2003 SSANGYONG MUSSO torque

REAR DRIVE AXLE 3D-17
Inspection
Remove the LSD assembly and check the pre-load torque.
If necessary, replace LSD assembly.
Procedure
1. Fix the right shaft of LSD to the special tool (A).
2. Install the special tool (B) to the left shaft and rotate counterclockwise and check the pre-load torque.
Normal Torque 3.6 - 9.0kgm
Notice
If necessary, replace LSD assembly.

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-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

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.

MASTER CYLINDER 4B-3
Removal & Installation Procedure
1. Remove the oil level sensor connector.
2. Remove the tube from the master cylinder.Installation Notice Notice
Be careful not to drop the oil when removing the tube.
If the oil is dropped, promptly sweep up.
3. Remove the booster vacuum hose. Notice
Connect fully to the end of vacuum hose when installing.
4. Loosen the nut of master cylinder. Installation Notice
5. Remove the clevis pin and disconnect the pedal and brake booster push rod. Notice
Install in the upper hole when PBR brake.
Connect the snap pin in the hole of clevis pin fully.
Apply the grease around the hole of clevis pin.
Tightening Torque 14 - 22 Nm
Tightening Torque 15 - 19 Nm

4B-4 MASTER CYLINDER
6. Loosen the nut of booster and remove the booster from thedash panel. Installation Notice
Tightening Torque 8 - 18 Nm
7. Installation should follow the removal procedure in the reverse order.
8. Add the fluid and bleed.
9. If necessary, adjust the pedal height, pedal stroke and free play.

POWER BOOSTER 4C-3
Removal & Installation Procedure
1. Remove the oil level sensor connector.
2. Remove the tube from the master cylinder.Installation Notice Notice
Be careful not to drop the oil when removing the tube.
If the oil is dropped, promptly sweep up.
3. Remove the booster vacuum hose. Notice
Connect fully to the end of vacuum hose when installing.
4. Loosen the nut of master cylinder. Installation Notice
5. Remove the clevis pin and disconnect the pedal and brake booster push rod. Notice
Install in the upper hole when PBR brake.
Connect the snap pin in the hole of clevis pin fully.
Apply the grease around the hole of clevis pin.
Tightening Torque 14 - 22 Nm
Tightening Torque 15 - 19 Nm

4C-4 POWER BOOSTER
6. Loosen the nut of booster and remove the booster from thedash panel. Installation Notice
Tightening Torque 8 - 18 Nm
7. Installation should follow the removal procedure in the reverse order.
8. Add the fluid and bleed.
9. If necessary, adjust the pedal height, pedal stroke and free play.