1977 DATSUN PICK-UP brake light

Using
the

tester
check
the

two

black

yellow
BY
wires
from
the
in

hibitor
switch
in
the

ranges
N

and

I
and
the

tw
re
d

black

RBj
wir
s

in

the

range
R
for

continuity
Turn

range
select
lever
in
both

directions

from

each
lever
set

position
and
check

each

continuity

range
It

is
normal
if

the

electricity
is

on
while
the
lever
is

within
an

angle
of
about
30

on
both

sides
from
each
lever
set
line
How

ever
if
its

continl
ity

range
is
obvious

ly
unequal
on

both
sides

adjustment
is

required

If

any
malfunction
is

found
un

screw
the

fastening
nut
of
the

range

selector
lever

and
two

fastening
bolts

of
the
switch

body
and
then
remove

the
machine
screw
under
the
switch

body
Adjust
the
manual
shaft
correct

ly
to
the

position
N

by
means
of
the

selector
lever

When
the

slot
of
the

shaft

becomes
vertical
the
detent

works
to

position
the
shaft

correctly

with
a

clicking
sound

MSlVe
the

switch

slightly
asj
Je
so

that
the
screw
hole
will
be

aligned

with
the

pin
hole
of
the
internal
rotor

combined
with
the
manual
shaft
and

check
their

alignment
by
inserting
a

1
5
mm
0
059
in
diameter

pin
into

the
holes
If

the

alignment
is
correct

fasten

the
switch

body
with
the
bolts

pull
out
the

pin
tighten

up
the
screw

in

the
hole
and
fasten
the
selector

lever
as
before
Check
the

continuity

again
with
the
tester
If

the
malfunc

tion
still

remains

replace
the
inhibitor

switch
Chcck
whether
the

reverse

lamp

and
the
starter
motor

operate
normal

ly
in
these

ranges
If
Ihere
is

any

lrouble

first
check
the

linkage
If

no

fault
is
found
in

the

linkage
check
the

inhibitor
switch

Separate
the
manual
lever
from
Ihe

remote
control
selector

rod
and
turn

the

range
selcct

lever
to

N

Note

In
the

position
N

the
slot
of

the

manual
shaft

is
vertical

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission

and

engine
for
trou

ble

by
measuring
the
maximum
num

bers
of
revolutions
of

the

engine
while
Automatic

Transmission

vehicle
is
held
in
a

stalled

condition

The
carburctor
is
in

full
throttle

opera

tion
with

the
selector
lever
in

ranges

f
2

and
I

respectively
Com

pare
the

measured
results
with
the

slandard

values

Components
to

be
tested

and

test

items

I
Clutches
brake

and
band
in
trans

mission
for

slipping

2

Torque
converter

for

proper
fune

tioning

3

Engine
for
overall

properly

STALL
TEST

PROCEDURES

Before

Icsting
c
heck
the

engine
oil

and

torque
converter

oil
warm

up
the

engine
cooling
water
to
suitable
tem

perature
by
running
at

1
200

rpm
with

the
selector
lever
in

the

range
P
for

several
minutes
Warm

up
the

torque

converter
oil
to
suitable

temperature

6010
1000C
140
to

2l20F

I

Mount
the

engine
tachometer
at
a

location
that
allows

good
visibility

fro

the
dri
er
s
seat
and

put
a
mark

on

specified
revolutions
on
the
meter

2

Secure
the
front
and
rear
wheels

with
chocks
and

apply
the
hand
brake

Be
sure
to

depress
the
brake

pedal

fumly
with
the
left
foot
before
de

pressing
the
accelerator

pedal

3
Throw
the
selector
lever
into

the

range
1

4

Slowly
depress
the
accelerator

pedal
until
the

throttle
valvc
is

fully

opened

Quickly
read
and
record
the

engine
revolution
when

the

engine

begins
to
rotate

steadily
and
then

release
the
accelerator

pedal

5

Shift
the
selector
lever
to
N

and

operate
the

engine
at

approxi

mately
1
200

rpm
for
more
than
one

minute

to
cool
down
the

torque
con

ver
ter
oil

and
coolant

6

Make
similar
stall
tests
in

ranges

2
I
and
RIO

Note
The
stall
test

operation
as

speci

f
d
in
item
4

should
be

I
l3de

wiihin
five
seconds
If
it

takes
too

long
the
oil
deteriorates
an

the

clutches
brake

and
band
are
ad

versely
affected
Sufficient
cooling

time
should
be

given
between
each

AT
5O
test
for
the
four

ranges
0
2

I
and
R

JUDGEMENT

High
stall
revolution
more

than

standard
revolution

If
the

engine
revolution
in
stall

condition
is

higher
than
the
standard

values
it

indicates
that
one

or
more

clutches
in

the
transmission
are

slipping
and
therefore
no
further
test

is

required

For
the

following
abnormalities

the

respective
causes
are

presumed

High

rpm
in

all

ranges
low
Iine

pressure

High
rpm
in
D
2
and
I

and

normal

rpm
in
R
Rear
clutch

slipping

High
rpm
in
0

and

normal

rpm
in
I

clutch

slipping

High
rpm
in
R

only
Front

clutch
or
low
and
reverse

brake

slipping

To

determine
which
is

slipping

front
clutch
or
low

and
reverse
brake

a
road
test
is
nceded

If
whilc

coasting
after

starting

with
the
lever
in
1

range
engine

braking
does

not
work

properly
the

low
and

reverse
brake
is

slipping

Otherwise
the
front
clutch
is

slipping

Slipping
of
the
band
brake
is

diffi

cult
to
ascertain

However
if
it

occurs

with
the
lever
in
2

range

engine

revolution
increases

Jp
to
thesarne

level
as
in

I

strange
It

is

impossible

to
check

it
in
the
stall
test
2
and

One

way

2
Standard
stall
revolution

If
the

engine
revolution
in

stall

condition
is
within

the
standard

values
the
control
elements
are

nor

mally

operating
in
the

ranges
0

2
I

and
R

Also

tIle

engine
and
one

way

clutch
of
the

torque
converter
are

normal
in

performance
and

operation

The
one

way
clutch
of

the

torque

converter
however
sometimes

sticks

This
is
determined
in

the
road
test

3
Lower
stall
revolution
than
stand

ard
revolution

If
the

engine
revolution
in
stall

condition
is

lower
than
the
standard

The

design
of
the
front

suspension

adopts
the

independent
double

wishbone

type
suspension
used
the

torsion
bar

spring
Both
the

upper
and

lower
links

are
installed
on
the
bracket

which
is
welded
on
the
frame

A
1d
the

above
links

swing
to
allow
the
knuckle

spindle
to
move

freely
in
a
vertical

dimension

The

top
and
bottom

of
the
knuckle

spindle

support
are
connected
to
the

upper
link

through
rubber

bushing
and

to
the
lower
lick

through
screw

bushing

The
tension

rod
held

by
the
brack

ets
on
the
chassis
frame
and
lower
lick

wiih
rubber

bushings
bears
the
force

of
fore
and
aft
direction

The
front
end

of
the
torsion

bar

spring
is

installed
to
the

torque
arm

which

attaches
to
the
lower
link
The

opposite
end
is

installed
to
the

spring

anchor
that

secures
to
chassis
frame

firmly
The
both
ends
of

the
torsion

bar

spring
are
serrated

The

shock
absorber
is

double

action

telescopic

hydraulic
type

The

upper
stem
is
attached
to
the

bracket
of
the
chassis
frame
The

lower
insulated
bracket
is

bolted
to

the
lower
lick

The

bumper
rubber
secured
to
the

bracket
Of
the
frame
limits
the
verti

cal
motion
of
the

suspension
lick

The
knuckle

spindle
is

connecied
to

the
k

ufkle
spindle
arm

by
the

king

pin
The

king

pin
bushings
are
fitted

to

the

upper
and
lower
arm

portIOns
of

the
knuckle

spindle
and

seals
are

provided
at
the

portions
mentioned
to

keep
water
and

dirt
from
enteri

g

The
knuckle
arm
is

connected
to

the
lower
end
of
the
knuckle

spindle

to
transmit

ttLe
movement
of
the

steering
wheel
to
the
knuckle

spindle

The
wheel
hub
is

supported
by
two

taper
roller

bearings
on
the

knuckle

spindle
Tlie
brake
drum
and
wheel
are

secured
to
ihe
hub

by
the

hub
bolts
Front
Axle
Front

Suspension

FRONT
AXLE

REMOVAL
AND

INSTALLATION

Removal

I
Jack

up
and

support
vehicle
on

the
stands

at
the
frame
in

a
safe

manner

2
Remove

front
wheel

3
Re

ove
brake
hose

together
with

connector
from
wheel

cylinder

4
Remove

brake
drum

S

Remove
hub

cap
and
then

remove

cotter

pin
adjusting
cap
and

spindle

nut
from
knuckle

spindle

6
Remove
wheel
hub
outer
and

inner

wheel

bearings
bearing
washer

and

grease
seal
from
knuckle

spindle

7
Remove
brake
disc

assembly
from

the

flange
of
knuckle

spindle

8

Remove
knuckle
arm
from

knuckle

spindle

9
Remove

king
pin
lock
bolt

FA225

Fig
FA
R

mol1ing
king
pin
loch
nut

10
After

removing
air
breather
re

move

plug
from
the

top
of

king
pin

with
the

following
method
Drill
a

10
5
mm
0
413
in

diameter
hole
on

the

plug
thread
hole
with
a

tap

M
12
1
2S
screw
a
bolt
into
threaded

hole
and

pull
out
the

plug

II

Apply
drift
to
the

top
of

king

pin
and
drive
out

king
pin
along
with

lower

plug

12

Tap
spindle
with
a
soft
haJnmer

and

detach
it
from
knuckle

spindle

support
Take

care
not
io

drop
thrust

bearing

FA
3
FA226

Fig
FA
3
R

moving
knuckle

piridle

Installation

Install
front
axle
in
reverse
se

quence
to
removal

by

noting
the
fol

lowing
matters
Furthermore

when

installing
front
axle

lightly
coat

grease

to

sliding
parts

I
Insert

O

ring
on
the
lower
end
of

knuckle

spindle
support
Install
thrust

bearing
and

spindle
shim

together
with

knuckle

spindle
to
knuckle

spindle

support

In

this

operation
select

spindle

shims
to
obtain
the

specified
clearance

between
knuckle

spindle
and
knuckle

spindle
support
To

measure
the
Clear

ance
with

a
filler

gauge
jack
up
the

bottom
of

spindle
slightly

Standard
clearance

0
1

mOl
0
004
in
or
less

Note
Be

sure
to
iristsll
thrust

bearing

to
face
coverea
side

upward

2
Line

up
locking
bolt
hole
of

knuckle

spindle
support
with
the

notch
in

king
pin
and

secure
lock
bolt

Be
sure
to
check
killJckle

spindle
for

smooth
movement
Be

certain
to
move

knuckie

spindle
smoothly
and

reailjust

shim
if

necessary
In
addition
check

bushings
and

king
pin
as

required

3
Press
fit

plug
to
the

upper
of

knuckle

spindle
Then
install
lower

plug
to
the
lower
knuckle

spindle

Note
Make
sure
to

place
lower

plug

conectly

4

Secure
knuckle

arm
to
knuckle

Front
Axle
Front

Suspension

SERVICE
DATA
AND
SPECIFICATIONS

King
pin

Clearance
limit
between
the

king
pin

and

bushing
mm
in
0
15
0
0059

Bushing
inner
diameter
when
fitted

mm
in
20
010
to
20
035

0
7878
to
0
7888

Clearance
between
the
knuckle

spindle

support
and

spindle
mm
in
less
than

0
1

0
004

Wheel

bearing

Tightening
torque
kg
m
ft
Ib
3
0
to
3
S

22
to
2S

Spindle
nut

returning

angle
40
to
700

Wheel

bearing
rotation

starting
torque

When

both

bearing
and
seal
are

new

kg
em
in
Ib
less
than
IS
13

0

When

readjusted
kg
em
in

lb
less
than
7

6
1

At
the
hub

bolt

When

both

bearing
and
seal
are
new

kg
lb
less
than
2
1
4

6

When

readjusted
kg
lb
less
than
1
0
2
2

Suspension
link

Upper
link

sliding
resistance
kg
m
ft
Ib
less
than
O
S
3

6

Lower
link

sliding
resistance

kg
m
ft
lb
less
than
O
S
3
6

lightening
torque

kg
m
ft
Ib

Brake
hose

connecting
nut
1
9
to
2
S
14

to
18

Wheel

bearing
lock

nu
t
3
0
to
3
5
22
to
2S

Brake
disc
fIXing
bolt
4

2
to
S
O
30

to
36

Knuckle
arm

fixing
bolt
10
3
to
12
1
74

to
88

King
pin
lock
bolt
2
1
to
2
S

IS
to
18

Torque
arm

Arm
end
2
7
to
3
7

20
to
27

Serration
boss
1
8
to
2
6

13
to
19

Lower
link

spindle
nut
74

to
8
0
S4

to
58

Upper
link
screw

bushing
24

to
35

174
to
2S3

Upper
link

spindle
bolt

fIXing
to
bracket
7
to
9
51

to
6S

Cotter

pin
lock
nut
0
8

to
l
l
5
8
to
8
0

Lower
link
screw

bushing
25
to
32

181
to
231

Fulcrum
bolt
3
9
to
S
3
28
to
38

Tension
rod

Lock
nut
1
6
to
2
2
12
to
16

Bracket
bolt
1
6
to
2
2
12

to
16

Shock
absorber

Lock
nut

of
the

upper
end
1
6
to
2
2

12
to
16

Lower
end
3
1
to
4
1

22
to
30

Stabilizer

Bracket
bolt
1
6

to
2
2
12
to
16

Lock
nut
of
the

anchor
bolt
3
1

to
4
1

22
to

30

Bumper
rubber
bolt
0
8
to
l
l
5
8
to
8
0

FA

13

REMOVAL

1

Removing
flare

nuts
on

both
ends

and

clips
effects
the

removal
of

brake

tube
and
brake
hose

2

Rear
brake
hose
can
be

removed

by
disconnecting
the
tube
and
then

turning
round
the
hose

Note
When

removing
brake
tubes
and

hoses

use
Flare
Nut

Torque

Wrench
GG943IOOOO

Never
use

an

OpeD
end

or
an

adjust

able
wrench

INSPECTION

1
Examine

all
hoses
for
swell

rubbing
marks
or
ozone
cracking

re

placing
those

found
with

any
of
above

badly
beyond
use
Also

inspect
end

fittings
and
be
sure
that
no
fluid
leak

through
staked
end

has
taken

place

replace
if

necessary
Hose

with

badly

rusted

fitting
should

also
be

replaced

with
a
new
one

2

Clean
all
tubes

to
remove
dust

and

dirt
with

isopropyl
alcohol

check

ing
for

collapse
wear

cracking
swell

or

rusting
Replace
if
foun
d

with

any

of
wove
Use
care
not
to

damage

brake
tubes

while

operation

Check
if
tubes

are

clamped
secure

ly

Mter
all

brake
lines

have
been

installed

retighten
aU
connections
if

necessary
to

assist
in

obtaining
correct

torque
In

retightening
at
front
wheel

cylinder
first
remove
hose

clamp
and

loosen
flare
nut
on

opposite
side
to

avoid

twisting
hose

Hold

pedal
as
far
downward
as

possible
80

kg
176
lb
or
more

examining
evidence
as
to
whether
fluid

is

leaking
through
brake

lines
or

con

nections

Leakage
in

any
manner
can

not
be

permitted
here
In

case
fluid

leaks

tightening
to

specified
torque

tighten
additionally
up
to
2
5

kg
m

J
8
ft
lb
Under

no
circumstances

should
not

be

tightened
over
2
5

kg
m

18
ft
Ib

torque
since
this

elongates

end

fitting
making
it

impossible
to

reuse
brake
tube

Under
no
circumstances
should
rear

brake
hose
and
3

way
connector
be

retightened
over

specified
torques
In
Brake

System

stead

replace

copper
washer
with
a

new
one

after

checking
for

sign
of

damage
on

seating
surface
Never
reuse

an
old

copper
washer

INSTALLATION

Brake
hose

Front
brake

hose

In

installing
brake
hose
first

jack

up
vehicle

to
take
off
the

weight
of

vehicle
from

wheels
so
that

suspension

is
in
rebound

Steering
wheel
should

also
be

kept
in

straight
ahead

position

To
connect
brake

line
first

connect

brake

hose
to
wheel

cylinder
with
the

specified
torque

Tightening
torque

1
7
to
2

0

kg
m

12
to

14
ft
Ib

Then
secure

brake
hose
to
the

bracket
with
lock

plate
so
as
not
to

twist
or

abnormally
bend
the
hose

Note

After

connecting
brake
hose

at

both
eiuIs

pay
keen
attention
not

to
twist
the
hose
when
additional

tightening
is

required

Fig
BR

12
Front
brake

hose

Rear

brake
hose

First
secure
rear
brake
hose
to

3

way
connector
on
rear
axle
case
to

the

specifications
Mter

connecting

hose
do
not

tighten
it

at
3

way

connector

additionally
since
this

oper

ation

causes
hose
to
be
twisted

Tightening

torque

I
7

to
2
0

kg
m

12
to
14
ft
Ib

BR
8
Fig
BR
13
Rear
brake
ho
e

After
brake
hose
has
been
installed

check

to
be

sure
that
there
is

enough

clearance
between
hose
and

adjacent

parts
to
avoid
contact
with
other
ones

The
check
should
be
carried
out
while

moving
wheel

up
and
down

through
its

full

stroke
and

rotating
steering
wheel

between
two
extreme
lock

positions

The
wow
clearance
must
be
as

follows

Hose

to

rotating
or

mOving
parts

such
as
tire
and

rim

40
mm
1
57
in

and
more

Hose
to

stationary

part

2S

mm
0

98
in
and
more

In

case
that
the

above
clearance

cannot
be
obtained
it

may
be
caused

by
the
hose

twisted

Accordingly

carry
out
the
correction
with
hose

connection

again
following
the
above

instructions

Brake
tube

In

installing
a
brake
tube
use
care

to
locate
its

end

squarely
on

mating

seat

noting
the
fact
that
nut
can
be

turned

freely
by
a

light
finger
twist

Then

tighten
to
correct

torque
with
a

Brake

Pipe
Torque
Wrench

GG943
10000

Tightening
torque
Flare
nut

1
5
to
1

8

kg
m

11
to

13
ft
Ib

In
addition
care
should
also
be

exercised
to
avoid

damaging
or
col

lapsing
brake
tube

during
operation

Be
sure
to
make

enough
clearance

between
all
tubes
and
other

adjacent

parts
to
avoid
contact

In

installing
tube

through
hood

ledge

grommet
be
sure
to

position
it

at
the

center
of

grommet

After

connecting
brake
tube
be

sure
to

check
the
clearance
to

prevent

from

damage
The
clearance
at

the

following
portions
must
be

specified

distance
or

more

Tube
to

body
panel
and

frame

Over
5

mm
0
20
in

Tube

to
edge
of
each

panel

Over
10
mm
0
39

in

Tube
to
tube

Loop
pitch

OVer
5
mm
0
20
in

Between
front
tube
and

rear
tube

Over
9

mOl
0
35

in

Tube
to

moving
parts

Over
10
mm
0
39
in

Loop
tube
to

hood

ledge

panel

Over
10

mm
0
39
in

Notes

a
Brake
tubes
are

shaped
at

factory

to
secure

specified
clearance
and

may
not

require
reshaping
Discard

if

they
call
for
excessive

reshaping

b
In

reshaping
a
brake
tube
take
care

to
avoid

damaging
galvanization
or

collapsing
section

Mter
brake
lines
have
been

asssem

bled
check
to
make
sure
that
all

fittings
and
flare
nu
Is
ale

lightened
to

correct

torques

Tightenint
torque

Brake
tube
to
connector

I
Ston

kg
m

II
to

13
ft
Ib

Brake
tube
to
brake
hose

1
7
to

2
0

kg
m

12
to
14
ft
lb

Connector
and

clip
fixing
bolt

O
3S
to
O
4S

kg
m

2
5

to
3
3

ft
lb

3

way
connector

fixing
bolt

on
rear

axle
case

0
8
to
1
1

kg
m

6
to
8
ft
lb

N
L
S
V

DESCRIPTION

The

Nissan
Load

Sensing
Valve

N
L
S
V

serves
to

change
braking

power
of
the

rear
wheels
in

response

to

changes
in
the
load
and
fluid

pressure
improving
braking
stability

and

shortening

stopping
distances
Brake

System

The
N
L
S
V

is
installed
on
the

frame

being
inclined
at
10

degrees
A
summary
of

the
N

L
S
v

operation
is

given
in

Figures
BR
14

and
BR
15

r
Master

cylinder
TI
II

I

y

1

J

I

l
Attaching
angle

D

Wheel

cylinder

BR928

Fig
BR
14
Construction

of
N
L
S
V

Performance
curve
of
brake
fluid

pressure
is
as

follows

0

S

c
A

0

C

o

l
0
oadea

U1U

Front
wheel

cylinder

fluid

pressure
BR769

Perfonnance
curve

of
fluid

pressure
Fig
BR
15

N
L
S
V
TEST

the

following
occurs

When
rear
wheels
lock

stopping

distance
is
shorter
than
13
1

m
43

0

ft
whether
loaded
or
unloaded

Stopping
distance
should
be

measured

from
the

place
where
the
brake

pedal

is

first

applied
to
the

place
the
vehicle

actually

stops
Front
wheels
lock

simultaneously
with
or
ahead
of
rear

wheels
Operating
test

The

test
should
be
conducted
under

these
conditions

Drive
a
vehicle
with

pay
load
and

then
with

only
driver
on

a

dry
flat

concrete
or

asphalt
road

applying
the

brake
suddenly
at
40
km

h
25
MPH

N
L
S
V
is

functioning
normally
if

BR
9

REMOVAL

Referring
to

Figure
BR
29

remove

parts
in
numerical
order

enumerated

1

cD
2

BR17S

Fig
BR
29
Removal
method

of

Mcuter
Vae

DISASSEMBLY

When

disassembling
Master
Vac

ob

serve
the

following
instructions

a

Thoroughly
clean
mud
or
dust
from

Master
Vac

b
Extreme

care
should
be
taken
not

to
allow
dirt
dust
water
or

any

other

foreign
matter
into

any
com

ponent
parts

Be

sure
to

select
a
clean

place

before

disassembly
or
assembly

c
Mark

mating
joints
so
that

they

may
be
installed

exactly
in
their

original

positions

d

Keep
all
disassembled

parts

arranged
properly
so
that

they
may

readily
be
assembled

at

any
time

e
Clean
rubber

parts
and

synthetic

resin

parts
in

alcohol

f
Mter
all
disassembled

parts
are

cleaned
in
a

suitable
clean
solvent

place
on
a
clean
work
bench
Use

care
not
to
allow

dirt
and

dust
to

come
into

contact
with
these

parts

1
Install

spacer
on

rear
shell

spacer

temporarily
Place
Master
Vac
in
a

vise
Use
soft

jaws

2

Remove
clevis
and
lock
nut
De

tach
valve

body

guard

rW

ID

1

Clevis

2
Lock

nut
3
Valve

body

guard

BRD7S

Fig
BR

30

Removing
rear
hell
Brake

System

3

Identify
front
shell
and

rear
shell

clearly
so
that

they
may
be
reassem

bled
in
their

original

positions
from

which

they
were
withdrawn

Bolts

attached
on
dashboard
are

not
the

same
in

pitch

4

Using
Master
Vac
Wrench

ST08080000
remove
rear
shell
seal

assembly
and
disassemble

diaphragm

plate
assembly
front
shell

assembly

diaphragm
spring
and

push
rod

assem

bly

f

Q
BA076

Fig
BR
31

Removing
reor
shell

Rear
shell
seal

Pry
off
retainer
with

use
of

screw

driver

as
shown
and

detach

bearing

and
seal

Note
Do

not
disassemble
seal
assem

bly
unless

absolutely
necessary

Whenever
this
is
to
be

removed
use

care
not
to

damage
it

BRD7S

Fig
BR
32

Removing
retainer

Diaphragm
plate

Place

diaphragm
plate
assembly

on

a
clean
work
bench
Detach
dia

phragm
from

groove
in

plate
as
shown

BR
16
BA079

FlIf
BR

33

Separating

diaphragm

2

Using
a
screwdriver

as
shown

evenly
pry
air
silencer
retainer

until
it

is
detached
from

diaphragm
plate
as

sembly

Note
Never

use
a

hammer
to

remove

this
retainer
since
this
win
be
the

sure

y
of

damaging
it

BA322

Fig
BR
34

Removing
air
silencer

retainer

3
Pull

out
valve

plunger

stop
key

and
withdraw
silencer
and

plunger

assembly

Note
To

remove
valve

plunger

stop

key

properly
proceed
as

follows

With

key
hole

facing
down

lightly

push
valve

operating
rod
simulta

neously
while

applying
vibration
to

it

BA180

Fig
BR
35

Pulling
out

top
key

BA1Bl

Fig
BR
36

Remouing
ualue

operating

rod

assembly

4

Withdraw
reaction

disc

BA286

Fig
BR
37

Remouing
reaction
disc

Front

shell
seal

I

Detach

flange
from

front
shell

assembly

BR287
g

Fig
BR
38

Removing

lange

2

Withdraw
front
seal

assembly

INSPECTION

I
Check

poppet
assembly
for
condi

tion
If
it

shows
evidence
of

wear
or

damage

replace
it

and
valve

operating

rod

assembly

2
Check
other

component
parts
for

condition
If

any

part
shows
evidence

of
wear
or

damage
replace
it
with

a

new
one
Brake

System

ASSEMBLY
AND

ADJUSTMENT

Assemble
in
the

reverse

sequence
of

disassembly

Rear
shell

seal

1

Apply
a

coating
of

Master
Vac

grease
to

the

sealing
surface
and

lip
of

seal
and

install
that
seal
in

rear
shell

with
the

use
of

Master
Vac
Oil
Seal

Retainer
Drift

ST08060000

Fig
BR
39

Installing
oil
seal

Note

Referring
to

Figure
BR
40
in

stall
seal
in

place

by
properly

aligning
the

pawl
of

special
tool

with

seal
hole

Adjustment
is
cor

rect
when

specified
length
at

A
is

obtained

Length
A

6
7
to
7
Omm

0
264
to
0

276
in

BA1S5

Fig
BR
40

Length
at
A

Diaphragm
plate

I

Apply
a
thin

coating
of

grease
to

the

sliding
contact

portion
on
the

periphery
of

plunger
assembly

BR
17
1

SR1S6

Fig
BR

41

Requiring

grease
place

2

Install

plunger
assembly
and

silencer
in

diaphragm
plate
and

lightly

push

plunger

stop
key
in

place

Note

Diaphragm

plate
is
made
of

bakelite
Exercise

care
in

instaJJing

plunger
assembly
not
to

damage

diaphragm
plate

BROB3

Fig
BR
42

Inserting
stop
key

3
Before

installing

diaphragm
into

position
apply
a
thin

coating
of
mica

power
to
it

except
outer
diameter

and

seating
portion
with
which
shell
comes

into

contact

4
Before

installing
reaction
disc
in

place
on

diaphragm
plate
apply
a
thin

coating
of
Master
Vac

grease

Front
shell

seal

Before

installing
front

shell
seal
as

sembly

apply
a

coating
of
Master
Vac

grease
to
the
inner
wall
of
seal
and

front

sheU
with
which
seal

comes
into

contact

Final

sssembly

Apply
thin

coating
of
Master
Vac

grease
to
the
outer

edges
of

diaphragm

with
which

rear
and
front
shells

come

into
contact
before

instaIling
dia

phragm
in

position

2
Before

installing
push
rod
assem

bly
in

place

apply
a

coating
of

Master
Vac

grease
to
the

sliding
con

tact
surface
of

diaphragm
plate

1
Control
bracket

2
Control
lever

3
Control
stem

4
Front

cable

5

Balance
lever

6
Rear
cable
R
H

7

Rear
cable
L
H

REMOVAL

Control
stem

I

Disconnect

terminal
from
hand

brake

warning
switch

2

Remove
nuts

securing
control

bracket
in

place
on
dash

panel
Brake

System

BAS6l

Fig
BR

46
Hand
brake

linkage

3

Pull
out
lock

pin
and
colter

pin

and

then

remove
control
stem

assem

bly

y
J

b
i1

I

I
1

II

i

l

I
BR773

Front

cable

Fully
release

control
stem

2

Loosen

adjusting
nut
at
balance

lever

3

Disconnect
front
cable
from
con

trollever

4

Remove
retainer

spring
at

cable

guide
bushing
Fig
BR

47
Control

stem

5

Disconnect
rear
cables
R
H
and

L
H
from
balance
lever
brackets

See

Figure
BR
48

6
Remove
balance
lever
brackets

from
crossmember

7

Detach
front
cable

clip
and

pull

front
cable

rearward

BR
19
k

1

BR663

Fig
BR
48
Balance
lever

Rear
cable

Fully
release
control

stem

2

Remove
both
rear

brake
drums

and
disconnect
rear
cable
from

toggle

lever

3

Detach

spring
and

spring
retainer

4

Remove

rear
cable
from
brake

disc

5

Disconnect
rear

cable
from

balance
lever
bracket

6

Detach
cable

clips
and

remove

rear
cable

INSPECTION

1

Check
control
stem
and
ratchet

for

evidence
of
wear
or

other

damages

Replace
parts
which
are

faulty

2

Replace
worn
or

fatigued
springs

3

Check
wires

for
evidence
of
dis

continuity
or
other
deterioration
Re

place
if

necessary

4

Replace
faulty
warning
light

and
or
switch

S

Check

parts
at
each
connection

and
if
found
deformed

or

damaged

replace

INSTALLATION

Install

hand
brake

assembly
in
the

reverse

sequence
of
removal

by
closely

observing
the

following
instructions

When

installing
apply
a

coating

of

grease
to

sliding
contact
surfaces

Make
Sure
that

each
sliding

part
func

lions

smoothly

2

Upon
completion
of
installation

of
hand
brake

assembly

adjust
the

entire

system
referring
to
the
instruc

lions
described
under

topic

Adjust

ment

3

Make
sure
that
each
cable
is

not

interfered
with

by

any

adjacent
parts

Do
not

apply
an
undue
stress
to

cables