REAR AXLE - neon.lofis.netneon.lofis.net/SsangYong/Service_Manuals/Korando/KorandoB3D0.pdf · SSANGYONG MY2002 3D-8 REAR AXLE ON-VEHICLE SERVICE AXLE SHAFT ASSEMBLY (WITH DISC BRAKE)

SECTION 3D

REAR AXLE

TABLE OF CONTENTS

General Description and Operation ................. 3D-2

Specifications ................................................... 3D-2

Fastener Tightening Specifications .................. 3D-2

Diagnostic Information and Procedures ........ 3D-3

Component Locator ......................................... 3D-4

Rear Axle Assembly ......................................... 3D-4

Cross Sectional View ........................................ 3D-5

Rear Axle Shaft Assembly ............................... 3D-6

Maintenance and Repair .................................. 3D-8

On-Vehicle Service .............................................. 3D-8

Axle Shaft Assembly (With Disc Brake) .......... 3D-8

Axle Shaft Assembly (With Drum Brake) ...... 3D-11

Rear Axle Housing .......................................... 3D-13

Unit Repair ....................................................... 3D-18

Axle Assembly ............................................... 3D-18

Differential Gear Assembly ............................ 3D-20

Drive Shaft ...................................................... 3D-25

Special Tools and Equipment ....................... 3D-26

Special Tools Table ........................................ 3D-26

SSANGYONG MY2002

3D-2 REAR AXLE

Disc Brake

Drum Brake

50 - 65

4 - 8

85 - 105

50 - 65

150 - 180

30 - 45

30 - 45

150 - 180

150 - 180

70 - 80

12 - 23

6 - 8

1 - 19

Lb-Ft

Axle Shaft Type

Axle Housing Type

Differential

Reduction Ratio

Oil

Type

Gear

Gasoline + M/T

Diesel + M/T

Gasoline + A/T

Diesel + A/T

Capacity

Specification

Semi-floating

Build up

Conventional Type

Hypoid Gear

3.73

4.27

4.56

4.89

1.9

SAE 80W/90 or API GL-5

GENERAL DESCRIPTION AND OPERATIONSPECIFICATIONS

37 - 48

35 - 71

63 - 77

37 - 48

111 - 133

22 - 23

22 - 23

111 - 133

111 - 133

52 - 59

9 - 17

53 - 71

11 - 14

Flange fixing Bolt

Dust shield Bolt

Caliper Bolt

Fixing Nut

N”””””mApplication Lb-In

-

-

-

-

-

-

-

-

-

-

-

-

-

FASTENER TIGHTENING SPECIFICATIONS

Rod Bolt

Shock absorber Bolt

Stabilizer bar cap bolt

Upper arm nut

Lower arm nut

Propeller shaft fixing bolt

LCRV Mounting Bolt

Air Breather Hose Bolt

Brake oil pipe (M10)

REAR AXLE 3D-3

SSANGYONG MY2002

DIAGNOSTIC INFORMATION AND PROCEDURES

Lack of Oil

Low Viscosity of Oil

Inferior Oil

Excessive Backlash of Ring Gears

Worn or Damaged Tooth of Ring and Pinion Gear

Worn or Damaged Tooth of Drive Pinion Gear

Wear of Side Bearing and Side Gear Spline

Bending of Axle Housing

Distortion of Differential Case

Wear of Pinion Shaft

Incorrect Drive Pinion Preload.

Incorrect Contact of Ring Gear and Pinion

Excessive Oil

Fault Seal of Carrier Contact Surface

Axle Housing Crack

Worn or Damaged Oil Seal

Worn or Damaged Tooth of Pinion or Side Gear

Wear of Pinion Shaft

Excessive Backlash of Pinion Gear and Side Gear

Excessive End-Play of Rear Axle Shaft

Incorrect Contact of Side Gear and Differential Case

Axle Housing Crack

Distortion or Poor Installation of Drive pinion Oil Seal

Damaged of Torn Drive Pinion Oil Seal

Loosened Bearing Collar

Worn or Damaged Universal Joint

Worn or damaged Axle Shaft Bearing

Lock of Oil

Insufficient Backlash of Gears

Excessive Preload of Bearing

Replenish

Replace

Replace

Adjust

Replace

Replace

Replace

Replace

Replace

Replace

Adjust

Reassembly

Adjust

Correct

Replace

Replace

Replace

Replace

Replace

Adjust

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replenish

Adjust

Adjust

ChecksPhenomena

Noise

(During Straight

Driving)

Oil Leakage

Noise (During Turning)

Heating

Action

SSANGYONG MY2002

3D-4 REAR AXLE

COMPONENT LOCATORREAR AXLE ASSEMBLY

KAA3D010

1 Axle Shaft/Tube2 Stabilizer Bar3 Spring Seat & Spring4 Upper Arm

5 Shock Absorber6 Lateral Rod7 Input Shaft8 Axle Housing

REAR AXLE 3D-5

SSANGYONG MY2002

CROSS SECTIONAL VIEW

KAA3D020

1 Rear Axle Shaft Assembly2 Bracket Assembly3 Hub Oil Seal4 Bolt5 Axle Shaft Tube

6 Coil Spring Seat (Lower)7 Caliper Assembly8 Input Shaft/Flange9 Rod Mounting Bracket

10 Wheel Speed Sensor

SSANGYONG MY2002

3D-6 REAR AXLE

REAR AXLE SHAFT ASSEMBLYWith disc brake

KAA3D030

1 Brake Disc2 Plug3 Rear Axle Shaft4 Nut5 Washer6 Parking Brake Cable

7 Parking Brake Lining & Back Plate Assembly8 Brake Caliper Assembly9 Spring Washer

10 Bolt11 Rear Axle Housing

REAR AXLE 3D-7

SSANGYONG MY2002

With drum brake

KAA3D040

1 Brake Drum2 Plug3 Rear Axle Shaft4 Wheel Bolt5 Nut6 Washer7 Retainer Plate8 Oil Seal

9 Bearing10 Snap Ring11 Snap Ring12 Oil Seal13 Brake Shoe & Back Plate Assembly14 Bolt15 Rear Axle Housing

SSANGYONG MY2002

3D-8 REAR AXLE

ON-VEHICLE SERVICEAXLE SHAFT ASSEMBLY(WITH DISC BRAKE)Removal

1. Remove the tire.

KAA3D050

KAA3D070

KAA3D060

2. Release the parking brake.

3. Remove the fixing pin of parking brake.

4. After detaching the parking brake lever, detachthe cable.

5. Remove the two fixing bolt of brake caliper.

Notice: Be careful not to damage the brake oilhose.

6. Remove the brake caliper assembly.

Notice: If replacing the brake pad only, remove theupper fixing bolt of caliper pad and lower it.

MAINTENANCE AND REPAIR

REAR AXLE 3D-9

SSANGYONG MY2002

8. Remove the four fixing bolt of dust shield coverand then pull out the dust shield cover.

KAA3D100

KAA3D110

KAA3D090

9. Remove the two plastic plug in the axle shaftflange.

10. Remove the four fixing bolts & washers of axlehousing flange from the retainer plate.

11. Remove the rear axle drive shaft.

KAA3D080

7. Remove the brake disc.

SSANGYONG MY2002

3D-10 REAR AXLE

KAA3D140

KAA3D150

KAA3D130

2. Tighten the flange fixing bolts and washers withthe retainer plate.

Installation Notice

3. Assemble the plastic plug n the rear axle flangeand install the dust shield.

Installation Notice

4. Install the brake disc and caliper assembly.

Installation Notice

5. Install the parking brake cable and tire.

Tightening torque 85 - 105 N•m

KAA3D120

InstallationClean the detached axle shaft, check the damage orwear.

1. After checking the spline & shaft of rear axle shaft,assemble the shaft into the rear axle housing.

Tightening Torque 50 - 65 N•m(37 - 48 lb-ft)

Tightening Torque 4 - 8 N•m(35 - 71 lb-in)

REAR AXLE 3D-11

SSANGYONG MY2002

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AXLE SHAFT ASSEMBLY(WITH DRUM BRAKE)Removal

1. Release the parking brake.

2. Remove the tire.

KAA3D160

KAA3D170

KAA3D180

KAA3D190

3. Remove the brake drum.

Notice: Insert the bolt into the service hole, whiletightening the both side bolts uniformly, removethe brake drum.

4. Remove the fixing pin of parking brake.

5. After detaching the cover of parking brake,disconnect the cable.

6. After pulling out the two plastic plug of axle shaftflange, remove the fixing nuts of inner bracket.

SSANGYONG MY2002

3D-12 REAR AXLE

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7. Remove the axle shaft.

KAA3D200

KAA3D210

KAA3D230

KAA3D220


Installation1. Check the rear axle shaft.

2. Insert the rear axle shaft into the axle housing andtighten the fixing nuts of axle shaft flange.

Installation Notice

3. Connect the brake cable and install the brakedrum.

4. Install the tire and test the braking force.

REAR AXLE 3D-13

SSANGYONG MY2002

REAR AXLE HOUSINGRemoval

1. Remove the tire.

2. Remove the connecting rod of LCRV assembly &fixing nut of axle housing bracket.

KAA3D240

KAA3A250

KAA3D260

KAA3D270

3. Disconnect the brake oil hose & oil line (pipe)

• Brake pipe nut.

• Brake pipe mounting clip

• 3-way connector

• Brake pipe assembly

4. Detach the air breather.

5. Remove the propeller shaft from rear axle inputshaft.

Notice: Do alignment marks before removing.

SSANGYONG MY2002

3D-14 REAR AXLE

KAA3D280

KAA3D300

KAA3D290

6. Pull out the fixing pin of parking brake.

7. After removing the parking brake lever, pull outthe cable.

KAA3D310

8. Remove the lower arm mounting nuts and removethe lower arm from the axle housing.

9. Detach the lower mounting of shock absorber fromthe axle housing.

10. Remove the upper arm mounting nuts and removethe upper arm from the axle housing.

REAR AXLE 3D-15

SSANGYONG MY2002

11. Remove the stabilizer bar.

KAA3D320

KAA3D330

KAA3A350

KAA3A340

12. Remove the lateral rod mounting nut and detachthe lateral rod from the axle housing.

13. Lowering the axle slowly, remove the coil spring& spring seat.

14. Lower the axle housing by using the safety jack.

Installation1. Placing the rear axle housing on the assembly

position, install both coil springs.

SSANGYONG MY2002

3D-16 REAR AXLE

KAA3D360

KAA3D370

KAA3D390

KAA3D380

2. Install the lateral rod in axle hosing.

Notice: Do not tighten the nuts completely.

Installation Notice

3. Install the shock absorber in axle housing.

Installation Notice


Tightening Torque 150 - 180 N•m


4. Install the stabilizer bar and upper/lower arm inaxle housing

Installation Notice

5. Install the propeller shaft of rear axle side andtighten above the fixing bolts/nuts.

Installation Notice

6. Install the brake cable, air bleeder hose, oil pipe,LCRV unit in rear axle assembly with assembledcompletely.

Installation Notice

7. Bleeding the air in brake, install the tire.

30 - 45 N•m(22 - 33 lb-ft)

150 - 180 N•m(111 - 133 lb-ft)

150 - 180 N•m(111 - 133 lb-ft)

Stabilizer bar cap bolt

Upper arm nut

Lower arm nut

12 - 23 N•m(9 - 17 lb-ft)

6 - 8 N•m(53 - 71 lb-in)

15 - 19 N•m(11 - 14 lb-ft)

LCRV Mounting Bolt

Air Breather Hose Bolt

Brake Oil Pipe (M10)

REAR AXLE 3D-17

SSANGYONG MY2002

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2. Measure the run-out of shaft.

KAA3D400

KAA3D410

KAA3D430

Inspection1. Check the shaft spline for the wear and damage.

KAA3D420

Specified value Within 1.0 mm

3. Measure the run-out of shaft flange.


4. Install the axle shaft and measure the clearanceof shaft direction.


SSANGYONG MY2002

3D-18 REAR AXLE

UNIT REPAIRAXLE ASSEMBLY

KAA3D440

REAR AXLE 3D-19

SSANGYONG MY2002

1 Drive Pinion Lock Nut........................... 240 - 310 N•m (177 - 229 lb-ft)

2 Washer3 Companion Flange4 Pinion Oil Seal5 Bearing Slinger6 Bearing7 Shim8 Shim9 Bearing Cup

10 Breather Nipple11 Rear Axle Housing12 Oil Drain Plug............ 28 - 42 N•m (21 - 31 lb-ft)13 Shim14 Bearing15 Drive Pinion16 Bearing Cap

17 Bolt ......................... 87 - 124 N•m (64 - 94 lb-ft)18 Bearing19 Shim20 Ring Gear21 Shaft Lock Pin22 Differential Case23 Ring Gear Mounting Bolt

.................................. 75 - 90 N•m (55 - 66 lb-ft)24 Thrust Washer25 Differential Pinion26 Thrust Washer27 Side Gear28 Differential Shaft29 Housing Cover30 Bolt ............................ 38 - 46 N•m (28 - 34 lb-ft)31 Oil Filler Plug ............ 28 - 42 N•m (21 - 31 lb-ft)

SSANGYONG MY2002

3D-20 REAR AXLE

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DIFFERENTIAL GEAR ASSEMBLYDisassembly

1. Remove the drain plug and drain oil. Reinstall thedrain plug.

Installation Notice

KAA3D450

KAA3D470

KAA3D460

KAA3D480


2. Remove the axle housing cover.

Notice: Clean the cover and housing contactsurface.

3. Remove the bearing cap bolts and remove thebearing cap. Pull out the differential carrierassembly.

Notice: Do alignment marks on the bearing capnot to change the caps before removal. When pullingout, be careful to damage the axle housing.

4. Disassemble the parts of differential carrierassembly.

REAR AXLE 3D-21

SSANGYONG MY2002

5. Remove the drive pinion lock nut. Disassemblethe parts of drive pinion

KAA3D490

SSANGYONG MY2002

3D-22 REAR AXLE

Adjust backlash(Drecrease backlash)

• Select proper shin tomove the drive piniontoward the ring gear(toward toe)

Adjust backlash(Increase backlash)• Select proper shim tomove the drive pinionagainst the ring gear(toward heel)

Adjust backlash(Increase pinion shim)

• Move the drive piniontoward the ring gear(toward center of ringgear)

Adjust backlash(Decrease pinion shim)

• Move the ring geartoward the drive pinion(toward r ing gearcenter line)

Excessive backlash

• Noise can be occurred

Insufficient backlash

• Tooth can be damagedor broken under heavyload

Excessive backlash

• Drive pinion shaft isapart from the ring gear


Insufficient backlash

• Gear contacts on thelow flank

• Gear can be damagedor worn


Inspection of Ring Gear Tooth ContactPattern

1. Normal Contact

Apply gear-marking compound (prussian blue/redlead) on the ring rear teeth. Rotate the ring gearand check the to the contact pattern.

KAA3D500

Tooth contact pattern Possible cause Remedy

KAA3D510

KAA3D530

KAA3D550

KAA3D520

KAA3D540

KAA3D560

KAA3D570 KAA3D580

2. Abnormal contact

1. Heel contact

2. Toe contact

3. Face contact

4. Flank contact

REAR AXLE 3D-23

SSANGYONG MY2002

Assembly1. Clean all parts and check the followings.

• Check the ring gear, drive pinion for wear anddamage. If damaged, replace it as a set.

• Check the bearing for sticks, wear, noise andturning resistance.

• Check the side gear, pinion, pinion shaft andthrust washer for wear and damage.

• Check the differential carrier for crack and wear(bearing contact surface). Check the gear casefor crack.

KAA3D590

KAA3D600

KAA3D620

KAA3D610

2. Assemble the drive pinion assembly to the axlehousing and then tighten the pinion lock nut.

Installation Notice

Tightening torque 240 - 310 N•m


3. Assemble the differential carrier assembly. Alignthe ring gear to the mark of differential carrier,tighten the fixing bolts.

Installation Notice

4. Measure the backlash of side gear and pinion gear.

Specified value 0 - 0.5 mm

SSANGYONG MY2002

3D-24 REAR AXLE

KAA3D630

KAA3D640

KAA3D650

5. Install the differential carrier assembly into the axlehousing. Set up the bearing cap and then tightenthe cap bolts.

Installation Notice

Notice: Be careful not to change the caps. Be sureto keep the original position of the caps.


6. Measure the backlash of drive pinion and ringgear.

Specified value 0.13 - 0.20 mm

7. Install the axle housing cover. Tighten the fixingbolts.

Installation Notice


REAR AXLE 3D-25

SSANGYONG MY2002

KAA3D670

KAA3D660

DRIVE SHAFTTools Required661 589 15 33 00 Rear Hub Bearing Installer

661589 18 33 00 Axle Bearing Puller Plate

661 589 18 33 01 Rear Axle Bearing Remover

661 589 18 33 02 Rear Axle Oil Seal Remover

Disassembly Procedure1. Remove the rear drive shaft from the vehicle. Refer

to “Rear Drive Shaft” in this section.

2. Remove the toothed ring using the axle bearingpuller plate 661 589 18 33 00 and rear axle bearingremover 661 589 18 33 01 by press.

3. Remove the rear drive shaft oil seal bearing usingthe axle bearing puller plate 661 589 18 33 00 andrear axle oil seal remover 661 589 18 33 02 bypress.

4. Remove the rear disc brake rotor shield.

3. Install the retainer drive shaft bearing using therear hub bearing installer 661 589 15 33 00 by press.

4. Install the rear drive shaft. Refer to “Rear DriveShaft” in this section.

KAA3D690

KAA3D680

Assembly Procedure1. Install the rear disc brake rotor shield.

2. Install the rear drive shaft bearing oil seal usingthe rear hub bearing installer 661 589 15 33 00 bypress.

SSANGYONG MY2002

3D-26 REAR AXLE

SPECIAL TOOLS AND EQUIPMENTSPECIAL TOOLS TABLE

661 589 13 33 00Ball Joint Remover

661 589 18 33 00

Axle Bearing Puller

Plate

KAA3D700

KAA3D710

KAA3D720

661 589 18 33 02Rear Axle Oil Seal

Remover

661 589 15 33 00

Rear Hub Bearing

Installer

661 589 18 33 01

Rear Axle BearingRemover

KAA3D740

KAA3D750

KAA3D760

J-8059

Snap Ring Plier

DW340-090-01

Differential Assembly

Remover/Installer

DW340-090-03

Rear DifferentialAssembly

Remover/Installer

KAA3D730 KAA3D770

Documents

REAR AXLE - neon.lofis.netneon.lofis.net/SsangYong/Service_Manuals/Korando/KorandoB3D0.pdf · SSANGYONG MY2002 3D-8 REAR AXLE ON-VEHICLE SERVICE AXLE SHAFT ASSEMBLY (WITH DISC BRAKE)