2003 SSANGYONG MUSSO Service Manual

REAR DRIVE AXLE 3D-5
1 Spring Seat
2 Coil Spring
3 Lateral Rod
4 Shock Absorber5 Upper Arm
6 Lower Arm
7 Connecting Link
8 Stabilizer Bar
COMPONENT LOCATOR

3D-6 REAR DRIVE AXLEMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
AXLE SHAFT
1 Brake Disc
2 Dust Plug
3 Rear Axle Shaft
4 Nut ....................................................... 50-65 Nm
5 Washer
6 Parking Brake Cable
7 Parking Brake Lining and Back Plate Assembly
8 Caliper Assembly
9 Gasket
10 Bolt .................................................... 85-100 Nm
11 Rear Axle Housing

REAR DRIVE AXLE 3D-7
Removal & Installation Procedure
1. Remove the tire.Installation Notice
2. Release the parking brake. Steel Wheel
Aluminum Wheel
Tightening Torque
3. Remove the bolts and the brake caliper.
Installation Notice Be careful not to damage the brake hose.
Tightening Torque 85 - 100 Nm
4. Remove the brake disc. Notice
To remove the disc, install the bolts (M8 x 1.25) into the service hole and uniformly tighten the bolts.
5. Disconnect the parking brake cable.
80 - 120 Nm
110 - 130 Nm

3D-8 REAR DRIVE AXLE
Tightening Torque 50 - 65 Nm
6. Remove the plug from the axle shaft flange and remove theinner shaft mounting nuts. Installation Notice
7. Remove the axle shaft, parking brake lining and back plate assembly.
8. Installation should follow the removal precedure in the reverse order.

REAR DRIVE AXLE 3D-9
AXLE Removal & Installation Procedure
1. Lift up the vehicle and support the frame safely.
2. Remove the axle shaft.
Tightening Torque 150 - 180 Nm
3. Remove the propeller shaft from the rear axle input shaft.
Installation Notice Notice Place alignment marks before removal.
Tightening Torque 81 - 89 Nm
4. Disconnect the parking brake cable and brake hose.
5. Remove the lower arm mounting nuts and remove the lower arm from the axle housing. Installation Notice

3D-10 REAR DRIVE AXLE
6. Separate the lower shock absorber from the axle housing.Installation Notice
7. Remove the upper arm mounting nuts and remove the upper arm form the axle housing. Installation Notice
Tightening Torque 50 - 65 Nm
8. Remove the stabilizer bar. Installation Notice
Tightening Torque 150 - 180 Nm
9. Remove the lateral rod mounting nuts and remove the lateral rod from the axle housing. Installation Notice
Tightening Torque 30 - 45 Nm
10. Lowering the axle housing slowly, remove the coil springs and spring seats.
11. Installation should follow the removal precedure in the reverse order.
Tightening Torque 150 - 180 Nm

REAR DRIVE AXLE 3D-11
UNIT REPAIR
AXLE HOUSING Preceding Work : Removal of the axle shaft Removal of the axle housing
1 Drive Pinion Lock Nut ......................240-310 Nm
2 Washer
3 Companion Flange
4 Pinion Oil Seal
5 Bearing Slinger
6 Bearing
7 Shim
8 Shim
9 Bearing Cup
10 Breather Nipple
11 Rear Axle Housing
12 Oil Drain Plug ....................................... 28-42 Nm
1 3 Shim
14 Bearing
15 Drive Pinion
16 Bearing Cap 17 Bolt
.................................................... 87-124 Nm
18 Bearing
1 9 Shim
20 Ring Gear
21 Shaft Lock Pin
22 Differential Case
23 Ring Gear Mounting Bolt ......................75-90 Nm
24 Thrust Washer
25 Differential Pinion
26 Thrust Washer
27 Side Gear
28 Differential Shaft
29 Housing Cover
30 Bolt ...................................................... 38-46 Nm
31 Oil Filler Plug ....................................... 28-42 Nm

3D-12 REAR DRIVE AXLE
Disassembly Procedure
1. Remove the drain plug and drain the oil. Reinstall the drainplug.
2. Remove the axle housing cover. Notice Clean the cover and housing contact surface.
3. Remove the bearing cap bolts and remove the bearing caps. Pull out the differential carrier assembly. Notice Place 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.
4. Disassemble the parts of the differential carrier assembly.
Tightening Torque 28 - 42Nm