2003 SSANGYONG MUSSO Service Manual

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.

3A-20 FRONT DRIVE AXLE
2. Assemble the parts of the drive pinion.
3. Assemble the parts of the differential carrier.
4. Measure backlash of the side gear and pinion.
5. Install the differential carrier assembly into the axle housing.Notice Be careful not to change the caps. Be sure to keep the original position of the caps.
Tightening Torque of the Lock Nut 240 - 310 Nm
Tightening Torque of the
Ring Gear Bolts 75 - 90 Nm
Standard 0 -
0.05 mm
Tightening Torque of the
Bearing Cap Bolts 48 - 69 Nm

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

Diesel Gasoline (M161) Gasoline (M162)
Diesel Gasoline
Application
Joint Type Number of Spider Front FrontRear Front Rear
Front (Full-Time)
Front (Part-Time)Rear Front Rear
SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 General Specifications . . . . . . . . . . . . . . . . . . 3C-1
Component Locator . . . . . . . . . . . . . . . . . . . 3C-2 M/T & A/T (Part-time T/C) . . . . . . . . . . . . . . . . 3C-2 Maintenance and Repair . . . . . . . . . . . . . . . 3C-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . .
3C-3
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description
Single or Single & Double Cardan Single Cardan
Constant Velocity(CV) & Double Carden Single Cardan
3 22
CV Joint : 1, Double Spiders : 1 2
Diesel Gasoline
Shaft Dimensions (L×O.D ×I.D)
When CompressedFully FrontRearFrontRear Front Rear- --M/T & MB A/T
BTRA A/T (2p-Type) TONGIL KSC-
576
×59.5 ×63.5
973 ×
63.5 ×659.5
583.5 ×
44.7×50.8
973 ×
63.5 ×459.5
380.8 ×
63.5×59.5
591.5 ×
63.5×59.5
601.6 ×
50.8×44.7
579.6 ×
50.8×44.7
776.8 ×
63.5×59.5

3C-2 PROPELLER SHAFT
1 Flange Yoke
2 Cross and Bearing Assembly (with Snap Ring)
3 Cross and Bearing Assembly (with Snap Ring)
4 Slip Yoke Assembly
5 Grease Nipple
6 Dust Cap
7 Oil Seal
8 Split Washer
9 Slip Tube Shaft
10 Tube
Notice Only the length of shaft is different and the components of front/rear shaft are the same.(The deadener is inserted to the inside of tube of rear shaft, both ends) COMPONENT LOCATOR
M/T & A/T (PART-TIME T/C)
1. Gasolin : E32 - Fromt Propeller Shaft
2. Diesel/Gasolin : E23,20 - Fromt Propeller Shaft
: A/T + Full - Time T/C
3. Gasolin - Rear Propeller Shaft
Diesel - Fromt & Rear Propeller Shaft
: M/T & A/T + FPart - Time T/C
11 Tube Yoke
12 Flange Yoke
13 Diesel : Cross and Bearing Assembly (with Snap Ring)
Gasoline : CV Joint (DOJ)
14 Diesel : Double Cardan
Gasoline : Stub Shaft
15 Tube
16 Cross and Bearing Assembly (with Snap Ring)
17 Center Couping Yoke
18 Boots Band

PROPELLER SHAFT 3C-3
1 Front Axle
2 Bolt...................................................... 70-80 Nm
3 Front Propeller Shaft (661LA/662LA)
4 Front Propeller Shaft (E32)
5 Bolt ...................................................... 81-89 Nm
6 Transfer Case MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
PROPELLER SHAFT7 Bolt ...................................................... 81-89 Nm
8 Rear Propeller Shaft
9 Bolt ...................................................... 70-80 Nm
10 Rear Axle
11 Front Propeller Shaft (E20/E23)

3C-4 PROPELLER SHAFT
Removal Procedure
1. Place alignment marks and remove the propeller shaft.
2. Place alignment marks before removing the spider.
3. Using a snap ring pliers, remove the snap ring.
GasolineDiesel