1998 SSANGYONG MUSSO Workshop Repair Manual

REAR DRIVE AXLE 3D-7
Removal & Installation Procedure
1. Remove the tire.
Installation Notice
2. Release the parking brake.Steel Wheel
Aluminum Wheel
Tightening Torque
3. Remove the bolts and the brake caliper.
Installation Notice
Be careful not to damage the brake hose.
Tightening Torque 85 - 100 Nm
4. Remove the brake disc.
Notice
To remove the disc, install the bolts (M8 x 1.25) into the
service hole and uniformly tighten the bolts.
5. Disconnect the parking brake cable.
80 - 120 Nm
110 - 130 Nm

3D-8 REAR DRIVE AXLE
Tightening Torque 50 - 65 Nm
6. Remove the plug from the axle shaft flange and remove the
inner shaft mounting nuts.
Installation Notice
7. Remove the axle shaft, parking brake lining and back plate
assembly.
8. Installation should follow the removal precedure in the
reverse order.

REAR DRIVE AXLE 3D-9
AXLE
Removal & Installation Procedure
1. Lift up the vehicle and support the frame safely.
2. Remove the axle shaft.
Tightening Torque 150 - 180 Nm 3. Remove the propeller shaft from the rear axle input shaft.
Installation Notice
Notice
Place alignment marks before removal.
Tightening Torque 81 - 89 Nm
4. Disconnect the parking brake cable and brake hose.
5. Remove the lower arm mounting nuts and remove the lower
arm from the axle housing.
Installation Notice

3D-10 REAR DRIVE AXLE
6. Separate the lower shock absorber from the axle housing.
Installation Notice
7. Remove the upper arm mounting nuts and remove the
upper arm form the axle housing.
Installation Notice
Tightening Torque 50 - 65 Nm
8. Remove the stabilizer bar.
Installation Notice
Tightening Torque 150 - 180 Nm
9. Remove the lateral rod mounting nuts and remove the
lateral rod from the axle housing.
Installation Notice
Tightening Torque 30 - 45 Nm
10. Lowering the axle housing slowly, remove the coil springs
and spring seats.
11. Installation should follow the removal precedure in the
reverse order.
Tightening Torque 150 - 180 Nm

REAR DRIVE AXLE 3D-11
UNIT REPAIR
AXLE HOUSING
Preceding Work : Removal of the axle shaft
Removal of the axle housing
1 Drive Pinion Lock Nut......................240-310 Nm
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
1 3 Shim
14 Bearing
15 Drive Pinion
16 Bearing Cap1 7 Bolt....................................................87-124 Nm
18 Bearing
1 9 Shim
20 Ring Gear
21 Shaft Lock Pin
22 Differential Case
23 Ring Gear Mounting Bolt......................75-90 Nm
24 Thrust Washer
25 Differential Pinion
26 Thrust Washer
27 Side Gear
28 Differential Shaft
29 Housing Cover
3 0 Bolt......................................................38-46 Nm
31 Oil Filler Plug.......................................28-42 Nm

3D-12 REAR DRIVE AXLE
Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall the drain
plug.
2. Remove the axle housing cover.
Notice
Clean the cover and housing contact surface.
3. Remove the bearing cap bolts and remove the bearing caps.
Pull out the differential carrier assembly.
Notice
Place alignment marks on the bearing cap not to change
the caps before removal. When pulling out the differential
carrier assembly, be careful not to damage the axle housing.
4. Disassemble the parts of the differential carrier assembly.
Tightening Torque 28 - 42Nm

REAR DRIVE AXLE 3D-13
5. Remove the drive pinion lock nut. Disassemble the parts of
the drive pinion.
Assembly Procedure
1. Clean the all parts and check the followings.
lCheck the ring gear and drive pinion for wear or damage.
If damaged, replace it as set.
lCheck the bearing for sticks, wear, noise or turning
resistance.
lCheck the side gear, pinion, pinion shaft and thrust
washer for wear or damage.
lCheck the differential carrier for crack or wear (bearing
contact surface). Check the gear case for crack.
2. Assemble the parts of the drive pinion.
3. Assemble the parts of the differential carrier.
Tightening Torque of The
Pinion Lock Nut240 - 310 Nm
Tightening Torque of The
Ring Gear Bolts75 - 90 Nm

3D-14 REAR DRIVE AXLE
4. Measure backlash of the side gear and pinion gear.
Specified Value 0 - 0.05 mm
5. Install the differential carrier assembly into the axle housing.
Tightening Torque of The
Bearing Cap Bolts48 - 69 Nm
Notice
Be careful no to change the caps. Be sure to keep the original
position of the caps.
6. Measure backlash of the drive pinion and ring gear.
7. Install the axle housing cover.
Specified Value 0.13 - 0.20 mm
Tightening Torque 39 - 46 Nm