lock DATSUN 210 1979 Service Manual

wheels

2
Remove

splaahboard
if

necessary

3

Back
off
nut

securing
tension
rod

to
bracket
and
remove
bolts
which

secure
tension
rod
to
lower
arm

Tension
rod

can
then
be

taken
out

4
Remove
nuts

securing
stabilizer

bar
to

connecting
rod

Note
Two
wrenches

are

n
1
in

this
B

5
Remove
bolts
and
nuts

securing

stabilizer
bar
bracket
in

position

Stabilizer
bar
can
then
be
iaken
o

t

CV
3

@

I
Lower
ann

5
Tension
rod

2

Stabilizer
bar

bracket

connecting
rod

6
Tension
rod

3
Stabilizer
bar

4
Stabilizer
bar

bracket
FA129

Fig
FA

31
Removing
Tension
Rod

and
Stabilizer
Bar

INSPECTION

I

Check
tension
rod
and
stabilizer

bar
for

evidence
of
deformation
or

cracks
if

necessary
replace

2
Check

rubber

parts
such
as
ten

sion
rod
and
stabilizer

bar

bushings
to

be

sure

they
are

not
deteriorated

or

cracked
if

1ecessary

replace

INSTAllATION

Install
tension

rod
and
stabilizer
bar

in

tJ
1e
reverse
order
of
removal

noting

the

following

I

Be
sure
stabilizer
bar

is
not

closer

to
either
side
but
is
located
at

the

middle

If
stabilizer
bar
is

new
use
the

following
procedure
to
center
the

stabilizer

bar

Position
arm
with
white

paipt
mark

toward
left

side
of
car
Front
Axle
Front

Suspension

Set

slabillz
rliar
mount

bushingS
So

that
outer
side
of

stabilizer
bar

bushing
is

brought
into
inner

side

of

marking

e

o

I

19

e
1

Marking

2

Bushing

3

Marking

4

While

painting

5

Marking
0

A

F

A667

Fig
FA
32

Centering
8lDbilize
Bar

2
Chec
to
be

sure
that
tension

rod

bushing
is

propelly
centered
in
its

seat

3
Be

sure
that
tension
rod
bracket

bolt

is

correctly

torqued

Note

a

Noting
direction
of
tension
rod

bushing

properly
center

bushing

in

tension
rod

bushing
washer

Fig
FA
33
Direclion

of
Tension
Rod

BUlhing

b
After

installation
make
sure
mini

mum

clearances
between
tension

rods
end

stabilizer
bar
are

equal
on

both
sides

c

Closely
observe

torq
ue

specification

when

tightening
tension
rod

bracket

retaining
bolts

d
First

tighten
tension
rod
on
bracket

side
to

specified
torque
setting

then
install
the
other
end

on
lower

arm

fJ
Tightening

tOlque

Tension
rod

bushing

installation
nut

4

5
to
5

11rg

33
to

37
ft
lbl

FA
10
Tension
rOd

to

Lower

ann

5
1
to
6
1

kg
m

137
to
44

ft
Ibl

Tension
rod
bracket

to

body

3
2
to
4
3

kg
m

23
to
31
ft

Ibl

Stabilizer
bar
bleck
t

1
6to2

11rg

112
to
15
ft
lbl

Stabilizel
bel

connecting
rod

1
6

to
2
1

kg
m

12
to
15
ft

lbl

LOWER
ARM
AND

LOWER
BALL
JOINT

The
lower
ann
is

connected
to
the

suspension
member

through
a
rubber

bwhing
end
to
the
strut

through
a

ball

joint

The
lower
ball

joint
is
assembled
at

the

factory
and
cannot
be
disassem

bled

REMOVAL

1
Block
rear
wheels
with
chocks

2
Jack

up
front
of

car
and

support

it

with
safety
stands
remove
wheel

3
Remove

splashboard

4

Separate
knuckle
arm
from

strut

5

Pry
colter

pin
off
and

separate

side
rod
fromknilckle
arm

using
Ball

Joint
Remover
HT72520000

FA661

Fig
FA

34

Remoliing8ideRod

Ball
Joint

6
Remove
tension

rod
and
stabilizer

bar
from
lower
ann

7
Remove
bolt

connecting
lower

ann
to

suspension
crossmember

WHEEL

BEARING

Wheel

bearing
axial

play

Wheel

bearing
nut

tightening

torque

Return

angle

Rotation

starting

torque

With
new

grease
seal

With

used

grease
seal

At

wheel
hub

bolt

With
new

grease
seal

With
used

grease
seal

SUSPENSIONBA
JOINT

Turning
torque

New

parts

Used

parts

TIGHTENIN

TORQUE

LOWERBAl
L
JOINT

Ball

joint
socket

to
lower

arm

Ball

joint
to
knuckle

arm
Stud
nut

STRUT

Steering
knuckle

arm
to
strut

Strut
to

hoodledge

Piston
rod
self

locking
nut

Gland

packing

DISC
BRAKE

Rotor
to

hub

SIDE
ROD

Side
rod
ball

jOIDt
to
knuckle
arm

LOWER
ARM

Lower
arm
bolt
nut

Side
rod

adjusting
nut

TENSION
ROD

Tension
rod

bushing
installation
nut

Tension

rod
to
lower
arm

Tension

rod
bracket
to

body
Frpn
Axle

Front

Suspension

mm
in

0
0

kg
m
ft
lb

degree
3
0

to
3
5
22
to
25

900

kg
cm
in

lbr

kg
em
in
Ib
Less
than
7
0
6
1

1
0
to
4
5
0

9
to

3
9

kg
lb

kg
lb
Less
than
1
2
2

6

0
1
7
to
0

79
0
37
to
1
74

kg
cm
in

Ib

kg
cm
in

Ib
40
to
100
35
to
87

More
than
20
17

kg
m
ft
Ib

5
1
to
6
1

37
to
44

5
5

to
10
0
40

to
72

7
3
to
9
9

53
to
72

2
5
to
3
5

18
to

25

6
0

to
7
5
43
to
54

8
0
to
11
0

58
to
80

3
9
to
5
3
28

to
38

3
0

to
7
0
22
to
51

3
9
to
5

0
2810
36

8
0

to
10
0
58
to
72

4
5
to

5
1
33
to
37

5
1
to

6
1
37
to
44

3
2

to
4
3
23
to
31

FA
14

REAR
AXLE

REAR

AXLE
ASSEMBLY

Remove

L
Block
front
wheels
with
chocks

2
Raise
rear

of
car

high
enough
to

pennit
working
underneath
and

place

stands

solidly
under

body
member

on
both
sides

RA544

Fig
RA
2

Supporting
Point

3

Support
under
center
of
dif

ferential
carrier

with
a

garage
jack

4

Remove
rear
wheels

5

Disconnect

propeller
shaft

by
re

moving
bolts

CD
securing
propeller

shaft

flange
to

companion
flange
of

differential
carrier

6
Disconnect

brake
hose
from

brake
tube
at

body
@
and

rear

cable

adjuster
@

Fig
RA

3
Removing
Propeller
Shaft

and
Brohe
Hose

CAUTION

e
When

disconnecting
brake
tube

use
suitable
tube
wrench
Never

use

open
end
or

adjustable
wrench

b

Cover
brake
hose
end

pipe
open

ings
to

prevent
entrance
of
dirt
Rear
Axle
Rear

Suspension

7
Remove
bolts

securing
shock

absorber
lower
ends

on
each
side

RA485

Fig
RA

4
Removing
Bolt
Securing

Shock
Absorber
Lower
End

Note
When

removing
shock
absorber

lower
end

from
bracket

squeeze

shock
absorber
and
lift
it
out

right
above
to
accommodate
em

bossment
inside
bracket

C

AA486

Fig
RA
5
Shock
Absorber
Lower
End

8
Lower

jack
slowly
and
remove

cojI
springs
on
each
side
after

they

are

fully
extended

AA546

Fig
RA
6

Removing
Coil

Spring

9
Raise

jack
to
its

original

position

10
Remove
bolts

CD
and

@
se

curing
upper
and
lower
links
at
axle

case
side

RA
3
Fig
RA

7

Disconnecting
Upper
Link

and
Lower
Link

II
Release

garage
jack
slowly
and

pull
it
out
toward
rear
of
car

In
tenetlon

Install

rear
axle
in
the

reverse
order

of
removal

CAUTION

a
When

installing
brake
tubes
use

Flare
Nut

Torque
Wrench

GG94310000

b
Before

tightening
link

bushing
nuts

temporarily
attach

upper
and
lower

links
to
axle
case
Alter

jacking
up

center
of
differential
carrier
until

upper
Bnd
lower
links
are
almost

horizontal

securely
tighten
link

bushing
nuts

c
When

supporting
car

weight
at

Cl
nter
of
differential
carrier
do
not

put
a
load
in
car

j
Tightening
torque

Brake
tube
flare
nut

1
5
to
1
8

kg
m

11
to
13
ft
lb

Propeller
shaft

to

companion

flange
connecting
nut

2
4
to
3
3

kg
m

17

to
24
ft

Ibl

Shock
absorber
lower
end
nut

7
0

to
8
0

kg
m

51

to
58
ft
Ibl

lower
link

fixing
nut

7
0

to
8
0

kg
m

51

to
58
ft
Ib

Upper
link

fixing
nut

7
0
to
8
0

kg
m

51

to
58
ft
lb

I

AA552

Fig
RA
18
Shock
A
bllOrber

Upper

End

2

Remove
bolt

securing
shock

ab

sorber
lower
end

and
remove
shock

absorber

Note
When

removing
shock
ebsorber

lower
end
from
bracket

Iueeze

shock

absorber
end
lift
it

out

right

aJ
o
J
to
accommodate

emb
ss

ment

inside
bracket

c

RA486

Fig
RA
19
Shock
Absorber

Lower

End
Brocket

Inspection

I

Test
shock
absorber
and

compare

with

specification

given
in

Service

Data
and

Specifications
Replace
if

nece

ry

2

Check
for
cracks

Also
check

pis

ton
rod
for

straightness

3
Check

all
rubber

parts
for
wear

cracks

damage
or

deformation
Re

place
if

necessary

Installation

Install
shock
absorber
in
the
reverse

order
of
removal

Note

Tighten
shock

absorber

upper

end
nut
to

specification
until
it
is

fully

tightened
to
thread
end
of

pis

ton
rod

Then

securely

tighten
lock

nut
Rear
Axle
Rear

Suspension

@
Tightening
tonlU1l

Shock
absorber

upper
end
nut

1
5

to
2
0

kg
m

11
to
14
ft
b

Shock
absorber
lower

end

n1
t

7
0
to
8
0

k
l
m

51
to
58

ft
bl

CAUTION

I
Be
careful
not
to

damage
or
bend

piston
rod

during
operation

b
Do

not

open
or
heat

gas
filled

type

shock
absorbers

COIL
SPRING

Removal

Block
front
wheels
with

chocks

2
Raise

rear
of
car

high
enough
to

permit

working
underneath
and

place

stands

solidly
under

body
member

on
both
sides

3

Support
under
center
of
dif

ferential
carrier
with

a

garage
jack

4
Remove

rear
wheels

5

Remove
bolts

securing
shock

absorber
lower
ends
on
each
side

C
J

1
v

I
JJJ

RA485

Fig
RA
20

RemoviTIII
Bolt

Securing

Shock

Abwrber
Lower
End

6
Lower

jack
slowly
and
remove

coil

springs
on
each
side
after

they

are

fully
extended

RA546

Fig
RA
21

Removing
Coil

Spring

RA
6
Inspection

1

Check
coil

spring
for

yield
defor

mation
or

cracks

2
Test

spring
and

compare
with

specifications
given
in
Service
Data

and

Specifications

3

Check
all
rubber

parts
for
wear

cracks

damage
or
deformation

Re

place
if

necessary

InsteDatlon

Install
coil

spring
in

the
reverse

order
ofremoval

CAUTION

Correctly
fit

open
end
on

spring
seat

CD
Tightening

torque

Shock
absorber
lowel
end
nut

7

010
8
0

kg

51

to
58
ft
b

LINK

ASSEMBLY

Removal

It
is

possible
to

remove
one
link

assembly
alone
When

removing
more

than

two
link

assemblies
remove
axle

assembly
first
Refer
to

Rear
Axle

Assembly
for
removal

Remove

upper
link
or
lower

link

alone

by

removing
bolt

on
each

end

Fig
RA
22

Removing
Upper
Link

RA553

Fig
RA
23

Remouing
Lower
Link

BRAKE
PEDAL

a

a

Fr

play

h
Free

height

d

Depressed
height

Tightening
torque
Icg
m
ft
tb

@

@
Push
rod
or

operating
rod
lock

nut

1

6
to
2
2

12
to

16

Brake

lainp
switch
lock
nut

1
2
to

I
5
9
to
11

BR121A

Fig
BR
1

Adjusting
Broke
Pedal

I

Adjust

pedal
height
h
to
the

specifications
by
moving
brake

lamp

switch
and

operating
rod
if

equipped

with
brake
booster

Pedal

height
h

143
to
149
mm

5

63
to
5
87

inl

Then
secure
brake

lamp
switch
and

operating
rod

C
l
Tightening
tOlque

Blake

lamp
witch
lock
nut

1
2
to
1

5

kg
m

9
to
11
ft

lb

Operating
lad
lock
nut

1

6
to
2

2
kg
m

12

to
16
ft
b
Brake

System

ADJUSTMENT

2
With
brake

booster

Adjustment
is
not

necessary
under

normal
conditions
Check
pedal
free

play
If
it
exceeds
the
above

specifica

tion

adjust
push
rod

length
refer
to

brake
booster
for

adjustment
by
re

moving
master

cylinder
rerer
to
Mas

ter

Cylinder
for
removal

3
After

adjustment
is

completed

depress
brake

pedal
several
times
to

ensure
that
it

travels
over
its
entire

stroke

smoothly
without

squeaking

noise

twisting
or
interference

Pedal

depr
d

Might
d

more
than
70
mm
2
76

in

FRONT
DISC
BRAKE

Front
disc
brake
does
not

require

adjustment
under
normal
conditions

since

pad
to
rotor
clearance
is

auto

malically
adjusted
by
elasticity
of

piston
seal

REAR
BRAKE

Auto

edJuster
type

Adjustment
is
not

necessary
under

normal
conditions
since
brake
drum

t
shoe
clearance
is

automatically

compensated
for

by
operating
hand

brake

Wlien
brake
drum
to
shoe

clearance

is

correct

operating
noise

of

adjuster

is

not
heard
even
if
hand
brake
is

operated

HAND
BRAKE

I

Adjust
rear
brake
shoe

to
drum

clearance
before

adjusting
hand
brake

2
Turn

turnbuckle
so
that
when

hand
brake
control
lever
is

pulled

by
specified
force

lever
stroke
or

number
of
notches
is
as

follows

Pulling
fOil
20

kg
44
Ib

lever
stroke

93
to
106

mm

3
66
to
4

17
in

Numbel
of
notches
7
to
8

BR

2
f

BAQ05A

Fig
BR
2
Adjusting
Hand
Brake

Then

tighten
lock
nut

securely

3

After

returning
hand
brake
con

trol

lever
to
its

original
position

ensure
that

e
All
rear
brake

toggle
levers

return

to
their

original
positions

Rear
cables
are
not
slack

HAND
BRAKE
WARNING

LAMP
SWITCH

Bend
hand
brake

warning
lamp

switch

plate
down
so
that
brake

warn

ing
light
comes
on
when
ratchet
at

hand
brake
lever
is

moved
back
one

notch
and

goes
out
when
returned
to

its

original
position

BLEEDING

HYDRAULIC
SYSTEM

Hydraulic
brake

system
must
be

bled
whenever

any
line
has
been
dis

connected
or
air
has
in
some

way

entered

system

Spongy

pedal
action
is
an
indica

tion
that
air
has
entered
brake

system

Bleeding
hydraulic
system
deserves

much
attention
as
it
is
an
essential

element
in

regular
brake

servicing

Clean
all

dirt
around
master
cyl

inder
reservoir
remove
reservoir

cap

and

top
up
reservoir
with
recommend

edbrake
fluid

Note
Do
not
mix

two
different
brand

oils

2

Thoroughly
clean
mud
or
dust

from
bleeder
valve

so
that
outlet
hole

is
free
from

foreign
particles
Install
a

bleeder
hose
on
bleeder
valve

L

@
fl
JJ

l

f
m

ff
v
1

II
2

I

I
II

B

s1

r
Dip
other
end

of
hose
into
brake

fluid
bled
in

a
container

3

Pepress
brake

pedal
two
or
three

times
and
then

keep
pedal
fully
de

pressed

4

With
brake

pedal
fully
depressed

open
bleeder
valve

to
exhaust
air

Note

a
Carefully
monitor
brake
fluid
level

at
master

cylinder
during
bleeding

operation

BRAKE
PEDAL

REMOVAL

I

Remove

snap
pin
installed
at
the

end

of
clevis

pin
Draw
out

clevis

pin

and

separate
push
rod
or

operating
rod

from
brake

pedal

2
Remove
bolt
and
E

ring
securing

fulcrum

pin
and
draw
out
fulcrum

pin

Then
brake

pedal
can
be
taken
out

along
with
return
coil

spring
Brake

System

b
Do
not
reuse

brake
fluid
drained

during
bleeding
operation

c
Bleed
air
in
the

following

sequence

Master

cylinder
Rear

wheel

front
wheel

d

Be
careful
not
to

splash
brake
fluid

on

painted
areas

5

Close
bleeder
valve

quickly
as

brake

pedal
is

on
down
stroke

6
Allow
brake

pedal
to
return
slow

ly
with
bleeder
screw
closed

SERVI
CE

BRAKE

fJ

Brake

lamp
switch

Lock

nut

Fulcrum

pin

Brake

push
rod
or

operating
rod

Snap

pin

Bolt

E

ring

Tightening
torque
kg
m
ft
Ib

@
1

6
to
2
2

12
10
16

@
1
2
to

l
S
9
to

II

BROS8A

Fig
BR
3
Broke
Pedal

INSPEctioN

Check
brake

pedal
for

the

following

items

servicing
as

necessary

I
Check
brake

pedal
for
bend

2
Check
return

springs
for

fatigue

3
Check

clevis
for

deformation
and

crack
at
welded

part

BR
3
7

Repeat
bleeding
operations
until

no
air

bubbles
show
in

hose

Note

a

Brake
fluid

containing
air
is

white

and
contalns
air
bubbles

b
Brake
fluid

containing
no
air

rons

out
of
bleeder
valve
in
a
solid

stream
free
of
air

bubbles

8

Repeat
steps
above
on

remaining

brake
line
to

expel
air

INSTALLATION

Install
brake

pedal

following
the

reverse

procedure
of
removal

paying

attention
to
the

following
items

I

Apply
coating
of
recommended

multi

purpose
grease
to

sliding
portion

and
return
coil

spring

BA113A

Fit
BR

4
Lubricating
Point

2
Be

sure
to

install
E

ring
and
bolt

securely

3
Insert
CleviS

pin
through
brake

pedal

4

Adjust
brake

pedal
after

installa

tion
Refer
to
Blake
Pedal
for

adjust

ment

j
Tightening

torque

Push
rod

or
op8leting
rod

lock
nut

1
6
to

2
2

kltm

12
to
16
ft

Ibl

Brake

lamp
switch
lock
nut

1
2
to
1
5

kltin

9
to
11
ft
lb

REMOVAL

I

Disconnect

wiring
to
brake
fluid

level

gauge

2
Disconnect
front
and
rear
brake

tubes
from
master

cylinder

CAUTION

When

removing
brake
tubes

use

suitable
tube

wrench

Never
use

open
end
or

edjustllble

wrench

Note
When

disconnecting
brake

tubes

be
sure
to
use
a
container

to
receive

draining
brake
fluid

Use
of

raga
is
also

suggested
to

keep
adjacent
perts
and
area

clean

3
Remove

master

cylinder
securing

nut
Master

cylinder
can
then
be
taken

out

DISASSEMBLY

1
Remove
reservoir

caps
and

filtern

and

drain
out
brake
fluid

2

Pry
off

stopper
ring
using
a

screwdriver

3
Remove

stopper
screw
and
take

out

stopper

primary
piston
assembly

spring
and

secondary
piston
assembly

in

the
order

shown

Note

Discard

caps
if

they
are
reo

moved
from

piston
assemblies
and

use

new
ones

4

Unscrew

pluga
to

gain
access
to

check
valve
for

disassembling

Note

a

Never
detach
reservoir
tanks

If

they
are
removed
for

any
reason

discard
them
and
install
new

ones

b
Do

not
remove
or
disassemble

brake
fluid
level

gauge

INSPECTION

Thoroughly
clean
all

parts
in
a

suitable
solvent
and
check
them
for

wear
or

damage
Replace
any

part
that

is

faulty
Brake

System

CAUTION

Use
brake
fluid

to
clean
Never

use

mineral
oil

I
Check

cylinder
and

pistons
for

evidence
of
abnonnal

wear
or

damage

Replace
if
found

faulty

2
Check

piston
to
cylinder
clear

ance
If
it

exceeds
the

specified
value

replace
either

piston
or

cylinder

Piston
to

cylinder
clearance

less
than
0
15

mm
0

0059
in

3

Check

springs
for
weakness

fatigue
or

damage
Replace
if
neces

sary

4
When

master

cylinder
is
disas

sembled
be

sure
to
discard

caps
and

valves

Replace
any
other

parts
which

show
evidence
of

deformation
wear
or

other

damage

S

Replace
damaged
oil
reservoirs

and

caps

ASSEMBLY

Assemble
master

cylinder
following

the
reverse

procedure
of

disassembly

paying
particular
attention

to
the
fol

lowing
note

Note

a

Replace
gaskets
and

packing
with

new
ones

b

Apply
brake
fluid

or
rubber

grease

to

sliding
contact
surface
of

parts

to
facilitate

assembly
of
master

cylinder

c
The
brake
master

cylinder
is

avail

able
in

both
NABCO
make
and

TOKICO
make
There
is

no
inter

changeability
of

repair
kits
or
com

ponent
parts
between

NABCO
and

TOKlCO
makes

When

replacing
the

repair
kit
or

component
parts
ascertain
the

brand
of
the
brake

master

cylinder

body
Be
sure

to
use

parts
of
the

same

make
as
the

fonner
ones

INSTALLATION

Install

master

cylinder

following

the
reverse

procedure
of
removal

After

installation
bleed
brake

system

BR
5
CAUTION

When

installing

Flare
Nut

6694310000
brake
tubes

use

Torque
Wrench

CiJ

Tightening
torque

Brake
master

cylinder

securing

nut

0
8
to
t
1

kg
m

5
8
to
8
0
ft
lb

Brake
tube
flare
nut

1
5
to
1
8

kg
m

11
to
13
ft
b

BRAKE
FLUID

LEVEL
GAUGE

Inspection

I

Disengage
hand

brake
control

lever

2
Raise

cap
and

make
sure
that

hand

brake

warning
lamp

goes
on

when

float
comes
into
contact
with

stopper

BRAKE
LINE

REMOVAL

I
Remove
flare

nuts
on
both
ends

and

remove
retainers
and

clips

CAUTION

When

removing
brake
tubes
and

hoses
use
suitable
tube
wrench

Never
use

open
end
or

adjustable

wrench

2
To
remove
brake
hose

first
re

move
flare

nut

securing
brake
tube
to

brake
hose
and

withdraw
lock

spring

End
of
hose
can
then
be

removed
from

bracket
Next
remuve

brake
hose
Do

not
twist

brake
hose

INSPECTION

Check

brake
lines
tubes
and

hoses

for
evidence

of
cracks
deterioration
or

other

damage
Replace
any
faulty

parts

FOREIGN
DISC
PAD
INSTALLATION
INSTRUCTIONS

Typical
Ate
Teves

System

Removel

1

Drain
about
half

of
the

brake
fluid
out
of
the

master

cylinder
prior
to

replacing
the

disc
brake

pads
This
will
allow
sufficient

expansion
room

for
the
brake
fluid
in
the

lines
when
the

pistons
are
pushed
back

into
their
bores
to
make
room
for
the
added

Ihickness
of
the
new

pad
linings

2

Reise
the
car
and
lemove
tire
and
wheel

3
The
breke

pads
can

be
removed
without

lemovinll
the

caliper
from
the
car

4
The
brake

pad
reteining
pins
are

held
in

plaCe
bY
lock
rinlls
in
Ihe
inner

caliper

housing
The

pins
must
be
knocked
out
with

e
hammel
end

punch
from
theoulllide

5
Remove

spreader
spring
which
is

positioned
under
the

pins

6
A

special
tool
is
available
flom
the
car

manufacturer
forremoving
pads
from
caliper

or

pliers
can
be
used
to

pull
them
oul
be
careful
not
to

damage
the
rotor

7
Push
Ihe
brake

pistons
back
into

their
boros
If

you
encounter

difficulty
in

pushingil

he

pistofls
back
lhere

may
very
weIL
Wr9Jl
l

ern
in
lh

e
caliper
that
calls
for
more

attention
than

simplY
replecing
worn
out

pads
IUhe
pistons
are

eticking
or
If
the

seals
are

leaking
you
should
disassembl
the

caliper
and

repair
il

8

Lift
out
old

pads
from

Ihe

caliper

9
Remove
O

Ring
from
inside

caliper

Inslallatlon

II

1

Apply
silicone
lubricanl
to
Ihe

O

Rings
ana
to

grooveS
inside
each

caliper

2
Assemble
an
O

Ring
in

each

groove

3
Position
innor

pads
in

caliper

4
Position

oulpad
in

caliper

5

Replacespreadet
spring

8

ReplaceiPtnsaM
lighter

7
Install
wheel
and
lire

l

Final

Checl

A
Iter
Ihe
new

padS
have
been
installed
on

bolh
front

wheel
check
the

master

cylinder

fluid
level
Rlllhe

reservoiril

necessary
Depress
Ihe
brake

pedal
firmly
severaUlmes

to
sellhe
new

pads
on
he
rotor

i

See
Inst
ctionsOnBat
k
of
Box
For
rr

l8ge
of

EMP

l
iL
1
f

J

TypIcal
Ale

System

New
Brake
Division
Boston
MA
02135
Commerce
CA
90040
Fort
Worth
TX
76106

BR563

Fig
BR
10

Removing
Pad

Inspection

Clean

pads
with

cleaning
solvent

CAUTION

Use
brake
fluid
to
clean
Never
use

mineral
oil

2
When

pads
are

heavily
fouled

with
oil
or

grease
or
when

pad
is

deteriorated

or
deformed

replace
it

3
If

pad
is
worn
to
less
than
the

specified
value

replace

Pad
wear

limit

Minimum
thickness

t
6

mm
0
063
in

Note

Always
replace
pads
in

pad
kit

four

pads
two

clips
four

pad
pins

and
four

pad
springs

4
Check
rotor

referring
to
Rotor

for

inspection

Installetlon

I
Clean

and

apply
P
RC

grease
on

yoke
guide
groove
of

cylinder

body

sliding
contact

portions
of

yoke
and

end
surface
of

piston

Note

a
Do
not

use
common
brake

grease

b

Be
careful
not
to

get
brake

grease

on
rotor
and

pads

2
Loosen
air
bleeder

and

push
pis

ton
B

outer

piston
in

cylinder
until

end
surface
of

piston
B

coincides
with

end
surface
of

retaining
ring
on
boot

Then

inner

pad
can
be

installed
Brake

System

BR564

Fig
BR
11

Pushing
Piston

CAUTION

Piston
can
be

easily
pushed
in

by

hand
but
if

pushed
too
far

groove
of

piston
will

go
inside
of

piston
seal
as

shown
in

Fig
BR
12

At
this

point
if

piston
is

pressured
or
moved

piston

seal
will
be

damaged
If

piston
has

been

pushed
in
too
far

remove
brake

assembly
and
disassemble
it
Then

push

piston
out
in
the

direction
shown

by
arrow

Assemble
it

again
referring
to
follow

ing
section

00

I
Normal

I

position

L

BR409

Fig
BR
12
Position

for
Pushing
Piston

3
Push

piston
A
inner

piston
in

cylinder
by

pulling
yoke
as
shown

The

outer

pad
can
then

be
installed

BRS6S

Fig
BR
13

Pulling
in
Piston
A

BR
7
4

After
installing

pads
depress

brake

pedal
several
times
and

pads

will
settle
into

proper
position

Note

When
worn
out

pads
are
re

placed
with
new
ones
brake
fluid

may
overflow
reservoir
While
re

placing
pads
keep

loosening
bleeder

to
release
brake
fluid

5
Install

wheels
and
lower
car
to

ground

REMOVAL

I
Remove

pads
Refer
to
Pad
Re

placement

2

Remove
brake

tube
from

caliper

assembly

CAUTION

When

removing
brake
tube
use
suit

able
tube

wrench
Never
use

open
end

or

adjustable
wrench

Note

Plug
up
hole
in

caliper
so
that

brake
fluid
does

not
flow
out
from

cylinder
body

3
Loosen
bolts

securing
cylinder

body
to
knuckle

spindle
and

remove

caliper
assembly
from
strut

DISASSEMBLY

I
Drain
brake
fluid
from

top
hole

of

cylinder
body

2
Push
both

pistons
A
and
B
into

cylinder
Refer
to

Pad

Replacement

3

Tap
cylinder
body
lightly
with

a

plastic
hammer
Cylinder
will

then

separate
from

yoke

BR115A

Fig
BR
14

Tapping
Cylinder
Block

INSPECTION

Brake
drum

I
Check
inner
diameter
of
brake

drum
to
make
sure

it
is

properly
round

and

tapered
If

it
is
not

repair
or

replace
brake

drum

Inner
diameter

Standard
diametel

203
2
mm
8

in

Maximum
diameter

204
5

mm
8
05
in

Out
of
loundness

ellipticity

less
than

0
02
mm
0
0008
in

Radial
runout

less
than
0
1
mm
0

004
in

Total
indicator

reading

Taper

less
than

0
02
mm
0
0008
in

Measured

at
a

point
40

mm

1
57
in
flam
inlet

2

Contact
surface
with

which
lin

ings
come
into

contact

should
be

fine
finished
with

No
120

to
150

sandpaper

3

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
has

been

completely
re
conditioned

or
re

placed
check
drum
and
shoes
for

proper
contact

pattern

Brake
e

embly

1

Replace
any
linings
which
are

cracked
worn

or
oil
stained

2
If

lining
is
worn

to
less
than
the

specified
value

replace

Lining
wear
limit

Minimum

thickness

1
5

mm
0
059

in

3

Replace
any
shoe
return

springs

which
are

broken
or

fatigued

4

Replace

fatigued
anti

rattle

spring

damaged
pin
and
or
retainer

Wheel

cylinder

I

Replace
any
cylinder
or

piston

which
is

scratched

scored
or

worn
on

its

sliding
contact
surface
Brake

System

2

Replace
worn

parts
if

piston
to

cylinder
clearance
is

beyond
limit

Piston
ta

cylinder
clearance

less
than
0
15
mm
0

0059
in

3

Replace
any
piston
cup
which
is

worn

or
otherwise

damaged

4

Replace
if

contacting
face
of

cyl

inder
and
shoe
is
worn

locally
or
in

step

5

Replace
any
damaged
dust
cover

fatigued
piston
spring
or

faulty
thread

ed

parts

6

Replace
any
tube
connector

which
is

worn
on
its

threaded

portion

INSTALLATION

Install
rear
brake
in
reverse
order

of

removal

closely

observing
the
follow

ing

1

Tighten
following

parts
to

speci

fied

torque

CAUTION

When

installing
brake
tube

use
Flare

Nut

Torque
Wrench

6694310000

ifl

Tightening
torque

Flared
nut

1
5
to
1
8

kg
m

11
to
13
fHb

Ail
bleedel

0
7
to
0
9

kg
m

15
1
to
6
5
ft
Ib

Wheel

cylinder

mounting
bolt

0

6
to

0
8

kg
m

4
3

to
5
8
ft
b

2
There
are

two

types
of

adjusters

which
have

right
thread
or
left
thread

R
H
brake

Right
thread

adjuster

L
H

brake

Left
thread

adjuster

3

Sparingly

apply
a
coat
of
brake

grease
to
the

following
points

Lubricating
points

e

Adjuster
nut
and
rod
threads

Mating
surfaces

between

adjuster

and

toggle
lever
and

pin
and

roller

BR

ll
0

J

o

BR
117
A

Fig
BR
24

Lubricating
Points

of

Adju
ter

4

Referring
to

Fig
BR

25
for

locations
of

lubricating
points
apply
a

coat
of
brake

grease
to
these

points

Exercise

care
not
to
allow

grease
to

come
into

contact
with

lining
or
ad

juster
screws

Lubricating

points

e

Contact
areas

between
wheel

cyl

inder
anchor
block
and
brake
shoe

e

Mating
surfaces
between
brake
shoe

and

brake
disc

Contact
areas

between
hand
brake

adjuster
and
brake

shoe

Contact
areas
between
brake

disc

brake

shoe
and

toggle
lever

Contact
areas
between

anti
rattle

pin

spring
retainer
and

brake
shoe

Fig
BR
25

Lubricating
Points

5

To

prevent
water
from

entering

brake
drum

apply
dry
sealant
to

brake

disc

mounting
surfaces
of
the

follow

ing

parts

Wheel

cylinder

Anti
rattle

spring

6
Make

sure
that

entire
brake

shoe

fits
in

place

7

Make
sure
that

adjuster
operates

properly

8
After
installation
is

completed

check
and

adjust
shoe

to
drum
clear

ance

by
operating
hand
brake
several

times

9

Bleed
brake

system