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SsangYong Stavic / SsangYong Rodius (2005 year). Manual - part 401

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

BRAKE - GENERAL

STAVIC - 2004.09

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

BRAKE - GENERAL

STAVIC - 2004.09

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

BRAKE - GENERAL

STAVIC - 2004.09

7. TROUBLE DIAGNOSIS

Repair

Retighten

Replace

Clean

Replace

Repair

Lubrication

Retighten

Adjust

Repair

Replace

Repair

Replenish or replace

Bleeding

Repair

Replace

Repair

Bleeding

Repair

Adjust

Repair

Adjust

Replace

Repair

Replace

Lubrication

Replace

Adjust

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

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

BRAKE - GENERAL

STAVIC - 2004.09

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

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

Content .. 399 400 401 402 ..