caliper BMW 5 SERIES 1991 E34 User Guide

and push it through until the forward end
comes out at the handbrake lever.
8Insert the cable conduit through the
backplate, and attach the rear end of the
cable to the handbrake lever (rear drum
models) or the actuator (rear disc models).
Make sure you don’t kink the cable while
connecting it.
9Refit the cable conduit to the clips on the
back of the trailing arm.
10On rear drum models, refit the brake
shoes and drum (see Section 6). On rear disc
models, refit the handbrake shoes and
actuator (see Section 12) and the rear brake
disc (see Section 5).
11Lower the vehicle, and refit the adjusting
nut at the handbrake lever. Adjust the
handbrake cable (see Section 11) and refit the
handbrake lever boot.
11 Handbrake- adjustment
2
Rear drum brake models
Note:Adjustment of the handbrake cable(s)
on models with rear drum brakes should only
be necessary when you renew a cable or
detach if from the rear brake assembly for
some reason. Failure of the handbrake system
to hold the vehicle usually indicates worn
brake shoes or a faulty self-adjusting
mechanism.
1Raise the rear of the vehicle, and place it
securely on axle stands.
2Fully release the handbrake lever, then
apply the brakes firmly several times with the
footbrake pedal.
3Pull the handbrake lever up five clicks.
4Tighten or loosen the adjusting nuts by
equal amounts until the rear brake shoes just
begin to drag on the brake drum. You should
feel the same amount of resistance at both
wheels when you rotate them.
5Release the handbrake lever, and verify that
the wheels rotate freely. If they don’t, re-
adjust them.
Rear disc brake models
Note: The handbrake system is not self-
adjusting on models with rear disc brakes. The
handbrake therefore requires periodic
adjustment to compensate for wear. It should
also be adjusted anytime either cable, brake
disc or handbrake assembly is renewed or
removed for some reason.
6Slowly apply the handbrake, and count the
number of clicks at the lever. If the lever can
be pulled up further than the eighth click,
adjust the handbrake cable as follows.
7Peel back the handbrake lever boot, and
loosen the cable adjusting nut (see
illustration 10.1). On some models, it may be
necessary to remove the centre console
completely for access.
8Loosen a single bolt in each rear wheel.Raise the vehicle and place it securely on axle
stands.
9Remove the bolt you loosened in each rear
wheel. Turn the wheel until, using a torch, you
can see the adjuster starwheel through the
bolt hole.
10Turn the adjuster - clockwise to expand
the shoes, anti-clockwise to retract them -
until the brake shoes just contact the brake
drum (see illustration 5.6d). Back off the
brake shoes so the wheel spins freely (three to
four teeth on the adjuster). Note:If the
adjuster starwheel is hard to turn, remove the
wheel and brake disc, lubricate the adjuster
wheel, and try again.
11With the disc fitted, apply the handbrake
three times to stretch and seat the cables,
then slowly pull up on the handbrake lever to
the fifth click. Tighten the cable adjusting nuts
by equal amounts until the rear brake shoes
just touch the brake drum. Verify that both
wheels have the same amount of resistance.
12Release the handbrake, and verify that
both rear wheels rotate freely.
13Tighten the wheel bolts to the torque
listed in Chapter 1 Specifications.
12 Handbrake assembly-
check, removal and refitting
2
Warning: The handbrake linings
on rear disc brake models may
be manufactured of asbestos-
based material. Refer to the
warning at the start of Section 6. When
servicing these components, do not create
dust by grinding or sanding the linings.
1The handbrake system should be checked
regularly. With the vehicle parked on a hill,
apply the handbrake, select neutral, and
check that the handbrake alone will hold the
vehicle when the footbrake is released (be
sure to stay in the vehicle during this check).
However, every 2 years (or whenever a fault is
suspected), the assembly itself should be
inspected.
2With the vehicle raised and supported onaxle stands, remove the rear wheels.
3On rear brake drum models, refer to
Chapter 1; checking the thickness of the
brake shoes is a routine maintenance
procedure.
4On rear disc brake models, remove the rear
discs as outlined in Section 5. Support the
caliper assemblies with a coat hanger or
heavy wire; do not disconnect the brake line
from the caliper.
5With the disc removed, the handbrake
components are visible, and can be inspected
for wear and damage. The linings should last
the life of the vehicle. However, they can wear
down if the handbrake system has been
improperly adjusted, or if the handbrake is
regularly used to stop the vehicle. There is no
minimum thickness specification for the
handbrake shoes, but as a rule of thumb, if
the shoe material is less than 1.5 mm thick,
you should renew them. Also check the
springs and adjuster mechanism and inspect
the drum for deep scratches and other
damage.
Removal and refitting
Note:The following procedure applies only to
models with rear disc brakes. The handbrake
system on models with rear drum brakes is an
integral part of the rear brake assembly (see
Section 6).
6Loosen the rear wheel bolts, raise the rear
of the vehicle and place it securely on axle
stands. Remove the rear wheels. Remove the
brake discs (see Section 5). Work on only one
side at a time, so you can use the other side
as a reference during reassembly, and to
avoid mixing up parts.
7Remove the shoe return and hold-down
springs (see illustrations).
8Remove the shoes (see illustration).
9Refitting is the reverse of removal. When
you’re done, the actuator should be properly
seated between the two shoes as shown (see
illustration).
10After refitting the brake disc, adjust the
handbrake shoes. Temporarily refit two wheel
bolts, turn the adjuster (see illustration 5.6d)
and expand the shoes until the disc locks,
9•12 Braking system
12.7b Remove the upper shoe
return spring12.7a Remove the lower shoe return
spring (diagonal cutting pliers are being
used here because they grip the spring
well, but care must be taken not to cut or
nick the spring)

then back off the adjuster until the shoes
don’t drag (see Section 11). Refit the wheel
bolts, and tighten them to the torque given in
Chapter 1 Specifications.
13 Brake pedal- adjustment
1
Note:You should always adjust brake pedal
height after the master cylinder or brake servo
has been removed or renewed. You should
also adjust the stop-light switch (see Sec-
tion 14).
1Measure the distance between the lower
edge of the brake pedal footpad (ie the edge
furthest from the bulkhead) and the bulkhead
(see illustration), and compare your
measurement with the dimension listed in this
Chapter’s Specifications. If it’s not as listed,
loosen the locknut on the pushrod, and rotatethe pushrod while holding the clevis stationary
until the distance is correct. Note:On right-
hand-drive models, the adjustment is carried
out at the left-hand side of the cross-shaft,
after removing the glovebox, but the
dimension is still measured at the pedal.
14 Stop-light switch-
check and adjustment
1
Note:The stop-light switch should be
checked and, if necessary, adjusted after the
master cylinder or brake servo has been
removed or renewed.
1The stop-light switch is located on a
bracket at the top of the brake pedal. The
switch activates the brake lights whenever the
pedal is depressed.
2With the brake pedal in the rest position,
measure the distance between the switch
contact point on the brake pedal and the
switch housing (see illustration)and
compare your measurement with dimension A
listed in this Chapter’s Specifications.
3If your measurement is outside theindicated dimension, disconnect the wires
from the switch. Loosen the locknuts, screw
the switch in or out until the plunger
dimension is correct, and retighten the
locknuts. Reconnect the wires and check for
correct operation.
15 Brake hoses and lines-
inspection and renewal
4
Warning: Brake fluid is
poisonous. It is also an effective
paint stripper. Refer to the
warning at the start of Section 16.
Inspection
1At the intervals specified in Chapter 1, the
brake hoses and lines should be inspected.
With the vehicle raised and placed securely
on axle stands, the flexible hoses should be
checked for cracks, chafing of the outer
cover, leaks, blisters and other damage.
These are important and vulnerable parts of
the brake system, and inspection should be
thorough. The metal pipes should be checked
for excessive pitting and corrosion. If a hose
or pipe exhibits any of the conditions
described, renew it.
Flexible hose renewal
2Clean all dirt away from the ends of the
hose. Have ready a suitable container to catch
spilled brake fluid when the hose is
disconnected.
3To disconnect the hose at the chassis end,
use a spanner to hold the hex-shaped fitting
on the end of the flexible hose, and loosen the
nut on the metal brake line (see illustration).
If the nut is stuck, soak it with penetrating oil.
After the hose is disconnected from the metal
line, remove the spring clip from the bracket
and detach the hose from the bracket.
4To detach the flexible hose from the caliper,
Braking system 9•13
12.9 When you’re done, the actuator
should be properly seated between the
two shoes as shown (hub removed for
clarity)12.8 Remove the shoes12.7c Remove the shoe hold-down springs
14.2 To adjust the stop-light switch,
loosen the locknuts (1) and screw the
switch (2) in or out until dimension A is
correct
13.1 To adjust the brake pedal height,
loosen the locknut (1) and turn the
pushrod (2) while holding the clevis (3) until
dimension A (the distance between the
lower edge of the brake pedal and the
bulkhead/”firewall”) is within the range
listed in this Chapter’s Specifications (left-
hand-drive shown, right-hand-drive similar)
9
A torch and mirror will prove
helpful for a complete hose
and line check.

simply unscrew it. Plug the open fitting in the
caliper if the hose is removed for any length of
time, to prevent dirt ingress.
5Refitting is the reverse of the removal
procedure. Make sure the brackets are in
good condition and the locknuts are securely
tightened. Renew the spring clips if they don’t
fit tightly.
6Carefully check to make sure the
suspension and steering components do not
make contact with the hoses. Have an
assistant turn the steering wheel from lock-to-
lock during inspection.
7Bleed the brake system as described in
Section 16.
Metal brake line renewal
8When renewing brake lines, use genuine
parts only - preferably from a BMW dealer.
9Genuine BMW brake lines are supplied
straight. You’ll need a pipe-bending tool to
bend them to the proper shape.
10First, remove the line you intend to renew,
lay it on a clean workbench and measure it
carefully. Obtain a new line of the same
length, and bend it to match the pattern of the
old line.
Warning: Do not crimp or
damage the line. No bend should
have a smaller radius than
14 mm. Make sure the protective
coating on the new line is undamaged at
the bends.
11When fitting the new line, make sure it’s
well supported by the brackets, that the
routing matches the original, and that there’s
plenty of clearance between movable
components or those components which will
become hot.
12After refitting, check the master cylinder
fluid level, and add fluid as necessary. Bleed
the brake system as outlined in Section 16,
and test the brakes carefully before driving the
vehicle. Be sure there are no leaks.
16 Brake hydraulic system-
bleeding
3
Warning: Wear eye protection
when bleeding the brake system.
If the fluid comes in contact with
your eyes, immediately rinse
them with water, and seek medical
attention. Most types of brake fluid are
highly flammable, and may ignite if spilled
onto hot engine components, for example.
In this respect, brake fluid should be
treated with as much care as if it were
petrol. When topping-up or renewing the
fluid, always use the recommended type,
and ensure that it comes from a freshly-
opened sealed container. Never re-use old
brake fluid bled from the system, and don’t
top-up with fluid which has been standing
open for a long time, as it is potentially
dangerous to do so.
Note:Bleeding the hydraulic system is
necessary to remove any air which has
entered the system during removal and
refitting of a hose, line, caliper or master
cylinder.
1It will probably be necessary to bleed the
system at all four brakes if air has entered the
system due to low fluid level, or if the brake
lines have been disconnected at the master
cylinder.
2If a brake line was disconnected at only one
wheel, then only that caliper or wheel cylinder
need be bled.
3If a brake line is disconnected at a fitting
located between the master cylinder and any
of the brakes, that part of the system served
by the disconnected line must be bled.
4Bleed the right rear, the left rear, the right
front and the left front brake, in that order,
when the entire system is involved.
5Remove any residual vacuum from the
brake servo by applying the brakes about 30
times with the engine off. This will also relieve
any pressure in the anti-lock brake system
(where applicable).
6Remove the master cylinder reservoir
cover, and fill the reservoir with brake fluid.
Refit the cover. Note:Check the fluid level
often during the bleeding operation, and add
fluid as necessary to prevent the fluid level
from falling low enough to allow air into the
master cylinder.
7Have an assistant on hand, an empty clear
plastic container, and a length of clear plastic
or vinyl tubing to fit over the bleed screws.
Alternatively, a “one-man” bleeding kit can be
used. A “one-man” kit usually contains a tubeor bottle with a one-way valve incorporated -
in this way, the pedal can be pumped as
normal, but air is not drawn back into the
system when the pedal is released. If a one-
man kit is used, follow the instructions
provided with it; similarly with pressure
bleeding kits. In any case, you will also need a
supply of new brake fluid of the
recommended type, and a spanner for the
bleed screw.
8Beginning at the right rear wheel, loosen the
bleed screw slightly, then tighten it to a point
where it is tight but can still be loosened
quickly and easily.
9Place one end of the tubing over the bleed
nipple, and submerge the other end in brake
fluid in the container (see illustration).
10Have the assistant pump the brakes a few
times, then hold the pedal firmly depressed.
Note:If the vehicle is equipped with ABS,
have the assistant pump the pedal at least 12
times.
11While the pedal is held depressed, open
the bleed screw just enough to allow a flow of
fluid to leave the caliper or wheel cylinder.
Your assistant should press the brake pedal
smoothly to the floor, and hold it there. Watch
for air bubbles coming out of the submerged
end of the tube. When the fluid flow slows
after a couple of seconds, close the screw
and have your assistant release the pedal.
12Repeat paragraphs 10 and 11 until no
more air is seen leaving the tube, then tighten
the bleed screw and proceed to the left rear
wheel, the right front wheel and the left front
wheel, in that order, and perform the same
procedure. Be sure to check the fluid in the
master cylinder reservoir frequently.
Warning: Never re-use old brake
fluid. It absorbs moisture from
the atmosphere, which can allow
the fluid to boil and render the
brakes inoperative.
13Refill the master cylinder with fluid at the
end of the operation.
14Check the operation of the brakes. The
pedal should feel solid when depressed, with
no sponginess. If necessary, repeat the entire
process. Do not operate the vehicle if you are
in doubt about the effectiveness of the brake
system.
9•14 Braking system
16.9 Place one end of the tubing over the
bleed screw, and submerge the other end
in brake fluid in the container
15.3 A typical brake line-to-brake hose
connection: To disconnect it, use one
spanner to hold the hex-shaped fitting on
the end of the flexible hose (lower right
arrow) and loosen the threaded fitting on
the metal line with a split ring (“brake”)
spanner (upper right arrow), then remove
the spring clip (left arrow)
Brake fluid is an effective
paint stripper, and will attack
plastics; if any is spilt, wash it
off immediately with copious
amounts of water.

problem exists, a new subframe or steering
arm (5-Series) or steering knuckle (3-Series),
which is integral with the strut housing, should
be fitted as well as the new balljoint.
Renewal
Note: None of these balljoints can be serviced
or renewed individually. If one of them is worn,
a complete new arm must be fitted.
8 Front hub and wheel bearing
assembly-
removal and refitting
3
Note:Removing the front hub/bearing
assembly renders it unfit for re-use. A new
assembly will be required for refitting.
Removal
1Loosen the wheel bolts, then raise the front
of the vehicle, and support it securely on axle
stands. Remove the wheel bolts and the
wheel.
2Using a hammer and chisel, remove the
dust cap from the centre of the wheel hub
(see illustration).
3Unstake the hub nut (see illustration).
4Refit the wheel and lower the vehicle to the
ground. Loosen, but do not remove, the hub
nut.
Warning: Always loosen and
tighten the hub nut with the
vehicle on the ground. Theleverage needed to loosen the nut (which
is very tight) could topple the vehicle off a
lift or an axle stand.
5Raise the front of the vehicle, support it
securely on axle stands, and remove the front
wheel again.
6Remove the front brake caliper and
mounting bracket (see Chapter 9). There is no
need to disconnect the brake hose. Hang the
caliper out of the way with a piece of wire.
7Remove the brake disc (see Chapter 9).
8Remove the hub nut, and pull the hub and
bearing assembly off the stub axle. You may
have to tap it off if it’s stuck (see illustration).
If the inner race of the bearing remains on the
stub axle (it probably will), remove the dust
shield (rubber boot) behind the bearing, and
use a puller to remove the inner race (see
illustration).Refitting
9Fit a new dust shield.
10Push the new hub and bearing onto the
stub axle. If it’s necessary to use force, press
or drive only against the bearing inner race
(see illustration).
11Fit a new hub nut, and tighten it finger-
tight at this stage.
12Refit the brake disc, its countersunk
retaining screw, and the brake caliper (see
Chapter 9).
13Refit the wheel, and lower the vehicle to
the ground.
14Tighten the hub nut to the torque listed inthis Chapter’s Specifications. Again, make
sure you do this with the vehicle on the
ground, not up on axle stands.
15Raise the front of the vehicle and place it
securely on axle stands. Remove the wheel.
16Stake the collar of the nut into the groove
of the spindle.
17Apply suitable sealant to a new grease
cap, and fit the cap by driving it into place
with a soft-faced mallet.
18Refit the wheel and wheel bolts. Lower the
vehicle to the ground, and tighten the wheel
bolts to the torque listed in the Chapter 1
Specifications.
9 Rear shock absorbers
(3-Series)-
removal and refitting
3
Removal
Note:Although shock absorbers don’t always
wear out simultaneously, renew both left and
right shock absorbers at the same time, to
prevent handling peculiarities or abnormal ride
quality.
1Chock the front wheels.
2Raise the rear of the vehicle, and support it
securely on axle stands. Support the trailing
arm with a trolley jack. Place a block of wood
on the jack head to serve as a cushion.
3Remove the shock absorber lower
mounting bolt (see illustration).
10•8 Suspension and steering systems
9.3 Remove the shock absorber lower
mounting bolt (arrowed)8.10 Use a large socket or a suitable piece
of pipe to drive against the inner race of
the new bearing8.8b If the inner race of the bearing sticks
to the stub axle, use a puller to get it off
8.8a If the hub sticks, knock it loose with a
hammer8.3 Using a chisel, knock out the staked
portion of the hub nut8.2 Using a hammer and chisel, knock out
the dust cap in the centre of the hub

the longer side of the sleeve facing towards
the centre of the vehicle.
Refitting
12Refitting is the reverse of removal. Refit
the inner pivot bolt first. Don’t fully tighten the
nuts on the pivot bolts or the shock absorber
yet.
13Bleed the brakes as described in Chap-
ter 9.
14Support the trailing arm with a trolley jack,
and raise it to simulate normal ride height.
Tighten the bolts and nuts to the torques
listed in this Chapter’s Specifications.
15 Rear wheel bearings-
renewal
4
3-Series models
1Loosen the driveshaft nut and the rear
wheel bolts, then chock the front wheels.
Raise the rear of the vehicle and place it
securely on axle stands. Remove the rear
wheel. Note: Depending on the type of rear
wheel, it may be necessary to remove the
wheel first, remove the hubcap, then refit the
wheel and loosen the driveshaft nut.
2Remove the driveshaft (see Chapter 8).3On models with rear brake drums, remove
the drum. On models with rear disc brakes,
remove the brake caliper and mounting
bracket. Don’t disconnect the hose. Hang the
caliper out of the way with a piece of wire.
Remove the brake disc (see Chapter 9).
Working from behind, drive the wheel hub out
of the wheel bearing with a large socket or a
piece of pipe.
4Remove the large circlip (see illustration)
that holds the wheel bearing in the wheel
bearing housing, then drive out the bearing
with a large socket or piece of pipe.
5Refitting is basically the reverse of removal,
bearing in mind the following points:
a) Be extremely careful where you place the
socket or piece of pipe when you drive
the new bearing into the housing. It
should be butted up against the outer
race of the bearing. Driving in the new
bearing using the inner race will ruin the
bearing.
b) Refit the wheel and lower the vehicle to
the ground before attempting to tighten
the driveshaft nut to the torque listed in
the Chapter 8 Specifications.
5-Series models
6Chock the front wheels, then raise the rear
of the vehicle and support it securely on axle
stands. Disconnect the outer CV joint from the
drive flange (see Chapter 8). Support the outer
end of the driveshaft with a piece of wire -
don’t let it hang, as this could damage the
inner CV joint.
7Prise out the lockplate that secures the
drive flange nut (see illustration). Once
you’ve prised out an edge of the lockplate,
pull it out with a pair of needle-nose pliers.
8Lower the vehicle and unscrew the drive
flange nut, but don’t remove it yet. You’ll need
a long bar (see illustration).
Warning: Don’t attempt to loosen
this nut with the vehicle on axle
stands. The force required to
loosen the nut could topple the
vehicle from the stands.
9Loosen the rear wheel bolts, raise the rear
of the vehicle again, place it securely on axle
stands and remove the wheel.
10Remove the brake caliper and the brake
disc (see Chapter 9). Hang the caliper out of
the way with a piece of wire.
11Remove the drive flange nut. Using a
suitable puller, remove the drive flange (see
illustration).
12Using a soft-faced hammer, drive the stub
axle out of the bearing (see illustration). If the
bearing inner race comes off with the stub
Suspension and steering systems 10•11
15.7 Prise out the lockplate that secures
the drive flange nut - once you’ve prised
out an edge of the lockplate, pull it out
with a pair of needle-nose pliers15.4 An exploded view of the 3-Series rear
wheel bearing assembly14.8 On 1983 and later models, remove
one of these trailing arm-to-axle carrier
bolts (it doesn’t matter which one you
remove - one attaches the link to the
trailing arm, and the other attaches the link
to the axle carrier)
15.12 Using a soft-faced hammer, drive
the stub axle out of the bearing15.11 Remove the drive flange with a
puller15.8 Lower the vehicle and loosen the
drive flange nut
10
If the bearing inner race
sticks to the hub (it probably
will), use a puller to remove
the race from the hub.

REF•3
REF
MOT Test Checks
Exhaust system
MStart the engine. With your assistant
holding a rag over the tailpipe, check the
entire system for leaks. Repair or renew
leaking sections.
Jack up the front and rear of the vehicle,
and securely support it on axle stands.
Position the stands clear of the suspension
assemblies. Ensure that the wheels are
clear of the ground and that the steering
can be turned from lock to lock.
Steering mechanism
MHave your assistant turn the steering from
lock to lock. Check that the steering turns
smoothly, and that no part of the steering
mechanism, including a wheel or tyre, fouls
any brake hose or pipe or any part of the body
structure.
MExamine the steering rack rubber gaiters
for damage or insecurity of the retaining clips.
If power steering is fitted, check for signs of
damage or leakage of the fluid hoses, pipes or
connections. Also check for excessive
stiffness or binding of the steering, a missing
split pin or locking device, or severe corrosion
of the body structure within 30 cm of any
steering component attachment point.
Front and rear suspension and
wheel bearings
MStarting at the front right-hand side, grasp
the roadwheel at the 3 o’clock and 9 o’clock
positions and shake it vigorously. Check for
free play or insecurity at the wheel bearings,
suspension balljoints, or suspension mount-
ings, pivots and attachments.
MNow grasp the wheel at the 12 o’clock and
6 o’clock positions and repeat the previous
inspection. Spin the wheel, and check for
roughness or tightness of the front wheel
bearing.
MIf excess free play is suspected at a
component pivot point, this can be confirmed
by using a large screwdriver or similar tool and
levering between the mounting and the
component attachment. This will confirm
whether the wear is in the pivot bush, its
retaining bolt, or in the mounting itself (the bolt
holes can often become elongated).
MCarry out all the above checks at the other
front wheel, and then at both rear wheels.
Springs and shock absorbers
MExamine the suspension struts (when
applicable) for serious fluid leakage, corrosion,
or damage to the casing. Also check the
security of the mounting points.
MIf coil springs are fitted, check that the
spring ends locate in their seats, and that the
spring is not corroded, cracked or broken.
MIf leaf springs are fitted, check that all
leaves are intact, that the axle is securely
attached to each spring, and that there is no
deterioration of the spring eye mountings,
bushes, and shackles.MThe same general checks apply to vehicles
fitted with other suspension types, such as
torsion bars, hydraulic displacer units, etc.
Ensure that all mountings and attachments are
secure, that there are no signs of excessive
wear, corrosion or damage, and (on hydraulic
types) that there are no fluid leaks or damaged
pipes.
MInspect the shock absorbers for signs of
serious fluid leakage. Check for wear of the
mounting bushes or attachments, or damage
to the body of the unit.
Driveshafts
(fwd vehicles only)
MRotate each front wheel in turn and inspect
the constant velocity joint gaiters for splits or
damage. Also check that each driveshaft is
straight and undamaged.
Braking system
MIf possible without dismantling, check
brake pad wear and disc condition. Ensure
that the friction lining material has not worn
excessively, (A) and that the discs are not
fractured, pitted, scored or badly worn (B).
MExamine all the rigid brake pipes
underneath the vehicle, and the flexible
hose(s) at the rear. Look for corrosion, chafing
or insecurity of the pipes, and for signs of
bulging under pressure, chafing, splits or
deterioration of the flexible hoses.
MLook for signs of fluid leaks at the brake
calipers or on the brake backplates. Repair or
renew leaking components.
MSlowly spin each wheel, while your
assistant depresses and releases the
footbrake. Ensure that each brake is operating
and does not bind when the pedal is released.
3Checks carried out
WITH THE VEHICLE RAISED
AND THE WHEELS FREE TO
TURN

REF•6Tools and Working Facilities
Compression testing gauge Clutch plate alignment setBrake shoe steady spring cup removal tool
Micrometer setVernier calipers
Dial test indicator and magnetic stand
Piston ring removal/installation toolCylinder bore hone Three-legged hub and bearing puller
Valve spring compressorPiston ring compressorSpline key set

REF•7
REF
Tools and Working Facilities
MImpact screwdriver
MMicrometer and/or vernier calipers (see
illustrations)
MDial gauge (see illustration)
MUniversal electrical multi-meter
MCylinder compression gauge
(see illustration)
MClutch plate alignment set (see illustration)
MBrake shoe steady spring cup removal tool
(see illustration)
MBush and bearing removal/installation set
(see illustration)
MStud extractors (see illustration)
MTap and die set (see illustration)
MLifting tackle
MTrolley jack
Buying tools
For practically all tools, a tool factor is the
best source, since he will have a very
comprehensive range compared with the
average garage or accessory shop. Having
said that, accessory shops often offer
excellent quality tools at discount prices, so it
pays to shop around.
Remember, you don’t have to buy the most
expensive items on the shelf, but it is always
advisable to steer clear of the very cheap
tools. There are plenty of good tools around atreasonable prices, but always aim to
purchase items which meet the relevant
national safety standards. If in doubt, ask the
proprietor or manager of the shop for advice
before making a purchase.
Care and maintenance of tools
Having purchased a reasonable tool kit, it is
necessary to keep the tools in a clean and
serviceable condition. After use, always wipe
off any dirt, grease and metal particles using a
clean, dry cloth, before putting the tools away.
Never leave them lying around after they have
been used. A simple tool rack on the garage
or workshop wall for items such as
screwdrivers and pliers is a good idea. Store
all normal spanners and sockets in a metal
box. Any measuring instruments, gauges,
meters, etc, must be carefully stored where
they cannot be damaged or become rusty.
Take a little care when tools are used.
Hammer heads inevitably become marked,
and screwdrivers lose the keen edge on their
blades from time to time. A little timely
attention with emery cloth or a file will soon
restore items like this to a good serviceable
finish.
Working facilities
Not to be forgotten when discussing toolsis the workshop itself. If anything more than
routine maintenance is to be carried out,
some form of suitable working area becomes
essential.
It is appreciated that many an owner-
mechanic is forced by circumstances to
remove an engine or similar item without the
benefit of a garage or workshop. Having done
this, any repairs should always be done under
the cover of a roof.
Wherever possible, any dismantling should
be done on a clean, flat workbench or table at
a suitable working height.
Any workbench needs a vice; one with a
jaw opening of 100 mm is suitable for most
jobs. As mentioned previously, some clean
dry storage space is also required for tools, as
well as for any lubricants, cleaning fluids,
touch-up paints and so on, which become
necessary.
Another item which may be required, and
which has a much more general usage, is an
electric drill with a chuck capacity of at least 8
mm. This, together with a good range of twist
drills, is virtually essential for fitting
accessories.
Last, but not least, always keep a supply of
old newspapers and clean, lint-free rags
available, and try to keep any working area as
clean as possible.
Bush and bearing removal/installation setStud extractor setTap and die set

REF•14Fault Finding
Brakes
Note:Before assuming that a brake problem exists, make sure that:
a) The tyres are in good condition and properly inflated (Chapter 1).
b) The wheel alignment (tracking) is correct (Chapter 10).
c) The vehicle is not loaded with weight in an unequal manner.
Vehicle pulls to one side during braking
m mIncorrect tyre pressures (Chapter 1).
m mWheel alignment (tracking) incorrect (Chapter 10)
m mUnmatched tyres on same axle.
m mRestricted brake lines or hoses (Chapter 9).
m mMalfunctioning caliper assembly (Chapter 9).
m mLoose suspension parts (Chapter 10).
m mLoose calipers (Chapter 9).
Noise (high-pitched squeal) when the brakes are
applied
m mFront and/or rear disc brake pads worn out. The noise comes from
the wear sensor rubbing against the disc. Renew the pads
immediately (Chapter 9).
Brake vibration (pedal pulsates)
Note:If the vehicle has ABS, it is normal for the brake pedal to pulsate
when the system is working.
m mExcessive lateral disc run-out (Chapter 9).
m mParallelism not within specifications (Chapter 9).
m mUneven pad wear - caused by caliper not sliding, due to improper
clearance or dirt (Chapter 9).
m mDefective disc (Chapter 9).
Excessive brake pedal travel
m
mPartial brake system failure (Chapter 9).
m mInsufficient fluid in master cylinder (Chapters 1 and 9).
m mAir trapped in system (Chapters 1 and 9).
Excessive pedal effort required to stop vehicle
m
mMalfunctioning brake servo unit (Chapter 9).
m mPartial system failure (Chapter 9).
m mExcessively-worn pads or shoes (Chapter 9).
m mCaliper piston stuck or sluggish (Chapter 9).
m mBrake pads contaminated with oil or grease (Chapter 9).
m mNew pads fitted and not yet seated. It will take a while for the new
material to seat against the disc.
Dragging brakes
m mMaster cylinder pistons not returning correctly (Chapter 9).
m mRestricted brakes lines or hoses (Chapters 1 and 9).
m mIncorrect handbrake adjustment (Chapter 9).
m mRear drum brake self-adjuster mechanism faulty (when applicable)
(Chapter 9).
Grabbing or uneven braking action
m mMalfunction of brake servo unit (Chapter 9).
m mBinding brake pedal mechanism (Chapter 9).
Brake pedal feels “spongy” when depressed
m
mAir in hydraulic lines (Chapter 9).
m mMaster cylinder mounting bolts loose (Chapter 9).
m mMaster cylinder defective (Chapter 9).
Brake pedal travels to the floor with little resistance
m
mLittle or no fluid in the master cylinder reservoir, caused by leaking
caliper piston(s), loose, damaged or disconnected brake lines
(Chapter 9).
Handbrake does not hold
m mHandbrake linkage incorrectly adjusted (Chapter 9).
m mHandbrake shoe linings worn out or contaminated (Chapter 9).

REF•15
REF
Fault Finding
Suspension and steering
Note:Before assuming that a problem exists, check the following
items:
a) Tyre pressures and tyre condition (also check for out-of-round or
out-of-balance tyres, and bent wheel rims).
b) Steering universal joints from the column to the steering gear (for
play or wear).
c) Front and rear suspension, and the rack-and-pinion assembly (for
loose or damaged parts).
d) Wheel bearings (wheel wobble or roughness when spun).
Vehicle pulls to one side
m mMismatched or uneven tyres (Chapter 10).
m mBroken or sagging springs (Chapter 10).
m mFront wheel or rear wheel alignment incorrect (Chapter 10).
m mFront brake problem (Chapter 9).
Abnormal or excessive tyre wear
m
mFront wheel or rear wheel alignment incorrect (Chapter 10).
m mSagging or broken springs (Chapter 10).
m mTyre out of balance (Chapter 10).
m mWorn shock absorber (Chapter 10).
m mOverloaded vehicle or unsympathetic driving style.
m mTyres not rotated regularly.
Wheel makes a “thumping” noise
m
mBlister or bump on tyre (Chapter 10).
m mFaulty shock absorber action (Chapter 10).
m mWheel bolts loose.
Shimmy, shake or vibration
m
mTyre or wheel out of balance or out of round (Chapter 10).
m mLoose, worn or incorrectly-adjusted wheel bearings (Chapter 1).
m mWorn tie-rod ends (Chapter 10).
m mWorn balljoints (Chapter 10).
m mExcessive wheel run-out (Chapter 10).
m mBlister or bump on tyre (Chapter 10).
m mWheel bolts loose.
High steering effort
m
mLack of lubrication at balljoints, tie-rod ends and steering gear
(Chapter 1).
m mIncorrect front wheel alignment (Chapter 10).
m mLow tyre pressure(s) (Chapter 1).
m mPower steering fluid low, or steering pump drivebelt slipping,
where applicable (Chapter 10)
Poor steering self-centring
m mLack of lubrication at balljoints and tie-rod ends (Chapter 1).
m mBinding in balljoints (Chapter 10).
m mBinding in steering column (Chapter 10).
m mLack of lubricant in steering gear (Chapter 10).
m mInaccurate front wheel alignment (Chapter 10).
Abnormal noise at the front end
m
mLack of lubrication at balljoints and tie-rod ends (Chapter 1).
m mDamaged shock absorber mounting (Chapter 10).
m mWorn control arm bushings or tie-rod ends (Chapter 10).
m mLoose anti-roll bar (Chapter 10).
m mLoose wheel bolts.
m mLoose suspension mounting bolts (Chapter 10).
Wandering or poor steering stability
m
mMismatched or uneven tyres (Chapter 10).
m mLack of lubrication at balljoints and tie-rod ends (Chapter 1).
m mWorn shock absorbers (Chapter 10).
m mLoose anti-roll bar (Chapter 10).
m mBroken or sagging springs (Chapter 10).
m mFront or rear wheel alignment incorrect (Chapter 10).
Erratic steering when braking
m
mWheel bearings worn (Chapter 1).
m mBroken or sagging springs (Chapter 10).
m mLeaking wheel cylinder (rear drum brake models) or caliper
(Chapter 9).
m mWarped discs (Chapter 9).
Excessive pitching and/or rolling around corners or
during braking
m mLoose anti-roll bar (Chapter 10).
m mWorn shock absorbers or mountings (Chapter 10).
m mBroken or sagging springs (Chapter 10).
m mOverloaded vehicle.
Suspension bottoms
m
mOverloaded vehicle.
m mWorn shock absorbers (Chapter 10).
m mBroken or sagging springs, or incorrect springs fitted (Chapter 10).
Unevenly-worn tyres
m
mFront wheel or rear wheel alignment incorrect (Chapter 10).
m mWorn shock absorbers (Chapter 10).
m mWheel bearings worn (Chapter 10).
m mExcessive tyre or wheel run-out (Chapter 10).
m mWorn balljoints (Chapter 10).
Excessive tyre wear on outside edge
m
mTyre pressures incorrect (Chapter 1).
m mExcessive cornering speed.
m mWheel alignment incorrect (excessive toe-in) (Chapter 10).
m mSuspension components damaged (Chapter 10).
Excessive tyre wear on inside edge
m
mTyre pressures incorrect (Chapter 1).
m mWheel alignment incorrect (excessive toe-out) (Chapter 10).
m mLoose or damaged steering components (Chapter 10).
Tyre tread worn in one place
m
mTyres out of balance.
m mDamaged or buckled wheel. Inspect and renew if necessary.
m mDefective tyre (Chapter 1).
Excessive play or looseness in steering system
m
mWheel bearing(s) worn (Chapter 10.
m mTie-rod end loose or worn (Chapter 10).
m mSteering gear mountings loose (Chapter 10).
Rattling or clicking noise in steering gear
m
mInsufficient or incorrect lubricant in rack-and-pinion assembly
(Chapter 10).
m mSteering gear mountings loose (Chapter 10).