SsangYong (KGM) SsangYong Korando (Mk2) Common Problems & Reliability
The second-generation SsangYong Korando (KJ series) is a compact, retro-styled three-door short-wheelbase 4x4 sold in the United Kingdom between 1997 and 2006. Penned by British designer Ken Greenley, its distinctive exterior blended neo-classical Willys Jeep styling cues—such as twin circular headlamps and prominent separate front wings—with a modern, boxy rear. Built on a shortened ladder-frame chassis shared with the Musso, the Korando offered serious off-road credibility, a tight turning circle, and generous ground clearance. Powertrains were sourced under licence from Mercedes-Benz, comprising a 2.3-litre four-cylinder petrol (M111, 140bhp) and the renowned 2.9-litre five-cylinder turbodiesel (OM662, 120bhp), paired with a five-speed manual or four-speed automatic transmission and BorgWarner part-time 4WD. Rebadged as the Daewoo Korando between 1999 and 2002, it proved a durable, left-field alternative to the Jeep Wrangler and Land Rover Freelander, though vacuum hub failure, chassis rust, and handbrake wear are common.
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Detailed fault breakdown, symptoms, and estimated repair bills by production year.
Most Common SsangYong (KGM) SsangYong Korando (Mk2) Faults & Repair Costs
Front Vacuum Hub Lock Failure on Shift-on-the-Fly 4WD
The Korando's part-time 4WD system uses engine vacuum delivered through flexible rubber pipes to automatically lock the front wheel hubs when shifting from 2H to 4H. With age, exposure to road salt, and off-road grit, the rubber vacuum pipes crack and the hub seals perish. Vacuum pressure leaks away, leaving the front hubs disengaged even though the 4WD dashboard light illuminates, leaving the vehicle stuck in rear-wheel drive.
4WD indicator illuminates on the dashboard but front wheels fail to pull on slippery ground, Hissing air leak audible from the front wheel arches when 4WD is switched on, Front driveshafts spin but wheels do not lock to the hubs
- Jack up the front axle and engage 4WD; attempt to spin the front wheels to check if hubs lock
- Inspect the rubber vacuum lines running to the steering knuckles for dry rot or splits
- Check whether manual locking aftermarket hubs have been installed to replace the vacuum system
Chassis Outrigger and Wheelarch Corrosion
The compact ladder-frame chassis and steel bodywork are vulnerable to aggressive mud and road-salt traps beneath the vehicle. Defective or punctured plastic splash liners allow wet mud and grit to accumulate around the sills, rear spring hangers, and body mount outriggers. Without factory internal cavity wax, severe perforating corrosion develops, leading to MOT structural failure.
Perforating rust holes and flaking metal around the chassis outriggers and body mounts, Bubbling and surface corrosion along the lower sill seams and wheelarch lips, Cracking noises from the cabin mounts when flexing over uneven ground
- Inspect all four body mounting outriggers with a torch and hammer for rot
- Check behind the plastic wheelarch liners for trapped mud and severe rust
- Examine the rear suspension coil spring perches on the chassis frame for thinning metal
Handbrake Cable Stretch and Rear Caliper Seizure
The Korando uses rear disc brakes with a drum-in-hat parking brake setup. Because of the heavy 1.8-tonne kerb weight, handbrake cables stretch over time, causing excessive lever travel and failing to meet the MOT minimum 16% braking efficiency requirement. Road salt and damp ingress also cause the rear parking brake shoes and expander linkages to stick and drag on the drums.
Handbrake lever pulls up almost to the vertical stop without holding the vehicle securely, Vehicle rolls on hills despite the handbrake being fully applied, Hot rear wheel hubs and burning brake smell after driving
- Test handbrake holding power on a steep incline with the vehicle in neutral
- Count how many clicks the handbrake lever travels before holding firmly (should be 5–7 clicks)
- Check rear brake cables for split outer sheaths and internal corrosion
Buying a used SsangYong (KGM) SsangYong Korando (Mk2)? Always check for hidden finance and write-off history.
Mechanical problems are only half the battle. Over 1 in 3 UK used cars checked have unpaid finance or accident write-off records that could cause you to lose the car or thousands in value.