light DATSUN 210 1979 Workshop Manual

CD

@

I

I

TL

@
@

AT290

Assembl

I
Prior
to

assembly
dip
all

parts
in

clean

automatic
transmission
fluid

Reverse

disassembly
procedure
to

assemble
brake

2
Use
extreme
care
to
avoid
dam

aging
rubber

ring
when

installing
seal

lace

3
Blow

compressed
air

from

apply

side
of

piston
to
test
for
definite

piston
operation

Fig
AT
67
Te

ling
Pi
ton

Apply
Side

4
With

apply
side
of

piston
plugged

with
thumb
blow

compressed
r
into

cylinder
from
release
side
If
retainer
is

raised
a
little
it
is

an
indication
that

attaching
bolts
are
loose

calling
for

retightening
Automatic
Transmission

I
Anchor
end

pin

2
Band
strut

3

Apply

4

Release

S
Return

spring

6

Band
servo

piston
stem

7
Band
servo

piston

8
Servo
retainer

9
Brake
band
usembly

10

Transmission
cue

Fig
A
T
66
Sectional
Voew
of
SenJo
PUlOn

Fig
AT
68
Te

ting
Pi
ton

Rele
ide

GOVERNOR

D1sessembl

I

Separate
governor
from
oil
dis

tributor

by

unscrewing
attaching
bolts

2
To

disassemble

secondary
gover

nor
remove

spring
seat

spring
and

secondary
governor
valve
from

valve

body
in
that

order

To
control
valve

Governor

preuure
IS
I

a

@

From
control

val
e

I
Line

preS
UJe

I

I

Primary

governor

2

Secondary
govern
r

3
Governor
valve
body

Fig
AT
69
Te

ling
SecondQry

Governor
AT090

4
Oil
dj

tributor

5

Output
shaft

AT
34
3
If

primary
governor
is

to
be
dis

assembled
for

any

purpose
remove

spring
seat

primary
governor
valve

spring
and

spring
seal

Inspection

I

Check
valve
for
defective
condi

tion

Replace
spring
if
found
weaken

ed

beyond
use
Defective

piston

should
also

be

replaced
with
a
new

one

2
Examine
to
see
if

primary
gover

nor
slides

freely
without

binding

3
To
determine
if

secondary

gover

nor
is
in

good
condition
blow
ir

under
light

pressure
into
hole
at
A

and
listen
for
noise

like
thaI
of
a

model

plane

Assembl

Reverse

disassembly

procedure
to

assemble

governor

Note
Do
not
confuse

spriDp
Sec

ondary

spring
is

than

1

governor
sprinS
Af

ter
insteIIation
check
thet

spring
is

not
deflected

OIL
PUMP

D1sessembl

I
Free

pump
cover
from

pump

housing
by
removing

allaching
bolts

2
Take
out
inner

and
ouler

gears

from

pump
housing

Note
Be
cerefnl
not
to
confuse
Ie

specti
sides
of
inner

end
outer

geon

Inspection

I

Inspect
for
wear
or

damage
to

gear
teeth

Replace
rub
bel

ring
if

found

damaged
beyond
use

2

Using
a

straight
edge
and
feelers

measure

pump
and

gear
clearances
as

follows

Clearance
between

inner
or
outer

gear
and

pump
cover

SUndin
deer1lnee

0
02
to
0

iJ4
mm

0
001
to
0
002
in

Replace
if
over
0
08
mm
0
00
11

in

Place
the
vehicle
in
a

pit
and

by

sampling
the
lealeed
oil
deiermine
if
it

is
the

torque
converter
oil
The

torque

converter
oil
has

a
color
like
red
wine

so
it
is

easily

distinguished
from

engine

oil
or

gear
oil

Wipe
off
the

lealeing
oil
and

dust

and
detect
the

spot
of
ill

lell8e

nonflammable

organic
solvent
such
as

carbon
tetrachloride
for

wiping

Raise
the
oil

tcmperature
by

op

erating
the

engine
and
shift
the
lever

to
D

to
increase
the
oil

pressure

The
sp

Q
of
o
1

1I8
u

J1en
be

found
more

easily

Note
As

oil

leakage
from
the
breath

er
does
not
talee

place

except
when

running
at

high
peed
it

iSimpos

sible
to
ate
this

lealcage
with

vehicle

stationary

CHECKING
ENGINE
IDLING

REVOLunON

The

engine

idling
revolution
should

be

properly
adjusted

If
the

engine
revolution
is

too
low

the
e

gine
does
not

operate
smoothly

and
if
too

high
a

strong
shocle
or

creep
develops
when

changing
over

from
ON
to

Dn
or
R

CHECKING
AND

ADJUSTING

KICK

WN

SWITCH

AND

DOWNSH
FT

SOLENOID

When
the
Ieickdown

operation
is

not
made

properly
or
the

speed

chang

ingpoint
is
too

high
check
the
kick

down
switch
downshift
solenoid

and

wiring
between
them
When
the

igni

tion

Ieey
is

po
iti
ned
at
the
1st

stage

and
the
accelerator

pedal
is

depressed

deeply
the
switch

contact
hould

be

closed
and
the
solenoid
should
clicle
If

it
does

not
click
it

indicates
a
defect

Then
check
each

part
with
the

testing

inatrumen15
Auto
lT1atic

Transmissiqn

Fi
J
A
T
84
Down

ltift

Sole
id

Note
Watch
for
oil

leekage
from

tnnsmission
case

INSPECTION
AND

ADJUSTMENT
OF

MANUAL

LINKAGE

The

adjustmcnt
of
manual

linkage

i

equany
important
as

Inspection
of

Oil
Level
for
the
automatic
transmis

sion
Therefore

great
care

should
be

cxercised
oecause

incorrect

adjustment

will
result
in
the

breakdown
of
the

transmission

Inspection

pun
the
selector
lever
toward

you

and
turn
it
as
far
as
p
to

range

where
clicks
will
be
ell

by
the
hand

This
is
the

detent
of
manual
valve
in

the
valve

body
and
indicates
the

corrett

position
of
the
lever

Inspect
whether
the

pointer
of

selector
dial

corresponds
to
this

point

and
also
whether
the
lever
comes
in

alignment
with
the

stepping
of

posi

iion

plate
when
itis
released

CHECKING
AND
ADJUSTING

INHIBITOR

SWITCH

The
inhibitor
switch

lights
the

re

verse

lamp
in
the

range
R

of
the

transmission

operation
and
also
rotates

the

starter
motor
in

the

ranges
N

and
P

AT
40
i

j

tI

IlV

@

@

AT

I

Inhibitor
switch

2
Manual
shaft

3
Washer

4

Nut

5
Manual

plate

Fi
J
AT
85
Comtruction

of
Inhibitor

Switch
6
Nut

1

Washer

8

Inhibitor
wilch

9

Ran
q
Iect
lever

Check
w

ethcr
he
leverse

lal
1p

and

the
starter
motor

operate
nonnal

Iy
in
these

ranges
If
there
is

any

trouble
first
check
the

inkage
If
no

defect
is

fo
nd
in

the

Ii
leage
check

tlie

inhibitor
Swi
ch

Separate
the
manual

lever
from
the

remote
control
selector
rod
and
turn

the

range
select
lever
to
N

Note
In
the

position
N

the
slot
of

the

manual
shaft
is
vertical

Using
the
tester
check
the
two

black

yellow
BY
wire

from
the
in

hibitor
switch
in

the

ranges
N
and

p
and
the
two
red
blacle
RB
wires

in

the

lange
R
for

continuity
Turn

range
select
lever
in

both
directions

from
each
lever

set

position
and
check

each

continuity
range
It
is

normal
if

the

electricity
is
on
while
the
lever
is

within
an

angle
of
about
30

on
both

sides
from
each
lever
set
line
How

ever
if
its

continuity
range
is

obvioUs

ly
u
nequal
on

both
sides

adjustment
is

required

If

any
malfunction
is

found
un

screw
the

fastening
nut
o
the

range

selector
lever
and

two

fastening
bolts

of
the
switch

body
and
then

remove

the
machine
screw

under
the
switch

body
Adjust
the
manual

shaft
correct

Iy
to
the

position
N

by
means
of

the

selector

leVer

When
the
slot
of
the

shaft
becomes
vertical
the
detent

worles
to

position
the
shaft

correctly

with
a

clicking
sound

Move
the
switch

slightly
aside

so

that
the

scie
hole
will
be

aligned

they
are
worn

damaged
or
otherwise

faulty
and
how

they
are
affected
Re

pair
or

replace
all

faulty

parts
which

ever
is

necessary

1
Check

gear
teeth

for

scoring

cracking
or

chipping
and
make
sure

that

tooth
contact

pattern
indicates

correct

meshing
depth
If

any
fault

is
evident

replace

parts
as

required

Note
Drive

pinion
and

ring
gear
are

supplied
for

replacement
as
a

set

therefore
should
either

part
be

damaged

replece
as
a
set

2
Check

pinion
shaft
and

pinion

mates
for
scores
and

signs
of
wear

and

replace
as

required

F
oUow
the
same

procedure
for
side

gear
and
their
seats
on
differential

case

3

Inspect
all

bearing
races
and
roU

ers
for

scoring
chipping
or
evidence
of

excessive
wear

They
should
be
in

tiptop
condition
such
as
not
worn
and

with
mirror

like
surfaces

Replace
if

there
is
a

shadow
of

doubt
on
their

efficiency
as
an

incorrect

bearing
op

eration

may
result
in
noises
and

gear

seizure

4

Inspect
thrust
washer
faces
SmaU

faults
can
be

corrected
with

sand

paper
If

pinion
mate
to
de

gear

backlash
exceeds

specified
value
re

place
thrust

washers

Pinion

mate
to
side

gear
backlash

0
10
to
0
20
mm

0
0039
to
0
0079
in

5

Inspect
gear
carrier
and
differ

ential
case
for
cracks
or
distortion
If

either

condition
is
evident

replace

Jaulty

parts

6
As
a

general
rule
oil
seal
should

be

replaced
at
each

disassembly

ASSEMBLY
AND

ADJUSTMENT

Assembly
can
be
done
in
the

reverse
order
of

disassembly
The

foUowing
directions
for

adjustment

and

usage
of

special
tools
enable
to

obtain
a

perfect
differential

operation
Propeller
Shaft
Differential
Carrier

PRECAUTIONS
IN

REASSEMBLY

I

Arrange
shims
washers
and

the

like
to
install
them

correctly

2

Thoroughly
clean
the

surfaces
on

which
shims

washers

bearings
and

bearing
caps
are
installed

3

Apply
gear
oil
when

installing

bearings

4

Pack

grease
cavity
between

lips

when

fitting
oil
seal

ASSEMBLY
OF

DIFFERENTIAL
CASE

1

Assemble

pinion
mates
side

gears

and
thrust
washers
in
differential
case

2
Fit

pinion
shaft
to
differential

case

so
that
it

meets
lock

pin
hole

3

Adjust
pinion
mate

to
ide

gear

backlash
or
the
clearance
between
the

rear
face
of
side

gear
and

thrust

washer
to
the

specified
value

by

selecting
side

gear
thrust
washer

Pinion
mate
to
side

gear
backlash

0
10
to
0
20

mm

10
0039
to
0
0079
in

PD023

Fig
PD

l1
Measuring
Clearance

Side

gear
thrust

washer

Thickness
mm
in

0
785
0
0309

0
835
0

0329

0

885
0
0348

4

Lock

pinion
shaft
lock

pin
using
a

punch
after
it
is

secured
into

place

5

Apply
oil

to

gear
tooth
surfaces

and
thrust
surfaces
and
check
if

they

turn

properly

6

Place

ring

gear
on
differential
case

and
install
bolts
and
lock

straps
Tor

que
bolts
to

specification
and
bend

up

lock

straps

PO
5
tiJ
Tightening
torque

Ring
gear
bolt

6
0
to
7
0

kg
m

43
to
51
ft
Ib

CAUTION

e
Use

only
genuine
ring
gear
bolts

end
new
lock

straps

b

Tighten
bolts
in
criss
crilss
fashion

lightly

tapping
around
bolt
heads

with
a
hammer

7

When

replacing
side

bearing

measure

bearing
width

using
Side
Bear

ing
Adjust
Weight
ST3250S000

Weight
mock
ST3250
I

000
and

Master

Gauge
ST325020oo
or
suit

able

standard

gauge
17
5
nun
0
689

in

thickness
and

a

weight
block
2
5

kg
5
5
Ib

prior
to
installation

Standald

bearing
width

17
5
mm
10
689
in

y

ST32501000

8
Select
side

bearing
shims
re

ferring
to

Adjustment
of
Side

Bearing

Shims

9
Press
fit
side

bearing
cone
into

differential
case

using
Gear
Carrier

Side

Bearing
Drift
ST33220oo0
and

Adapter
ST33052000

w

I
ST33220000

PD244
1000

ST33052000

Fig
PD
13

lnatalling
Side

Bearing

Cone

EX

2

A
0

B
3

C
I
D
2

E

O
I
F

0
08
H
I

Left
side

T
A

C
D
H

xO
OI

0

20
E

0
H

2
1

x
0

01

0
20

0
11

0
0
20

0
1

0
31

The

correct
shims

are
0
10

plus

lI
re
e

pi

ce
s
of

9
Q7
I
Il1I
thick

Right
side

T2
B
D
H
xO
OI

020
F

3
2
I
xO

01

0
20

0
08

0
02
0
20
0

08

0
30

The
correct

shims
are
0
10

plus

0

20
mm
thick

Note

If
w1ues

sigoifying
A
B
C
D

and
H

are
not

giVen
regard
them

as

zero
end

compote

After

essembly
clteek
to
see
that

preload
and
backlesb
ere
correct

If
not

readjust

Side

bearing

adjusting
shim

Thickness
mm
in

0
05
0

0020

0
07
0

0028

0
1
0
0
0039

0
20
0
0079

0
50
0

0197

2
Fit
determined

side

bearing
ad

justing
shim
on
differential
case
and

press
fit
left
and

right
side

bearing

inner

races
on
it

using
Side

Bearing

Drift
ST3322OO00
and

Adapter

ST33052000

3
Install
differential
case

assembly

into

gear
carrier

tapping
with
a
rubber

mallet

4

Align
mark
on

bearing
cap
with

that
on

gear
carrier
and
install

bearing

cap
on
carrier

And

tighten
bolts
to

specified
torque
Propeller
Shaft
Differential
Carrier

@Tightenirig
tOrque

Side

bealingcap
bolts

5
0

to
6

0

kg
m

36
to
43
ft
b

5

M
easure
L

dimension
between

left
and

right
bearing

cap
edges
with

a
micrometer

e

cljmension

153
40
to
153
45

mm

6

0394
to
6
0413

inl

PD271

Fig
PD
20

Measuring
L
Dimension

6
Measure

ring
gear
to
drive

pinion

backlash

If
backlash
is

too
smaU
decrease

thickness
of
left
shim
and

increase

thickness
of

right
shim

by
the
same

amount

If
backlash
is

too

great
reverse
the

above

procedure

Ring
gear
to
drive

pinion
backlash

0
10

to
0
15
mm

0

0039
to
0
0059
in

PD272

Fig
PD
21
Mea

uring
Backlash

7
At

the
same
time

check
side

bearing
preload
Bearing
preload

should

be

specified
torque

If

preload
does
not
accord
with
tJiis

specification

adjust
it

with
side
bear

ing
shims

PD
B
Side

bealing
preload

8

to
10

kg
cm

6
9

to
8
7
in

bl

At

ring
geer
bolt

1
5
to
1
9

kg

3
3
to
4
2
Ibl

8
Check

and

adjust
the
tooth
con

t

c

pattern
of

ring

gear
and
drive

pinion

I

Thoroughly
clean

ring
and
drive

pinion
gear
teeth

2
Paint

ring
gear
teeth

lightly
and

evenly
with
a
mixture
of

recommend

ed

powder
and
oil
of
a
suitable
consist

ency
to

produce
a

contactpaUern

3
Rotate

pinion
through
several

revolutions
in
the
forward
and

reverse

direction
until
a
definite
contact

pat

tern
i

developed
on

ring
gear

4

When
contact

pattern
is

in

correct
readjust
thickness

oLadjust

ing
shim

Be
sure
to

wipe
off

powder
com

pletely
upon
completion
of

adjust

ment

5
Incorrect
contact

pattern
of

teeth
can
be

adjusted
in
the

foUowing

manner

Contact

pettern

a
Heel
contact

To
correct
increase
thickness
of

drive

pinion
adjusting
washer
in

order

to

bring
drive

pinion
close
to

ring
gear

P0193

Fig
PD
22
Heel
Contact

b
Toe
contact

To

correct
reduce
thickness
of

drive

pinion

adjusting
washer
in
order

to
make
drive

pinion
go

away
from

ring
gear

t
PD194

Fig
PD
23
Toe

Contact

Front
Axle

Front

Suspension

INSPECTION
AND
ADJUSTIVIENT

INSPECTION

Inspect
in
accordance
with

periodic

maintenance
schedule

Block
rear
wheels
with
chocks

2

Jack

up
the
front

of

car
and

support
it
with

safety
stands

Refer
to

Section
GI
for

lifting

points
and

towing

3

Shaking
each
fiont
wheel

by

grasping
the

upper
and

lower
surfaces

of
the
tires
check

suspension
parts
for

looseness
wear
or

damage
Tighten
aU

loose
bolts
and

nuts
to
the

specified

torque
Replace
all
worn

parts
as

described
under
Front

Suspension

4

Check
wheel

bearings
If

there
is

any
axial
end

play
adjust

bearings
to

specifications

Replace
worn
or

damaged
bearings

as
described
under
Front

Axle

S
Check

strut
for
oil

leakage
or

damage

ADJUSTMENT

WHEEL

BEARING

Block

rear
wheels
with
chocks

2

Jack

up
the
front
of
car
and

support
it

with

safety
stands

3

Remove
brake

pads
Refer
to

Section
BR
for

pad
replacement

4

Remove
hub

cap
cotter

pin
ad

justing

cap
and
wheel

bearing
nut

S

Sparingly
apply
recommended

multi

purpose

grease
to
threaded

por

tion

of

spindle
and

contact
surface

between
wheel

bearing
washer
and

outer
wheel

bearing

6

Tighten
wheel

bearing
nut

using

a
suitable

torque
wrench

P
Tightening

torque

Wheel

bearing
nut

3
0
to
3
5

kll
m

22

to
25
ft

Ibl
Fig
FA

Tighlening
Wheel

Bearing

Nul

7
Turn

wheel
hub
several
times
in

both
directions
to

seat
wheel

bearing

correctly

again
tighten
wheel

bearing

nut
to
the
above

torque

8
Turn
back
wheel

bearing
nut
A

degrees

Return

engle
AU

900

Install

adjusting
cap
and

align
any

of
its
slots
with
hole
in

spindle
If
the

above

procedure
fails
to

align
hole
and

slot

together
then

tighten
lock

nut
as

much
as
I

S

degrees
until
hole
in

spindle
is

aligned
with

eny
slot

CAUTION

00
not

overtighten
wheel

bearing
nuts

as
this

can
cause
wheel

bearing
seizure

9
Turn

hub
in
both

directions
two

or
three
times

measuring
its

turning

torque
and

axial

play
to

ee
if

they
are

within
the

specified
range
If

they
are

not

adjust

Axial

play

Omm

Din

Wheel

bealing
starting
torque

With

new

gleaS8
l8al

A

measured
et

wheel

bearing

nut

less
than
7

kg
cm

G
1
in
Ibl

FA
2
AJ
measuled
et
wheel
hub

bolt

Less
then
1
2

kg
12
G
Ibl

With
u
ed

gr
seal

AJ
measured

at
wheel

bealing

nut

1
0
to
4
5

kg
cm

0
9
to
3
9
in
b

AJ
measuled
at

wheel
hub

bolt

0

17
to
0
79

kg

0
37
to
1
741bl

FA413

Fig
FA
2
Metr

uring
Bearing
Starting

Torq
ue

Repeat
above

procedures
until
cor

rect

starting
torque
is

obtained

Note

a

Correctly
meas
e
rotation

slar
ting

force

toward

tangential
direction

against
hub
bolt

b

Above

figures
do
not

include

dragging
resistance
with

pads
re

moved
on
disc
brake
models

c

Any

slightest
wheel

bearing
axial

play
cannot
be
tolerated

10
Insert
new
cotter

pin
with
the

legs
through
hese
two

parts
spread

legs
away
from
each
other

against
sides

of
wheel

bearing
nut

Front
Axle
Front

Suspension

Condition

Instability
of
car

Stiff

steering
wheel

Checking
up
procedure

Jack

up
front
wheels
detach
the

steering

gear
arm

and

operate
the

steering
wheel

and

If
it
is

light
check

steering
linkage
and

suspension
parts

If
it
is

heavy
check

steering
gear
and

steering
column

parts

Excessive

steering
wheel

play

Noises
Probable

cause

Improper
tire

pressure

Worn
rubber

bushings
for
transverse
link
and

tension
rod

Incorrect
wheel

alignment

Worn

or
deformed

steering
linkage
and

suspension
link

Incorrect

adjustment
of

steering
gear

Deformed
or

unbala
1ced
wheel

Improper
tire

pressure

Insufficient
lubricants
or

mixing
impurities

in

steering
gear
box
or

excessively
worn

steering
linkage

Stiff
or
damaged

suspension
ban

joint
or

lack
of

grease

Worn

or

incorrectly
adjusted
wheel

bearing

Worn
or

damaged
steering
gear
and

bearing

Incorrectly
adjusted
steering
gear

Deformed

steering
linkage

Incorrect
wheel

alignment

Damaged
strut

mounting
bearing

Damaged
or
stiff

piston
or
shock
absorber

piston
rod

in
the
strut

Interference
of

steering
column
with

turn

signal
switch

Incorrectly
adjusted
steering
gear
housing

Worn

steering
linkage

Improperly
fitted

gear
housing

Incorrectly

adjusted
wheel

bearing

Worn
transverse
link

and
tension
rod

bushings

Improper
tire

pressure

Insufficient

lubricating
oil
and

grease
for

suspension
ball

joint
and

steering
linkage
or

their

breakage

Loose

steering
gear
bolts
linkage
and
sus

pension
parts

Faulty
shock
absorber

inside
the
strut

Faulty
wheel

bearing

Worn

steering

linkage
and

steering
gear

Worn
transverse
link
and
tension
rod

bushings

Broken

or

collapsed
coil

spring

FA
17
Corrective
action

Adjust

Replace

Adjust

Replace

Adjust

Correct
or

replace

Adjust

Replenish
grease
or

replace
the

part

Replace

Replace
or

adjust

Repalce

Adjust

Replace

Adjust

Replace

Replace

Adjust

Adjust

Replace

Retighten

Adjust

Replace

Adjust

Replenish
lubri

cating
oil
and

grease

or

replace

Retighten

Replace

Replace

Replace

Replace

Replace

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

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

Remove
bias

ring
from

piston
A

S

Remove

retaining
rings
and
boots

at
the
end

of
both

pistons
A

and
B

I

Biuring

2

Boot

3

Retaining
ring

BA567

Fig
BR
15

Cylinder

Body
and
Pi
tan

6

Force
out

pistons
from

cylinder

by
feeding

compressed
air

gradually

WARNING

Gradually
increase
air

pressurs
10

that

piston
does
not

pop
out

7

Remove

piston
seals

CAUTION

Be
careful

not
to

damBlle
piston
and

cylinder
boily

8
Remove

yoke
spring
from

yoke

INSPECTION

Clean
au

parts
and
check
u
fol

lows

CAutiON

Use
brake

fluid
to

claan
Never

use

minersl

oil

Cylinder
bod

1

Check

inside
surface
of

cylinder

for
score
rust

wear

damage
or

pres

ence
of

foreign
substances
If

any

surface
fault
is
detected

replace
cyl

inder

body

2
Minor

damage
from
rust
of

foreign
substances

may
be
eliminated

by
polishing
surface

with
a
fme

emery

cloth
If

damage
is

major
cylinder

assembly
must
be

replaced
Brake

System

Yoke

Check
for
wear
cracks
or

other

damage

Replace
if

any
fault
is

de

tected

PIston

Check

piston
for
score
rust
wear

damage

orpresenco
of

foreign
sub

stances

Replace
if

any
fault
is

de

tected

CAUTION

Piston

sliding
surface
is

plated
00
not

polish
with

emery
peper
even
if

rust
or

foreign
matter

is
sticked
on

sliding

surface

PIston
seal
end
dust
seel

Replace
piston
seal
and
dust
seal
at

each

dis
mbly

ASSEMBLY

1

Apply
rubber

grease
to

cylinder

bore

and
install

piston
seal

2

Insert
bias

ring
into

piston
A
so

that
the

roundish

portion
of
it

faces

the
bottom
of

piston
A

bore

I

ID

J

if
C

jt

11

e

1

@

I

j
BA

I
Roundish

portion
3
Chamfer

2
Piston
A
4
Yoke

Fig
BR

16

A
embly
af
Bia

Ring

to
Piston

A

CAUTION

a

Be
careful
not
to

mistaka

piston
B

for

piston
A

b

Pistons
A

and
B
are

distinguished

from
each

other

by
a

dent
at
the

inner

bottom
of

piston
A

BR
8
Piston
A

Piston
B

BR41S

Fig
BR
17

Pisto
A
and
B

Note
Bias

ring
must

be
instaDed
on

the

original

position

3

Apply
rubber

grease
lightly
to
the

sliding

portions
of

pistons
and
insert

into

cylinder

Note

a
Insert

pistons
A

and
B

from

each

outside

b
When

inserting
pistons
be
careful

not

to
insert
too
far
Refer

to
Pad

Replacemeni

c
Install

piston
A

so
that

yoke

groove

of
bias

ring
of

piston
A
coincides

with

yoke
groove
of

cylinder

4

Instau

boot
and

retaining
ring

S
Install

yoke
springs
an

bias

ring

on

yoke

Front
face

1
1
0

Rear
face

BA416

1
Bias

Sprinl

2
Yoke

spring

Fig
BR
18
Yoke
with
Yoke

Spring