1997 SSANGYONG KORANDO Pedal

SSANGYONG MY2002
4C-4 POWER BOOSTER
DIAGNOSTIC INFORMATION AND PROCEDURES
KAA4C020
2. Push the pedal down and hold in this position.
3. Start the engine.
4. The booster is OK if the pedal drops further because
of extra force produced.
If the brake pedal does not drop, the vacuum system
(vacuum hoses, check valve, etc.) is probably
defective and should be checked. If no defect is
revealed by checking the vacuum system, the defect
is in the booster itself.POWER BOOSTER FUNCTIONAL
CHECK
1. With the engine stopped, eliminate vacuum in the
booster by pumping the brake pedal several times.

POWER BOOSTER 4C-5
SSANGYONG MY2002
REPAIR INSTRUCTIONS
KAA4C030
KAA4A040
KAA4C050
ON-VEHICLE SERVICE
POWER BOOSTER ASSEMBLY
Removal and Installation Procedure
1. Remove the master cylinder. Refer to Section 4B,
Master Cylinder.
2. Remove the vacuum hose from the booster.
3. Remove the clevis pin and disconnect the pedal
and brake booster push rod.
Installation Notice:
•Apply the grease around the hole of clevis pin.
4. Remove the power booster mounting nuts and re-
move the booster from the dash panel.
Installation Notice
Tightening Torque 17 Nm (13 lb-ft)
Install the new gasket.
5. Installation should follow the removal procedure
in the reverse order.

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.

FRONT BRAKES 4D-5
SSANGYONG MY2002





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DIAGNOSTIC INFORMATION AND PROCEDURES
KAA4D020
PAD INSPECTION
1. Raise and suitably support the vehicle.
2. Remove the front wheel. Refer to Section 2E, Tires
and Wheels.
3. Visually check the linings for minimum thickness
and wear.
4. Measure the thickness.
Important: The minimum discard thickness of the
lining is 2 mm (0.08 inch).
5. Install the pads in axle sets only.
6. Install the rear wheels. Refer to Section 2E, Tires
and Wheels.
7. Lower the vehicle.
FRONT DISC BRAKE ROTOR
INSPECTION
Thickness variation can be checked by measuring the
thickness of the rotor at four or more points around the
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the
rotor.
A rotor that varied by more than 0.013 mm (0.0005
inch) can cause pedal pulsations and/or front end
vibration during brake applications. A rotor that does
not meet these specifications should be refinished to
specifications or replaced.
During manufacturing, the brake rotor and the toler-
ances of the braking surface regarding flatness, thick-
ness variation, and lateral runout are held very close.
The maintenance of close tolerances on the shape of
the braking surfaces is necessary to prevent brake
roughness.In addition to these tolerances, the surface finish must
be held to a specified range. The control of the braking
surface finish is necessary to avoid pulls and erratic
performance and to extend lining life.
Light scoring of the rotor surfaces not exceeding 0.4
mm (0.016 inch) in depth, which may result from normal
use, is not detrimental to brake operation.
Using a commercially available dial indicator, check
lateral runout as follows:
Notice: Permissible lateral runout is a maximum 0.07
mm (0.003 inch). If lateral runout exceeds the specifica-
tion, ensure that there is no dirt between the rotor and
the hub and that contact surfaces are smooth and free
from burrs.
1. Position the transaxle in NEUTRAL.
2. Remove the rotor. Refer to “Rotor” in this section.
3. Fasten the brake rotor to the wheel hub with two
wheel nuts. Refer to Section 2E, Tires and Wheels.
KAA4D030
4. Fasten a dial indicator to the brake caliper.
5. Set the gauge probe tip to approximately 10 mm
(0.394 inch) from the outer edge of the brake rotor,
perpendicular to the disc and under slight preload.
6. Remove the dial indicator and the wheel nuts that
connect the rotor to the hub.
Important: Since accurate control of the tolerances
is necessary for proper performance of the disc
brakes, refinishing of the rotor should be done only
with precision equipment.
7. Refinish the rotor, if required, with precision equip-
ment. Discard the rotor if it fails to meet the above
specifications after refinishing.
8. Install the rotor. Refer to “Rotor” in this section.

FRONT BRAKES 4D-7
SSANGYONG MY2002
KAA4D060
KAA4D070
CALIPER ASSEMBLY
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 brake hose mounting nut and
disconnect the hose. Plug the openings in the
caliper and the brake hose to prevent fluid loss
and contamination.
Installation Notice
Tightening Torque 30 Nm (22 lb-ft)
4. Remove the caliper mounting bolts and then
remove the caliper assembly.
Installation Notice
Tightening Torque 95 Nm (70 lb-ft)
Bleed the caliper. Refer to Section 4A, Hydraulic
Brakes.
Notice: do not move the vehicle until a firm pedal
is obtained or improper braking action will result.
Repeatedly press the brake pedal to bring the
pads in contact with the rotor.
5. Installation should follow the removal procedure
in the reverse order.
SPLASH SHIELD
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. Refer to “Front
Disc Brake Rotor” in this section.
5. Remove the splash shield bolt.
Installation Notice
KAA4D090
Tightening Torque 6 Nm (53 lb-ft)
6. Installation should follow the removal procedure
in the reverse order.

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

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

REAR BRAKES 4E-7
SSANGYONG MY2002
Max. 0.07 mm
Max. 0.03 mm
2. If lateral run out exceeds the specification, replace
the brake disc to prevent the pedal’s vibration at
braking.
YAD4C090
YAD4C100
Brake Disc Thickness
1. Measure the thickness of the rotor at four or more
points around the circumference of the disc.
2. If the thickness of the brake disc is below the
specified value, replace the brake disc.
Disc Thickness Limit 8.5 mm
Brake Disc Run Out
1. Set a dial indicator to the brake disc side and
measure the run out by rotating the disc.
On-Vehicle
Disc only
Run Out Limit