SsangYong Stavic / SsangYong Rodius (2005 year). Service manual — part 401
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
17
BRAKE - GENERAL
STAVIC - 2004.09
4J
Operating
rod
Operating rod
lock nut
Stop lamp
s w i t c h
Stop lamp
switch lock nut
Specified value (A)
177 mm (from carpet surface)
Specified value (C)
138 mm
Brake Pedal Check
Pedal Height / Maximum Stroke
Pedal height
Maximum stroke
[Notice]
If the value is out of the specified range, adjust the pedal
height by using lock nut of stop lamp switch.
[Notice]
If the value is out of the specified range, adjust the maximum
stroke by using stop lamp and lock nut.
Check the brake pedal with below procedures:
1. Start the engine.
2. Depress the brake pedal around 3 times.
3. Depress the brake pedal with approx. 30 kg and measure
the distance (A) between the upper surface of pedal pad
and the lower dash panel.
4. If the measured value is below the specified value, check
the following causes:
Pad wear, Shoe wear, Air in brake system, Defective
automatic clearance adjuster of rear brake shoe.
5. If the measured value is out of the specified range, adjust
the length of push rod by using lock nut in the brake
booster push rod.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
18
BRAKE - GENERAL
STAVIC - 2004.09
4J
Specified value
3 ~ 8 mm
If the free play is below the specified value, check if the clear-
ance between the outer case of the stop lamp and the brake
pedal is within the specified range.
If the clearance is out of the specified range, the clearance
between the clevis pin and the brake pedal arm is too large.
Check the components and repair if needed.
Faulty
Engine running
Normal
Engine stop
Pedal Free Play
Depress the brake pedal several times to discharge the vacuum
pressure of the power booster. Measure the pedal free play
while pressing the brake pedal by hand.
Brake Booster Check
1. Let the engine run for 1 ~ 2 minutes and stop it. If the
brake pedal stroke is shortened as pumping the brake
pedal, the system is normal. If not, the system is
defective.
2. Depress the brake pedal several times with engine off. If
the brake goes down when starting engine with pedal
depressed, the system is normal. If not, the system is
defective.
3. Depress the brake pedal when the engine is running. If
the pedal height is not changed when stop the engine,
the system is normal. If not, the system is defective.
If the above 3 conditions are not satisfied, check the parts
concerned such as valve, vacuum hose, booster, etc.
CHANGED BY
EFFECTIVE DATE
AFFECTED VIN
19
BRAKE - GENERAL
STAVIC - 2004.09
4J
7. TROUBLE DIAGNOSIS
Repair
Retighten
Replace
Clean
Replace
Repair
Repair
Lubrication
Retighten
Adjust
Repair
Replace
Replace
Repair
Repair
Replenish or replace
Bleeding
Repair
Repair
Replace
Repair
Repair
Repair
Repair
Bleeding
Repair
Adjust
Repair
Adjust
Replace
Repair
Replace
Lubrication
Replace
Adjust
Replace
Replace
Replace
Repair
Adjust lever travel or
check the cable
Incorrectly mounted back plate or caliper
Loosened bolt of back plate or caliper
Crack or uneven wear of brake drum or disc
Foreign material inside the brake drum
Pad or lining sticking to contact surface
Excessive clearance between caliper and pad
Uneven contact of pad
Lack of lubrication
Loosened suspension
Incorrect tire pressure between left and right
Poor contact of pad or lining
Oil or grease is applied to pad or lining
Bent or uneven wear of drum
Incorrectly mounted wheel cylinder
Faulty auto adjuster
Dirty or lack of fluid
Air in brake system
Faulty brake booster
Poor contact of pad or lining
Oil or grease on pad
Faulty auto adjuster
Over heated rotor due to dragging pad or lining
Clogging brake line
Faulty proportioning valve
Air in brake system
Fluid leaking
Excessive clearance between push rod and m/cylinder
Parking brake is not fully released
Incorrect adjustment of parking brake
Weak return spring of brake pedal
Incorrect pedal free-play
Broken rear drum brake shoe return spring
Lack of lubrication
Damaged master cylinder check valve or piston return spring
Insufficient clearance between push rod and master cylinder
Worn brake lining
Dirty brake lining surface by grease or oil
Binding parking brake cable
Faulty auto adjuster
Excessive lever stroke
Noise or vehicle vibra-
tion when applied
Pulls to one side when
braking
Poor braking
Increasing pedal stroke
(Pedal goes to floor)
Brake dragging
Poor parking brake
Symptom
Cause
Action
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EFFECTIVE DATE
AFFECTED VIN
20
BRAKE - GENERAL
STAVIC - 2004.09
4J
FRONT BRAKE
1. GENERAL INFORMATION
Caliper
The disc brake is normally used for front wheels, however,
currently it is also used for rear wheels. The floating cali-
per type disc brake installed in this vehicle has only one
brake cylinder at one side of caliper. The hydraulic pres-
sure generated by master cylinder pushes the piston to
contact the pad against the disc. The caliper is moved to
contact to the opposite pad.
The brake disc features:
* Excellent radiation due to it is exposed to ambient air
* Less braking force changes
* No uneven braking
* Simple structure and operation
Adjustment of Clearance
When the hydraulic pressure is applied to the piston, the
piston moves to push the pad. The piston seal, which ex-
tent considerable pressure against the piston, moves with
cylinder.
However, the piston seal shape is deformed since the pis-
ton seal is fixed at the cylinder groove as shown in below
figure.
When the pressure is released from the piston, the piston
comes back to its original position by a restoring and elastic
force of the seal.
When the pad wear is excessive, the piston seal cannot
reach to the desired point because the seal’s deformation
is limited.
Accordingly, the piston always comes back by the de-
formed distance of piston seal, it keeps the initial clearance.
Piston
Disc
Pad
Specifications
Ventilated disc type
φ
42.9 x 2 mm
10.5 mm
26 mm
Item
Specification
Type
Inner diameter of caliper cylinder
Pad thickness
Disc thickness
1. Piston
2. Piston seal
3. Pad
a. Clearance
* General description
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