ECU FORD CAPRI 1974 Owner's Guide

) Chapter 6 Manual gearbox and automatic transmission 119
11. 1~) 2nd (Ie", [Inti thrust w,1shcf h.1l1. showioO t .. llloctltinu hole
(",,()w~d)
20 Slide 3ul \jC,lf 01110 the f,aiH 01 the mninsh<Jll. then Iccme the
syndHOlllscr rill\) 011 the gOilf cone. 2! lUC,ll(llhc 3rd/4lh synchlOniscr unit on the l11.1inshaft spllllcs with the long side 01 the huh f"cinO the front (pholo). Tllp the unit fully hOllle lISIrl\)" melal tube. then fit the ci'clip . Milke sure th aI the sluts in the 3([) geM synchroniser ring (lrc <lligned with till} slidinU keys .. 5 the
synchroniser unit is being fitled.
13 Input sh(lf( (S·speed) -dismantling Dnd reassembly
!'ld!;! to Section 6
11 GCil,ho)l ([i·spced) -C)lamin,lIion [In(1 rcnov[ltioll
Ref or 10501:[ '0 118 hut now the lollowlng pOllltS :
(,1)
111<:,,) ,1fI! five sYllcll,v rillYs (h) /IlL' I"yshlft lI[1s 110 IIIlIIsl w,lsllt"s (e) (lielL',1ro IWO ball-/)cmiIJYs ,lrId olle ,01lcI hCMiny (d) Wile" ,cnewi"y Ihc IIL'cr/lL' ,01lcI /)(1,1/ill[lS ill I!lc I,Jyslml/, (ISO wllels 25 75 111111 (1 OTt! ill) fony. IIlhc Oligin,ll ,ollers W{!lC 33 111/11 (T 299 ill) lony, two exll,l space's will be requi,ed
(Fiy 623)
15 Gcarbox (5'SI}Cc(l) -rC<lssemhly
I Loc~tc the l11il\j 11ellc disc In the uottom 01 the m(!in c~sin\j. 2 Fit the rcvcrsc relDy Icvel 01110 tilc pivot (llld retain with the cllclip_
Fit the \juidc to the leve r 3 Posit ion the reverse idler \Je~r in the m~in cDsill\j with the Ion,) shoulder facing the reill and en{lllued with thc ,eiDy Icver. Slide ill thc Idler shalt lInci t<lP fully horlle WIth a solt·f1lced m1lllet. 4 5me,lr ,)Ieasc Inside Ihe end of the IJyshlllt \Jeill clUSlCr then fit the SflilCerS and needle roller ueilrings -there Me 21 needle rolters. If ilddltional spacers (He being used. place them behind the needle rollers {Fig. 6 23}. Make sure that there is sulficient grease to hold the needle rolters in position whIle the lilyshaft is fltled. Due to the high levels of torque trilnsmitted Ihrough the auov e transmissions, il is important tha t all the needle ,ollers of a countcrshaft needle rolter bearin\J have CXilctly the same diDmctcr. If the needle rollers in a be(! ling have dlfieronl diameters, this w ill CDuse uneven load distribution which can .esull in prOI11,l!urc we<lr. II It is I\cCCSSilry \0 rcnew the counlersh1lft
nee(lIe .ol lers, 1l111ke sure Ih1l1 the rollcrs used for an y onc location all
)me from t he SMne l"JilCk It more than one pDck is purchased, do not ,ni x lho needlc rol lers from sepilrate p~cks. 5 Insert the layshJlI in the gear cluster unlil the front of Ihe shah is flush With the frunt \Ie~r on lhe cluster.
1221 3 r(I/41h syl1chro unit
Fig 6.23 Layshaft necdle roll.)/ he<lring (Sec 14)
11 Lays""'1 o NCf!dlf! follf!IS
G Loc,.tc the lilyshah iln!! gCilr ell/stP' III tho hOllom of the .11il;n
caslnu_ 7 Pos.1I0n ,. n(.'w \Jaskot on the Ill;nll (;;05"'11. Ihen hi the mllinshah ilnt! inlCrll1ed"l\C houslIlg. and IClllpor;I"ly secu.e w,th twO bolts. 8 Fit the mll"t Shilh needte roller heilrrn\J to the end 01 lhe mainshJlt
or In the centle 01 lho input Shilh (photo).
.....
,
~
; , .. '-; . '. ~, .
,
15.8 Input sh<lft needle roller beilrinU
, I I
i 1 ,1
I
procarmanuals.com

)20 Chapter 6 M anual gearbox and automatic transmissio n
9 F it the 4th gCill syncluolliser "n9 to the 3rd/4lh sym;luOI"s(1f 'HUI with lhe c:ul-outs over the slidlllg k(lYs. then fit the UlPUl shalt asscnlhly i]n(l lilP the bearing fully into tho casing up 10 the rclo1llunu circtip (photo).
10 Invert Ihe \jCo1rilox so Ihil! the l<lysh,lll gear clusler meshes wllh the input ShiltJ and m,Hnshollt geilrs.
11 USU1U iI soft llletJI doft, d,;v(llhc I;;!yshafl into the miJin CilSUlO unt,1 flush ilt the front lace -the flat on the rcar end 01 the Inyshilh must he horiZOlllal (Dhow)_
12 Us;n!).1 mel,lilllbe. lilfl the Inyshaf gear cluster be,IIPI'!J 11110 the inlcrmcd'<lt(! hOUSing ilnd secure with the eirelip {photo}_ 13 Fit the SpilCCf 'lilt! then, usin!) n mow I tube !<Ip 51h \jCilr 01110 the splines of the 1,1yshilft oc'" Cluster.
14 FII Ihe tlllu~1 wnshcr "nd ICl<linlllg nul. Select 31d tle", "nd 1~lIher 1 st 0' 2n(1 !IV.l1 hI' pushin(J Ihe lespec tlve synchloniSCI sleeve. WhIle an aSSI~t,lIlt holds the ge"rbox sl<ltlonmy. tighten the IIUI 10 Ihe specrllcd torque. then lock It by peen Inn the coli", on Ihc nut ",to the slol III Ihe Oe;I( cruste, (phOI05)
• ,
15 Seleci neulrnl. then slide 5th ge", IlItO mesh WIth the driVing Be",. 16 Slide the 51h gem synchroniser unll complete with sp"ce[ Onto 51h Oll"r. Then. usrng.l metal tube, drive Ihe dO\1 huh "lid 51h synchronlser flng OnlO Ihe 1ll",nsh,,11 splines whIle UlOld"l!) the synchronIse! 111111 onto Ihe shdlll[J keys. Fit the circhp (pholUs).
17
T"p Ihe sp eedometer drivegeilr "HO ItS COrreCI poslilon on Ihe mollllsh"ft -the dlsWllce belwoon Ihe HeM 'Illd the 5th gO,l[ dOll hub c"cllp should be 123.0 to 1 24 .0 111m (4 843 10 <1 882 Ill) (nhoto). lB Loc"le Ihc 5th He", selector fOlk In liS syn ch ronlSN sleeve "nd loc"le Ihe Interlock sleeve in Ihe uroov", hhol! Shollider 10 front). then InSurt the seleClor sh~1t through the sleeve ,1nd SeleCIOr fOlk InlO the "'aOll r.,lsll1\J (photo).
19 LocnlC the lSI/2nd "nd 3rd/4th Sf)I&#39;~rIOr IOlks 1(1 Ihell respecllve ~Yllcillonlser sleeves. posilion the selectOl !ross <lnd lockrng plate, ,1rld 1I1S(~lt the selector shah through Ihe cOlllpo&#34;en1~ InlO the frail! of the mam caSillO The roll pin hole in the 3,~lel:I&#34;[ 1'035 rHUSt he tow.>rd s the Irolll
20 If If!rnoverl. 'ef'l Ihe seleCIOr sh,,11 (:&#34;nlr,, 11~1I1!1 sprinU ",ui 51h \Ie",
.' /
15.9 FI1l1I1\1 Inpul shnl1 15.11 L;,ysh;r!t corruc tly located hefore inst,111,11101l 15.12 F,ltintllile Inysllilft hearing
15. 14A Tlghtelllng thc rn"insha fl nut
15.16B F'lllI'\) 5th genr synchlO to m~inshalt
15.148 Slak,n\1 the rH.lloslrall nul
15.16C 5th \le,,, haulk flng Jod hull
15.16A 5th gem synchro spacer
15. 160 51h gear hub {:ilchp
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130 Chapte r 7 Pro pelle r sh aft
14
. 12 ~
"> ., I>
" 10 11
9 a
·6)6f
. -r 3
~I&#34;&#34;)~ 2
Fig. 7 .2 CCllIre bearing and CV joint cOIll I)onenls (Sec 3)
1 FIO,,/ sll,1// 2 Inncr (/(IS/ cJ(cfudm 3 Cemrc bC.1riny 11 Rubber in$u/.l/(J'
5 1f00wl/f/ 6 Du/!)( rlusl cXl;/mh'I 7 AIlYflml'lJ/ shim 8 flull
FiU · 7.3 T ho recess (;ufo\l\lcd) in the <:orllre bearing housing m ust la ce forw(.rd (Soc J)
10 To lI~fll the bearing. first f,lI the 51)<lCO between the bC<I,iny and dust e~clu(tcrs with 11 general purpose urease . Selec t 11 piece of piping or tubing that is just 11 hnclion smaller in (h;lInctcr than the bCilring. place the sphncd p,HI of the shill I upright in a vice, position the bCiI.ing 011 Ihe shaf t and, using a soft hilrlHn cr o n the end of the piece of lubing. drivc\ho bearing firmly and squarely OntO the shalt . 11 Slido lhc con Ire bearing housing and fubber insulalof Ollef the bearing. milking sure lhallhe prelliously nOled recess faces lhe IrOnl 01 lhe shalt. Relil lhe Outef dUSl cxcludCl . 12 loca1O the l1anyc on the splmes of lho frOIll shal l. making SUfe th,l1 tho PfOlliously made marks are aligned . Rel it the cenue bolt and
washOf and tig h10n the boll. 13 Assemble thc two shahs togothCl with lho previously made marks
alrgned. Ihen refit and tighten the constanillclocity joint housing bolts. 14 Refit the propeUef shalt With ,efefcnce to Section 2.
4 U nillorsal joints in sp ectio n
) Weaf in the
needle rollef heafings is Ch,Uoclefi sed by vibfalion in the tfan srnission. 'clonks' on takrng up the drille. and in e~treme cases 01 tack 0 1 lubficat ion. mOlalhc squoaking. and ultimately grating and
shrie king sounds as the bOilflngs breiJk up.
9 Fl.",!!.: /0 C('/IIf<.' 1",11 /1 Cllcllf'S 12 CV /01111 ilssl:mbly
13 Sprillg c.lf' 14 Boll
Fig. 7.4 Using.~ plillor 10 withdraw the centre bClI ring (Sec 3)
Fig. 7.5 Bendi" g the metal tabs to secure the insulator (Sec 3)
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1
134 Chapte r 8 Rea r axl e
FiO. 8.5 Discorlllccti!l9 the rcar sI"biliser Iwr (Sec 3)
7 U~&#34;&#39;!I u"ps (FlU 8 5) I)UU rile s1.1h,l,s(lI b.ll 10 lilt:! lCol. while unstocwIIlIJ the mOlllllnlU I)oIIS from the Ie;)' ;l~II!. flcl110vc the C!JIllI'S 8 W,lh the rC:II Ildc sUlt,lbly SUIlI>o.ICd. lIIlSCICW rhe nulS hom the hallom 01 the U-bolts i1rld reOlOlle rhe lowel S I)llrlU p l;lrcs .. ",t! 1115 .. 1<11015. 9 Wllh rhe help of an asslSlilnt. hft the rem a~lc over the &#34;~<lr ~p&#39;!I1\1s iUld withdraw i t from undcr the CilL 10 To refit the ICtllr axle, lirst cher.k Ihal the upper insul<l ,ors ;lnd 1",lCkclS a.e correctly located on the springs. 11 Wllh rhe help of an assistant hft the rear ;'!Kli! into 1)05'1'011 on the W:1r 5Il flrl!JS. 17. COIIIWC l rhe IUOI)clle. shall 10 Ihe dflllc flanUc with rile IlfClllous ly 111;1,1 " "'o1rks :11111110<1. ,1nd loosely fll the four bOl ts. tOljclhe. W Ith new hl':kw;,s he.s
13 I O.:.lt!"! the ul~&#34;&#39;&#39;&#39;&#39;o.s 1m!! lowe. SP""1J pl~ws all the sp rin!jS thclI "1 Ihn 1)·llo\1s. W!IClhc. wilh Il/!W sld/.locklll\) lIutS T'!Jhlf:l1 thc IHII S l"o!Jlnsslvuly 10 Ihe spo{;lf ,/!(IIOIQUC. III 1')<;,lIe Ihc CI;1I1IP~ 011 liIe Slilhd,scr bilr "'0\I1111\1 tubhers tlrCII pull 1 hili IlltO poslllon WIllI thl) grips <l1l(1 fIt the mountlllll bolts. TIUhtell .Il hl>l1~ 10 the S IICclllI .. '(l toIlIUI) . • ,. j<lck up the reM a~l{l ,1S neceSSilry and push the shock <lhso<be .s
, Ihe" I/.ac ket s. In se'l Ihe nloum"lU bolts and tlghlel1 the nUI S. H i Ilelll Ihe lIexll/le b.,lko hose and lIuhten the nuts. 17 Rel1lovc the hoso cl,lrn p or polythene sh eet then blcL,{/ Ihe hr<lke s n~ d(!sCllhed ill Ch<lpWr 9
t 8 nelll t he h<llldhr<lke c,1blc and. where <lpphcllhle. the tr~&#34;sverse lad II) thfl ICi"lI n K le WIth referen ce to Chapter 9 . 19 T,ohtell Ihe dllve ""nne·to·propeller shall holls to lhe speCIfI ed to.que. 20 R el'l the .ear wheels "nd lowe. the car to the ground. 21 Check Ihe .en. aKle 0,1 level <lnt! top up II 'Hlcessi"lIy .
1 AxleshMt -removal ilnd refilting
Chock Ihe front wheels then jack up the re,lr of the c~r ilnd support with onle stilnds. Remove the .ear wheel 2 Ilelea se the hilndb.nke and .emove Ihe brake drum.
3 USIng a socket through the special holes in the drive lI.::tnge. unsc'ew the bollS secu.ing the b.::tckp late and bearing ,el.::tinor to tho a~le cilSln g (pholo). 11 Withdraw tho a~leshnft. together with the bearing. " it is tight due 10 tho oulor Ir<lc k seizing in the casing tcmporarily refil Iho wheel .::tnll Iwll on the wheel. If Ihis is unsuccessfu l. use n slide hammer allached
1 0 the dtive lIange. or ,1Iternil1ively sc rew two long baits th.ough Ihe jng al diametlicaUy opposite pOInts (FIg. 8 .7) and lighten them I,·...r<jressiv ely un!11 the be.::tring is freo . 5 To .e"l the a~leshafl. IU$I w ipe clean Ihe bcallng .(!(:ess in the casing and al>ply a liule Illhium based glease both 1 0 the casing and bear ing outer !rack . F
ig. 8
.6 RelHoving t h o Mdeshalt .e l'l ining hoits (Soc 4)
If
I
/1
II
I
\,
Fig 8 .7 U sing long bolls to ""ithdra"" tho a~leshaft (Sec 4)
cd
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m
)
Chapter 8 Rear axle 135
Fig 8 .8 Drilling the beMing rf!t<lining rino prior to splitl;l\g with ,1 eol ( 1 chisel (Sec 5)
6 ju sen the ilxlesh.1h "nd CIl!jol\JC the spl"u,d end of Ilu) ~h;,ft Wit I! the ulHcrcnliJI side gC;II, TilP tile shnft wllh <l mall,,( lIIl(,lltl(lI)C<lrill\j is
fully entered III the c .. sing. 7 Align the backplilW ,md be,1"'}!) rC1<lUHH holes with the C.1Sll1g holes. insert the bolts ilnd li\Jhwll them evenly 10 the spccllicd torque. S Relit the b'<Jke drum t1nd fCil' wheel <lnd lower the CM to the
ground. 9 Check the 'Cilt axle 0,1 level and lOp up II necess ary,
5 AxlcshiJft homing -renewal
Noto: A SfJL'CI.1f 1001 IS "Hlliller! /0 n&#39;III<!V~&#39; lilt' 1>1:''''''[1 (,0111 lilt' axles/mIl (s,:c Fly 89) 1 Remove the ;,xlushalt as ,h:sG"hcd 1(' St;CIl0n 1 2 Usin\J all 8 mill (0.31 In) dldl, 1Il;,kc a hole III the he,Hlnt! ,etauun\1 119 . t<lkllllJ CillO not to p,,"eto;Ito Into tlH~ .1xlesh"l!. 3 SupPOI1 the 1m\) 0" il v,ce thell spl>t 11 ;1{;II)SS tho hole with a sholp pllJ (;h,sel. RUlllove tlH~ ""9 hom the shafl ·1 PIC'SS th e l>earinIJ oH the shall lJSIIl\) " sUlt&#34;hl,~ jllJllcr or press. The specil1l Ford tool is shown '" FlU 89. 5 Remove lhe I>e,'''''o ,eiJll1e,
G Cleiln the l1xlcshnf1. be,non\) ,,,t;WlC' ,Hld "xle C.,1511l\) 7 Locl1le the loe1ll1ll9 HIWlIlel 011 the l1xleshl1lt. followed uy tho new uoa,ing wIth the 001 sel1l [l1CIll\) l1WilY ['om the l1~leshaft Hallge. 8 Slide on the new hea'lIl\) rcta"lIn\) '1119 and pr ess J fully 11\l111l1st tile hearing inner IWck. uSIng a slJItJIJle puller or J ICWlth oftuue. 9 Re fIt Ihe l1xleshalt wllh refe'ence to S ectIon <1
6 Axle reM cover relllov,,1 ilnd refitting
Chock the hont wheels then lilck up the re,l( o f the Cl1r il'l(l SOPPOI1 on axle stands.
2 Cl em1 the reM cover .Jnd surroundIng .Jre" (photo) 3 Remove the hllmlbr"ke relay le ver lind seco nd.Jry cable. or
transverse ,od (as ;;Jpplicilblc) with reletCnce to Ch"pter 9. <1 Place a suitable container helle~th the reM "x Ie to c~tch the oil as the rear cover is removed.
5 Undo and remove t he ten IJOlt s and sprinU washers lhilt securo the reill cover to the llIl,l l drive housillg LIlt aWilY th e re"r cover and its
\Jasko!. ~ Before refitting the ,oar cover Illilke sure thm the mating fJces ilre free of th() old Uaskct or 10nlting compound.
7 FIt a new uasket Jnd then the lea, cover and secure wIth the ten bolts and spring washers. The cover bolts protrude IntO the fillal drive hOUSor1U so it is important that a SUlwble oll·resist.Jr1t scaling
... __ ro*
Fig. 8.9 Usill(J the special Ford tool to removc the axlesllilfl henring (Sec 5)
r;olllpoulid IS SlIll:ilr() d onto lioe Ihro,'ds of each boll bef ore it IS [,twd. 8 TIUhwll tllr: cover secu,,"!.! holls 10 lhe spec,[,ed torque Wfl:IICh
se ttln\)
9 ReCOlillect
Iht! h,lndbr,l~e components with re ference to ChJp ter 9. 10 R efil l ti,e 1e;1I ,ule with the correct 9rJde 01 oil then lower the C,lr to
the UIOUIl(i
G
2 Axle reM cover
7
Pinion oil seal -re"cw,,1
This ope r,ltion may be performed WIth the rear axle in position or on
the benc h
2 Undo ~nd remove the two holts. sprinU Jlld plain washers that secure lhe centre bearing support to the under51(fe of the body (reler to
Chapter 7) 3 With a sc"ber 0' fde. Ill<lrk a 1000e across the propeller shalt alld rear ~xle drive fI~nu()s so thatlhcy Illay be ,cll ed \()gelloer ill thell o&#34;gin~1
positions <1 UndO ~nd remove the four bolts Jnd sprinu washers secu"n9 the propeller shalt and rear a~le dlivOllg flanges and carefully lower the
propeller sha h to ttt() flool I I
J m
procarmanuals.com

Chapter 8 Rear axle 136 )
5 C~rellJlly cle~n Ihe Ir Oll 1 01 the Im,ll d"ve housinU ~s there will Ilroll<lhly be a considerilble <!IllOUni 01 drll and orl rl Ihe se<ll has heen leilkillg lo r a willie (phO IO). 6 Remove Ihe wheels ,lilt! b.ake drums Ihen U Sing ellhe. <I sp"ng halance and a lenUth of co.d w'illlpcd .ound lho drove pUlion. 01 a
10lque w.ench. check and . ecor d the lurnrng IOrque of the pillion. On eally models lilted wllh ~ tl~ed longlh spacer (see SectIon 1) lI11S procedure is nOt neceSS<lry . HowevC/. unless the ',nill drive hilS beell conlplelely dismanlled prevIously. there is no WJy 01 delerminlng which spacer is !rued. 7 USIng a suilahle long·hilndled tool or large w.ench. g"p Ihe re", ,"xlf) p,nIOn flange and wllh il socket undo and . emove Ihe pillion lIan\Jo ,elainmg sell·lockmg nul. ThIS nUll11uSI be dIscarded ilnd il new Ollr. oblalned .e<ldy for rea ssembl y. 8 PI,lee il conWlIler undcr tho ir ani at tho lon<ll drove hOUSlllg to ciltch ""Y all Ih<ll rn<ly como out. then uSIng a unlvorSal puller and sUlt"llle thrusl p"d putt o ft tho 10 M <lxle pillion lIanUC from the alive pInion 9 USing a screwdrivcr 01 slllJl1 chlsol C<lrel\,lIy renlove the old all sl!,,1 It Will plOb"bly be necess<lry 10 p<llti;;llly destroy rt Note t he COIII~&#39;:1 way round is wrth the hp I;;ICnln ulw<lrds to Belo.o Iruill!1 a ne w so;;ll apply son'e !)re"s o 10 Ihe lillIe. 1.1I:e )I\\ICCII the two h,)S 01 the so,,1 11 AplllY;1 hule IOlnlon\! compo"nd 1 0 Ih,;! outer I,lce 01 tlie 50,,1 • USnlg a tuhuh .. drov o 01 :,ulwhle <I.;;III1<;tr:r. c;ucluliV dnvc the all
.,1 "\10 Ihe l ,n ,11 dllv!! hOllslnu unto! Ihl~h w'lh Ihe cas",o 13 Ilcfo1 Iho 1(';;1' "xlo p""nl1 fI.1IlUc ilnd on,:o "!I'"n hold sqll;,,,:ly wllh til" luol 0' wrench. 1~ SClew on " ncw s&#34;II·I()c~&#34;lll I1l1t IJIlIII Illl: (,ndllo,,1 ,s III~I dlll"n.llcd . II"", l'Uh h,n Iho nUL .1 1,;,,:11011 ill;r I"'h' whll" du":k"'!lII,,, prmO" lumlnu lor<ll'" wllh Ihe SI""'!I IJolrolllCU or 10r'l"0 wH;nd, COlltinuc tluhlen,"u untIl tho to '{ lue Cllu;rrs IIr<lt recnHle<l III l'a"'\I'''llh 6 1)lus <I furthel 02 1 0 04 Nm (015 to 030 Ihl It) to .1110w lo r tho ,l(ldruonallr,ct,on 01 tire new all se,,1. Do nOI trHhten the IIl1t lurtl"". olherwlse. rl a collapsible SllolCOf .s Illled. II Will he over·cornprr:sse<l and the assembl~ Will Ihell h,lVe 10 be drsnwntled to hi ;, new ~p;rcu&#39; Howover. il Ihe minimum speClfred torq uo wrench scWng lor th e pInion nut h"s not been re"ched. the sp"cer I'lle d IS p.olJi"lbly 01 Ihe
fixed ICllnth type "nd I he nul should be tIghtened lurthor WhIle domu Ih,s cheC k Ih"l Ihe pimon lurnrnn lorque doos not mcre;;lse. 15 flelll the h",ke <I"ml mId whee ls I G fl" co.mec i Ihe IlrOIl()lIe' ~h;llt ;rhlinmu thl,! p • ..,vlousty rllade fII;'lks 1)11 Ihe lIan!lf:S. '''III rc!lttlrll holts wuh new Splillg w.1"hels TIUhll!ll tel lire spec"'ed ta.que w.ench ~C1llll0 1 7 fle llt lir e r.:ellile I'c;un'!] ~&#34;I)P(Ht ,.ecllllI'(J l,olt5, ~I&#34;&#34;&#39;!J ;uHI pl.1111 w;r~lrerS ;;Inti t'lllrll'lI. 1 B FIIl.1l1y check IllI! (HI IlIvr:1 "' th" "';11 ,1>1" ,,"d l O p up II 1\&#34;,:eS~lIly
P ReM axle -o verh;;lul
Note: Mosl ymilycs wtlf Ilft'h" 10 If.'IWW Iflt' comfllelC IC,ll ,Jxfc ,15 .1 111111 d II IS WOII! ,.II/IC' I/Ioll! 10 rf,SllliI",fc Ille UII/I 10 lel/t·w '''IV r/;/11I.Jycd 01 WOIII poll Is ro do tlw ,ob correclly Icquires Ifle usc 01 spccial <111(1 cxpellsive loofs willch tin' "'",u/lly of y"WY"'S do 1/01 h,lVl' The P"n1<UY oh,eC I o f Ilrose speCIal lools is 10 e""hle Ille mesh 0 1 Iho crownwhcelto Ihe pIllIon 10 be very accur,1lely SCI "nd thus cnsuro that n o,se is kcpl 1 0 <I mm"num II illly lI,c ,e,lse In nOIse cmmot he 10loJHI\ed (p,ovlded Ih<ll the ,e,l, "de 'S nO t already na,sy due 10 "
, le lccl,v e Pol.l ) then IllS besllo Ilu.ch"se "II e~ch;lnHe bUIlt UJl le;;l. ilxl/! 01" Uoad secon (lh,lnd Uillt 1 Remove the rO;;lr "xle I,orn the ,:,1r (S(.'(;t,on 3) illld tha,oughly cleiln
,' . 2 Remove the a xlesh;;lhs (Sec lIon 4) "nd the;lxle ,e". covel (Secllon 6) . If rleceSS;;Jry remove lire !H" ke !liIckpl;,ws 3 WOlk,n!) inside IIlI! axle casUlU . undo .lnd .emove Ihe four bolts th" t hold Ihe IWO U'Shill>cd dlllerentl,ll be"rmg CilPS III the Cilsing. 4 W,lh a sc.iber. m<llk Ihe .e lilhve paSltlons ollhe Iwo be",,"U caps so Ih;uthey C,lll bo .elllled III therr o"g,nal poSItIons. LIlt away the twO end caps. the'e may ;rl .e"dy ho mallng numbe,s shown In FIg. 8 .1 1 . 5 OIJlaln Iwo,) JlIC'- OS 01 50 mm (2 in) squ",e woo d al le<lst 300 mill (12 in) long and. wrth a sharp knlle. !<Ipor the ends "iang J lenglh 01 150 mm (6 in) 6 Place Ihe tapered ends 01 the ..... ood..,o lr:vc lS rll the two cut'i1ways
i h a dlffl!renliiJl casrny (Illd. uS"'IJ the lea, cove. 1;;Jr.:e o f thl! Irnal drrvo asing as" lu lc ,um. CDielully leve , Ihe (Mle.entlal asS(!mbly I.om the Ilna l d"ve housrng.
15 Froni I'll Im<ll dflvo housing showIIlg pinIon n"nge ilnd nul
7 1I'lls IIfJcess,lIY la ",move th e Iwo (hffelenlral casc l1'-'alll'gs Ihese
",.IY I,,, ",move(1 Ih:xl uSlnU " ulllvers,,1 two·leuged puliCI and sui!<lhle
111111'.1 1,.ld C"rfully uase e;lch bca'"'IJ Irom liS local ron . necovor Ihe ~IIOIII p.IO:k s hom hehmll e"ch be"rrnu nOlmU from whIch SId e Ihey (.,rlOr'! 8 thou!] a sCflhcr. m;;lrk Iho relative positions of Ihe crawnwhee l ilnd ,hU",,"rtl.,llrousinu so that the oownwhcelmay be f,tte d on rts origin al p&#34;~H&#39;OII. unless ,t .s to be lenewed. 9 Undo ,11", r enlo ve the eruht holtS thai secure Ihe crownwheello the ,hl,,,""'11:11 hOllS"'II. U S1nll a solt·faced h"n""cl. I,ll! 0\11 Iho cllJwllwhuci Irom liS locillion on Ih e d,ffe,enl,,,1 housin!) I 0 lJ~III\1 ;r sU I\(Ih l{) (i"unete. parallel pIn pmch. lap 0\11 Ihe pin Ihal Iud , ... Ilu, rI,'lcrelll,;,1 Illnial1 gea. Shilll 10 the dlftmrmll.11 housrnlJ.
NOLI! : 1 hu h"le 11110 willch thc peu Irts IS shghlly "'I>c.ed. lind the I>pl''''.'I'! "",1 may he IrIJhLly peelH)d over ;'Iml should he r.:!e;rned with a ·.u,I.II,I" ,".11111;1". ,tr,ll 11 th'''!1 a ... "It IIlI;t.11 dllfl. "'i> out Ihe drllelenli"l p"uon Ue", slr"h. 1.011 .Iw.ly tlr" d,lh;u!Oltl;r1 pinian ue,us. sido {leMS "lid IhruSI was hers; IA"'!l':,"" 10 ell::ure Ih"t the th,usl washe.s ",e lell wllh Ihe ir relative
liP,"" 12 1&#39;&#34;,1&#34;~&#34;If)f .. ,1 Il1te.s (It Ihe <le<lle'5 usc a 51)OClal 1001 la r hlJldln(lthe pillion ,llIvl: lI;rllue StilIIOllil'Y wlulsl Ihe nul OIl Ihe cenl.e 01 rhe n"nge IS \l1I ... ".;w"d SI nce II IS ve,y \Oght ,I Wlllle(IUOfe sOllie lor ce 10 ullda il. ll,,! .IV\l,.IHe oWlle, w,1I not n O''''iJlIv hilV C the use 01 Ihls ~p(.&#39;C,.111001 so.,,~ .1" "11,,,11;lllve method. clamp the pnllon lIanU e in;r vic e "lid then unoi"lir" "ul Any (1'''''"\le cJused 10 I he edge of Ihe flail!] " hy the vice ~llIluld I,e calelully I lled smOOlh This nut must 1101 he u s1!1I .1\).111' SO II l1"w """ WIll he le' 11JUed durinU ,eilssem!)ly 1 J lJ.."'!I ,1 ullive rs;tl Iwa·lenued pullel "lid suilable th.uS I polll drllw (1)0) jllI"')I) dllve lIiuIue from Ihe en d 01 the pInion shMI 14 11", pmlon shalt m"y now be Icmoved from the I,nill (h ,ve housrng. C,'lI"lully "'SIICCI lire la'ge w per loller beirring behInd Ihe pUlIon gear .111(1 " ,I :.hows s'Ul1s o f weill or 1);lIing an tho roliers Of cilge the lm:ulIl\1 must Il() renewed. 1 5 U~&#34;ll1 " lllllversaltwo·leVged pulle. ""d soitable th.uS I pad. dr~w till! !>,)<III"\) 110m Iho 1)1Il10n shah 1 G Tllu slI1;;1l1e. taper rolle. heolllnu and oil seil l may next be ,emoved IlUm till! 1111011 (IIIVO housing. pillion dlivo flanVe end. 1.0 do Ihis uso a solt l\lr:wl drift wllh a I<lpered end 01 $ui l<lble d'ilmetCI lube <Ind. wo,kl"!) OIlsI(le Ihe housing. lilP Ihe bC,l'"IU circumfe,ence OulwardS so rel e;;lsII' U fllst the 0,1 se al and then Iho OOallnu . 17 AU,,"1 u srn g thO solt metal drrft and wo.kmU ,n Slde Ihe housing. d,,1t olllll1e I>carrn!) CUllS. These mUSI nOl be used wllh new beallngs. 18Th" Ilnal UIIV(! assembly rs now drSl1lilllllod and should ho washed ,,,,,I d,u,d wrth <I cleJn tinl· I,ee rag leildy for inspoctlon Check all be;;l,rrilis lor silIns at WColl or piwrrg "nd II ovidenl a new ~I&#39;I 01 h Catings ~h{)uld he ohlmned 19 Ex;r"",,e the lCelh 01 the crownwheel and prn,on or J/'Ulllg. score marks. ch ll >PinU and uene'ill weal. If a c.ownwheel ami pinIon is .equllt.-d. a mated c.ownwheel and p inion muSI be II1I..,d and undor no
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•
Chapter 8 Rear axle 139
ci,cumS«"Ulces mny only one pmt of the two be renewed. fnspect the dllfe,enti,ll pinions nnd side gems for signs of pitting. score mMks. Chipping nnd general wem. Obtain new gears as necessa,y . Inspect the th,ust washers lor signs of weM or deep sco,ing. Obwin new thrust wnshe,s as necessary. Once the pinion o il senl has been disturbed it must be discMded and a new one obtained. 20 When new pnrts have been obwined ns required. reassembly cnn begin. First lit the thrust washers to the side gems and place them in position in the differential housing. The ground side of the thrust washers IllUSt lace the side gC.Jrs. 21 Place tile thrust wilshers behind the dillelentini pinion genrs i1nd mesh these twO Oems with the Side gears through the tWI) ilpertores in the lilllerentlill housing. Milke sure they ilre diametlicilily opposite 10 each other. RO«l!e the clillerent'i11 pinion gears through 90' so brinUlI1\j them into line with the pinion genr shnlt bore 111 the housinlt 22 Insert the pinion genr shnft with the lock In!) p'n hole III line with the pill hole. 23 Usinu leeler 1),IU!Jcs. measure the en{lll(",t 01 ench s,de Be,,,. II the speclficd h\Jure IS excecrt"d. IU!W tl&#34;u~t washlllS mu"t he olJt,uned
-omnlllie the a~~el)lhly ,lg,llll ,trld ht new thll,st wa:,lu'<IS . Lock the P""O" near shalt U~I&#34;\I the pill whn:h should hc wpped hilly h01)1I, UStrlO n SlIlIah l" d,a",,:ter parallel pill pUIH.:h. Peen ()V,,' thc ()I the p", hole to stop the pill WOlklll!J liS wily out t." The tlowllwhcui m;,y next I,,, Idllted F,,~t heat 11 101 nppro~I&#39; ","lllly 10 nHIHltc~ III 1I0111IIIJ W,lter Wipe the ,,,nl"IIJ l aces 01 the c,ownwhuui ,Ind dllferuntlal houslI'U ;,nd. II OliOlnal p,lItS ,lie l,utnU used. plate the Clownwlll!cl tnto p(l~ltton With the prev,oll~ly m,llie marks nhOllud Relit the elO1ot IHlllS th;11 sucule the ,;r()wllwlwel ,trld tighten Ihese III a I"og'esslve and dla\lunill rlt"nner to the spe.:,fled torquc. 26 PI<lce the Shlill packs b<ltk III thell Oll!)lnal foiled pOSition on the differential housing be<lrlllU IOC<lllon USllllJ .1 p,cce of sUlla!Jle diameter tube ve,y c,1refully ftt tim d ifferential housln!J bearlllgs with the smaller dlnmeter 01 the taper outw,Hds The hearing t,lge must nut in nny wny be dilrllnged. 27 PI,1ce the shims hehllld the hcnd of the pinion geM nn[1. using ,I
suilahle dinmetci tul!c . cmclully lit the larg"r ti!per rollI)' benllll\) onto Ihe pillion shafl. The lar\ler dlilllleter 01 the be,lllllU !\lust be nex110 the pInion head
28 Using soitable diameter tubes. fit the two Wper roller bearing cones into the finnl dlive housing. making sure that they ale litted the correct way round. 29 Slide the shim and spncer onlO the pinion shalt and insert inlo t he final drive housing. 30 Relit the second and smaller diameter wper loller bea,ino onto the end of the pinion shaft lind 101i0w Ihis Wilh a new oil seal. Sefore Ihe senl is nctually fitted. apply some grense to the inner Ince between the two lips of the seal. 31 Apply n little jOinting compoond to the outer Ince of the seD I. 32 Using n tuhulilr dllft 01 suitable dinmeter, carefully drive the oil seal into the fillal (hive housinlJ. Make quite sore thnt it is lilted squarely and flush with the housinU. 33 Refn the drive pinion IInnge nnd hold securely in n bench vice. It II fixed lenIJth spncCl is Itlted. fit ilnd tighten the pinion nut 10 the spec ,lied lorque. If a collapsihle spnce r is f,tte d. follow the prOCedlHe
g iven in Section 7 paragraph 14. setting the pinion turning to'que to hetween 25 nnd 2.7 Nnt (1.810 2 0 Ihf It) which includes 0.2 to 0.<1 Nm (0.15 10 0.30 Ibl It) lor the ndriitional friction of the new oil senl II new hea,inns h~ve heen filted. logether With n li~e(l len(Jth SP,lCer. check thm the tOrlllllg torque is bel ween the limits just stmed. If not. a longer or shorter spilcer must he I,tted until the setting IS correct 34 Fit the healing cones to the cf,fierenllal houslIlg heallll(Js and carefully ease the housing Into posilion in the finill drive housmg 35 Relit the be,IIII'!J CilpS in thell originnl pOSitions. Srnc,ll n httle JOlntmg compound on the threilcfs 01 each cnp secuIII'O bolt nnd fit 11110 position. When ,111 low halts have bcen rein ted tiUhten these up in a (h"IJonal and progresSive milnne, to the speCi fied torque. 36 I I pOSSIble. 1Il00nt n dlnl in(licntor onu(Je so thnt the probe IS resting on one of the teeth of the crownwheel and determine the backlash hetween the clownwheel and pillion. The bileklash may be vMicd by elecreasll'\) the thickness of the shims bellind one beilling nnd incrensing the thickness of shirns behind the othcr. thus moving the crownwheel ;nlO or out ofmcsh as requi,ed. The tOt.llthlckness 01 the shims must not be chnn\)ed. 37 The hesl check the do·it·yourself owner cnn make to aSCerta", the correct meshinu of the crownwheel ilnd pinion is to smear ,I htt le engineer's blue onto the crownwheel and pinion iJnd then lot"te the pinion. The con1<lct lIlil,k should nppenr rl\fht ill the Iluddle oJ th..,
COlleCI 100110 CO"t.1ct
_
t Heavy conWCl 0" huel. at 100lh !,leu Move p'",on lowa,ds crownwhcd u:.!:.crt:1 3nd c,ownwhuel towards p,n,on
.~\;!~&#34; •. ,;.';,;,"",.,=,"--
l ' Fig. 8.17 CrownwheeJ and pinion setting chart (Sec 8)
, ,
, ,
"
procarmanuals.com

Chapter 9 Braking system
Fault rflnunosis -hrnking sys tem Foothrnk.c I)(!dnl -removal .1nd refluing From m ake caliper -overhau l .. Front blake cillipCf -removal ;1nd 'Cl,UUl\1 .... ______ ._ .................... . Front brake discs -inspection, ,enlov,,1 and rcl,!\in(J Front disc pilds -renewal , ....... _ ...... .. General description ..... .... ........ . ............ . H andb<ake - adjus tment ................ ................................... ___ __ ...... . Handbrake cable(s) and rod -removal and rcfiuing . Handbrakc lever -removal and refilling ........ ........... ..... ..... ......... . Hydraulic pipes and hoses -removal and refiUing . Hydraulic system -bleeding . . .............. .
Spcci/ic:ltions
Syste m type
I=rOl1t brakes ~c tt,ickncss :
Now ....................................... .
Min rmum.
Oisc fun ·out (ma~inlum including hub).
Mini'l1ulll disc pad lining Ihickness
Re ar brakes MInimum bfake shoe lining thickness.
Torque w re nch settings Caliper ....... ................. ................................... . Brake disc .................... . Backpl"te ........................... .................... .......... ................ .... .. .. .......... . Hydraulic unions. Bleed screw (ma~) .... Aecuf>Cfaling valve 'Clainel (Gi,ling)
Gonoral description
23
16
5 ,
G 3 1 18 20 19 14 15
Oisc brakes aro f;tted 10 Iho front wheels and drum brakes to the lea. wheels. Tho cable or cablo and rod opelilled handbrake oper:11es independently on the real wheels. A vacuum sorvo unit is fiued
" "tween the mastel cytinde. and loolbrake pedal to provide assistance 'en the pedal is depressed.
T he hy,aulic circui t is split frOnt and rear. Undel normal conditions
M,lSIC' cylinder -ove.hilul Milsle. cylinder -removill ilnd .e liuing . P.eSStue d,ffcrenliill swit c h -desoiplion .• e m ov,,1 and .el,ning P,essure ,educing valve · description. relllovill ilnd .er,llonu
Reil' i),lGkplilte · ,emov"r ilnu refining Hei!( i)r"ke shoes -renewal ....... .................. .............. . . Routine m"intenance ........ . ................. .
SlOp·lilmp switch - removal. re/rUlng and ildJustmcflI . Vilcuum servo unil _ description . Vncuum servo unil -rcrnovnl nod rcfiUing Wheel cylindcr -rcmovnl. ove.haul and ref'lIing
11 10 12 13 ,
7 2 17 21 22 8
Dlml hyd'i1ulic cif cuit. snlol Ironl i1nd rCilr WIth IlreSSU,e reducing v:llve in reil r ci.cui t on Iiller models. DISC I,onl brilkes i1nd self·ndjust illu rca .
(!rum brilkes. all wilh servo aSSIstance. Calrle or c.,blc .1nd rod operated handbrake on rear l)f"k es
12 .7 mm (0.5 in) 11.4 rnm (0.45 in) 009 nlln (0.0035 in) 3 .0 mm (0.118 in)
1.5 mm (0.059 in)
Nm 471068 41 1046 271031 71010 10 491062
Ibl It 351050 301034 20 to 23 5 to 7 7 36 to 46
both ci.cuilS operale in unison. howeve •. in the event of faIlure o f one circui t Ihe lemaining ci.cui l will p<ovide adequate bfaking 10 SlOp Ihe car in an emergency. late. models incorporate a pfessure reducing valve in Ihe r(la. hydraulic Cifcu il to prevent rca, wheel locking during heavy braking . When working on the bo"aking system. remembef Ihat blake fluid is loxic and will also damage painlwo.k. II spilt II should be washed away immediately with cold water.
procarmanuals.com

144 Chapter 9 Braking systom
9 II there Dre no inspec tion holes, remove the wheels and drums In inspect the linings . 10 Where any lining is less Ih,111 the nllnimufll thickness, renew Ihp. complete SCI 01 re,ll b,~ke shoes. 11 Refi ' the drums lind wheels as necessary then lowe. tho em \0 thl) 9lOund.
Ch eck operation of servo lIoil 12 Visually inspCCllhe vaCUUll1 hose IClIding hom the inlet mlllllfolll Of air box 10 the servo unit fOf dc\c,iOf1l1lon and security. 13 Wit h the engine Slopped. dCI).es s the bra ke pedal several ,imes to dissipate t he VOC U\Ull hoUl the sorvo Imit. 14 Depress the b'i1kc 11Cdll1 wilh moderate pressure then Sin' I the
cnU illC . As the V<leuum bwlds up. the l)Cdal should move sh Utl1ly IOw ;uds the floo. indlc;uulg that Ihe $Crvo is p.ovidlllg .esis tilnCfl
L ubrietl!£! /wndbh7ke linkage 15 Jilck up Ihe .eolf of Ihe Colf illid SIIIIPOII on ilxle Slilnds . 16 Oltthe prim,uy eil!>le connOChon to the boltom of Ihe halldh&#39;;,~&#34; level. 17 011 1974/1975 models. u,ease Ihe pflmolfy callie whe,e II p;,sses over Ihe pulley wheel. ,111(1 0,1 Ihe pull ey ilnd lever pivot pO"'IS . 18 On lillCr models grease Ihe 1,i1nw c.se rod SUI)I)Olt hC;lfinU 19 011 the clcv is IIUIS i1I the w", l>olckpl" ,es. 20 lower thc cm !O the gr ound
R/mew fhe /)rilke I/Ilid 21 lJIucd Ihe hyd.; ."loc sySle m as d"scllherl III Seelloll 15 ilUOwnl! II",
Ihe new h ,,,k\) Ih"d to COnlph: lely 1,lIlhe C:"CUtt he"I!1 bled . 22 AI Ihe sanl\) I"ne rcn,uve Ihe 'Ci" ",ake \I'lOn,s alld check tho wlu,,,1
cylonclers 10' leak"IJe.
3 Front disc pl1ds - renewal
Apply t
he handbr<lke then Jack U') Ihe Ioonl of the Cill <lnd supporl on <I~le s tandS.
I
I .
. ~ .. " ,) •. :Y.
2 RemOV(l Ihe hont wheels.
3 It Ihe fhnd level in the maste' cylondel reservoir is high. when the pistons l1re moved into thei, respecI,ve bo,es to accommodate new pi1ds. thO leyel could rise sulticienlly fo, Iho fluid 10 oyerflow. Place ilhsoruent clOlh .1round the reSe,yO". o. syphon a Imlo Ituid oul. so 1)'Cven tUlg Pil"ltwOlk <lilmage UCUlIl caused by the hydraulic lIuid . 4 Usmg iI 1)11" of tong·no~ed pile,s. exl,aCt the two smiltt clips Ihat
hOld the m;"n ,clalfl,ng pins in plilce (photo) 5 RemOYfl Ihe m"in le tainm g pin~ which ,un through Iho c.lliper and the mel,, 1 h.,r. krnn of th o pads and Ihe ShUllS. 6 The flll ;t, o n l),le1S cil n now bo removed from the cahper. If they prnv!! \III1ICIIII to ,emove by Iland . II pair of long·nosed pi ie,s can be lIscd Lill :Iway the shims and tens.on sPflnus (whe,e lilted) (phoIOS). 7 Ca.eh,liy clcall Ihe .ecesses in the cahl>Of in which Ihe h,ction pads :md ShUllS he. and Ihe exposed faces 01 caCh pis ton. rem oving allu3ces 01 d"t 0' rllst 8 Us",u a p,nte 01 wood. e.l,eh,lIy rUlI,1et Ihe pis tons. n 1'1,11;\1 IhH t&#34;,&#39;~e p"d tens,on SI""'U" Oil Ihe hr~ke 1)o1ds i1fl<l shims ililfl locale mlhe t,lhpCf . NOle Ihi11. whe,e ,11)I)hcal)le. the affOWS on the ~hUllS m&#34;~1 I<le.: Ihe lo,w.,rd rOIi1UOII 01 Ihe iron! wheels (photo). 10 ,,,,,Crlthe maon p;,(1 Ictitlll,nU prlls. tIIilklt1IJ ~&#34;,e th,11lhe 1i1nus of the IUII51(1I1 SP"II\j" .lIe under Ihe rCtallllll\ J pins Secure Ihe pillS with Ihe ~&#34;,,,II w,w d,l's 11 R&#39;·IM~<lt (hf! I" ocl,tlu,e on the .emil"' .. ,\! hom bri1ke then ,cl,t the ....heels <llIti lowe, Ihe Cilr 10 Ihc U,ou'HI 12 To co,,,,(;l ly ~eill t hc p'stons. 1l'''''))lhe !,,;.ke pedal suveral tim cs ",,<I j,n:,lIy top "p Ihe hydri1uh c Ih"d level in Ihe m.1ste, cylinde.
&#39;&#39;&#39;~&#39;&#39;&#39;&#39;&#39;&#39;&#39;&#34; ;,S n,~:&#34;sS,l&#39;y
<1 F rollt brake caliper _ rcmoy'll iltld refitting
1 nemove the f,on! disc pads i1S tie sc"lJc(/ in Section 3. 2 1111 'S Itll,,,,d,,(1 10 lit ncw Ci1tiper pistoll s "nd/o, seals. dep,ess the tH.1k'J Iwel,,1 10 hlUlU the pistons i"to COI11i1ct with thO (fisc and <lssist ~&#34;hs<:qllc&#34;l H:fllOV<l1 of the p'stons. ) FII a h{JS(l ciilt1lp 10 the lteK'ble hose ICi1d,llg \0 thc c'l hpcr. If a hose dallip 's not ilYil,li1bto. tighten" p,ece of l)Qlylhelle she"t beneath the
3 .4 A pad .et<llnn1U pin and clo,) (ilffOWt:d) 3 6A Ret1lovinU a d,sc pad 3.6B The two disc pads remOved
.>.6C Disc pad and shim 3.9A T he shim allow must lace tho forwa,d rotation o f Ihe f.ont wheel
'-.. ~
, .
3 .9B Fitting the tenS ion springs
.--.::.:.:; .
....... . ~,&#39;
灲潣慲浡湵慬献捯m

1 Chapter 9 Braki ng system 1 49
,1 M aste r cylinder -overhaul
With tho m<lster cylinder removed (SeClion 10) clean the exterior sudaces.
Girling type 2 Removo the SCleW$ and withdraw rhe fluid reservoir. twisting i as necesS,,'y from Ihe end seal. 3 Remove the twO seals afler cdraC ling the circlip ovor Ihe cnd seal. <1 Using II hOKagon key. unscrew Ihe relainer and hit oUllhe primary
recuperating valvo. Oepress Ihe primll'y piston during Ihis procedure. 5 Exl.;'!ct Ihe primary and secondary pistons. IOgether wi,h their associated components. noting Ihe order of lemOlln l. H nccessary top Ihe master cylinder on a block of wood or use air pressure from il foot pUIllP through the inlel porlS. G Separate rhe primmy ,10d secondary l)is10 11S irani lha intermediilte
sprinu . Uso tho !inUe.s 10 remove tile Ulilnd seDI from the primil'Y
r""' lon .
The secondil'y piSlon assembly should ho sOfh"ated by lilting the u"mblo leaf ove , Ihe shouldered cnd 01 tho viston . Using the lingo,s.
rr 'wo the se<ll from Ihe second,lfy I).ston . l ,opross Iho sccondilry sprinH. illiowinn Ihe vDlve stern 10 slide throu!Jh the keyholo in tho thimble. thus releasing tho tension on Iho
spnJlg
9 Dotach lhe villve space ,. tilking c<lre of the spring washer which win he lound IOCille(1 under tho villve he<l(!.
Teves (ATE) type 10 Dopress Ihe primary piston, thon oxtrnCtlhe circlip from the mOUlh of th o c ylindo r and also unscrew Ille SlOp screw. 11 Extract the primary piston componen ts noting Ihe order 0 1 removal. followed by Ihe secondary piston componenlS. If necessary top the
master cylinder on a block of wood or use air pressure from a 1001 pump through tho inlet ports. 12 Prise the seals from the pistons, nOling which way round they are lilled. then il necessary remove tho springs and seals. The prima ry
pis ton spring is retained by a screw.
Both types 13 Clean all tho components in melhylated spirits or brake fluid then
inspec t them for wear and damage. Check the cylinder bore and pistons for scorinu and corrosion. and if eviden t renew the complete nI<lster cylinder. If the componen ts are in good condition obtain a
.opair kit of seals. 14 Di p Ihe piston and seills in hydrilulic Iluid then reassemble Ihe m<lster cylinder in revorse order to dismantling. Make sure that Ihe seals a ro assemble d tho COffect way round as previously noted. Note thaI the secondary seals may be idontif ied with a silver band. On Iho Girling Iype make sure Ih<lllhe shim on Iho end valve is fined with liS
convex side against Ihe shoulder nange. Belore refiuing the fluid reservoi r on lhe Girling type ch ock that the recupera ling valve is open wllh Ihe prim<lry piston released, and closed when I he piston is
depressed.
1
2~
3~
13
1
2
3
4 5 6
7 8
R
22
21
Fig. 9
.8 Exploded view 01 the Girlin g master cylinder (Sec 11)
Filler cap 9 Seal 16 Secondary piston
Seal 10 MaSler cylinder body 17 Seal
Seal !Clainer
11 WiJslrer 18 Rell11i1er
Fluid reservoi r 12 Reservoir relaining screw 19 Spring
Seal
1 3 Seal 20 Spring fl/Miner
Relainer
14 Primary piSlon 21 Valve
Primary fCCllpCfaling valve
15 Spring 22 Seal
Circlip
10
!
" 1 ,
1
I
!
!
I ,
J
,[
1
I
I
; .
!I ' i ;.
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