1997 SSANGYONG KORANDO brake rotor

0B -- 14 GENERAL INFORMATION
D AEW OO M Y_2000
EACH TIME THE OIL IS CHANGED
Brake System Inspection
This inspection should be done when the wheels are re-
moved for rotation. Inspect the lines and the hoses for
proper hookup, binding, leaks, cracks, chafing, etc. In-
spect the disc brake pads for wear. Inspect the rotors for
surface condition. Inspect other brake parts, the parking
brake, etc., at the same time. Inspect the brakes more
often if habit or conditions result in frequent braking.
Steering, Suspension and Front Drive Axle
Boot And Seal Inspection
Inspect the front and rear suspension and the steering
system for damaged, loose or missing parts, signs of
wear or lack of lubrication. Inspect the power steering
line and the hoses for proper hookup, binding, leaks,
cracks, chafing, etc. Clean and inspect the drive axle
boot and seals for damage, tears or leakage. Replace
the seals if necessary.
Exhaust System Inspection
Inspect the complete system (including the catalytic
converter if equipped). Inspect the body near the ex-
haust system. Look for broken, damaged, missing, or
out -- of -- position parts as well as open seams, holes,
loose connections, or other conditions which could
cause heat buildup in the floor pan or could let exhaust
fumes seep into the trunk or passenger compartment.
Throttle Linkage Inspection
Inspect the throttle linkage for interference or binding,
damaged, or missing parts. Lubricate all linkage joints
and throttle cable joints, the intermediate throttle shaft
bearing, the return spring at throttle valve assembly, and
the accelerator pedal sliding face with suitable grease.
Check the throttle cable for free movements.
Engine Drive Belts
Inspect all belts for cracks, fraying, wear and proper ten-
sion. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the sec-
ondary latch. It should keep the hood from opening all
the way when the primary latch is released. The hood
must close firmly.
AT LEAST ANNUALLY
Lap and Shoulder Belts Condition and Operation
Inspect the belt system including: the webbing, the
buckles, the latch plates, the retractor, the guide loops
and the anchors.
Movable Head Restraint Operation
On vehicles with movable head restraints, the restraints
must stay in the desired position.
Spare Tire and Jack Storage
Be alert to rattles in the rear of the vehicle. The spare
tire, all the jacking equipment, and the tools must be se-
curely stowed at all times. Oil the jack ratchet or the
screw mechanism after each use.
Key Lock Service
Lubricate the key lock cylinder.
Body Lubrication Service
Lubricate all the body door hinges including the hood,
the fuel door, the rear compartment hinges and the
latches, the glove box and the console doors, and any
folding seat hardware.
Underbody Flushing
Flushing the underbody will remove any corrosive mate-
rials used for ice and snow removal and dust control. At
least every spring clean the underbody. First, loosen the
sediment packed in closed areas of the vehicle. Then
flush the underbody with plain water.
Engine Cooling System
Inspect the coolant and freeze protection fluid. If the
fluid is dirty or rusty, drain, flush and refill the engine
cooling system with new coolant. Keep the coolant at
the proper mixture in order to ensure proper freeze
protection, corrosion protection and engine operating
temperature. Inspect the hoses. Replace the cracked,
swollen, or deteriorated hoses. Tighten the clamps.
Clean the outside of the radiator and the air conditioning
condenser. Wash the filler cap and the neck. Pressure
test the cooling system and the cap in order to help en-
sure proper operation.

SUSPENSION DIAGNOSIS 2A-3
SSANGYONG MY2002
Perform a rack bearing preload adjustment.
Replace the seals and the hoses, as needed.
Lubricate the steering gear. Repair or replace the
steering gear, as needed.
Tighten the steering gear mounting bracket nuts and
the bolts. Check the steering gear preload adjustment.
Check the hydraulic system. Test the power steering
system pressure with a gauge.
Inspect for binding or catching in the steering gear.
Inspect for a loose steering gear mounting.Action ChecksBalance the tire or the wheel.
Measure the hub flange runout. Replace the hub, as
needed.
Adjust the brakes. Replace the brake rotor, as needed.
Replace the outer tie rods.
Balance the wheel.
Replace the lower ball joint.
Measure the wheel runout. Replace the wheel, as
needed.
Match-mount the tire and the wheel assembly. Inspect for an out-of-balance tire or wheel.
Inspect for excessive wheel hub runout.
Inspect for excessive brake rotor imbalance.
Inspect for worn tie rod ends.
Inspect for wheel trim imbalance.
Inspect for a worn lower ball joint.
Inspect for excessive wheel runout.
Inspect for excessive loaded radial runout on the tire
and the wheel assembly.Action ChecksAction
Balance the tire or the wheel. Checks
Inspect for an out-of-balance tire or wheel.Align the front and the rear wheels.
Adjust the toe on the front and the rear wheels.
Replace the spring.
Balance the tires.
Rotate the tires. Replace the tires, as needed.
Maintain the proper load weight.
Inflate the tires to the proper pressure. Check the front-wheel and the rear-wheel alignment.
Inspect for excessive toe on the front and the rear wheels.
Inspect for a broken or a sagging spring.
Inspect for out-of-balance tires.
Check for a failure to rotate tires.
Check for an overloaded vehicle.
Inspect for low tire inflation.
Abnormal or Excessive Tire Wear
Shimmy, Shake, or Vibration
Hard Steering
Wheel Tramp
Action Checks

SUSPENSION DIAGNOSIS 2A-7
SSANGYONG MY2002
KAA2A010
HUB AND BEARING
Perform the following test to check for looseness in
the hub and bearing assembly:
1. Raise and suitably support the vehicle.
2. Remove the rear wheel. Refer to Section 2E, Tires
and Wheels.
3. Remove the caliper and the disc brake rotor. Refer
to Section 4E, Rear Disc Brakes.
4. Mount a dial indicator set with a magnetic base to
a stationary part of the vehicle.
5. Push and pull the wheel hub by hand. If the wheel
hub movement exceeds 0.03 mm (0.001 inch),
replace the hub and bearing assembly. Refer to
Section 2D, Rear Suspension.
6. Install the caliper and the disc brake rotor. Refer
to Section 4E, Rear Disc Brakes.
7. Install the rear wheel. Refer to Section 2E, Tires
and Wheels.
8. Lower the vehicle.

SSANGYONG MY2002
2B-6 WHEEL ALIGNMENT
VIBRATION DIAGNOSIS
Wheel imbalance causes most highway speed vibration
problems. A vibration can remain after dynamic balanc-
ing because:
A tire is out of round
A rim is out of round
A tire stiffness variation exists
Measuring tire and wheel free runout will uncover only
part of the problem. All three causes, known as loaded
radial runout, must be checked using method of substi-
tuting known good tire and wheel assemblies on the
problem vehicle.
Tire Balancing
Balance is the easiest procedure to perform and should
be done first if the vibration occurs at high speeds. Do
an off-vehicle, two-plane dynamic balance first to
correct any imbalance in the tire and wheel assembly.
An on-vehicle finish balance will correct any brake drum,
rotor, or wheel cover imbalance, If balancing does not
correct the high-speed vibration, or if the vibration oc-
curs at low speeds, runout is the probable cause.
Preliminary Checks
Prior to performing any work, always road test the car
and perform a careful visual inspection for:
Obvious tire and wheel runout.
Obvious drive axle runout.
Improper tire inflation.
Incorrect trim height.
Bent or damaged wheels.
Debris build-up on the tire or the wheel.
Irregular or excessive tire wear.
Improper tire bead seating on the rim,
Imperfections in the tires, including: tread deforma-
tions, separations, or bulges from impact damage.
Slight sidewall indentations are normal and will not
affect ride quality.
KAA2B040

TIRE AND WHEELS 2E-7
SSANGYONG MY2002
KAA2E030
1. Mount the wheel and tire assembly.
2. Install the wheel nuts in the sequence shown. Do
not tighten the wheel nuts .
Installation Notice
Tightening Torque120 Nm (89 lb-ft)
3. Lower the vehicle.
4. Install the wheel cover.
ON-VEHICLE BALANCING
On-vehicle balancing will help correct vibrations due to
brake drum, rotor, and wheel cover imbalances.
Notice: Do not allow the front suspension to hang free.
When the drive axle is run at an extreme angle, extra
vibrations can occur, as well as damage to seals and
joints.
1. During on-vehicle balancing, do not remove the
bal-ance weights from the off-vehicle dynamic
balance.
2. If more than 28.4 grams (1 ounce) of additional
weight is required, split the weight between the inner
and the outer rim flanges.
Caution: Do not spin the drive wheels faster than
55 km/h (35 mph) as indicated by the
speedometer. This limit is necessary because
the speedometer indicates only one-half of the
actual wheel speed when one drive wheel is
spinning and the other drive wheel is stopped.
Personal injury and damage may result from
high-speed spinning.
3. Spin the driven tire and wheel assemblies using
the engine.

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.

HYDRAULIC BRAKES 4A-15
SSANGYONG MY2002
Front Disc Brake Rotor
Type
Diameter
Thickness (New)
Discard Thickness
Thickness Variation
Lateral Runout (Installed)
Light Scoring of the Rotor Surface
Rear Disc Brake Rotor
Type
Diameter
Thickness (New)
Discard Thickness
Thickness Variation
Lateral Runout (Installed)
Booster
Dual
Ratio
Master Cylinder
Bore Diameter (Nominal)
Caliper
Minimum Piston Diameter (Front)
Minimum Piston Diameter (Rear)
Pad and lining
Front
Thickness (New)
Minimum Discard Thickness
Rear (Disc)
Thickness (New)
Minimum Discard ThicknessApplication
Ventialated
278.30
24.00
22.00
0.013
0.03
0.40
Solid
299.00
10.40
8.50
0.013
0.03
-
7 : 1
25.40
60.00
38.00 (42.9)
10.00
2.00
9.50
1.50
E32
SPECIFICATIONS
GENERAL SPECIFICATION
mm in
Application
Capacity
LublicantDescription
0.7
(0.7 qt)
DOT 4
10.96
0.95
0.87
0.0005
0.001
0.002
11. 77
0.41
0.33
0.0005
0.001
8″
& 9″
-
1.00
2.36
1.50
0.39
0.08
0.39
0.06

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