2003 SSANGYONG MUSSO Service Manual

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

HYDRAULIC BRAKES 4A-5
ABS / ABD1 Actuation Assembly (Booster+TMC)
2 Master Cylinder 1st Tube (Primary)
3 Master Cylinder 2nd Tube (Secondary)
4 Hydraulic Modulator
5 Front Tube (LH) 6 Front Tube (RH)
7 Rear Tube (RH)
8 Rear Tube (LH)
9 2-way Connector

4A-6 HYDRAULIC BRAKES
NON-ABS/ABD1 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 REPAIRON-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 NmItem
Front Bleeder Screw
Rear Bleeder Screw
Notice
Do not reuse the bled brake fluid.
Always bleed the air after replacing brake fluid or
master cylinder, caliper, brake hose and pipe.
Always 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 tobuild 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 PEDAL1 Clevis Pin
2 Brake Pedal
3 Stop Lamp Switch
4 Pad
5 Nut ....................................................... 21-35 Nm
6 Yoke Pin
7 Fulcrum Pin
8 Return Spring
9 Pedal Mounting Bracket
10 Washer 11 Nut ....................................................... 16-32 Nm
12 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 boosterpush rod. Notice
Install in the upper hole (1), in case of Mando brake and
in the below hole (2), incase of PBR brake.
Install the snap pin fully in the hole of clevis pin.
Apply 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 Torque 8 - 18 Nm

HYDRAULIC BRAKES 4A-11
Adjustment Procedure
1. Pedal HeightNotice 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.