Page 145 of 513

BRAKE
Brake
pedal
height
I
Fl
I
Jl
BRAKE
MASTER
CYllN
ADJU
SHI
1
I
195mm
001971011
THICKNESSIO
8
mm
00315
Inl
116mm
00630In
TOP
LAMP
SWrTCH
r
b
O
ZOlTlI
I
A
12
n
Y
1
O
09
ttr
i
l
Fig
BR
52
Brake
pedal
adjustment
1
Loosen
the
stopper
up
to
such
extent
that
the
brake
pedal
stopper
is
separated
from
the
pedal
arm
2
Measure
height
of
the
brake
pedal
head
from
the
dash
panel
and
adjust
the
adjusting
shim
between
the
brake
master
cylinder
and
dash
panel
so
that
height
is
143
5
mm
5
65
in
Adjusting
shim
thickness
for
selection
0
5
mm
0
0197
in
0
8
mm
0
0315
in
1
6
mm
0
0630
in
Note
When
adjusting
be
sure
to
use
adjusting
shims
having
same
thickness
for
upper
and
lower
brake
master
cylinder
installation
bolts
3
Upon
completion
of
adjusting
shim
adjustment
tighten
the
stopper
down
to
such
an
extent
that
height
of
the
pedal
head
is
141
5
t2
mm
5
57
to
0787
in
and
tighten
the
lock
nut
securely
4
Free
travel
of
the
brake
pedal
is
5
to
15
mm
0
197
to
0
591
in
and
the
stroke
is
120
mm
4
72
in
Hand
brake
Turn
the
turn
buckle
properly
and
adjust
hand
brake
lever
operating
stroke
correctly
so
that
operating
stroke
is
78
5
mm
3
091
in
6
notches
at
operating
force
of
11
to
15
kg
24
3
to
33
1
1b
Upon
completion
of
adjustment
be
sure
to
tighten
the
lock
nut
I
I
Rear
cable
2
Turn
buckle
3
Lock
nut
1451
Front
cable
Propeller
shaft
Fig
BR
53
Adjusting
turn
buckle
BR
21
Page 146 of 513

CHASSIS
2
Upon
completion
of
the
adjustment
release
the
hand
brake
lever
and
make
sure
that
the
rear
wheels
are
not
braked
Normal
stroke
78
5
mm
3
091
in
6
notches
Limited
stroke
136
0
mm
5
35
in
10
notches
The
term
Stroke
means
height
from
the
standard
position
220
mm
8
7
in
above
the
hand
brake
lever
fulcrum
Note
Readjust
hand
brake
stroke
when
it
reaches
the
limited
stroke
136
mm
5
35
inl
10
notches
Bleeding
hydraulic
system
Bleeding
the
hydraulic
brake
system
deserves
much
attention
as
it
is
an
essential
factor
for
regular
service
brake
operation
As
a
matter
of
fact
during
the
brake
service
air
is
likely
to
creep
into
the
circuit
with
the
result
that
the
fluid
action
is
altered
and
the
brake
pedal
becomes
spongy
at
the
travel
end
Bleeding
should
be
carried
out
at
first
with
the
masler
cylinder
then
from
the
longest
line
from
the
master
cylinder
and
then
finish
up
with
the
shortest
Note
Always
clear
away
any
dirt
around
master
cylinder
reservoir
cover
before
removing
cover
for
any
reason
Never
depress
pedal
while
brake
drums
are
removed
unless
bleeder
valve
is
open
Top
up
the
reservoir
master
cylinder
with
fluid
of
the
recommended
type
2
Thoroughly
wipe
the
bleeder
screw
and
from
any
mud
or
dust
present
so
that
the
outlet
hole
is
free
from
foreign
matter
3
Attach
a
vinyl
hose
to
the
wheel
cylinder
bleeder
screw
Dip
the
end
of
the
vinyl
hose
in
a
jar
con
taining
some
brake
fluid
BR
22
I
I
I
Air
bleeder
I
2
I
Vinyl
hose
Fig
BR
54
Connecting
vinyl
hose
to
air
bleeder
rear
4
Depress
the
brake
pedal
two
to
three
times
and
keep
the
pedal
fully
depressed
5
With
the
brake
pedal
fully
depressed
loosen
the
bleeder
screw
exhaust
air
and
retighten
the
bleeder
screw
quickly
6
Return
the
brake
pedal
slowly
7
Repeat
the
operations
4
through
6
above
Air
will
no
longer
come
out
from
the
bleeder
screw
but
brake
fluid
comes
out
When
air
still
exists
in
brake
fluid
it
appears
white
due
to
air
bubble
8
Conduct
air
bleeding
on
other
wheel
cylinders
in
the
same
manner
Note
a
Check
the
reservoir
for
fluid
level
during
bleed
ing
operation
b
Fluid
withdrawn
in
the
bleeding
operation
should
not
be
used
again
for
refilling
c
When
the
master
cylinder
is
disassembled
or
replaced
conduct
air
bleeding
on
the
wheel
cyl
inder
which
is
located
most
near
the
master
cylinder
d
Ordinarily
air
bleeding
is
performed
in
the
following
sequence
Rear
left
Rear
right
Front
left
Front
right
e
Do
not
retum
the
brake
pedal
before
re
tightening
the
bleeder
screw
Page 147 of 513

BRAKE
SERVICE
DATA
AND
SPECIFICATIONS
Brake
pedal
Pedal
free
height
Full
stroke
of
pedal
head
Master
cylinder
mm
in
mm
in
141
5
t2
5
57
to
0787
120
4
72
17
5
11
16
Inner
diameter
of
master
cylinder
mm
in
Allowable
maximum
clearance
between
cylinder
and
piston
mm
in
Wheel
cylinder
Inner
diameter
of
wheel
cylinder
Front
drum
disc
Rear
front
disc
Allowable
maximum
clearance
between
cylinder
and
piston
Brake
drum
and
rotor
disc
Drum
brake
inner
diameter
Rotor
disc
outer
diameter
Rotor
thickness
Drum
inside
out
of
roundness
Max
allowable
drum
inner
diameter
Run
out
of
the
rotor
Max
allowable
rotor
thickness
Lining
dimensions
Front
drum
brake
Lining
width
x
thickness
x
length
Total
braking
area
0
13
0
0051
mm
in
mm
in
mm
in
mm
in
20
6
13
16
48
1
1
894
20
6
13
16
1746
11
16
mm
in
0
18
0
0071
mm
in
mm
in
mm
in
mm
in
203
2
8
00
212
5
837
9
5
03740
Below
0
Q2
0
0008
mm
in
mm
in
204
5
8
051
Below
0
03
0
0012
mm
in
8
4
03307
mm
in
cm2
sq
in
35
x
4
8
x
195
1
378
x
0
1890
x
7
68
273
423
BR
2J
Page 148 of 513

Lining
material
Front
disc
brake
Pad
width
x
thickness
x
length
Total
braking
area
Rear
brake
Lining
width
x
thickness
x
length
Total
braking
area
Tightening
torque
Brake
pedal
fulcrum
pin
Master
cylinder
installation
bolt
Brake
tube
installation
flare
nut
Rear
brake
hose
and
connector
installation
nut
Front
wheel
cylinder
installation
bolt
Brake
warning
switch
installation
bolt
Front
brake
disc
installation
bolt
Caliper
assembly
installation
bolt
Rear
brake
adjuster
installation
bolt
Hand
brake
cable
hanger
strap
installation
bolt
Hand
brake
lever
installation
bolt
Rotor
and
hub
installation
bolt
CHASSIS
mm
in
cm2
sq
in
mm
in
cm2
sq
in
kg
m
ft
1b
kg
m
ft
lb
kg
m
ft
lb
kg
m
ft
lb
kg
m
ft
lb
kg
m
ft
lb
kg
m
ft
lb
kg
m
ft
lb
kg
m
ft
lb
kg
m
ft
lb
kg
m
ft
lb
kg
m
ft
Ib
B40
Akebuno
make
42
5
x
10
3
x
53
I
1
673
x
0
406
x
2
091
90
3
14
0
35
x
4
8
x
195
1
378
x
0
1890
x
7
68
273
42
3
2
0
to
3
0
11
6
to
217
2
1
to
2
9
15
2
to
21
0
1
5
to
1
8
l
0
8
to
13
0
1
5
to
1
8
10
8
to
13
0
a
0
5
to
0
7
3
6
to
5
I
b
1
6
to
2
2
I
1
6
to
15
9
0
32
to
0
44
2
31
to
3
18
2
7
to
3
7
19
5
to
26
8
4
6
to
6
1
33
3
to
44
1
1
6
to
2
2
11
6
to
15
9
0
32
to
0
44
2
31
to
3
18
1
0
to
I
4
7
23
to
10
1
44
to
59
31
8
to
42
7
TROUBLE
DIAGNOSES
AND
CORRECTIONS
Condition
Spongy
pedal
Air
in
brake
lines
Probable
cause
Swollen
hose
due
to
deterioration
or
use
of
poor
quality
brake
fluid
BR
24
Corrective
action
Bleed
thoroughly
Replace
hose
and
bleed
the
system
Page 149 of 513

Pedal
yields
under
slight
pressure
Excessive
pedal
travel
All
brakes
drag
One
brake
drags
Unbalanced
brakes
BRAKE
Use
of
a
brake
fluid
with
a
boiling
point
which
is
too
low
Reservoir
filler
cap
ven
t
hole
clogged
This
promotes
a
vacuum
in
master
cylinder
that
sucks
in
air
through
rear
seal
Deteriorated
check
valve
External
leaks
Master
cylinder
leaks
through
primary
cap
System
has
not
been
bled
Improperly
adjusted
clearance
Fluid
level
in
master
cylinder
is
too
low
Thermal
expansion
of
drums
due
to
over
heating
Insufficient
shoe
tlrdrum
clearance
Weak
shoe
return
springs
Brake
shoe
return
no
free
travel
Seized
master
cylinder
piston
Loose
or
damaged
wheel
bearings
Weak
broken
or
unhooked
brake
shoe
return
springs
Insufficient
clearance
between
brake
shoe
and
drum
Grease
or
oil
on
linings
Seized
piston
in
wheel
cylinder
Tires
improperly
inflated
Loose
wheel
bearing
BR
25
Change
with
the
specified
brake
fluid
and
bleed
system
Clean
reservoir
filler
cap
and
bleed
the
system
Fit
a
new
check
valve
and
bleed
the
system
Check
master
cylinder
piping
and
wheel
cylinder
for
leaks
and
make
necessary
re
pairs
Overhaul
master
cylinder
Bleed
the
system
Adjust
shoe
to
drum
clearance
Full
up
with
specified
brake
fluid
Bleed
the
system
if
required
Allow
drums
to
cool
off
Check
brake
shoe
linings
and
drums
Replace
damaged
parts
Adjust
clearance
Replace
the
springs
Adjust
pedal
height
Service
the
master
cylinder
replace
the
piston
and
bleed
the
system
Adjust
or
replace
wheel
bearings
Replace
spring
Adjust
brakes
Clean
brake
mechanism
replace
lining
and
correct
cause
of
grease
or
oil
getting
on
lining
Service
the
wheel
cylinder
and
bleed
the
system
Inflate
tires
to
correct
pressure
Adjust
wheel
bearing
Page 150 of 513
CHASSIS
Front
suspension
faulty
Thoroughly
check
and
adjust
all
front
sus
pension
components
Excessive
pedal
pressure
required
poor
brakes
Grease
mud
or
water
on
linings
Remove
drums
Clean
and
dry
linings
or
replace
Full
area
of
linings
not
contacting
drums
Replace
shoes
Scored
brake
drums
Reface
drums
and
install
new
linings
Brake
chatter
squeak
or
squeal
Dust
on
drums
or
oil
soiled
linings
Remove
and
clean
drums
thoroughly
Eliminate
oil
leak
Weak
shoe
return
springs
Check
springs
and
replace
as
required
Drum
out
of
round
Turn
drums
on
lathe
Worn
linings
Replace
linings
SERVICE
JOURNAL
OR
BULLETIN
REFERENCE
DATE
JOURNAL
or
BULLETIN
No
PAGE
No
SUBJECT
BR
26
Page 151 of 513
DATE
BRAKE
SERVICE
JOURNAL
OR
BUllETIN
REFERENCE
JOURNAL
or
BULLETIN
No
PAGE
No
SUBJECT
BR
27
Page 152 of 513
I
DATE
CHASSIS
SERVICE
JOURNAL
OR
BULLETIN
REFERENCE
JOURNAL
or
BULLETIN
No
PAGE
No
SUBJECT
BR
28