wheel DATSUN PICK-UP 1977 Workshop Manual

Rear
Axle
Rear

Suspension

Spring
front

pin

Spring
shackle

Bearing
cage

fIXing
bolt

Wheel

bearing
lock
nut

Air
breather

Differential

gear
carrier

to
axle
case
nut

Propeller
shaft

flange
bolt

Drain
and
filler

plug

Bumper
rubber

fixing
bolt

Wheel
nut
kg
m
ft
lb

kg
m
ft
Ib

kg
en
ft
lb

kg
m
ft

Ib

kg
m
ft
Ib

kg
m
ft
Ib

kg
en
ft
Ib

kg
m
ft

Ib

kg
m
ft
Ib

kg
m
ft

lb
11
5
to
13
0
83

to
94

11
5

to
13

0
83
to
94

S
4
to
6
4
39

to
46

IS
to
20
108

to
l4S

0
7

to
0

9
S
I

to
6
S

17
to
2
7

12
to
20

2
0
to

2
7

14
to
20

6
to
10
43

to
72

1
6
to
2
2

12
to
16

8
to
9
S8

to
6S

TROUBLE

DIAGNOSES

AND
CORRECTIONS

When

rear
axle
and

suspension
is

suspected
of

being
noisy
it
is

advisable

to
make
a

thorough
test
to
determine

whether
the
noise

originates
in

the

tires

road
surface
exhaust

propeller
shaft

engine
transmission
universal

joint
wheel

bearings
or

suspension

Noise
which

originates
in

other

places
can
not

be
corrected

by
adjust

ment
or

replacement
of

parts
in
the
rear
axle

and
rear

suspension

In
case
of

oil
leak

first
check
if

there
is

any

damage
or

restriction
in

breather

Condition
Probable
cause

Noise
Loose
wheel
nuts

Loose
one
or

more

securing
bolts

Lack
of

lubricating
oil
or

grease

Faulty
shock
absorber

Incorrect

adjustment
of

rear
axle
shaft
end

play

Damaged
or
worn
wheel

bearing

Worn

spline
portion
of
rear
axle
shaft

Broken
leaf

spring

Loose

journal
connections

or
so
no

Wheel
and
tire

unbalance

Damaged
rubber

parts
such
as
leaf

spring

bush
shock
absorber
moun

ting
bush

Faulty
universal

joints

Instability
in

driving
Loose
wheel
nuts

Worn
shock
absorber

Worn

or
broken
leaf

spring

Oil

leakage

Damaged
or

restricted
air

breather

Damaged
oil
seal
in

rear
axle
case
or
differ

ential
carrier

Oil

leakage
from
between
the
differential

carrier

and
axle
case

RA
8
Corrective
action

Tighten
the

wheel
nuts

Tighten
the

bolts
to
the

specified
torque

Lubricate

as

required

Replace
the
shock
absorber

Adjust
the
rear
axle

shaft
end

play

Replace
wheel

bearing

Replace
if

necessary

Replace
leaf

spring

Tighten
to

the

given
torque

Balance
wheel

and
tire

Replace
the

required
parts

Adjust
or

replace

Tighten
to
the

given

torque

Replace
faulty
shock
absorber

Replace
leaf

spring

Clean
or

replace
air

breather

Replace
the

damaged
oil
seal

Tighten
to
the

specified
torque
or

replace

gasket

The
620

series
vehicles

are
equip

ped
with

hydraulic
brakes

on
the
four

wheels
and
mechanical
hand
brakes

on

the
rear
wheels
The
front
brake
is

the
uni
servo

type
and
the
rear
the

duo

servo
with
the
built
in

hand

BRAKE
PEDAL

FRONT
BRAKE

REAR
BRAKE

BRAKE
PEDAL

Qi

f

l

II

t

Unit

mm
in

I
Under
the
condition
that
the

push
rod
of
brake

lamp
swi

tch
is

pushed
in

position
the

height
of
brake

pedal
from
toeboard
to
148
mm
5
83

in

operating
the
switch

adjusting

nuts
Then

tighten
nuts

securely

Tightening
torque

1
2

to
1
5

kg
m

9
to
I
I
ft
Ib

2

Adjust
the

length
of

push
rod
Brake

System

GENERAL
DESCRIPTION

brake
The
mechanical
hand
brake
is

controlled

by
a
hand
brake
lever
locat

ed
in
the
driver

s

compartment

For
added

safety
the
tandem

I
1lI3ter

cylinder
Master
Vac
and

Nissan
Load

Sensing
Valve
N

L
S
V

ADJUSTMENT

CONTENTS
are
standard

equipment
on
all
models

The
Master
Vac
is
installed
to
increase

braking
force
The
N
L

S
V
ensures

greater
safety
and

reliability

BR
2

BR
2

BR
3
HAND

BRAKE

Parking
brake

BLEEDING
HYDRAULIC
SYSTEM
BR
3

BR
3

Free

height

Full
stroke
at

pedal
pad
A
148

5
83

B
134

10
140

5
28
to
5
51

C
43
to
49

1
69

to
1
93
Depressed
height

1
Push
rod

adjusting
nut

2
Switch
adjusting
nuts

3
BraKe

lamp
switch

BA765

Fig
BR
l

Adjusting
brake

pedal

with
its

adjusting
nut
so
as
to
become

0
6
to
1
2
mOl
0
024
to
0

047
in
in

play
Then

tigh1en
nut

securely

Tightening
torque

1

6
to
2

2

kg
m

12

to
16
ft
lb

Note
Take
care
not
to
allow
the

push

rod
to

get
into
master

cylinder
in

free
condition

BR

2
3
After
completing

adjustment

operate
brake

pedal
several
times
to

ensure
that
it
travels
over
its
entire

stroke
of
137
mm
5

39
in

smoothly

without

showing
squeak
noise
twist

ing
or
interference

FRONT
BRAKE

1
Raise

vehicle
until
wheel
clear

floor

2

Remove
rubber
boot
from
brake

disc

3

Ughtly
tap
adjuster
housing
and

move
it

forward
Turn
down

adjuster

wheel
with
a

screwdriver
and

spread

brake
shoes

Stop
turning
adjuster

wheel
when
a
considerable

drag
is
Jelt

and
lock

up
brake
drum

Note
For
both

right
and
left
brakes

brake
shoes

spread
when

adjuster

wheel
is
turned
downward

4
Return

adjuster
wheel
12
ratches

to
obtain
correct
clearance
between

brake
drum
and
brake
shoes
Turn

brake
drum
and
make
sure
that
brake

drum
turns
without

dragging
when

brake
shoes
interfere
with
brake
drum

then

readjust
clearance

5

Install
rubber
boot

Fip
BR
2

Adjusting
front
brake

REAR
BRAKE

With
hand
brake

fully
released

adjust
rear
brake
shoe
clearance
For

the
service

procedures
refer
to
Front

Brake

Fig
BR
3
Adjusting
rear
brake

HAND
BRAKE

Parking
brake

I
Raise

vehicle
until
rear
wheels
are

clear
of
the
floor

2

Apply
hand
brake
lever

operate

lock
nuts
to
be
80
to
100

mrn
3
lS
to

3
94
in

in
hand
brake
lever
stroke

and
tighten
lock
nuts

securely

Applying
force
to
hand
brake

lever

20

to
30

kg
44

to
661b
Brake

System

1
t

0
t

6

0

I

o

nJ
c

BA655

Fig
BR
4

Adjusting
lock
nut

3

Fully
release
hand
brake
and

rotate
rear
wheels
No

drag
should
be

present

Notes

a
Before

adjusting
hand
brake
com

plete
the

adjustment
of
rear
brakes

b
After

adjusting
hand
brake

operate

the
brake
lever
to
make
cable

stable

c
Hand
brake
must
be

operated

smoothly
while

being

pulled
and

released
Make
sure

that
no
abnor

mal
noise
dragging
twisting
or

other
faulty
condition
occurs

BLEEDING

HYDRAUL
Ie
SYSTEM

Hydraulic
brake

system
must
be

bled
whenever

any
line
has
been
dis

connected
or
air
has

entered
into

system

When

pedal
action
has
a

spongy

feel
it
is
an
indication
that
air
has

entered
the

system

Bleeding
the

hydraulic
system
is

an

essential

part
of

regular
brake
service

BR
3
I

Clean
all
dirt
around
master

cyl

inder
reservoir

I
remove
cap
and

top
up

reservoir

with
recommended
brake

fluid

2

Thoroughly
clean
mud
and

dust

from
bleeder
valve

so
that
outlet

hole

is

free
from

any
foreign
material

Install
a

bleeder
hose
on
bleeder
valve

Place
the
other
end
of
hose
in

a

container

filled
with
brake
fluid

3

Depress
brake

pedal
two
or
three

times
then

keep
pedal
fully
depressed

4

With
brake

pedal
fully
depressed

open
bleeder
valve
to

expel
air

Notes

a

Pay
attention
to
brake
fluid
level
in

master

cylinder
reservoir

during

bleeding

operation

b
Do
not

reuse
brake
fluid
drained

during
bleeding

operation

c

Bleed
air
as
follows

1
Master

cylinder
front

2
Master

cylinder
rear

3
N
L
S
V

front

4
Front

wheels

S
Rear

wheels
left
one
first

6
N
L

S
V

rear

7
N
L

S
V
center

d
Exercise

care
not
to

splash
brake

fluid
on

exterior
finish
as
it

will

damage
the

paint

5

Close
bleeder
valve

quickly
as

brake

pedal
is
on
down
stroke

6
Allow
brake

pedal
to
return
slow

ly
with
bleeder
screw
closed

7

Repeat
bleeding
operations
until

no
air

bubbles
show
in
hose

Notes

a
Brake
fluid

containing
air
is

white

and

has
visible
air

bubbles

b
Brake
fluid

containing
no
air

nms

out
of
bleeder
valve
in
a

solid

stream
free
of
air

bubbles

8

Repeat
above

steps
on
the

re

maining
brake
lines

to

expel
all
air

REMOVAL

1

Removing
flare

nuts
on

both
ends

and

clips
effects
the

removal
of

brake

tube
and
brake
hose

2

Rear
brake
hose
can
be

removed

by
disconnecting
the
tube
and
then

turning
round
the
hose

Note
When

removing
brake
tubes
and

hoses

use
Flare
Nut

Torque

Wrench
GG943IOOOO

Never
use

an

OpeD
end

or
an

adjust

able
wrench

INSPECTION

1
Examine

all
hoses
for
swell

rubbing
marks
or
ozone
cracking

re

placing
those

found
with

any
of
above

badly
beyond
use
Also

inspect
end

fittings
and
be
sure
that
no
fluid
leak

through
staked
end

has
taken

place

replace
if

necessary
Hose

with

badly

rusted

fitting
should

also
be

replaced

with
a
new
one

2

Clean
all
tubes

to
remove
dust

and

dirt
with

isopropyl
alcohol

check

ing
for

collapse
wear

cracking
swell

or

rusting
Replace
if
foun
d

with

any

of
wove
Use
care
not
to

damage

brake
tubes

while

operation

Check
if
tubes

are

clamped
secure

ly

Mter
all

brake
lines

have
been

installed

retighten
aU
connections
if

necessary
to

assist
in

obtaining
correct

torque
In

retightening
at
front
wheel

cylinder
first
remove
hose

clamp
and

loosen
flare
nut
on

opposite
side
to

avoid

twisting
hose

Hold

pedal
as
far
downward
as

possible
80

kg
176
lb
or
more

examining
evidence
as
to
whether
fluid

is

leaking
through
brake

lines
or

con

nections

Leakage
in

any
manner
can

not
be

permitted
here
In

case
fluid

leaks

tightening
to

specified
torque

tighten
additionally
up
to
2
5

kg
m

J
8
ft
lb
Under

no
circumstances

should
not

be

tightened
over
2
5

kg
m

18
ft
Ib

torque
since
this

elongates

end

fitting
making
it

impossible
to

reuse
brake
tube

Under
no
circumstances
should
rear

brake
hose
and
3

way
connector
be

retightened
over

specified
torques
In
Brake

System

stead

replace

copper
washer
with
a

new
one

after

checking
for

sign
of

damage
on

seating
surface
Never
reuse

an
old

copper
washer

INSTALLATION

Brake
hose

Front
brake

hose

In

installing
brake
hose
first

jack

up
vehicle

to
take
off
the

weight
of

vehicle
from

wheels
so
that

suspension

is
in
rebound

Steering
wheel
should

also
be

kept
in

straight
ahead

position

To
connect
brake

line
first

connect

brake

hose
to
wheel

cylinder
with
the

specified
torque

Tightening
torque

1
7
to
2

0

kg
m

12
to

14
ft
Ib

Then
secure

brake
hose
to
the

bracket
with
lock

plate
so
as
not
to

twist
or

abnormally
bend
the
hose

Note

After

connecting
brake
hose

at

both
eiuIs

pay
keen
attention
not

to
twist
the
hose
when
additional

tightening
is

required

Fig
BR

12
Front
brake

hose

Rear

brake
hose

First
secure
rear
brake
hose
to

3

way
connector
on
rear
axle
case
to

the

specifications
Mter

connecting

hose
do
not

tighten
it

at
3

way

connector

additionally
since
this

oper

ation

causes
hose
to
be
twisted

Tightening

torque

I
7

to
2
0

kg
m

12
to
14
ft
Ib

BR
8
Fig
BR
13
Rear
brake
ho
e

After
brake
hose
has
been
installed

check

to
be

sure
that
there
is

enough

clearance
between
hose
and

adjacent

parts
to
avoid
contact
with
other
ones

The
check
should
be
carried
out
while

moving
wheel

up
and
down

through
its

full

stroke
and

rotating
steering
wheel

between
two
extreme
lock

positions

The
wow
clearance
must
be
as

follows

Hose

to

rotating
or

mOving
parts

such
as
tire
and

rim

40
mm
1
57
in

and
more

Hose
to

stationary

part

2S

mm
0

98
in
and
more

In

case
that
the

above
clearance

cannot
be
obtained
it

may
be
caused

by
the
hose

twisted

Accordingly

carry
out
the
correction
with
hose

connection

again
following
the
above

instructions

Brake
tube

In

installing
a
brake
tube
use
care

to
locate
its

end

squarely
on

mating

seat

noting
the
fact
that
nut
can
be

turned

freely
by
a

light
finger
twist

Then

tighten
to
correct

torque
with
a

Brake

Pipe
Torque
Wrench

GG943
10000

Tightening
torque
Flare
nut

1
5
to
1

8

kg
m

11
to

13
ft
Ib

In
addition
care
should
also
be

exercised
to
avoid

damaging
or
col

lapsing
brake
tube

during
operation

Be
sure
to
make

enough
clearance

between
all
tubes
and
other

adjacent

parts
to
avoid
contact

In

installing
tube

through
hood

ledge

grommet
be
sure
to

position
it

at
the

center
of

grommet

After

connecting
brake
tube
be

sure
to

check
the
clearance
to

prevent

from

damage
The
clearance
at

the

following
portions
must
be

specified

distance
or

more

Tube
to

body
panel
and

frame

Over
5

mm
0
20
in

Tube

to
edge
of
each

panel

Over
10
mm
0
39

in

Tube
to
tube

Loop
pitch

OVer
5
mm
0
20
in

Between
front
tube
and

rear
tube

Over
9

mOl
0
35

in

Tube
to

moving
parts

Over
10
mm
0
39
in

Loop
tube
to

hood

ledge

panel

Over
10

mm
0
39
in

Notes

a
Brake
tubes
are

shaped
at

factory

to
secure

specified
clearance
and

may
not

require
reshaping
Discard

if

they
call
for
excessive

reshaping

b
In

reshaping
a
brake
tube
take
care

to
avoid

damaging
galvanization
or

collapsing
section

Mter
brake
lines
have
been

asssem

bled
check
to
make
sure
that
all

fittings
and
flare
nu
Is
ale

lightened
to

correct

torques

Tightenint
torque

Brake
tube
to
connector

I
Ston

kg
m

II
to

13
ft
Ib

Brake
tube
to
brake
hose

1
7
to

2
0

kg
m

12
to
14
ft
lb

Connector
and

clip
fixing
bolt

O
3S
to
O
4S

kg
m

2
5

to
3
3

ft
lb

3

way
connector

fixing
bolt

on
rear

axle
case

0
8
to
1
1

kg
m

6
to
8
ft
lb

N
L
S
V

DESCRIPTION

The

Nissan
Load

Sensing
Valve

N
L
S
V

serves
to

change
braking

power
of
the

rear
wheels
in

response

to

changes
in
the
load
and
fluid

pressure
improving
braking
stability

and

shortening

stopping
distances
Brake

System

The
N
L
S
V

is
installed
on
the

frame

being
inclined
at
10

degrees
A
summary
of

the
N

L
S
v

operation
is

given
in

Figures
BR
14

and
BR
15

r
Master

cylinder
TI
II

I

y

1

J

I

l
Attaching
angle

D

Wheel

cylinder

BR928

Fig
BR
14
Construction

of
N
L
S
V

Performance
curve
of
brake
fluid

pressure
is
as

follows

0

S

c
A

0

C

o

l
0
oadea

U1U

Front
wheel

cylinder

fluid

pressure
BR769

Perfonnance
curve

of
fluid

pressure
Fig
BR
15

N
L
S
V
TEST

the

following
occurs

When
rear
wheels
lock

stopping

distance
is
shorter
than
13
1

m
43

0

ft
whether
loaded
or
unloaded

Stopping
distance
should
be

measured

from
the

place
where
the
brake

pedal

is

first

applied
to
the

place
the
vehicle

actually

stops
Front
wheels
lock

simultaneously
with
or
ahead
of
rear

wheels
Operating
test

The

test
should
be
conducted
under

these
conditions

Drive
a
vehicle
with

pay
load
and

then
with

only
driver
on

a

dry
flat

concrete
or

asphalt
road

applying
the

brake
suddenly
at
40
km

h
25
MPH

N
L
S
V
is

functioning
normally
if

BR
9

Ibove
mentioned

st
is
available
when
op

the

FRONT
BRAKE
Brake

System

entire
brake

system
except

N

L
S
V
is

correctly

adjusted

After
shoe
return

spring

Adjuster
assembly

8

Adjuster
head

9

Adjuster
head
shim

10
Lock
spring

11

Adjuster
housing

12

Adjuster
wheel

13

Adjuster
screw

14

Retaining
spring

15
Lock

plate

16

Adjuster
shim

17
Rubber
boot
1
Brake

disc

2
Brake

shoe
assembly

3
Wheel

cylinder
assembly

4

Brake
shoe

upper
return

spring

5
Brake
shoe
lower

return

spring

REMOVAL

I
Jack

up
front
of
vehicle

just
high

enough
to
remove
tire
and

support
it

with

safety
stands

2

Remove
wheel

and
brake
drum
If

brake
drum
cannot
be

easily
removed

return
brake

adjuster
install
two
bolts

M8
x
1
25
in
holes
on
the

flange
face

of
brake
drum

and

tighten
bolts
even

ly
until
brake
drum
is
driven
out

3
In
order
to

ease

operation
re

move
hub

assembly
from
knucRle

spindle
Refer
to
Front
Axle

4

Unhook

upper
lower
and
after

shoe
return

springs
and
then
remove

brake
shoe
assemblies

S
Disconnect
brake
hose
from

wheel

cy
linder

6
Loosen

securing
nut
and
remove

wheel

cylinder

7
Remove
rubber
boot

adjuster

shim
lock

plate
and

retaining
spring

and
then
remove

adjuster
assembly

from
brake
disc
Fig
BR
I

6
Front
brake

1
Brake
hose

2
Wheel

cylinder
attaching

bolt

BA312

3
Rubber
boot

Fig
BR
17

Removing
wheel

cylinder

DISASSEMBLY
AND

ASSEMBLY

Wheel
cylinder

@

rr
l

@

t

a

Wheel

cy
linder

housing

2
Piston

3
Piston

cup

4
Dust

cover

5
Retainer
BR649

6
Connector

7

Packings

8
Connector
bolt

9
Bleeder

screw

10

Bleeder

cap
Wheel
cylinder
can
be

disassembled

simply
by
the

following
procedures

described
below

Remove
retainer
and
dust
cover

and
take
out

piston
from
wheel
cyl

inder
Be

careful
not
to

damage

sliding

part
of

piston
and

piston
cup

Thoroughly
wa
sh

u
disassembled

parts
in

brake
fluid
or
alcohol

Note
Do

not
wash
rubber

parts
with

mineral
oil

since
they
are
deterio

rated

When
alcohol
is
used
however
do

not
immerse
rubber

parts
in
alcohol

longer
than
30
seconds
After

parts

are
cleaned

dry
them
with
com

pressed
air

Assemble
wheel

cylinder
in

reverse

sequence
of

diassembly

When

securing
connector
bolt
in

sert
its
location

tip
to
the
hole
of

wheel

cylinder
firmly
and

tighten
it

securely

Carry
out

operations
carefully
so

that

component
parts
are
not
damaged

or
no
dust
and
other

foreign
materials

enter

cylinder

Note

The
brake
wheel

cylinder
is

available

in
both
NABCO
make
and

TOKICO
make
There
is

no
inter

changeability
of

repair
kits
or
com

ponent
parts
between
NABCO
and

TOKICO
makes

When

replacing
the

repair
kit
or

ent

parts
ascertain
the

brand

of
the
brake
wheel

cylinder

body
Be
sure
to
use

parts
of
the

same
make
as
the
former
ones

INSPECTION

Brake
drum

I

Replace
brake
drum
whose
dia

meter
is

beyond
the
limit
of

1
5
mm

0
OS9
in
with

respect
to
the

standard

inner
diameter
of
2S4
0
rom
10
00

SR
tO
Fig
BR
18
Front
wheel

cylinder
in

2
The
allowable
maximum

out
of

round
of
brake
drum
is
0
02

mm

0

0008
in

Re

condition
or

replace
brake
drum

if

specified
limit
is
exceeded

3

Measure
for

tapered
brake
drum

If

specified
limit
of
0

02
mm
0

0008

in
is

exceeded
as
measured
at

a

position
where
the
distance
of
4S
mm

177
in
is

kept
away
from
inlet

re
condition
or

replace
brake
drum

4

Contact
surface
with
which

linings
come
into

contact
should
be

finished
to

such
an
extent
that
it
is

ground
by
a
No
120
to
150
sand

paper

S

Using
a
drum

racer
finish
brake

drum

by
machining
if
it

shows

any

sign
of
score
marks

partial
wear
or

stepped
wear
on
its
contact
surface

Note
After
brake
drum
is

completely

re
conditioned
or
renewed
check

drum
and
shoes
for

proper
contact

pattern

Brake

assembly

I
When
brake
shoe

linings
are

cracked

incompletely
seated
uneven

Iy
worn

andlor
deteriorated
due
to

excessive

heating
or
soiled
with

oil

grease
and
brake
fluid

replace

2

Replace
linings
if
the
thickness
is

worn
down
to
less
than
1
0
mm
0
039

in

Note

When
brake
shoe

lining
is
in

stalled

grind
brake
shoe

lining
face

to
diameter

equal
to
that
of
brake

drum

lining
dimension

Width
x
Thickness
x

Length

4S
x

4
S
x

244
mm

1
77
x
0

177
x

9
61
in

3

Check

adjuster
for
smooth

oper

ation

4

Replace
shoe
return

springs
which

are
broken
or

fatigued
Brake

System

Standard
dimensions
of
shoe

springs

Free

length
Dia

of

spring
No
of
Installed

Item

lengthlload

mOl

in
mOl
in

coils

mm

kg
in
lb

Upper
136
5

2
0
0

079
37
IS9
S
14

to
16

S

37
6
28
31

to
3S

Lower
134
S

2
3
0
091
35
IS9
5
21

to
23

5
30
6
28
46
to

Sl

After
shoe
83
2

1
4
O
OSS
27
S
99
4

to
S

3
28
3

90
9
to
II

Wheel

cylinder

I

Replace

any
cylinder
or

piston

which
is
scratched
scored
or
worn
on

its

sliding
contact
surface

2

Replace
worn

parts
if

piston
to

cylinder
clearance
is

beyond
O
IS
mm

0
OOS9
in

Wheel

cylinder
inner
diameter

19
0S
mOl

Y
in

3

Replace
piston
cup
which
is

worn

or
otherwise

damaged

4

Replace
if

contacting
face
of

cyl

inder
and
shoe
is
worn

locally
or
in

step

S

Replace

damaged
dust
cover

fatigued
piston
spring
or

faulty

threaded

parts

6

Replace
tube
connector
which
is

worn
on
its

threaded

portion

INSTALLATION

Install
front
brake
in
the

reverse

sequence
of
removal

paying
particular

attention
to
the

following
instructions

I

When

assembling
adjuster
assem

bly

apply
brake

grease
to

adjuster

housing
bore

adjuster
wheel
and
ad

juster
screw

When
installing
adjuster

assembly

to
brake
disc

apply
brake

grease
to

disc

adjuster
and

retaining
spring
slid

ing
surfaces

to
slide

adjuster
smoothly

Measure

adjuster
sliding
resistance

Adjust
by
adjuster
shim
when

sliding

resistance
is

in
rrect

BR
ll
Adjuster
sliding
resistance

S
to

12

kg
II
to
261b

2

When

installing
wheel

cylinder
be

sure
to
secure
the

cylinder
with
R

mark

to
right
hand
disc
and
the
one

with
L
mark
to

left
hand
disc

Otherwise
brake
hoses

may
interfere

with
other

adjacent
parts
As

to
the

connecting
instructions

of
brake
hose

no
twist
or

contact
is
existed
on

brake

hose

referring
the

related

topic
Brake

line

Tightening

torque

Wheel

cylinder

SA
to

6
6

kg
m

39
to
48
ft

lb

Connector
bolt

1
9
to
2
5

kg
m

14
to
18
ft
Ib

Brake
hose

1
7
to
2

0

kg
m

12
to
14
ft
lb

Air
bleeder

0
7

to
0
9

kg
m

5
to
7
ft

Ib

Brake
disc

4
2

to
S
O

kg
m

30

to
36
ft
lb

3

Before
installing
brake
shoe
as

semblies

apply
brake

grease
to
wheel

cylinder
and

adjuster
brake
shoe
in

stalling
grooves
and
brake
disc
and

brake
shoe

assembly
contact
faces

two

places
Exercise

care
not
to

allow

grease
to

come
into
contact
with

linings
and

adjuster

BA313

Fig
BR
19
Greasing

points

REAR
BRAKE
Brake

System

4

Adjust
brake
shoe
clearance
and

bleed
brake

system
Refer
to
the

instructions
under

topic

Adjustment
in

this
section

Upon
completion
of
the
above
ad

justments
make
sure
that
brake

oper

ates

correctly
and
no
brake

fluid
leaks

BA315

REMOVAL

I
Jack

up
rear
of
vehicle

just
high

enough
to
remove
lire
and

support
it

with

safety
stands

2
Remove
wheel
loosen

hand
brake

and
detach
brake
drum

3
Turn

pin
by
900
and
remove

antirattle

springs

4

Open
brake
shoe
assemblies
out

ward

against
return

spring
and
remove

extension
link

S

Remove
return

springs

6
Remove
brake
shoe
assemblies

Note

that
after

secondary
brake
shoe

assembly
must
be

separated
from

toggle
lever
When

separating
after

secondary
brake
shoe

assembly
from
toggle
lever
withdraw
clevis

pin

7
Disconnect

toggle
lever
from

hand
brake
rear
cable

BR316

Fig
BR
21

Remouing

toggle
leuer

BR
12
1

Brake
disc

2
Brake
shoe

assembly

3
Wheel

cylinder
assembly

4
Return

upper
spring

5
Return
lower

spring

6
After
shoe
return

spring

7
Retainer

8
Antirattle

spring

9

Spring
seat

10

Adjuster
assembly

11

Adjuster
head

12

Adjuster
head
shim

13
Lock

spring

14

Adjuster
housing

15

Adjuster
wheel

16

Adjuster
screW

17

Toggle
lever

18

Extension
link

19

Return
spring

20

Adjuster
spring

21
Lock

plate

22

Adjuster
shim

23
Rubber
boot

24
Antirattlc
pin

Fig
BR

20
Reor
brake

8
Disconnect
brake
tube
at
wheel

cylinder
by
loosening
flare
nut

9
Remove
wheel
cylinder
from

brake
disc

by
loosening
installation

nuts

10
Remove
rubber
boot

adjuster

shim
lock

plate
and

adjuster
springs

and
remove

adjuster
assembly
from

brake
disc

DISASSEMBLY
AND

ASSEMBLY

Wheel

cylinder

Remove
dust
cover
and

pull
out

piston
head
and

piston
assembly

Refer
to
Wheel

Cylinder
of

Front

Brake

CD

l
ID

345

0

1
Dust

cover

2

Piston
head

3
Piston

4

Piston
Cll

p

5

Wheel

cylinder

housing

6

Bleeder

cap

7

Bleeder
screw

8

Connector

9
Washer

10
Connector
bolt
BR318

Fig
BR
22

Rear
wheel

cylinder

INSPECTION

Brake
drum

Check
brake

drum
in

the
same

manner
as

outlined
in
the
Front
Brake

Drum

Brake

assembly

I
When

brake
shoe

linings
are

cracked

incompletely
seated
uneven

ly
worn
andlor
deteriorated
due
to

excessive

heating
or

soiled
with
oil

grease
and
brake
fluid

replace

2

Replace

linings
if
the
thickness
is

WOol
down

to
less
than

1
0
rom
0
039

in

Note
When
brake

shoe

lining
is
in

stalled

grind
brake

shoe

lining
face

to
diameter

equal
10

lha
I

of
brake

drom

Lining
dimemion

Width
x
Thickness
x

Length

4S

x
4

5
x
244

rom

1
77
x
0
177
x
9
61
in
Brake

System

3
Check

adjuster
for
smooth

oper

ation
4

Replace
shoe
return

springs
which

are

broken
or

fatigued

Standard
dimensions

of
shoe

springs

Dia
of

spring
No

of
Installed

Free

length

lengthlload
Item

mOl
in

mOl
in

coils

mmlkg
in
lb

175

2

0
0
079
32
5
184
11
to
13

Upper

6
89

7
24
24
to
29

158

2
3

0

091
30
176
18

to
20

Lower

6
22

6
93
40
to
44

83
2

1
4
0
055

27
5
99
4

to
S

After
shoe

3
276

3

90
9

to

II

20
5

1

6
0
063
3
5
12
3

S
to
4
5

AntiratUe

0
807

0
47
8
to
9
9

Wheel

cylinder

I

Replace
any
cylinder
or

piston

which
is

scratched
scored
or
worn
on

its

sliding
contact
surface

2

Replace
worn

parts
if

piston
to

cylinder
clearance
is

beyond
O
IS

rom

0

00S9
in

Wheel

cylinder
inner

diameter

19

0S
rom

Xin

3

Replace
piston
cup
which

is
worn

or

damaged

4

Replace
if

contacting
face
of

cyl

inder

and
shoe

is
worn

locally
or
in

step

5

Replace
damaged
dust

cover

fatigued
piston
spring
or

faulty

threaded

parts

6

Replace
tube
connector
which
is

worn
on
its
threaded

portion

INSTALLATION

Install
rear

brake
in

the
reverse

sequence
of
removal

paying
particular

attention

to
the

following
instructions

I

Rear

adjuster
assembly
is

the

same
as
front
Refer
to
the

paragraph

covering
Front
Brake
Installation

Adjuster
sliding
resistance

S
to
12

kg
II
to
261b

BR
13
2

When

assembling
toggle
lever

and

after
brake
shoe

assembly

adjust
clear

ance
between

toggle
lever
and

after

brake
shoe

assembly
to
0
to
0
3
mOl
0

to
0

012
in
with

a

properly
selected

toggle
pin
washer

Toggle

pin
washer

No

Thickness
rom
in

I
2
0
0
079

2
2
3
0
091

3
2

6
0
102

4
2
9
0
114

S

3
2
0
126

3

Before
installing
brake
shoe

as

semblies

apply
brake

grease
to
the

following

places

1
Brake
shoe

installing
grooves
of

adjuster
and
wheel

cylinder

2
Extension
link

installing
grooves

3
Lower
surface
of

spring
seat

4

Contact
surfaces
between
brake

disc
and
brake
shoe

assembly
six

places

At
this
time

be
sure
not
to
coat

brake

grease
to
brake

linings

f

BR317

Fig
BR
23

Gre
ing
point

4

Tightening

torque

Wheel

cylinder

J
S
to
1

8

kg
m

II
to

13ft
Ib

Connector
bolt

1

9
to
2
5

kg
m

14
to
18
ft
Ib

Brake
tube

1
5
to
1

8

kg
m

II

to
13

ft
Ib

Air
bleeder

0
7
to
0
9

kg
m

S

to
7
ft
Ib

Brake
disc

5
4

to
6
4

kg
m

39
to
46
ft

Ib

S

Adjust
brake
shoe
clearance
and

bleed
brake

system
Upon
completion

of

the
above

adjustments
make
sure

that
brake

operates
correctly
and
no

brake
fluid
leaks

MASTER
VAC

DESCRIPTION

A
vacuum

suspended
Master
Vac

is

installed
behind
the

master

cylinder

As
the

brake

pedal
is

depressed
fluid

is

forced
under

high
pressure
through

the
brake

pipes
to
the
wheel

cylinders

to
retard

or

stop
the

vehicle

The
Master
Vac
contains

a

spring

loaded

diaphragm
of
IS2
4

mm
6
in

in

diameter
It

operates
on

negative

pressure

produced
n
the

engine
intake

manifold

The
tandem

master

cylinder
is

capable
of

producing
high
pressure

even
if
the
Master
Vac
is

faulty
Brake

System

Note
The
Master
Vac

diaphragm
dif

fers
from
fonner
ones
for

improved

braking
force
Do
not
install
fonner

Master
Vac
on
1976
models
The

1

Plate
and
seal

2
Push
rod

3

Diaphragm

4

Rear
shell

5

Diaphragm

plate
Master
Vacs

are
identified

by
the

label
color
as
follows

1976
model
Caution

Label

Former
models
YeJlow

BR321

11

Valve

operating
rod

12
Valve

return

spring

13

Poppet
return

spring

14
Exhaust
valve

15
Valve

plunger

16
Reaction

disc

17

Diaphragm
return

spring

18
Front
shell
6
Seal

7

Vacuum
valve

8

Poppet
assembly

9
Valve

body
guard

10
Air

silencer
filter

INSPECTION
OF

OPERATION

Checking
yscuum

pressure

I
Connect

a
vacuum

gauge
in
the

line
between
check
valve

and
Master

2
Start

engine
and
increase

engine

speed
Stop
engine
when
vacuum

gauge
indicates
SOO

mmHg
19
69

inHg

BR
14
Fig
BR
24
Sectionall1iew

of
Master
Vac

Vac
as

shown
in

Figure
BR
25

1

Check
valve

2

Vacuum

gauge

BA169

Fig
BR

25
Air

tight
t
t
t

up

Air

tight
test

I
Fifteen

seconds
after

engine
is

stopped
observe
the

rate
of

drop
in
air

pressure
registered
by
vacuum

gauge

If
a

pressure
drop
of
25

mmHg
0
98

inHg
is

exceeded
refer
to
the
follow

ing
chart
to
determine
the
cause
of

failure