air condition DATSUN PICK-UP 1977 Manual PDF

Condition

Seizure
of

breakage

Oil

leakage
PROPELLER
SHAFT

IFFERENTIAl

CARRIER

Probable
cause

Shortage
of
oil
or

use
of
unsuitable
oil

Excessively
small
backlash

Incorrect

adjustment
of

bearings
or

gears

Severe
service
due

to
an
excessive

loading

improper
use
of

clutch

Loose
bolts
and
nuts
such
as

ring
gear
bolts

Worn
out
damaged
or

improperly
driven

front
oil
seal

or
bruised
dented
or
abnor

mally
worn
slide
face

of

companion
flange

Loose

gear
carrier

bolts

Faulty

gasket

Loose
fIller
or

drain

plug

Clogged
or

damaged
breather

PD

15
1

j

Corrective
action

Replace

faulty
parts
and

use
reconunended

gear
oil

Adjust
backlash
and

replace
as

required

Replace

faulty
parts

Replace
faulty
parts

Replace

faulty
parts

Replace
faulty
oil
seal

Repair
the

affected

flange
with

sandpaper
or

replace
if
nee

essary

Tighten
the

bolts
to

specified
torque

Replace
faulty

gasket
with
new
one

Tighten
the

plug

Repair
or

replace

Level
line

Level
line

FA230

Fig
FA
8

Bushing
location

3
Remove

grease
nipple
and
drill

grease
hole
on

bushing
through
thread

ed

grease
nipple
hole
When

grease

hole
is
drilled
remove
metal

chip
and

burr

thoroughly

Drilling
diameter

approximate
3
mOl
0
118
in

Note
When
a

spindle
bushing
has
a

grease
nipple
hole
in
it

an
ad

ditional
hole
need
not
be

drilled

When

pressing
it
into

position
align

grease
nipple
hole

with
that
in

spindle
bushing

4
Ream
the

inside
of

bushing
to
the

specified
value
with

King
Pin

Bush

Reamer
HT56802000

Bushing
inner
diameter

when

fitted

20
010

to
20
03S
mOl

0
7878

to
0
7888
in

Note

Carry
out

reaming
from
both

upper
and

lower

bushings
When

reaming
upper
side
use
lower
side

as

reaming

guide
and
when
reaming

lower
side
use

upper
side
as
ream

ing

guide
to

align
the
center
line

correctly

5
Press

fit

grease
seal
on

upper
arm

with

King
Pin

Grease
Seal
Drift

ST35390000
In

installing
grease
seal

take
care
not
to

damage
seal

lip

51
35390000

FA231

Fig
FA
9

Installing

grease
seal
Front
Axle
Front

Suspension

Wheel
hub

1
After

removing
grease
seal
with

screwdriver
lightly
tap
outer

race
cir

cumference
with
a
hammer

by
ap

plying
a
brass
bar
and

remove
outer

bearing
race
from
hub
When

tapping

outer
race
circumference

tap
evenly

2
Remove
all
traces
of
old

grease

from

bearings
hub
and

knuckle

spindle

3

Install
inner
and
outer

bearing

races
in

hub
with
a

suitable
tool
Be

sure
to

seat
the
races

properly
in
hub

4

Pack
the
inside
of
hub
and
hub

cap
with

specified
grease
to
the
de

scribed
level
See

Figure
FAA
Also

pack
the

bearing
cone
and
roller
as

semblies
with
the
same
lubricant

FA009

Fig
FA
10

Greasing
bearing
cone
and

roller
assembly

5
Place
inner

bearing
cone
and
rol

ler
assembly
in
hub

Coat

grease
slight

ly
to
the

lips
of
new

grease
seal
and

seat
it

properly
INSPECTION

King
pin
and

bushing

Check
and

replace
king
pin
andlor

bushing
if
tne

following
faulty
condi

tion
is
detected

deformation
scores

partial
wear
and

excessive
clearance

between

king
pin
and
bushing
in
dia

meter
direction

exceeding
limit

listed

below

Clearance
limit

0
15
mOl
0

00S9
in

Standard
dimensions

King
pin
outer
diameter

19
979

to
20
000
mm

0
7866
to
0

7874
in

Bushing
inner
diameter

20
010

to
20
035
mOl

0

7878
to
0
7888
in

2
Wheel

bearing

ThorougWy
clean

grease
and
dirt

from
wheel

bearing
with

cleaning
sol

vent
and

dry
with

compressed
air
free

of
moisture
Check
wheel

bearing
to

see
that
it
rolls

freely
and
is
free
from

noise

crack

pit
ing
or
wear
Also

check
outer
race

for
condition
Re

moval
of
outer
race
from
drum
is
not

necessary

Shown
below
is
the
cha
rt
which

furnishes
the

necessary
information
on

Visual
Serviceability
Standard
for

Wheel

Bearing

Visual

serviceability
standard
for
wheel

bearing

@

J

@

@

@

@

@
A

Q
jJ

2

@

CD

FA
5
1
Outer
race

2
Roller

3
Small
collar

4
Inner
race
fitted
surface

5
Collar

surface

6
Inner
race
surface

7
Outer
race

tilted
surface

8
Outer
race
surf
lcc

9
Roller

rolling
surface

10
Inner
race

11

Large
collar

12

Supporter

FADD6

Fig
FA
11
Wheel

bearing
assembly

s

Install
tension

rod
at
rear
end

tighten
nut
to

make
the

distance
of

rubber

bushing
to
be
33
4
mm
1
315

in
and

torque
lock
nut
to
1

6
to
2
2

kg
m
12

to
16
ft
lb

6

Install
tension
rod
bracket

to

chassis

frame
bracket
and

torque
nut

to
1

6
to
2
2

kg
m

12
to
16
ft
lb

When

two
rubber

bushings
are
dif

ferent
in
size

arrange
adjusting
nut

Standard
dimension
is
11
0
mOl
0
433

in

as
shown
in

Figure
FA

16

Torque

lock
nut

to
1
6
to
2
2

kg
m

12
to
16

ft
lb

Il
0

11

0
0
433

t

lP

33
4
1
315

I

11
0

0
433
1
0
11
0

0

433

Adjusting
nut

Y
i

w

36
6
l
441

Unit
mm

in

FA235

Fig
FA
16
Tension
rod
detail

INSPECTION

I

Check
tension

rod
for
bend
and

the

thread
for

faulty
condition

Repair

or

replace
as

required

2

Check

bushing
rubber
for
wear

and
deterioration

Replace
if
neces

sary

TORSION

BAR

SPRING

REMOVAL
AND

INSTALLATION

Removal

1
Raise
vehicle
on
a
hoist
or
stands

2
Remove
wheel

3
Loosen
nuts
at

spring
anchor

bolt
Front
Axle
Front

Suspension

4
Remove
dust

cover
at
the
rear

end

of
torsion
bar

spring
and

detach

snap

ring

S
Withdraw
torsion
bar

spring
rear

ward

after

pulling
ou
t
anchor
arm

realWard

I

nstallalation

Install
torsion
bar

spring
in
the

reverse

sequence
of

removal

noting

the

following
instructions

I

Coat

grease
on
the
serrations
of

torsion
bar

spring
and
install
it

to

torque
arm

Note
Be

sure
to
install

right
and
left

torsion
bar

springs
correctly
They

can

be
identified
with
R

Right

and
L

Left
marked
on
the
end

surface

2
Install

anchor
arm
and

tighten

adjusting
nut
to

obtain
A
dimen

sion
See

Figure
F
A
17

When
anchor

arm
is

properly
adjusted
to
A

specification
upper
link
should
be
in

contact
with

rebound

bumper
rubber

See

Figure
FA
18
Install

snap
ring
and

dust
cover

Temporarily
tighten

adjust

ing
nut
until
B

specification
is

reached

I

I

I

FA236

Fig
FA
17

Installing
anchor
arm

Specifications
for
torsion
bar

spring

Diameter
x

length
mOl

in

Torsional

rigidity

kg
m

deg
ft
lb

deg

FA
9
Anchor
arm

setting
post
ion
A

ISt02Smm

0
59
to

0
98
in

Temporary
tightening
distance
B

60
to
70

mOl

2
36
to
2

76
in

UjPPje
Rebound

bumper

rubber

j

4W

Fig
FA

18

Setting
procedure

Notes

3
A

and
8

specifications
are

only
the

preliminary
rough
settings

directions
for

performing
the
final

adjustment
that

determines
the
ride

height
are
found
on

page
F
A
II

under

Adjustment

b
Discard
old

snap
ring
after

re

moving
it

Replace
with
new

one

during
reinstallation

3
Install
wheel
and

lower
vehicle

Adjust
vehicle

posture
at
curb

weight

full
fuel

tank
no

passengers
refer

ring
to

Adjustment

4

Torque
lock
nut
to
3
1
to
4
1

kg
m
22
to
30

ft
lb

INSPECTION

Check
torsion
bar

spring
for
wear

twist
etc
When

adjusting
vehicle

posture
replace
torsion
bar

spring

with
a
new
one
if
the

specified
height

can
not

be
obtained

All
models

21

9
x
830
0
862
x

32
68

3
74
27
I

Note
When

installing
fulcrum

pin

insert
it

from
rearward

of
vehicle

12

Install

tension
rod
shock
ab

sorber

I
stabilizer
torsion

bar

spring

and

knuckle
arm

referring
to
the

related

paragraphs

13

Install
brake
disc

to
knuckle

spindle
and

torque
securing
bolt
to
4
2

to
5

0

kg
m
30

to
36
ft
Ib

14

Install
wheel
and
brake

drum
as

an

assembly
and

torque
knuckle

spin

dle

nut
to
8
0

to
9
0

kg
m
58
to
65

ft
Ib

DISASSEMBLY

AND

ASSEMBLY

Upper
link

I

Detach

upper
link

spindle
from

upper
links
and

remove

clamp
dust

cover
and
dust
seal
Secure

upper
link

in
a
vise
and

loosen
screw

bushing

Assemble
link

spindle
in
reverse

sequence
to

disassembling
noting
the

following
instructions

2

Torque
screw

bushing
on

upper

link
to
3S
to

55

kg
m
253
to

398

ft
Ib

Install
new
dust
seal
and
dust

cover
and
secure
them
with

clamp

3

Coat

grease
to

screw

bushing
in

side
and
the
thread

portion
of

upper

link

spindle

liberally
Screw
front
and

rear
links
to

upper
link

spindle
in
the

same

length
so
as
to
obtain

the

speci

fied

figures
as
shown
in

Figure
FA

23

Unit
mm
in

I

44

6
1
156
FA2

Upper
link

and

upper
link

spindle
Fig
FA
23
Front
Axle
Front

Suspension

4

Make
sure
to

operate
upper
link

spindle
smoothly
after

installation

5

Replace
filler

plug
with

grease

nipple
and

pack
grease
until

grease

comes
out
from

dust
cover

Reinstall
f1ller

plug

Lower
link

When

installing
torque
arm
on

lower
link

tighten
it

to
the

following

specifications

Serration
boss

1
8

to
2

6

kg
m

13
to

19
ft

Ib

Arm

head

2
7

to
3
7

kg
m

20
to

27
ft
tb

INSPECTION

Upper
link

spindle
fulcrum

pin

and
screw

bushing

Apply
screw

bushing
to

upper
link

spindle
or
fulcrum

pin
and
measure

axial
end

play
between

them

When
the
end

play
exceeds
0
35

mm
0

0138
in

replace

upper
link

spindle
or
fulcrum

pin
together
with

screw

bushings

Condition

Vehicle

empty
no

payload

Vehicle
loaded

Notes

a
Vehicle

empty
no

payload
consists

of
the

following
conditions

I
Full

tank
of

gasoline
radiator

f1lled
and

engine
oil
level
full

2

Spare
tire
wheel

jack
and

jack

handle
in

design
position

b
Vehicle
loaded
consists
of
the
fol

lowing
conditions

For
all
models
2

persons
and
SIlO

leg
I
103lb

payload

FA
Check
the
screw
of

upper
link

spindle
fulcrum

pin
and
screw
bush

ing
and

repair
or

replace
if

necessary

Note

Discard
dust
cover
and

dust
seal

when
disassembled

ADJUSTMENT

VEHICLE
POSTURE

Vehicle

posture
may
be
incorrect

due

to
weakened

spring
or

other

faulty

condition
The

following
procedures

are

necessary
when

adjustment
is

Ie

quired

That
is

the
vehicle

posture
can
be

adjusted
by

obtaining
only
the

speci

fied
H

dimension

changing
the

length
of
anchor
bolt

I

Raise
front
of
vehicle

on
stands

2

Adjust
H

dimension
with

turn

ing
nut

adjusting
anchor
bolt
H

dimension

changes
approximately
3
5

mm
0

J38
in

vertically
when

adjust

nut
is
turned

one

complete
turn

3
To

make
the
best

vehicle

posture

H
dimension
must
be
in
the
follow

ing
range

H

dimension
mOl

in

All
models

79
to

84
3

11
to
3
31

54
5
2

15

o
i

Fig
FA

24
FA242

Dimension

for
standard

vehicle

postl4re

Front
Axle
Front

Suspension

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Vibration
shock
and

shimmy

ing
of

steering
wheeL

Vehicle

pulls
to
right
or
left
Probable
cause

Vibration
Too

much
backlash
of

steering

gear
wear

of
each

part
of

linkage
and
vibration
of
front

wheels
are
in

many
cases
transmitted
to
the

steering
wheel
This
is

Very
much
noticeable
when

traveJling
over
bad
roads
and
at

higher

speeds

Shock
When

the
front
wheels
are

travelling
over

bumpy
roads
the

play
of
the

steering
linkage
is

transmitted
to
the

steering
wheel
This
is

especially

noticeable
when

travelling
rough
road

Shimmy
Abnormal
vibrations
of
the
front

suspen

sion

group
and
the
whole

steering

linkage
which

occur
when

a

specific
speed
is
attained

Improper
air

pressure
of
tire

Unbalance
and
deformation
of
roadwheel

Unevenly
worn
tire
or

insufficient
tightening

Improperly
adjusted
or

worn
front
wheel

bearing

Faulty
wheel

alignment

Worn
or
loose

suspension
link
screw

bushing

Damaged
idler
arm

Insufficiently

tightened
steering
gear
housing

Worn

steering
linkage

Improper
steering
gear
adjustment
insufficient
back

lash

Faulty
shock
absorber
or
loose
installation

Unbalanced
vehicle

posture

When

driving
with
hands
off
the

steering
wheel

on
a

fiat
road
the
vehicle

gently
swerves
to

right
or

left

Note
A

faulty
rear

suspension
may
also
be
the
cause

of
this
condition
and
therefore
see
also
the

chapter
dealing
with
the
rear

suspension

Improper
air

pressure
of
tire

or
insufficient

tightening

of
wheel
nu
ts

Difference
in

height
of

right
and
left
tire
treads

Incorrect

adjustment
or
abrasion
of
front
wheel

bearing

Weakened
front
torsion

spring
or
deviation
from

standard

specification

Improper
wheel

alignment

Worn

or
loose

suspension
link

screw

bushing

FA
14
Corrective
action

Adjust

Correct
the
unbalance

or
re

place

Replace
or
tighten

Adjust
or

replace

Adjust

Replace

Replace

TIghten

Replace
ball

joint

Adjust

Replace
or

tighten

Adjust

Adjust
or

tighten

Replace
tires

Adjust
or

replace

Replace

Readjust

Replace

Condition

Vehicle

puBes
to

right
or
left

Instability
of
vehicle

Stiff

steeirng
wheel

Excessive

steering
wheel

play

Noise
Front
Axle

Front

Suspension

Probable
cause

Deformed
of

steering

linkage
and

suspension
link

Unbalanced

vehicle
level

Improper
air

pressure
of
tire

Worn
or

loose

suspension
link
screw

bushing

Incorrect
wheel

alignment

Worn
or
deformed

steering

linkage
and

suspension

link

Incorrect

adjustment
of

steering
gear

Deformed
unbalanced
wheel

Check

and
correct
in
the

following
manner

Jack

up
front

wheels
detach
the

steering
gear
and

operate
the

steering
wheel
and

a

If
it
is

light
check

steering
linkage
and

suspension

groups

b
If
it
is

heavy
check

steering

gear
and

steering

column

groups

Improper
air

pressure
of
tire

Insufficient
lubricants
or

mixing
impurities
in

steering

linkage
or

excessively
worn

steering

linkage

Insufficient
lubricant
in

gear
box
or
contaminated

lubricant

Unsmooth

king
pin
damaged
part
Or
insufficient

lubrication

Worn

or

incorrectly
adjusted
wheel

bearing

Worn

damaged

steering
gear
and

bearing

Incorrectly
adjusted

steering
gear

Deformed

steering
linkage

Incorrect
wheel

alignment

Interference
of

steering
column
with
turn

signal

switch

Incorrectly
adjusted
steering
gear

Worn

steering
linkage
idler

arm

Improperly
fitted
of

gear
box

Incorrectly
adjusted
wheel

bearing

Worn
or
loose

suspension
link

screw
bushing

Improper
air

pressure
of
tire

Insufficient

lubricating
oil
and

grease
for

suspension

link
screw

bushing
and

steering
linkage
or
their

breakage

FA

15
Corrective
action

Replace

Correct

the
unbalance

Adjust

Replace

Adjust

Replace

Adjust

Correct

or

replace

Adjust

Replenish
grease
or

replace

the

part

Add

or

replace
gear
oil

Replace

Replace
or

adjust

Replace

Adjust

Replace

Adjust

Adjust

Adjust

Replace

Retighten

Adjust

Replace

Adjust

Replenish
lubricating
oil
and

grease
or

replace

Condition

Noise

Grating
tire
noise

Jumping
of

disc
wheeL

Excessively
or

partially
worn

tire
Front
Axle
Front

Suspension

Probable
cause

Loose

steering
gear
bolts

linkage
and

suspension

groups

Faulty
shock
absorber

Damaged
wheel

bearing

Worn

steering
linkage
and

steering
gear

Worn
of
loose

suspension
link
screw

bushing

Improper
air

pressure
of
lire

Incorrect
wheel

alignment

Deformed
knuckle

spindle
and

suspension
linkage

Rough
driving

Improper
air

pressure
of
tire

Unbalanced
wheels

Faulty
shock
absorber

Worn
tire

Deformed
wheel
rim

Improper
air

pressure
of
tire

Incorrect
wheel

alignment

Damaged
wheel

bearing

Incorrect
brake

adjustment

Improper
tire

shifting
rotation

Rough
and

improper
wiving
manner

FA
16
Corrective
action

Retighten

Replace

Replace

Replace

Replace

Adjust

Adjust

Replace

Avoid

rough
driving

Adjust

Adjust

Replace

Replace

Replace

Adjust

Adjust

Replace

Adjust

Adjust

Drive
more

gently

Rear
Axle
Rear

Suspension

Spring
front

pin

Spring
shackle

Bearing
cage

fIXing
bolt

Wheel

bearing
lock
nut

Air
breather

Differential

gear
carrier

to
axle
case
nut

Propeller
shaft

flange
bolt

Drain
and
filler

plug

Bumper
rubber

fixing
bolt

Wheel
nut
kg
m
ft
lb

kg
m
ft
Ib

kg
en
ft
lb

kg
m
ft

Ib

kg
m
ft
Ib

kg
m
ft
Ib

kg
en
ft
Ib

kg
m
ft

Ib

kg
m
ft
Ib

kg
m
ft

lb
11
5
to
13
0
83

to
94

11
5

to
13

0
83
to
94

S
4
to
6
4
39

to
46

IS
to
20
108

to
l4S

0
7

to
0

9
S
I

to
6
S

17
to
2
7

12
to
20

2
0
to

2
7

14
to
20

6
to
10
43

to
72

1
6
to
2
2

12
to
16

8
to
9
S8

to
6S

TROUBLE

DIAGNOSES

AND
CORRECTIONS

When

rear
axle
and

suspension
is

suspected
of

being
noisy
it
is

advisable

to
make
a

thorough
test
to
determine

whether
the
noise

originates
in

the

tires

road
surface
exhaust

propeller
shaft

engine
transmission
universal

joint
wheel

bearings
or

suspension

Noise
which

originates
in

other

places
can
not

be
corrected

by
adjust

ment
or

replacement
of

parts
in
the
rear
axle

and
rear

suspension

In
case
of

oil
leak

first
check
if

there
is

any

damage
or

restriction
in

breather

Condition
Probable
cause

Noise
Loose
wheel
nuts

Loose
one
or

more

securing
bolts

Lack
of

lubricating
oil
or

grease

Faulty
shock
absorber

Incorrect

adjustment
of

rear
axle
shaft
end

play

Damaged
or
worn
wheel

bearing

Worn

spline
portion
of
rear
axle
shaft

Broken
leaf

spring

Loose

journal
connections

or
so
no

Wheel
and
tire

unbalance

Damaged
rubber

parts
such
as
leaf

spring

bush
shock
absorber
moun

ting
bush

Faulty
universal

joints

Instability
in

driving
Loose
wheel
nuts

Worn
shock
absorber

Worn

or
broken
leaf

spring

Oil

leakage

Damaged
or

restricted
air

breather

Damaged
oil
seal
in

rear
axle
case
or
differ

ential
carrier

Oil

leakage
from
between
the
differential

carrier

and
axle
case

RA
8
Corrective
action

Tighten
the

wheel
nuts

Tighten
the

bolts
to
the

specified
torque

Lubricate

as

required

Replace
the
shock
absorber

Adjust
the
rear
axle

shaft
end

play

Replace
wheel

bearing

Replace
if

necessary

Replace
leaf

spring

Tighten
to

the

given
torque

Balance
wheel

and
tire

Replace
the

required
parts

Adjust
or

replace

Tighten
to
the

given

torque

Replace
faulty
shock
absorber

Replace
leaf

spring

Clean
or

replace
air

breather

Replace
the

damaged
oil
seal

Tighten
to
the

specified
torque
or

replace

gasket

Fip
BR
2

Adjusting
front
brake

REAR
BRAKE

With
hand
brake

fully
released

adjust
rear
brake
shoe
clearance
For

the
service

procedures
refer
to
Front

Brake

Fig
BR
3
Adjusting
rear
brake

HAND
BRAKE

Parking
brake

I
Raise

vehicle
until
rear
wheels
are

clear
of
the
floor

2

Apply
hand
brake
lever

operate

lock
nuts
to
be
80
to
100

mrn
3
lS
to

3
94
in

in
hand
brake
lever
stroke

and
tighten
lock
nuts

securely

Applying
force
to
hand
brake

lever

20

to
30

kg
44

to
661b
Brake

System

1
t

0
t

6

0

I

o

nJ
c

BA655

Fig
BR
4

Adjusting
lock
nut

3

Fully
release
hand
brake
and

rotate
rear
wheels
No

drag
should
be

present

Notes

a
Before

adjusting
hand
brake
com

plete
the

adjustment
of
rear
brakes

b
After

adjusting
hand
brake

operate

the
brake
lever
to
make
cable

stable

c
Hand
brake
must
be

operated

smoothly
while

being

pulled
and

released
Make
sure

that
no
abnor

mal
noise
dragging
twisting
or

other
faulty
condition
occurs

BLEEDING

HYDRAUL
Ie
SYSTEM

Hydraulic
brake

system
must
be

bled
whenever

any
line
has
been
dis

connected
or
air
has

entered
into

system

When

pedal
action
has
a

spongy

feel
it
is
an
indication
that
air
has

entered
the

system

Bleeding
the

hydraulic
system
is

an

essential

part
of

regular
brake
service

BR
3
I

Clean
all
dirt
around
master

cyl

inder
reservoir

I
remove
cap
and

top
up

reservoir

with
recommended
brake

fluid

2

Thoroughly
clean
mud
and

dust

from
bleeder
valve

so
that
outlet

hole

is

free
from

any
foreign
material

Install
a

bleeder
hose
on
bleeder
valve

Place
the
other
end
of
hose
in

a

container

filled
with
brake
fluid

3

Depress
brake

pedal
two
or
three

times
then

keep
pedal
fully
depressed

4

With
brake

pedal
fully
depressed

open
bleeder
valve
to

expel
air

Notes

a

Pay
attention
to
brake
fluid
level
in

master

cylinder
reservoir

during

bleeding

operation

b
Do
not

reuse
brake
fluid
drained

during
bleeding

operation

c

Bleed
air
as
follows

1
Master

cylinder
front

2
Master

cylinder
rear

3
N
L
S
V

front

4
Front

wheels

S
Rear

wheels
left
one
first

6
N
L

S
V

rear

7
N
L

S
V
center

d
Exercise

care
not
to

splash
brake

fluid
on

exterior
finish
as
it

will

damage
the

paint

5

Close
bleeder
valve

quickly
as

brake

pedal
is
on
down
stroke

6
Allow
brake

pedal
to
return
slow

ly
with
bleeder
screw
closed

7

Repeat
bleeding
operations
until

no
air

bubbles
show
in
hose

Notes

a
Brake
fluid

containing
air
is

white

and

has
visible
air

bubbles

b
Brake
fluid

containing
no
air

nms

out
of
bleeder
valve
in
a

solid

stream
free
of
air

bubbles

8

Repeat
above

steps
on
the

re

maining
brake
lines

to

expel
all
air

2
The
allowable
maximum

out
of

round
of
brake
drum
is
0
02

mm

0

0008
in

Re

condition
or

replace
brake
drum

if

specified
limit
is
exceeded

3

Measure
for

tapered
brake
drum

If

specified
limit
of
0

02
mm
0

0008

in
is

exceeded
as
measured
at

a

position
where
the
distance
of
4S
mm

177
in
is

kept
away
from
inlet

re
condition
or

replace
brake
drum

4

Contact
surface
with
which

linings
come
into

contact
should
be

finished
to

such
an
extent
that
it
is

ground
by
a
No
120
to
150
sand

paper

S

Using
a
drum

racer
finish
brake

drum

by
machining
if
it

shows

any

sign
of
score
marks

partial
wear
or

stepped
wear
on
its
contact
surface

Note
After
brake
drum
is

completely

re
conditioned
or
renewed
check

drum
and
shoes
for

proper
contact

pattern

Brake

assembly

I
When
brake
shoe

linings
are

cracked

incompletely
seated
uneven

Iy
worn

andlor
deteriorated
due
to

excessive

heating
or
soiled
with

oil

grease
and
brake
fluid

replace

2

Replace
linings
if
the
thickness
is

worn
down
to
less
than
1
0
mm
0
039

in

Note

When
brake
shoe

lining
is
in

stalled

grind
brake
shoe

lining
face

to
diameter

equal
to
that
of
brake

drum

lining
dimension

Width
x
Thickness
x

Length

4S
x

4
S
x

244
mm

1
77
x
0

177
x

9
61
in

3

Check

adjuster
for
smooth

oper

ation

4

Replace
shoe
return

springs
which

are
broken
or

fatigued
Brake

System

Standard
dimensions
of
shoe

springs

Free

length
Dia

of

spring
No
of
Installed

Item

lengthlload

mOl

in
mOl
in

coils

mm

kg
in
lb

Upper
136
5

2
0
0

079
37
IS9
S
14

to
16

S

37
6
28
31

to
3S

Lower
134
S

2
3
0
091
35
IS9
5
21

to
23

5
30
6
28
46
to

Sl

After
shoe
83
2

1
4
O
OSS
27
S
99
4

to
S

3
28
3

90
9
to
II

Wheel

cylinder

I

Replace

any
cylinder
or

piston

which
is
scratched
scored
or
worn
on

its

sliding
contact
surface

2

Replace
worn

parts
if

piston
to

cylinder
clearance
is

beyond
O
IS
mm

0
OOS9
in

Wheel

cylinder
inner
diameter

19
0S
mOl

Y
in

3

Replace
piston
cup
which
is

worn

or
otherwise

damaged

4

Replace
if

contacting
face
of

cyl

inder
and
shoe
is
worn

locally
or
in

step

S

Replace

damaged
dust
cover

fatigued
piston
spring
or

faulty

threaded

parts

6

Replace
tube
connector
which
is

worn
on
its

threaded

portion

INSTALLATION

Install
front
brake
in
the

reverse

sequence
of
removal

paying
particular

attention
to
the

following
instructions

I

When

assembling
adjuster
assem

bly

apply
brake

grease
to

adjuster

housing
bore

adjuster
wheel
and
ad

juster
screw

When
installing
adjuster

assembly

to
brake
disc

apply
brake

grease
to

disc

adjuster
and

retaining
spring
slid

ing
surfaces

to
slide

adjuster
smoothly

Measure

adjuster
sliding
resistance

Adjust
by
adjuster
shim
when

sliding

resistance
is

in
rrect

BR
ll
Adjuster
sliding
resistance

S
to

12

kg
II
to
261b

2

When

installing
wheel

cylinder
be

sure
to
secure
the

cylinder
with
R

mark

to
right
hand
disc
and
the
one

with
L
mark
to

left
hand
disc

Otherwise
brake
hoses

may
interfere

with
other

adjacent
parts
As

to
the

connecting
instructions

of
brake
hose

no
twist
or

contact
is
existed
on

brake

hose

referring
the

related

topic
Brake

line

Tightening

torque

Wheel

cylinder

SA
to

6
6

kg
m

39
to
48
ft

lb

Connector
bolt

1
9
to
2
5

kg
m

14
to
18
ft
Ib

Brake
hose

1
7
to
2

0

kg
m

12
to
14
ft
lb

Air
bleeder

0
7

to
0
9

kg
m

5
to
7
ft

Ib

Brake
disc

4
2

to
S
O

kg
m

30

to
36
ft
lb

3

Before
installing
brake
shoe
as

semblies

apply
brake

grease
to
wheel

cylinder
and

adjuster
brake
shoe
in

stalling
grooves
and
brake
disc
and

brake
shoe

assembly
contact
faces

two

places
Exercise

care
not
to

allow

grease
to

come
into
contact
with

linings
and

adjuster