2003 SSANGYONG MUSSO brakes

4A-14 HYDRAULIC BRAKES
LCRV SETTING METHOD
1. LCRV setting should be performed with unladen vehiclecondition.
2. Install the connecting rod (a) to the No.1 hole.
Tightening Torque 14 - 18 Nm
3. Adjust the clearance “X” to be 0 mm and tighten the bolt (c) using the lock nut (b).
Tightening Torque 14 - 18 Nm
4. Remove the connecting rod (a) from the No.1 hole and reinstall it to the No. 2 hole.
5. Place alignment marks between the lock nut (b) and adjusting screw (c) after the valve setting.

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 & NutCaliper Bolt
N 

 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 tires7 Front Disc Assembly
8 Brake Pad
9 Brake Hose and Nut ............................. 25-35 Nm
10 Gasket ................................................... Replace
11 Washer
12 Bolt .................................................... 85-105 Nm

FRONT DISC BRAKES 4D-3
Removal & Installation Procedure
1. MANDO Brake
Tightening Torque 25 - 35 Nm
2. PBR Brake Remove the eye-hose bolt and disconnect the hose. Installation Notice
Tightening Torque 15 - 18 Nm
3. Remove the wheel speed sensor (for ABS vehicies). Installation Notice
Tightening Torque 6 - 8 Nm
4. Remove the mounting bolts and then caliper assembly. Installation Notice
Tightening Torque 85 - 105 Nm
Remove the hose mounting nut and disconnect the hose. Installation Notice

4D-4 FRONT DISC BRAKES
5. Pull out the brake pads. Replace pads if necessary.Notice Always change the all pads on one wheel at a time.
6. Installation should follow the removal procedure in the reverse order.
7. Bleed the air from the system.

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. Check the cylinder and piston for wear, rust or damage.
Check the caliper body and guide pin for wear, damage
or crank.
Check the pads for uneven wear or oiliness.
Check the boots for damage or tear.
2. Measure caliper housing inner diameter.
Item
With PBR
With MANDO Wear Limit

61.4 mm
61.0 mm
Standard
10 mm Wear Limit
2.0 mm
Standard
60.4 mm
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 mm Wear Limit
22 mm

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 HoseCaliper Bolt
N 

 m
85 - 105 15 - 18
20
Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-2
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 4E-4 Rear Disc Brake . . . . . . . . . . . . . . . . . . . . . . . 4E-4

4E-2 REAR DISC BRAKES
1 Rear Brake Disc Assembly
2 Brake Pad
3 Brake Caliper
4 Gasket ................................................... Replace
5 Bolt........................................................... 20 Nm
6 Gasket ................................................... Replace MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
REAR DISC BRAKE Preceding Work : Removal of wheels and tires7 Brake Hose
8 Gasket ................................................... Replace
9 Eye-hose Bolt ...................................... 15-18 Nm
10 Washer
11 Bolt .................................................... 85-105 Nm