SsangYong Rexton. 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