1968 FIAT 500 Brake

CHAPTER 8
FRONT SUSPENSION AND HUBS
8:1
8:2
8:3
8:4
8:5
8:6Description
Front suspension removal and dismantling
Leaf spring
Swinging arms
Kingpin housing
Steering knuckle and wheel hub
8:1 Description
The independent front suspension assembly fitted to
the 'new 500' range comprises a transverse leaf spring
which is anchored to the body through two rubber
mountings and kingpins through 'estendblocks' as
shown in FIG 8:1. The leaf spring also acts as an anti-
roll bar which gives normal spring reaction even when the
front road wheels encounter a rough road surface.
Special polyethylene insulating strips are fitted
between the five springs leaves which are all clamped
together by t w o rubber cushioned clamps.
Upper movement of the kingpins in the swinging arm
is obtained by 'estendblocks'. The half arms are anchored
to the body as shown in FIG 8 : 3 and pivot on their pins
through rubber bushes. Double acting hydraulic shock
absorbers are fitted to the kingpin housings at the lower
end and anchored at the top to the vehicle body. Two
rubber buffers are secured to brackets mounted onto the
body to limit the spring oscillations. The spring centre
bolt is also fitted with a rubber pad.
8 : 2 Front suspension removal and
dismantling
To remove the front suspension assembly proceed as
follows:
F50087
1 Remove the hub caps and carefully slacken the road
wheel retaining bolts. Using a garage hydraulic jack
raise the front of the vehicle and place on firmly
based stands. Remove the road wheels.
2 Disconnect the steering linkages from the pitman arm,
the drag link and the steering knuckle arms.
3 Remove the shock absorber upper mounting nut from
the body, lift away the half rubber bush and push d o w n
the outer cylinder.
4 Blank off the brake fluid reservoir outlet by inserting
a suitable wooden peg through the reservoir filler
opening and disconnect the brake hydraulic lines at
the wheel cylinders.
5 Fit Fiat crossbeam Arr.2072 under the leaf spring
and support this, using a garage hydraulic jack.
6 Remove the self-locking nut securing the leaf spring
to the kingpin housing and ease o u t the spring
mounting bolt taking care not to damage the thread.
Also remove the nuts securing the swinging arm pin
to studs on the body and remove the swinging arm
assembly. Carefully lift out the adjusting shims and
spacers from the studs making a careful note of the
number of the shims and their locations.
7 Remove the nuts securing the leaf spring elastic
mounting to the body (see FIG 8 : 4) , and lower the 8:7
8:8
8:9
8:10
8:11Hydraulic damper
Front suspension assembly and
installation
Steering geometry
Modifications
Fault diagnosis

2 Check that the surface of the pin that is in contact with
the camber and castor adjuster shims does not show
any signs of indentation or roughness which could
affect the accuracy of adjustment on reassembly. If
there are any signs of rust or small markings these
should be smoothed out using a file.
3 Inspect the condition of the half arm bushes, the inner
surface of which must not show signs of seizure and
the clearance of the bush to pin must not be greater
than .01 57 inch. Upon initial assembly the fit clearance
is .00059 to .0059 inch. Ensure t h a t the rubber parts
of the bush are not torn, cracked or show signs of
weakness which, if evident, must be renewed.
4 Use Fiat tool A.66058 or a suitably sized drift for
refitting the rubber bushes into the swinging arms.
Upon reassembly it should be observed that the
tightening of the two swinging arms m o u n t i n g nuts 5
(see FIG 8 : 3) , must be carried out whilst keeping
the axis of the swinging arm and the pin hole for the
screws 7 on the same plane otherwise distortion can
occur.
8 : 5 Kingpin housing
1 To remove and replace the 'estendblocks' use Fiat
tool A.66056 as shown in FIG 8 : 8. Ensure t h a t the
'estendblocks' is not worn and that there are no signs
of seizure on its inner surface, or that the rubber has
hardened. Renew if necessary.
2 Check that the kingpin to bush clearance is not
greater than .0079 inch. The clearance when fitted
new is .00063 to .00213 inch. If the clearance is
excessive the t w o bushes must be renewed and also
the kingpin if excessive wear is evident. To remove and
refit the kingpin bushes use Fiat tool A.66016 and
after reassembly the bushes must be accurately
refaced using a reamer set to a diameter of .5912 to
.5922 inch. If considered necessary use Fiat Fixture
C.1004 to check that the kingpin housing has not been
distorted which, if evident, the housing must be
renewed.
3 Whilst the kingpin assembly is being inspected ensure
that the lubrication hole is free to allow the passage of
oil.
4 To prevent incorrect loading of the 'estendblocks' that
is press fitted into the kingpin housing, the housing
to swinging arm pin nut must be tightened with the
parts so arranged that the angle between the swinging
arm plane and the housing axis is approximately
95 deg. as shown in FIG 8:14.
8:6 Steering knuckle and wheel hub
Dismantling:
1 To remove the wheel hub cap use Fiat puller A.46023
as shown in FIG 8 : 9 .
2 Using a universal t w o leg puller or Fiat puller A.40005
together with items 1 and 9 remove the wheel hub/
drum assembly having first extracted the splitpin and
released the hub retaining nut (see FIG 8:10). Later
models have a staked nut w i t h no splitpin. The nut
should be freed with a punch and discarded.
3 Remove the outer roller bearing, the oil seal and the
inner roller bearing outer race from the drum and pull
out the steering knuckle inner roller bearing inner ring
using Fiat puller A.46000
F500PULLER
A.46023
FIG 8 : 9 Removing right front wheel hub cap by
remover A.46023
UNIVERSAL PULLER A. 40005/
FIG 8:10 Removing left front wheel brake drum by
puller A.40005
4 Release the t w o brake to steering knuckle mounting
nuts and remove the complete brake housing flange.
5 To remove the steering knuckle from the kingpin
housing, remove the 'estendblock' from the kingpin
housing using Fiat drift A.66056 or a suitably sized
drift as shown in FIG 8 : 8.
6 Using a suitably sized punch drive the lockpin from the
kingpin, remove the lower plug and slide off the
kingpin. The steering knuckle is then disengaged
together with the snap ring, two thrust washers and a
shoulder ring.
Inspection:
Thoroughly clean all parts and dry using a compressed
air jet and to inspect proceed as follows:
1 Check that the steering knuckle and steering arm show
91

FIG 8:14 Swing arm setting
car. Ensure t h a t the upper elastic supports on the
studs projecting from the underside of the vehicle
body are correctly located and insert the spring. Fit
the two support lower caps w i t h elastic pads and
screw onto the stud nuts to a torque wrench setting
of 28.9 Ib/ft.
2 Assemble the brake housing flange onto the steering
knuckle and tighten the nuts to a torque wrench
setting of 14.5 Ib/ft.
3 Assemble the roller bearings and seal into the drum
hub. Pack the bearings and fill the recess between the
bearings w i t h Fiat MR3 grease or an equivalent, and
lightly smear the stub axle. Fit the drum assembly over
the stub axle and replace the washer and nut. Note
that from vehcle number 043624 the righthand hub
has a lefthand thread, the nut being identified by a
circular groove on the outside face. On hubs locked
with a splitpin, tighten the nut to 21.7 Ib/ft, back it off
by approximately 60 deg. (one flat) and fit the splitpin.
On the later pattern hub, with no splitpin, fit a new nut
and make sure it screws in freely. Tighten it to 14.5
Ib/ft, while rocking the hub four or five times to make
sure the bearing is properly seated. Undo the nut
completely, then tighten it again to 5.1 Ib/ft. Back it
off 30 deg. (half a flat) and lock it by staking the rim
into the stub axle spline. Hub end play should be
.001 to .0039 inch.
4 Using Fiat tool A.66059 as shown in FIG 8:13,
reassemble the cap to the hub. Also reassemble the
steering knuckle to the kingpin housing replacing
the t w o upper
thrust rings, the snap ring and the
lower packing ring whose thickness has already been
selected as detailed in Section 8:6 to take up any
play between the knuckle and the kingpin housing.
Secure the steering knuckle pin with the cotter.
5 Reconnect the swinging arm to the wheel assembly
using the special nut and bolt. The nut must be
screwed onto the bolt A (see FIG 8:14), by arranging
the parts so that the angle between the arm plane
and the kingpin housing is approximately 95 deg. as
shown in FIG 8:14. Tighten the nut to a torque
wrench setting of 39.8 Ib/ft.
94
Key to Fig 8:15(9° = Kingpin housing castor angle) FIG 8:15 Section through steering knuckle and leaf
spring mounting at kingpin

VERTICAL LINE DB
S
EB
OIL SUMPF
GF
FIG 8:16 Castor, camber angles
6 Insert the swinging arm pin onto the two studs that
are welded to the body sides so as to support the
front suspension and wheel assembly.
7 Reconnect the kingpin housing to the spring eye by
inserting the bolt and tightening the self-locking nut
to a torque wrench setting of 28.9 Ib/ft. It is important
that during this operation the spring is always kept
in the 'set' position by fixture A.66061 so as to
ensure correct assembly and prevent excessive strain
on the 'estendblocks'.
8 Slide off the swinging arm and insert the spacers and
shims S (see FIG 8:16) onto the studs ensuring
that the resulting thickness is the same as was found
during dismantling. Reattach the swinging arm.
Screw on the nuts securing the pin to the body and
tighten to a torque wrench setting of 28.9 Ib/ft.
9 Refit the shock absorber securing it to the kingpin
housing and to the body inserting the plain washer
between the rubber pad and the toothed washer.
10 Carefully remove Fiat fixture A.66061, connect the
steering rods, hydraulic brake pipes and refit wheels.
Remove the wooden plug from the brake fluid tank
inlet opening. Carefully raise the vehicle using a
garage hydraulic jack, remove the axle stands and
lower slowly to the ground.
11 When both left- and righthand suspension units have
been refitted to the vehicle the front end steering
geometry must be checked and adjusted.
8:9 Steering geometry
Checking of the front wheel geometry is necessary
95
F500
if either excessive tyre wear or irregular steering per-
formance is noticed or if the front suspension assembly
has been dismantled for repair. The values for the front
end setting under a normal static load normally con-
sidered to comprise four passengers should be as
follows:
Camber angle — 1 d e g . ± 20'
Castor angle — 9 deg.± 1 deg.
The camber angle shown in FIG 8:14 and the castor
angle shown in FIG 8 : 1 6 adjustments are performed by
inserting shims S (see FIG 8 : 1 6 ) between the swinging
arm pin and the spacers on the studs that are welded to
the body at points D and E (see FIG 8:16). Shims .0197
inch thick are supplied in service to enable the castor and
camber angles to be adjusted.
It is suggested that the castor and camber angles are
checked at the local agents as specialised equipment is
necessary for completion of these checks.
Adjustment of castor angle:
Slacken the t w o nuts securing the swinging arm pin
to the body and proceed as follows:
1 If the castor angle requires to be increased (see FIG
8:16) move the shims S from the rear screw E to the
front screw D.
2 If the castor angle requires to be reduced (see FIG
8:16) move the shims from the front screw D to the
rear screw E.
Adjustment of camber angle:
Slacken the t w o nuts securing the swinging arm pin DE
A
C

to the body and proceed as follows:
1 If the camber angle requires to be increased (see FIG
8:16) add the same number of shims S on both
screws D and E.
2 If the camber angle requires to be reduced (see FIG
8:16) remove the same number of shims from both
screws D and E.
The addition or removal of shims at the t w o points D
and E permits camber adjustment to be made without
any disturbing of the castor angle.
8:10 Modifications
Checking and adjusting castor and camber angles:
When checking the castor and camber angle the
static loading should be such that the distance between
the semi-elliptic spring mountings G (see FIG 8:16)
and the floor level to be approximately 6.81 inches, also a
distance between the lowermost portion of the sump and
the floor level of approximately 6.14 inch for the Model
500D. For the 500 Station Wagon version the distance
between centre rear bracket for jacking-up the vehicle
and the floor level should be approximately 8.90 inches.
All other front wheel alignment specifications are the
same as for the remaining 500 saloon models.
8:11 Fault diagnosis
(a) Wheel bounce
1 Tyre casing faulty
2 Uneven tyre pressures
3 Wheels out of balance
4 Semi-elliptic mounting spring worn5 Weak or seized shock absorber
6 Wheel rim or tyre misaligned
(b) Suspension noise
1 Lack of lubrication
2 Noisy or inoperative shock absorbers
3 Worn or loose wheel bearings
(c) Pull to one side
1 Low or uneven tyre pressures
2 Incorrect front wheel alignment
3 Suspension arms distorted
4 Inoperative shock absorbers
5 Brakes binding
(d) Excessive t y r e wear
1 Incorrect tyre rotation during servicing periods
2 Incorrect camber angle
3 Incorrect toe-in
4 Incorrect tyre inflation
5 Excessive play at wheel bearings
6 Wheel wobble
7 Stiff suspension arms
8 Brakes out of adjustment
(e) Wheel wobble
1 Uneven tyre pressures
2 Loose or worn wheel bearings
3 Inoperative shock absorbers
4 Loose steering knuckle or kingpin housing
5 Incorrect front wheel alignment
6 Control arm rubber bushings, or kingpin housing and
semi-elliptic spring 'estendblock' worn
96

normal straight-ahead position with the spokes
horizontal. Check that the wheels are in the straight-
ahead position.
2 Load the vehicle to static load conditions or with four
average size passengers.
3 Move the vehicle forwards for a distance of approxi-
mately six yards so that the suspension may settle
correctly.
4 The toe-in measurements should be taken at the same
point of the wheel rim. Measure at A (see FIG 9 : 8)
then back up the car to bring points A to the position B
and remeasure. The value obtained at A should be
equal to or greater than B within .0079 inch.
5 As previously described the steering rods are adjust-
able in length. Loosen the clamps and screw in or out
the adjusting sleeves and before tightening the clamp
ensure that the sleeve slot registers w i t h the clamp
joint. With the clamp fully tightened there should
always be a gap between the joint faces.
6 If the steering gear has been re-installed the correct
front wheel toe-in must be set. Then the relay lever pin
nut must be tightened to a torque wrench setting of 78
to 85 Ib/ft.
9 : 8 Fault diagnosis
(a) Front wheel shimmy
1 Incorrect tyre pressure
2 Incorrect front wheel alignment
3 Loose front wheel bearings
4 Wheels out of balance
5 Loose steering linkage connections
6 Loose steering gear or relay lever support at body
mountings
7 Incorrect fitting of steering worm to worm sector
(b) Hard steering
1 Incorrect tyre pressure
2 Incorrect front wheel alignment
3 Incorrect adjustment of steering worm to worm sector
(c) Hard turning when stationary
1 Incorrect tyre pressure
2 Incorrect adjustment of steering worm to worm sector
102
(d) Pull to one side
1 Incorrect tyre pressure
2 Incorrect front wheel alignment
3 Incorrect front wheel bearing adjustment
4 Distorted kingpin housing or swinging arms
5 Unequal brake adjustment
6 Semi-elliptic spring weak or broken
(e) Rattles
1 Loose steering linkage connections
2 Loose steering gear or relay lever support at body
mountings
3 Semi-elliptic spring weak or broken
4 Lack of lubrication
( f ) Loose steering
1 Incorrect front wheel bearing adjustment
2 Loose steering linkage connections
3 Loose steering gear mountings
4 Incorrect adjustment of steering worm to worm sector
(g) Jerky steering
1 Incorrect front wheel alignment
2 Incorrect front wheel bearing adjustment
3 Wheels out of balance
4 Loose steering linkage connections
5 Loose or incorrect fitting of worm to sector
(h) Side-to-side wander
1 Incorrect tyre pressure
2 Incorrect front wheel alignment
3 Loose steering linkage connections
4 Loose steering gear or relay lever support at body
mountings
5 Incorrect fitting of steering worm to worm sector
6 Distorted kingpin housing or swinging arm
7 Semi-elliptic spring weak or broken
(i) Tyre squeal on turns
1 Incorrect tyre pressure
2 Incorrect wheel alignment
3 Distorted kingpin housing or swinging arms

CHAPTER 10
THE BRAKING SYSTEM
10:1 Description
10:2 Maintenance
10:3 Front brakes
10:4 Rear brakes
10:5 Master cylinder
10:6 Wheel cylinder10:7 Self-adjusting device
10:8 Removing a flexible hose
10:9 Brake fluid reservoir
10:10 Bleeding the system
10:11 Hand parking brake
10:12 Fault diagnosis
10:1 Description
All four drum brake units are hydraulically operated by
the brake pedal and the handbrake lever operates the rear
brakes only through a mechanical linkage which normally
requires no separate adjustment (see FIG 10:1).
The brake units are of the internal expanding type with
one leading and one trailing shoe to each brake. A double
ended wheel cylinder expands both shoes into contact
with the drum under hydraulic pressure from the master
cylinder. When the brake pedal pressure is released the
shoes are retracted by means of springs.
The brake pedal is directly coupled to the hydraulic
master cylinder where pressure on the fluid is generated.
This is transmitted to the brakes by a system of metal and
flexible pipes.
The braking units fitted to the new 500 Sedan models
are equipped with a specially designed brake shoe
clearance self-adjustment device which eliminates the
need for manual adjustment of the brake shoe to drum
clearance as is normal practice w i t h a conventional
braking system. Every time the brake pedal is depressed
the self-adjustment device automatically takes up the
excess clearance which may have developed between
the lining and the drum due to normal service wear.
The brake units fitted to the 500 Station wagon model
have a normal brake adjuster which should be used when
F500103 the brake pedal travel becomes excessive. The adjuster
is shown in FIG 10:3.
On later models a dual circuit system is used. It is
described in Section 10:12
10:2 Maintenance
Brake adjustment {Station Wagon)
Jack each wheel in turn after first chocking the remain-
ing three wheels and releasing the handbrake. Depress
the brake pedal so as to force the brake shoes against the
drum and keeping the shoes in this position turn the
adjuster nuts until they contact the shoes and then back
the nuts 20 deg. This will correctly set the shoe to drum
clearance which should be checked for binding by
releasing the brake pedal and ensuring that the road wheel
revolves freely. The operation should then be repeated
on the other wheels. This adjustment will automatically
set the handbrake.
Preventative maintenance:
1 Thoroughly inspect the metal hydraulic fluid lines for
rusting, cracking or flattening and that they are
located away from any sharp edges which could cause
a failure.

FIG 10:1 Diagrammatic view of service and rear wheel parking brake system
Key to Fig 10:1 1 Bleeder connections 2 Brake fluid reservoir 3 Service brake pedal 4 Hand lever, mechanical
parking brake on rear wheels 5 Hand lever travel adjustment stretchers 6 Stop lamps 7 Mechanical brake operating lever,
controlled from lever 4 8 Shoe clearance self-adjusting device 9 Wheel cylinders 10 Master cylinder 11 Stoplight
pressure-operated switch
FIG 10:2 Left front wheel brake assembly (500 Sedan)
SHOE
RETURN
SPRINGSHOE MOUNTING
BRACKET SHOE
RETAINING
PLATE SHOES
DEVICESHOE
SELF-ADJUSTING
WHEEL CYLINDERSHOE RETURNSPRING
2 Check that the hydraulic flexible hoses are not con-
taminated with oil or grease which would destroy the
rubber.
3 Ensure that all pipeline fastening clips are secure
otherwise hydraulic line failure could occur due to
cracking caused by excessive vibration.
104
4 Carefully clean all connections and inspect for
hydraulic fluid leaks. Should any leaks be detected
then the connections should be tightened taking very
great care not to twist the pipes during this operation.
5 Ensure that the hydraulic fluid level in the reservoir is
correctly filled up to the top of the filter using Fiat
special 'Blue Label' brake fluid. Extra care must be
taken to ensure that no fluid is spilled over the body
paintwork, as this acts as a strong solvent.
6 Ensure that the play between the brake pedal pushrod
and the master cylinder plunger is .019 inch. This will
correspond to approximately .098 inch free pedal
travel.
Never use any fluid but the recommended hydraulic
fluid. Do not leave it in unsealed containers as it will
absorb moisture which can be dangerous. It is best to
discard fluid drained from the system or after a bleeding
operation. Observe absolute cleanliness when working
on all parts of the hydraulic system.
10:3 Front brakes
Front brake drum removal:
1 Remove the wheel trims and carefully slacken the road
wheel retaining bolts. Using a garage hydraulic jack
raise the front of the vehicle and place on firmly
based stands. Remove the road wheels.