1997 SSANGYONG KORANDO oil

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
4B-6 MASTER CYLINDER
YAD4A370
Remove the 1st piston and 2nd piston assembly
from the master cylinder assembly.
YAD4A380
YAD4A390
YAD4A400
Check the cylinder for excessive wear.
Notice:
Replace the cylinder assembly when there
occurs any damage or wear in the cylinder.
Clean the contaminated oil of the assembly.
Install the 1st piston and 2nd piston assembly
from the master cylinder assembly.
Installation Procedure
1. Install the retainer ring using the snap ring plier.
2. Install the master cylinder into the booster.
Installation Notice
Tightening Torque8 - 12 Nm
(71 - 106 lb-in)

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.

REAR BRAKES 4E-5
SSANGYONG MY2002
Lining Wear, Hardening
Oil or Water Contamination on the Lining
Inoperative Wheel Cylinder
Inoperative Clearance Automatic Control System
Lining Wear, Hardening
Oil or Water Contamination on the Lining
Inoperative Wheel Cylinder
Inoperative Clearance Automatic Control System
Damage of the Brake Shoe Return Spring
Inoperative Wheel Cylinder Returning
Lining Wear
Inoperative Clearance Automatic Control System
Lining Wear, Hardening
Foreign Material Inside Drum
Loosen the Brake Plate Bolt
Drum Deformation or Surface Damage
Lining Wear, Hardening
Oil Contamination on the Lining
Inoperative Clearance Automatic Control SystemReplace
Replace or Repair
Replace
Repair
Adjust
Replace or Repair
Replace
Repair
Replace
Replace
Replace
Repair
Replace
Clean
Tighten
Replace
Replace
Replace
Repair Poor Braking
Uneven Braking
Dragging Brake
Excessive Pedal Travel
Noise and Vibration When
Brake Applied
Inoperative Parking Brake
DIAGNOSTIC INFORMATION AND PROCEDURES
Symptom
Possible CauseAction

SSANGYONG MY2002
4E-6 REAR BRAKES





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INSPECTION
YAD4C060
YAD4C070
YAD4C080
Inside Diameter
φ 254 mmWear Limitφ 255.5 mm
DRUM BRAKE TYPE
1. Inspect the drum for crack or damage or defor-
mation.
2. Measure the inside diameter.
Measure two more position.
Brake Lining
1. Inspect the surface hardening or excessive wear
of the lining. Inspect the lining for stain with oil.
2. Measure the lining thickness.
Wear Limit 1 mm
If the measured value is below the limit value,
replace the brake lining.
DISC BRAKE TYPE
Pad Thickness
1. Remove the front wheel.
2. If the measured value is below the limit value,
replace the pad.
Wear Limit 2 mm

REAR BRAKES 4E-13
SSANGYONG MY2002
5. Disconnect the parking brake cable from the
parking brake lever.
6. Remove the brake disc.
7. Using the rubber hammer, hit to separate the
parking brake lining lightly and move the lining
upward.
Inspection
1. Clean the dissembled parts and visually check
the followings;
Wear, rust and damage on the cylinder and
piston
Damage, crack on the caliper body and
damage, wear on the guide pin
Pad uneven wear and oil contamination
Boot’s damage and tear
YAD4C160
YAD4C170
YAD4C180
YAD4C190