1997 SSANGYONG KORANDO oil

REAR AXLE 3D-15
SSANGYONG MY2002
11. Remove the stabilizer bar.
KAA3D320
KAA3D330
KAA3A350
KAA3A340
12. Remove the lateral rod mounting nut and detach
the lateral rod from the axle housing.
13. Lowering the axle slowly, remove the coil spring
& spring seat.
14. Lower the axle housing by using the safety jack.
Installation
1. Placing the rear axle housing on the assembly
position, install both coil springs.

SSANGYONG MY2002
3D-16 REAR AXLE
KAA3D360
KAA3D370
KAA3D390
KAA3D380
2. Install the lateral rod in axle hosing.
Notice: Do not tighten the nuts completely.
Installation Notice
3. Install the shock absorber in axle housing.
Installation Notice
Tightening Torque30 - 45 Nm
(22 - 33 lb-ft)
Tightening Torque150 - 180 Nm
Tightening Torque70 - 80 Nm
(52 - 59 lb-ft) 4. Install the stabilizer bar and upper/lower arm in
axle housing
Installation Notice
5. Install the propeller shaft of rear axle side and
tighten above the fixing bolts/nuts.
Installation Notice
6. Install the brake cable, air bleeder hose, oil pipe,
LCRV unit in rear axle assembly with assembled
completely.
Installation Notice
7. Bleeding the air in brake, install the tire.30 - 45 Nm
(22 - 33 lb-ft)
150 - 180 Nm
(111 - 133 lb-ft)
150 - 180 Nm
(111 - 133 lb-ft)
Stabilizer bar cap bolt
Upper arm nut
Lower arm nut
12 - 23 Nm
(9 - 17 lb-ft)
6 - 8 Nm
(53 - 71 lb-in)
15 - 19 Nm
(11 - 14 lb-ft)LCRV Mounting Bolt
Air Breather Hose Bolt
Brake Oil Pipe (M10)

REAR AXLE 3D-19
SSANGYONG MY2002
1 Drive Pinion Lock Nut
...........................240 - 310 Nm (177 - 229 lb-ft)
2 Washer
3 Companion Flange
4 Pinion Oil Seal
5 Bearing Slinger
6 Bearing
7 Shim
8 Shim
9 Bearing Cup
10 Breather Nipple
11 Rear Axle Housing
12 Oil Drain Plug............ 28 - 42 Nm (21 - 31 lb-ft)
13 Shim
14 Bearing
15 Drive Pinion
16 Bearing Cap17 Bolt......................... 87 - 124 Nm (64 - 94 lb-ft)
18 Bearing
19 Shim
20 Ring Gear
21 Shaft Lock Pin
22 Differential Case
23 Ring Gear Mounting Bolt
.................................. 75 - 90 Nm (55 - 66 lb-ft)
24 Thrust Washer
25 Differential Pinion
26 Thrust Washer
27 Side Gear
28 Differential Shaft
29 Housing Cover
30 Bolt............................ 38 - 46 Nm (28 - 34 lb-ft)
31 Oil Filler Plug............ 28 - 42 Nm (21 - 31 lb-ft)

SSANGYONG MY2002
3D-20 REAR AXLE


DIFFERENTIAL GEAR ASSEMBLY
Disassembly
1. Remove the drain plug and drain oil. Reinstall the
drain plug.
Installation Notice
KAA3D450
KAA3D470
KAA3D460
KAA3D480
Tightening Torque28 - 42 Nm
(21 - 31 lb-ft)
2. Remove the axle housing cover.
Notice: Clean the cover and housing contact
surface.
3. Remove the bearing cap bolts and remove the
bearing cap. Pull out the differential carrier
assembly.
Notice: Do alignment marks on the bearing cap
not to change the caps before removal. When pulling
out, be careful to damage the axle housing.
4. Disassemble the parts of differential carrier
assembly.

REAR AXLE 3D-25
SSANGYONG MY2002
KAA3D670
KAA3D660
DRIVE SHAFT
Tools Required
661 589 15 33 00 Rear Hub Bearing Installer
661589 18 33 00 Axle Bearing Puller Plate
661 589 18 33 01 Rear Axle Bearing Remover
661 589 18 33 02 Rear Axle Oil Seal Remover
Disassembly Procedure
1. Remove the rear drive shaft from the vehicle. Refer
to “Rear Drive Shaft” in this section.
2. Remove the toothed ring using the axle bearing
puller plate 661 589 18 33 00 and rear axle bearing
remover 661 589 18 33 01 by press.
3. Remove the rear drive shaft oil seal bearing using
the axle bearing puller plate 661 589 18 33 00 and
rear axle oil seal remover 661 589 18 33 02 by
press.
4. Remove the rear disc brake rotor shield.
3. Install the retainer drive shaft bearing using the
rear hub bearing installer 661 589 15 33 00 by press.
4. Install the rear drive shaft. Refer to “Rear Drive
Shaft” in this section.
KAA3D690
KAA3D680
Assembly Procedure
1. Install the rear disc brake rotor shield.
2. Install the rear drive shaft bearing oil seal using
the rear hub bearing installer 661 589 15 33 00 by
press.

SSANGYONG MY2002
3D-26 REAR AXLE
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
661 589 13 33 00
Ball Joint Remover
661 589 18 33 00
Axle Bearing Puller
Plate
KAA3D700
KAA3D710
KAA3D720
661 589 18 33 02
Rear Axle Oil Seal
Remover
661 589 15 33 00
Rear Hub Bearing
Installer
661 589 18 33 01
Rear Axle Bearing
Remover
KAA3D740
KAA3D750
KAA3D760
J-8059
Snap Ring Plier
DW340-090-01
Differential Assembly
Remover/InstallerDW340-090-03
Rear Differential
Assembly
Remover/Installer
KAA3D730KAA3D770

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.