0 Audi A3 1997 Repair Manual

Manufacturer: Audi
Model: A3
Year: 1997

Contains the following information and repairs for:

• Electrical
• Starter
• Current Supply
• Windscreen Wiper and Wash System
• Lights, Lamps, Switches - Interior
• Lights, Lamps, Switches - Exterior
• Wiring 
• Interior Equipment
• Passenger Protection
• Trim/Insulation
• Seat Frames
• Seats - Upholstery, Covers
• Maintenance

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File Size: 45 MB

File Type: PDF, RAR

0 Nissan Sentra B16 2008 Repair Manual

Manufacturer: Nissan
Model: Sentra B16, N16
Year: 2008

Contains the following information and repairs for:

• General Information
• Engine Mechanical
• Engine Lubrication System
• Engine Cooling System
• Engine Control System
• Fuel System
• Exhaust System
• Accelerator Control System
• Clutch
• Manual Transaxle
• CVT
• Front and Rear Axle
• Front and Rear Suspension
• Road Wheels and Tires
• Brake System
• Parking Brake System
• Brake Control Sytem
• Power Steering System
• Steering Control System
• Seat Belts
• Supplemental Restraint System (SRS)
• Body, Lock and Security System
• Glasses, Window System and Mirrors
• Roof 
• Exterior and Interior
• Instrument Panel
• Seat
• Manual Air Conditioner
• Starting and Charging System
• Lighting System
• Driver Information System
• Wiper, Washer and Horn
• Body Control System
• LAN System
• Audio Visual, Navigation and Telephone System
• Auto Cruise Control System
• Power Supply, Ground and Circuit Elements
• Maintenance

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File Size: 62 MB

File Type: PDF, RAR

0 LUV 1975-77 Drive Axles Repair Manual

DESCRIPTION

Axle housing is banjo type with removable differential carrier and semi-floating axle shafts. Ring and pinion gears are hypoid type in which centerline of pinion is set below centerline of ring gear. Differential case is a one piece, two-pinion design. The axle shafts are retained in housing by cone type roller bearings and bearing retainers at axle housing outer ends.

AXLE RATIO AND IDENTIFICATION

All LUV models are equipped with one type of rear axle assembly. To determine axle ratio, divide the number of ring gear teeth by the number of drive pinion gear teeth.

Fig. 1 Exploded View of LUV Rear Axle Assembly

REMOVAL AND INSTALLATION

Axle Shafts and Bearings

Fig. 2 Exploded View of Axle Shaft Assembly

Removal - Raise vehicle and remove wheel and tire assembly. Remove brake drum, brake shoes, and disconnect parking brake inner cable. Disconnect brake line from wheel cylinder and cover end to prevent loss of fluid and entry of dirt. From inboard side of brake backing plate, remove four nuts from the bearing holder through bolts. Pull axle shaft from housing.

Bearing Replacement - 1) Flatten locking tab of lock washer, then mount axle shaft in a vise, clamping vise jaws around lock nut. Using suitable tool (J-24246) positioned on lub bolts, turn axle shaft loose from lock nut, Mount axle assembly in a press and remove lock nut, lock washer, bearing and holder, and brake backing plate. Remove oil seal from outboard side of bearing holder, then drive off bearing outer race with a drift.

2) To reassemble, install bearing outer race and grease seal into bearing holder using suitable drivers. Apply wheel bearing grease to bearing holder, rear axle tube, and bearing inner race. Insert the four through bolts into backing plate, then install bearing holder to backing plate, making sure oil seal plate assembly over axle shaft, position bearing over axle shaft and press into bearing holder. Install new lock washer with dished side away from bearing, and thread lock nut onto shaft. Place lock nut between vise jaws, and using tool used during disassembly, tighten lock nut securely. Bend over portion of lock washer opposite to locating tab to prevent lock nut from turning.

Fig. 3 Sectional View of Axle Shaft Bearing
Assembly Measurement for Axle Shaft Shim
Requirements

Installation - 1) If both axle shafts were removed, insert a .079 (2 mm) shim between bearing holder and axle tube flange of first axle shaft to be installed. Insert shaft into axle tube and install and tighten bearing holder-to-flange bolts. For the second axle shaft (or if only one shaft was removed), insert shaft without shims into axle tube until it comes int contact with thrust block in differential. Measure clearance between bearing holder and axle tube flange (see illustration).

2) Proper size shim for this location may be determined by adding .004" (.1mm) to measurement just obtained. Select a shim or combination of shims, withdraw axle shaft, and install shims between bearing holder and flange face. Reinstall axle shaft and tighten four through bolts. Connect brake line to wheel cylinder, then install brake shoes, parking brake cable, and brake drum. Install wheel and tire assembly, adjust brakes and bleed system.

DIFFERENTIAL CARRIER

Removal and Installation - Raise rear of vehicle, remove wheels and brake drums, and disconnect brake lines of rear wheel cylinders. Disconnect parking brake cable brackets at rear spring location, remove four through bolts from each and flange, and partially withdraw axle shafts from axle tubes. Disconnect propeller shaft from pinion flange and place out of way. Remove nuts attaching carrier to axle housing and remove carrier assembly. To install, reverse removal procedure, making sure to refill axle with lubricant.

OVERHAUL

Disassembly

Fig. 4 Removing Pinion Shaft Lock Pin

1) Mark side bearing caps for reassembly reference, remove nuts and bearing caps, then remove differential case assembly. NOTE - Keep right and left side bearing races with respective bearings. Remove differential side bearings from case using a suitable puller and adapter (J-22888) and J-81072).

Record thickness of each side bearing and each shim pack then place with appropriate bearing race

2) Remove ring gear bolts and separate ring gear from case. Drive out pinion shaft lock pin using a long drift. NOTE - It may be necessary to remove caulking in lock pin using a 5 mm drill. Remove pinion shaft using a drift, then withdraw thrust block, pinion gears, and thrust washers. 

3) Remove pinion nut and pinion flange. Drive the pinion gear from carrier using a soft hammer or drift. Withdraw front pinion bearing and oil seal. Using a drift, remove pinion bearing races from carrier. Mount pinion gear in a press and remove rear pinion bearing and depth shim from pinion gear.

REASSEMBLY AND ADJUSTMENT

Fig. 5 Tool Arrangement for Measuring Drive
Pinion Installed Height

Drive Pinion Depth - 1) Install front and rear pinion bearing races into carrier bores, lubricate pinion bearings, and position in repective races. Install a suitable gauging plate (J-23597-7) and preload stud and pilot (J-23597-9) through pinion bearings and tighten nut snugly. Rotate bearings and insure proper seating, then tighten lock nut until 20 In. Lbs. (25 cmkg) of torque are required to rotate new bearings, or 8-10 In. Lbs. (9.2-11.5 cmkg) are required to rotate used bearings.

2) Place mounting discs (J-23597-8) onto arbor tool (J-23597-1) and place assembly in position in side bearing bores. Install bearing caps. Mount a dial indicator on arbor post, preload dial 1/2 revolution, then tighten indicator in this position. Position indicator plunger on gauge plate, slowly swing across until highest reading is obtained, then "zero" indicator on highest reading of gauge plate. Swing plunger off gauge plate and note indicator reading. Reading is the correct thickness of rear opinion bearing depth shim for a nominal drive pinion. NOTE - Shims are available in sizes from .086" to .101". An indicator reading of .000" or .001" requires shims of .100" and .101" respectively.

Fig. 6 Location of Pinion Depth Code on Head of
Drive Pinion

3) Examine head of drive pinion; pinion depth code is stamped by chemical ink and is the lower of three numbers. A "+" (plus) number indicates need for greater mounting distance (decrease shim thickness), while a "-" (minus) number indicates need for smaller mounting distance (increased shim thickness). See following chart to determine proper shim variation to compensate for plus or minus markings. NOTE - If no pinion depth code is present, pinion is "nominal" and no correction to dial indicator reading is required.

                              Pinion Depth Shim Chart

Pinion Code                                      Correction Required

+10.............................................  Subtract .003" (.13 mm)

+8...............................................  Subtract .004" (.10 mm)

+6...............................................  Subtract .003" (.08 mm)

+4...............................................  Subtract .002" (.05 mm)

+2...............................................  Subtract .001" (.03 mm)

0.................................................  No Correction Required

-2................................................  Add .001" (.03 mm)

-4................................................  Add .002" (.05 mm)

-6................................................  Add .003" (.08 mm)

-8................................................  Add .004" (.10 mm)

-10..............................................  Add .005"  (.13 mm)

Fig. 7 Using Pull Scale to Measure Drive
Pinion Bearing Preload

4) Place selected shim on drive pinion and press rear bearing on pinion. NOTE - Do not press on roller cage; press only on bearing inner race. Remove gauging tools from carrier.

Pinion Bearing Preload (W/ Collapsible Bearing Spacer) - 1) Place drive pinion and collapsible spacer into carrier, then install front pinion bearing and oil seal. Mount pinion flange on drive pinion, apply lubricant to pinion threads, install pinion nut and tighten to 85 ft. lbs. (11.3 mkg). Rotate pinion to insure bearings are seated, then wind a small amount of string (approximately 4-6 windings) around pinion flange. Using a pull scale, note reading required to rotate flange.

2) Continue tightening nut in small increments until pull required to rotate flange is 17 lbs. (7.7 kg) for new bearings or 7-9 lbs. (3.2-4.1 kg) for reused bearings. CAUTION - Preload builds quickly. Nut should be tightened only in small increments and pull scale used after each small amount of tightening. If preload is exceeded, a new collapsible bearing spacer must be installed.

Fig. 8 Ring Gear Bolt Tightening Sequence

Case Assembly - Install side gears and thrust washers in case. Position thrust washers 180 degrees apart, then roll gears into position making sure they are in alignment to allow installation of pinion shaft. Place thrust block between pinion gears and drive pinion shaft into position, making sure roll pin hole aligns with hole in case. Measure backlash between side gears and pinion gears; if greater than .003" (.06 mm), install selective thrust washers to bring backlash within specifications. Washers are available in thicknesses of .037" (.94 mm), .041" (1.04 mm), and .045" (1.14 mm). NOTE - Increasing washer thickness decreases backlash; decreasing washer thickness increase backlash. Install lock pin into pinion shaft and caulk end to prevent loosening. Install ring gear into position on case, apply Loctite to bolt threads, and install and tighten ring gear to case bolts in a diagonal sequence.

Fig. 9 Checking Ring Gear Backface Runout

Backlash & Side Bearing Preload - 1) If original side bearings, differential case, ring and pinion, and differential carrier are being reused, the original shims may be reinstalled in their respective positions. If only new side bearings are bearing installed, measure new bearings with a micrometer and compare thickness with original bearings. If new bearing is thicker, SUBTRACT difference from shim pack. If new bearing is thinner, ADD difference to shim pack.

2) If new bearings, and/or differential case, ring and pinion, or differential carrier are being installed, new shims must be selected as follows: Install side bearings onto differential case, but do not install shims at this time. Mount case into carrier bores. Move ring gear tightly against carrier on ring gear side (away from pinion), and hold in this position. Using a feeler gauge, measure clearance between bearing and differential carrier on side opposite ring gear. Record clearance.

3) Proper preload is established using the predetermined dimension of .002". Therefore, ADD this dimension to clearance obtained in step 2) for proper preload. This will give required total thickness of both shim packs. Equally divide the total dimension required shim pack thickness for each side.

Fig. 10 Checking Ring Gear-to-Drive
Pinion Gear Backlash

4) Remove case from carrier, remove side bearings and install shim packs, then reinstall bearings. Install differential case into carrier, tapping carefully into place. Install side bearing caps in original positions, install and tighten attaching bolts. Measure run-out of ring gear (see illustration). If run-out exceeds .002" (.05 mm), correct by clearing or replacement of parts.
5) Mount a dial indicator against ring gear teeth and measure backlash in three locations. Backlash should be .005-.007 (.13-.18 mm); if not, shims behind side bearings must be adjusted. NOTE - To maintain preload when backlash is adjusted, the total thickness of both shim packs must not be altered. Therefore, if it is necessary to increase one shim pack, the opposite shim pack must be decreased. To decrease backlash, right side shim must be decreased, and left side increased. NOTE - Backlash changes approximately .002" (.05 mm) for each .003" (.08 mm) shim change. After adjustment, make a gear tooth pattern check to insure correct assembly.

0 Chevrolet 1949-53 Passenger Car Shop Manual

Contains the following information and repairs for:

• General Lubrication
• Body
• Frame and Shocks
• Front Suspension
• Rear Axle and Suspension
• Brakes 
• Engine Assembly
• Transmission
• Fuel and Exhaust
• Steering Gear Assembly
• Wheels and Tires
• Chassis Sheet Metal
• Electrical System
• 1954 Supplement

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File Size: 52 MB

File Type: PDF, RAR

0 BMW 1969-73 6 Cylinder Models Brake Repair Manual

Models Covered

• 2500 (1969-70)
• 2800 (1969-70)
• 2800 CS & CSA (1969-71)
• 3.0 CS & CSA (1969-71)
• Bavaria (1972-73)

DESCRIPTION

Models 2800 CS and CSA use ATE four-piston fixed caliper disc brakes on front and leading-trailing shoe drum brake on the rear. All other models use four wheel ATE disc brakes with four-piston caliper on front and two-piston caliper on the rear. All models use twin circuit, tandem piston master cylinders. Four wheel disc brake system use a pressure limiter to control hydraulic pressure applied to rear brakes. Hydraulic pressure to rear brakes is adjustable with the pressure limiter. Hand brake actuates cable to rear brake shoes. A special duo-servo drum-disc combination is used on rear wheels with disc brakes.

ADJUSTMENT

DRUM BRAKES 

2800 CS & CSA - Release handbrake, hoist vehicle and using suitable wrench (6038) loosen each brake shoe with its eccentric adjusting screw. While revolving wheel, turn left adjusting screw counterclockwise and right screw clockwise, until wheel will no longer turn. Loosen each screw ⅛ turn at a time until wheel turns freely.

DISC PADS

Front and rear disc brake assemblies are self-adjusting, therefore, no adjustment in service is required.

PARKING BRAKE

PISTON ALIGNMENT

Disc Brakes (With Integral Drum On Rear) - Release parking brake lever, raise and support vehicle and remove rear wheels. Insert brake adjusting tool through .6" hole in rotor. Turn start wheel adjuster until rotor can no longer be turned, then back off adjuster two or three teeth. Working inside driver compartment, tighten adjustment nut on hand lever until parking brake holds vehicle (before fifth ratchet stop is reached).

Models With Rear Drum Brakes - Drum brakes must be adjusted before attempting to adjust handbrake. Handbrake should be adjusted if hand operated lever can be pulled up more than five notches. Adjust with handbrake lever completely disengage, by turning adjuster on cable and next to hand brake lever. Adjustment is correct when handbrake will lock rear wheels without passing through more than four or five notches on ratchet.

HYDRAULIC SYSTEM BLEEDING

NOTE - Manufacturer recommends replacing brake fluid entire system once a year to avoid moisture build-up. Attach a pressure bleeder to master cylinder reservoir. CAUTION - Do not exceed 29 psi. Raise and support vehicle and remove wheels. Attach a bleeder hose to bleeder screw, and immerse opposite end of hose into a container partially filled with brake fluid. Open bleeder screw, allow all air has been expelled  from system. NOTE - On front wheel four piston calipers, bleed lower inboard screw before bleeding lower outboard screw.

REMOVAL AND INSTALLATION

DRUM BRAKE SHOES

Removal - Hoist vehicle, remove rear wheels and brake drums. Detach brake shoes from bottom support, then pull shoes out of wheel cylinders. Disconnect hand brake cable from rear shoes. Separate shoes by removing return springs.

Installation - Reverse removal procedure and note the following: Install long end of shoe push rod spring toward handbrake lever. Adjust brakes.

DISC PADS

Removal - Raise and support vehicle and remove wheels. Drive out retaining pins toward inside of vehicle and remove cross spring. Using a suitable extractor tool (3.9314-14002), remove disc pads from caliper assembly.

Installation - 1) NOTE -  Replacement of disc pads should be done in complete sets only. Using a cylinder brush, clean guide surface and support surface in caliper. Siphon sufficient fluid from outer cylinder reservoir to prevent overflowing, then press pistons to bottom of bores.

2) On rear two piston calipers, ensure machines position of piston face makes a 20° angle to lower caliper wall. Install disc pads, cross spring and retaining pins. After installation, depress brake pedal several times to position pads against rotor.

CALIPER ASSEMBLY

Removal - Remove master cylinder reservoir cap and plug fluid outlet lines. Raise and support vehicle and remove tire and wheel assembly. Disconnect hydraulic line(s), remove caliper mounting bolts, and separate caliper from caliper from backing plate.

Installation - Reverse removal procedure and bleed hydraulic system.
ROTOR
Removal & Installation (Front) - With caliper assembly removed, remove hub grease cap, cotter pin, and nut. Remove hub and rotor assembly. Remove Allen head bolts retaining rotor to hub and remove rotor. To install, reverse removal procedure, tighten all bolts and fittings evenly, and bleed hydraulic system if necessary. Adjust front wheel bearing. See Wheel Bearing Adjustment in WHEEL ALIGNMENT Section.
Removal & Installation (Rear) - Remove rear wheel and caliper assembly, then pull rotor out from axle shaft flange. To install, reverse removal procedure, tighten all bolts and fittings evenly, and bleed hydraulic system if necessary.
PARKING BRAKE SHOES
Removal - With rear caliper and rotor removed, disconnect lower return spring using brake spring pliers. Turn retaining springs 90 degrees using suitable tool (7014) and remove. Pull brake shoes apart at bottom and lift away upwards.
Installation - Reverse removal procedure and adjust parking brake shoes and cables.
MASTER CYLINDER
Removal - Remove master cylinder reservoir cap and plug fluid outlet lines. Remove hose fittings from master cylinder and raise above reservoir fluid level. Mark hydraulic lines for reassembly reference and disconnect from master cylinder. Remove nuts attaching cylinder to power unit, and separate master cylinder from power brake unit.

POWER UNIT PUSH ROD ADJUSTMENTS

Installation - Reverse removal procedure and note the following: Make sure rubber "O" ring seal between master cylinder and power unit is not damaged. Check clearance between power unit thrust rod and master cylinder piston with Plastigage and, if necessary, set to .020" by inserting a shim behind plunger head. Bleed hydraulic system and check for fluid leaks.
POWER BRAKE UNIT
Removal - 1) Remove air cleaner and battery, disconnect oil reservoir for power steering (if equipped) and move to one side. Block brake fluid reservoir outlets and remove hoses from master cylinder.
2) Remove lower left instrument panel housing and secure to one  side. Remove brake pedal clevis pin, and disconnect vacuum hose from intake manifold. Remove hydraulic lines from master cylinder marking positions for reassembly reference. Remove nuts retaining power unit to support and remove power unit.
Installation - Reverse removal procedure, bleed hydraulic system, and check following adjustments: Adjust length of piston rod (A) to 14.49-14.53". Adjust pedal height (B) to 9.65". Adjust exposed depth of brake light switch plunger (C) to .24-.28". See illustration.
Check Valve Replacement - Check valve is located in power unit vacuum line at intake manifold. To remove, loosen hose clamps, remove vacuum hoses, and remove valve. To install, reverse removal procedure, making sure arrow or block portion of valve faces intake manifold.
Filter Replacement - With power brake unit removed from vehicle, pull back rubber dust boot and remove retaining ring. Remove silencer and filter. To install, reverse removal procedure.
REAR BRAKE PRESSURE LIMITER
Removal & Installation - Plug fluid outlets in brake fluid reservoir. Disconnect brake hose and rear brake lines from pressure limiter. Remove mounting bolts and pressure limiter. To install, reverse removal procedure and bleed hydraulic system.

OVERHAUL

DRUM BRAKE WHEEL CYLINDER
Disassembly - With wheel brake drum removed, back off shoe adjusting cams, disconnect brake line and remove cylinder from backing plate. Disassemble wheel cylinder and pay particular attention to location and direction of parts.
Cleaning & Inspection - Clean all parts in alcohol or other suitable non oil base solvent. Discard all rubber parts and inspect all other parts for wear or damage.
Reassembly - Dip new parts in clean brake fluid or apply ATE cylinder paste. To install cylinder, reverse disassembly procedure and bleed brakes.
BRAKE CALIPER
Disassembly - With caliper removed from vehicle and disc pads remove from caliper, remove clamping rings and rubber protecting caps. Hold one piston in place using a suitable clamp, insert a piece of wood in caliper  cavity, then apply compressed air to fluid inlet and remove opposite piston. Remove sealing ring using a suitable plastic tool. Remove remaining piston(s) and seal(s) in same manner. NOTE - DO NOT separate caliper halves unless a leak is detected. To disassemble, remove expansion bolts, separate caliper halves and remove sealing rings.
Cleaning & Inspection - Clean all parts in alcohol and check for wear or damage; replace parts as necessary.
Reassembly - Reassemble caliper (if separated) using new seals and expansion bolts. Tighten expansion bolts from inside out. Coat pistons and caliper bores with ATE brake cylinder paste (or equivalent), install sealing rings, then install pistons into bores. Make sure pistons are not tilted when inserting. On two pison calipers, make sure machined surface of piston face makes a 20 degree angle to lower caliper wall. Install rubber protecting caps and clamp rings.
MASTER CYLINDER
Disassembly - Push in on primary piston and remove secondary piston stop screw. Remove snap ring from end of cylinder and remove primary and secondary piston assemblies and return spring. Disassemble piston assemblies noting number of parts used.
Cleaning & Inspection - Clean all parts in alcohol and inspect for wear or damage. NOTE - Cylinders with surface defects in bores must be replaced; do not overhaul.
Reassembly - Reassemble piston assemblies using a thin coating of ATE brake cylinder paste (or equivalent). Install piston assemblies into cylinder bore using a suitable guide sleeve (BMW 6063) to prevent damaging seals. Install secondary piston stop screw, making sure that piston is pushed fully forward before screw is installed and tightened. Install retaining ring in end of master cylinder bore.

0 BMW 1963-73 4 Cylinder Brakes Repair Manual

Models Covered

• 1600 (1966-71)
• 1600-2 (1966-71)
• 1800 (1963-66)
• 1800 Ti (1963-66)
• 2000 (1966-69)
• 2000 Ti & Tilux (1966-68)
• 2000 CS & CA (1966-67)
• 2002 (1968-73)
• 2002 Ti (1967-72)
• 2002 Tii (1972-73)

DESCRIPTION

Brakes on all models consist of ATE fixed caliper front disc brakes and leading-trailing shoe rear drum brakes. Disc calipers are either two or four piston units. All vehicles from 1970 onward, use tandem piston master cylinders. Hand brake system is operated by lever and cable, and attached to rear brake shoes.

ADJUSTMENT

FRONT DISC BRAKE PADS

Front dis brakes are self-adjusting, therefore, no adjustment in service is required.

REAR DRUM BRAKE SHOES

Raise and support rear of vehicle and release parking brake. Using an offset wrench (BMW 6038), tighten eccentric adjustment nuts while rotating wheel until wheel locks. Loosen adjusting nuts ⅛ turn or until wheel is just free to turn.

PARKING BRAKE

With rear brakes properly adjusted, pull rubber boot on parking brake lever and loosen lock nuts. Pull brake lever up to fifth ratchet stop and check for braking action at rear wheels. If adjustment is required, tighten adjusting nuts until rear wheels are locked. Tighten lock nuts and ensure wheels turn freely with parking brake lever released.

HYDRAULIC SYSTEM BLEEDING

NOTE - Manufacturer recommends replacement of brake fluid in entire system once a year to avoid moisture build-up. Attach a pressure bleeder to master cylinder reservoir. 

NOTE - DO NOT exceed 29 psi. Raise vehicle and remove front wheels. Attach a bleeder hose to bleeder screw and immerse opposite end of hose into a container of brake fluid. Open bleeder screw, allow all air to escape, then close bleeder screw. Continue operation until all air has been bled from system. NOTE - On front disc brakes, bleed lower inboard screw before bleeding lower outboard screw.

REMOVAL AND INSTALLATION

FRONT DISC BRAKE PADS

DISC PAD REMOVAL & INSTALLATION

Removal - Raise and support front of vehicle and remove wheels. Drive retaining pins out toward center of vehicle and remove cross spring. Using a suitable pulling tool (ATE 3.914-1800.2), remove brake pads. If pads are to be reinstalled, mark for reassembly reference. NOTE - Pads are not interchangeable.

Installation - NOTE - Replacement of disc pads should be done in complete sets only. Using a cylinder brush, clean guide surface and support surface in caliper. NOTE - DO NOT use oil based solvents. Siphon sufficient fluid from master cylinder reservoir to prevent overflowing, then press pistons to bottom of bores. Install disc pads, cross spring, and retaining pins. Pump brake pedal several times to position pads against rotor.

FRONT DISC BRAKE CALIPER

Removal - Raise and support front of vehicle and remove wheels. Disconnect hydraulic lines and plug openings. Remove bolts securing caliper to steering knuckle and remove caliper.

Installation - Reverse removal procedure and note the following: Left and right calipers are not interchangeable. When installed, bleeder screws must face upward. Tighten all bolts and fittings evenly and bleed hydraulic system.

FRONT DISC BRAKE ROTOR 

Removal - Remove caliper. NOTE - Do not allow caliper to hang from hydraulic line after removal; support out of way. Remove hub grease cap, cotter pin and nut, then remove hub and rotor assembly from axle. Remove Allen bolts and separate brake rotor from wheel hub. 

Installation - Install rotor onto wheel hub and tighten bolts securely. Install hub and rotor assembly onto axle, install outer wheel bearing, washer and nut. Adjust wheel bearings and install cotter pin and grease cap. See Wheel Bearing Adjustment in WHEEL ALIGNMENT Section. Install caliper and bleed hydraulic system if necessary.

REAR BRAKE DRUM

Removal - Remove tire and wheel assembly and loosen eccentric adjusting nuts. Pull drum straight out from axle to remove.

Installation - Install brake drum to axle, install tire and wheel assembly, and adjust brake shoes and parking brake (if required).

REAR BRAKE SHOES

REAR BRAKE ASSEMBLY

Removal (Exc. 1600-2 Models) - Hoist vehicle, remove rear wheels and brake drums. Detach brake shoes from bottom support, then pull shoes out of wheel cylinder. Disconnect hand brake cable from brake lever. Seperate brake shoes bye removing returning springs.

Removal 1600-2 Models - Release hand brake, hoist vehicle and remove cotter pin from axle castle nut. Remove wheel brake drum and axle flange as a unit. NOTE - If flange will not slide off axle, it will be necessary to remove wheel and drum from flange.

Installation (All Models) - Reverse removal procedure and adjust brake shoes. See Drum Brake Adjustment.

REAR BRAKE WHEEL CYLINDER

Removal - With brake drum removed, disconnect hydraulic line, and remove bleeder screw and wheel cylinder attaching bolts. Using on offset wrench (BMW 6038), turn brake shoe eccentric adjusting nuts until shoes are spread out from wheel cylinder as for as possible. Remove wheel cylinder maneuvering out of backing plate.

Installation - Reverse removal procedure and note the following: Make sure rubber "O" ring is installed on master cylinder between cylinder and power unit. Check clearance between master cylinder piston and power unit push rod. Clearance should be .020" and is adjusted by removing or installing shims behind head of power unit push rod.

POWER BRAKE UNIT

Removal - With master cylinder removed, disconnect power unit push rod from pedal assembly by removing clevis pin. Disconnect vacuum line from check valve, remove nuts attaching power unit to support, and remove power brake unit.

Installation - Reverse removal procedure, taking care to install rubber "O" ring on master cylinder between cylinder and power unit.

Check Valve Replacement - Vacuum check valve is located in vacuum line at intake manifold. To remove, loosen hose clamps, separate vacuum hoses from valve, and remove valve. To install, position check valve so that arrows or black portion of valve face intake manifold, install vacuum hoses, and install and tighten clamps.

Filter Replacement - With power brake unit removed from vehicle, remove rubber dust boot, retainer, silencer, and filter. To install, reverse removal procedure making sure slots in filter and silencer are offset 180° in relation to one another.

OVERHAUL

FRONT DISC BRAKE CALIPER
Disassembly - With caliper removed from vehicle, remove rubber protective caps, taking care not to damage pistons. Insert a piece of wood in caliper cavity, and remove pistons by applying compressed air to inlet holes of caliper. Using a plastic (or other soft material) tool, remove sealing rings from caliper bores. NOTE - Do not separate caliper halves unless a leak is detected. To disassemble caliper, remove expansion bolts and separate caliper halves. Remove sealing rings.
Cleaning and Inspection - Clean all parts in alcohol and dry with compressed air. Check cylinder bores, pistons and flange surfaces for rust, corrosion or other damage. Replace parts as necessary, do not attempt to machine caliper bores or pistons.
Reassembly - Reassemble caliper with new sealing rings and expansion bolts if halves were separated. Tighten caliper extension bolts alternately and evenly from inside out. Coat pistons and sealing rings with ATE brake cylinder paste (or equivalent) and install into caliper bores. Install protective caps.
REAR WHEEL CYLINDER 
Disassembly - Remove dust caps, then withdraw piston and seal assemblies and spring. Remove bleeder screw. Remove rubber seals from pistons.
Cleaning and Inspection - Clean all parts in alcohol. Check all parts for wear or damage; replace parts as necessary. Make sure that grooves on cylinder body are not corroded.

PRIMARY (REAR) PISTON ASSEMBLY

Reassembly - Coat all parts with ATE brake cylinder paste (or equivalent) and reverse disassembly procedure. NOTE - Manufacturer recommends replacing piston seals whenever cylinder has been disassembled.
MASTER CYLINDER
Disassembly - Push in on primary piston and remove piston stop screw on top of master cylinder. Remove retaining ring from end of cylinder and withdraw primary piston assembly. Use compressed air to remove secondary piston assembly from cylinder bore, then remove piston return spring. Disassemble piston assemblies, noting number and position of parts used.

SECONDARY (FRONT) PISTON ASSEMBLY

Cleaning and Inspection - Clean all parts in alcohol and check for wear or damage. NOTE - Cylinders with surface defects in bores must be replaced; do not overhaul.
Reassembly - Reassemble piston assemblies using a thin coating of ATE brake cylinder paste (or equivalent). Install piston assemblies into cylinder ore using a suitable guide sleeve (BMW 6063) to prevent damaging seals. Install secondary piston stop screw, making sure that piston is pushed fully forward before screw is installed and tightened. Install retaining ring in end of master cylinder bore.

0 Austin Marina 1973-75 Brake Repair Guide

DESCRIPTION

Brake system is hydraulically operated, utilizing dual piston and pad front disc brakes and rear wheel drum brakes. Drum brakes are single piston, sliding cylinder type. A dual piston master cylinder is used in conjunction with a Supervac power unit. Parking brake is hand operated and cable/lever actuated, operating the sliding wheel cylinder. A pressure differential warning valve is fitted to all vehicles to distribute hydraulic pressure evenly and to indicate pressure loss in system. Warning system is completed with a light on instrument panel that activates during pressure loss.

ADJUSTMENT

FRONT DISC BRAKES

No adjustment is required.

Fig. 1 Assembled View of Parking Brake Adjustment

REAR DRUM BRAKES

Raise rear of vehicle and block front wheels. Fully release parking brake and check that cables are not pulling on wheel cylinders. Turn adjuster screw in backing plate clockwise (viewed from center of vehicle) until brake drum cannot be turned. Loosen adjuster screw until wheel can just be turned.

PARKING BRAKE

With rear wheels properly adjusted, set parking brake lever on fourth ratchet tooth and check for braking effect on rear wheels. If braking effect is inadequate, loosen adjuster lock nut. Turn adjusting nut clockwise while holding cable sleeve from turning until correct adjustment is obtained. Tighten lock nut. Release parking brake lever and check that rear wheels rotate freely.

HYDRAULIC SYSTEM BLEEDING

1) Ensure rear wheel cylinder is free to slide on backing plate. Make sure all hydraulic fittings are tight and that wheel cylinder bleeder screws are closed. Fill master cylinder reservoir with brake fluid and make sure level is maintained throughout bleeding operation.

2) Attach bleeder tubes to bleeder screws on left-front and left-rear brakes, noting that bleeder screw on left-rear brake controls bleeding of both rear brakes. Commence bleeding with light strokes of pedal. NOTE - Do not push pedal through its entire stroke. Do not test pedal until system is fully bled.

3) Bleed right-front brake after all air has been expelled from left side of vehicle. If warning light should be activated during bleeding operation, continue bleeding until all air has been expelled from system. Determine which brake caused light to be activated.

Fig. 2 Front Disc Brake Assembly With Pads Removed

4) Attach a bleeder tube to a bleeder screw at opposite end of vehicle and open bleeder screw. Slowly depress pedal; or soon as light goes out, release pedal and tighten bleeder screw. Check fluid level in master cylinder reservoir and fill as necessary.

REMOVAL AND INSTALLATION

FRONT DISC BRAKE PADS

Removal  - Raise and support front of vehicle. Remove tire and wheel assembly. Remove spring clips and brake pad retaining pins. Remove brake pads and anti-squeal shims.

Installation - 1) Clean exposed end of piston and ensure that caliper is free of rust and dirt. Loosen bleeder screw and push pistons to base of cylinder. CAUTION - Level of fluid in master cylinder will rise. Siphon off sufficient fluid to prevent overflowing. Tighten caliper bleeder screw.

2) To complete installation, reverse removal procedure and note the following: Brake pads are interchangeable from side to side. Install anti-squeal shims with arrow pointing upwards, indicating forward direction of disc. With pads installed, pump brake pedal several times to reposition pistons. Bleed hydraulic system if necessary.

FRONT DISC BRAKE CALIPER

Removal - Raise and support front of vehicle. Remove tire and wheel assembly. Disconnect metal hydraulic line from flexible hose and from caliper. NOTE - Plug flexible hose to prevent loss of fluid. Remove caliper mounting bolts and remove caliper from vehicle.

Installation - To install, reverse removal procedure and note the following: Tighten caliper mounting bolts securely. Bleed hydraulic system.

FRONT DISC BRAKE ROTOR

Removal - Raise and support front of vehicle and remove tire and wheel assembly. Remove brake caliper. Remove grease cap, cotter pin, nut retainer, nut, and splined washer. Remove hub and rotor assembly. Remove four bolts retaining brake rotor to disc, and remove brake rotor.

Installation - 1) Install brake rotor onto hub, tightening retaining bolts securely. Install hub and rotor assembly onto axle and install bearing (if removed), splined washer, and nut. Spin hub and tighten nut to 5 ft. lbs. (.69 mkg). Loosen nut and then retighten finger tight.

2) Install nut retainer so that half of cotter pin hole is covered by one of the arms retainer. Loosen nut and retainer until cotter pin hole is fully uncovered, install cotter pin, and lock by turning legs of pin around nut retainer.

Fig. 3 Austin Marina Rear Drum Brake Assembly

3) CAUTION - Bearings must not be preloaded. Do not tighten nut so there is less than .001" (.025 mm) free play, measured with a dial indicator. To complete installation, reverse removal procedure.

REAR BRAKE DRUM

Removal & Installation - Raise and support rear of vehicle. Remove wheel and tire assembly. Remove two screws retaining drum to axle shaft flange. Loosen brake adjusting screw and remove brake drum. To install, reverse removal procedure and adjust brakes.

REAR BRAKE SHOES

Removal - With brake drum removed, disconnect cups and springs from anchor pins and remove pins. Disconnect return springs by lifting shoes from backing plate, disengaging front shoe from parking brake lever, and maneuvering shoes until spring tension is released.

Installation - Lightly coat shoe webs and anchor pins with Girling Brake Grease, taking care not to get any on shoe linings. Install return springs to shoes, engage parking brake lever into front shoe slotted web, and maneuver shoes into position on backing plate. Install anchor pins, springs and cups. Install drum and adjust brakes.

REAR WHEEL CYLINDER

Removal - With brake drum and shoes removed, disconnect flexible brake hose from metal line, plug metal line to prevent loss of fluid, and disconnect flexible line from wheel cylinder. Disconnect parking brake cable clevis from parking brake lever. Remove dust plate, retaining plate and spring clip, and remove cylinder from backing plate.

Installation - To install, reverse removal procedure and bleed hydraulic system.

MASTER CYLINDER

Removal - Disconnect master cylinder hydraulic lines at pressure differential warning valve and at master cylinder. Plug cylinder outlet parts and valve inlet parts to prevent loss of fluid. Remove nuts retaining master cylinder to power unit, and remove master cylinder.

Installation - To install, reverse removal procedure, tighten mounting nuts securely, and bleed hydraulic system., and note the following: Power unit operating rod must be retained to brake pedal lever with clevis pin installed in bottom hole of two holes in pedal lever.

PRESSURE DIFFERENTIAL WARNING VALVE

Removal - Disconnect battery and wiring to warning valve. Disconnect master cylinder-to-warning valve hydraulic lines, and disconnect warning valve-to-front and rear brake lines. Remove retaining bolts and remove warning valve.

Installation - To install, reverse removal procedure and bleed hydraulic system

Fig. 4 Exploded View of Disc Brake Caliper
and Pads

OVERHAUL

FRONT DISC BRAKE CALIPER

Disassembly - With caliper removed from vehicle, remove disc pads. Remove dust boot retaining rings and dust boots. Insert a piece of clean cloth between caliper pistons, then remove pistons by applying compressed air to fluid inlet part. Remove sealing rings from caliper. CAUTION - DO NOT  separate caliper halves.

Inspection - Clean all parts in Girling Cleaning Fluid or alcohol. Examine piston and caliper for scoring, corrosion or other wear; replace parts as necessary.

Reassembly - Lubricate all parts in clean brake fluid. Loosen bleeder screw. Install sealing rings inside caliper bores and press into seal grooves. Install dust boot on piston shoulder. Using a suitable tool (18G 590), press piston into caliper until .31" of piston is protruding. Install dust boot on cylinder shoulder and install retaining ring. Repeat procedure for remaining piston. Tighten bleeder screw and install brake pads.

Fig. 5 Disassembled Rear Wheel Cylinder

REAR WHEEL CYLINDER

Disassembly - With cylinder removed from vehicle, remove rubber dust boot and withdraw piston and seal assembly. Remove seal from piston. Clean all parts in Girling Cleaning Fluid or alcohol and inspect for wear or damage; replace parts as necessary.

Reassembly - Lubricate all parts with clean brake fluid. Using finger only, install new seal onto piston with lip of seal toward bottom of cylinder. Install piston and seal assembly into cylinder and install dust boot.

MASTER CYLINDER

Disassembly - 1) Separate fluid reservoir from master cylinder, then take out reservoir mounting seals. Clamp cylinder, then take out reservoir mounting seals. Clamp cylinder in a vice, push plunger down bore and withdraw secondary plunger stop pin.

2) Remove circlip from mouth of cylinder and withdraw primary plunger assembly using air pressure at secondary outlet port. Separate vacuum spring, seal retainer, seal and washer from primary plunger. Similarly, disassemble secondary plunger and note position of seals.

Inspection - Clean all parts in Girling Cleaning Fluid or alcohol and dry thoroughly. Check master cylinder bore. If not scored or ridged, new seals may be installed. If damaged, master cylinder must be replaced. Ensure that inlet and outlet ports are free from obstruction.

Fig. 6 Master Cylinder Reservoir, Body and Piston
Assembly

Reassembly - Reverse disassembly procedure following kit manufacturers instructions and incorporating the following: Press plunger into cylinder bore to facilitate secondary plunger pin reassembly. Secondary plunger return spring is larger of the two springs. Lubricate plunger return spring is larger of the two springs. Lubricate vacuum seals, spacers and plunger where necessary.

POWER UNIT

NOTE - Manufacturer does not recommend overhaul of power brake unit. However, a service kit consisting of a check valve, front seal and plate assembly, and filter may be installed once unit has been removed from vehicle.

Disassembly - Pull back dust cover over push and remove end cap and filter. From front of power unit, remove seal and plate assembly from shell recess, and remove check valve and grommet.

Fig. 7 Supervac Power Unit

Reassembly - Lubricate check valve grommet with Girling Grease and install into front shell. Install new  check valve into grommet. Coat new seal and plate assembly with Girling Grease and install into front shell, making sure that plate forces inward. Install new filter into neck of diaphragm plate and install new end cap. Install new dust cover over lugs of rear shell