SsangYong Korando II (1996-2006 year). Manual - part 221

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 Procedure

1. Clean the all parts and check the followings :

•

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

•

Check the bearing for sticks, wear, noise and
turning resistance.

•

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

•

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

KAA3A420

KAA3A430

KAA3A660

KAA3A420

Tightening Torque

of the Lock Nut

240 - 310 N•m

(177 - 229 lb-ft)

Tightening Torque

of 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 axle

housing.

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

6. Measure backlash of the drive pinion and ring

gear.

Tightening Torque of

the 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 and

housing 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) to
move the drive pinion
toward the ring gear
(toward toe)

Adjust backlash
(Increase backlash)

•

Select proper shim(s) to
move the drive pinion
against the ring gear
(toward heel)

Adjust backlash
(Increase pinion shim)

•

Move the drive pinion
toward the ring gear
(toward center of ring
gear)

Adjust backlash
(Decrease pinion shim)

•

Move the ring gear toward
the drive pinion (toward
ring gear center line)

Excessive backlash (little)

•

Noise can be occurred

Insufficient backlash (little)

•

Tooth can be damaged
or broken under heavy
load

Excessive backlash (much)

•

Drive pinion shaft is
apart from the ring gear

•

Noise can be occurred

Insufficient backlash (much)

•

Gear contacts on the
low flank

•

Gear can be damaged
or worn

•

Noise can be occurred

Inspection of Ring Gear Tooth Contact
Pattern

Normal Contact

Apply gear-marking compound (Prussian blue / red
lead) on the ring gear teeth. Rotate the ring gear and
check 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 SEAL

Tools Required

J-8059

Snap Ring Plier

Disassembly and Assembly Procedure

1. 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  5.46
ounces) of the recommended grease. Repack
the 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 drive
shaft.

Caution: Do not disassembly the outer joint
assembly. Parts are match fit and cannot be
serviced separately. Improper reassembly will
adversely affect both performance and safety.

6. Remove the seal from the joint assembly.