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SsangYong Korando II (1996-2006 year). Manual - part 239

SSANGYONG MY2002

4D-4 FRONT BRAKES

YAD4B080

CALIPER ASSEMBLY

Front Caliper Brake

1 Brake Caliper Assembly
2 Guide Rod Set
3 Brake Pad
4 Brake Pad Spring
5 Caliper Mounting Bolt

6 Piston Seal
7 Piston
8 Piston Boot
9 Caliper Guide Rod Bolt

10 Bleeder Screw

FRONT BRAKES 4D-5

SSANGYONG MY2002

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DIAGNOSTIC INFORMATION AND PROCEDURES

KAA4D020

PAD INSPECTION

1. Raise and suitably support the vehicle.

2. Remove the front wheel. Refer to Section 2E, Tires

and Wheels.

3. Visually check the linings for minimum thickness

and wear.

4. Measure the thickness.

Important: The minimum discard thickness of the
lining is 2 mm (0.08 inch).

5. Install the pads in axle sets only.

6. Install the rear wheels. Refer to Section 2E, Tires

and Wheels.

7. Lower the vehicle.

FRONT DISC BRAKE ROTOR
INSPECTION

Thickness variation can be checked by measuring the
thickness of the rotor at four or more points around the
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the
rotor.

A rotor that varied by more than 0.013 mm (0.0005
inch) can cause pedal pulsations and/or front end
vibration during brake applications. A rotor that does
not meet these specifications should be refinished to
specifications or replaced.

During manufacturing, the brake rotor and the toler-
ances of the braking surface regarding flatness, thick-
ness variation, and lateral runout are held very close.
The maintenance of close tolerances on the shape of
the braking surfaces is necessary to prevent brake
roughness.

In addition to these tolerances, the surface finish must
be held to a specified range. The control of the braking
surface finish is necessary to avoid pulls and erratic
performance and to extend lining life.

Light scoring of the rotor surfaces not exceeding 0.4
mm (0.016 inch) in depth, which may result from normal
use, is not detrimental to brake operation.

Using a commercially available dial indicator, check
lateral runout as follows:

Notice: Permissible lateral runout is a maximum 0.07
mm (0.003 inch). If lateral runout exceeds the specifica-
tion, ensure that there is no dirt between the rotor and
the hub and that contact surfaces are smooth and free
from burrs.

1. Position the transaxle in NEUTRAL.

2. Remove the rotor. Refer to “Rotor” in this section.

3. Fasten the brake rotor to the wheel hub with two

wheel nuts. Refer to Section 2E, Tires and Wheels.

KAA4D030

4. Fasten a dial indicator to the brake caliper.

5. Set the gauge probe tip to approximately 10 mm

(0.394 inch) from the outer edge of the brake rotor,
perpendicular to the disc and under slight preload.

6. Remove the dial indicator and the wheel nuts that

connect the rotor to the hub.

Important: Since accurate control of the tolerances
is necessary for proper performance of the disc
brakes, refinishing of the rotor should be done only
with precision equipment.

7. Refinish the rotor, if required, with precision equip-

ment. Discard the rotor if it fails to meet the above
specifications after refinishing.

8. Install the rotor. Refer to “Rotor” in this section.

SSANGYONG MY2002

4D-6 FRONT BRAKES

KAA4D080

FRONT DISC BRAKE ROTOR

Removal and Installation Procedure

1. Raise and suitably support the vehicle.

2. Remove the front wheels. Refer to Section 2E,

Tires and Wheels.

3. Remove the hub bearing assembly. Refer to

Section 2C, Front Suspension.

4. Remove the front disc brake rotor.

5. Installation should follow the removal procedure in

the reverse order.

KAA4D040

REPAIR INSTRUCTIONS

ON-VEHICLE SERVICE

BRAKE PADS

Removal and Installation Procedure

1. Raise and suitably support the vehicle.

2. Remove the front wheels. Refer to Section 2E,

Tires and Wheels.

3. Remove the caliper guide lower bolt.

Important: Caliper assembly removal is not
necessary to service the brake pad.

Installation Notice

•

Take care not to damage the piston seal when
the retaining frame is pulled down.

Tightening Torque

31 N•m (23 lb-ft)

KAA4D050

4. Remove the brake pads.

Installation Notice:

•

Measure the minimum brake pad thickness.
Refer to “Lining Inspection” in this section.

•

Always change the all pads on one wheel at a
time.

5. Installation should follow the removal procedure in

the reverse order.

FRONT BRAKES 4D-7

SSANGYONG MY2002

KAA4D060

KAA4D070

CALIPER ASSEMBLY

Removal and Installation Procedure

1. Raise and suitably support the vehicle.

2. Remove the front wheels. Refer to Section 2E,

Tires and Wheels.

3. Remove the brake hose mounting nut and

disconnect the hose. Plug the openings in the
caliper and the brake hose to prevent fluid loss
and contamination.

Installation Notice

Tightening Torque

30 N•m (22 lb-ft)

4. Remove the caliper mounting bolts and then

remove the caliper assembly.

Installation Notice

Tightening Torque

95 N•m (70 lb-ft)

•

Bleed the caliper. Refer to Section 4A, Hydraulic
Brakes.

Notice: do not move the vehicle until a firm pedal
is obtained or improper braking action will result.

•

Repeatedly press the brake pedal to bring the
pads in contact with the rotor.

5. Installation should follow the removal procedure

in the reverse order.

SPLASH SHIELD

Removal and Installation Procedure

1. Raise and suitably support the vehicle.

2. Remove the front wheels. Refer to Section 2E,

Tires and Wheels.

3. Remove the hub bearing assembly. Refer to

Section 2C, Front Suspension.

4. Remove the front disc brake rotor. Refer to “Front

Disc Brake Rotor” in this section.

5. Remove the splash shield bolt.

Installation Notice

KAA4D090

Tightening Torque

6 N•m (53 lb-ft)

6. Installation should follow the removal procedure

in the reverse order.

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