1998 SSANGYONG MUSSO brakes

SERVICEMANUAL
FOREWORD
This manual includes procedure for mainte-
nance, adjustment, service operation and re-
moval and installation of components.
All information, illustrations and specifications
contained in this manual are based on the latest
product information available at the time of
manual approval.
The right is reserved to make changes at any
time without notice.
SECTION INDEX
DRIVE LINE/AXLE
BRAKES
TRANSMISSION
STEERING
HVAC
(HEATING, VENTILATION,
AND AIR CONDITIONING)
RESTRAINTS
BODY AND ACCESSORIES 3
4
5
6
7
8
9
ENGINE
SUSPENSION1
2 FRONT MATTER GENERAL INFORMATION0A
0B
SSANGYONG-DAEWOO
MOTOR CO., LTD. 1998
KORANDO
MUSSO

GENERAL INFORMATION 0B-7
MAINTENANCE AND REPAIR
MAINTENANCE AND LUBRICATION
Fuel Filter Replacement
Replace the engine fuel filter every.
lGasoline Engine : 60,000km (36,000 miles)
lDiesel Engine : 45,000km (24,000 miles)
Spark Plug Replacement
Replace spark plugs with same type.
lType : BOSCH : F8DC4
BERU : 14F-8DU4
Champion : C11YCC
lGap : 0.8 ± 0.1 mm
Spark Plug Wire Replacement
Clean wires and inspect them for burns, cracks or other
damage. Check the wire boot fit at the Distributor and at
the spark plugs. Replace the wires as needed.
Brake System Service
Check the disc brake pads or the drum brake linings.
Check the pad and the lining thickness carefully.
Tire and Wheel Inspection and Rotation
Check the tires for abnormal wear or damage. To
equalize wear and obtain maximum tire life, rotate the
tires. If irregular or premature wear exists, check the
wheel alignment and check for damaged wheels. While
the tires and wheels are removed, inspect the brakes.
NORMAL VEHICLE USE
The maintenance instructions contained in the
maintenance schedule are based on the assumption
that the vehicle will be used for the following reasons:
lTo carry passengers and cargo within the limitation
of the tire inflation prassure. Refer to “Tire and Wheel”
in section 2E.
lTo be driven on reasonable road surfaces and within
legal operating limits.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
The services listed in the maintenance schedule are
further explained below. When the following maintenance
services are performed, make sure all the parts are
replaced and all the necessary repairs are done before
driving the vehicle. Always use the proper fluid and
lubricants.
Engine Oil and Oil Filter Change
Always use above the API SH grade or recommended
engine oil.
Engine Oil Viscosity
Engine oil viscosity (thickness) has an effect on fuel
economy and cold weather operation. Lower viscosity
engine oils can provide better fuel economy and cold
weather performance; however, higher temperature
weather conditions require higher viscosity engine oils
for satisfactory lubrication. Using oils of any viscosity
other than those viscosities recommended could result
in engine damage.
Cooling System Service
Drain, flush and refill the system with new coolant. Refer
to “Recommended Fluids And Lubricants” in this section.
Air Cleaner Element Replacement
Clean the air cleaner element every.
lGasoline Engine : 15,000km (10,000 miles)
lDiesel Engine : 10,000km (6,000 miles)
Replace the air cleaner element every .
lGasoline Engine : 60,000km (36,000 miles)
lDiesel Engine : 30,000km (18,000 miles)
Replace the air cleaner more often under dusty
conditions.
Tire Rotation (Left - Hand Drive Type)

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.

2B-4 WHEEL ALIGNMENT
1. Perform wheel alignment preliminary inspection.
2. Check the brakes for dragging.
3. Road test the vehicle.
Does the vehicle lead/pull?
1. Cross switch the front tire and wheel assemblies.
2. Road test the vehicle.
Does the vehicle lead/pull?
1. Check the front wheel alignment.
Is the alignment within specifications?
1. Compare the front camber and front caster to
specifications.
Are they within specifications?
1. Check the vehicle frame.
Is the frame bent?
1. Straighten the frame.
Is the repair complete?
1. The probable cause is the tires.
2. Switch the left front tire and wheel assembly with
the left rear tire and wheel assembly.
3. Road test the vehicle.
Does the vehicle still lead/pull?
1. Switch the left front tire and wheel assembly with
the left rear tire and wheel assembly and replace the
left front tire.
Does the repair complete?
1. Switch the right front tire and wheel assembly with
the right rear tire and wheel assembly.
2. Road test the vehicle.
Does the vehicle still lead/pull?
1. Switch the right front tire and wheel assembly with
the right rear tire and wheel assembly and replace
the right front tire.
Is the repair complete?Action
Radial Tire Lead/Pull Diagnosis Chart
Step
1Values(s)
-Yes
Go to
Step 2
Go to Step 3
Go to Step 4
Go to Step 7
Go to Step 6
Go to Step 3
Go to Step 9
System OK
Go to
Step 1
System OKNo
System OK
System OK
Adjust
alignment
Go to
Step 5
Go to Step 1
-
Go to
Step 8
Go to Step 1
Go to Step 10
Go to Step 1
2
3
4
5
6
7
8
9
10-
-
-
-
-
-
-
-
-

SECTION 4A
HYDRAULIC BRAKES
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
General Specifications . . . . . . . . . . . . . . . . . . 4A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Noise or Vehicle Vibration When Applied
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Pulls to One Side When Braking . . . . . . . . . . . 4A-2
Poor Braking . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Increasing Pedal Stroke (Pedal Goes to
Floor) or Brake Dragging . . . . . . . . . . . . . . . 4A-3
Poor Braking of Parking Brake . . . . . . . . . . . . 4A-3
TABLE OF CONTENTS
Component Locator . . . . . . . . . . . . . . . . . . . 4A-4
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4
ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Non-ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Maintenance and Repair . . . . . . . . . . . . . . . 4A-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4A-7
Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . 4A-7
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
LCRV (Load Conscious Reducing Valve) . . . 4A-12
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this
cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK
unless otherwise noted.
Type
Pedal Ratio
Pedal Stroke
Pedal Freeplay
Type
Inner Diameter
Type
Ratio
Type
I.D. of Caliper Cylinder
Thickness of Brake Pad
Thickness of Disc Plate
Type
I.D. of Caliper Cylinder
Thickness of Brake Pad
Thickness of Disc Plate
Type
Operation
SpecificationPBR Brake
4.3 : 1
132 mm
f23.81 mm
5.0 : 1
f60.4 mm
¬
f40.5 mm
9.5 mm
¬ Suspended
1 - 4 mm
Tandem Type with Lever Sensor
Vacuum Booster Type
Ventilated Disc
10 mm
24 mm
Rear Wheel Internal Expansion Type
Mechanical
SAE J1703, DOT3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Brake Pedal
Master Cylinder
Brake Booster
Front Brake
Rear Brake
Parking Brake
Brake FluidMANDO Brake
4.3 : 1
138 mm
f25.4 mm
5.6 : 1
f60 mm
Solid Disc
f38.2 mm
10.0 mm
10.4 mm
Application

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 )

HYDRAULIC BRAKES 4A-3
Check
Air in Brake system
Fluid Leaking
Excessive Clearance Between Push Rod and M/cylinder
Parking Brake is not Fully Released
Incorrect Adjustment of Parking Brake
Weak Return Spring of Brake Pedal
Incorrect Pedal Freeplay
Broken Rear Drum Brake Shoe Return Spring
Lack of Lubrication
Damaged Master Cylinder Check Valve or Piston Return SpringAction
Bleeding
Repair
Adjust
Repair
Adjust
Replace
Repair
Replace
lubricate
Replace
INCREASING PEDAL STROKE (PEDAL GOES TO FLOOR)
OR BRAKE DRAGGING
Check
Insufficient Clearance Between Push Rod and Master Cylinder
Worn Brake Lining
Oil or Grease on Lining
Binding Parking Brake Cable
Faulty Auto Adjuster
Excessive Lever StrokeAction
Adjust
Replace
Replace
Replace
Replace
Adjust or Check Cable
POOR BRAKING OF PARKING BRAKE

4A-4 HYDRAULIC BRAKES
COMPONENT LOCATOR
ABS
1 Actuation Assembly (Booster+TMC)
2 ABS Control Unit
3 Master Cylinder 2nd Tube (Secondary)
4 Master Cylinder 1st Tube (Primary)
5 Front Tube (LH)
6 Front Tube (RH)7 Brake Hose
8 Rear Tube
9 Bolt......................................................25-35 Nm
10 2-way Connector
11 3-way Connector