1969 DATSUN 610 brake

Rear
Axle
Rear

SuspensIon

DESCRIPTION

REAR
AXLE
AND
SUSPENSION
Removal
Saloons

COIL
SPRINGS
Saloons

REAR
SHOCK
ABSORBERS
Saloons

REAR
SUSPENSION
ARM

Saloons

DESCRIPTION

Saloon
models
are
fitted
with

independent
rear

suspension

with
semi

trailing
arms

suspension
arms
coil

springs
and

telescopic
hydraulic
double

acting
shock

absorbers
The
differ

ential

gear
carrier
and

suspension
member
is
mounted

directly

onto

the

body
structure

via
rubber

mountings
See
Fig
H
I

Estate
cars
and
1800
ce
Vans
are
fitted

with
a
semi
floating

rear
axle
with
semi
elliptic
leaf

springs
and

telescopic
hydraulic

shock
absorbers
mounted
on
rubrer
bushes
See

Fig
H
2

REAR
AXLE
AND
SUSPENSION
Removal

Saloon
models

I
Jack

up
the
rear
of
the
vehicle
and

support
it
on
stands

2
Remove
the
road
wheels
disconnect
the
hand
brake

linkage

and
the
return

spring
Fig
H
3

3
Remove
the
exhaust
tail

pipe
and
silencer

4
Disconnect
the
brake
hoses
and
plug
the
openings
to

prevent

the

ingress
of
dirt

5
Remove
the

propeller
shaft

assembly
as
described
in
the

relevant
section
after

marking
the

propeller
rear

flange

and
differential

pinion
flange

6
Jack

up
the

suspension
ann

and
remove

the
shock

absorber

lower

mountings
taking
care
not
to
lose
the
rubber

bushings

7
Place

ajack
under
the
centre
of
the

suspension
member

and
differential

carrier
and
remove

the
nuts

securing
the

suspension
member
to
the

body
7
in

Fig
H
3
Remove

the
differential

mounting
nuts
8

8
Carefully
lower
and
remove
the

suspension
assembly

REAR
SUSPENSION

Inspection

Saloons

Examine
all

parts
for

wear
and

damage
paying
particular

attention
to
the
rubber
bushes

in
the

suspension
arms
and
the

bump
rubbers
Check
the
condition
of
the

spring
rubber
insulators

in
the

suspension
member

and
differential

mounting
memrer

The
rubber
insulators
must
be

replaced
if
the
dimension
A

in

Fig
H
4
is
less

than
5mm
0
2
in
REAR
AXLE
SHAFTS
BEARINGS
AND
SEALS
Saloons

DRNE
SHAFTS

REAR
AXLE
Removal
Estate
cars
and
Vans

REAR
SPRING
Estate
cars
and
Vans

REAR
SHOCK
ABSORBERS
Estate
cars

and
Vans

REAR
SUSPENSION
Installation

Saloons

Installation
is
a
reversal
of
the
removal

procedures
noting

the

following
points

Ensure
that
the
suspension
member
and
differential
mount

ing
member
are

correctly
aligned
as
shown
in

Fig
U
5
and
insert

the
rubber
insulators
from
the
underside
of

the
vehicle

Tighten
the
differential

mounting
member
the

suspension

member
and
lower
shock
absorber
nuts
to

the
specified
tighten

ing
torques

COIL
SPRINGS
Removal

Saloons

Jack

up
the
rear
of
the
vehicle
and

support
it
on
stands

2
Remove
the
road
wheels
and
disconnect
the
handbrake

linkage
and
return

spring

3
Remove
the
drive
shaft
flange
nuts
at
the
wheel
side

Fig

H
6
and
the

bump
rubber

securing
nuts

4
Place

ajack
under
the
suspension
ann
and
remove
the

shock
absorber
from
the
lower

mounting
bracket
Carefully

lower
the

jack
and
remove

the
coil

spring
spring
scat

and

bump
rubber
Fig
H7

COIL
SPRINGS
Installation

Saloons

Oleck
the
coil

springs
for

signs
of
deformation
or
cracks

Test
the

spring
for
its
free

length
and
height
under
load
and

compare
the

figures
obtained
with
the
information
in
Technical

Data
Inspect
all
rubber

parts
and

replace
any
which
are

damaged

or
deformed

Installation
is
a
reversal
of
the
removal

procedure
making

sure
that
the
flat
face
of

the
spring
is
at
the

top

REAR
SHOCK
ABSORBERS
Removal
and
Installation

Saloons

Remove
the
trim
in
the
boot
trunk
and
take
off
the
two

nuts

securing
the

upper
shock
absorber

mounting
See

Fig
H
S

Detach
the
shock
absorber
from
the
lower

mounting
bracket

The
shock
absorber
should
be
tested
and
the

fIgUres
com

pared
with
the

specifications
in
Technical
Data
Cbeck
for
oil

leaks
and
cracks
Make

sure
that
the
shaft

is
straight
and
that
the

rubber
bushes
are
not

damaged
or
defonned
Renew
all
unsatis

75

factory
parts

Installation

is
a

reversal
of
the
removal

procedure

REAR
SUSPENSION

ARM
Removal
and
Installation

Saloon

I
J
ad

up
the
car
at

the
rear
and

support
it
on
stands

2
Remove
the
road
wheel
and
brake
drum
as
described
in

the

section
BRAKES

3
Disconnect

the
drive
shaft
from
the
axle
shaft

4
Disconnect

the
handbrake
cable
from
the

equalizer
bracket

and
the
wheel

cylinder
lever
Disconnect

the
brake
hose

from
the
brake
line

by
removing
the
lock

spring
and
then

withdrawing
through
the
connector

Plug
the
end
of
the

brake

line
to

avoid
loss

of
fluid
and

ingress
of
dirt

5
Remove
the
wheel

bearing
locknut

Fig
H
9
the
rear

axle

shaft

wheel

bearings
and
oil
seal
Remove
the
rear
brake

assembly
from
the

suspension
ann
See
section
BRAKES

6
Jack

up
the

suspension
arm
to

relieve
the
tension
on
the

shock
absorber
and
disconnect
the
shock
absorber
from

the
lower

mounting
Lower
the

jack
gradually
and
remove

the
coil

spring
seat
and

bump
rubber

7
Remove
the
bolts

securing
the

suspension
arm
to

the

suspension
member

Fig
H
IO
and
withdraw
the

suspension

arm

The
rubber
bushes
can

be
drawn
out

of
the

suspension
arm

if

necessary
using
the

special
tool
ST
38280000

Fig
H
Il

O1eck
the

suspension
arm
for
distortion
or

cracks
and

inspect
the
rubber
bushes
for

signs
of
wear
or

damage
Renew

any
part
which

is

unsatisfactory

Installation

is
a

reversal
of
the
removal

procedure
Tighten

all
the

suspension
arm

mounting
bolts
with
the

weight
of

the

vehicle

resting
on
the
rear
wheels
The
self

locking
nuts
must

be
renewed
at
each
overhaul

REAR

AXLE
SHAFTS
BEARINGS
AND
SEALS

Saloon
Removal
and

Dismantling

I
Raise
the
vehicle
at
the

rear
and

place
stands
under
the

body
member

2
Remove

the
road
wheel
and
brake
drum

3
Disconnect
the
drive
shaft
from
the
axle
shaft
and
remove

the
wheel

bearing
locknut
The

special
wrench
ST
38060001

can
be
used
to
hold
the

flange
as

shownin

Fig
H
12

4
Withdraw

the
axle

shaft

assembly
as
shown
in

Fig
H
13

using
the

special
tool
ST
07640000

and
sliding
hammer

ST
36230000
Remove

the
rear
axle
drive

flange

5
Use
a
suitable
drift
or

special
tool
ST
37750000
See

Fig

H
14
to
drive

out
the
inner

bearing
and
oil
seal

F
6
Remove

the

grease
retainer
and
withdraw
the
outer

bearing
with
a
conventional

puller
DO
NOT
re
use
this

outer

bearing

REAR
AXLE
SHAFTS
BEARINGS
AND
SEALS
Saloon

Assembly
and
Installation

Oleck
the
axle
shaft
for

straightness
make
sure
that
it
is

not
cracked
or

damaged
in

any
way
00
NOT
heat
the
shaft

if

attempting
to
re
straighten

Make
sure
that
the

lip
of
the
oil

seal
is
not

damaged
or

distorted
Check
the

bearing
for
excessive

wear
and

damage

Oean
the
wheel

bearings
the
oil
seal

and
the
inside
of
the

axle

housing

When

installing
the
wheel

bearings
the
sealed
side
of
the

outer

bearing
should
face

the
wheel
and
the
sealed

side
of

the

inner

bearing
should
face
the
differential
See

Fig
H
IS

Pressure
must
be

applied
to
the
inner
race
when

fitting

When

replacing
the

suspension
arm
check
that
the
distance

piece
is
0
05
mm
0
002
in
shorter
than
the

length
of
the

housing
dimension
LI
See

Fig
H
16
The
distance

piece
and

axle

housing
code

markings
must
coincide

The
wheel

bearing
grease
must
be

replaced

every
50
000

km
30
000
miles
Pack
the
wheel

bearings
with

grease
at
the

positions
shown
in

Fig
H
IS
and
coat
the

lip
of
the
oil
seal

Renew
the
locknut
and
oil
seal
at

each
overhaul

Wheel

bearing
adjustment

Tighten
the
locknut
to

the

specified
torque
reading
of

25
33

kgm
181
239
lb
ft
and
check
that
the
rear
axle
shaft

end

play
does
not
exceed
0
15
mm
0
006
in
with
a

turning

torque
of
less
than
7

kg
em
6
11b
in
for
the
1400
and
1600cc

models
510

series
or
4
5

kg
em
3
91b
in
for
the
1800cc

610
series

If
the
correct
end

play
or

turning

torque
cannot
be

obtained
it
will
be

necessary
to

change
the
distance

piece
See

above

DRIVE
SHAFTS
Removal
and

Dismantlill8

Disconnect
the
end

flanges
and
remove
the
shaft
See

Fig
H
17
The
drive
shaft
should

only
be
dismantled
to

lubricate
the

splines
This

operation
will

only
be

necessary
every

two

years
or
50
000
km
30
000
miles

Remove
the
universal

joint
spider
at
the
differential
side

Refer
to
the

propeller
shaft
section
Remove
the

snap
ring

securiilg
the
sleeve

yoke
plug
and
take
out

the

plug
Compress

the
drive
shaft
and

remove
the

snap
ring
and

stopper
Fig
H
17

Disconnect
the
boot
and

split
the
shaft
Make
sure
that
the

balls
and

spacers
are
retained

DRIVE
SHAFTS

Inspection
and

Assembly

The
drive
shaft
should
be

replaced
as
an

assembly
if

any

part
is
found
to

be
defective

Check
the
shaft
for

straightness
damage
or
wear
Old

79

the
steel
balls
and
the
sleeve

yoke
for

damage
or
wear
Renew

the
boots
and
the
sleeve

yoke
plug
0

ring
if

necessary
Renew

the
universal

joint
jf

faulty

Check

the

play
in
the
drive
shaft

using
a
dial

gauge
as

shown
in

Fig
H
18
The
measurement
taken
with
the

dri
le

shaft

fully

compressed
should
not

exceed
O
lmm
0
004
in

Renew
the
drive
shaft
as

embly
if
the

specified
value
is
not

obtained

Oean

the
old
grease
from

the
sleeve

yoke
and
the
drive

shaft
ball

grooves
and
lubricate
with
oil

Asse

bly
of

the
drive
shaft

is
a

reversal
of
the

dismantling

procedure
noting
the

following
points

Align
the

yokes
and
make
sure
that

the
steel
balls

and

spacers
are
fitted

in
the
correct
order
Select
a

snap
ring
which

will

adjust
the
axial

play
of

the

universaIjoints
to
within
0
02mm

0
0008
in

Snap
rings
are
available
in

four
thicknesses
of

1
49
1
52
1
55

and
1
58
mm

0
0587
0
0598
0
0610

0
0622
in

Apply
a

generous

quantity
of
multi

purpose
grease
to
the

ball

groove
and
the
area
shown
in

Fig
H
19

REAR
AXLE
Removal
See

Fig
H
2

Estate
car
and
Van

Jack

up
the
vehicle
at
the
rear

and

support
it
on
stands

Remove

the
road

wheels
and
brake

drums
I

3
Disconnect
the
brake
hose
from
the

brake

pipe
Plug
the

end
of
the
hose
to

prevent
the

ingress
of

foreign
matter

4
Disconnect
the
handbrake
rear
cable
from

the
balance

lever

assembly

5
Disconnect

the

propeller
shaft
from
the
differential

flange

Release
the
lower
shock
absorber

self

locking
nuts
and

slide

the

mounting
eyes
of
the
shock
absorber
from
the

rear

spring
seat

pivot

6

Support
the
rear

axle
with

ajack
loosen
the
U
bolts
and

remove
the
nuts
from
the
rear

spring
shackles
Withdraw

the
shackles
from
the

spring
eyes

7
Remove
the
V
bolt
lock
nuts

completely
and
lower
the

jack
to

withdraw
the
rear
axle

assembly

REAR
AXLE

Dismailtling
and

Inspection

Disconnect
the
brake

pipes
from

the
wheel
cylinders
and

remove

the
brake

pipe
and
three

way
connector
Remove
the

cross
rod

clamp
and
the
balance
lever
from
the
rear
axle
case

Remove
both
cross
rod

ends
from
the

wheel

cylinder
lever

assembly

Unscrew
the
oil
drain

plug
and
drain
the
oil
from
the
axle

case
into
a
clean
container
The
oil

may
be
re
used
if
it
is
in

good
condition

Remove
the
nuts

securing
the
brake

backplate
to
the
axle

case
and
draw
out
the
axle
shaft

assembly
with
the

backpl
te

and
grease
catcher
A

sliding
hammer

ST
36230000
should
be

used
for
this

operation
as
shown
in

Fig
H
2Q

The

bearing
collar
can
be
removed
with
a

press
or

by

cutting
with
a
cold
chisel

and
the

bearing
withdrawn
with
the

puller
ST
3712001
as
shown
in

Fig
H
2t
Remove
the
brake

backplate
and
withdraw

the

gear
carrier
from

the
axle
case

Check
the
axle
shafts
for

straightness
wear
and
cracks

00
NOT

attempt
to

straighten
a
bent
shaft

by
heating
Check

the
oil
seal
lips
for

signs
of

damage
or
distortion
Make
sure

that

the

bearing
is
not
worn
or

damaged
REAR
AXLE

Assembly
and
Installation

Assembly
is
a
reversal
of
the

removal

procedure
noting
the

following
points

Thoroughly
clean
all

parts
and
fit
a
new

gasket
between

the
axle
case

and

gear
carrier

Tighten
the
nuts
in
a

diagonal

pattern
and
to

the

specified
torque
readings

Fit

the
grease
catcher

bearing
spacer
bearing
and
new

bearing
collar
onto
the
axle
shaft
A
load
of
4
5
tons
will

be

required
to

press
the

bearing
onto

the
shaft

Insert
the
wheel

bearing
with
the
seal
side

facing
the

wheel
and
ensure
that
the

oil
seal

lips
are
coated
with
wheel

bearing
grease
prior
to

fitting

Check
and

adjust
the
axial

play
between
the
wheel

bearing

and
the
axle

housing
using
a

dial
gauge
as

shown
in

Fig
H
22

The
axial

play
should
be

adjusted
to
within
0
3
0
5mm

0
0118
0
0197
in

on
the
1400
and
1600cc

models
and
to

within
O
lmm
0
0039
in
on

the
1800cc
models

Fill
the
rear
axle
with
the

specified
amount
of

oil
and

bleed
and

adjust
the
brake

system
as
described
in

the

appropriate

section

REAR
SPRING
Removal
and

Inspection

Estate
cars
aud
Vans

The
rear

springs
can
be
removed
in
the
following
manner

Jack

up
the

vehicle
at
the

rear
until
the
wheels
are
clear

of

the

ground
and

place
stands
under
the
rear
frame

Disconnect
the
shock
absorber
from

the

spring
seat

Fig
H
21a
and

support
the
rear
axle

housing
with

ajack

3
Take
off

the
locknuts

and
remove

the
U
bolts
shown

arrowed
in

Fig
H
2t
the

spring
seat
location

plates
and

seat

pads

4
Remove
the
nuts

securing
the
front
bracket
to
the

body

remove
the
bracket
from

the

spring
eye
and
car

body
and

withdraw
the
rear

spring

5
Remove

the

upper
and
lower

rear
shackle
nuts

Fig
H
23

and
remove
the
rear

spring
from
the
vehicle

Clean
the

spring
leaves

thoroughly
and
examine

them
for

fractures
or
cracks
Renew
the

assembly
if

necessary

Check
the
front

pin
shackle
U
boIts
and

spring
seat

for

signs
of
wear
cracks
and

damaged
threads
Renew
the

components
as

required

REAR
SPRING
Installation

Installation
of
the
rear

spring
is
a
reversal
of
the
removal

procedure
noting
the
following

points

The
front
bracket

pin
front
bracket

bushing
shackle

pin

and
shackle

bushing
should
be
coated
with
a

soapy
solution

prior
to

assembly

Tighten
the
front

pin
securing
nut

and
the
shock
absorber

lower

securing
nut
with
the
vehicle

weight
resting
on
the
rear

wheels

Ensure

that
the
flange
of

the
shackle

bushing
is

clamped

evenly
on
both
sides

The

tightening

torque
values
can

be
found

on
the

page

entitled
TIGHTENING

TORQUES

81

Front

SuspensIon

DESCRIPTION

WHEEL
HUBS

WHEEL
BEARINGS

Adjusting

FRONT
AXLE
AND
SUSPENSION
ASSEMBLY

DESCRIPTION

The
front

suspension
is
of
the
strut

type
with
the
coil

spring
and

hydraulic
damper
units
mounted
on
the

suspension

member
and
transverse
link

assembly
See

FigJ
1

Vertical
movement
of
the

suspension
is
controlled

by

the
strut

assembly
the
tension
rod
absorbs
the
forward
and

backward
movement
of
the
transverse
links
whilst
side
move

ment
of

the

body
is
controlled

by
the
stabilizer
rod
which
is

attached
to
the

body
and
transverse
links

WHEEL
HUBS
Removal

1
Jack

up
the
vehicle
remove
the
road
wheel
and
disconnect

the
brake
hose
at
the
strut
outer

casing
bracket
as

described
under
the

previous
heading
Plug
the

opened
end

of

the
hose
to

prevent
loss
of
fluid

2
Remove

the
brake

calliper
assembly
or
the
brake
drum

as
described
in

the
section
BRAKES

3
Remove
the

grease

cap
from
the
hub

by
tapping
lightly
at

the

joint
using
a
screwdriver
and
hammer

4
Withdraw
the
cotter

pin
from
the
wheel

bearing
locknut

and
remove
the
nut
Remove
the
wheel
hub

together
with

the
wheel

bearing
and
washer

Fig
J
2

On
cars
fitted
with
disc
brakes
the
hub
is
removed

complete

with
brake
disc

5
The
wheel

bearing
outer
race
can

be
removed
from

the
hub

using
a
drift
as
shown
in

Fig
I
3

WHEEL
HUBS

Inspection
and
Overhaul

Gean
the
hub

and

bearings
by
washing
in

petrol
Examine

the

grease
seal
and
make
sure
that
it
is
not
worn
or
cracked

renew
the

seal
if

necessary
Ensure
that
the
races
are
not

pitted

or
scored
rotate
them
and
check
for

signs
of
wear
and

play

A
sectional
view
of

the
wheel

bearing
assembly
is

given
in

Fig

14
to

provide
an
indication
of
the

points
to
be
checked

WHEEL
HUB
AND
BEARING
Installation

The
wheel

bearing
outer
race
can
be
refitted
with
a
suitable

drift
or

special
tool

ST
35310000

Fill
the
wheel
hub
and
the
hub

cap
to
the

positions
shown

in

Fig
J
5
with
multi

purpose
grease

Fill
the

spaces
between
the

bearing
rollers
and
the

lip
of

the

grease
seal
with
the
same

type
of

grease
Lightly
smear

the

spindle
shaft
and
threads
the

bearing
washer
and

bearing
lock
SPRING
AND
STRUT
ASSEMBLY

TRANSVERSE
LINK
AND
LOWER
BALL
JOINT

FRONT
WHEEL
ALIGNMENT

ADJUSTING
THE
STEERING
ANGLE

nut

with

grease
and
assemble
the

parts
onto
the
wheel

spindle

Make
sure
that
dirt
and

foreign
matter
does
not
adhere
to

the

greased
surfaces

Adjust
the
wheel

bearings
as
described
under
the

following

heading

WHEEL
BEARINGS

Adjusting

The
wheel

bearings
can
be

adjusted
with
the
road
wheel

the
hub

cap
and
the

bearing
locknut
cotterpin
removed
as

previously
described

Tighten
the
wheel

bearing
locknut
to
a

torque
reading
of

3
0
3
5

kgm
21
7

25
3lb
ft
Turn
the
hub
several
times
in

each
direction
to

settle
the

bearing
and
then
retighten
the

bearing
locknut
to
the

specified

torque
reading

Slacken
the

bearing
locknut
to

an

angle
between
40
to
700

a

ay
from
the

previously
tightened
position
and

align
the
cotter

pin
hole
with

the
hole
in
the
spindle
Turn
the
wheel
hub
a
few

times
in
each
direction
and
then
measure
the

torque
required

to
cause

the
hub
to

turlI
A

spring
balance
should
be
used
as

shown
m

Rig
J

p
make
sure
that
the
brake

pads
are
not

binding

on
the
disc

type
of
brake
unit
and
check
that
the
force

required

to
turn

the
hub
is
within
the
following
fIgures

Wheel

bearing
rotation

starting
torque

1800ce
With
new

bearing
7

0

kg
cm
97
in
oz

1400
1600cc
With
new

bearing
8
0

kg
cm
111
2

in
oz

With
used

bearing
4
0

kg
cm

56
0
in
oz

Starting
torque
at

the
hub
bolt

lWth
new

bearing

ith
used

bearings
1
57

kg
3
46
lb

0
7

kg
1
541b

Adjust
the
locknut

slightly
if
the

fIgures
do
not
conform
and

replace
the

cotterpin

Refit
the
hub
cap
and
the
road
wheel

FRONT
AXLE
AND
SUSPENSION
ASSEMBLY
Removal

Jack

up
the
front
of
the
vehicle
and

place
stands
under

the
ront
side
members

Remove
the
road
wheels
and
the

splash
board

3
Disconnect
the
front
brake
hoses
and
remove
the
brake
hose

locking

springs
Withdraw
the

plates
and
remove
the
hoses

from
the
strut

assembly
Plug
the
ends
of

the
hoses
to

prevent
the
ingress
of
dirt
and
loss
of
fluid

4
Remove

the
cotter

pin
from
the
tie
rod
ball

joint
remove

83

the
castle
nut
and
detach
the
tie
rod
from
the
knuckle
arm

5
Remove
the
tension
rod

securing
nuts

Fig
J
7
remove

the
bolts
and
withdraw
the
tension
rod
Withdraw
the
nut

shown
arrowed
in

FigJ
8
and
remove
the
stabilizer

6

Support
the

engine
with
suitable

lifting
tackle
so
that

the

engine
mounting
bolts
can

be
removed
and
the

suspension

crossmember
detached
from
the

engine
FigJ
9

7
Place

ajack
under
the
crossmember
Remove
the
bolts

indicated
in

Fig
J
IO
and

separate
the
crossmember
from

the

body

8
Remove
the
strut

assembly

upper
attachment
self

locking

nuts
at
both
sides
Fig
J
ll

and
lower

the
front

suspension

assembly
to
remove
it
from
the
vehicle

FRONT
AXLE
AND
SUSPENSION
ASSEMBLY
Installation

Installation
is
a
reversal
of

the
removal

procedure
noting

the

following
points

Make
sure
that
all
rubber

parts
are
free
from
wear
and

deterioration

Any
part
of

the
suspension
assembly
which
has

been

damaged
or
distorted
must
be

replaced
The
front
wheel

alignment
should
be
checked
after

completing
the
installation

a
brief

description
is

given
at
the
end
of
this
section
Camber

and
castor

angles
are

preset
and
cannot
be

adjusted

SPRING
AND
STRUf
ASSEMBLY
Removal
and
Installation

The
strut

assembly
consists
of
the
outer

casing
piston
rod

piston
rod

guide
and
cylinder
etc
An

exploded
view
of
the

components
is

given
in

Fig
J
12

The
inner

components
must

be
replaced
as
a

complete

assembly
Replacement
and
overhaul

procedures
for

the
inner

components
together
with
the
removal
of
the
front

springs

should

only
be
carried
out

by
a
specialist
Datsun

workshop

The
strut

assembly
can
be
removed

prior
to

dismantling
by

following
the

procedures
outlined
below

Jack

up
the
front
of
the
vehicle
and

support
it
on
stands

2
Disconnect
the
brake
hose
from
the
strut

assembly
bracket

as

previously
described
under
the

heading
FRONT
AXLE

and
SUSPENSION
ASSEMBLY
Removal

3
Remove
the
stabilizer
bar
and
tension
rod
from
the
trans

verse
links
Loosen
and
remove

the
knuckle
arm

fixing

bolts

Fig
J
9
And

separate
the

strut
assembly
from
the

ball

joints

4
Remove
the
strut

assembly

upper
attachment
self

locking

nuts

Fig
J
11
and
withdraw
the
strut

assembly
from

the

body
Fig
J
13

Installation
is
a
reversal
of
the
removal

procedure
Ensure

that
the
bolts
are

tightened
to

the
specified
torque
readings

given
under
TIGHTENING

TORQUES
SPRING
AND
STRUT
ASSEMBLY

Dismantling
and

Assembly

Care
must
be
taken
when

dismantling
the
assembly
to

ensure

that
aU

parts
are
maintained
in
a
clean
condition

Clamp
the

suspension
strut

assembly
in
a
vice
and
fit
the

special
attachment
ST
2770000
I
to
the
lower
end
of
the
strut

Prise
off
the
dust
cover

snap
ring
Use
the
coil

spring
compressor

ST
35650001
to

slightly

compress
the

spring
Remove
the
self

locking
nut
and
take
off
the
mounting
insulator
thrust
bearing

spring
seat
and

bump
rubber
Slacken
the

spring
compressor
and

remove

the

spring
Push
down
the
shock
absorber

piston
until
it

bottoms
and
remove

the

gland
packing
with
the

special
tool

ST
35500001

Fig
J
14
Remove
the
O

ring
from
the

piston

rod

guide
and
lift
out

the
piston
rod
and

cy
linder

assembly

00
NOT

separate
the

piston
and

cylinder
which
are
serviced

as
a

complete
assembly
Drain
all
fluid
from
the

suspension
unit

and
shock
absorber

assembly
Wash
all

parts
thoroughly
not

rubber

parts
in

petrol
or
a
suitable
solvent

The

gland
packing
and
0

ring
must
be
renewed
at

each

overhaul

Always
refill
with
the
correct

grade
of
fresh
oil
in

accordance
with
the
information
in
the
table
below

ATSUGI
KAYABA

Part
No

54302
UO
100

UOl10
325
cc
332
cc

54302
3
U0500
1

54302
N
1200
325
cc
300
cc

The
oil

quantity
is
extremely
critical
as
it
will
affect

the

damping

power
of
the
shock
absorber

To
assemble
fit
the
rubber
O

ring
on
the

top
of
the

piston

rod
and
refit
the

gland
packing
Take
care
that
the
oil
seal
does

not
become

damaged
during
the
latter

operation
Lift
the

piston

rod

up
by

approximately
90
mm
3
5
in
before

tightening
the

gland
packing
to
facilitate

bleeding
then

tighten
the
packing

to
a

torque
reading
of
7
13

kgm
51
94Jb
ft
Bleed
the

shock
absorber
by
pumping
the

piston
rod

up
and
down
until

the

pressure
is
the
same

in
both
directions

Position
the
coil

spring
bump
rubber

spring
seat
and
dust

cover
on
the

top
of
the

piston
rod
The

piston
rod
must
be
in

the

fully
extended

position
Compress
the

spring
fit
the
strut

mounting
insulator
and

bearing
assembly
Tighten
the
self

locking
nut
to
a

torque
reading
of

6
7
5

kgm
43
541b
ft

SPRING
AND
STRUT
ASSEMBLY
Installation

Installation
is
a
reversal
of

the
removal

procedure

Thoroughly
grease
the

parts
marked
in

Fig
J
15
Tighten
the

fixing
bolts
to
the

torque
readings
given
in
TIGHfENING

TORQUES

TRANSVERSE
LINK
AND
LOWER
BALL
JOINT
Removal

The
transverse
link
with
rubber

bushing
is
connected
to

the

suspension
crosSlTIember

by
a

mounting
bolt
as
shown
in

Fig
J
11
and
to

the
strut

assembly
via
the
lower
ball

joint

87

inter
G

@lfi

r

OIl

ll

V
V

1
Re
rvoir

azp

2

Resovoir
tank

3

condDry
piston
rrtrun

rprins

4
Secondary
pitton

5

Primary
piston
tum

spring

6

Primary
piston

7
uvd

gau

Fl
L
I
Tandem
master

cylinder
level

gauge

on
SSS
models

only
Fig
L
2
Section

through
the

single
master

cylinder

I

Independent
axle
Rigid
axle

Fig
L
3

Layout
of
brake
lines
with
tandem

master

cylinder

A
Ji

I
I

f

tf

A1

r

Fig
L
4
Section

through
the
brake

warning

light
switch

Fl
L
5
View
of
the
front
drum

brake

98

BrakIng

System

DESCRIPTION

MASTER
CYLINDER
Removal

dismantling
and
Overhaul

BRAKE
LINES

Replacing

BRAKE
WARNING
LIGHT
SWITCH

FRONT
DRUM
BRAKE
Removal

inspection
and
Overhaul

REAR
DRUM
BRAKE
Removal

inspection
and
Overhaul

FRONT
DRUM
BRAKE

Adjusting

DESCRIPTION

The
vehicle
is
fitted
with
either
disc

brakes
or
two

leading

shoe

type
drum
brakes
for
the
front
wheels
and

leading
trailing

shoe

type
drum
brakes
for

the
rear

wheels

All
brakes
are

hydraulically
operated
from
the
brake

pedal

with
the
rear
brakes

additionally
operated

by
a
mechanical

handbrake
and

linkage
system
Either
a

single
or
a
tandem

master

cylinder
can
be
fitted
The
tandem
master

cylinder

provides
a
dual

braking
circuit
in
which
the
front
and
rear

brakes
are

separately
supplied
If
ODe
circuit
fails
the
other

circuit
will

still

operate
and
provide
a
reduced
but
efficient

braking
action

The
brake

pipes
are

double
wall
steel
tubes
and
are

galvanized
at
the
sections
beneath
the
vehicle
floor
to

prevent

corrosion

MASTER

CYLINDER
Removal

Either
a

tandem
or

single
master

cylinder
can

be
fitted

to

the
vehicle

Fig
L
I
shows
a
cross
sectional
view

through
the

tandem
master

cylinder
and

Fig
L
2
a
cross

sectional
view

through
the

single
master

cylinder
The
removal
and

dismantling

procedures
are

similar
for
both

types
and
are

carried
out
in

the

following
manner

1
Remove
the
clevis

pin
and

separate
the
brake

pedal
from

the
master

cylinder
push
rod

2
Disconnect
the

brake
tubes
from

the
master

cylinder

3
Remove

the
master

cylinder
mounting
bolts
withdraw

the
shims
and
take
out
the
master

cylinder
assembly

MASfER
CYLINDER

Dismantling
and
Overhaul

Drain
the
brake
fluid
from
the

cylinder
and
remove
the

stopper
bolt
Remove
the

dust
cover

the

snap
ring
the

stopper

ring
and
the

pusbrod
assembly

Take

out
the
primary

piston
and

secondary
piston

assemblies
and
the

piston
spring

Remove
the
valve

cap
and
take
out
the
valve

assembly

Oean
all
the

components
with
brake

fluid
and
check

them

for
wear
or

damage
Make
sure
that
the

cylinder
bore
and

piston
are
not

damaged
or

unevenly
worn

The
clearance

between

cylinder
and

piston
must
not
exceed
0
15mm
0
006

in
REAR
DRUM
BRAKE

Adjusting

FRONT
DISC
BRAKE
Friction

pads

FRONT
DISC
BRAKE
Removal
and

Dismantling

FRONT
DISC
BRAKE

Assembly
and
Installation

HANDBRAKE
Removal
and
Installation

BLEEDING
THE
HYDRAULIC
SYSTEM

BRAKE
PEDAL
ADJUSTMENT

Check
the
return

springs
for

damage
or
loss

of
tension

Replace
any
part
which

is
in
an

unsatisfactory
condition

MASfER
CYLINDER

Assembly
and
Installation

Assembly
of
the
master

cylinder
is
a
reversal
of
the

dismantling
procedure
noting
the

following
points

Wet
the

cylinder
bore
and

piston
etc

with
brake
fluid

before

assembling
Care
must
be
taken
to

prevent
dust
and

foreign
matter

entering
the

cylinder
and
reservoir
Ensure
that

cups
and
soals
are
not

damaged
when

locating
them

After
the
master

cylinder
is
reinstalled
the

system
must

be
bled
and
the

pedal
height
adjusted
as
described
under
the

appropriate
headings

BRAKE
LINES

Replacing

The

layout
of
the
metal
brake

pipes
and
flexible

hoses
is

shown
in

Fig
L
3

The
brake

pipes
can

be
removed

by
taking
off
the
flare

nuts
at
both
ends
of
the

pipe
and

removing
the

clips
securing

the

pipe
to

the

body
Similarly
the
brake
hoses
can
be
removed

by
taking
off
the
flare
nuts

Thoroughly
clean
the

pipe
or
hose
after

removing
from

the
vehicle
and
check
for

collapsing
cracking
or

rusting
of

the

pipe
and
for

signs
of

expansion
and

weakening
of
the
hose

Any
pipe
or
hose
which
is
not
in
a

satisfactory
condition
must

be
renewed
Remove

any
dust
from
the
brake

clip
and
replace

the

clip
if
the

vinyl
coating
is
torn

Installation
is
a
reversal
of
the
removal

procedure
Make

sure
that
the
brake

pipes
cannot
vibrate

against
any
part
of

the
vehicle
and
the
brake
hoses
are
not
twisted
and

rubbing

against
the

tyres
or

suspension
units
If
the
brake
hose
is

disconnected
from

the
three
way
connector
on

the
rear
axle

housing
it
will
be

necessary
to
fit
a
new

copper
sealing
washer

Do
not

overtighten
the
installation
flare
nuts

the
correct

tightening
torques
are
as
follows

Three

way
connector
master

cylinder
and
brake
hoses

1
5
1
8

kgm
II
13Ib
ft

Fill
the
master

cylinder
with
recommended
fluid
and
bleed

the

system
as
described
under
the

appropriate
heading
Make

sure
that
fluid
is
not

leaking
from

any

part
of
the

system
by

fully
depressing
the
brake

pedal
for
several
seconds
Check
the

pipes
and
connections
and

replace

any
defective

part

99

inter
Il
IT
Q

riA

I

I

II

l

11
L
6
Removing
the
wbeel

cylindeIli

1
Brd
be

2
Wllul

cylinder
bolts

J
BridI
pip

I

g
L
8
Front
drum
brake
lubricating

positions

Fig
L
9
Removing
the
rear
wheel

cylinder

1
BnrIce

pip

2
Handblllke
cable

J
CIMJ

pin

4
Lnu

5
DustCI1ft
1
Fig
L
7
Front
drum
brake

components
J

T
Broke
rim

Return

Print

J
rhoe
cmembly

4
Front
wM
1

cylinder

5
Rear
wMtl

cylindu

6
A
iT
bleed
W

o

1

Fig
L
I0
Rear
drum
brake

components

1

BllIke
ckp
tzrc

2
RthUn

spring

3

Brate

ad
JlSkr

4
Front
brake
h

5

Anti
rottk

pin

6
Lever

7
Wheel

cylinder
8
Return
sprins

9
Air

bleed
JCrew

10

Lockp
orc

11

Lockp
tzrc

12

Lockplizte

13
Dust
cover

14

Rt
t1T
brake
dr
oe

Fig
L
II
View
of
the
rear
drum
brake

I
Broke
3Iwe

adjuJter

2
BraJ
e
shot

3
Retum

4
A
ntHuttle

pin

100
11
L
12
The
front
brake
shoe

adjusting

cams