1998 SSANGYONG MUSSO Workshop Repair Manual

4A-6 HYDRAULIC BRAKES
NON-ABS/ABD
1 Actuation Assembly (Booster+TMC)
2 3-way Connector
3 Front Tube (LH)
4 Front Tube (RH)5 2-way Connector
6 Rear Tube
7 3-way Connector
8 LCRV

HYDRAULIC BRAKES 4A-7
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BLEEDING THE BRAKES
For Master Cylinder Replacement
1. Add oil after master cylinder replacement.
2. Run the engine and depress the brake pedal several times
to build pressure and then keep the pedal fully depressed.
3. Loosen the screws of primary and secondary pipe at the
master cylinder outlets to bleed air.
4. Repeat above step No.3 several times until there are no
more air bubbles.
5. Bleed air in the system at the hydraulic unit outlet pipe and
wheel if pressure building is not enough by depressing the
pedal only after above air bleeding.
For Caliper and Brake Hose Replacement
1. Check the oil level from the oil reservoir and refill if necessary.
2. Run the engine and depress the pedal several times to
build pressure and then keep the pedal fully depressed.
3. Connect a vinyl tube to the caliper breather and prepare a
container to coentain brake oil.
4. Loosen the breather screw until there are no more bubbles.
5. Bleed air in the system at four (4) wheels in order as shown
in right figure if pressure building is not enough by depressing
the pedal after above air bleeding.
Tightening Torque
9 - 14 Nm
Item
Front Bleeder Screw
Rear Bleeder Screw
Notice
lDo not reuse the bled brake fluid.
lAlways bleed the air after replacing brake fluid or
master cylinder, caliper, brake hose and pipe.
lAlways operate in normal order.

4A-8 HYDRAULIC BRAKES
For Hydraulic Unit Replacement
1. Add oil after hydraulic unit replacement.
2. Run the engine and depress the pedal several times to
build pressure and then keep the pedal fully depressed.
3. Loosen hydraulic pipe screws at the hydraulic unit outlets
to bleed air.
4. Repeat above step No.3 several times until there are no
more air bubbles.
5. Bleed air in the system from the wheels if pressure building
is not enough by pressing the pedal only after above air
bleeding.

HYDRAULIC BRAKES 4A-9
BRAKE PEDAL
1 Clevis Pin
2 Brake Pedal
3 Stop Lamp Switch
4 Pad
5 Nut .......................................................21-35 Nm
6 Yoke Pin
7 Fulcrum Pin8 Return Spring
9 Pedal Mounting Bracket
10 Washer
11 Nut .......................................................16-32 Nm
1 2 Bolt........................................................8-18 Nm
13 Stopper Bolt..............................................Adjust
14 Rubber Pad........................................... Replace

4A-10 HYDRAULIC BRAKES
Removal & Installation Procedure
1. Remove the stop lamp switch connector.
2. Remove the clevis pin and disconnect the brake booster
push rod.
Notice
lInstall in the upper hole (1), in case of Mando brake and
in the below hole (2), incase of PBR brake.
lInstall the snap pin fully in the hole of clevis pin.
lApply the grease around the hole of clevis pin.
3. Loosen the nut (4EA) and bolt (2EA) and remove the brake
pedal.
4. Installation should follow the removal procedure in reverse
order.
Tightening Torque8 - 18 Nm

HYDRAULIC BRAKES 4A-11
Adjustment Procedure
1. Pedal Height
Notice
If pedal height is not in specified value, loosen the stop
lamp nut (B) and adjust the pedal height.
2. Pedal Stroke
Height (A) 150 mm (From the carpet)
Notice
If pedal stroke is not in specified value, loosen the stop bolt
and lock nut (F) and adjust the pedal stroke.
3. Free Play
Stroke (C)Mando : 138 mm
PBR : 132mm
Notice
To adjust, depress the brake pedal several times until there
is no more vacuum left in the vacuum line.
To adjust, loosen the lock nut (D) of the push rod and turn
the rod.
Free Play (E)1 - 4 mm
Inspection Procedure
1. Inspect the wear of bushing.
2. Inspect the warp and bend of brake pedal.
3. Inspect the return spring of brake pedal.
4. Inspect the conductivity when connecting the tester to the
stop lamp switch connector.

4A-12 HYDRAULIC BRAKES
LCRV (LOAD CONSCIOUS REDUCING VALVE)
1 Brake Tube (from the master cylinder)
2 Brake Tube (from the rear brake)
3 LCRV Bracket
4 Bolt........................................................... 12 Nm5 LCRV Assembly
6 Connecting Link
7 Spring Washer
8 Nut .......................................................14-18 Nm

HYDRAULIC BRAKES 4A-13
Construction
LCRV consists of sensing part and hydraulic control part.
1. Sensing Part
It detects the changes of vehicle height caused by vehicle
load. It consists of load sensing spring and control lever
which change according to vehicle load.
2. Hydraulic Control Part
It consists of valve stem devices which controls hydraulic
pressure according to load detected by sensing part.
Trouble Shooting
Poor Braking
Possible Cause
Air in Brake System
Poor Adjustment of Sensor Spring
Damaged Sensor Spring
Fluid Leaking from LCRVRemedy
Bleeding
Adjust
Replace
Replace
Possible Cause
Poor Adjustment of Sensor Spring
Internal Fluid Leaking of LCRVRemedy
Adjust
Replace
Abnormal Locking