1997 SSANGYONG KORANDO service

Description and Operation...................................4D-2
General Description..............................................4D-2
Brake Caliper.......................................................4D-2
Brake Pads..........................................................4D-2
Brake Rotor.........................................................4D-2
Component Locator.............................................4D-3
Front Brake Assembly.........................................4D-3
Caliper Assembly................................................4D-4
Diagnostic Information and Procedures..............4D-5
Pad Inspection....................................................4D-5
Front Disc Brake Rotor Inspection........................4D-5Repair Instructions................................................4D-6
On-Vehicle Service.................................................4D-6
Brake Pads.........................................................4D-6
Front Disc Brake Rotor .........................................4D-6
Caliper Assembly................................................4D-7
Splash Shield......................................................4D-7
Unit Repair............................................................4D-8
Brake Caliper......................................................4D-8
Specifications.....................................................4D-10
Fastener Tightening Specifications.....................4D-10
SECTION 4D
FRONT BRAKES
TABLE OF CONTENTS

SSANGYONG MY2002
4D-2 FRONT BRAKES
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION
When the brakes are applied, fluid pressure is sent to
each brake caliper. The pressure at the caliper is ex-
erted equally against the caliper piston. The pressure
applied to the piston is transmitted directly to the
inboard brake pad. This forces the pad against the inner
surface of the brake rotor. At the same time, fluid
pressure within the caliper piston bore forces the caliper
to slide inward on its guide pins. This action brings the
outboard pad into contact with the outer surface of the
brake rotor. This pressure on both sides of the brake
rotor causes friction, bringing the vehicle to a stop.
BRAKE CALIPER
The caliper has a single bore and is mounted to the
steering knuckle with two mounting bolts. Hydraulic
pressure, created by applying the brake pedal, is con-
verted by the caliper to a stopping force. This force
acts equally against the piston and the bottom of the
caliper bore to move the piston outward and to slide
the caliper inward, resulting in a clamping action on
the rotor. This clamping action forces the linings against
the rotor, creating friction to stop the vehicle.Important:
•Replace all components included in the repair kits
used to service the caliper.
Lubricate the rubber parts with clean brake fluid to
ease assembly.
Do not use lubricated shop air on brake parts, as
damage to the rubber components may result.
If any hydraulic component is removed or discon-
nected, it may be necessary to bleed all or part of
the brake system. Refer to Section 4F, Antilock
Brake System And Traction Control System.
Replace the pads in axle sets only.
The torque values specified are for dry, unlubricated
fasteners.
Perform the service operations on a clean bench,
free from all oily material.
BRAKE PADS
There are two brake pads mounted to each caliper, one
inboard and one outboard. As front disc brake pad wear,
master cylinder reservoir brake fluid level will drop. Fluid
level should be checked after replacing pads.
BRAKE ROTOR
Each front disc brake rotor is vented to help cool it dur-
ing and after brake applications.

SSANGYONG MY2002
4D-6 FRONT BRAKES
KAA4D080
FRONT DISC BRAKE ROTOR
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E,
Tires and Wheels.
3. Remove the hub bearing assembly. Refer to
Section 2C, Front Suspension.
4. Remove the front disc brake rotor.
5. Installation should follow the removal procedure in
the reverse order.
KAA4D040
REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE
BRAKE PADS
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Remove the front wheels. Refer to Section 2E,
Tires and Wheels.
3. Remove the caliper guide lower bolt.
Important: Caliper assembly removal is not
necessary to service the brake pad.
Installation Notice
Take care not to damage the piston seal when
the retaining frame is pulled down.
Tightening Torque 31 Nm (23 lb-ft)
KAA4D050
4. Remove the brake pads.
Installation Notice:
Measure the minimum brake pad thickness.
Refer to “Lining Inspection” in this section.
Always change the all pads on one wheel at a
time.
5. Installation should follow the removal procedure in
the reverse order.

SECTION 4E
REAR BRAKES
TABLE OF CONTENTS
Description and Operation...................................4E-2
Drum Brake.........................................................4E-2
Disc Brake..........................................................4E-3
Service Specifications ..........................................4E-4
Diagnostic Information and Procedures..............4E-5
Inspection.............................................................4E-6
Drum Brake Type.................................................4E-6
Disc Brake Type..................................................4E-6
Cross Sectional View ...........................................4E-8
Drum Brake (KDAC).............................................4E-8
Disc Brake..........................................................4E-9Component Locator...........................................4E-10
Drum Brake.......................................................4E-10
Disc Brake........................................................4E-11
Rerair Instructions..............................................4E-12
On-Vehicle Service...............................................4E-12
Disc Brake Assembly ........................................4E-12
Drum Brake Assembly .......................................4E-17
Unit Repair..........................................................4E-22
Wheel Cylinder..................................................4E-22
Parking Brake Lever...........................................4E-23
Specifications.....................................................4E-24
Fastener Tightening Specifications.....................4E-24

SSANGYONG MY2002
4E-2 REAR BRAKES
DESCRIPTION AND OPERATION
DRUM BRAKE
This drum brake assembly is a leading/trailing shoe
design.
Both brake shoes are held against the wheel cylinder
pistons by the lower return spring and the fixed anchor
plate near the lower return spring. When the brakes
are applied, the wheel cylinder pistons move both
shoes out to contact the drum. With forward wheel
rotation, the forward brake shoe will wrap into the drum
and become selt-energized. With reverse wheel
rotation, brake shoes is transferred to the anchor plate
through the braking plate to the axle flange.
Adjustment is automatic and occurs on any service
brake application. Do not switch the position of shoes
that have been in service, as this may render the self-
adjustment feature inoperative and result in increased
pedal travel.
The brake drum must have high abrasion resistance,
heatproof, high stiffness, fatigue stiffness and strength
enough not to make any deformation. The temperature
of the drum surface comes up to 500 - 700 °C on brake
operation by the friction with the lining. When the
temperature of the drum surface continues to keep
high, the friction coefficient goes down and the ‘fade
development’ occurs. When the brake is applied often
on the hill, any accident may be occur.
YAD4C010
Wheel Cylinder
Both wheel cylinder diameters are same in order to
balance the friction forces of both shoes.
The hydraulic pressure from the master cylinder is
provided to the wheel cylinder and the piston in the
wheel cylinder allows to push both shoes toward the
drum resulted in generating the braking force.
Brake Lining
The brake lining is installed with the brake shoe and
pushed toward the drum for applying the brake pedal.
Thus, lining must have high-heat tolerance, abrasion
resistance and high friction coefficient.
Brake Lining and Drum Clearance Automatic
Control System
If the lining’s wear is excessive, the piston moves to
long distance and the pedal travel increases. The
clearance between the drum and the brake lining
should be adjusted.
Generally the drum brake must be adjusted regularly
and thus the clearance automatic control system
enables to adjust the clearance between the brake
lining and the drum resulting from brake lining wear.
YAD4C020
1 Cylinder Housing
2 Boot
3 Spring
4 Piston Cup
5 Piston
6 Air Bleeder1 Cylinder Housing
2 Boot
3 Spring
4 Piston Cup
5 Piston
6 Air Bleeder

SSANGYONG MY2002
4E-4 REAR BRAKES
Application
Delphi Korea
-
-
-
-
φ 42 mm
10 mm
10.4 mm Drum I.D.
Shoe Type
Lining Width x Length x Thickness
Wheel Cylinder I.D.
Caliper Cylinder I.D.
Brake Pad Thickness
Disc Thickness
SERVICE SPECIFICATIONS
MANDO
-
-
-
-
φ 42.9 mm
10 mm
10.4 mmDisc Brake
Drum Brake
φ 254 mm
Leading and Trailing
55 x 243 x 4.7 mm
φ 23.81 mm
-
-
-

SSANGYONG MY2002
4E-12 REAR BRAKES
ON-VEHICLE SERVICE
DISC BRAKE ASSEMBLY
Removal Procedure
1. Remove the rear wheel.
Notice:
Park the vehicle on the flat ground and fix the
vehicle not to move it.
Release the parking brake.
Position the transmission in NEUTRAL.
2. Remove the brake hose from the rear brake
caliper.
Notice: Be carefully to prevent the brake fluid loss
and contamination.
3. Remove the caliper cylinder mounting bolt and
remove the disc pad and the cylinder.
YAD4C130
YAD4C140
RERAIR INSTRUCTIONS
4. Remove the caliper mounting bolt and remove the
caliper assembly.
YAD4C150

REAR BRAKES 4E-17
SSANGYONG MY2002










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DRUM BRAKE ASSEMBLY
1. Remove the tires
Notice:
Park the vehicle on the flat ground and fix the
vehicle not to move it.
Position the transmission in NEUTRAL.
2. Disconnect the brake pipe from the rear brake.
Notice: Be carefully to prevent the brake fluid loss
and contamination.
3. Insert the bolt (M8) to the service hole of the brake
drum and remove the brake drum.
4. Remove the service hole plug of the axle shaft.
YAD4C290
YAD4C300
YAD4C310
5. Remove the return spring.
(1) Disconnect the upper return spring.
(2) Disconnect the lower return spring.
(3) Disconnect the lever spring.
(4) Disconnect the adjuster lever from the adjuster.
YAD4C320