 360 , red)
20 Corrugated Tube
21 Clip
22 Clip

FRONT DRIVE AXLE 3A-7
Removal & Installation Procedure
1. Be careful not to change the valve when connecting thecheck valve and each hose.
2. Adjust the clearance between the retainer ring (5) and locking hub (7) using the shim(6).
Notice Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0 mm
Normal Max. 0.2 mm
3. Tighten the auto locking hub cap bolt to the specified torque and order.
Tightening Torque 50 - 60 Nm

3A-8 FRONT DRIVE AXLE STEERING KNUCKLE AND DRIVE SHAFT1 Front Axle Inner Shaft
2 Front Axle Drive Shaft
3 Spring Washer
4 Bolt ...................................................... 45-60 Nm
5 Steering Knuckle

FRONT DRIVE AXLE 3A-9
Removal & Installation Procedure
1. Remove the tire.Installation Notice
Steel Wheel
Aluminum Wheel
Tightening Torque80 - 120 Nm
110 - 130 Nm
2. Remove the autolocking hub vacuum hose.
3. With ABS Remove the wheel speed sensor from the steering knuckle. Installation Notice
4. Remove the mounting bolts and pull off the caliper assembly. Installation Notice
Tightening Torque 6 - 8 Nm
Hose Bolt
Mounting Bolt
Tightening Torque25 - 35 Nm
85 - 105 Nm
Notice Be careful not to damage the brake hose.

3A-10 FRONT DRIVE AXLE
5. With part time transfer case. 5-1.Remove the cover mounting bolts and pull off the cover. Installation Notice
5-2. Remove the snap ring of the drive shaft and pull off the
hub body. Notice
For assembly, adjust the clearance between the snap ring and hub not to exceed 0.2 mm (Shim thickness : 0.1, 0.2,0.3, 0.5, 1.0 mm).
Tightening Torque 50 - 60 Nm
6. With full time transfer case
6-1. Detach the hub cap with screw driver and remove the snap ring on drive shaft. Installation Notice
Tightening Torque 2 - 4 Nm
5-3. Remove the screws and pull off the locking hub washer.
Installation Notice Notice
For assembly, adjust the clearance between the snap ring and hub not to exceed 0.2 mm (Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0 mm).
Tightening Torque 15 Nm