2004 DACIA SUPERNOVA brake

31
FRONT BEARING ELEMENTS
31 - 6
BRAKE GASKETS
NOTE
In order to maintain the brake efficiency,
the replacement of the brake pads shall be
made only in complete kit.
Never fit brake pads of diffe rent makes
and different qualities .
DISMOUNTING
Lift t he vehicle by means of a two columns
elevator;
Dismount the front wheel;
Disconnect the wear sensor wire;
Dismou nt : - the safety of the wedges (1);
- the wedges, by sliding them.
Detach the caliper assembly from the fork
together with the flexible hose;
Remove : - the elastic blades - the brake pads
Remount :- the brake pads their places in the fork;
- the elastic blades;
- the caliper;
- the wedges and their locks.
Reconnect the wear sensor wire.
Pr ess several times the brake pedal.
Mount the wheels.
Get down the vehicle from the elevator the
ground. NOTE
It
is forbidden to push the brake pedal
after the calipers were dismounted from
the fork. If the brake pads are not fully used but
on their friction surface, especially i n the
middle pad c hannel, there are material
traces, i t i s recommended t he cleaning of
these surfaces in order to avoid the noise
when braking.
REMOUNTING
Push the c aliper pi ston by means of the
FR 500 s pecial t ool.
SPECIAL TOOLS
FR 500 Pushing piston device
FR 500
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31
FRONT BEARING ELEMENTS
31 - 7
BRAKE CALIPER
DISMOUNTING
Lift the vehicle by means of a two columns
elevator.
Dismount the wheel.
Disconnect the wear sensor wire
Drain the brake fluid from the reservoir
Remove the locks and the caliper wedges;
Unscrew the rigid duct screw from the brake
flexible hose and detach the caliper assemb ly.
NOTE
If it is necessary to dismount the
caliper fork, unscrew the two attachment
s crews M 12.
When remounting the fork, replace the
Grower washers, tighten the screws at the
r equired moment of 6.5 daNm then seal
them with FIXAMED R 58. REPAIR
ING
Dismount the protection gasket.
Extract the piston using a wooden wedge and
a compressed air source. Remove the sealing gasket from its seat in the
caliper groove by means of a steel blade. Clean with alcohol the parts, replace t he
damaged ones, mounting being performed in the
dismounting reverse order, after previously all
parts have been oiled with brake fluid.
NOTE
Before remounting to t he wheel, c heck
the sealing of the caliper assembly.
TIGHTENING MOMENTS (daNm)
Wheel nuts 7,5
Rigid duct on front flexible screw 1,5
Purging screw 1
Flexible hose - caliper 2
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31
FRONT BEARING ELEMENTS
31 - 8
BRAKE CALIPER
REMOUNTING
Perform the dismounting operations in the reverse order plus the following operations : - fill the caliper with brake fluid in order to facilitate the brake system purging;
- purging the brake system.
BRAKE CALIPER SEALING CHECKING
Connect to the caliper, a pressure gauge attached to a compressed air source.
P lace a wooden wedge in order to block the piston.
Create a 0,3 bars pressure in the caliper.
Dip the caliper into a vessel with alcohol.
Move the piston several times to remove the air from the sealing gasket seat.
Check the sealing of the brake caliper at various pressu res, without exceeding the pressure of 2 bars.
If the brake shows air leaks by the piston, perform at its dismounting.
Replace the piston, the ga sket, or the caliper body, as the c ase stands.
Perform again the sealing test.
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31
FRONT BEARING ELEMENTS
31 - 9
DISMOUNTING
Lift the vehicle by means of a two col-
umns elevator.
Dismou nt :
- the wheel;
- the two attachment screws M 12 ( B)
of the brake disk assemb ly on the steering knuckle;
- the brake pads;
- the t wo sunk screws attaching t he
disk on the hub. BRAKE DISK
The brake disks can be not rectified.
A bigger wear or an important mark on the brake disk braking surfaces impose obligatory its
replacement.
- The minimal accepted thickness : 19 mm
- The maximum accepted axial deviation 0,1 mm on a diameter of F 215.
TIGHTENI NG MOMENTS (daNm)
steering nuckle 6,5
Disk attachment screw on the hub 2,5
Front wheel steering knuckle nut 21
Wheel screws 7,5
Before remounting, check:
- the wear of the flexible hose;
- the wear of the bra ke pa ds and
replace them if necessary. REMOUNTING
Remount :
- the disk on the hub by means of the two
sunk screws M8 and tighten them to the required
moment; - the brake disk assembly on the steering
knuckle, tightening the M 12 screws at t he
required moment. Press the brake pedal several times, in order
to bring the piston in contact with the brake pads.
NOTE :
In case of replacing the brake disk it is ab-
s olutely necessary to replace the brake pads.
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31
FRONT BEARING ELEMENTS
31 - 10
SPECIAL TOOLS
Hub disk extractor PF600
Ball joint extractor PF476
DISMOUNTING
Disconnect the battery.
Lift the vehicle by means of an elevator with
two column. Dismou nt :
- the wheel
- the brake disk assembly together with
the flexible connection;.
- the transmission gear nut.
- the brake disk a ssembly by means by
means of the PF 600 extractor.
Continue by dismounting t he steering
knuckle, observing the operations sequence: - dismount the steering ball joint nut;
- depre ss the steeri ng ball joint by
means of the PF 476 extractor;
- dismount the t wo screws that attach
the steering knuckle on the shock absorber; - dismount the attachment screws that
attach the steering ball joint – steering knuckle;
- detach the steering knuckle.
TIGHTENING MOMENTS (daNm)
Wheel attachment screw 7,5
Steering ball joint nut 3,5
Transmission nut 21
Attachment fork screw on steering knuckle 6,5
The screw nut of the steering knuckle
attachment with the shock absorber leg 7,5
The attachment screw nut of the ball
joint with the steering knuckle 5,5
STEERING KNUCKLE
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33
REAR BEARING ELEMENTS
REAR AXLE
TIGH TENING MOMENTS (daNm)
Wheel attachment screw 7.5
Axle attachment nut 8.5
S hock absorber bottom attachment nut 8.0
Re ar axle arm elastic bushing axle nut 12.0
Br ake rigid piping connection screw 1.5
Purgi ng screw 1.0
DISMOUN TING
Lift the vehi cle on two column s
elev ator.
Dismo unt the tw o rear whee ls.
Drain the braking sys tem.
Dis mou nt th e bra ke dr um s.
Disconnect the two-connector screws of
the brake rigid piping of the brake cylinder.
Loosen the connections of the
secondary cable from the hand brake levers
and remove the cable from the brake plates.
Dismou nt th e ope rating rod supp ort of
the brake limiter from the right side axle
arm, after previously both arms protectors
have been dism oun ted . Di
smount the lower attachment screws (A)
of the shock absorber with the re ar axle. Push upward the shock absorbers.
Di smount the springs.
Dism ount the conn ecting screws (B)
between the rear axle arms and the chassis. Dismount completely the rear axle.
Check the elastic bushings condition.
S
PECIAL TOOLS
DENOMINATION CODE
Drum cover pliers R0 441
Hub extractor PF 600
Dismounting pliers for shoe s
return spr ing FR03
S hoes protectors FR09
P liers for ma intaining brake
cylinders pistons FR05A
Dynamometric wrench MOT30
Com paring dial gauge R054A
33 - 2
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33
REAR BEARING ELEMENTS
REAR AXLE
Check and adjust the hand brake cable.
Ad just the cleara nce at t he l imi ter ope rating rod (se e chapt er 37- Bra ke l imite r
adjustment). REMOUNTING
Before remounting, grease with grease the attachment screws of the rear axle shock
absorber bottom and the chassis, consequently, the connecting screws rear a xle-c hassis. Line up the arm s beari ngs right to t he c hassis supports, mounting them without t ighten-
ing at the moment, the nuts with the screws, assembling the axle to the chassis.
Remount the springs.
Compress the axle so that rear springs bear on the tray and set back the shock absorber
inner attachment screws. Tighten at the prescribed moment the connecting screws.
Perform the dismounting operations in the reverse order.
Check the maximum allowed axial cleara nce of the bearing using a dial gauge and the
s upport RO541A.
Note
The maximum allowed axle clearance of the bearing is 0.05mm.
Mount the rear wheels, lower t he vehicle on the ground.
Refill with fluid the brake assembly.
Pu rge the braking system.
33 - 3
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33
REAR BEARING ELEMENTS
BRAKE DRUM
The t wo brake drums having the same di ameter; t he rectifyi ng of one of t hem obligatory
implies the same opera tion for t he other one.
SPECIAL TOOLS
DISMOUNTING
Extract the plug out of the drum using the
extracting pliers RO441.
Release the hand bra ke, loosening the sec-
ondary cables in order t o allow the hand brake
lever re turn. Pass a screwdriver through the wheel at-
tachment whole from the drum and operate
on the brake lever sector loosening the its
gearing with the hand brake lever. Dismount:
- the steering knuckle nut and washer;
- the drum using PF600 extractor.
REMOUNTING
Clean the drum and the brake plate assembly by means of a cleaner (vacuum cleaner)
for brake. Place back:
- the drum;
- the steering knuckle washer and nut tightening them at the re quired moment;
- the drum plug.
A djust:
- the shoes by applying a repeated pressure to the brake pedal;
- hand brake ( see chapter 37-“Controls”).
DENOMINATION
CODE
Plug extracting pliers RO441
Dr um extractor PF600
TIGHTENING MOMENTS (daNm)
Wheel attachment screw 7.5
Steering knuckle nut16
33 - 7
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