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SECTION 3D
REAR AXLE
TABLE OF CONTENTS
General Description and Operation ................. 3D-2
Specifications ................................................... 3D-2
Fastener Tightening Specifications .................. 3D-2
Diagnostic Information and Procedures ........ 3D-3
Component Locator ......................................... 3D-4
Rear Axle Assembly ......................................... 3D-4
Cross Sectional View ........................................ 3D-5
Rear Axle Shaft Assembly ............................... 3D-6
Maintenance and Repair .................................. 3D-8
On-Vehicle Service .............................................. 3D-8
Axle Shaft Assembly (With Disc Brake) .......... 3D-8
Axle Shaft Assembly (With Drum Brake) ...... 3D-11
Rear Axle Housing .......................................... 3D-13
Unit Repair ....................................................... 3D-18
Axle Assembly ............................................... 3D-18
Differential Gear Assembly ............................ 3D-20
Drive Shaft ...................................................... 3D-25
Special Tools and Equipment ....................... 3D-26
Special Tools Table ........................................ 3D-26
SSANGYONG MY2002
3D-2 REAR AXLE
Disc Brake
Drum Brake
50 - 65
4 - 8
85 - 105
50 - 65
150 - 180
30 - 45
30 - 45
150 - 180
150 - 180
70 - 80
12 - 23
6 - 8
1 - 19
Lb-Ft
Axle Shaft Type
Axle Housing Type
Differential
Reduction Ratio
Oil
Type
Gear
Gasoline + M/T
Diesel + M/T
Gasoline + A/T
Diesel + A/T
Capacity
Specification
Semi-floating
Build up
Conventional Type
Hypoid Gear
3.73
4.27
4.56
4.89
1.9
SAE 80W/90 or API GL-5
GENERAL DESCRIPTION AND OPERATIONSPECIFICATIONS
37 - 48
35 - 71
63 - 77
37 - 48
111 - 133
22 - 23
22 - 23
111 - 133
111 - 133
52 - 59
9 - 17
53 - 71
11 - 14
Flange fixing Bolt
Dust shield Bolt
Caliper Bolt
Fixing Nut
N”””””mApplication Lb-In
-
-
-
-
-
-
-
-
-
-
-
-
-
FASTENER TIGHTENING SPECIFICATIONS
Rod Bolt
Shock absorber Bolt
Stabilizer bar cap bolt
Upper arm nut
Lower arm nut
Propeller shaft fixing bolt
LCRV Mounting Bolt
Air Breather Hose Bolt
Brake oil pipe (M10)
REAR AXLE 3D-3
SSANGYONG MY2002
DIAGNOSTIC INFORMATION AND PROCEDURES
Lack of Oil
Low Viscosity of Oil
Inferior Oil
Excessive Backlash of Ring Gears
Worn or Damaged Tooth of Ring and Pinion Gear
Worn or Damaged Tooth of Drive Pinion Gear
Wear of Side Bearing and Side Gear Spline
Bending of Axle Housing
Distortion of Differential Case
Wear of Pinion Shaft
Incorrect Drive Pinion Preload.
Incorrect Contact of Ring Gear and Pinion
Excessive Oil
Fault Seal of Carrier Contact Surface
Axle Housing Crack
Worn or Damaged Oil Seal
Worn or Damaged Tooth of Pinion or Side Gear
Wear of Pinion Shaft
Excessive Backlash of Pinion Gear and Side Gear
Excessive End-Play of Rear Axle Shaft
Incorrect Contact of Side Gear and Differential Case
Axle Housing Crack
Distortion or Poor Installation of Drive pinion Oil Seal
Damaged of Torn Drive Pinion Oil Seal
Loosened Bearing Collar
Worn or Damaged Universal Joint
Worn or damaged Axle Shaft Bearing
Lock of Oil
Insufficient Backlash of Gears
Excessive Preload of Bearing
Replenish
Replace
Replace
Adjust
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Reassembly
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replenish
Adjust
Adjust
ChecksPhenomena
Noise
(During Straight
Driving)
Oil Leakage
Noise (During Turning)
Heating
Action
SSANGYONG MY2002
3D-4 REAR AXLE
COMPONENT LOCATORREAR AXLE ASSEMBLY
KAA3D010
1 Axle Shaft/Tube2 Stabilizer Bar3 Spring Seat & Spring4 Upper Arm
5 Shock Absorber6 Lateral Rod7 Input Shaft8 Axle Housing
REAR AXLE 3D-5
SSANGYONG MY2002
CROSS SECTIONAL VIEW
KAA3D020
1 Rear Axle Shaft Assembly2 Bracket Assembly3 Hub Oil Seal4 Bolt5 Axle Shaft Tube
6 Coil Spring Seat (Lower)7 Caliper Assembly8 Input Shaft/Flange9 Rod Mounting Bracket
10 Wheel Speed Sensor
SSANGYONG MY2002
3D-6 REAR AXLE
REAR AXLE SHAFT ASSEMBLYWith disc brake
KAA3D030
1 Brake Disc2 Plug3 Rear Axle Shaft4 Nut5 Washer6 Parking Brake Cable
7 Parking Brake Lining & Back Plate Assembly8 Brake Caliper Assembly9 Spring Washer
10 Bolt11 Rear Axle Housing
REAR AXLE 3D-7
SSANGYONG MY2002
With drum brake
KAA3D040
1 Brake Drum2 Plug3 Rear Axle Shaft4 Wheel Bolt5 Nut6 Washer7 Retainer Plate8 Oil Seal
9 Bearing10 Snap Ring11 Snap Ring12 Oil Seal13 Brake Shoe & Back Plate Assembly14 Bolt15 Rear Axle Housing
SSANGYONG MY2002
3D-8 REAR AXLE
ON-VEHICLE SERVICEAXLE SHAFT ASSEMBLY(WITH DISC BRAKE)Removal
1. Remove the tire.
KAA3D050
KAA3D070
KAA3D060
2. Release the parking brake.
3. Remove the fixing pin of parking brake.
4. After detaching the parking brake lever, detachthe cable.
5. Remove the two fixing bolt of brake caliper.
Notice: Be careful not to damage the brake oilhose.
6. Remove the brake caliper assembly.
Notice: If replacing the brake pad only, remove theupper fixing bolt of caliper pad and lower it.
MAINTENANCE AND REPAIR
REAR AXLE 3D-9
SSANGYONG MY2002
8. Remove the four fixing bolt of dust shield coverand then pull out the dust shield cover.
KAA3D100
KAA3D110
KAA3D090
9. Remove the two plastic plug in the axle shaftflange.
10. Remove the four fixing bolts & washers of axlehousing flange from the retainer plate.
11. Remove the rear axle drive shaft.
KAA3D080
7. Remove the brake disc.
SSANGYONG MY2002
3D-10 REAR AXLE
KAA3D140
KAA3D150
KAA3D130
2. Tighten the flange fixing bolts and washers withthe retainer plate.
Installation Notice
3. Assemble the plastic plug n the rear axle flangeand install the dust shield.
Installation Notice
4. Install the brake disc and caliper assembly.
Installation Notice
5. Install the parking brake cable and tire.
Tightening torque 85 - 105 N•m
KAA3D120
InstallationClean the detached axle shaft, check the damage orwear.
1. After checking the spline & shaft of rear axle shaft,assemble the shaft into the rear axle housing.
Tightening Torque 50 - 65 N•m(37 - 48 lb-ft)
Tightening Torque 4 - 8 N•m(35 - 71 lb-in)
REAR AXLE 3D-11
SSANGYONG MY2002
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AXLE SHAFT ASSEMBLY(WITH DRUM BRAKE)Removal
1. Release the parking brake.
2. Remove the tire.
KAA3D160
KAA3D170
KAA3D180
KAA3D190
3. Remove the brake drum.
Notice: Insert the bolt into the service hole, whiletightening the both side bolts uniformly, removethe brake drum.
4. Remove the fixing pin of parking brake.
5. After detaching the cover of parking brake,disconnect the cable.
6. After pulling out the two plastic plug of axle shaftflange, remove the fixing nuts of inner bracket.
SSANGYONG MY2002
3D-12 REAR AXLE
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7. Remove the axle shaft.
KAA3D200
KAA3D210
KAA3D230
KAA3D220
Tightening Torque 50 - 65 N•m(37 - 48 lb-ft)
Installation1. Check the rear axle shaft.
2. Insert the rear axle shaft into the axle housing andtighten the fixing nuts of axle shaft flange.
Installation Notice
3. Connect the brake cable and install the brakedrum.
4. Install the tire and test the braking force.
REAR AXLE 3D-13
SSANGYONG MY2002
REAR AXLE HOUSINGRemoval
1. Remove the tire.
2. Remove the connecting rod of LCRV assembly &fixing nut of axle housing bracket.
KAA3D240
KAA3A250
KAA3D260
KAA3D270
3. Disconnect the brake oil hose & oil line (pipe)
• Brake pipe nut.
• Brake pipe mounting clip
• 3-way connector
• Brake pipe assembly
4. Detach the air breather.
5. Remove the propeller shaft from rear axle inputshaft.
Notice: Do alignment marks before removing.
SSANGYONG MY2002
3D-14 REAR AXLE
KAA3D280
KAA3D300
KAA3D290
6. Pull out the fixing pin of parking brake.
7. After removing the parking brake lever, pull outthe cable.
KAA3D310
8. Remove the lower arm mounting nuts and removethe lower arm from the axle housing.
9. Detach the lower mounting of shock absorber fromthe axle housing.
10. Remove the upper arm mounting nuts and removethe upper arm from the axle housing.
REAR AXLE 3D-15
SSANGYONG MY2002
11. Remove the stabilizer bar.
KAA3D320
KAA3D330
KAA3A350
KAA3A340
12. Remove the lateral rod mounting nut and detachthe lateral rod from the axle housing.
13. Lowering the axle slowly, remove the coil spring& spring seat.
14. Lower the axle housing by using the safety jack.
Installation1. Placing the rear axle housing on the assembly
position, install both coil springs.
SSANGYONG MY2002
3D-16 REAR AXLE
KAA3D360
KAA3D370
KAA3D390
KAA3D380
2. Install the lateral rod in axle hosing.
Notice: Do not tighten the nuts completely.
Installation Notice
3. Install the shock absorber in axle housing.
Installation Notice
Tightening Torque 30 - 45 N•m(22 - 33 lb-ft)
Tightening Torque 150 - 180 N•m
Tightening Torque 70 - 80 N•m(52 - 59 lb-ft)
4. Install the stabilizer bar and upper/lower arm inaxle housing
Installation Notice
5. Install the propeller shaft of rear axle side andtighten above the fixing bolts/nuts.
Installation Notice
6. Install the brake cable, air bleeder hose, oil pipe,LCRV unit in rear axle assembly with assembledcompletely.
Installation Notice
7. Bleeding the air in brake, install the tire.
30 - 45 N•m(22 - 33 lb-ft)
150 - 180 N•m(111 - 133 lb-ft)
150 - 180 N•m(111 - 133 lb-ft)
Stabilizer bar cap bolt
Upper arm nut
Lower arm nut
12 - 23 N•m(9 - 17 lb-ft)
6 - 8 N•m(53 - 71 lb-in)
15 - 19 N•m(11 - 14 lb-ft)
LCRV Mounting Bolt
Air Breather Hose Bolt
Brake Oil Pipe (M10)
REAR AXLE 3D-17
SSANGYONG MY2002
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2. Measure the run-out of shaft.
KAA3D400
KAA3D410
KAA3D430
Inspection1. Check the shaft spline for the wear and damage.
KAA3D420
Specified value Within 1.0 mm
3. Measure the run-out of shaft flange.
Specified value Within 0.13 mm
4. Install the axle shaft and measure the clearanceof shaft direction.
Specified value Within 0.38 mm
REAR AXLE 3D-19
SSANGYONG MY2002
1 Drive Pinion Lock Nut........................... 240 - 310 N•m (177 - 229 lb-ft)
2 Washer3 Companion Flange4 Pinion Oil Seal5 Bearing Slinger6 Bearing7 Shim8 Shim9 Bearing Cup
10 Breather Nipple11 Rear Axle Housing12 Oil Drain Plug............ 28 - 42 N•m (21 - 31 lb-ft)13 Shim14 Bearing15 Drive Pinion16 Bearing Cap
17 Bolt ......................... 87 - 124 N•m (64 - 94 lb-ft)18 Bearing19 Shim20 Ring Gear21 Shaft Lock Pin22 Differential Case23 Ring Gear Mounting Bolt
.................................. 75 - 90 N•m (55 - 66 lb-ft)24 Thrust Washer25 Differential Pinion26 Thrust Washer27 Side Gear28 Differential Shaft29 Housing Cover30 Bolt ............................ 38 - 46 N•m (28 - 34 lb-ft)31 Oil Filler Plug ............ 28 - 42 N•m (21 - 31 lb-ft)
SSANGYONG MY2002
3D-20 REAR AXLE
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DIFFERENTIAL GEAR ASSEMBLYDisassembly
1. Remove the drain plug and drain oil. Reinstall thedrain 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 contactsurface.
3. Remove the bearing cap bolts and remove thebearing cap. Pull out the differential carrierassembly.
Notice: Do alignment marks on the bearing capnot to change the caps before removal. When pullingout, be careful to damage the axle housing.
4. Disassemble the parts of differential carrierassembly.
REAR AXLE 3D-21
SSANGYONG MY2002
5. Remove the drive pinion lock nut. Disassemblethe parts of drive pinion
KAA3D490
SSANGYONG MY2002
3D-22 REAR AXLE
Adjust backlash(Drecrease backlash)
• Select proper shin tomove the drive piniontoward the ring gear(toward toe)
Adjust backlash(Increase backlash)• Select proper shim 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 geartoward the drive pinion(toward r ing gearcenter line)
Excessive backlash
• Noise can be occurred
Insufficient backlash
• Tooth can be damagedor broken under heavyload
Excessive backlash
• Drive pinion shaft isapart from the ring gear
• Noise can be occurred
Insufficient backlash
• Gear contacts on thelow flank
• Gear can be damagedor worn
• Noise can be occurred
Inspection of Ring Gear Tooth ContactPattern
1. Normal Contact
Apply gear-marking compound (prussian blue/redlead) on the ring rear teeth. Rotate the ring gearand 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
Assembly1. Clean all parts and check the followings.
• Check the ring gear, drive pinion for wear anddamage. 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.
KAA3D590
KAA3D600
KAA3D620
KAA3D610
2. Assemble the drive pinion assembly to the axlehousing 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. Alignthe 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
SSANGYONG MY2002
3D-24 REAR AXLE
KAA3D630
KAA3D640
KAA3D650
5. Install the differential carrier assembly into the axlehousing. Set up the bearing cap and then tightenthe cap bolts.
Installation Notice
Notice: Be careful not to change the caps. Be sureto 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 ringgear.
Specified value 0.13 - 0.20 mm
7. Install the axle housing cover. Tighten the fixingbolts.
Installation Notice
Tightening Torque 39 - 46 N•m(29 - 34 lb-ft)
REAR AXLE 3D-25
SSANGYONG MY2002
KAA3D670
KAA3D660
DRIVE SHAFTTools Required661 589 15 33 00 Rear Hub Bearing Installer
661589 18 33 00 Axle Bearing Puller Plate
661 589 18 33 01 Rear Axle Bearing Remover
661 589 18 33 02 Rear Axle Oil Seal Remover
Disassembly Procedure1. Remove the rear drive shaft from the vehicle. Refer
to “Rear Drive Shaft” in this section.
2. Remove the toothed ring using the axle bearingpuller plate 661 589 18 33 00 and rear axle bearingremover 661 589 18 33 01 by press.
3. Remove the rear drive shaft oil seal bearing usingthe axle bearing puller plate 661 589 18 33 00 andrear axle oil seal remover 661 589 18 33 02 bypress.
4. Remove the rear disc brake rotor shield.
3. Install the retainer drive shaft bearing using therear hub bearing installer 661 589 15 33 00 by press.
4. Install the rear drive shaft. Refer to “Rear DriveShaft” in this section.
KAA3D690
KAA3D680
Assembly Procedure1. Install the rear disc brake rotor shield.
2. Install the rear drive shaft bearing oil seal usingthe rear hub bearing installer 661 589 15 33 00 bypress.
SSANGYONG MY2002
3D-26 REAR AXLE
SPECIAL TOOLS AND EQUIPMENTSPECIAL TOOLS TABLE
661 589 13 33 00Ball Joint Remover
661 589 18 33 00
Axle Bearing Puller
Plate
KAA3D700
KAA3D710
KAA3D720
661 589 18 33 02Rear Axle Oil Seal
Remover
661 589 15 33 00
Rear Hub Bearing
Installer
661 589 18 33 01
Rear Axle BearingRemover
KAA3D740
KAA3D750
KAA3D760
J-8059
Snap Ring Plier
DW340-090-01
Differential Assembly
Remover/Installer
DW340-090-03
Rear DifferentialAssembly
Remover/Installer
KAA3D730 KAA3D770