2013 SSANGYONG TURISMO Service Manual

08-6
4. TROUBLESHOOTING
Problem Possible Cause Action
Noise or vehicle
vibration when
appliedIncorrectly mounted back plate or caliper Repair
Loosened bolt of back plate or caliper Retighten
Uneven wear of brake disc Replace
Brake pad contamination Clean or replace
Sticking brake pad on contact surface Replace
Wear or hardening of brake pad Replace
Excessive clearance between caliper and pad Repair
Uneven contact of pad Repair
Lack of lubrication in sliding parts Lubricate
Improper operation of caliper Replace
Dust cover missing Repair
Loosened suspension mounting bolt Retighten
Pulls to one side
when brakingUnbalanced tire pressure between left and right Adjust
Poor contact of brake pad Repair
Oil or grease on brake pad Replace
Scratch, uneven wear, distortion of brake disc Replace
Improperly installed brake caliper Repair
Improper operation of auto adjuster Repair
Crack or distortion of brake pad Replace
Poor braking Oil leak or contamination Repair or replace
Air in brake line Bleed air
Improper operation of brake booster Repair
Poor contact of brake pad Repair
Oil or grease on brake pad Replace
Improper operation of auto adjuster Repair
Clogged brake line Repair
Improper operation of proportioning valve Repair

08-74850-03
Problem Possible Cause Action
Increased pedal
stroke
Air in brake line Bleed air
Oil leak Repair
Worn brake pad Replace
Excessive clearance between push rod and master
cylinderAdjust
Worn or damaged piston seal Replace
Brake dragging Parking brake is not fully released Replace
Incorrect adjustment of parking brake Adjust
Incorrectly adjusted clearance of parking brake shoe Adjust
Faulty brake pedal return spring Replace
Incorrectly adjusted free play of brake pedal Adjust
Faulty master cylinder Replace
Lack of lubrication in sliding parts Lubricate
Faulty brake booster (vacuum leak) Repair
Poor parking brake Wear, hardening or poor contact of brake pad Replace
Oil or water on lining Repair or replace
Fixed or broken parking brake cable Replace
Excessive stroke of brake lever Adjust notch
Faulty auto clearance adjuster Repair
Increased stroke of
parking brake leverLoosened parking brake cable Adjust or replace
Incorrectly adjusted parking brake cable Adjust
Defective automatic lining clearance adjuster Repair or replace
Worn brake lining Replace

08-8
Problem Cause Action
Burning smell
around tireToo frequent braking in high driving speed Reduce the use of
foot brake/use
engine brake
properly Use only foot brake during downhill driving
Driving with foot on brake pedal Get off the foot from
pedal
Foreign materials such as dirt or sand in brake system Replace: caliper,
wheel cylinder,
master cylinder,
return spring
Broken return spring in shoe assembly Replace
Incorrectly adjusted parking brake cable Adjust
Incorrect wheel or wheel cover
(generating the heat)Replace

08-94850-03
Measure the disc thickness at over four
points.
If any of measured points is below the wear
limit, replace the brake disc with new one. 1.
2.
Clean the dissembled components and visually check the followings:
- Wear, rust and damage on the cylinder and piston
- Damage, crack and wear on cylinder body and guide pin
- Uneven wear and oil contamination on pad
- Damage and tear on boot
- Scratch and bending on disc plate
▶Pad Thickness
Remove the front tire.
Measure the pad thickness and replace it if it
is below the wear limit. 1.
2.
New pad Wear limit
28.0 mm 25.4 mm
▶Brake Disc Thickness
New pad Wear limit
10.5 mm 2 mm
5. INSPECTION
1) Front Brake System
Replace the brake pads at both sides as a
set.

08-10
Install the dial gauge on the side of brake disc
and measure the run-out while rotating the
brake disc.
If the measured value exceeds the limit,
replace the brake disc with new one.
Otherwise, it may cause the pedal vibration
and shimmy when braking. 1.
2.
Limit0.03 mm
(before installation)
0.07 mm (after installation)
Disc Run-Out ▶

08-114850-03
Clean the dissembled components and visually check the followings:
- Wear, rust and damage on the cylinder and piston
- Damage, crack and wear on cylinder body and guide pin
- Uneven wear and oil contamination on pad
- Damage and tear on boot
- Scratch and bending on disc plate
Remove the rear tire.
Measure the pad thickness and replace it if it
is below the wear limit. 1.
2.
New pad Wear limit
20.0 mm 18.4 mm
Replace the brake pads at both sides as a
set.
Measure the disc thickness at over ten
points.
If any of measured points is below the wear
limit, replace the brake disc with new one. 1.
2.
New pad Wear limit
10 mm 2 mm
2) Rear Brake System
Pad Thickness ▶
Brake Disc Thickness ▶

08-12
Let the engine run for 1 to 2 minutes and
stop it. If the brake pedal stroke is shortened
as pumping the brake pedal, the system is
normal. If not, the system is defective. 1.
Depress the brake pedal several times with
engine off. If the brake goes down when
starting engine with pedal depressed, the
system is normal. If not, the system is
defective. 2.
If the above three checks are OK, the system is
normal. If any condition is not met, check the
valve, vacuum hose and brake booster.
3) Brake Booster
OK
NG
Engine stopped
Engine running
Depress the brake pedal when the engine is
running. If the pedal height is not changed
for 30 seconds after stopping the engine, the
system is normal. If not, the system is
defective. 3.

08-134850-03
Stop Lamp Switch
Connector Internal circuit
4) Stop Lamp Switch
Connect the multimeter to stop lamp switch
connector (N.O.) and check if the continuity
exists when pushing in the plunger. If the
continuity doesn't exist, the stop lamp switch
is normal.
Connect the multimeter to stop lamp switch
connector (N.C.) and check if the continuity
exists when pushing in the plunger. If the
continuity doesn't exist, the stop lamp switch
is normal. 1.
2.
TypePlunger
Pushed Not pushed
N.C ContinuityNot continuity
N.O Not continuity
Continuity
5) Pedal Free Play
Check the pedal free play with below
procedures: -
Stop the engine.
Depress the brake pedal several times to
discharge the vacuum pressure of the
brake booster.
Depress the brake pedal until you feel the
resistance, and measure the movement
(A). 1.
2.
3.
Specified value(A)3 ~ 10 mm
If the free play is below the specified value, check if
the clearance between the outer case of the stop
lamp and the brake pedal is within the specified
range. If the clearance is out of the specified range,
the clearance between the clevis pin and the brake
pedal arm is too large. Check the components and
repair if needed.