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Section Group

5 50.55
Repairsand Brakes
Maintenance 240,260
Contents-Brakes,Repairand Maintenance

Group50: Erakes,General Page

Specifications 1
SpecialTools 3
GeneralP.ocedures .. , . ., . ,,.. 5
SetuiceDiagnosis 6

Group 51: Wheel Brake Assemblies

Brake p a d s. . . . . . . . . . . . 8
Front brakecalipers 10
SparePans lllustlalions 12
near brakecalipers 14

Group 52: Footbrake System

MasterCylinder 1l
Brake(reducer)valves 18
Brake l i n e s. . . . . . . . . . . . . 19
B l e e d i n.g. . . . . . . . . . . . . . .. 19
Powercylinder 22
Vacuumpump 23

Group 55r Parking Brake

SpareParb lllusrration
Adjustingparkingbrake 25
Parkingbrakeshoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
P a r k i nbgr a k ec a b l e .s. . . . . . . . . . . . . . . . 27
Additional inlo.mation 29
Ab6sivepads 31

changesinlexl and/orspecilication

TP 11405/4
Printedin U.S.A.
non-ventilated US
arake discsr Damele. 263 mm r0.35"
T h i rt ' - : 5 n F 4 1 4 . 3m m o 563"
\,4 . rr, \'- . {hen a.o-o.rondd 1 3 . 4m m 0.536"
\,4a. (" p .. 0 l0 .nm 0004"

Brake linings: 0 394"

E f f e c t v ea r e a c r . g .... .. 166cm2 25.7 n,
A T E( 1 9 7 5 .) . . . .. .... 145cm2 22.5in'z

Giring,andATE DB 8]8

W h e e lc v l a d . r s A a d . C r ' t 1 S1 9 5 10.25cm, I 59 in'z

a 04 ^L "ptr A r " a c r r t i r g- 9 7 6 _ . 1 1 . 3 c4m , 1 . 7 6i n ,
A-t (197q) L58 in,

B r a k ed i s c s D" P- 263 mm 10.35"
T r l i ! r r e .\ n 4 ( 24 mm o.94"
w r i e n r e c o . al r o n e o .. 20.8rnm 0.43"
010 mh 0.004"
d ilerent

Frcnlandrearmax.0.004" measured atfudhest

poinlon cifcumference.
Fronldiscnon-ven|ated,machned min. 13.2mm (0.51968")
Fronldiscventilared(girlingCalipeomachined,min. 20.4mm (0.8189"1
Frontdscvenlilated(ATECaipe0machined, rnin. 22.8mm (0.89764',1
Reardiscsmachined, min. 8.4mrn (0.33071)

Brakelininss: T h r c k n e .sesw
. ... .. lO mm 0.394
fffecl,vedrea.Cr{19 .. .. .. 166cm, 25.7 in2
Ef'eclivea ea ATE 22.5n,

Gd r g P"f/ _1ode s
ATE G ning,lalemodes DB8]8

Wheel cylinders: Area, 1975 1 . 5 8i n ,

Area, 1 9 7 6 - 1 . 7 6i n '

Rearwheelbrakes(discbrakes).all models
B r a k ed i s c s Di.merer 281 mm 11.06"
96 mm o.378"
M r n . t h l c k n e s sw h e n r e c o n . l n o n e d. . . . 0.331"
Max warp O . l Om m 0.004'

arake liningsl Gir[ng 8mm 0.3r5-

ATE .. .. o 394
Efiecrve area. Gtr ng loo cm2 15.5in'?
ATE rO5 cm2 16.3in'?
Group 50
gftkes, Genercl
Rearwheelbrakes(disc brakes),all models
ATE,Gjrling DA-828

Wheel cylinders Ar€a. G rl,ng

12 per whe€l) ATE I 1 . 3 3c m r 1.75 in2

Mastercylinder(tandem-type,step-bored),4 cyt.,6 cyt.

Oiamete. S e c o n d a r vb o r e . . rb 75 mm 0.620"
Prma.y bore 223 mm o.477"
Brake lines

B r a k e( r e d u c e rv)a l v e( A T E B R M 1 8 1
242 2441975
3 0 lvlPa
480psi J
245 1915-1976 45MPa 640psi
50MPa 730psi
264 2 5 N4Pa 3s5psi
265 3 4 \4Pa 4€0psi
Vacuumbooster cylinder,240, 260
Make: A l l ( 2 4 0 1, 9 7 8 - )

Tvpe D aphram
Parkingbrake,all models
Brike d,um Dam.rp. 160.45mm 6 32"
\,4d\ wdrp ... O15 mm 0.006
02 mm 0008
B'ake linings: trfe r !F aroa 176 cm'z 27 n,

Fronr brak€ caIper rerain]ngbohs 9 0 1 r 0N m 65-72 ft. lbs
Bear brake cal,pe. r€rainng bolts 52 64 Nm 38-46 lr. bs.
Whee n,le .. 1 0 0 1 3 0N m
Va r-r.t'.o..,or. , 1 9 D or \ 30 50 Nm 22,36 fr. bs
B "ede ppes 3.5-5.5Nm 25 40ft lbs.
B a \ e p p e c o r n e c n o rr 812Nm 6 9i1 bs
B dle l'o,e Lolnec ol. ro orala ' edJce l !al/c 1 2 - 1 6N m 912ft bs
D-r. 1' 45-55Nm 33 40 ft. lbs.
S aur\ r€d dt d, hmF p ar"
o" rr'9 oolls r' . ho 30 50 Nm 22 36

Gtoup 50

Brak€ calipersof make ATE are slpplied for certain
markels.Where the instructionsfor these differ frorn
the other brake calipermake (G ning),the lettersATE

The followng specia tools are used for repair work 5

on the brake system. The specal lools are marked
999 or SVO \e.9.,999 2142 ot SvO 2142.
The tester 2741 is usedio diagnosethe brakesyslem.
Wooden nsens as shown faci tate rernova ot lrre
brakecaliperpistons.A brakebLeederun i of th€ type
shown is requlredto maintan constantpressurewhen
servicng lhe hydraulicsystem.A conneciioncov€rior
the brake fluid container is aso needed.

274'l i Tester 2
to d.gnose fie brale system

2809 Press tool

pressng in and checkng piston in brake cali-
petholder ior p ate and dia gauge

2917 Exrractor

2918 Tool
to revove pston n rear brake caliper (ATE)

2919 lTemplare
piston ln rear brake caliper (ATE)

2971 Bleederwrench
2aO9 Press rool
presslngin and checklig piston in
brakecal per/holder for plateand
ro maintain fluid pressure when seruicins dial ga!9e
the hydraulicsystem

for the brake fuid container

29'17 Extractor

Bftke' Genercl 3

2918 Tool
lo revolvopislonin rsarbraks
2919 Template
pistonin rearbrakecaliper(ATE)

2971 Blssderwrench
for ATE brakes
Genen/ Procedurcs


meanswhen feh betweenrhe fingersn lacksthe no.

HydraulicBrakeSystemComponentsshouldbe clean- mal feellngof a lighl ubricalingfi m).Such brakeflLrd
should be replacedby new lluid. Th s shoud also be
ed in cleanbrakelluidor specialsolveniwhich doesnol
done when mastercylinderand wheel brakeunits 3re
beingoverhauled.The brakesho! d beoverhauledand
Do nol use gasoline,kerosene,trichloroethylene or
the brake furd changed regulany.s€rvicescheduled
alcoholwlh benzenetor cleanng. Such solvenls,as
ai45,000m les(75,000 km)or€verylhirdyear.whend ving
welLasthe slighlestvace of mineraloil.attack rubber
Jnderextrerely d (ondilons.h\e moLnlarldnvngor In
seals and cause them to sweloul. For this reason,
hands also should be wash€d with soap and water humidclimate,lhe everyyear.
braketLud shoud be replaced
beforeinte.nalpartsare touched,lt is an excelLentidea
to provrdethe me€hanicworking wnh hydrauliccom
ponenls wilh rlbber gloves. Checkingbrakefluid level
F nal r nsing should be made i. a cleanrngagent free Every lime lhe lle tank is li ed lhe brake ilud level
from imp!rities and after that the parrs can be dried shoudalso bechecked.Theevelln lhe maslefcylinder
in the open air. Fiheredand compressedan free from containershould nol be belowlhe l\,4in.mark.Thiscan
moisrure can also be used, bedonewtholtremoving lhe cap.Every7500 miles(12500
ll s very importanllhal no alcoholicfesidue is lefl km),orwhennecessary, topupto lhe Max conlainermark.
in lhe syslemwhen il is liled with b€ke fluid.Traces Obserue maximum cleanlinesswhenill ngiluid.Avod spilling
ot cleaningalcoholin blake llud rcduceslhe boiing b6kelluidontopainlworkasitmightbedmaged. Checkthat
poinl and can resut in lormalionol vapourwh ch sev- lhebrealher
holeinlhecapis notblocked,
After beingcleanedand dried,the componenlsshould
be immeGedin brake fluid before assembling.Then
Checkingbrake pads
lhe bfake systefi should be filled with brake fluid as
soon as possble n order lo pr€venlcotrosiona(acks Checklheb6kepadslorwearregularly oral leaslevery7,500
mies (12,500km).The padsshoLldbe replaced whenlhey
To counteractcoiiosion on brake parts which are to drpwom l o dr hc h l " s s o " e s s l h a_nI 3mn.LJndernocil
beslo.edor for any othe. reasonnol immersedin brake clmslances mustpadsbeworndown below1/6' = 1,5mrir,
tlud, coal pllngers, cylindersand seals with a thrn
layer oi brake paste.Under no co.dito. whatsoever
musrorher typesof greaseor rustproofingoilbe used. Operationcheck
h addtionlo reguldchecksby lhe diver whendrivinglhe
BrakeFluld bakesshoud bechecked every7500 miles(r2,500km).
BEke lluid is hygrcscopicin natureand absobs walervapor
fiom lhe aar,Forthis r€ason,it is imporlanrlo keopbrak€tluid The servrcebrakesyslem sho!ld be checkedto make
ina lighllysealod slre that the operanon is corect. li necessaryuse
conlaln€r,llonly a smallanbuntollluidis
proper lesrLngequ pmenr. Also check ro make sure
r€quircdit shouldb€ purchas€d in smallcans.Avo'dsloring
lhat lhere is no le.kage and thal lhe bfake are
smallquanlnie€ oi fiuldin bulkconlainels- Thoboilingpoint
nor exposedro damage rhat may resuh n leakages.
lorbrakolluiddop€nds ons€v€€llaclo€including thsa96ol
The parklngb.ake should providefull brakingpower.
lhe llud andclimaleconditonsAnyb'akelluds ett.'6ncy
the parking take should be fuly appliedat nolches
willddsnoralsas il b€comes older.n shouldb6changed at
3-4. Olherwise adjusl according to insrruciions.
l€ast6voryihleoyoa|slorca|sln normalserylco.
On y brakelluid with designationDOr 4 (SAEJ 1703)
shouldbe used.Useonlyhighqua ily b raketluidwhich
rs guaranleedby a welfknown manulactureto fulil The b.ake systemshould be ovefhaued and lhe brake lluid
lheserequrremenls. Brake| lids whichonlylu tfitttower changedevery lhird year. Every lhid year or 45 000 miles
requnemenls(example:SAE70 R 1,AE qlalliesor FS, (75,000km)brakesyslemsealsand airl lerforthe powercy-
VH H 910 A) must nol be used.Avoidmlxingdillerent ind€rshouldbe rep eed. Whered vingcondiiionsa.emoslly
brandsol braketluid. duslylhe airlille.shou d be replacedmoreoilen.
Utmosr cleanlinessshould be obse.ved in order ro For rhardrF sub "dad ro brakiT coldiliols /i.e.
"ars "-vere
prevenrdin lrom gening inro rhe system when fo. mouniaind ving,lraileftowing)ordiven in hoi, high humidiv
instancefilling rhe maslff cylinder.Ooly cleanunused areas thefu d shou d be changedal leaslonceayeaf.
b r a k ef l u i ds h o u l db e f i l l e dB. r a k e f l u i d w h
ch sexpelled
dunng. e.g. bleeding.must .ot be re-!sed.
Duringerlendedpe.iodsol lime,it is normalrhateven
fi|sl-classbrake luid graduallydelerioraleslhrough
dbsorblionol'noisrureand sra'l mp"r tes Delerio'a-
ted brake fluid can be recognizedby rhe facr thar.
compared wnh new brake fluid. it s darker or has Gtoup 50
changedco our. is relalivelyodourlessand walery {thal Brakes.Genenl 5
The followingseruicediagnosiscan be usedwhen the a pedajack Checkrhepressuregauge whenlhe warn-
seNice blake system is behavingabnormallyo. 1o ng ighlcomeson.ll shoud comeonat thepressure
rerenlarol 70 210 psl =5 15 kp/cm?belweenthe
1. Check th.l the level of the brake fluid is up ro
r h e M c x - d , k o n _ l . e . o n , a. r up,' -e- Afierlesling,shulotllheb
eedernpp eandremovepedal
2. Removeboth insidebleeclernipplesat one of the
f.ont brakecalipersand connecttester2741. For
r l e A T r b r d r e sd l s o a i p p l e2 9 2 0 r s u s " o .


L Checkthe brakekeducer)of one circlit. Connect

the tester to the bleedernipple on the eft .ear
2. wheel brake and to rhe upper nipple on one of
3. the front whee brakes.
Read incoming pressureon the pressuregauge
3 . Depressthe take pedal several trmes to even
for the front wheel brake.Readoutgoingpressure
out any vacuum n the power cylinder,thereby
on the gaugewhich is connected10the rearwheel
dsconnecting it. When free, the brake peda
sholld be abolt eve wth the cutch pedal.
Appy and re easethe b.ake pedaLwhie readng Operatingpressure:
the pressuregaugesof the tester.The pressure 2 4 2 a n d2 4 4 . . . . . . . . . . 3 . 4 MPa = 48O ps
n boih circuitsshoud be obserued.At 1420 psi 2 4 5 . _. . . . . . _. . . . . . . . . . . 4 . 5
= 10Okp/cmz. the pressurernustnotcliffermore 264 . . . . . . . . . . . . . . . . . . . .2.5 MPa = 35s psi
than 43 psi = 3 kp/cm2. 265.. .... ... ....... ... . 3.4
5. Use an assisiantor a pedaljackto applythe foot 10. Checkthe olher brakevalvethe same way. Con
brake.Obiain a brake pressureof approx. 1420 nect the tester 1o the right rear wheel brake and
ps = 1O0 kp/cm2. Checkpipes the inner,lower nipple of the front wheeLbrake.
for damage and leakages.The pressureshould 11. Raise up the vehicle so that the wheels rotare
renrain unchangedfor at least 15 seconcls. treey. Appy and releasethe brake.The wheets
6 . Bemovethe pedallack. Depressthe brake peda should be free half a secondafter the pedal has
and maintain the pressure.Start the engine.A beenreeased.The test shoud be made with and
considerableloweringof the pedalshoud be felt witholt va€ulm n rhe power brake cylinder.
when the power cyllnder stans op€rating.
NOTE:TheNvopressurereadingsshouldbe appotimatey
L Stop the engineafier runningforat leastI m nute.
equal!plo thepressuresndcaledinrhetabe aboveAbove
Usean assstanl or a pedaljackto applya hydra!
lhosepressures the.earpressure shouldincreases owerlhan
c p r e s s l r eo r r 5 ! p s r = 2 5 r p / c m - .
Observethe pressure for a coupleofm nutes.The
hydraulc pressureis noi allowed to drop more
tnan /u ps = 5 [p/cm.
Check the warning va ve.
Connectthe testing deviceto one of the bleeder
nipples.Open. Apply the footbrake slowly with


P€dal too low or roo high

Feplace the damased Ine

Diifefenceberween crclils 3 ockaqe in one oI rhe crcurs

Fecondron masler cy nder

Tghlen conneclio.s aid

replacelne of recondnrof

o The pedal does nor qo down

Leakrngsea n wheel unt cy|nder
Leakng sea rn masler cyinder
R e c o n d i r o nw h e e u n c y i n d e r
Fecondinonmaster cyifder

Blocked ar tlrer or eakng

seal for front presslre plunger

Detecrve power cy inder R e p a c ep o w e r c y l n d e r

The pressured^ropsmore F e m o v ea n d b l o w c e a n l h e
lhan 5 kp/cmz 171ps) v a v e a n d r e p a c et h e s e a l
r i n g .l f n s ! t i c e n t , f e p l a c e

Leakinqseal ior outgong Remove master cylnder and

thrust rod In power cylnder
Inte..a faur ii power cylnder Replacepower cylnder compele
L e a ( n s r e 6 r s € a i n gr n g i n F e p l a c €r e a r s e a l n gr n g

The park n9 brake warnifs Wrongly adrusredswitch

Defectve €leclricalparrs Replacedei€crive pa{s
FoorbrakewarninS amp

Warning lamp does nor qo Fep ace warning va ve

our when prstonsnave
reiu.ned ro norma posiiion
Warn ng when pressure Defectivewarni.g valve
dtierence is other lhan
5 15 kp/cm2(7 213 ps)

9 r0 hcoriecrourcorngpressure

t1 All wheel brakes fade Incotredly adjustedtf onr Adjust the p.€ssLreplunger
pre$lre plungef in power cylinder
Blocked equ€lizinghole n Reconditon ihe master cylnder

The reaf wheel brakes fade Pa.kn9 brake cable chaies

Incorecrly adjusredp€rkrnqbrake AdtLst lhe parkng brake

Reconditionwheel brake unit

12 Adjlsrlronrwheelboaings
Brakeds sudacelnev€n
Loosefronrwheelbeaings Adtuslironlwheelbearngs
l,lachineor fepacebrak€discs

inbackoi manual
Gtoup 50

Group5 1

Wheel BrakeAssemblies

Replacingbrake pads maged.ll dill has penelratedinto lhe cyhnderdue

' o . o a - d g e d c o ' - . I P c o - d , t , o _t h e b ' a l p . n i ' .
Check the friciion area of the brake disc. Grind
off rusl ihe brake pads should not be used for
The brake pads should be repaced when approx 3
m m ( 1 / 8 ' ) o f t h e l i n i n gt h i c k n e srse m a r n sO n n o a c - 6. To provideroom for the new brake pads, press
c o u n l m a y t h e l i nn g s b e w o r n d o w . b e l o w 1 . 5 m m the pislons into the cy nders.The pistonscan be
(1/16 ).

L Removethe hub capsand slackenthe wheelnuts


2. Jack up the vehicleand pul slandsunderrhe r€ar

axle and fronl jack attachments. Bemove the
whee nuts and ft off the wheels.

3a.Girling:Removethe hairpn shapedlockingc ps

lor .t.9ude pns Pulloul oneol he lo,I oin'
whileholdingthe dampersprngsin pace.
Bp-ovF r.1espr_g. ._d _l'eorl'e o' \ pa.

3b.ATE:Tap out the upperguide pin wilh a driil, p r e s s e idn e v e n l ya n dw i r h o ! l r i s k w l h l o o l 2 8 0 9

diameter2.5 mm (9/64"), see Fig. beow accordng 10 Flg. below:
spring.Tap oul lhe lower
Takeoutthe iensloning f done propery, ihe pislons can be pressedh
guidepin. p€rhaps more rapidy with another tool in the

Pushingin Piston

4 Puloulthepadswilhloo 2917.lilhe usedpadsarelobe same way but, for exampl€, f a screwdirver s

rp-rsHled, maa thAmto ensurFrt.y dre reslorpdlo used ancl wro.gly app[ed, the pad, rubb-"rseal
a n c lp s r o . m a y b e d a m a g e d N . ote thal when
pressing in the pisions, lhe brake tlud level in
5. Carefullyclean ou1 the cavilYin whrch the pads r h ec o n l a l fe r r i s e s o t h a tt h eb r a k ef l ! d c a ns p u r t
ar€ located.Replaceany dust coversthat are da'

Gtoup5 |
Brake pads

7_ FeafwheelbrakesATE:Checktomakesurerhepisrons previouslybeen installed,they should be re

a.einlheproperposilion lo avoidbake squeal. Thepis lowardslhepad
1onrecessshoLrld incline20" inreationtolhelowergude Use a leele qauge for lhe r'rslallalion,
areaon thecalipercheckposition wirhremplare 2s19 greaseor glue.
seeFlg.beow.Thelolerances 1 2', lhal is,whenthe
lemplaleisplaced agansltheonefecess.lhe distance
theolher(meas.A)maybema;.1 nm = 0.04".lineces
sary adjuslth-alocation
this movelhetoolintoposlionasshown

A Damperwashers

Intermediateplates must nor be nsralledln cat-

ipers eq!ipped with round damper washers.Po-
sition one of ihe lock p ns and instattthe dar,,pc,
Pfess the tool.against the pston and force spr ngs and the oiher lock pin. Fix the pins with
the Shoesby screwing in the handle.Turn new ocking cl ps. Checkthal the padsare mova
piston,reieaseihe too and re-measurewith
8b ATE lrstalllhenewpads P aceoneot theguidepmsn
positionandlap it in wth a hammerwilhoulhelptroma
loo. seeFlgbelow.

of guidepin,ATE

N O T E : T h e g !d e p i n m u s ln o l b e k n o c k e di n w t h
d dr 1 which l_dsd db.n"re malle' rhan l-e pin
s 1 _ pl \ P r e r so r n 9 \ p F v pc a nl h e - s h e d ro < fl h e
p i . . t d n o et - s r a L dn e w l F r s i o n rg " p . r r g t o r r t - a
8a. G; ing: Install the new pads. lf the caliper pre pads. Install the olher gude pin wh e pushing
v o l s y h a s b e e n e q up p e d w t h i n t e r m e d r a i e ' r l p l p n s i o r i n q) p . i _ q .C h F . l r l ' a r t l - ep a d s , .
pates between pad and ca per, they should be
re nslalled. 9. A r . r , p p l d c : nbSr d t eo c d s d e p F < sr h pb | a ( p p "
ll, on lhe olherhand,rounddamperwashe.shave ddl severa r mer ro .he.l rl-ar rle r overnenrb

Gtoup 5l
Frcnt brake calipers

normal. Generally,the system does not require Disassembly

bleedingaiter replscingthe brak€ pads. 1. Bemove th€ brake pads.see operslions 3a and
lO. Be instal the whees after cleaningth€ contact 3 b u n d e r" R e p a c n g b r a k e p a d s .
surfacesand blake disc of sand,dirt. etc. Tighten 2. Remove the retaining rrgs andlhe rubberdustcove6
the nuts slfficienty so that the wheels are se Placeawoodendisc. seeFig.beow betleenthepstons
cureLyheld. Lower the veh cle and tighlen finally andpresslhem oltrowardslhediscwnhairasshown
the wheel nuts. Tighten every olher nut a little
at a time until a I a.e f na y tighlenedto a torque
o i 1 0 0 l 4 0 N m ( 7 0 - 1 O Ol b . f l . l n s t a l lt h e h l b

N.B.The function and Lifetme of the liningswl

benefit if lengthyand hefty brakng is avoidedin

Reconditioningwheel brake units

When working with the hydraulicsystem,obs€rvethe
Instucriorsuopr"C..1rrS a-o B'dreflu,d Gro o

Front brake calipers

Wooden inserr Jo. brake calipeis

AA = 15.5 l5/8") ior lfonr brake caipers
1 3 m m { l / 2 " ) f o r r e a r b r a k ec a i p e f s
1 F e n o l e l h e l - - b c a p , d n ds l r ' I e 1 l h " w h e P r . r .
c [ q h r r . T e m o o ' a ' i v b l o ( l t h e v e n t - h o l ei n h e
brake flurd container cover to reduce leakage.
2. J a - k d p l ' e f , o n _. _ d d n d p - r s t a n d ,L 1 d - r r r p
1 o . 1 F c l d r r . c h m " ns T h e ' o - n o r a r m <s F o Lc l
oe off oaded so rhat the brdke hoses(dn be -
>td ed r rl_e po{Ion. 3.move rle whFel
nuls and lift off the whees.
3. Di,conr r fl " bra!- hles arlte .arpe Tl-ele.ova
therelaining screws(2)andthecaliper.
r€. :
' :":...


I Woodendisc

T h ep s t o n s c a nt h e nb e e a sL y r e m o v e d . l fpai s t o n
feels stlff io remove, lse a r pressure.Lever off
the rubber covers.
3. Remove lhe seas with a blunl lool. Be carefull
no o d"m"ge _l'eedqesol the g'oovps Scr-w
olr the bleeder n pple ancl brake ines.
The brakecal per halvesshouldnot be separated.The
reasonfor thls s that slibsequentassemblywould re
qu re test pressureequipmentand speciaLfLuid for the

Gtoup5 |
10 WheelBrakeUnits
Front brake calipers

5. Instal brakepads,se€operatonsSaand 8b und€r

brake pads".
6. l n s t a l b e e d e r n i p p l e sa n d b r a k el n e s .

L Positionthe ca ipers.Checkthat the contact sur-
fac€sof the retainerare cleanand nol damaged.
Checkthe localionof the brakecaliperln relation
to the brak€d sc. Axial dev ation s checkedwlih
a ieeler galge on both sidesof the d sc the dis
tance between d sc and calipers!pport nib. The
difference in rneaslrement is max. 0.022" =
0 . 0 1 0 n r m . I h e c a l i p e rs h o u l db e p a r al e w t h
t h e d s c T h s i s c h e c k e db y m e a s u r n gi h e d i s
lance to ihe upper and lower srpport nibs ln the
ca per The ocalion of th€ brake calipercan be
Removingpisron adlusiedwirh shims,which are avaiablein thrck
A = rlbber dlsl cover n e s s e so f O O 0 8 " a n d 0 . 0 1 6 = 0 . 2 a n d o . 4 m m .
nstal the att6ching bolts after they have been
coaied wilh a colpe of drops of Loclite. type
Inspection AV Check that the brake dsc can rotale easily
Before nspeclion,cleanall parls accordifg 10 ihe n rn the brake pads.
s n d e r" C l e a n l n g 'G, r o u p5 0 . M a k €s u r er h e
s t r u c t i o nu 2. C o n n e c t h e b r a k el n e s t o t h e c a l l p e r R
. emove
t h e p l u g i n t h e m a s t e rc y l i n d € r
Seals and rubber dust covers shoud be r€paced. lf
cylindersarescoredor scratchecithecompletecy nder
housing should b€ replaced.Inspectthe other parts
and replace .ny damaged or worn.
Check also the brake dsc, see under "Brake Disc ,
page5 13.

1. Coat the working suriacesof pislons and cylin-

ders wrth brake flu d.
2. Inslall the seals in lhe cy nders.
3. lrsta I the pislons with rhe large diameter end
lac ng nwards.Makesurethepistonsareinstalled
straighr and nol scralched.
4. l n s l a l l h e r u b b e r c o v e r o n l h e p i s r o n a n d lhl rosut sailn g


3. nsta I the wheel after the contacl sudaces have

b " e n . e d n e do ' d r F r . . a n d r l p r S l r p . n e
n - . c s u f fI r - a ry , o r t d r r l e r h e e . a l n o - o F o s
p a c € do n t h e h ! b . L o w e . l h ev € hc l e a n d t i g h t e n
l l _ ew h e a l J r - . .p1 p\pn o her rJt l.
a t a l l m e l ] n l a l l a r ef i n a l yt i g h t e n e dt o a i o r q u e
o{ l a o N - ' / O 1 0 0 o . l r ) I n < l d lr h e n . u

Bleed the brake system, see Group 52.

Spare Patts Illustrations

ATEfront wheelbrakes
242 - 53864

'Q., 244 42979

245 - 54149
264 9674

:Q; e
Girlinglronl wheelbrakes
242 53464
244 42979
245 - 54109
264 9674

Girlinglront wheelbrakes

242 53465
244 A29AA -
245 54710
262 all
264 9615
265 all

Sparc Pafts lllustntion

ATE rear wheel brakes

(code 2 on Service Plate)


Girling rear wheel brakes

t:"> (codeI on Servce Pate)

'qi <


Rearbrake calipers

1. Removethehubcapsandslackenlhewheelnuts
prJglhe brakeflud co'rlaire
caplo reduceleakage.
2. Jackup the 'edrerd andpur srdnds ulder rh.
rearaxe.Removewheelnuts andthewheel. Rel
easethe parkingbrake.
3. Disconnectihebrakelineandinslalllheproteclive
cover.Removelhe attachingbolts.Flemovelhe

Disassembly Removingpiston
1. Removethe brakepads,see 3a and 3b under A = rubberdusrcover
''Replaclng brakepads".
2. FemovF rhe r€tair,ng ring and the rubber dus' Remove the seals with a blunt tool, so as not
covers olacea wooden disc be'weFn r\e psrons to damagethe edgesof the grooves.Screw out
and prFss rl.Frr oJr _owardsrhe disc, using d,
pressL.e.The pislons Ld_ | he1 be easilyrFmovecl. The brakec; iper halvesshouldnot be separated
Lever off the rubber covers. The reasontor ih s |s thatsubsequentassemblrn;
3. lf p:ston feels sriff to remove. use atr presslrre woJld requrp tesrp essurepqu pre']l and special
to blow it out. The cylindercan be sealedby a
rubber washer and tool 2809:

Gtoup5 |
Rear bnke calipers

Before inspectingcean all the parts accordingto the
instructions!nder "Cleaning",Group 50. Make s!re
the ch.nnels are clean.
Sealsand rubber dusi covers are replacedafler each
recondiloning.lfcy inderls scored,scralched,etc.,lhe
entrrecylinderhousingmu b€ repaced compleiely.
Inspectolher parts an-drep ace if damaged or wom.
Also check brake disc, see Brake Disc'-

1. Coat the working slrfaces of the pistons and
cylinderswith bral(e fluid.
2. Instal new seals in the cylinders.

o 3a. Girlngi InstaI one of the pistons in the caliper.

Make sure the piston is installedsralghl ancl is

3b- ATE: Check to make sure the pistons are in rhe Adjustins106tion
proper positionto avoid brakesquea. The pston

o recessshould incllne2Oo in relaton to the lower

guide areaon the caliper.Checkthe locatof wth
template 2919, see below:
Pressitagainsl lhe pistonandforce out the shoes
byscrew ng in the handle.T!rn the pislon,release
the tool and re-measurewilh the iemplate.


The toleranceis t20, that is, when the template

is placed againstihe one recess,the distanceto
the other(meas.A may be m;x- 0.040' = 1 mm.
lf iecessary,adjusllhe location
of lhe pislonwithtool
2914.To dolhis,movetheloolinloposilion asshown. Rearbrakecaliperassembled

Installand test the olher piston in the same way

as above. Placethe new rubber dlst covers on
ihe p|slonand housing.Installnew reta ning rings.
5. Instalthe brake pads,see 8a and 8b under "Re
placing brake pads".
6 Screw in ihe bleeder n pple.

Gtoup5 |
WheelBrakeUnits 15
Rear bnke caltperc

1. P o s i to n t h e c a p e r ,C h e c kt h a i t h e c o n l a c rs r r L
fac€sof ihe reta ner are cleanand not damagecl
Checkthe locatioi of the brakeca per In relation
to the brake disc when the drv€ shaft |s at the
outer posirion wrth n the clearancelirn ts. Atia
deviarlon s check€dby measurngwrth a teeler
gaugeof both sidesof the disc the dislancebel
ween dlsc and ca rp€rsuppoft nib. Permitledd t
f e r e n c ei s O . 0 1 O = 0 . 2 5 m m
The calipersho! cl be paraLlewirh the drsc.Th s
s checked by rneasurlngthe drstance1l) upper
a . d o w e r s u p p o r ln i b so n t h e c a L p € rT h e b r a k e I
ca iper ocationcan beadlusted\'!ith sh ms. which
are availabe in thick.essesbetwe€n 0.024 ancl
0072" = 06 and 1.8 mm. Coaithe attaching warp
bots wth a colple ol drops oi Locnte,rype av,
and lhe. instalth€m
F rst check thar the whe€l beaf ngs are cotrectly ad
2 connect the brake line Removethe p ug ior the
breatherhole i the brake fluid conta ner cover l l s t e d a n d t h a t t h e d i s cf i t s s e c u r e Yo n t h e h ! b T h e
t h l c k n e s s m e a s ! r e dw i 1 hf,o r e x a m p l ea. m i c r o m e l e r .
3. Cleanlhe wheel contactsurlacesand disc beiore
n s t al a l i o no f i h e w h e e . T i g h t e n| h e w h e e n l t s
s o m ! c h t h a t t h e ! ! h € e l c a n n obt e m o v e d .L o w e r
It sholld not vary more than 0.0008" = 0.02 mm.
when the disc is rotated one l!rrn,srnceth s can cause
a v brat ng brake pecla.
the vehicle and tighten ihe wheel nuls fna y.
f a f a ! l t s d i s c o v e r eddu r i n g t h en s p e c t o nt h e b r a k e
Tg'lLe'rev"'volh' nLla linle"l"lime Jnl' '' -r'
disc shoLrd be replaced.
finally lighlenedto a lorqle ol 70 100 lb fi =
When do n9 th s, th€ brak€ ca Lp€rshoud f rsr be re
1 0 0 - 1 4 0 N m .l n s t a l l h u b cap.
m o v e d .T h e n r e m o v el h e o c k b o t s a n d i f l o f f t h e
4. Bleed the brake caliper.see Group 52
brake disc.Tap o. the nsde of the d sc with s€veral
ght blows from a plaslic hammer or similar lool
Brake disc
ll for some reaso. a new brake disc is not ava Labl€.
The brakedisc shouldbe examinedwith regardto l.ic_ the old one can b€ recondtioned by fine polishng or
tion surlace,warp and thickness. i l n € t ! r n n s A c c u r a t e d i sac l i g n i n gisrequired a n dt h e
Small marks on the irlction surlace or linings are oi rurn ng sho! d be eqla on both sides.
minor mportance,bul radialscraichesincreasebrake After r!rn ng, the disc thicknessmay not be more tha.
' 0.050 = I) olgao rhirle.s \-r
pad wear.The warpmusl notexceed0.004 = 0.1 mm ''Specificar
f o r t h e l r o n t w h e e l b r a k e s a n d 0 . 0 0: 60 . 1 5 r . m l o r l h e ons The surlace fin sh sho! d b€ max. 3
rear wheel brakes al the ouler edge of the disc and is r i m e a s l r e do n a n a r b i t r a r yd a m e l e r a n d m a x 5 I
measu.edr.dlaly. Aiier recoid lioning. the dlsc warp
may not exceed0.004" = O I mm. aid ils thlckn€ss
may nolvary nrorethan 0.0008" = 0.02 mm.

Priorto machining
Nieasureihe lhicknessof the disc and inspectior de- 0'
iects such as corosion, deep groovesand pad marks.
Nlinmumthicknessmuslalwaysbe mainlairedaflerthe
machiningoperation. I
The rninlmumthlcknessofthe dlsc is casl inlo the disc


Master cylinder Removethe containerby pulllnglt upwards.Re
move rhe containersealsfrom the masler cylin

When the mastercylinder s removed.the brakepeda 3. Remove the snap ring (F g. below)
should not be depressedbecausethe resultingabnor Remove pistons and ret!rn spring.
mal position of the power cylinderpans may cause Cleanthe master cylinderand ali parts in a coho
l or other slitabe solvent. Bow compressedair
ihroLrghequalizingand ovedlow hole.
I Removal 5. Examinethe nside of the cylinder carefully.lf
Placea cover over thefender and ragsunderihe mas- scored or scratched.the cyinder should be re-
ter cylinderin order to avoid posslbledamageto the placed.Eorh pstons with connectorsleeveand
paintwork from the brake fluid. s e a l sa r e r e p l a c e d ' a sa n a s s e m b y .
Removebrakelines(1 and 2, Fi9.below)andfit plastic 6 . Coal rhe cylinderwth brake f uid and ubricate
plugs.Then removethe retalningnLrts(3)and remove the pislon seals with specia brake grease {av
ailabLe ar vendors).Then nstalpistons,sprng seat
and spring, see below:

1. Removefiller cap and strainerand 1. PoshlonthecyLinderoverthe pBtons and the spl



FootbakeSystem 17
Bftke lreducel) valves

8. lnsiallthe snap ring fo. the Brake(reducer)valves

F o r c h e c k i n gt h e b r a k ev a l v ew t h t e s l e r 2 7 4 1 . s e e
separateInstructions.The valve cannot be repanedif
defectve and riust be replaced.

L lnsia L the brake f uid conia ne. with seals.


6 R g h r b r a k ev a v e
2 Bfake hose ro lell rear 7. From lhe master cyif-

9 From lhe masrer cyln

5. Brake hose 10 riqht rear der secondarycrcui

1. Disconnectand p ug connection{9) of the brake
p i p e .L o o s e nb r a k eh o s e{ 5 ) m a x i m u ml / 4 i u r n
I I at the valve. Removeatlaching screw and valve
from the brake hose:

Posilof the masler cylinclerand installthe reta ning
nuls. connecl the brake ines and bleed the brake
syslem accororngto nstructrons. 0l

Removansbrake valve

2. Screw ihe new brake va ve onro the brake hose

wth new seal.Posiion the valve and check that
t h e r e i sn o l e n so n i i t h e h o s e . I n s r a l l t ha€t t a c hn g
screw and connect the brake pp€. Tighlen the
c o n n e c t i o nB. e e d l h e b r a k €s y s t e m .

Brake lines bleeding

The brake linescan be cleanedby flushingwlh brake
fluid or alcoholand then by blow ng theri cleanwith
moisture+ee, f hered,compressedair. This is to .e
move all brake fluid and dirt pariices and sholld be
madein conneclionwith reconditioningof the hydraul
ic system and a nesfrlring.
When recondilioningsystem, lhe brake service unit
(seeGroup50) can be connecledb lhe mastercylinder
and lher l\e syslem enplied lhroLghrhe bleederrp-
ple. The system should thereiore be flushedwlth al
cohol and blown cleanwhh compresseda r. The com-
ponentsof the hydra!lic syslem should be laken o!1

o and checkedto ensureihat any dirt and flushingfluld

have been effectively removed.
NOTE: See generalinstructons in Grolp 50 for re-
quirementsconcerningcleanrngagent. Do not top up
Frontwhel bEke hoseslearliermodels)

whh brake fluid which has been drained from the

Replacing brake lines

lf leakaseoccurs or if the blake lines have b€en ex-
posed to such externaldamagethal leakageor block
age can resuk,the damagedlinesshoud be replaced
according to lnstructionsbelow lf the replacemenl
concernsthe front brakehoses,it sho!ld be madewllh
no load on rhe front wheels.
1. To preventunnecessary spillingof brakefluid,the
exisl,ngfikercap o'1the masrercy[nderconrarrer
should be temporarilyreplacedwith one wilhout
Froni wheel bEke hoses (later models)
2. Cleanround the conneclionsand removethe da
rnaged brake line.
pedalcan be depressed wthout any appreciable re,
3. Take a new brake line, blow I cjean inlernally
sislance,or it ieelsspongy.
with moisturejree. fikered. conrpressedarr and
f r l r r . l v l a . e s L r e r h e b r a li.eehI e s 1 s u c r - .p o s , n o a
As soonas anypartol lhe systemhasbeenremoved,
bleeding muslbe made-Aircanalsoenlerlhe system
rhat it doesnot chafeaganst anythingduringdnv
ing. Padicularlyimponant po nts are where lh€
lf thereis too smalla quantityoi b€ke lluid in the con,
pipespassthe steeringrod, where they must nol lainer.lfonlyonerearbrakecaliper hasbeenremoved
andlittlebrakeJuidrunsout,it is generallyonly neces-
'0 c o m e n e a . e rt h a n 1 0 m m ( 3 / 8 " ) .
lf the pipe is not bent corrccdy,h should be ad-
lusted manuallybelofe being Installed.Bending
saryto bleedihe b€ke caliper.Otherwise, b €edthe

a pipe which is aheady connectedoften resulls No brakelluidmuslbe pemittedto comeintoconiact

in detormationar theconnections.Thefronl brake wilhfictionsurlacesor linings.Avoidspillinganylluid
hoses ray only be installedaccordirg ro FtgJres on lhe painlwork as thiscan damageit.
above right. Shouldthe car be on standsduringthe b eeding,lhe
rearendshouldbe higherlhanthe lronl end.
Bleedthe brakesystem accordingio instrlrciions
below. Then re- nsta the fi er cap wirh the
Whenfiliingfluid,thelollowing shoud beobserved:The
breather hoie on ihe container.
brakeluid mustfullll ihe reqliremenlsaccordinglo
DOT4 SAEJ 1703.Blakelluldwhlchhas beenoeo
fromthe systernmustunderno circurnstances be re
Bleedinghydraulicsystem l-.ned lo lhe b eederJlil or lhe brale . uioconainel
A signlhal thereis air in the systemis lhatthe brake Bleedinqoi the entireb€ke syslemis as follows.

FootbrakeSystem 19

Bl€edingthe brakesystemwith bleederunit 4. Open the lhre€ bleedingnippes. Pump the brake
pedalfive lim€s and then closethe bleedingnip
This procedure concerns bleeding when the brake
rnaster cylinder has been €mpted of brake fluid. lf
5. Move the hosesand coll€ctingvesselto the righl
the master cylinclerhas not been emptied,disregard
front wheel. Open the nipples,pump the pedal
9. 10 and 11.
five limes and then close the nlpples.
I Plr the vehicleon stands and remove the tront
6 Connect one hose and the collectingvessel ta
the right rear wheeLbleedrngnipplel
2. Conneci rhe bLeed€rsit ro rhe take fluid con-
iainer (Fig. below) and set the work pressure10
3.5 4 kp/cm2 = 50 60 psi.

7 . Open the bleedirg nipple. Check that the blake

fluid does not conrainany bubblesand closethe
3 . Siart on left front wheel. Conneci hoses to a
three beeding nipplesand rolte them into a col Connect hos€ and collectingvesselto left rear
wheel.Openthe nipple,checkthatthe brakeillid
does not containany air bubblesand then close

9. Be-connectthe hoses and the collectingvessel

\ to left front wheel, open the nipples,pump th€
pedalthreetimes3nd c osethe nipples.
1 0 . Fepeat on righi front wheel, pumping the brake

' It . R e p e apt o i n t s6 , 7 a n d8 .
1 2 . Checkby depressinglhe brakepedaLwitha pedal
force of approx. 20 kg = 45 lbs. that therc is
no air in the systrem.The pedal travel may not
exceed60 mm = 2 3lA" ard the bfake f8ilure
wafning ight must not light or flash- lf incorcct.
rep€t steps9, 10 and 11. (NOTE:withoutvacuum

13. Disconnectthe and check the brake

Installprotectivecaps on the bleedernipples,in

stallihe fronrwheelsand restore-

Group 52

Bleeding without bleeder unit plesof rhe fronl left wheel.Openthe threenipples
a n dp u m pt h ep e d a l af e w t m e s .C o s e t h en i p p l e s .
1. Put rhe vehlcleon stands and .emove the front
Adjusting brake pedal position
2- Check the brake fluid level.
The brake pedal travel can be measur€donLywhen
NOTE:The flu d leve shouldbe watchedthrough
bleedingthe two brake cncuhs sirnultaneousy.The
out the procedure.
s t r o k eA s h o u l db e a p p r o x 6. . 1 " ( 1 4 5 1 6 5 m m ) a n d
3. Slart on lefi front whee.
r l p p " d a b o r r o - d p o r o ' .0 . 4 - l 0 m - l B ) ' r o 1 r l e
Connect hoses io the three bleedernipplesand
immersethe other ends n brakefluid in a v€ssel.
Do not depressthe brakepedalwith the mastercy n-
der removed.The resuhingabnormalpositionwill da
\ mage th€ power brake parts.

The nipple connectionsshould be tght aid the

hose ends aLwaysimmersed.
4. Pump the pedal 1Olimes. Use assistantsto open
the nippes when depressingthe pedaland close
at the end of the stroke. All nippes should be
opened and closed simutaneously.
5. Repeat the procedureat the right front wheel.
6. Depressthe pedal 3 5 iimes, all nippl€scosed.
to out'the master cylinder.
7. Connectone hoseand the vesseLalthe rear right
Approx.6.1 (145 165 mm)
wheel bleeder nippe.
Approx.04 (approx.l0 mm)
When released.ihe brakepedaLsho!ldbesame height
as the culch pedal.To adjusl, slackenrhe ock nut,
remove the cotter pln and tlrn the iork.

Adjusting brake warning light switch

8. Open the nippleand "gravity beed . no pump ng

of the pedal. Close the nippLewhen brake f Lrid
free from bubbles comes out.
L Repeat the rear left wheel.
10. To re-assurecorrect bleedingof the mastercylin T h e d i s i a n c eA s h o u l db e O . 1 6 "( 2 - 6 m m ) .T o a d i u s t .
d e r .r e . o . 1 e c t h o q e sa n dv e s s ed r _ h Fr t r e en p reLeas€the relaining screws and move the brackel

FootbnkeSystem 21
valve repair kj.t

9l!t \'

c' dlaphragln

rePair kit

I *---.
u "t O(

Replacing power cylinder Installing

1. Checkthat the rubbercover is presseddown pro
perlyat the protectivewasherfor the cleaner.Se-
Removing cure the fork to ihe ink a.m. Push in the power
cy inderso that the attachingbolts come into po-
1. Removethe master cylinder.Disconnectthe va-
cuum hose from the power cylinder.
2. Place rhe resilientwashers lnder the attachlng
2. Disconnectthelinkfromthe brakepedal.Remove
nuts. Secure the cylinder.
the brackel with clutch pedal stop.
3. Fit the bracketfor the clutch pedal. Secure the
3. Removethe 4 nuts securingthe power cylinder.
link arm ro the brake pedal.
4. Pull ihe power cylinderforwards and disconneci
4. Fit the vacuum hose.The connectionfor the va-
the fork from the link arm.
cuum hose should face downwards.
5. Bleed the brake system.

Thevacuumpumpdiaphram shouldbe@placed
km)asparlol regularmalntenance
io ensureet'

1. Pui lhe plmp n a'vise. Use soft jaws. Remove
rhe va ve housing cover.
2. M a r k t h e p o s l i o n o f i h e v a l v eh o u s L n gB.e m o v e
ihe vaLvehousing.

3, InstaI bottom cover and gasket,

4. P l a c e w a s h e r a nOd r n g o n t h e c l i a p h r a gsmc r e w .
Apply lockng illid on the screw end.


3. Removediaphragm,washersand springfrom ihe

5. I n s l a Ldl r a p h r a g ma s s e m b l y .
6. I n s r a l vl a l v eh o u s i n ga c c o r d i n g1 0 m a r k n g
7. Inslall valves and seas.

4. Turn the pump upsde down and removethe bol

5. Bemove pump lever pin. Remove pump lever,

pump rod and nylon bushing.

1. Place the bushing on the plmp rod. Insla the I n p o o r " d { o F o f r h Fd . ' s s h o - l dp o i n rr o w d r d.
rod in the pump housing.
2- l n s t a Ll le v e ra n d p n . 8. l n s t a l l v a v e h o u s l n g c o v e r w i t h s p r i n ggaansdk e t .

Gtoup 52
FootbrakeSystem 23


o (



1 050 11608
Patkiw Bmke
Adiusting pa*ing brake

Adjusting parking brake

T n e p d r < r n gb r d l e s l o - l o o F ' u v d p o r e da r n o r '\ ' s

3-4. Olherwise adiust th€ parking brake as follows:
I Remove the rear ash tray.
2. Tlghren the wires with the adlustmentscrew a1
the rear end of the parking blake lever so that 3 . R e m o v ec l a m p( l ) f o r t h e b r a k eL i n eS. c r e w o u t
the brakeis fully appliedafter2 3notches: the retainingscrews (2) for the yoke:

3. lnsia I the ash tr3y. 4. Hang up the brakeyoke in a w re so that no sharp

berrds are made on the brake line:


1 . Removethe rear ash tray and screw out the ad

justment screw at ihe rear end of the parking
brake Leverso that the cable is slackened.
Plt the rear end on standsand removelhe rear 5 . Removethe boltsfor the brakedrum and remove

6. Unhookthe spnngswnh a brakespringloo Fe
m o v el ! e b ' d l F o h o a (d n d . l " d d j u s r e _ r d e v i , e .

/. B"fo e n\Idlltr 9 nFw \l op. l_e. rle e o

noo lp.,dSFl'omr1-r"" a^,- Al,ocne.l r1"_
leva's. cabes ard aojLsrnFnt device: d.e ror
worn or seired The b'ahed'urs s'louldbe e-
p acedil they are scored,convexor out ol round
morprh"a 02 m = 0008 C e"1 rr- ho1,
>L taL-< fo r\- brctp shoes or 't-F b 116 .t 6id.
L A p p y a t h i a y e r o fh e a tr e s s t a ngi r a p h h eg r e a s e
o n . r - pb , Lo p s t : d i n g\ J r r o . p ( o r r t e D . c - .
\ h : p t . l . o n r f a t a \o . a n d o n r t € d o _ u s r r - . rc t F
9. nsta L brake shoes and lower rerlrn spring

Stop turning when rhe dr!m tusr about cannoi

be t!rned around.then iurn back 5-4 teeth. Turn
10. Installupper rctum sp ng and adisstmentdevrce: the brake drum and check rhat the brake snoes
11. Installbrakedrum and b6ke catiper.Usea tocking do not drag. f that s the case,turn back anolher
fluid for the caliperretainings€rews.Check that 2 3 teeth.
the brckediscis freefrom the brakepads. 14. lnstal the wheels.
1 2 . C l a m pt h e b r a k e l i n e t o t hree a r a r t e : 15. Tghlen th€ wires with the adluslnrentscrew ar
13. Align the blake drum so its hote is in front of the rear end of the parking brake ever so th61
the adjustmentscrew and adiust the shoes by the brake s fully appliedafler 2 3 notch€s.Res
turning the adjuslmentwheet with a screwd ver.

Patkins brcke shoes

Replacing parking brake cable, one 7. Hangup the a wirc so that no sharp
side bendsarc causedon the b€ke line
t n t, . ,

Renrovethe parkingbrakelev€rcover.Disconnect
the wlre for the ash tray lghi.
2 Slackenthe wlre by-screwingolt the adluslmeni

8 Bemove the brake drurn.

I Unhook the spr ngs wlih a brake spring tool and
remove the brake shoes:


Bemovenut {2) while retainingthe cablewlth a

small screwdriveral the end.
NOTE: The cables cross each olher under the
floor which means that eft cable controls right
w h e e la
, ndviceve6a.
3. Lift the ffont end of lhe rear seat cushion,fo d
away the {loor mat and loosenthe clamps hold-
ing the wire to the floor.
Disconnectthe wire end sleeveand rubbergrom-
met lrom lhe rearseatsuppon. '".,,';
Put the reaf end on standsand removethe rear

Femovethe clamp(l ), for the brakeline, Bemove 1 0 . Pressout the lock pin .etainingthe cableto the
the retainingscrews(2)for the brakecaliper:

Gtoup 55
Pa*ing brckeshoes
1. Rernove thescrew(1).Pllloutthecab e (2) and heat ressiant gr.phite grease.Attach the lev€r
plaslictube(3) withrubberseat:

17. Push in the cableand locatethe lever beh nd the

12. P u l o u t t h e c a b e a s s e m b yf r o m r h e c e n r e rs u p
port and the iloor passage rear axle ilange:
l 3 Align the plasiic lube through rhe tacker and
insta the rlbber seal:

18. App y a thin ayerof graphitegreaseon rhe sliding

surfacesfor the brakeshoes.Installbrake sues
ano ower .eru.n spr ng:

Route the new cable through the center support

a n d r h r o u g ht h e h o l e i n t h e f o o r .
NOTE: The left wheel cable should be rolred
thro!gh the holeto the rightof the propellershafl,

Fight whee cablegoes on lop when rh€y cross.

t 5 Boute the cablethroughihe plasricp pe and con
nect it to rhe bracket.
1 6 . Lubricate the lever pivol as well as the slidng
slrfaces for the brake shoeswith a thin layer of


To avoidexcesstemperalure buildupin the brakesys-

lem,carefuldfivingiechniques,including enginebrak-
ingon down-hill
is heavilyloaded,Sinceefficientbrakecoolingis also
impodantunderthesecondilions, accessoryspoil€rs
shouldonlybe usedinconjunclion wilhVolvoalloyrims,
whichprovidegreatea brakecooling.


On vehiclespriorto chassisnumberslistedb6low,in-
slallahardtypebushingP/N1221982-0onlh€ rightside
Manual,Section 6 {TP300001)).
242 -131408 244 -3m353 245 -1a3700
262 3415 2U -52806 265 -12930
NOTE:Theharderbushingis standardon theleftside
on vehicleabovethesechassisnumbers. Thebushing
canb6 insp€cted withoulb€ingremovedandidenlified
as illuslraledbelow.The bushingshouldalso be in-
spected lordamagesuch ascackswhichwillcausethe
1205826€ 1221W24 bushing to loseitsresiliency.

Brakedisc condition "A" and"8" shallbe conectedwilh the useol ABRA-
To assislin diagnosisandto detemine coflectivemea- SIVEbrakepads.
sureslisledbelo{dare examplesol brakediscsurfaces: Discshavinga lrictionsurfaceas shownunder"C"and
'' D" mayhavelo be resurfacedlhroughthe useol a spe-
Brakediscshevingafriclionsurfaceas illustraled


Seve|al elongatsd mark!.

csu3lng hlgh 3pol3.
c D

Slngl€ msft 2"-3" long cau.lng Smalldeeppltt€dhol*.

low sDots3 ahown.

Characteristicsol AbrasiveBrakePads Experiencehasshownthe necessity tor machining of
padconsislsof a slandard brakediscsasnotverycommon. Shouldit,however, be
Theabrasive padwilha very
€quked,discsshouldbe machinedin pails,i,e.,lrcnt
thinlopcoatingof abrasive material.Therclore,it is not
wheelsandrcafwheels,withthecutlingdepthkeptto a
necessarv lo reinstall
Somebrakesouealandnoisewill be Dresenluntillhe
ab€sivelaveris womdown.Thiscouldlasl uDto 300
miles,depending onlrequency of brakeapplication.
Inmoslcases, it issulfcienttbuseabGsivepadsonthe
liontdiscsonly.Dueto lhe possibility of rearwheelloc-
kup,abrasive brakepadsshouldnotbe insialled on the

Thelaloslvsrsionabrasivepadslorthelont brakesdoosnot
haveanabrasive layer,bulae slighlry

lNtituts for
luto 0n$

8YT E t{.t.^.S.E.