SsangYong Korando II (1996-2006 year). Service 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