SECTION 4A

HYDRAULIC BRAKESCAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or whena tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.

TABLE OF CONTENTSDescription and Operation ................................... 4A-2

General Description ............................................. 4A-2

Diagnostic Information and Procedures .............. 4A-3

Brake System Testing .......................................... 4A-3

Brake Hose Inspection ......................................... 4A-3

Brake Warning Lamp Circuit Description .............. 4A-4

Brake Warning Lamp Diagnosis ........................... 4A-5

LCRV (Load Conscious Reducing Valve) .............. 4A-8

Repair Instructions .............................................. 4A-10

On-Vehicle Service ............................................... 4A-10

Manual Bleeding The Brakes ............................. 4A-10

Front Brake Hose ............................................... 4A-13

Rear Brake Hose ............................................... 4A-13

Stoplamp Switch ................................................ 4A-14

Brake Pedal ....................................................... 4A-14

Specifications ..................................................... 4A-15

General Specification ......................................... 4A-15

Fastener Tightening Specifications ..................... 4A-16

SSAMGYONG MY2002

4A-2 HYDRAULIC BRAKES

DESCRIPTION AND OPERATIONGENERAL DESCRIPTIONBrake fluid should meet the DOT 4 specification. Useonly clear fluid from a sealed container.

Fluid that is exposed to the air will absorb moisture.Water in the brake fluid will cause the fluid to boil andthe rubber components to deteriorate.

Thoroughly clean the master cylinder reservoir cap be-fore removing it. Do not let any dirt or foreign materialfall into the fluid reservoir.

There is a brake fluid level switch under the mastercylinder reservoir.

When the fluid level is low, the BRAKE lamp in theinstrument cluster will turn on.

The correct brake fluid level is marked on the bothside of the brake fluid reservoir. If the fluid level isbelow the MIN indicator mark, check the hydraulic brakesystem for leaks. Fix any leaks. Then refill the reservoirto the MAX indicator mark.

The hydraulic brake system is parallel split on AntilockBrake Systems. This means the left front and left rearbrakes are on one hydraulic circuit and the right frontand right rear are on the other.

HYDRAULIC BRAKES 4A-3

SSANGYONG MY2002

DIAGNOSTIC INFORMATION AND PROCEDURESBRAKE SYSTEM TESTINGBrakes should be tested on a dry, clean, reasonablysmooth and level roadway. A true test of brake perfor-mance cannot be made if the roadway is wet, greasy,or covered with loose dirt which can cause tires not togrip the road unequally. Testing also will be inaccurateon a crowned roadway because the wheels tend tobounce.

Test the brakes at different vehicle speeds with bothlight-and heavy-pedal pressure; however, avoid lockingthe brakes and sliding the tires. Locked brakes andslid-ing tires do not indicate brake efficiency sinceheavily braked but turning wheels will stop the vehiclein less distance than locked brakes. More tire-to-roadfriction is present with a heavily braked, turning tirethan with a sliding tire.

Because of the high deceleration capability, a firmerpedal may be felt at higher deceleration levels.

There are three major external conditions that affectbrake performance:

• Tires having unequal contact and grip of the roadwill cause unequal braking. Tires must be equallyinflated, and the tread pattern of the right and theleft tires must be approximately equal.

• Unequal loading of the vehicle can affect the brakeperformance since the most heavily loaded wheelsrequire more braking power, and thus more brakingeffort, than the others.

• Misalignment of the wheels, particularly conditionsof excessive camber and caster, will cause thebrakes to pull to one side.

To check for brake fluid leaks, hold constant foot pres-sure on the pedal with the engine running at idle andthe shift lever in NEUTRAL. If the pedal gradually fallsaway with the constant pressure, the hydraulic systemmay be leaking. Perform a visual check to confirm anysuspected leaks.

Check the master cylinder fluid level. While a slightdrop in the reservoir level results from normal liningwear, an abnormally low level indicates a leak in thesystem. The hydraulic system may be leaking eitherinternally or externally. Refer to the procedure belowto check the master cylinder. The system may appearto pass this test while still having a slight leak. If thefluid level is normal, check the vacuum booster pushrodlength. If an incorrect pushrod length is found, adjustor replace the rod.

Check the master cylinder using the following procedure:

• Check for a cracked master cylinder casting or abrake fluid leak around the master cylinder. Leaksare indicated only if there is at least one drop offluid. A damp condition is not abnormal.

• Check for a binding pedal linkage and for anincorrect pushrod length. If both of these parts arein satisfactory condition, disassemble the mastercylinder and check for an elongated or swollenprimary cylinder or piston seals. If swollen sealsare found, substandard or contaminated brake fluidshould be suspected. If contaminated brake fluidis found, al l the components should bedisassembled and cleaned, and all the rubbercomponents should be replaced. All of the pipesmust also be flushed.

Improper brake fluid, or mineral oil or water in the fluid,may cause the brake fluid to boil or cause deteriorationof the rubber components. If the primary piston cups inthe master cylinder are swollen, the rubber parts havedeteriorated.

If deterioration of the rubber is evident, disassembleall the hydraulic parts and wash the parts with alcohol.Dry these parts with compressed air before reassemblyto keep the alcohol out of the system. Replace all therubber parts in the system, including the hoses. Whenworking on the brake mechanisms, check for fluid onthe linings. If excessive fluid is found, replace thelinings.

If the master cylinder piston seals are in satisfactorycondition, check for leaks or excessive heat conditions.If these conditions are not found, drain the fluid, flushthe master cylinder with brake fluid, refill the mastercylinder, and bleed the system.

BRAKE HOSE INSPECTIONThe hydraulic brake hoses should be inspected at leasttwice a year. The brake hose assembly should bechecked for road hazard damage, cracks, chafing ofthe outer cover, and for leaks or blisters. Inspect thehoses for proper routing and mounting. A brake hosethat rubs on a suspension component will wear andeventually fail. A light and a mirror may be needed foran adequate inspection. If any of the above conditionsare observed on the brake hose, adjust or replace thehose as necessary.

SSAMGYONG MY2002

4A-4 HYDRAULIC BRAKES

KAA4A010

BRAKE WARNING LAMP CIRCUIT DESCRIPTION

Diagnostic AidsThe BRAKE lamp glows brightly when the ignition isON and either the parking brake lever switch or thebrake fluid level switch is closed.

If neither switch is closed, the BRAKE lamp receivesa ground through the generator, and it glows dimlywhen the ignition is ON and the engine is off. Whenthe engine starts, the generator creates voltage. Withvoltage on both sides of the lamp, the lamp turns off.

Test DescriptionThe numbers below refer to steps in the diagnostictable.

1. This step begins the test sequence for a BRAKEwarning lamp that stays on when the engine is run-ning.

2. This step begins the test sequence for a BRAKEwarning lamp that never turns on.

HYDRAULIC BRAKES 4A-5

SSANGYONG MY2002

Value(s)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

BRAKE WARNING LAMP DIAGNOSIS

Step

1

2

3

4

5

6

7

8

9

10

11

12

13

14

ActionStart the engine and leave it running.Does the BRAKE warning lamp stay on?With the engine running, release the parking brake.Is the BRAKE warning lamp off?Check the brake fluid level.Is the fluid level OK?1. Fill the brake fluid reservoir with clean DOT-3

hydraulic fluid.2. Check the cap on the fluid reservoir.3. Start the engine and leave it running.Is the BRAKE warning lamp on?Disconnect the wiring harness connector from thebrake fluid level switch.Is the BRAKE warning lamp on?Replace the brake fluid lever switch.Is the repair complete?1. Connect the brake fluid level switch.2. Disconnect the parking brake lever switch.3. Start the engine and leave it running.Is the BRAKE warning lamp on?Replace the parking brake lever switch.Is the repair complete?1. Connect the parking brake lever switch.2. Disconnect the STICS (Super Time and Alarm

Integrated System).3. Start the engine and leave it running.Is the BRAKE warning lamp on?Replace the STICS.Is the repair complete?Repair the short circuit in the instrument wiringharness between terminal D10 of the instrumentcluster and ground.Is the repair complete?1. Disconnect the electrical connector from the fluid

level switch.2. Connect a jumper wire between ground and

terminal 1 of the fluid level switch harnessconnector.

Does the BRAKE warning lamp turn on?1. Disconnect the electrical connector from the fluid

level switch.2. Connect a jump wire between terminals 1 and 2

of the fluid level switch harness connector.Does the BRAKE warning lamp turn on?1. Replace the brake fluid level switch.2 The switch can be removed and replaced without

draining the brake fluid from the reservoir.Is the repair complete?

Yes

Go To Step 2

System OK

Go To Step 5

Go To Step 5

Go To Step 7

System OK

Go To Step 9

System OK

Go To Step 11

System OK

System OK

Go To Step 13

Go To Step 14

System OK

NO

Go To Step 12

Go To Step 3

Go To Step 4

System OK

Go To Step 6

-

Go To Step 8

-

Go To Step 10

-

-

Go To Step 15

Go To Step 15

-

SSAMGYONG MY2002

4A-6 HYDRAULIC BRAKES

Action1. Turn the ignition ON.2. Apply the parking brake.Does the BRAKE warning lamp turn on?Check fuse F30.Is fuse F30 blown?Check for a short circuit and repair it, if necessary.Replace fuse F30.1. Turn the ignition ON.2. Check the voltage at F30.Is the voltage equal to the specified value?Repair the power supply to fuse F30.Is the repair complete?1. Disconnect terminal A1 of the instrument cluster.2. Turn the ignition ON.3. Use a voltmeter to check the voltage at terminal A1.Is the voltage equal to the specified value?Repair the open circuit between terminal A1 of theinstrument cluster and fuse F30.Is the repair complete?1. Reconnect terminal A1 of the instrument cluster.

Turn the ignition ON.2. Use a voltmeter to backprobe terminal D10 of the

instrument cluster.Is the voltage equal to the specified value?1. Remove the BRAKE warning lamp from its socket.2. Test the Brake warning lamp.Is the BRAKEwarning lamp OK?Replace the instrument cluster.Is the repair complete?Replace the BRAKE warning lamp.Is the repair complete?1. Disconnect terminal C10 of the STICS.2. Connect a jumper wire between terminal C10 and

ground.3. Turn the ignition ON.Is the BRAKE warning lamp on?Replace the STICS.Is the repair complete?1. Disconnect the STICS connector.2. Connect a jump wire between terminal C19 and

ground.3. Turn the ignition ON.Is the BRAKE warning lamp on?Replace the brake warning lamp switch.Is the repair complete?Repair the open circuit between the brake warninglamp switch and terminal C19 of the STICS

BRAKE LAMP WARNING CIRCUIT (Cont’d)

Yes

Go To Step 31

Go To Step 17

System OK

Go To Step 20

System OK

Go To Step 22

System OK

Go To Step 26

Go To Step 24

System OK

System OK

Go To Step 27

System OK

Go To Step 29

System OK

System OK

NO

Go To Step 16

Go To Step 18

-

Go To Step 19

-

Go To Step 21

-

Go To Step 23

Go To Step 25

-

-

Go To Step 28

-

Go To Step 30

-

-

Step

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Value

-

-

-

11 - 14 v

-

11 - 14 v

-

11 - 14 v

-

-

-

-

-

-

-

-

HYDRAULIC BRAKES 4A-7

SSANGYONG MY2002

BRAKE LAMP WARNING CIRCUIT (Cont’d)

Action1. Disconnect the brake fluid level switch.2. Use an ohmmeter to check the resistance between

terminal 2 of the switch connector and ground.Is the resistance equal to the specified value?Repair the open circuit between ground and the brakefluid level switch.Is the repair complete?Repair the open circuit between terminal 1 of the brakefluid level switch and terminal D10 of the instrumentcluster.Is the repair complete?

Yes

Go To Step 32

System OK

System OK

NO

Go To Step 33

-

-

Step

31

32

33

Value(s)

≈ 0 Ω

-

-

SSAMGYONG MY2002

4A-8 HYDRAULIC BRAKES

YAD4A170

YAD4A180

LCRV (LOAD CONSCIOUSREDUCING VALVE)LCRV consists of sensing part and hydraulic controlpart.

1. Sensing Part

It detects the changes of vehicle height causedby vehicle load. It consists of load sensing springand control lever which change according tovehicle load.

2. Hydraulic Control Part

It consists of valve stem devices which controlshydraulic pressure according to load detected bysensing part.

YAD4A190

4. Place alignment marks between the lock nut (b)and adjusting screw (c) after the valve setting.

5. LCRV setting should be performed with unloadedvehicle condition.

Setting Method1. Install the connecting rod (a) to the No.1 hole.

2. Adjust the clearance “X” to be 0mm and tightenthe bolt (c) using the lock nut (b).

Installation Notice

Tightening Torque 14 - 18 N•m (10 - 13 lb-ft)

3. Remove the connecting rod (a) from the No.1 holeand reinstall it to the No.2 hole.

Installation Notice

Tightening Torque 14 - 18 N•m (10 - 13 lb-ft)

HYDRAULIC BRAKES 4A-9

SSANGYONG MY2002

InspectionWhen it occurs the malfunction in the LCRV, the sensorspring, valve body assembly, rear axle or rear springmay be replaced. For these replacement, the followinginspection should perform;

Symptom

Poor Braking Performance

Rear Wheels Lock Early

Possible Cause

Air in Brake System

Poor Adjustment of Sensor Spring

Damaged Sensor Spring

Fluid Leaking from LCRV

Poor Adjustment of Sensor Spring

Internal Fluid Leaking of LCRV

Action

Bleeding

Adjust

Replace

Replace

Adjust

Replace

Notice:

• Fluid leaking from LCRV results from poor valveopen/close or sealing wear caused by the foreignmaterials in the LCRV.

• When you change or repair the LCRV, it may affectthe braking performance. Thus, ensure to use theapproved part.

SSAMGYONG MY2002

4A-10 HYDRAULIC BRAKES

KAA4A020

KAA4A030

Notice: Keep brake fluid away from painted surfacesbecause brake fluid will damage the paint finish.

2. Fill the master cylinder reservoir with brake fluid.Keep the master cylinder reservoir at least one-half full during the bleeding operation.

ON-VEHICLE SERVICEMANUAL BLEEDING THE BRAKESRemoval and Installation ProcedureImportant: Manual bleeding of the hydraulic modulatoris not possible. If air enters the antilock brake hydraulicmodulator, or if an unfilled modulator is installed, usethe scan tool to bleed air out of the brake system.Replacement modulators are shipped already filledand bled. In normal on-vehicle service proceduresinvolving the modulator, such as the procedure toreplace the electronic brake control module, air willnot enter the modulator. In such cases, use thebleeding procedure in this section.

1. Remove the booster reserve by applying thebrakes several times with the engine off, until allthe reserve is depleted.

Important: If no air is suspected to be in themaster cylinder, begin the bleeding procedure atStep 12. If it is suspected that air is in the mastercylinder bore, then the master cylinder must bebled, beginning with step 2.

REPAIR INSTRUCTIONS

HYDRAULIC BRAKES 4A-11

SSANGYONG MY2002

KAA4A040

KAA4A020

KAA4A040

KAA4A050

3. Disconnect the brake line at the front of the mastercylinder.

4. Allow the brake fluid to fill the master cylinder untilit begins to flow from the port.

5. Reconnect the brake line at the front of the mastercylinder.

6. Slowly push and hold the brake pedal.

7. While the brake pedal is pushed down, loosen thebrake fitting at the front of the master cylinder topurge the air from the cylinder.

8. Slightly tighten the brake fitting. Then release thebrake pedal slowly. Wait 15 seconds before continu-ing with the next step.

9. Repeat Steps 6-8 until all of the air is removedfrom the master cylinder bore.

10. Tighten the brake line fitting.

Installation Notice

11. After the air has been bled at the front connection,bleed the master cylinder at the rear connectionusing the same sequence as with the topconnection.

Installation Notice

Tightening Torque 22 N•m (16 lb-ft)

Tightening Torque 17 N•m (13 lb-ft)

SSAMGYONG MY2002

4A-12 HYDRAULIC BRAKES

13. Slowly push and hold the brake pedal. Avoid rapidpumping of the brake pedal.

14. While the brake pedal is pushed down, loosen thebleeder valve to purge the air from the caliper.

15. After the air bubbles have escaped into thecontainer of brake fluid, slightly tighten the rearbleeder valve.

16. Slowly release the brake pedal. Wait 15 secondsbefore proceeding with the next step.

Notice: Keep brake fluid away from paintedsurfaces because brake fluid will damage the paintfinish.

17. Repeat Steps 13 - 16 until all of the air is removed.You will know all of the air is removed when nobubbles appear in the container when the bleedervalve is loosened. Keep the master cylinder reservoir at least one-half full during the bleedingoperation.

18. Tighten the front bleeder valve.

Installation Notice

12. Attach a transparent tube over the rear bleedervalve at the right rear caliper. Allow the tube tohang submerged in the brake fluid in a transparentcontainer. (After the right rear caliper is bled inthe following steps, use this procedure at the leftfront, the left rear and the right front bleeder valves.)

19. Bleed the remaining calipers in the following order: left rear, right front, and left front. Use theprocedure in Steps 12 - 17.

20. After all calipers have been bled, check the brakepedal for sponginess. If the brake pedal is not firm,repeat the entire bleeding procedure to correct thiscondition.

Tightening Torque 10 N•m (89 lb-ft)

KAA4A060

KAA4A070

HYDRAULIC BRAKES 4A-13

SSANGYONG MY2002

Tightening Torque 17 N•m (13 lb-ft)

FRONT BRAKE HOSERemoval and Installation Procedure

1. Raise and suitably support the vehicle.

2. Disconnect the brake line from the brake hose support bracket on the front frame on each side of thevehicle and remove the retainer.

Installation Notice

KAA4A080

KAA4A090

KAA4A100

KAA4A110

3. Remove the brake hose from the brake hosesupport bracket on the upper control arm.

4. Remove the front brake hose-to-front caliperassembly bolt.

5. Remove the ring seals and the disc brake hose.

Installation Notice

Tightening Torque 30 N•m (22 lb-ft)

• Bleed the brake system. Refer to “ManualBleeding the Brakes” in this section.

• Check the brake system for leaks.

6. Installation should follow the removal procedurein the reverse order.

REAR BRAKE HOSERemoval and Installation Procedure

1. Raise and suitably support the vehicle.

2. Disconnect the brake line from the disc brake hoseat the rear axle bracket on each side of the vehicle.

Installation Notice

Tightening Torque 17 N•m (13 lb-ft)

SSAMGYONG MY2002

4A-14 HYDRAULIC BRAKES

KAA4A120

KAA4A130

KAA4A140

STOPLAMP SWITCHRemoval and Installation Procedure

1. Remove the stoplamp switch connector.

2. Remove the stoplamp switch.

3. Installation should follow the removal procedurein the reverse order.

BRAKE PEDALRemoval and Installation Procedure

1. Remove the stoplamp switch connector.

2. Remove the clevis pin and disconnect the brakebooster pushrod.

Installation Notice:

• Install in the upper hole.

• Install the snap pin fully in the hole of clevispin.

• Apply the grease around the hold of clevis pin.

3. Remove the brake pedal mounting nut and removethe brake pedal assembly.

Installation Notice

Tightening Torque 13 N•m (10 lb-ft)

4. Installation should follow the removal procedurein the reverse order.

KAA4A070

3. Remove the rear bleeder valve from the caliper assembly.

Installation Notice

Tightening Torque 10 N•m (89 lb-ft)

• Bleed the brake system. Refer to “ManualBleeding the Brakes” in this section.

• Check the brake system for leaks.

4. Installation should follow the removal procedure inthe reverse order.

HYDRAULIC BRAKES 4A-15

SSANGYONG MY2002

Front Disc Brake Rotor

Type

Diameter

Thickness (New)

Discard Thickness

Thickness Variation

Lateral Runout (Installed)

Light Scoring of the Rotor Surface

Rear Disc Brake Rotor

Type

Diameter

Thickness (New)

Discard Thickness

Thickness Variation

Lateral Runout (Installed)

Booster

Dual

Ratio

Master Cylinder

Bore Diameter (Nominal)

Caliper

Minimum Piston Diameter (Front)

Minimum Piston Diameter (Rear)

Pad and lining

Front

Thickness (New)

Minimum Discard Thickness

Rear (Disc)

Thickness (New)

Minimum Discard Thickness

Application

Ventialated

278.30

24.00

22.00

0.013

0.03

0.40

Solid

299.00

10.40

8.50

0.013

0.03

-

7 : 1

25.40

60.00

38.00 (42.9)

10.00

2.00

9.50

1.50

E32

SPECIFICATIONSGENERAL SPECIFICATION

mm in

Application

Capacity

Lublicant

Description

0.7 (0.7 qt)

DOT 4

10.96

0.95

0.87

0.0005

0.001

0.002

11. 77

0.41

0.33

0.0005

0.001

8″ & 9″

-

1.00

2.36

1.50

0.39

0.08

0.39

0.06

SSAMGYONG MY2002

4A-16 HYDRAULIC BRAKES

10

13

-

22

-

Brake Pedal Mounting Nut

Brake Lind Fitting

Front Bleeder Valve

Front Brake Hose-to-Front Caliper Assembly Bolt

Rear Bleeder Valve

N•mApplication Lb-In

FASTENER TIGHTENING SPECIFICATIONS

Lb-Ft

13

17

10

30

10

-

-

89

-

89