2003 SSANGYONG MUSSO drive shaft

FRONT DRIVE AXLE 3A-19
5. Unscrew the bearing cap bolts and remove the bearing caps.Pull out the differential carrier assembly. NoticePlace 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.
6. Disassemble the parts of the differential carrier assembly.
7. Remove the drive pinion lock nut. Disassemble the parts of the drive pinion.
Assembly Procedure
1. Clean the all parts and check the followings : Check the ring gear and drive pinion for wear and damage. If damaged, replace it as a set.
Check the bearing for sticks, wear, noise and turning resistance.
Check the side gear, pinion, pinion shaft and thrustwasher for wear and damage.
Check the differential carrier for crack and wear (bearingcontact surface). Check the gear case for crack.

FRONT DRIVE AXLE 3A-21
6. Measure backlash of the drive pinion and ring gear.
7. Install the axle housing cover.
8. Assemble the parts of the front axle shaft and housingmounting bracket. NoticeApply grease to the oil seal rib.
9. Align the axle shaft and differential carrier spline and insert the axle shaft. Assemble the axle housing mounting bracket to the axle housing.
Specified Value 0.13 - 0.20 mm
Tightening Torque 39 - 46 Nm
Tightening Torque 55 - 65 Nm

3A-22 FRONT DRIVE AXLE
Inspection of Ring Gear Tooth Contact Pattern Normal Contact Apply gear-marking compound (prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern. Abnormal Contact
Tooth Contact pattern Possible CauseRemedy
1. Heel Contact
2. Toe Contact
3. Face Contact
4. Flank ContactInsufficient backlash (little)

Tooth can be damaged or broken under heavy load
Excessive backlash (much)
Drive pinion shaft is apart from the ring gear
Noise can be occurred
Insufficient backlash (much)
Gear contacts on the low flank
Gear can be damaged orworn
Noise can be occurred Adjust backlash(Decrease backlash)

Select proper shim(s) to move the drive pinion toward the ring gear (toward toe)
Adjust backlash(Increase backlash)
Select proper shim(s) to move the drive pinion against the ring gear (toward heel)
Adjust backlash(Increase pinion shim)
Move the drive pinion toward the ring gear (toward center of ring gear)
Adjust backlash(Decrease pinion shim)
Move the ring gear toward the drive pinion (toward ring gear center line)
Excessive backlash (little)

Noise can be occurred

PROPELLER SHAFT 3C-5
5. If difficult to remove, clamp the yoke side in a vise and tapoff the needle bearing, using a proper tool.
6. Disassemble the universal joint parts. As axles move up and down, universal joints allow drive angles to change without binding propeller shaft.
1 Grease Nipple
2 Flange Yoke
3 Spider4 Seal
5 Needle Roller Bearing
6 Snap Ring
4. Slightly tapping the yoke shoulder using a brass hammer,
remove the bearing. Remove the remaining bearings in the
same way.

PROPELLER SHAFT 3C-7
Installation Procedure Clean the disassembled parts and replace them if damaged.
1. Align the alignment marks of the yoke and assemble thespider, bearing and snap ring.
2. Apply grease to the inner of the bearing cap of the needle roller bearing and assemble the needle roller.
Grease EP #2
6. Possible cause of vibration.
Drift away of balance weights.
Excessive runout of the propeller shaft.
Using normal bolts.
Excessive wear of the universal joint.
Sticks in sleeve joint.
Drive angle changes in universal joints or cross causes vibration and can be detected around 60~100 km/h.
5. Universal joint starting torque.
Starting Torque 3 - 8 kg

cm

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

3D-2 REAR DRIVE AXLEFASTENER TIGHTENING SPECIFICATIONS
Application
Inner Bracket Mounting Nut Propeller Shaft to Rear Axle Input ShaftLower Arm Mounting Nut Lower Shock Absorber to Axle Housing Upper Arm Mounting NutStabilizer Bar Mounting BoltLateral Rod Mounting NutDrive Pinion Lock Nut Oil Drain Plug Ring Gear Mounting BoltOil Filler Plug
N 

 m
50 - 65 70 - 80
150 - 180 50 - 65
150 - 180 30 - 45
150 - 180240 - 310 28 - 4275 - 9028 - 42
4.55 4.554.55 4.27 5.863.733.734.89
1.9 L
SEA 80W/90, API GL - 5
M/TA/T (MB) M/T A/T (MB)A/T (BTRA)M/TA/T (MB) A/T (BTRA)
Oil Capacity Oil Specification
Application Description
GENERAL SPECIFICATIONS(CONT'D)
E20 E23 E32
Reduction Ratio

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