bolt pattern DATSUN PICK-UP 1977 Service Manual

Speci
ol

Cylinder
Head
Bolt

Wren
h

8110120000

Tightening
torque

1st
turn

4

0

kg
m
29

ft
lb

2nd
turn

6
0

kg
m
43
ft
lb

3rd
turn

6
5

to
8
5

kg
m

47
to
61
ft
lb

B
O

A

A

B

A

A
B
O

B
O

R
O

EM
176

Fig
EM
I02

Cylinder
head
boll

Notes

a
Be
sure
to

tighten
two
small
bolts

b
After

engine
has
been

operated
for

several
minutes

retighten
if
neces

sary

23
Install
oil

pump
and
distr
butor

driving

spindle
in

front
cover

Tightening
torque

1
1
to
1
5

kg
m

8
0

to
10
8
ft
lb

Notes

a
Assemble
oil

pump
and
drive

spin

die
aligning
driving

spindle
face

with
oil

pump
hole

b
Install
oil

pump
together
with

drive

spindle
so
that
the

projection
on
its

top
is
located
at
the
II
25
a
m

position
At
this

point
the
smaller

bow
shape
will
be

facing
toward
the

front

c
Do
not

forget
to
install

gas
et
Engine
Mechanical

I

Fig
EM

I04

11l6lalling
oil

pump

24
Install
fuel

pump
water
inlet

elbow
and
front

engine
slinger
in

their

positions

Fuel

pump
tightening
torque

1
2

to
1
8

kg
m

8
7

to
13

0
ft
lb

Note
Do
not

forget
to
install
fuel

pump
spacer
and

packing
between

spacer
and
block

spacer
and

fuel

pump

25
Install
oil
strainer
oil

pan
gasket

and
oil

pan

27

Install
rocker
cover
to

cylinder

head

Note
Make

sure
that
one
of
the

rocker
cover
bolts
is

longer
than
the

others
It
secures
F
I
C
D
assist

bracket

28
Install
air

pump
bracket
and

cooler

compressor
to

cylinder
block

EM
25
Tightening
torque

Oil
strainer

bolts

0

8
to
I
l

kg
m
5

8
to
8
0
ft

lb

Oil

pan
bolts

0
6
to
0
9

kg
m
4
3

to
6
5
ft

lb

Notes

a

Apply
sealant
to
the

step
portions

at

four

mating
surfaces

as
shown

in

Figure
EM
80

b

Oil

pan
should
be

tigh
tened
in

criss
cross

pattern
to
a
final

torque

of
0
6
to
0

9

kg
m
4
3
to
6
5
ft
lb

26

Adjust
valve
clearance
to
the

specified
dimensions

Special
tool

Pivot

Adj
iier
STl064000l

Tightening
torque

5

0
to
6
0

kg
m

36
to
43
ft
lb

Fig
EM
I05

Adjusting
valve
clearance

b
After

engine
has
been
assembled

run
it
for
at
least
several
minutes

and

finally
adjust
clearance
to
the

warm

specifications

29

Install
intake
manifold
to

ex

haust
manifold
The
intake
manifold

face
which
comes
into
contact
with

gasket
should
be
even
with
that
of

exhaust
manifold
Note
that
two
dif

ferent

sizes
of

attaching
bolts
are
used

Tightening
torque

2
5

kg
m

18
0
ft

lb

PROPELLER
SHAFT
DIFFERENTIAL
CARRIER

REMOVAL

I
Jack

up
rear
of
vehicle
and

sup

port
it

by
placing
a

safety
stand
under

rear
axle
case
Drain

gear
oil

2
Remove

propeller
shaft
and
rear

axle
shafts
These
works
can
be
done

by
referring
to
Rear
Axle
and
Rear

Suspension

3
Loosen
off
bolts

securing
differ

ential
carrier
to
rear
axle
cas
and

take
out
differential
carrier

assembly

PRE
DISASSEMBLY

INSPECTION

Differential
carrier

should
be
in

spected
before

any

parts
are
removed

from
it

These

inspections
are

helpful
to

fmd
the

cause
of
a

problem
and

to

determine
the
corrections

needed

I

Mount
differential
carrier
on
Dif

ferential
Attachment
ST063
I
0000

ST063
10000

Fig
PD
7

Holding
differential
can
ier

2

Visually
inspect
parts
for
wear
or

damage

3

Rotate

gears
to
see
if
there
is

any

roughness
which
would
indicate
dam

aged
bearings
or

chipped
gears
Check

the

gear
teeth
for

scoring
or

signs
of

abnormal
wear

Measure

preload
of

drive

pinion
See

Figure
PD
19

4

Set

up
a
dial
indicator
and
check

the
backlash
at
several

points
around

ring
gear
Backlash
should
be
0
15

to

0
20
mOl
0
00S9
to
0
0079
in

S
Check
the

gear
tooth
contact

with
a
mixture
of
ferric
oxide
and

g
ar
oil
to
all

ring
gear
teeth

For
the
tooth
contact

pattern
see

paragraph
dealing
with
tooth
contact

pattern
adjustment
DISASSEMBLY

I
Put
match

tpark
on
side

bearing

caps
and
carrier
and

remove
side

bearing
caps
and
take
out

differential

case
assembly

P0203

Fig
PD

B
Removing
differenlwl

case
assem

bly

Note
Care

should
be

taken
not
to

confuse
the
left
and

right
hand

bearing

caps
and

bearing
outer
race

so
that

reassembly
will
be

easily

carried
out
with
the
same
parts
in

the

original
position

2
Remove

drive

pinion
nut

using

Drive
Pinion

Flange
Wrench

ST31530000
and

pull
off

companion

flange
using
a
standard

puller

Fig
PD
9

Removing
drive

pinion

nul

3

Extract
drive

pinion
assembly
to

the
rearwards

by
tapping
the
front
end

with
a
soft
hammer
Drive

pinion
can

be
taken
out

together
with
rear
bear

ing
nner
race

bearing
spacer
and

washer

4
Remove
oil
seal
and
take
out

front

bearing
inner
race

Note
Oil
seal
must
not
be
used

PD
7
5

Hold
rear

bearing
inner

race
with

Drive

Pinion
Rear

Bearing
Inner

Race

Puller
ST30031000
and
extract
from

drive

pinion
with
a

press

STJ0031000

PD205

Fig
PD
10

Removing
pinion
rear

bearing
inner
race

6
To

remove
outer
races
of
both

front
and
rear

bearing
apply
a

brass

drift
to

race
side
surface
and
with

draw

them

by
tapping
the

top
of
drift

with
a
hammer

Fig
PD
l1
Removing

pinion
front
and

rear

bearing
outer
races

Dissssembly
of
dHferentIeI

case

1
When

replacing
side

bearing
use

Differential
Side
Bearing
Puller
Set

ST3306S00
I

set
of
ST330S100
I

and

ST33061000

Fig
PD
12

Removing
ide

bearing

PROPElli

ER
SHAfT
DIFFERENTIAL
G

ARRIERf

Notes

a
PUller
should
be
handled
with

care

in

catchins
the

edge
of

bearing

inner

race

b
Be
careful

not
to

confuse
left
and

right
hand

parts

2
Remove

ring

gear
by
spreading

out
lock

strap
and

loosening
ring
gear

bolts
in

diagonally

3

Punch
off

pinion
mate

shaft
lock

pin
from

ring

gear
side

using
Solid

Punch
ICV31100300

KV31100300

PD022

Fig
PD

13

Removing
lock

pin

Note

Lock

pin
i
cauIked
at

pin
hole

mouth
on
differential
case

Do
not

punch
it
off

forCibly
without

checkins
how
it
is
uIked

4

Draw

out

pinion
shaft
and

re

move
thrust

block

pinion
mates
side

gears
and

thrust
washers

Note
Put
marks

on

gear
and
thrust

Wasliersotliat

they
can
be
reinstaD

ed
in

their

original
positions
from

which

they
were
removed

INSPECTION

Thoroughly
clean

all
disassembled

parts
and
examine

them
to
see
if

they

8re

worn

damaged
or
otherwise

faulty
and

how

they
are
affected

Repair
or

replace
ail

faulty

parts

whichever
is

necessaiy

I

Check

gear
teeth
for

scoring

cracking
and

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
replace
as
a
set

2

Check

pinion
shaft
and

pinic
m

mate
for
scores

and

signs
of
wear
and

replace
as

required

Follow

the
same

procedure
for

side

gear
and
their
seats

on
differential

case

3

Inspect
all

bearing
races
and

rollers
for

scoring
chipping
or
evi

dence
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

oil

their
efficiency
as
an
incorrect

bearing
operation
may
result
in
noises

and

gear
seizure

4

Inspect
thrust

washer
faces

Small

faults
can

be
corrected
with

sand

paper
If

pinion
mate

to
ide

gear

backlash
or

the
clearance

between

side

gear
and
thrust
washer
exceeds

limits
0

02

to
0
08
nun
0
0008
to

0
0031
in

replace
thrust
washers

S

Inspect
carrier

and
differential

case
for
cracks

or
distortion

If
either

condition
is

evident

replace

faulty

parts

6
As

a

general
rule

oil
seal
should

be

replaced
at
each

disassembly

ASSEMBLY

AND

ADjUSTMENT

Assembly
can
be

done
in

the

reo

verse

order
of

disassembly
The
foDow

ing
directions
for

adjustment
and

usage
of

special
tools
enable
to

obtain

a

perfect
differential

operation

PRECAUTIONS
IN

REASSEMBLY

I

Arrange
shims
w

shers
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

PD
8
ASSEMBLY
OF

DIFFERENTIAL
CASE

I

Assemble

pinion
mates
side

gears
thrust
block
and

thrust
washers

in
differential

case

2
Fit

pinion
shaft
to
differential

case
so

that
it

meets
lock

pin
holes

3

Adjust

pinion
mate

to
ide

gear

backlash
or
the
clearance

between
the

rear
face
of

side

gear
and
thrust

washer
to
0
02
to

0
08
mOl
0
0008

to
0

0031
in

by

selecting
side

gear

thrust
washer

Side

gear
thrust

WlISber

Thickness

nun

in

Over

0
7S

to
0
80

0
029S
to
0
03IS

Over

0
80
to
O
8S
Om

IS
to
0
033S

Over

0
8S
to
0
90
0

033S
to
0
03S4

Over

0
90
to
0
9S
0
03S4

to
0
0374

4

Lock

pinion
shaft
lock

pin
using
a

punch
after
it

is
secured
into

place

S

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
washers

Torque
bolts
to

specification
and

bend

up
lock

strap

Tightening

torque

7
0
to
8
0

kg
m

S1to
Sifft
Ib

Notes

ao
Use

only
genuine
ring
gear
bolts

and
new
lock

strap

b

Tighten
bolts
in

criss
cross
fashion

lighdy
tapping
fOund
bolt

heac
Js

with
a
hammer

7

When

replacing
side

bearing

measure

bearing
width

using
a

stand

ard

gauge
20
00
nun
0
7874
in

thickness
and
a

weight
block
2
5

kg

S
S
Ib

prior
to
installation
See

Figure
PD

I4

Standard
bearing
width

20
00
nun
0
7874
in

PROPELLER
SHAFT

DIFFERENTIAL
CARRIER

Ex
2

N

O
68mm
H
3
D

I

S
2

T

N
H
0

S
x

0
01

2
18

0
68
3

1
2

x
Om
2
18

0

68
3
1

2
x
0

01

2
18

0
68
2
x

0
01
2
18

0
68
0
02
N8

0
68

0
02
2

18

i
88

mm

The
correct

washer
is
2
88

mm

thick

Ex
3

N
0

70mm
H
O
0

0

S
O

T

N

H
0
S
x
0
01

2
18

0

70
0
0
0
x

0
01

2

18

0
70
0
x

0
01
2
18

0
70

0
2
18

0
70
2
18

2
88

mm

The

correct
washer
is
2
88

mm

thick

Note
If
lues

signifying
H
D

and
S

are
not

given

regard
them
as
zero

and
n
C

r
e
After

assembly

check
to
see
that

tooth
contact

is

correct
If
not

readjust
For
the

tooth
contact

pattern
see

page

PJ
12
for
Contact
Pattern
Drive

pinion
adjusting
washer

Thickness
mm
in

2
58
0

1016

2
61
0

1028

2

64
0
1039

2

67
0
1051

2
70
0
1063

2
73
0
107S

2
76
0
1087

2
79
0

1098

2
82
0
1110

2
85
OJ
122

2
88
OJ
134

2
91
0
1146

2

94
0
1IS8

2
97
0
1169

3
00

0
1181

3
03
0
1
193

3
06
0
1205

3
09
0
1217

3
12
0
1228

3
IS
0
1240

3
18
0
I2S2

S
Fit

determined
drive

pinion
ad

justing
washer
in
drive

pinion
and

preSs
fit

rear

bearing
inner

race
in
it

using
Base

ST30901000

ADJUSTMENT
OF
DRIVE

PINIONPI
IELOAD

AdjUst
the

preload
of
drive

pinion

with

spacer
and
washer
between
front

and
rear

bearing
inner

races

This

procedure
has

nothing
to
do

with
thickness

of
drive

pinion

adjust

ing
washer

This

adjustment
must
be
carried

out
without

oil
seal
inserted

I

Lubricate

pinion
front
and

rear

bearings
Install
drive

pinion
in

gear

carrier

Be
sure
that

spacer
t
washer

front

bearing
inner

race

Companion

flange
and
flat
washer
are
fitted

on

pinion
Tighten
nut
to

specified
torque

and
confum

preload

Tightening
torque

14
0
to
17
0

kg
m

101
to
123
ft

lb

PD
l0
Note

Replace

bearing
washer
and

spacer
with

thicker
ones
if

pinion

cannot
be
turned

by
hand
while
it

is

heing
tightened

2

Measure
pinion
bearing

prelo
d

using
Preload

Gauge
ST3I
27S000
and

select
washer
and

spacer
that
will

provide

required

preload

Preload

without
oil
seal

10
0

to
13
0

kg
cm

8
7

to
II
in

lb

At

companion

flange
bolt
hole

2
9

to

3
7

kg

6
4
to8

2Ib

Note
Preload
of
old

bearing
is
the

same
value

as
that
of

a
new

bearing

Fig
PD
19

Measuring
pinion
preload

Pinion

bearing
adjusting
spacer

Length
mOl
in

S4
50

2
14S7

S4
80
2
IS7S

SS
IO
2
1693

5S
40
2
1811

SS
70
2
1929

S6
00
2
2047

PROPELLER
SHAFT
DIFFERENTIAL
CARRIER

Drive

pinion
bearing
adjusting
washer

Thickness
mm

in

over
3
80

to
3
82
0

1496
to
O
lS04

over
3
82

to
3
84
O
lS04

to
0
ISI2

over
3
84
to
3
86
O
lSI2

to
0
IS20

over
3
86
to
3
88

O
lS20
to
O
IS28

over

3
88
to
3
90
O
lS28
to
0
IS3S

over
3
90
to

3
92
0
IS3S
to
O
IS43

over
3

92
to

3
94
0
IS43
to
O
lSS
I

over
3

94
to
3
96
O
lSSI
to
O
lS59

over
3

96
to
3
98
O
lSS9

to
0
IS67

over
3
98

to
4

00
O
lS67
to
O
lS7S

over

4
00
to
4
02
0
S7S
to

O
lS83

over

4
02
to
4
04
O
lS83
to
0
IS91

over

4
04
to
4
06
O
lS9I
to
0
IS98

over

4
06
to
4
08
O
lS98
to
0
1606

over
4

08
to
4
10
0
1606
to

0
1614

3
Check
and

adjust
tooth
contact

pattern
when

former

adjustment
of

bearing

preload
is

completed
Unless

anything
wrong
is

found
remove
drive

pinion
nut
and

companion
flange
and

press
n
oil
seal
into

gear
carrier

using
Oil
Seal

Fitting
Tool

KV38I02SS0

Apply
grease
cavity
be

tween
seal

lips

4

Again
install

companion
flange

and
washer
and

tighteh
nut
to

speci

fied

torque
14
0

to
17
0

kg

m
IO
to

123
ft
lb

S
Measure

preload
again

Preload
with
oil
seal

I
1

0
to
14

0

kg
cm

9
S

to
12
in
lb

At

companion
flange
bolt
hole

3
1
to
4
0

kg

6
8
to
8
81b

ADJUSTMENT
OF
SIDE

BEARING
SHIMS

I
If

hypoid
gear
set
carrier
dif

ferential
case
or
side

bearing
has
been

replaced
with
new
one

adjust
the
side

bearing
preload
with

adjusting
shim

The

required
thickness
of

adjusting

shim
can
be
calculated

by
the
follow

ing
formulas
T
A

C
D
H

xO
OI

O
l7S
E

T2
B
D
H
xO
OI

O
ISO
F

Where

T

1
Required
thickness
of
left
side

bearing
adjusting
shim
mm

T

2
Required
thickness
of

right
side

bearing

adjusting
shim
mm

A

Figure
marked

on
the

left
side

bearing
housing
of

gear
carrier

B

Figure
marked
on
the

right
side

bearing
of

gear
carrier

C
0

Figure
marked
on
the
differ

entia
case

E
F
These

are
differences
in
width

of
left
or

right
side

bearing
against

the
standard
width
20
00
mOl

mOl

If

bearing
width
is
19
89
the

differ

ence
will
be
as
follows

20
00
19
89
0
11

H

Figure
marked
on
the

ring

gear

See

Figures
PD

20
and
PD
2
I

Figures
for
A

B
C
0
and
H

are

dimensional
varia
tions
in
a
unit

of

1

100
mm

against
each
standard

meas

urement

f
@
a

rj

71

Markj
Mark
B

Mark
C
0

P0214

Fig
PD
20
Thickn
of
shim
on
l

ft

and

righ
t
sides

Fig
PD
21
Variation
number
on

ring
gear

PD
ll
Examples
of
calculation

Ex
I

A
I

B
2
C
2
0

3

E
0
11
mm
F

O
IS
mm

H
2

Left
side

T
A

C
0
H
x

0
01

O
liS

E

1
2
3

1
x

0
01

0
17S
0
11

1
2
3

2
x

O
O

O
l7S
0
11

4

x
0
01
0
175
0
11

0
04
0
1
7S

0
11

0
32S
mOl

The
correct
shims
are
as
follows

Thickness

0
07

0
20
Quantity

x
2
0

14

x
I
0

20

Total
thickness
0
34
mOl

Right
side

T2
B

0
H
x

0
01

O
lSO
F

2
3
2
x

0
01

O
ISO
0
15

2

3
2
x
0

01

O
ISO
0
15

3
x
O
OI
O
ISO
O
IS

0

03
O
lSO
O
lS

0
27
mm

The
correct
shims
are
0
07

plus

0
20
mm
thick

PROPELLER

SHAFf
DIFFERENTIAL

CARR
IER

Ex

2

A

0
B
3

C
I

0

0

E
0

20
mOl
F

0
17
mOl

H
2

Left
side

T

I
A
C

D
H
x
om

0

17S
E

0
I

0
2
x
0
01

0
I7S

0
20

0
I
0
2

x
0

01

0
17S
0
20

3

Om
0
17S

0
20

0
03
0
17S
0
20

O

34S
mrn

The
correct

shinjs

are
O

OS

plus

0
10

plus
0
20
mrn
thick

Right
side

T2
B
D
H

xO
0l

O
ISO
F

3
0
2
x

om

O
ISO

0
17

3

0

2
x

om

0
150
0
17

S
x
0
01

0
ISO
0
I7

O
OS

0
1S0
0
17

0
37

mrn

The

correct
shims
are
0
07

plus

0
1
0

plus
0

20
mm
thick

Note
If

w1ues

signifying
A

B
C
0

and

H
are
not

given
regard
them

as

zero
and

compute

Aft
assembly
check
to

see
that

preload
and
backlash

are
correct
If

not

readjust

Side

bearing

adjusting
shim

Thickness
mm
in

O
OS
0
0020

0
07
0
0028

0
1

0
0
0039

0
20
0
0079

0
50
0
0197
2

Fit
determined

side

bearing

adjusting
shim
on
differential
case
and

press
fit
left

and

right
side

bearing

inner

races
on
it

using
Side

Bearing

Drift
ST33230000
and

Adapter

ST33061000

3

Install
differential

case

assembly

into

gear
carrie

tapping
with
a
rubber

mallet

4

Align
mark

on

bearing
cap
with

that
on

gear
carrier

and
install

bearing

cap
on
carrier
And

tight
n
bolts
to

specified
torque

Tightening

torque

4
0
to
S
O

kg
m

29
to
36
fHb

S

Measure

ring

gear
to
drive

pinion

backlash

If
backlash
is
too

small
remove

shims
from
left
side
and

add
them
to

right
side
To
reduce

backlash
remove

shims
from

right
side
and

add
them
to

left

side

Backlash

O
1S
to
0
20

mrn

0
00S9
to
0
0079
in

Fig
PD

22

Mccuuring
back1aah

6
At

the
same
time

check

side

bearing
preload

Bearing
preload

should

read
12

0
to
20
0

kg
cm
10
to

17

in
lb
of

rotating
torque
3
S

to

S
8

kg
7
7

to
12
8

Ib
at

ring

gear
bolt

hole

PD
12
If

preload
does

not
accord
with

this

specification
adjust
it

with
side
bear

ing
shims

7

Check
and

adjust
the
tooth

con

tact

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
ferric

oxide

and

gear
oil

to

produce
a
contact

pattern

3
Rotate

pinion
through
several

revolutions
in

the
forward

and
reverse

directions
until

a
defmite
contact

pat

tern
is

developed
on

ring

gear

4
When

contact

pattern
is

incor

rect

readjust
thickness
of

adjusting

washer

S

Incorrect
contact

pattern
of

teeth
can
be

adjusted
in
the

following

manner

a
Heel
contact

To
correct
increase
thickness
of

pinion
height

adjusting
washer

in
order

to

bring
drive

pinio
close
to

ring

gear

P0193

Fig
PD
23
Hul

contact

b
Toe
contact

To

correct
reduce
thickness
of

pinion
height

adjusting
washer
in
order

to
make

drive

pinion

go
away
from

ring

gear

P0194
1

Fig
PD
24
To
contact

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