1967 FIAT 500 rear suspension

sections of the air conveyor securing with seven
screws, seven toothed washers and five nuts.
22 Slide the fuel pump control rod into its seating,
assemble the insulator between oil wetted graphite
gaskets and fit the pump to the crankcase using nuts
and toothed washers.
23 Fit the air conveyor cover complete with the accelera-
tor control relay lever and rod. Secure using eight
mounting screws, eight toothed washers, eight plain
washers and eight nuts. Fit the fuel line retaining clip
which is secured by one of the air conveyor upper
screws. Install the generator and fan drive pulley
having first placed four adjusting rings between the
pulley halves and the thrust ring on the outside.
Secure the pulley to generator shaft using three
screws and three toothed washers. Fit the generator
fan drive belt.
24 Refit the carburetter having first positioned the
bakelite heat shield between the t w o oil moistened
graphite gaskets. Secure the carburetter using t w o
copper washers and t w o self-locking nuts. Fit the
exhaust silencer and secure to the exhaust manifolds
with nuts and spring washers. Place the t w o graphite
gaskets between the manifold joints. Fit both exhaust
silencer upper mounting brackets and secure them
on the top side to the brackets already in place w i t h
nuts and toothed washers on the bottom side w i t h
screws and toothed washers.
25 Carefully position the distributor at a 10 deg advance
setting and secure w i t h a
nut, plain washer and
spring washer. Fit the fuel pump to carburetter line
complete w i t h mounting bracket rubber lining and
secure the line with two clamps. If difficulty is
experienced in positioning the fuel line into the pump
or carburetter funnels it is suggested that the line
ends should be heated in hot water and thoroughly
dried before installing.
26 Install the air cleaner elbow and rubber hose assembly
on the top of the carburetter using a graphite gasket
in between and secure w i t h nuts, plain washers and
spring washers. Carefully position the air cleaner, line
and hose assembly and connect it to the elbow.
Secure the cleaner to air conveyor cover using screws
and toothed washers.
27 Fit the spark plug cables complete with the rubber
grommet for cable mounting bracket on engine
cowling and connect the cables to the distributor
and spark plugs. Fit the oil pressure gauge sender
unit together w i t h its sealing washer.
28 Install the cylinder head cover and oil breather pipe
assembly w i t h a cork gasket inserted between.
Secure w i t h self-locking nuts and fibre washers.
Connect the accelerator control relay lever rod to the
carburetter and secure with the clip.
29 Fill the oil pan with the correct grade and quantity of
oil, insert the dipstick and the engine is ready for
refitting.
1:18 Engine assembly (station wagon)
Reassembly of this engine is straightforward as it is
the reverse procedure to dismantling. It is recommended
that Sections 1 :5 and 1 :17 are studied as the assembly
technique is similar for both the horizontal and vertical
F50031 cylinder engines. The following points should however
be noted:
1 Refer to FIG 1 :45 for the correct positioning of the
connecting rod-piston assembly on the 120.000
engine.
2 The sequence of tightening the cylinder head nuts is
different, the new order being given in FIG 1 :46.
Key to Fig 1 :47 1 Suspension arm 2 Screw,
rubber pad to bracket 3 Bracket-to-engine nut
4 Nut, arm to bracket 5 Arm bracket 6 Spring
7 Arm pin-to-support nut 8 Screws, pin to support
9 Pin arm to supportFIG 1 :47 Power plant rear suspension FIG 1:46 Cylinder head stud nut tightening sequence.
500 D. F and L Sedan and Station Wagon

FIG 5:10 Clutch throw-out mechanism
Key to Fig 5:10 1 Clutch throw-out yoke
2 Yoke return spring 3 Rod nut and counternut
4 Adjustable rod 5 Clutch throw-out
onto this shaft the outer operating lever is attached by
means of a key.
A return spring connected to the outer operating lever
is anchored onto the gearbox casing. When the clutch is in
its normal position the spring keeps the central thrust
carbon ring away from the withdrawal levers carrier ring.
The carbon ring is pressed against the carrier ring by the
throw-out ring which is connected to the forked lever as
shown in FIG 5 : 8 .
The clutch pedal must have free travel of 1"3/8 to 1"9/16 inch.
Should any adjustment be necessary release the locknut
from the adjustable tie rod and adjust the position of the
tie rod until the correct adjustment is obtained. Tighten the
locknut.
500F. L and later station wagon:
The free travel of the clutch pedal should be 19/32 to
1"3/16 inch which corresponds to a clearance of .059 inch
between the throw-out sleeve and the ring (see FIG 5 : 7).
Should any correction be necessary release the adjust-
able rod locknut (see FIG 5:10), and reposition the
adjustable rod using the rod nut until the recommended
clutch pedal travel is obtained. Retighten the locknut.
5 : 8 Fault diagnosis
(a) Drag or spin
1 Oil or grease on driven plate lining
64
(g) Driven plate fracture
1 Check 2 and 3 in (a)
2 Drag and distortion due to hanging gearbox in plate hub (f) Tick or knock
1 Worn first motion shaft spigot or bearings
2 Badly worn splines in driven plate hub
3 Release plate out of line
4 Faulty Bendix drive on starter motor
5 Loose flywheel
(e) Rattle
1 Check 3 in (c)
2 Worn release mechanism
3 Excessive backlash in transmission
4 Wear in transmission bearings
5 Release bearing loose on fork (d) Judder
1 Check 1, 2 and 3 in (a)
2 Pressure plate not parallel with flywheel face
3 Contact area of driven plate linings not evenly distribu-
ted
4 Bent first-motion shaft
5 Buckled driven plate
6 Faulty power unit mountings
7 Worn suspension mountings
8 Weak rear springs
9 Loose drive shafts (c) Slip
1 Check 1, 2 and 3 in (a)
2 Check 2 in (b)
3 Weak pressure springs or diaphragm spring (b) Fierceness or snatch
1 Check 1, 2 and 3 in (a)
2 Worn clutch linings 2 Misalignment between engine and gearbox first motion
shaft
3 Driven plate hub binding on first motion shaft splines
4 Binding of first motion shaft spigot bearing
5 Distorted clutch plate
6 Warped or damaged pressure plate or clutch cover
7 Broken driven plate linings
8 Dirt or foreign matter in clutch

CHAPTER 7
REAR SUSPENSION AND WHEELS
7:1
7:2
7:3
7:4Description
Removal of rear suspension assembly
Servicing swinging arms
Coil springs
7:1 Description
The rear wheels are independently sprung by means of
coil springs and V-shaped swinging arms acting on coil
springs and telescopic double acting hydraulic shock
absorbers. The swinging arms are m o u n t e d at their inner
ends on 'estendblocks', the coil spring is fitted at the outer
end of the swinging arm. At the wheel end of the suspen-
sion arm is attached a steel pressing to which the brake
backplate and wheel bearing housing are bolted so
forming a swinging unit to which is attached the road
wheel.
The inner pivots are so located vertical wheel move-
ments do not influence the drive shaft length which
means that there is no need to fit a splined joint at the
wheel end. Two taper roller bearings which are separated
by a specially designed collapsible spacer are located in
the rear wheel bearing housing and this carries the axle
shaft. The outer end of the axle shaft is flanged and it
is to this flange that the brake drum is bolted. The splined
inner end carries a rubber cushioned coupling to which
the drive shaft flange is attached.
7 : 2 Removal of rear suspension assembly
1 Jack-up the vehicle and place on firmly based stands.
Remove the road wheel on the side from which the
suspension unit is to be removed.
F50079 7:5
7:6
7:7
7:8Installation of rear suspension assembly
Checking and adjusting rear wheel toe-in
Modifications
Fault diagnosis
2 Using a garage hydraulic jack support the swinging
arm to facilitate the removal of the upper shock
absorber mounting nut which is located inside the
vehicle on the floor. To gain access to the nut remove
the rear wheel housing linings.
3 Unhook the parking brake shoe control lever return
spring.
4 Remove the three screws securing the drive shaft
flange to the flexible coupling. Pull back the sleeve and
remove the inner spring.
5 Remove the brake fluid reservoir cap, remove the filter
and plug the delivery hole in the brake f l u i d reservoir
and disconnect the flexible brake pipe from the
bracket on the body floor.
6 Disconnect the parking brake control tie rod by first
removing the cotter pin and removing the cable eye
from the pin on the shoe control lever. Release the
cable adjustment nuts and free the cable from the
fairlead on the swinging arm.
7 Using the hydraulic jack carefully lower the swinging
arm, fully retract the shock absorber by pushing in the
outer cylinder and carefully pull out the coil spring
together with its mounting rubber rings.
8 Remove the self-locking nut securing the swinging
arm to the internal support welded on the floor.
Extract the mounting pin and note the number and
arrangement of shims between the bushings and the
bracket. This will facilitate reassembly.

FIG 7 : 1 Rear suspension assembly
Key to Fig 7 : 1 1 Brake shoe control cable and sheath 2 Coil spring 3 Oil boot 4 Axle shaft 5 Bumper
6 Flexible joint 7 Swinging arm 8 Cable adjusting nut 9 Swinging arm-to-front bracket mounting pin
10 Swinging arm front bracket-to-underbody mounting screw 11 Engine front support crossmember 12 Swinging arm
rear self-locking nut 13 Shock absorber-to-swinging arm lower nut 14 Sleeve screws 15 Axle shaft-to-flexible joint sleeve
9 Remove the three swinging external support fixing
bolts securing the outer suspension arm bracket to the
vehicle floor and remove the rear suspension assembly.
Remove the special rubber pad located between the
support bracket and the vehicle floor.
7 : 3 Servicing swing arms
Dismantling:
1 Remove the cotter pin and release the nut fixing the
flexible joint to the wheel shaft. Remove the plain
washer and the joint.
2 Using Fiat tool A.40005.1.9 or a universal two-leg
puller, remove the wheel shaft and brake drum.
Extract the t w o oil seals and both the outer and inner
bearing inner rings, thrust ring of the joint and the
resilient spacer.
3 Using Fiat tool A.6511, remove the t w o bearing outer
rings.
4 Disconnect the brake hydraulic line at the wheel
cylinder and remove the swinging external support.
The bearing housing and brake housing flange may
then be removed.
Inspection :
Thoroughly clean all the parts and install the swinging
arm on Fiat fixture A.66064 as shown in FIG 7 : 4. If the
80
swinging arm has not been distorted its installation on the
fixture should be straightforward. Tighten the clamp
screws 1 (see FIG 7 : 3) on the road wheel brake drum,
connect the swinging arm inner member to the seating
2 on the fixture and finally fit the swinging arm external
support holes on the fixture pins 3. Should difficulty be
experienced in either one of these three operations then
this is an indication that the swinging arm is distorted and
should be straightened or a new assembly fitted. If this
check is satisfactory proceed as follows:
1 Check that the 'estendblocks' are a snug fit in their
respective seatings in the swinging arm and that the
mounting pin slides in freely w it h ou t excessive play.
To renew the 'estendblocks' use Fiat tool A.66056
which is suitable for both their removal and installation.
2 Check that the inner and outer bearing outer rings have
no play in their seatings and that the rollers and cages
are not broken, cracked, show signs of overheating
or are worn.
3 Ensure t h a t the o i l seals f i t snugly on the wheel shaft,
also on the joint spacer or shoulder ring and on the
hub seats. If the oil seals should show any signs of wear
then these should be renewed.
4 Inspect the resilient spacer for signs of hair line cracks,
which if not evident the spacer may be used again as
it is not permanently distorted during assembly.
Should, however, new bearings or bearing housings
be fitted it is considered good practice to fit a new
spacer.

FIG 7 :2 Right rear suspension assembly, sectioned through brake drum and arm mountings
5 Check the mating surface of the bearing inner rings on
the wheel shaft and ensure that it is perfectly smooth.
Also check that the shaft splines to flexible joint
splines are not distorted or show signs of excess wear.
The maximum permissible wear backlash is .0059 inch.
6 Ensure that the f l e xible joint is not damaged where the
rubber is bonded to the metal. If signs of strain are
indicated a new joint must be fitted.
F50081
Reassembly:
Reassembly of the swinging arm unit is the reverse
procedure to dismantling. The following points should
be noted:
1 Always use Fiat tool A.66056 to install 'estendblock'
on the swing arm.
2 The mounting nuts for the bearing housing to the
brake housing flange should always be tightened to a

FIG 7 : 3 Fixture A.66064, for swinging arm inspection
and adjustment
Key to Fig 7 : 3 1 Clamp screws, securing wheel shaft on
fixture 2 Alignment bracket, swinging arm member check-up
3 Nut, to secure swinging arm external support on fixture stud
4 Swinging arm external support centring pins
AB C
D
FIG 7 : 4 Adjusting right rear suspension swinging arm
on fixture A.66064
Key to Fig 7 : 4 A and B Swinging arm external support
adjustment shims C and D Swinging arm internal support
adjustment shims
torque wrench setting of 43.4 Ib/ft.
3 During assembly the bearings must be packed w i t h
Fiat MR grease, taking care not to overpack as this
can result in early bearing failure.
82
4 If the axle shaft to flexible joint tie sleeve has been
removed, the mating splines must be coated w i t h Fiat
B2G grease on re-installation.
5 Preload the wheel bearings and adjust the swinging
arm as described later on in this section.
Wheel bearing adjustment:
To ensure a long bearing life due to correct initial
adjustment the ballbearings should be preloaded and to
do this proceed as follows:
1 Tighten the wheel shaft nut gradually so that the
rotation torque does not exceed .36 Ib/ft.
2 To check the rotation torque install Fiat tool A.95697/2
on the wheel drum and insert the shank 2 (see FIG
7:5) of dynomometer A.95697 in the support and
securely hold the lever 3. Move the needle 5 to register
.36 Ib/ft on the dynomometer scale as shown in FIG
7:5 and using the operating lever 6 rotate the dyno-
mometer and the wheel shaft some turns in a clockwise
direction. During rotation check that the needle 5 does
not exceed the setting index 4. Should the rotation
torque prove to exceed .36 Ib/ft, this will indicate a
4
3
1
6
5 2
FIG 7 : 5 Bearing rotation torque dynamometer
KeytoFig7:5 1 Dynamometer A.95697 2 Dynamometer
shank to insert in item A.95697/2, fitted to wheel drum
3 Dynamometer grip lever 4 Rotation torque setting index
5 Adjustable needle 6 Dynamometer operating lever
Oil Sump Wheel Plane
HALF TRACK
FIG 7 : 6 Position of rear suspension and of vehicle for
rear wheel toe-in inspection and adjustment
Key to Fig 7:6 ~ 168 mm = 6.61 inch
567,5 ±1,5= 22.342 inch ± .059 inch

high bearing preload. To reset remove the wheel shaft
and fit a new resilient spacer. Repeat the rotation
torque test.
Swinging arm adjustment:
To adjust the swinging arm use Fiat fixture A.66064 as
shown in FIG 7 : 3 and proceed as follows:
1 At points A and B as indicated in FIG 7 : 4 between the
'estendblock' and the swinging arm to body front
mounting bracket fit three shims on each side. To
ensure that the shims are correctly centred use Fiat
alignment bar A.66057.
2 Whilst removing the alignment bar, carefully slip in the
mounting pin and screw on the nut. Once the rear
wheel geometry adjustment has been completed this
nut should be tightened to a torque wrench setting
of 43.4 to 50.6 Ib ft.
3 At points C and D (see FIG 7 : 4) , insert the number of
shims required to fill in the gap between the 'estend-
block' and the two fixture shoulders. Having deter-
mined the number of shims required both at locations
C and D, these must later be fitted between the
'estendblock' and the shoulders on the swinging arm
to body mounting bracket.
7 : 4 Coil springs
The coil springs should be thoroughly cleaned and all
traces of rust removed. Inspect the spring coils for hair
line cracks, which if evident, a new pair of springs must
be fitted to ensure correct vehicle height and stability.
Check the free
height and the height under loading of
the coil springs and these must correspond to the figures
quoted in Technical Data.
7:5 Installation of rear suspension assembly
To replace the rear suspension assembly proceed as
follows:
1 Insert the swinging arm inner end in the mounting
bracket which is welded onto the body floor. Place
between the 'estendblock' and bracket the number of
adjustment shims as previously determined using Fiat
fixture A.66064 as shown in FIG 7 : 4. Insert the Fiat
alignment bar A.66057 through 'estendblock' and
shims, aligning them with the holes in the mounting
bracket. Firmly hold the entire assembly using a garage
hydraulic jack if necessary, and carefully remove the
alignment bar and at the same time ease in t h e
mounting pin. Secure the nut which once the rear
wheels geometry has been checked must be tightened
to a torque wrench setting of 43.4 to 50.6 Ib/ft.
2 Screw in finger tight the three swinging arm external
bracket to body floor mounting screws together w i t h
the plain and spring washers. The screws will have to
be tightened to a torque wrench setting of 28.9 to
36.2 Ib/ft once the rear wheel geometry has been
adjusted.
3 Carefully insert the coil spring, lower insulator ring
onto the swinging arm, insert the spring on the shock
absorber which should be previously secured to the
arm and position the spring onto its seat on the arm.
Place the upper insulator ring onto the spring, raise the
suspension assembly using a garage hydraulic jack and
insert the spring onto its seating under the body floor.
F50083 4 Ensure that the shock absorber to floor rubber ring has
been correctly fitted and extend the shock absorber
until its upper mounting pin protrudes into the vehicle
through the hump in the floor panel. Secure the shock
absorber by its mounting nut and lockwasher having
first inserted the rubber ring and plain washer.
5 Refit the rear wheel housing in place, reconnect the
brake line to the connection on body floor and remove
the plug from the output hole in the brake fluid
reservoir. Bleed the hydraulic brake system as
described in Chapter 10.
Key to Fig 7:8 k Distance of centre rear bracket, for
jacking up the vehicle, from floor level (8.90 inch)
Half-track = 22.264 inch ±.059 inch
FIG 7 : 8 Position of rear suspension f o r rear wheel
toe-in inspection and adjustment ('500 Station Wagon') FIG 7 : 7 Adjusting rear wheel toe-in angle
Key to Fig 7 : 7 Rear wheel plane must be perpendicular to
ground and parallel to car longitudinal centerline with a
tolerance of 0° 10'
To adjust rear wheel geometry, move suitably the swinging arm
outer support. Slight movements are permitted by the play
existing between the support holes A and the mounting screws.
Screws B must be tightened to 28.9 to 36.2 Ibft (4000 to 5000
kg mm). Nuts C must be tightened to 43.4 to 50.6 Ib ft (6000
to 7000 kgmm), after adjustment has been carried out. (These
directions and specifications are also applicable to 500 Station
Wagon).

FIG 7:9 Adjusting rear wheel toe-in on '500 StationWagon'
FIG 7:10 Checking left rear wheel toe-in
84
6 Insert the inner spring between the axle shaft and the
wheel shaft and couple the spline sleeve to the joint
and tighten the screws to a torque wrench setting of
20.3 Ib/ft.
7 Reconnect the parking brake tie rod and adjust the
position of the cable using the two stretchers.
8 Refit the wheels and draw up the mounting screws to
a torque wrench setting of 32.5 to 39.8 Ib/ft. Carefully
lower the vehicle to the floor.
7 :6 Checking and adjusting rear wheel toe-in
This check should be carried out by a Fiat agent as
special setting equipment is necessary. However, details
of this check are given for reference purposes:
To check and adjust the rear wheel geometry proceed
as follows:
1 Place the vehicle on firmly based stands and remove
the front and rear wheels.
2 Install Fiat fixtures A.66062 as shown in FIG 7:12 to
enable correct spring compression and wheel location
in the vertical position.
3 Lift the rear suspensions by compressing the coil
springs and shock absorbers using garage hydraulic
jacks. Screw on the fixture lower shank until the
index registers with the mark 'Nuova 500' stamped on
the bracket. In this position the wheel plane is vertical
and the centre O (see FIG 7 : 6) of wheel shaft results
at 5.00 inch from the buffer stop bracket.
4 Secure Fiat support C.696/3 to the wheel drum and
connect gauge C.696 to the support. Tighten the two
clamping screws as shown in FIG 7:12.
5 Apply at the front of Fiat gauge C.696 bracket
numbered C.696/3 as shown in FIG 7:11.
6 Check that the pin mounted on the front end of the
bracket C.696/3 is in touch with the front suspension
swinging arm pin (see FIG 7:11). If these conditions
are not complied with, proceed with item 7.
Wheel toe-in angle
will vary by 0° 10' under
a movement of some 7/32 inch measured at 72.476 inch
from wheel centre for Model 500D, and at 76.413 inch
from wheel centre for 500 Station Wagon NOTE - - that the toe-in angle
Key to Fig 7 : 9 A Front support B Screw holes for
fixing support to underbody C Swinging arm pin nuts