1997 SSANGYONG KORANDO service

SECTION 3A
FRONT AXLE
TABLE OF CONTENTS
Specifications.......................................................3A-2
General Specifications.........................................3A-2
Fastener Tightening Specifications.......................3A-2
Component Locator.............................................3A-3
Front Axle Assembly ...........................................3A-3
Auto-Locking Hub................................................3A-4
Maintnance and Repair........................................3A-5
On-Vehicle Service.................................................3A-5
Vacuum Line........................................................3A-5Steering Knuckle and Drive Shaft.........................3A-7
Front Axle Assembly .........................................3A-12
Unit Repair.......................................................... 3A-16
Axle Housing.....................................................3A-16
Outer Joint Seal.................................................3A-23
Inner Tripot Seal................................................3A-24
Special Tools and Equipment............................ 3A-25
Special Tools Table............................................3A-25

FRONT AXLE 3A-5
SSANGYONG MY2002
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
VACUUM LINE
1 Hub A-Auto Vac Locking
2 Valve-Check
3 Valve A-Solenoid
4 Connector
5 House-Vcuum
6 Hose-Vacuum
7 Hose-Vacuum
8 Hose-Vacuum
9 Hose
10 Tube-corruagated
11 Clip
12 Band
KAA3A030
13 Clip
14 Bolt
15 Tube A-Vacuum
16 Clip-L/Hub Hose MTG
17 Cap-Hub Flange FRT
18 Flange-Hub FRT
19 Cap
20 Bolt
21 Washer
22 Ring-Retainer
23 Bolt

FRONT AXLE 3A-23
SSANGYONG MY2002
KAA3A550
KAA3A540
OUTER JOINT SEAL
Tools Required
J-8059Snap Ring Plier
Disassembly and Assembly Procedure
1. Remove the front drive shaft from the vehicle.
Refer to “Front Drive Shaft” in this section.
2. Remove the large seal retaining clamp.
3. Remove the small seal retaining clamp.
4. Degrease the joint.
Installation Notice:
Fill the joint seal with 135 to 155 g (4.76 to 5.46
ounces) of the recommended grease. Repack
the joint with 135 to 155 g (4.76 to 5.46 ounces)
of the recommended grease.
5. Spread the snap ring using the snap ring plier J-
8059 and remove the outer joint from the front drive
shaft.
Caution: Do not disassembly the outer joint
assembly. Parts are match fit and cannot be
serviced separately. Improper reassembly will
adversely affect both performance and safety.
6. Remove the seal from the joint assembly.

SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
Components Locator............................................3C-2
Diagnostic Information and Procedures...............3C-3
Propeller Shaft.....................................................3C-3
Repair Instructions................................................3C-4
On-Vehicle Service.................................................3C-4
Front Propeller Shaft............................................3C-4Rear Propeller Shaft.............................................3C-4
Unit Repair............................................................3C-6
Propeller Shaft.....................................................3C-6
Specifications.......................................................3C-7
Fastener Tightening Specifications.......................3C-7

SSANGYONG MY2002
3C-4 PROPELLER SHAFT
KAA3C070
KAA3C080
KAA3C060
ON-VEHICLE SERVICE
FRONT PROPELLER SHAFT
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the front propeller shaft-to-front axle
assembly bolts.
Installation Notice
REPAIR INSTRUCTIONS
Tightening Torque7.0 - 8.5 kgm
Make alignment marks on the front propeller
shaft and front axle housing.
3. Remove the front propeller shaft-to-transfer case
bolts.
Installation Notice
Tightening Torque8.1 - 8.9 kgm
4. Remove the front propeller shaft.
5. Installation should follow the removal procedure in
the reverse order.
REAR PROPELLER SHAFT
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the rear propeller shaft-to-rear axle assem-
bly bolts.
Installation Notice
Tightening Torque7.0 - 8.5 kgm
Make alignment marks on the rear propeller
shaft and rear axle housing.

SECTION 3D
REAR AXLE
TABLE OF CONTENTS
General Description and Operation.................3D-2
Specifications...................................................3D-2
Fastener Tightening Specifications..................3D-2
Diagnostic Information and Procedures........3D-3
Component Locator .........................................3D-4
Rear Axle Assembly .........................................3D-4
Cross Sectional View........................................3D-5
Rear Axle Shaft Assembly...............................3D-6
Maintenance and Repair..................................3D-8
On-Vehicle Service ..............................................3D-8Axle Shaft Assembly (With Disc Brake)..........3D-8
Axle Shaft Assembly (With Drum Brake)...... 3D-11
Rear Axle Housing .......................................... 3D-13
Unit Repair....................................................... 3D-18
Axle Assembly............................................... 3D-18
Differential Gear Assembly............................ 3D-20
Drive Shaft...................................................... 3D-25
Special Tools and Equipment....................... 3D-26
Special Tools Table........................................ 3D-26

SSANGYONG MY2002
3D-8 REAR AXLE
ON-VEHICLE SERVICE
AXLE SHAFT ASSEMBLY
(WITH DISC BRAKE)
Removal
1. Remove the tire.
KAA3D050
KAA3D070
KAA3D060
2. Release the parking brake.
3. Remove the fixing pin of parking brake.
4. After detaching the parking brake lever, detach
the cable.
5. Remove the two fixing bolt of brake caliper.
Notice: Be careful not to damage the brake oil
hose.
6. Remove the brake caliper assembly.
Notice: If replacing the brake pad only, remove the
upper fixing bolt of caliper pad and lower it.
MAINTENANCE AND REPAIR

REAR AXLE 3D-11
SSANGYONG MY2002










yyyyyyy yyyyyyy
yyyyyyy
yyyyyyy
yyyyyyy
yyyyyyy
yyyyyyy
yyyyyyy
yyyyyyy
yyyyyyy
yyyyyyy
AXLE SHAFT ASSEMBLY
(WITH DRUM BRAKE)
Removal
1. Release the parking brake.
2. Remove the tire.
KAA3D160
KAA3D170
KAA3D180
KAA3D190
3. Remove the brake drum.
Notice: Insert the bolt into the service hole, while
tightening the both side bolts uniformly, remove
the brake drum.
4. Remove the fixing pin of parking brake.
5. After detaching the cover of parking brake,
disconnect the cable.
6. After pulling out the two plastic plug of axle shaft
flange, remove the fixing nuts of inner bracket.