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

N”””””mApplication 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 N•m(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 N•m (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 N•m(59 - 89 lb-ft)

110 - 130 N•m(81 - 96 lb-ft)

Steel Wheel

AluminumWheel

Tightening Torque 6 - 8 N•m(53 - 71 lb-in)

TighteningTorque

25 - 35 N•m(18 - 26 lb-ft)

85 - 105 N•m(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 N•m(37 - 44 lb-ft)

Tightening Torque 2 - 4 N•m(18 - 35 lb-in)

Tightening Torque 15 N•m (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 N•m(52 - 66 lb-ft)

Tightening Torque 15 N•m (11 lb-ft)

Tightening Torque 4 - 6 N•m(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 N•m (30 lb-ft)

Tightening Torque 115 N•m (85 lb-ft)

Tightening Torque 150 N•m (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 kgf•m

SSAMGYONG MY2002

3A-12 FRONT AXLE

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

FRONT AXLE ASSEMBLY

9 Bushing10 Nut ......................... 95 - 142 N•m (70 - 105 lb-ft)11 Front Axle Assembly12 Nut .............................. 70 - 80 N•m(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 kgf•m

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

4. Remove the front axle bleeder hose.

Tightening Torque 35 N•m (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 kgf•m

SSAMGYONG MY2002

3A-14 FRONT AXLE

Tightening Torque 118 N•m (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 N•m (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 kgf•m

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 N•m (41 - 48 lb-ft)4 Oil Seal ................................................................

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

10 Breather Nipple11 Inner Shaft (Right)12 Pinion Lock Nut ..240 - 310 N•m (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 N•m (21 - 30 lb-ft)24 Bolt ............................ 39 - 46 N•m (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 N•m (55 - 66 lb-ft)32 Bolt ............................ 48 - 69 N•m (35 - 51 lb-ft)33 Washer34 Bearing Cap35 Thrust Washer36 Side Gear37 Differential Shaft38 Differential Pinion39 Thrust Washer

SSAMGYONG MY2002

3A-18 FRONT AXLE

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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 kgf•m

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 N•m(177 - 229 lb-ft)

Tightening Torqueof the Ring Gear Bolts

75 - 90 N•m(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 kgf•m

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 kgf•m

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