SsangYong Rexton. Service manual — part 492
REAR AXLE 3D-21
SSANGYONG Y200
1. Heel contact
2. Toe contact
3. Face contact
4. Flank contact
A
B
Adjust backlash
(Drecrease backlash)
•
Select proper shin to
move the drive pinion
toward the ring gear
(toward toe)
Adjust backlash
(Increase backlash)
•
Select proper shim 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
( t o w a r d r i n g g e a r
center line)
Excessive backlash
•
Noise can be occurred
Insufficient backlash
•
Tooth can be damaged
or broken under heavy
load
Excessive backlash
•
Drive pinion shaft is
apart from the ring gear
•
Noise can be occurred
Insufficient backlash
•
Gear contacts on the
low flank
•
Gear can be damaged
or worn
•
Noise can be occurred
Inspection of Ring Gear Tooth Contact
Pattern
1. Normal Contact
Apply gear-marking compound (prussian blue/red
lead) on the ring rear teeth. Rotate the ring gear
and check the to the contact pattern.
YAD3D500
Tooth contact pattern
Possible cause
Remedy
YAD3D510
YAD3D530
YAD3D550
YAD3D520
YAD3D540
YAD3D560
YAD3D570
YAD3D580
2. Abnormal contact
SSANGYONG Y200
3D-22 REAR AXLE
Assembly
1. Clean all parts and check the followings.
•
Check the ring gear, 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.
YAD3D590
YAD3D600
YAD3D620
YAD3D610
2. Assemble the drive pinion assembly to the axle
housing and then tighten the pinion lock nut.
Installation Notice
Tightening torque
240 - 310 N•m
Tightening Torque
75 - 90 N•m
(55 - 66 lb-ft)
3. Assemble the differential carrier assembly. Align
the ring gear to the mark of differential carrier,
tighten the fixing bolts.
Installation Notice
4. Measure the backlash of side gear and pinion gear.
Specified value
0 - 0.5 mm
REAR AXLE 3D-23
SSANGYONG Y200
YAD3D630
YAD3D640
YAD3D650
5. Install the differential carrier assembly into the axle
housing. Set up the bearing cap and then tighten
the cap bolts.
Installation Notice
Notice: Be careful not to change the caps. Be sure
to keep the original position of the caps.
Tightening Torque
48 - 69 N•m
(35 - 51 lb-ft)
6. Measure the backlash of drive pinion and ring
gear.
Specified value
0.13 - 0.20 mm
7. Install the axle housing cover. Tighten the fixing
bolts.
Installation Notice
Tightening Torque
39 - 46 N•m
(29 - 34 lb-ft)
SECTION 4A
BRAKE SYSTEM
TABLE OF CONTENTS
Description and Operation . . . . . . . . ... 4A-2
Braking System Testing . . . . . . . . . ... 4A-2
Hydraulic Brake System . . . . . . . . . .. 4A-2
Brake Pedal . . . . . . . . . . . . . . . 4A-2
Master Cylinder . . . . . . . . . . . . ... 4A-2
Brake Booster . . . . . . . . . . . . . . 4A-3
Specifications . . . . . . . . . . . . . .. 4A-4
Diagnostic Information and Procedures . . . .. 4A-5
Maintenance and Repair . . . . . . . . . . 4A-6
Bleeding the Brakes . . . . . . . . . . . 4A-6
Brake Pedal . . . . . . . . . . . . . . . 4A-7
Stoplamp Switch . . . . . . . . . . . . .. 4A-8
Brake Booster Functional Check . . . . . . ... 4A-9
LCRV (Load Conscious Reducing Valve) . . . .. 4A-9
Component Locator . . . . . . . . . . ... 4A-11
Hydraulic Line . . . . . . . . . . . . . 4A-11
Brake System (W/CBS) . . . . . . . . . .. 4A-12
Master Cylinder and Booster . . . . . . . .. 4A-13
Repair Instructions . . . . . . . . . . . .. 4A-14
On-Vehicle Service . . . . . . . . . . . . 4A-14
Vacuum Hose . . . . . . . . . . . . . 4A-14
Brake Oil Level Switch . . . . . . . . . ... 4A-15
Brake Fluid Reservoir . . . . . . . . . . . 4A-16
Master Cylinder . . . . . . . . . . . . . 4A-17
Brake Booster . . . . . . . . . . . . ... 4A-19
Stoplamp Switch . . . . . . . . . . . . 4A-20
Brake Pedal . . . . . . . . . . . . . ... 4A-20
Brake Hose & Pipe . . . . . . . . . . . 4A-21
LCRV (Load Conscious Reducing Valve) . . . 4A-24
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