1998 SSANGYONG MUSSO brake rotor

GENERAL INFORMATION 0B-13
Weather-Strip Lubrication
Apply a thin film silicone grease using a clean cloth.
EACH TIME THE OIL IS CHANGED
Brake System Inspection
This inspection should be done when the wheels are
removed for rotation. Inspect the lines and the hoses
for proper hookup, binding, leaks, cracks, chafing, etc.
Inspect 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 exhaust
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
tension. Adjust or replace the belts as needed.
Hood Latch Operation
When opening the hood, note the operation of the
secondary 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
securely 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
materials 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
ensure proper operation.

WHEEL ALIGNMENT 2B-5
VIBRATION DIAGNOSIS
Wheel imbalance causes most highway speed vibration
problems. A vibration can remain after dynamic
balancing because:
lA tire is out of round.
lA rim is out of round.
lA 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
substituting known good tire and wheel assemblies on
the problem vehicle.
Preliminary Checks
Prior to performing any work, always road test the car
and perform a careful visual inspection for:
lObvious tire and wheel runout.
lObvious drive axle runout.
lImproper tire inflation.
lIncorrect trim height.
lBent or damaged wheels.
lDebris build-up on the tire or the wheel.
lIrregular or excessive tire wear.
lImproper tire bead seating on the rim,
lImperfections in the tires, including: tread
deformations, separations, or bulges from impact
damage. Slight sidewall indentations are normal and
will not affect ride quality.
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 occurs
at low speeds, runout is the probable cause.

4A-2 HYDRAULIC BRAKES
Check
Dirty or Lack of Fluid
Air in Brake System
Faulty Brake Booster
Poor Contact of Pad or Lining
Oil or Grease on Pad
Faulty Auto Adjuster
Over Heated Rotor Due to Dragging Pad or Lining
Clogging Brake Line
Faulty Proportioning ValveCheck
Incorrect Tire Pressure Between Left and Right
Poor Contact of Pad or Lining
Oil or Grease is Applied to Pad or Lining
Bent or Uneven Wear of Drum
Incorrectly Mounted Wheel Cylinder
Faulty Auto AdjusterAction
Repair
Retighten
Replace
Replace
Repair
Repair
Lubricate
Retighten Check
Incorrectly Mounted Back Plate or Caliper
Loosened Bolt of Back Plate or Caliper
Crack or Uneven Wear of Brake Drum or Disc
Pad or Lining Sticking to Contact Surface
Excessive Clearance Between Caliper and Pad
Uneven Contact of Pad
Lack of Lubrication
Loosened Suspension
DIGNOSIS
NOISE OR VEHICLE VIBRATION WHEN APPLIED BRAKE
PULLS TO ONE SIDE WHEN BRAKING
Action
Adjust
Repair
Replace
Replace
Repair
Replace
Action
Replenish or Replace(Check eventual leakage)
Bleeding
Replace
Repair
Replace
Replace
Repair
Repair
Repair
POOR BRAKING
( If low cut-in : Adjust )
( If Leakage : Replace )

FRONT DISC BRAKES 4D-5
4. Measure rotor disc thickness.
UNIT REPAIR
FRONT DISC BRAKE
Inspection Procedure
1. Clean all components and visually check the followings.
lCheck the cylinder and piston for wear, rust or damage.
lCheck the caliper body and guide pin for wear, damage
or crank.
lCheck the pads for uneven wear or oiliness.
lCheck the boots for damage or tear.
2. Measure caliper housing inner diameter.
Item
With PBR
With MANDOWear Limit
f 61.4 mm
f 61.0 mm
Standard
10 mmWear Limit
2.0 mm
Standard
f 60.4 mm
f 60.0 mm
3. Measure pad thickness.
Notice
Always change the all pads on one wheel at a time.
5. Check the rotor disc for score or runout.
Standard
24 mmWear Limit
22 mm

4E-4 REAR DISC BRAKES
Standard
10.4 mmWear Limit
9.3 mm
UNIT REPAIR
REAR DISC BRAKE
Inspection Procedure
1. Clean all components and visually check the followings.
lCheck the cylinder and piston for wear, rust or damage.
lCheck the caliper body and guide pin for wear, damage
or crank.
lCheck the pads for uneven wear or oiliness.
lCheck the boots for damage or tear.
Standard
f40.5 mm
f38.2 mmWear Limit
f41.5 mm
f39.2 mm
2. Measure caliper housing inner diameter.
3. Measure pad thickness.
Standard
9.5 mmWear Limit
2.0 mm
Notice
Always change the all pads on one wheel at a time.
4. Measure rotor disc thickness.
5. Check the rotor disc for score or runout.
Item
With PBR
With MANDO

4F-14 ANTILOCK BRAKE SYSTEM
Description
- When measured by multi - meter (AC) :
output voltage > 70 mV
- When measured in oscilloscope :
output voltage ³ 120 mV/P-P
lReplace the sensor.
lCheck wire for ground and open.
lCheck connection of the wheel speed sensor con-
nector and ECU side connector.
(Standard air gap : 0.15 - 1.20 mm)
lCheck output voltage of the sensor by rotating the
wheel 1/2 - 1 revolution per second and shaking sen-
sor wire.
- When measured by multi - meter (AC) :
output voltage > 70 mV
- When measured in oscilloscope :
output voltage ³ 120 mV/P-P
lReplace the sensor.
lCheck wire for ground and open.
lCheck connection of the wheel speed sensor con-
nector and ECU side connector.
lMeasure air gap between wheel teeth and wheel
speed sensor and check installation of wheel tooth.
(Standard air gap : 0.15 - 1.20 mm)
lCheck output voltage of the sensor by rotating the
wheel 1/2 - 1 revolution per second and shaking sen-
sor wire.
- When measured by multi - meter (AC) :
output voltage > 70 mV
- When measured in oscilloscope :
output voltage ³ 120 mV/P-P
lReplace the sensor.
lCheck number of teeth on the wheel rotor and its
condition.
- Number of teeth : 52
lCheck valve relay voltage.
lCheck connection of connector and terminals in the
ECU and hydraulic modulator.
lCheck ground.
lCheck terminals for open or short.
(When connector is removed)
lReplace the hydraulic modulator. Defect Code
09
10
11
12Application
Rear/left Wheel Speed
Sensor (Signal)
Rear/right Wheel Speed
Sensor (Signal)
Wheel Rotor
Valve Relay