2003 SSANGYONG MUSSO differential

SECTION 3D
REAR DRIVE AXLE
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3D-1 General Specifications . . . . . . . . . . . . . . . . . . 3D-1
Fastener Tightening Specifications . . . . . . . . . 3D-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3 Noise (During Straight Driving) . . . . . . . . . . . . 3D-3
Oil Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3
Noise (During Turning) . . . . . . . . . . . . . . . . . . 3D-3
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-4 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3D-4
Component Locator . . . . . . . . . . . . . . . . . . . 3D-5
Maintenance and Repair . . . . . . . . . . . . . . . 3D-6
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 3D-6
Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-6
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-9
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3D-11 Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3D-11
LSD (Limited Slip Diffrential) . . . . . . . . . . . . . 3D-16
SPECIFICATIONS
GENERAL SPECIFICATIONS
Axle Shaft Type
Axle Housing TypeDifferential Reduction Ratio
Type Gear M/T M/TA/T (MB)M/TA/T (BTRA) M/T A/T (BTRA)
Description
Semi - floating
Salibury (Build-up)
Conventional Type Hypoid Gear
4.55 4.55 3.73 4.555.384.274.89Application
661NA 662NA 661LA 662LA

REAR DRIVE AXLE 3D-3
Checks
Worn or Damaged Tooth of Pinion or Side Gear Worn Pinion Shaft Excessive Backlash of Pinion Gear and Side Gear Excessive End-play of Rear Axle ShaftIncorrect Contact of Side Gear and Differential CaseAxle Housing CrackBent or Poor Installation of Drive Pinion Oil Seal
Damaged or Torn Drive Pinion Oil Seal Loosened Bearing CollarWorn or Damaged Universal JointWorn or Damaged Axle Shaft Bearing Checks
Excessive OilFaulty Seal of Carrier Contact Surface Axle Housing Crack Worn or Damaged Oil Seal Checks
Lack of OilLow Viscosity of OilInsufficient Oil Excessive Backlash of Ring Gear
Worn or Damaged Tooth of Ring and Pinion GearWorn or Damaged Drive Pinion BearingBent Axle HousingBent Differential Case Worn Pinion Shaft Incorrect Drive Pinion PreloadIncorrect Contact of Ring Gear and Pinion DIAGNOSIS
NOISE (DURING STRAIGHT DRIVING)
Action
Replenish
Replace Replace
Adjust
ReplaceReplaceReplaceReplace Replace Adjust
Retightening
OIL LEAKAGE
Action Adjust
Repair
Replace Replace
NOISE (DURING TURNING)
Action
Replace Replace Replace Adjust
Replace ReplaceReplace Replace ReplaceReplaceReplace
HEATING
Checks
Lack of Oil Insufficient Backlash of GearsExcessive Preload of Bearing Action
Replenish AdjustAdjust

REAR DRIVE AXLE 3D-11
UNIT REPAIR
AXLE HOUSING Preceding Work : Removal of the axle shaft Removal of the axle housing
1 Drive Pinion Lock Nut ......................240-310 Nm
2 Washer
3 Companion Flange
4 Pinion Oil Seal
5 Bearing Slinger
6 Bearing
7 Shim
8 Shim
9 Bearing Cup
10 Breather Nipple
11 Rear Axle Housing
12 Oil Drain Plug ....................................... 28-42 Nm
1 3 Shim
14 Bearing
15 Drive Pinion
16 Bearing Cap 17 Bolt
.................................................... 87-124 Nm
18 Bearing
1 9 Shim
20 Ring Gear
21 Shaft Lock Pin
22 Differential Case
23 Ring Gear Mounting Bolt ......................75-90 Nm
24 Thrust Washer
25 Differential Pinion
26 Thrust Washer
27 Side Gear
28 Differential Shaft
29 Housing Cover
30 Bolt ...................................................... 38-46 Nm
31 Oil Filler Plug ....................................... 28-42 Nm

3D-12 REAR DRIVE AXLE
Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall the drainplug.
2. Remove the axle housing cover. Notice Clean the cover and housing contact surface.
3. Remove the bearing cap bolts and remove the bearing caps. Pull out the differential carrier assembly. Notice Place alignment marks on the bearing cap not to change the caps before removal. When pulling out the differential
carrier assembly, be careful not to damage the axle housing.
4. Disassemble the parts of the differential carrier assembly.
Tightening Torque 28 - 42Nm

REAR DRIVE AXLE 3D-13
5. Remove the drive pinion lock nut. Disassemble the parts ofthe drive pinion.
Assembly Procedure
1. Clean the all parts and check the followings. Check the ring gear and drive pinion for wear or damage.
If damaged, replace it as set.
Check the bearing for sticks, wear, noise or turning
resistance.
Check the side gear, pinion, pinion shaft and thrust
washer for wear or damage.
Check the differential carrier for crack or wear (bearing
contact surface). Check the gear case for crack.
2. Assemble the parts of the drive pinion.
3. Assemble the parts of the differential carrier.
Tightening Torque of The Pinion Lock Nut 240 - 310 Nm
Tightening Torque of The
Ring Gear Bolts 75 - 90 Nm

3D-14 REAR DRIVE AXLE
4. Measure backlash of the side gear and pinion gear.
Specified Value 0 - 0.05 mm
5. Install the differential carrier assembly into the axle housing.
Tightening Torque of The Bearing Cap Bolts 48 - 69 Nm
Notice Be careful no to change the caps. Be sure to keep the original position of the caps.
6. Measure backlash of the drive pinion and ring gear.
7. Install the axle housing cover.
Specified Value 0.13 - 0.20 mm
Tightening Torque 39 - 46 Nm

3D-16 REAR DRIVE AXLE LSD (LIMITED SLIP DIFFERENTIAL)
1 Limited Slip Differential Assembly
2 Shaft, Hub (left)
3 Shim
4 Thrust Washer
5 Face Cam (left)
6 Cam Whillom
7 Thrust Bearing
8 Radial Bearing9 Shaft, Hub (right)
10 Thrust Washer
11 Face Cam (right)
12 Cage
13 Thrust Bearing
14 Plate Spring
15 Radial Bearing
16 Oil Catcher

ANTILOCK BRAKE SYSTEM 4F-7
ABD SYSTEM DESCRIPTION
General: The Automatic Brake Differential Lock (ABD) is a traction system by means of brake intervention only, available in a low speed range (< 60kph). It workes on µ-split roads with sidewise different friction coefficients.
The spinning driven wheel is braked and the drive torque can be transferred to the wheel on the high- µ side.
During ABD active, the ABD information lamp is blinking.The temperature of the brakes is calculated by a mathematical model and ABD is switched passive if the calculated temperature is greater than a threshold value(500 °C).
ABD is permitted again, when the calculated temperature is less than 350 °C.
Control Algorithm: The input signals for the control algorithm are the filteredwheel speed signals from the ABS speed processing. With the speed difference of the driven wheels, the control deviation is calculated. If the control deviation exceeds a certain threshold value,
the wheel with the greater slip is braked actively. The threshold value depends on the vehicle speed:It is reduced with increasing vehicle speed down to a constant value.
Pressure Modulation: Depending on the control deviation and the wheel acceleration of the spinning wheel, pressure increase, hold and decrease are made.
The pressure modulation is done with the conventional control with the valves. ASV, USV, EV and AV according the the following table:
Speed Range: ABD is available in the speed range 60 kph.
Above 60 kph vehicle speed, ABD is passive. It is possible to initiate ABD operation up to a vehicle speed of 55kph.
Increase Open
Open
Open
ASV Decrease
Hold
Closed
Closed
Closed
Closed
Closed
Open
Open
Closed
Closed
USV
EVAV
Speed difference driven wheels [kph]
18
6 12 60ABD operation
Vehicle speed[kph]