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SECTION 3A FRONT AXLE TABLE OF CONTENTS Specifications ....................................................... 3A-2 General Specifications ......................................... 3A-2 Fastener Tightening Specifications ....................... 3A-2 Component Locator ............................................. 3A-3 Front Axle Assembly ........................................... 3A-3 Auto-Locking Hub ................................................ 3A-4 Maintnance and Repair ........................................ 3A-5 On-Vehicle Service ................................................. 3A-5 Vacuum Line ........................................................ 3A-5 Steering Knuckle and Drive Shaft ......................... 3A-7 Front Axle Assembly ......................................... 3A-12 Unit Repair .......................................................... 3A-16 Axle Housing ..................................................... 3A-16 Outer Joint Seal ................................................. 3A-23 Inner Tripot Seal ................................................ 3A-24 Special Tools and Equipment ............................ 3A-25 Special Tools Table ............................................ 3A-25

FRONT AXLE - neon.lofis.netneon.lofis.net/SsangYong/Service_Manuals/Korando/KorandoB3A0.pdf · Remove the front propeller shaft-to-front axle bolts. ... change, always use front axle

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  • SECTION 3A

    FRONT AXLE

    TABLE OF CONTENTS

    Specifications ....................................................... 3A-2

    General Specifications ......................................... 3A-2

    Fastener Tightening Specifications ....................... 3A-2

    Component Locator ............................................. 3A-3

    Front Axle Assembly ........................................... 3A-3

    Auto-Locking Hub ................................................ 3A-4

    Maintnance and Repair ........................................ 3A-5

    On-Vehicle Service ................................................. 3A-5

    Vacuum Line ........................................................ 3A-5

    Steering Knuckle and Drive Shaft ......................... 3A-7

    Front Axle Assembly ......................................... 3A-12

    Unit Repair .......................................................... 3A-16

    Axle Housing ..................................................... 3A-16

    Outer Joint Seal ................................................. 3A-23

    Inner Tripot Seal ................................................ 3A-24

    Special Tools and Equipment ............................ 3A-25

    Special Tools Table ............................................ 3A-25

  • SSAMGYONG MY2002

    3A-2 FRONT AXLE

    M/T

    A/T

    M/T

    A/T

    M/T

    A/T

    M/T

    A/T

    SPECIFICATIONSGENERAL SPECIFICATIONS

    Application

    Drive Shaft Type

    Axle Housing Type

    Differential Type

    Differential Gear

    CV Joint

    Build - up

    Conventional

    Hypoid Gear

    4.56

    5.38

    4.27

    4.89

    4.55

    5.86

    3.73

    4.89

    1.3 L

    SEA 80W/90, API GL - 5

    Description

    661LA

    662LA

    E23

    E32

    Reduction Ratio

    Oil Capacity

    Oil Specification

    FASTENER TIGHTENING SPECIFICATIONSSteering Knuckle and Drive Shaft

    36.8 - 44.2

    18.4 - 25.8

    51.6 - 66.3

    11.0

    -

    62.7 - 77.4

    Drive Shaft Cover Bolt

    Drive Shaft to Front Axle Inner Shaft

    Hub Flange Bolt

    Hub Nut

    Locking Hub Washer Screw

    Wheel Speed Sensor

    NmApplication Lb-InLb-Ft

    50 - 60

    25 - 35

    70 - 90

    15

    2 - 4

    85 - 105

    -

    -

    -

    -

    17.7 - 35.4

    -

  • FRONT AXLE 3A-3

    SSANGYONG MY2002

    1 Drive Shaft2 Axle Housing Mounting Bolt3 Axle Housing4 Cross Member

    COMPONENT LOCATORFRONT AXLE ASSEMBLY

    5 Brake Disc6 Hub-Wheel7 Locking Hub

    KAA3A010

  • SSAMGYONG MY2002

    3A-4 FRONT AXLE

    AUTO-LOCKING HUB

    1 Cap2 Filter3 Vacuum Diaphragm4 Diaphragm Retainer5 Piston6 Bolt (M10)7 Lock Washer8 O-ring9 Retaining Ring

    10 Clutch Ring

    11 Body12 Return Spring13 Bearing14 O-ring15 Retaining Ring16 Inner Drive Gear17 Oil Seal18 Oil Seal Race19 Axle Retaining Ring

    KAA3A020

  • FRONT AXLE 3A-5

    SSANGYONG MY2002

    MAINTENANCE AND REPAIR

    ON-VEHICLE SERVICEVACUUM LINE

    1 Hub A-Auto Vac Locking2 Valve-Check3 Valve A-Solenoid4 Connector5 House-Vcuum6 Hose-Vacuum7 Hose-Vacuum8 Hose-Vacuum9 Hose

    10 Tube-corruagated11 Clip12 Band

    KAA3A030

    13 Clip14 Bolt15 Tube A-Vacuum16 Clip-L/Hub Hose MTG17 Cap-Hub Flange FRT18 Flange-Hub FRT19 Cap20 Bolt21 Washer22 Ring-Retainer23 Bolt

  • SSAMGYONG MY2002

    3A-6 FRONT AXLE

    Removal & Installation Procedure1. Be careful not to change the valve when

    connecting the check valve and each hose.

    2. Adjust the clearance between the retainer ring (5)and locking hub (7) using the shim(6).

    Notice: Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0mm

    3. Tighten the auto locking hub cap bolt to thespecified torque and order.

    Tightening Torque 50 - 60 Nm(37 - 44 lb-ft)

    Normal Max. 0.2 mm

    KAA3A040

    KAA3A050

    Installation Notice

  • FRONT AXLE 3A-7

    SSANGYONG MY2002

    STEERING KNUCKLE AND DRIVE SHAFT

    1 Front Axle Inner Shaft2 Front Axle Drive Shaft3 Spring Washer

    4 Bolt ............................ 45 - 60 Nm (33 - 44 lb-ft)5 Steering Knuckle

    KAA3A060

  • SSAMGYONG MY2002

    3A-8 FRONT AXLE

    Removal & Installation Procedure1. Remove the tire.

    Installation Notice

    2. Remove the autolocking hub vacuum hose.

    3. With ABS

    Remove the wheel speed sensor from the steeringknuckle.

    Installation Notice

    4. Remove the mounting bolts and pull off the caliperassembly.

    Installation Notice

    Notice: Be careful not to damage the brake hose.

    KAA3A070

    KAA3A080

    KAA3A090

    KAA3A100

    TighteningTorque

    80 - 120 Nm(59 - 89 lb-ft)

    110 - 130 Nm(81 - 96 lb-ft)

    Steel Wheel

    AluminumWheel

    Tightening Torque 6 - 8 Nm(53 - 71 lb-in)

    TighteningTorque

    25 - 35 Nm(18 - 26 lb-ft)

    85 - 105 Nm(63 - 77 lb-ft)

    Hose Bolt

    MountingBolt

  • FRONT AXLE 3A-9

    SSANGYONG MY2002

    5. With part time transfer case.

    5-1. Remove the cover mounting bolts and pull offthe cover.

    Installation Notice

    5-2. Remove the snap ring of the drive shaft and pulloff the hub body.

    Notice: For assembly, adjust the clearancebetween the snap ring and hub not to exceed0.2 mm (Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0mm).

    6. With full time transfer case

    6-1. Detach the hub cap with screw driver and removethe snap ring on drive shaft.

    Installation Notice

    5-3. Remove the screws and pull off the locking hubwasher.

    Installation Notice

    Notice: For assembly, adjust the clearancebetween the snap ring and hub not to exceed 0.2mm (Shim thickness : 0.1, 0.2, 0.3, 0.5, 1.0 mm).

    KAA3A110

    KAA3A120

    KAA3A130

    KAA3A140

    Tightening Torque 50 - 60 Nm(37 - 44 lb-ft)

    Tightening Torque 2 - 4 Nm(18 - 35 lb-in)

    Tightening Torque 15 Nm (11 lb-ft)

  • SSAMGYONG MY2002

    3A-10 FRONT AXLE

    8. Remove the hub and disk assembly.

    6-2. Unscrew the bolts and remove hub flange.

    Installation Notice

    Before installation, apply loctite on the matingsurface.

    7. Remove the hub nut with special tool.

    KAA3A150

    KAA3A160

    KAA3A170

    KAA3A180

    9. Remove the disk brake dust shield.

    Installation Notice

    Tightening Torque 70 - 90 Nm(52 - 66 lb-ft)

    Tightening Torque 15 Nm (11 lb-ft)

    Tightening Torque 4 - 6 Nm(35 - 53 lb-in)

  • FRONT AXLE 3A-11

    SSANGYONG MY2002

    10. Remove the cotter pin and slotted nut and thenremove the steering knuckle arm and tie-rod.

    Installation Notice

    11. Remove the cotter pin and nut from the steeringknuckle arm and upper arm ball joint connection.

    Installation Notice

    12. Remove the cotter pin and nut from the steeringknuckle arm and lower and lower arm boll jointconnection.

    Installation Notice

    13. Carefully remove the knuckle arm.

    Replace the cotter pin with new one.

    Replace the cotter pin with new one.

    KAA3A190

    KAA3A200

    KAA3A210

    Tightening Torque 40 Nm (30 lb-ft)

    Tightening Torque 115 Nm (85 lb-ft)

    Tightening Torque 150 Nm (111 lb-ft)

    14. Remove the drive shaft mounting bolts andremove the drive shaft.

    Installation Notice

    Observe the tighening torque and sequence.

    15. Installation should follow the removal precedurein the reverse order.

    KAA3A220

    Tightening Torque 4.6 - 60 kgfm

  • SSAMGYONG MY2002

    3A-12 FRONT AXLE

    1 Axle Mounting Bracket2 Breather Hose3 Bolt (Rear)4 Nut ......................... 95 - 142 Nm (70 - 105 lb-ft)5 Cross Member6 Bolt (Front)7 Bushing8 Spacer

    FRONT AXLE ASSEMBLY

    9 Bushing10 Nut ......................... 95 - 142 Nm (70 - 105 lb-ft)11 Front Axle Assembly12 Nut .............................. 70 - 80 Nm(52 - 59 lb-ft)13 Bolt14 Inner Axle Shaft (LH)15 Inner Axle Shaft (RH)

    Preceding Work : Removal of the front axle drive shaft

    Removla of the steering gear box

    KAA3A230

  • FRONT AXLE 3A-13

    SSANGYONG MY2002

    Tools Required

    DW340-80 Front Axle Support

    Removal and Installation Procedure1. Raise and suitably support the vehicle.

    2. Remove the lower cover.

    Installation Notice

    KAA3A240

    KAA3A260

    KAA3A250

    5. Remove the front drive shaft-to-front axleassemblybolts.

    Installation Notice

    Tightening Torque 4.5 - 6.0 kgfm

    3. Remove the rack and pinion assembly. Refer toSection 6C, Power Steering Gear.

    4. Remove the front axle bleeder hose.

    Tightening Torque 35 Nm (26 lb-ft)

    KAA3A270

    6. Remove the front propeller shaft-to-front axle bolts.

    Removal Notice

    Make alignment marks on the front propellershaft and front axle housing.

    Installation Notice

    Tightening Torque 7.0 - 8.5 kgfm

  • SSAMGYONG MY2002

    3A-14 FRONT AXLE

    Tightening Torque 118 Nm (87 lb-ft)

    7. Remove the front axle housing mounting nuts fromthe crossmember.

    Installation Notice

    KAA3A280

    KAA3A300

    KAA3A290

    9. Support the front axle housing with front axle sup-port DW340-080.

    Tightening Torque 78 Nm (58 lb-f t )

    8. Remove the lower ball joint using the ball joint re-mover 661 589 13 33 00.

    Installation Notice

    10. Remove the front axle mounting bracket nuts.

    Installation Notice

    KAA3A310

    Tightening Torque 9.5 - 14.2 kgfm

  • FRONT AXLE 3A-15

    SSANGYONG MY2002

    11. Lowering the jack carefully, remove the front axleassembly.

    12. Installation should follow the removal procedurein the reverse order.

    KAA3A320

  • SSAMGYONG MY2002

    3A-16 FRONT AXLE

    UNIT REPAIRAXLE HOUSING

    Preceding Work : Removal of the axle housing

    KAA3A330

  • FRONT AXLE 3A-17

    SSANGYONG MY2002

    1 Front Axle Housing Mounting Bracket2 Inner Shaft (Left)3 Bolt ............................ 55 - 65 Nm (41 - 48 lb-ft)4 Oil Seal ................................................................

    ........ Replace, Apply Grease to the Sealing Rib5 Snap Ring6 Bearing7 Snap Ring8 Oil Drain Plug............ 28 - 41 Nm (21 - 30 lb-ft)9 Front Axle Housing

    10 Breather Nipple11 Inner Shaft (Right)12 Pinion Lock Nut ..240 - 310 Nm (177 - 229 lb-ft)13 Washer14 Companion Flange15 Oil Seal ................................................................

    ........ Replace, Apply Grease to the Sealing Rib16 Bearing17 Shim18 Bearing Baffle19 Shim

    20 Bearing21 Oil Slinger22 Drive Pinion23 Oil Filler Plug ............ 28 - 41 Nm (21 - 30 lb-ft)24 Bolt ............................ 39 - 46 Nm (29 - 34 lb-ft)25 Axle Housing Cover .............................................

    ..... Apply Liquid Gasket to the Contact Surface26 Ring Gear27 Bearing28 Shim29 Shaft Lock Pin30 Differential Case31 Bolt ............................ 75 - 90 Nm (55 - 66 lb-ft)32 Bolt ............................ 48 - 69 Nm (35 - 51 lb-ft)33 Washer34 Bearing Cap35 Thrust Washer36 Side Gear37 Differential Shaft38 Differential Pinion39 Thrust Washer

  • SSAMGYONG MY2002

    3A-18 FRONT AXLE

    Disassembly Procedure1. Remove the drain plug and drain the oil. Reinstall

    the drain plug.

    Installation Notice

    2. Unscrew the axle housing and housing mountingbracket bolts and remove the bracket and innershaft assembly.

    3. Remove the bearing fixing snap ring of the innershaft and pull out the bearing. Separate the innershaft and the mounting bracket.

    4. Remove the axle housing cover.

    Notice: Clean the cover and housing contactsurfaces.

    KAA3A340

    KAA3A360

    KAA3A350

    KAA3A370

    Tightening Torque 2.8 - 4.2 kgfm

  • FRONT AXLE 3A-19

    SSANGYONG MY2002

    5. Unscrew the bearing cap bolts and remove thebearing caps. Pull out the differential carrierassembly.

    Notice:

    Place alignment marks on the bearing cap notto change the caps before removal. Whenpulling out the differential carrier assembly, becareful not to damage the axle housing.

    When adding fluid or making a complete fuidchange, always use front axle housing.

    7. Disassemble the parts of the differential carrierassembly.

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

    KAA3A380

    KAA3A410

    KAA3A390

    KAA3A400

    6. Pull out the differential assembly using thedifferential assembly remover/installer DW340-090-01 and front differental assembly/installerDW340-090-02.

  • SSAMGYONG MY2002

    3A-20 FRONT 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.

    Assembly Procedure1. Clean the all parts and check the followings :

    Check the ring gear and drive pinion for wearand damage. 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.

    KAA3A420

    KAA3A430

    KAA3A660

    KAA3A420

    Tightening Torqueof the Lock Nut

    240 - 310 Nm(177 - 229 lb-ft)

    Tightening Torqueof the Ring Gear Bolts

    75 - 90 Nm(55 - 66 lb-ft)

    Standard 0.025 mm

  • FRONT AXLE 3A-21

    SSANGYONG MY2002

    5. Install the differential carrier assembly into the axlehousing.

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

    6. Measure backlash of the drive pinion and ringgear.

    Tightening Torque ofthe Bearing Cap Bolts

    4.8 - 6.9 kgfm

    KAA3A670

    KAA3A360

    KAA3A440

    KAA3A680

    7. Install the axle housing cover.

    8. Assemble the parts of the front axle shaft andhousing mounting bracket.

    Notice: Apply grease to the oil seal rib.

    Specified Value 0.165 mm

    Tightening Torque 3.9 - 4.6 kgfm

  • SSAMGYONG MY2002

    3A-22 FRONT AXLE

    1. Heel contact

    2. Toe contact

    3. Face contact

    4. Flank contact

    Adjust backlash(Drecrease backlash)

    Select proper shim(s) tomove the drive piniontoward the ring gear(toward toe)

    Adjust backlash(Increase backlash)

    Select proper shim(s) 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 gear towardthe drive pinion (towardring gear center line)

    Excessive backlash (little)

    Noise can be occurred

    Insufficient backlash (little)

    Tooth can be damagedor broken under heavyload

    Excessive backlash (much)

    Drive pinion shaft isapart from the ring gear

    Noise can be occurred

    Insufficient backlash (much)

    Gear contacts on thelow flank

    Gear can be damagedor worn

    Noise can be occurred

    Inspection of Ring Gear Tooth ContactPattern

    Normal Contact

    Apply gear-marking compound (Prussian blue / redlead) on the ring gear teeth. Rotate the ring gear andcheck the tooth contact pattern.

    KAA3A450

    Abnormal Contact

    Tooth contact pattern Possible cause Remedy

    KAA3A460

    KAA3A470

    KAA3A480

    KAA3A500

    KAA3A510

    KAA3A520

    KAA3A490 KAA3A530

  • FRONT AXLE 3A-23

    SSANGYONG MY2002

    KAA3A550

    KAA3A540

    OUTER JOINT SEALTools Required

    J-8059 Snap Ring Plier

    Disassembly and Assembly Procedure1. Remove the front drive shaft from the vehicle.

    Refer to Front Drive Shaft in this section.

    2. Remove the large seal retaining clamp.

    3. Remove the small seal retaining clamp.

    4. Degrease the joint.

    Installation Notice:

    Fill the joint seal with 135 to 155 g (4.76 to 5.46ounces) of the recommended grease. Repackthe joint with 135 to 155 g (4.76 to 5.46 ounces)of the recommended grease.

    5. Spread the snap ring using the snap ring plier J-8059 and remove the outer joint from the front driveshaft.

    Caution: Do not disassembly the outer jointassembly. Parts are match fit and cannot beserviced separately. Improper reassembly willadversely affect both performance and safety.

    6. Remove the seal from the joint assembly.

  • SSAMGYONG MY2002

    3A-24 FRONT AXLE

    KAA3A580

    KAA3A570

    4. Degrease the tripot assembly.

    Installation Notice

    Fill the tripot housing with 185 to 205 g (6.53 to7.23 ounces) of the recommended grease.Repack the tripot with 185 to 205 g (6.53 to7.23 ounces) of the recommended grease.

    5. Remove the shaft retaining ring using the snapring plier J-8059.

    6. Remove the tripot and the tripot joint retaining ringfrom the front drive shaft.

    7. Remove the tripot joint seal from the front driveshaft.

    KAA3A560

    INNER TRIPOT SEALTools Required

    J-8059 Snap Ring Plier

    Disassembly and Assembly Procedure1. Remove the front drive shaft from the vehicle.

    Refer to Front Drive Shaft in this section.

    2. Remove the large seal retaining clamp.

    3. Remove the small seal retaining clamp.

  • FRONT AXLE 3A-25

    SSANGYONG MY2002

    SPECIAL TOOLS AND EQUIPMENTSPECIAL TOOLS TABLE

    661 589 13 33 00Ball Joint Remover

    661 589 18 33 00

    Axle Bearing Puller

    Plate

    KAA3A590

    KAA3A600

    KAA3A610

    J-8059

    Snap Ring Plier

    DW340-080

    Front Axle Support

    DW340-090-02Front Differential

    Assembly

    Remover/Installer

    KAA3A630

    KAA3A640

    KAA3A650

    DW340-100

    Front Axle BearingRemover

    DW340-090-01

    Differential Assembly

    Remover/Installer

    KAA3A620