SsangYong Korando II (1996-2006 year). Manual — part 229
SSANGYONG MY2002
3D-20 REAR AXLE
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DIFFERENTIAL GEAR ASSEMBLY
Disassembly
1. Remove the drain plug and drain oil. Reinstall the
drain plug.
Installation Notice
KAA3D450
KAA3D470
KAA3D460
KAA3D480
Tightening Torque
28 - 42 N•m
(21 - 31 lb-ft)
2. Remove the axle housing cover.
Notice: Clean the cover and housing contact
surface.
3. Remove the bearing cap bolts and remove the
bearing cap. Pull out the differential carrier
assembly.
Notice: Do alignment marks on the bearing cap
not to change the caps before removal. When pulling
out, be careful to damage the axle housing.
4. Disassemble the parts of differential carrier
assembly.
REAR AXLE 3D-21
SSANGYONG MY2002
5. Remove the drive pinion lock nut. Disassemble
the parts of drive pinion
KAA3D490
SSANGYONG MY2002
3D-22 REAR AXLE
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.
KAA3D500
Tooth contact pattern
Possible cause
Remedy
KAA3D510
KAA3D530
KAA3D550
KAA3D520
KAA3D540
KAA3D560
KAA3D570
KAA3D580
2. Abnormal contact
1. Heel contact
2. Toe contact
3. Face contact
4. Flank contact
REAR AXLE 3D-23
SSANGYONG MY2002
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.
KAA3D590
KAA3D600
KAA3D620
KAA3D610
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
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