1997 SSANGYONG KORANDO oil level

SSAMGYONG MY2002
4A-2 HYDRAULIC BRAKES
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION
Brake fluid should meet the DOT 4 specification. Use
only clear fluid from a sealed container.
Fluid that is exposed to the air will absorb moisture.
Water in the brake fluid will cause the fluid to boil and
the rubber components to deteriorate.
Thoroughly clean the master cylinder reservoir cap be-
fore removing it. Do not let any dirt or foreign material
fall into the fluid reservoir.
There is a brake fluid level switch under the master
cylinder reservoir.When the fluid level is low, the BRAKE lamp in the
instrument cluster will turn on.
The correct brake fluid level is marked on the both
side of the brake fluid reservoir. If the fluid level is
below the MIN indicator mark, check the hydraulic brake
system for leaks. Fix any leaks. Then refill the reservoir
to the MAX indicator mark.
The hydraulic brake system is parallel split on Antilock
Brake Systems. This means the left front and left rear
brakes are on one hydraulic circuit and the right front
and right rear are on the other.

HYDRAULIC BRAKES 4A-3
SSANGYONG MY2002
DIAGNOSTIC INFORMATION AND PROCEDURES
BRAKE SYSTEM TESTING
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake perfor-
mance cannot be made if the roadway is wet, greasy,
or covered with loose dirt which can cause tires not to
grip the road unequally. Testing also will be inaccurate
on a crowned roadway because the wheels tend to
bounce.
Test the brakes at different vehicle speeds with both
light-and heavy-pedal pressure; however, avoid locking
the brakes and sliding the tires. Locked brakes and
slid-ing tires do not indicate brake efficiency since
heavily braked but turning wheels will stop the vehicle
in less distance than locked brakes. More tire-to-road
friction is present with a heavily braked, turning tire
than with a sliding tire.
Because of the high deceleration capability, a firmer
pedal may be felt at higher deceleration levels.
There are three major external conditions that affect
brake performance:
•Tires having unequal contact and grip of the road
will cause unequal braking. Tires must be equally
inflated, and the tread pattern of the right and the
left tires must be approximately equal.
Unequal loading of the vehicle can affect the brake
performance since the most heavily loaded wheels
require more braking power, and thus more braking
effort, than the others.
Misalignment of the wheels, particularly conditions
of excessive camber and caster, will cause the
brakes to pull to one side.
To check for brake fluid leaks, hold constant foot pres-
sure on the pedal with the engine running at idle and
the shift lever in NEUTRAL. If the pedal gradually falls
away with the constant pressure, the hydraulic system
may be leaking. Perform a visual check to confirm any
suspected leaks.
Check the master cylinder fluid level. While a slight
drop in the reservoir level results from normal lining
wear, an abnormally low level indicates a leak in the
system. The hydraulic system may be leaking either
internally or externally. Refer to the procedure below
to check the master cylinder. The system may appear
to pass this test while still having a slight leak. If the
fluid level is normal, check the vacuum booster pushrod
length. If an incorrect pushrod length is found, adjust
or replace the rod.Check the master cylinder using the following proce
dure:
Check for a cracked master cylinder casting or a
brake fluid leak around the master cylinder. Leaks
are indicated only if there is at least one drop of
fluid. A damp condition is not abnormal.
Check for a binding pedal linkage and for an
incorrect pushrod length. If both of these parts are
in satisfactory condition, disassemble the master
cylinder and check for an elongated or swollen
primary cylinder or piston seals. If swollen seals
are found, substandard or contaminated brake fluid
should be suspected. If contaminated brake fluid
is found, all the components should be
disassembled and cleaned, and all the rubber
components should be replaced. All of the pipes
must also be flushed.
Improper brake fluid, or mineral oil or water in the fluid,
may cause the brake fluid to boil or cause deterioration
of the rubber components. If the primary piston cups in
the master cylinder are swollen, the rubber parts have
deteriorated.
If deterioration of the rubber is evident, disassemble
all the hydraulic parts and wash the parts with alcohol.
Dry these parts with compressed air before reassembly
to keep the alcohol out of the system. Replace all the
rubber parts in the system, including the hoses. When
working on the brake mechanisms, check for fluid on
the linings. If excessive fluid is found, replace the
linings.
If the master cylinder piston seals are in satisfactory
condition, check for leaks or excessive heat conditions.
If these conditions are not found, drain the fluid, flush
the master cylinder with brake fluid, refill the master
cylinder, and bleed the system.
BRAKE HOSE INSPECTION
The hydraulic brake hoses should be inspected at least
twice a year. The brake hose assembly should be
checked for road hazard damage, cracks, chafing of
the outer cover, and for leaks or blisters. Inspect the
hoses for proper routing and mounting. A brake hose
that rubs on a suspension component will wear and
eventually fail. A light and a mirror may be needed for
an adequate inspection. If any of the above conditions
are observed on the brake hose, adjust or replace the
hose as necessary.

Description and Operation...................................4B-2
General Description.............................................4B-2
Component Locator.............................................4B-3
Repair Instructions................................................4B-4
On-Vehicle Service.................................................4B-4Brake Oil Level Switch .........................................4B-4
Brake Fluid Reservoir ...........................................4B-4
Master Cylinder...................................................4B-5
Specifications.......................................................4B-8
Fastener Tightening Specifications.......................4B-8
SECTION 4B
MASTER CYLINDER
TABLE OF CONTENTS

SSANGYONG MY2002
4B-2 MASTER CYLINDER
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION
The master cylinder is designed for use in a parallel
split system. One front and one parallel to rear brakes
are served by the primary piston. The opposite front
and rear brakes are served by the secondary piston.
The master cylinder incorporates the functions of the
standard dual master cylinder, plus a low fluid level
indicator. The brake fluid level switch is attached under
the body of the plastic brake master cylinder reservoir.
Notice: Do not use lubricated shop air on the brake
parts, because oil will damage the rubber components.Important:•Replace all the components included in the repair
kits used to service the master cylinder.
Lubricate the rubber parts with clean brake fluid to
ease assembly.
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.
The torque values specified are for dry, unlubricated
fasteners.
Perform all service operations on a clean bench,
free from all traces of mineral oil.

SSANGYONG MY2002
4B-4 MASTER CYLINDER
ON-VEHICLE SERVICE
BRAKE OIL LEVEL SWITCH
Removal and Installation Procedure
1. Disconnect the brake fluid level switch connector.
2. Disconnect the switch wiring connector.
3. Disconnect the switch from the brake oil tank.
4. Installation should follow the removal procedure
in the reverse order.
REPAIR INSTRUCTIONS
BRAKE FLUID RESERVOIR
Removal and Installation Procedure
Important: Remove the brake fluid reservoir only when
it must be replaced because of damage or leaks.
1. Disconnect the brake fluid level switch connector.
2. Drain the brake fluid.
KAA4B020
KAA4B020
KAA4B050
3. Remove the brake fluid reservoir fromthe master
cylinder body by tilting the reservoir and pulling
it up-ward.

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.

5A-38 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
DIAGNOSIS
BASIC KNOWLEDGE REQUIRED
You must be familliar with some basic electronics to
use this section of the Service Manual. They will help
you to follow diagnostic procedures.
Notice: Lack of the basic knowledge of this transmis-
sion when performing diagnostic procedures could re-
sult in incorrect diagnostic performance or damage to
transmission components. Do not, under any circum-
stances, attempt to diagnose a transmission problem
without this basic knowledge.
Notice: If a wire is probed with a sharp instrument
and not properly sealed afterward, the wire will corrode
and an open circuit will result.
Diagnostic test probes are now available that allow
you to probe individual wires without leaving the wire
open to the environment. These probe devices are
inexpensive and easy to install, and they permanently
seal the wire from corrosion.
Special Tools
You should be able to use a Digital Volt Meter (DVM),
a circuit tester, jumper wires or leads and a line
pressure gauge set. The functional check procedure
is designed to verify the correct operation of electronic
components in the transmission. This will eliminate the
unnecessary removal of transmission components.
FUNCTIONAL CHECK
PROCEDURE
Begin with the Functional Check Procedure which pro-
vides a general outline of how to diagnose automatic
transmission. The following functional check procedure
will indicate the proper path of diagnosing the transmis-
sion by describing the basic checks and then referenc-
ing the locations of the specific checks.
Check the fluid level according to the Fluid Level
Service Procedure.
Check the transmission fluid leak.
Check if the transmission fluid is not burnt by smell.
Notice: The specific fluid used in this transmission
turns brown during normal operation. Brown fluid
does not indicate a transmission fault.
Ensure that the transmission is not in Limp Home
Mode (LHM).
Check the battery terminals and the earth connec-
tions for corrosion or looseness.
Check that the cooler flow is not restricted.
Check all electrical plug connections for tightness.
Use on-board diagnostic tool or a scan tool to see
if any transmission trouble codes have been set.
DIAGNOSTIC INFORMATION AND PROCEDURES
Refer to the appropriate “Diagnostic Trouble Code
(DTC)” information and repair the vehicle as
directed. After repairing the vehicle, perform the
road test and verify that the code has not set again.
Perform the Electrical/Garage Shift Tests.
Perform the Road Test Procedure in this section.
Inspect the oil and check for metal or other contami-
nants in the oil pan.
TRANSMISSION FLUID LEVEL
SERVICE PROCEDURE
This procedure is to be used when checking a concern
with the fluid level in a vehicle. A low fluid level will
result in slipping and loss of drive/ reverse or delay on
engagement of drive/ reverse when the vehicle is cold.
The vehicle is first checked for transmission diagnostic
messages on the scan tool. If the oil level is low, it is
possible to register a vehicle speed signal fault.
The vehicle is to be test driven to determine if there is
an abnormal delay when selecting drive or reverse, or
loss of drive. One symptom of low fluid level is a
momentary loss of drive when driving the vehicle around
a corner. Also when the transmission fluid level is low,
a loss of drive may occur when the transmission fluid
temperature is low.
If there is no loss of drive when the vehicle is driven
warm and a vehicle speed signal fault is registered,
then fluid should be added to the transmission.
When adding or changing transmission fluid use only
Castrol TQ 95 automatic transmission fluid. The use of
incorrect fluid will cause the performance and durability
of the transmission to be severely degraded.
Fluid Level Diagnosis procedure
1. If the vehicle is at operating temperature allow the
vehicle to cool down for two hours, but no greater
than four hours. Or if the vehicle is at cool status,
start the engine and allow the engine to idle for
approximately 5 minutes or, if possible, drive the
vehicle for a few kilometers. This will allow the
transmission to be within the correct temperature
range. Transmission fluid level should be checked
at temperature 50 - 60 °C (82 - 140 °F).
Caution: Removal of the fluid filler plug when
the transmission fluid is hot may cause injury if
fluid drains from the filler hole.
2. With the brake pedal pressed, move the gear shift
control lever through the gear ranges, pausing a
few seconds in each range. Return the gear shift
control lever to P (Park). Turn the engine OFF.
3. Park the vehicle on a hoist, inspection pit or similar
raised level surface. The vehicle must be control
level to obtain a correct fluid level measurement.

5A-62 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Circuit Description
The Transmission Fluid Temperature (TFT) sensor is a
thermistor located in the solenoid wiring loom within
the valve body of the transmission. This sensor is a
typical Negative Temperature Coefficient (NTC) resistor
with low temperatures producing a high resistance and
high temperatures producing a low resistance.
If the transmission fluid temperature exceeds 135 °C
(275 °F), the TCM will impose converter lock-up at lower
vehicle speeds. Favour a lower gear to increase engine
speed, and in some vehicles flashes the mode indicator
lamp. This results in maximum oil flow through the exter-
nal oil cooler and eliminates slippage in the torque
converter. Both these actions combine to reduce the
oil temperature in the transmission.
The DTC P0710 sets when the TFT sensor signal is not
feasible.
Conditions for Setting the DTC
Transmission fluid temperature sensor signal is
greater than 4.88 volts (immediate detection).
Transmission fluid temperature sensor signal is less
than 0.21 volts (immediate detection).
Transmission temperature has not changed by 2 °C
in 15 minutes since ignition on and temperature is
less than 20 °C or greater than 125 °C.
Action Taken When the DTC Sets
Transmission fluid temperature is assumed to be
120 °C (248 °F).
All shifts will be firm until the transmission has
warmed up because a high transmission fluid
temperature is assumed.
DIAGNOSTIC TROUBLE CODE (DTC) P0710
TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT
MALFUNCTION
Conditions for Clearing the DTC
The DTC will clear when the malfunction has not oc
curred for 3 seconds.
A history DTC will clear after 40 TCM power-up cycles
with a warm transmission (>50 °C) and without a
fault.
History DTCs can be cleared by using a scan tool.
Diagnostic Aids
The voltage measured by the TCM across the trans-
mission fluid temperature input terminals has been
outside acceptable levels.
If the DTC sets when an accessory is operated,
check for a poor connection or excessive current
draw.
Inspect the wiring for poor electrical connections
at the TCM and at the 10-way transmission
connector. Look for possible bent, backed out,
deformed or damaged terminals. Check for weak
terminal tension as well. Also, check for chafed wires
that could short to bare metal or other wiring. Inspect
for broken wires inside the insulation.
In searching for a possible intermittent short or open
condition, move or massage the wiring harness
while observing test equipment for a change.
Test Description
The number(s) below refer to the step number(s) on
the Diagnostic Table.
5. This step simulates a DTC P0710 condition. If the
scan tool displays the specified value, the TFT
sensor signal circuit and the TCM are OK.
KAA5A5M0