2003 SSANGYONG MUSSO Service Manual

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.

3C-6 PROPELLER SHAFT
3. Clearance between the spider and bearing.
4. Propeller shaft runout Using a dial indicator, measure propeller shaft runout by turning the shaft. If runout exceeds limit, replace thepropeller shaft or correct it using a press.
Standard
0.03 - 0.098 mm Limit
0.25 mm
Inspection Procedure
1. Visual check.
Check the disassembled parts for wear or crack.
Replace them if necessary.
2. Spider outer diameter (mm).
Standard 16.668 Limit
16.647
Limit 0.4 mm

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

3C-8 PROPELLER SHAFT
3. Install the bearing cap to the yoke and insert the spider.Install the opposite side cap by tapping with a plastic
hammer. Adjust clearance of the spider pin to be within 0.1 mm and install the snap ring.
4. Align the alignment marks and install the front and rear propeller shaft. Tighten the nuts to the specified torque.
GasolineDiesel

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

3D-4 REAR DRIVE AXLEVIBRATION
Checks
Faulty Connection of Sliding Joint Bent Propeller ShaftSymmetry of Universal Joint Snap Ring
Loosened Yoke Bolts Action
Adjust
Replace Adjust
Tighten
NOISE
Checks
Worn or Damaged Universal Joint Bearing Fallen Off Universal Joint Snap Ring
Loosened Yoke ConnectionWorn Sliding Joint SplineInsufficient Grease Action
Replace
Adjust or Replace Tighten
Replace
Apply as Necessary