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