1998 SSANGYONG MUSSO service

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.

SECTION 4B
MASTER CYLINDER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4B-1
Fastener Tightening Specifications . . . . . . . . . 4B-1
Maintenance and Repair . . . . . . . . . . . . . . . 4B-2
TABLE OF CONTENTS
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Master Cylinder Nut
Booster NutN
· ·· ·
·m
14 - 22
8 - 18
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4B-2
Booster & Brake Master Cylinder . . . . . . . . . . 4B-2

4B-2 MASTER CYLINDER
1 Nut .......................................................14-22 Nm
2 Washer
3 Master Cylinder Assembly
4 Oil Level Sensor
5 Check Valve
6 Booster
7 Clevis Pin
8 Snap Pin9 Seal
10 Spacer
11 Nut .........................................................8-18 Nm
12 Front Tube (LH)
13 Front Tube (RH)
14 Rear Tube
15 1st Tube (Primary)
16 2nd Tube (Secondary)
MANDO
PBR
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER

SECTION 4C
POWER BOOSTER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4C-1
General Specifications . . . . . . . . . . . . . . . . . . 4C-1
Maintenance and Repair . . . . . . . . . . . . . . . 4C-2
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Type
RatioN
· ·· ·
·m
Vacuum Assisted
5.6 : 1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4C-2
Booster & Brake Master Cylinder . . . . . . . . . . 4C-2
Pedal Stroke Inspection . . . . . . . . . . . . . . . . . 4C-5

4C-2 POWER BOOSTER
1 Nut .......................................................14-22 Nm
2 Washer
3 Master Cylinder Assembly
4 Oil Level Sensor
5 Check Valve
6 Booster
7 Clevis Pin
8 Snap Pin
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
BOOSTER AND BRAKE MASTER CYLINDER
9 Seal
10 Spacer
11 Nut .........................................................8-18 Nm
12 Front Tube (LH)
13 Front Tube (RH)
14 Rear Tube
15 1st Tube (Primary)
16 2nd Tube (Secondary)
MANDO
PBR

SECTION 4D
FRONT DISC BRAKES
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4D-1
Fastener Tightening Specifications . . . . . . . . . 4D-1
Maintenance and Repair . . . . . . . . . . . . . . . 4D-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4D-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Caliper Mounting Bolt
Brake Hose Bolt & Nut
Caliper BoltN
· ·· ·
·m
85 - 105
25 - 35
22 - 34
Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-2
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 4D-5
Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4D-5

4D-2 FRONT DISC BRAKES
1 Eye-Hose Bolt......................................25-35 Nm
2 Gasket ................................................... Replace
3 Brake Hose
4 Brake Caliper
5 Bolt........................................................... 20 Nm
6 Washer
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
FRONT DISC BRAKE
Preceding Work : Removal of wheels and tires
7 Front Disc Assembly
8 Brake Pad
9 Brake Hose and Nut.............................25-35 Nm
10 Gasket ................................................... Replace
11 Washer
1 2 Bolt....................................................85-105 Nm

SECTION 4E
REAR DISC BRAKES
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4E-1
Fastener Tightening Specifications . . . . . . . . . 4E-1
Maintenance and Repair . . . . . . . . . . . . . . . 4E-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4E-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Caliper Mounting Bolt
Brake Hose
Caliper BoltN
· ·· ·
·m
85 - 105
15 - 18
20
Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-2
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-4
Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-4