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Bra kes
BRAKE PEDAL
Removal and Installation
Remove
the
return
spring and the
push
rod cleviS pin and
disconnect the
pedal
from the
master
cyltnder
Remove the
PIvot pin and 11ft
out
the
pedal
See
FIg
L 2
Check the
pedal
shaft bushes
the
pedal
and other
parts
for
damage
or
excessive
wear
or
dIstortIon and
replace
parts
as
necessary
Install the
pedal by
reversing the removal
procedure
Lubncate the shaft bushes and the
push
rod clevIs pm With
brake grease
Tighten
the PIvot
pIn nut to
a
torque setting of
3 5
40
kgm
25 3
289 Ib ft
BRAKE MASTER CYLINDER
Removal and
DIsmantling
Refer
to
Fig
L 3
Remove
or
disconnect
the
follOWing
parts
Push rod cleVIS
pin at
the brake
pedal
brake pipe
at
the
master
cylmder
and
master
cylinder
securing
nuts
from the
bulkhead
LIft the
master
cylinder
from
ItS
mounting
Drain all flUid from the
reservOir
and
remove
the dust
cover
and
the
piston stop
screw
from the bott
of the
cylinder
After
removIng the piston retaining ring and the abutment
washer
shake
out
the piston
assembly
the piston
return spring
valve
cap and check valve
BRAKE MASTER CYLINDER
Assembly
and InstallatIon
Thoroughly
clean all parts and check
as
follows
replacmg
any
defectIve parts
Cups
and valves shou Id be renewed
as a
matter
of
course
Check the piston and the
cylinder
bore for abnormal
wear
and
damage
The clearance between the piston and the
cylinder
wall
should
not
exceed 013
mm
0005
In
Springs
should be
checked
for
damage
or
weakness
Inspect
dust
cover
and
reservoIr
for
damage
The
assembly
of the brake
master
cylinder
IS a
reversal of the
dismantling
procedure
noting the
follOWing
pOints
Soak the
pIston
cup
In
brake flUid and coat the pIston and the
cylinder
working
surfaces WIth brake flUid prior
to
assembly
After the
complete
installatIon
adJust
the brake
pedal
height
and bleed
the
hydraultc
brake system
BRAKE PIPES
If any
leakage
IS
found
to
be due
to
brake
plp
S or
hoses
replace
the part
In
question
making
sure
they
do
not
foul any
movIng
parts
Connetors should be
tIghtened
to
1 5
1 7
kgm
108
1231bft
FRONT DRUM BRAKE
Removal and
InspectIon
Support
the vehIcle
on
stands and
remove
the brake drum hub
cap and hub
assembly by
removing the
spilt
pIn and the castle
nut
from the SWIvel
JOInt
spindle
DIsconnect the brake hose
from the wheel brake
cylinder
Unhook the
return
springs from
the brake shoes and 11ft off the brake shoes
From the
rear
of
th
brake
backplate
remove
the wheel
cyltnder
securing
screws
and detach the wheel
cylinders
after disconnecting the
bridge
pipe between them
If the wheel
cylinders
must
be dismantled
remove
the rubber dust
caps
and Withdraw the
Inner
parts
Check the brake drums for
run
Qut
and skim If the
run
out
exceeds 0 05
mm
0002
In
to
a maximum
dIameter of 229 6
mm
9040
In
Also check the drums for cracks
or
other
damage
and
replace
If necessary
If the
linings
are
not
seated
on
the
shoes
properly
worn
to
below 1 5
mm
006
In
In
thIckness grease
Impregnated Or
burnt
replace
them Check the
adjusting
cams
for freedom of
rotation
and the springs for
weakness The standard dimenSions
are as
follows
Wire dIameter
Free
length
Number of
turns
35mm
77 5
mm
215
Check the
brake
backplate
for distortion
Inspect
the wheel
brake
cylmder
bore
for
scoring and
the pIston surface for
corroSion
or
damage
The
maximum
running clearance of the
piston
In
the
cylinder
bore
must not
exceed 0 15
mm
0 05
In
It
IS
recommended
to
renew
the piston
cups
every
time
FRONT DRUIV BRAKE
Assembly
and InstallatIOn
Reverse the
dIsmantling
and removal
procedures
noting the
follOWing
pOints
Gnnd the
new
linings
If
fitted
to
the
diameter of the brake drums
Take
care
not to
bnng
011
or
grease
In
contact
With
the
brake
linings LIghtly
grease all
movIng parts
adjust
the brakes and bleed the brake system
FRONT DISC BRAKE
Removal and
DIsmantling
Support
the vehicle
on
stands
remove
the wheel and disconnect
the brake hose
Remove the bolts securing the brake
calliper
to
the
SWivel JOint
flange
and
remove
the
calliper
FIg
L 7
Remove the hub
nut
and Withdraw the hub
together
With the
brake disc
To dismantle the
calliper
remove
the
antI
rattle
clip
and
remove
the brake
pads
from the
callIper
Remove the
tension
spnngs
and
pull
the
cylinder
out
of the
callIper
Blowout the piston
uSing
air
or
hydraulic
Itne
at
the brake hose
connection
as
shown
In
Fig
L 8
Remove the rubber seal from the
cylinder
groove and the
retainer
and the wiper seal
If
any flUid
leaks
damage
or
defects
can
be found
on
the
cylinder assembly
It
should be
replaced
Check the brake
pads
for
wear or
cracks
If the
pads
areworn
down
to
a
thIckness of
1
mm
004
In
I they
must
be
replaced
In
sets
of four
ReplaCing
only
the
worn
brake
pads
causes
the brakes
to
pull
to
one
SIde
Check the brake diSC for scoring
out
of round and
run
out
The
run
out
IS
best
checked
as
shown
In
FIg
L 9
w
th the hub
mounted
to
the SWIvel JOint
If
It
IS
necessary
to
re
machlne the
brake dISC take
care
that
a mln
thIckness of 8 4
mm
0331
In
IS
not
exceeded
The nominal thIckness of the brake dISC
IS
10
mm
004
In
If the dISC
IS
cracked
or
damaged
In
any other
way
It cannot
be
salvaged
imd
must
be
replaced
79
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