Triumph 1974 Models Wheel Alignment Guide

TRIUMPH SPECIFICATIONS AND ADJUSTMENTS

TIRE INFLATION (COLD)

Before attempting to check or adjust wheel alignment, make sure tires are properly inflate. Refer to manufacturers specifications in owners manual.

CASTER

All Models - Caster angle is not adjustable. If caster angle is not to specifications, inspect suspension system for wear or damage and repair or replace components as necessary.

CAMBER

All Models - Before adjusting camber angle, inspect suspension for wear or damage and repair or replace components as necessary. To adjust, raise vehicle and support chasis on jack stands. Loosen nuts securing lower control arm bracket to chassis. Add shims equally to increase camber angle. After each adjustment is made, tighten bracket to chassis, remove stands and measure camber angle.

TOE-IN

All Models (Front) - Set front wheels in straight ahead position. If adjustment is necessary, loosen steering link (tie-rod) lock nuts and gaiter clips. Rotate adjusting sleeves equal amounts until correct toe-in is obtained. Tighten lock nuts and recheck toe-in.

Spitfire (Rear) - If toe-in is not to specifications, loosen bolts holding strut front support. Adjust as necessary by adding or removing from the shims fitted between support and body. Tighten bolts and recheck toe-in.

TR6 (Rear) - If toe-in is not to specifications, loosen bolts and nuts securing trailing arm outer bracket to chassis. Add or remove shims between chassis and bracket to obtain correct toe-in. Tighten bolts and recheck toe-in. NOTE - Drive vehicle forward or backward before rechecking rear toe-in.

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Jaguar XJ6 XJ12 XJS 1975 77 Drive Axles Repair Manual

DESCRIPTION 

The differential assembly is of hypoid design with centerline of drive pinion gear set below centerline of ring gear. A collapsible spaer is used to set drive pinion bearing preload and all other differential adjustments are accomplished using shims. Stub axles transmit power out of differential, through independent rear suspension, to drive wheels. A clutch pack limited slip unit, "Powr-Lok", is available as an option.

AXLE RATIO AND IDENTIFICATION

Jaguar uses only one basic rear axle design, however, unit may not be fitted with a traction lock device. Also several different axle ratios are used. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth. Whether or not axle is fitted with traction lock should be determined owner inquiry or test.

REMOVAL AND INSTALLATION

Rear Suspension Assembly

NOTE - This procedure is provided since many operations on the final drive require removal of rear suspension assembly before starting work on final drive.

1) Raise and support vehicle. Place stands forward of radius arms on body with wood blocks between body and stands. Remove wheels. Remove mufflers from tail pipes. Remove safety wire and bolts securing safety strap and radius arm from body mounting post. Disconnect and plug brake lines at body.

2) Remove clevis pin securing hand brake cable to actuating levers on crossmember. Loosen lock nut and remove outer hand brake cable screw from adjuster block. Detach drive shaft from differential. Place jack under rear suspension. Remove bolts and lock nuts securing crossmember mounts to frame. Lower and remove rear suspension from vehicle. To install, reverse removal procedure and note the following. Bleed brakes. Tighten radius arm nuts on lower control arm when weight of vehicle is on wheels.

HALF SHAFT

1) Remove rear suspension assembly. Remove rear hub as follows: Remove fulcrum shaft grease fitting. Withdraw cotter pin and remove nut and washers from splined end of half shaft. Using suitable puller, pull hub and carrier from half shaft. Remove spacer from half shaft and examine inner oil seal track. Replace track if necessary. Remove one nut from outer suspension arm fulcrum shaft and using soft hammer, drift out shaft. Remove hub and carrier assembly from car.

2) Support suspension arm with jack and remove nut and bolt securing top of forward shock absorber. Remove nuts and washer securing shock absorber to suspension arm and remove shock. Remove four nuts securing half shaft flange to stub axle flange and brake rotor. Pull half shaft from suspension unit noting number of camber shims installed between half shaft flange and brake rotor. If necessary, remove joint shields by drilling out rivets.

3) To install, reverse removal procedure, noting the following if necessary, replace joint shield, positioning grease nipple access hole correctly. Cover joint lines in shield with non hardening waterproof sealing compound. Be sure to replace camber shims. To reinstall rear hub, proceed as follows: Install suitable dummy shaft (JD.14) in hub carrier fulcrum. Install carrier on suspension arm, installing shims removed from between carrier and suspension arm. Replace outer suspension arm fulcrum shaft, displacing dummy shaft. Secure shaft with nut and reinstall grease nipple.

Fig. 1 Exploded view of Jaguar "Power-Lok" Differential Assembly

4) If necessary, install oil seal track to half shaft splined flange, replace spacer. Thoroughly clean and de-grease splines of half shaft and bore of hub. Using a small brush sparingly apply Lactite "Stud Lock" to outer two thirds of half shaft splines. Assemble hub carrier to half shaft. Install washer and tighten hub carrier assembly nut. Install new cotter pin. Install dial indicator so it bears against hub and zero indicator. Using two levers, pry out on hub and measure hub bearing endfloat. If endfloat exceeds specifications, overhaul rear hub and carrier assembly. After installation of rear suspension in vehicle, check rear wheel camber.

STUB AXLE OIL SEAL

1) Remove half shaft. Remove locking wire and withdraw bolts securing brake caliper to final drive unit. Remove brake rotor, noting number of shims removed between rotor and stub axle flange. Remove lock wire and five bolts securing caliper mounting bracket. Withdraw drive shaft, together with caliper mounting shims, ball bearing and oil seal. Turn down tab washer and remove nut nut from stub axle. Remove ball bearing and caliper mounting bracket from stub axle.
2) Lightly oil seal and position carefully in final drive case. Press seal squarely and fully seat in case groove. Do NOT remove protruding portion of seal. Coat seal with hypoid oil and place caliper mounting bracket and seal assembly over stub axle. Slide ball bearing on drive shaft followed by new tab washer and nut. Ensure bearing seats square to stub axle shoulder and tighten nut. Turn up tab on washer.
3) Lightly oil stub axle splines and install shaft in final drive housing. Install bolts securing mounting bracket finger tight. Using feeler gauge, measure dimension between inside face of mounting bracket and final drive housing. The measurement obtained determines shim thickness required, and thinly coat mating faces and shims with suitable sealant (Hylomar). Tighten bolts in a diagonal sequence.
4) Wire lock securing bolts to tension in clockwise direction. Install brake rotors and half shaft flange, using shims removed from between rotor and flange. Install caliper on mounting bracket. Install suitable distance spacers (oversize nuts) to rotor studs and tighten nuts. Use feeler gauges to ensure that rotor is centrally located between jaws of caliper. If necessary add to or remove from shim pack between flange and disc to center rotor. Continue assembly in reverse of disassembly procedure.

PINION FLANGE AND SEAL

1) Disconnect propeller shaft. Check and record torque required to turn drive shaft flange clockwise (viewed from front) through backlash movement. Check rear wheels and remove flange securing nut and washer. Remove flange. Pry oil seal out of final drive case. Lightly score oil seal recess with tang of file.
2) Ensure oil seal recess is clean and free of oil. Lightly top new oil seal into recess ensuring seal is square with case. Reinstall flange, washer and nut. Tighten nut to 120 ft. lbs. (16.5 mkg) while rotating flange to ensure bearing seats correctly. Again check pinion preload. If preload is below specifications, continue tightening flange nut until specified preload is obtained. However, if preload exceeds maximum specified value, new collapsible spacer must be installed, see differential overhaul. Reconnect propeller shaft and remove wheel chocks.

FINAL DRIVE UNIT

1) Remove rear suspension assembly and drain final drive unit. Remove final drive mounting plate and shock absorber/spring units. Remove nuts securing half shaft inner universal joint to brake rotor and disconnect half shaft, noting shims removed. Remove nut from inner suspension arm fulcrum shaft and drift out shaft. Repeat for other side of unit. Disconnect and plug brake lines. Disconnect hand brake levers from compensator.
2) Remove locking wire from final drive mounting bolts, remove bolts and crossmember by tilting forward over pinion. Remove calipers from final drive unit. Remove brake rotors, noting number of shims removed from between rotor and stub axle flange. To install, reverse removal procedure  making sure brake rotor is centered between jaws of caliper and wire lock tension bolts in clockwise direction.

OVERHAUL

Fig. 2 Exploded View of Limited Slip
Differential Clutch Pack and Side
and Pinion Gears

1) Remove rear cover and discard gasket. Remove lock wire and bolts securing caliper mounting bracket. Withdraw stub axle along with caliper mounting brracket shims, ball bearing and oil seal. Turn down tab washer and remove nut, ball bearing and caliper mounting bracket from stub axle. Repeat procedure fro second stub axle. Remove bolts securing differential bearing caps and lift off caps. Pry out differential assembly using two levers and taking care not to damage housing.
2) Remove drive pinion nut and washer. Mark relative positions of flange and pinion and remove flange. Using a suitable press, remove pinion from differential housing. Remove oil seal, oil thrower and outer bearing cone. Examine inner and outer bearing cups fro wear. If replacement is required, extract cups using suitable tools (SL.14 and SL. 14/1). NOTE - If removal of bearing cups is difficult, gently heat final drive housing in rear of bearing caps. On "Powr-Lok" differentials only, proceed as follows:
3) Remove differential side bearings using suitable tools (SL.14 and 14/3). If no reference marks are present, scribe a line across both halves of differential case to ensure correct reassembly. Remove bolts securing both halves of differential case. Split case and remove clutch discs and plates from one side. Remove differential side ring, pinion side gear and pinion cross shafts complete with gears. Remove remaining side gear and ring and extract remaining clutch discs and plates.
4) On non "Powr-Lok" differential only, remove peening and drift pinion shaft lock pin out of carrier. Remove gears, shaft and shims from carrier.

REASSEMBLY AND ADJUSTMENT

 Fig. 3 Measuring Side Bearing Preload

Case Assembly - 1) On "Powr-Lok" differentials, install clutch plates and disc alternately into flange half of case. Installtwo belleville clutch plates so that convex sides are against case. Install side ring and position one side gear into ring recess. Install cross shafts. Install pinion cross shafts complete with pinion gears ensuring that ramps on shafts coincide with mating ramps in case.
2) Assemble differential case halves ensuring that reference marks are lined up and clutch friction plate tongues are aligned with grooves in differential case. Install bolts but do not tighten yet. Check alignment of splines by inserting both stub axles. Tighten differential case bolts with stub axles in position. With one stub axle locked, other axle must not turn more than .75" (19 mm) measured on a 6" (152 mm) radius.
3) On non "Powr-Lok" differentials, install pinion shaft, shims and gears into differential carrier. Secure lock pin by peening.
Side Bearing Preload - Install differential side bearing without shims, on differential case, making sure that bearing and housing are perfectly clean. Place differential assembly in housing. Install dial indicator with indicator leg against back face of ring gear. Using sutiable pry bars between housing and bearing cups, move differential assembly fully to one side of housing. Zero dial indicator and move assembly to other side. Record indicator reading and add .009" (.20 mm) to reading to give total shim pack required. Remove differential assembly from housing.

Fig. 4 Measuring Drive Pinion
Gear Installed Depth

Drive Pinion Depth - 1) Place pinion, together with inner bearing cone, into housing. Turn housing over and support pinion. Install pinion outer bearing cone, flange, washer and nut, omitting collapsible spacer, oil slinger and oil seal, tighten nut. Using suitable dial indicator support fixture (SL3), zero dial indicator on setting block (4.H.A.). Place dial indicator fixture firmly on face of pinion and not indicator reading to bottom of housing bearing bore (see illustration).
2) The indicator reading shows deviation of pinion setting from zero cone setting. This value agree with value etched on face of pinion at bottom. For example, if value etched on pinion is -2, dial indicator should read -.002". If setting is incorrect, dismantle pinion and remove pinion inner bearing cup. Add or remove shims as required, reassemble and recheck pinion depth.
3) When setting is correct, extract pinion fro housing sufficiently far to remove outer bearing cone. Install collapsible spacer to pinion ensuring that it seats firmly on machined shoulder of pinion. Insert pinion into housing, install outer bearing cone, oil slinger and oil seal. Lightly grease splines of pinion shaft and install flange. Install new washer on end of pinion with convex side facing end of shat. Install but DO NOT tighten nut.
Backlash Adjustment - 1) Place differential assembly complete with side bearings but less shims, in housing. Ensure that bearings and housing are perfectly clean. Install dial indicator on housing with feeler on back face of ring gear. Pry differential case and ring gear assembly away from pinion until opposite side bearing is seated against housing. Zero dial indicator at this point.
2) Move differential assembly towards pinion until ring gear is deeply meshed with pinion. Note indicator reading and from this value, subtract the backlash allowance etched on drive gear (eg B/L.007 dones .007"). This result will yield the thickness of shims (in inches) to be placed between differential case and side bearing on ring gear side of differential. Install this thickness of shims (in inches) to be placed between differential case and side bearing on ring gear side of differential. Install this thickness of shims, taking shims from pack determined previously under "Side Bearing Preload". Install balance of total shims required on opposite side of case. An example of calculations required follows
EXAMPLE:

Fig. 5 Measuring to Determine Ring Gear
Side Shim Thickness

     Side Bearing Preload Reading.....................  .080"
     PLUS Preload Value.................................   .009"
     Total Shim Pack.......................................  .089"

     Pinion-to-Ring Gear Clearance...................  .042"
     MINUS Etched Backlash Value..................  .007"
     Total Ring Gear Side Shims.......................  .035"

     Total Shim Pack.......................................  .089"
     MINUS Ring Gear Side Shims...................  .035"
     Opposite Ring Gear Shim Pack..................  .050"
3) With shims calculated installed, lower differential assembly into position, lightly tapping bearings home with a soft hammer. Make sure ring and pinion gears mesh as installation proceeds. Install side bearing cups, ensure proper cup is placed in proper bearing. Tighten cup bolts. Mount dial indicator on housing with feeler against back face of ring gear. Turn pinion by hand and check ring gear run out. If run out exceeds specifications, disassemble differential, clean all mounting surfaces and check for burns.

Fig. 6 Measuring  Ring Gear-to-Drive Pinion
Gear  Backlash

4) Now place dial indicator to measure ring gear backlash. Move ring gear and check that backlash is to specifications, transfer necessary shims from side of differential case to the other. NOTE - To increase backlash, remove shims from ring gear side and install on opposite side and vise versa. Finally run a gear tooth contact pattern and adjust shims as necessary.
Pinion Bearing Preload - Install pinion and stub axle of seals. Install stub axles following procedure given under stub axle removal and installation. Tighten flange nut to specified torque. During tightening process rotate flange to ensure correct seating of taper roller bearings. Use care not to over tighten nut. if nut is overtightened, install a new collapsible spacer as pinion bearing preload will otherwise be incorrect. Install final drive rear cover using new gasket and suitable sealer (Hylomar).

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Guaranteed Auto Repair Savings

Guaranteed auto repair savings would be nice if it was true. The truth is no one can guarantee auto repair savings nor will they want to. There are so many auto parts out there sitting on the shelves either going bad or is bad. And think about it, if some auto repair shop guaranteed auto repair savings they would be out of business. Human error is a contributor to autos breaking down sooner than expected. Auto repair savings can not be guaranteed is the bottom line. Now if you were giving away your auto repairs for free then maybe you can guarantee your auto repairs for the life of the car. Wouldnt that be nice having a auto repair shop guarantee your auto repair in savings in writing?


"Guaranteed auto repair savings" would look nice as a bill board over Las Vegas or some place like that! How many people would be lined up for guaranteed auto repair savings? Think about it your auto repairs are guaranteed. Guaranteed for how long is the question I would be asking the auto repair shop who is promising guaranteed auto repair savings. And in order to put that in writing that their auto repairs are guaranteed I would say they have a lot of kudos. Guarantee is a pretty strong word in the auto repair shops. So the next time you see a auto repair shop who guarantees their work ask them how is your auto repairs guaranteed. Guaranteed auto repair savings is something anyone can say who guarantees their auto repairs. lol See if you can say all of this real fast 3 times. Its a real tonge twister! Guranteed Auto Repair Savings.

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Porsche 964 Repair Manual

Manufacturer: Porsche
Model: 964/ 911 Carrera 4 Carrera 2


Contains the following information and repairs for:

• Engine Maintenance
• Automatic Transmission
• Manual Transmission
• Chassis
• Body
• Heating 
• Ventilation
• Air Conditioning
• Electrics
• Wiring Diagrams

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File Size: 154 MB

File Type: PDF, RAR

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Suzuki Samurai SJ Repair Manual

Manufacturer: Suzuki
Model: Samurai




Contains the following information and repairs for:

• General, Special Tools and Service Materials
• Periodic Maintenance Service
• Trouble Shooting
• Engine
• Fuel System (Carburetor, Air Cleaner, Fuel Pump, and Fuel Filter)
• Emission Control System
• Engine Cooling System
• Car Heater
• Ignition System
• Cranking System
• Charging System
• Clutch
• Gear Shifting Control
• Transmission
• Transfer Gear Box
• Propeller Shafts
• Differential
• Suspension
• Steering System
• Brakes
• Body Service
• Body Electrical Equipment
• Service Data

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File Size:

File Type: PDF, RAR

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Mitsubishi Eclipse Repair Manual

Manufacturer: Mitsubishi
Model: Eclipse
Year: 2000 to 2002


Contains the following information and repairs for:

• General
• Engine
• Engine Lubrication
• Fuel 
• Engine Cooling
• Intake and Exhaust
• Engine Electrical
• Engine and Emissions Control
• Clutch
• Manual Transaxle
• Automatic Transaxle
• Front and Rear Axle
• Wheel and Tire
• Power Plant Mount
• Front Suspension
• Rear Suspension
• Service Brakes
• Parking Brakes
• Steering
• Body
• Exterior
• Interior and Supplemental Restraint System (SRS)
• Chassis Electrical
• Heater, Air Conditioning and Ventilation
• Component Locations
• Configurations Diagrams and Splice Locations
• Circuit Diagrams
• Alphabetical Index

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File Size: 109 MB

File Type: PDF, RAR

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Audi S90 100 1970 73 Brake Repair Guide

Models Covered

• S90 (1970-72)
• 100 (1970-73)

DESCRIPTION

Brake system is hydraulically operated, utilizing a tandem master cylinder and Teves T 51/349 power brake unit. Front disc brakes consist of rotors attached to transmission output flanges, and two-piston calipers attached to transmission. Disc pads are equipped with a ceramic transmitter-type wear sensor. Transmitter is mounted on cross spring and will break when contact is made with pad plates, interrupting control circuit and causing indicator light on instrument panel to be activate. Rear brakes are leading-trailing shoe/drum type, using a dual piston wheel cylinder. Parking brake is cable actuated, operating secondary shoes of rear brake assemblies.

ADJUSTMENT

NOTE - Adjustments or readjustments should be carrier out on cold brakes. However, brakes must be warm when testing. Instrument panel trim must be removed to adjust master cylinder push rod free play.

MASTER CYLINDER PUSH ROD FREE PLAY

Check brake pedal free play by measuring distance between master cylinder push rod and master cylinder piston. This measurement should be .039" (1.0 mm), which would give free play of .20" (5.08 mm) at brake pedal. If necessary to adjust, loosen lock nut on push rod and turn push rod until correct clearance is obtained. Tighten lock nut and again measure pedal free play at brake pedal.

FRONT DISC BRAKES

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

REAR DRUM BRAKES

Raise and support rear of vehicle release parking brake. Using a 17 mm wrench, tighten eccentric adjusters until wheels can no longer be turned by hand. Loosen eccentric adjusters until wheels are just free to turn.

PARKING BRAKE

Raise and support rear of vehicle and adjust rear brakes. Lift parking brake lever until it engages third ratchet stop. Adjust nut at equalizer until rear wheels are just free to turn. When parking brake lever is pulled up one additional notch (to fourth ratchet stop), rear wheels should be locked.

HYDRAULIC SYSTEM BLEEDING

Fill master cylinder reservoir with brake fluid and maintain level throughout bleeding operation. Attach a hose to bleeder screw, and immerse opposite end in a container partially full of brake fluid. Open bleeder screw approximately one-half turn, depress brake pedal, close bleeder screw, and slowly return pedal. Continu operation until air bubbles are no longer seen in discharge fluid. Bleeding sequence is left-rear, right-rear, right-front, left-front.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal - Remove lock clips. Pull out retaining pins so they project into openings in side members. NOTE - Do not remove rubber grommets from side member holes. Using a suitable extractor tool (SB-3), remove disc pads from caliper.

NOTE - Disc pads can be removed on right side only after removing front exhaust pipe.

Installation - Press both pistons into caliper bores.

NOTE - Fluid level in master cylinder reservoir will rise.

Siphon sufficient fluid to prevent reservoir from overflowing. Ensure pistons are in correct alignment in bores using suitable tool (B-5). Install disc pads in recesses of caliper, slide in retaining pins, and install lock clip. Pump brake pedal several times to position disc pads. Bleed hydraulic system if necessary.

FRONT DISC BRAKE CALIPER & ROTOR

Removal - 1) On vehicles equipped with automatic transmission, disconnect steering damper from its bracket and move out of way. On all models, depress brake pedal approximately 1.2" (30.48 mm) and hold in this position by using suitable pedal support. Disconnect temperature transmitter wire from connector (near transmission)

2) On automatic transmission equipped vehicles, disconnect hydraulic line at union on transmission, EGR line at exhaust pipe, and exhaust pipe from hangers. On all models, disconnect and remove front exhaust pipe and shield from manifold, and drive shaft at stub axle.

3) Remove ball joint mounting bolts, pull wheel downward, and swing out steering knuckle after prying it off ball joint. Remove disc brake pads, leaving spring and wire in vehicle. Remove EGR filter from oil  pan. Remove caliper mounting nuts, then remove caliper and rotor from stub axle. NOTE - If necessary, pry engine assembly to one side to ease removal.

Installation - To install, reverse removal procedure, tighten caliper mounting bolts securely, and bleed hydraulic system.

REAR BRAKE DRUM

REAR BRAKE ASSEMBLY

Removal - Raise and support vehicle, remove wheel and tire assembly. Pry off dust cap, remove cotter pin from hex nut, and remove nut. Remove brake drum making sure that retaining washer and wheel bearing do not fall out.

Installation - To install, reverse removal procedure adjust brakes, and adjust wheel bearings. See Wheel Bearing Adjustment in WHEEL ALIGNMENT Section.

REAR BRAKE SHOES

Removal - With brake drum removed, remove retaining spring for brake shoes. Remove shoes as an assembly by disconnecting spring at bottom, pulling shoes back from wheel cylinder, and disconnecting parking brake cable.

Installation - To install, reverse removal procedure and not the following: Make sure long ends of retainin clip and spring are installed on secondary shoe and parking brake lever. Ensure brake shoes are correctly positioned on wheel cylinder pistons.

REAR BRAKE WHEEL CYLINDER

Removal - With drum and shoes removed, depress brake pedal approximately 1.4" (35.56 mm) and hold in this position by using suitable pedal support. Disconnect remaining hydraulic line and cylinder mounting nuts. Separate master cylinder from power unit, taking care not to lose "O" ring installed between units.

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

MASTER CYLINDER

Removal - Disconnect hydraulic line at rear of master cylinder. Depress brake pedal 1.2-1.6" and hold in position using a suitable pedal support. Disconnect remaining hydraulic line and cylinder mounting nuts. Separate master cylinder from power unit taking care not to lose "O" ring installed between them.

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

POWER BRAKE UNIT

Removal - Siphon brake fluid from master cylinder reservoir and disconnect hydraulic lines. Loosen hose clamp and disconnect vacuum hose from power unit. From inside vehicle, remove trim below instrument panel as necessary. Disconnect push rod form brake pedal, remove power unit adapter attaching nuts, and remove power unit and master cylinder from engine compartment as an assembly. Separate master cylinder and adaptor from power unit.

Installation - To install, reverse removal procedure and note the following: Be sure to install "O" ring between master cylinder and power unit. Install adaptor to power unit so that center punch mark on adaptor is located on lower right hand side facing engine. To complete installation, adjust pedal push rod free play and bleed hydraulic system.

Check Valve Replacement - A vacuum check valve is locate in vacuum line between intake manifold and power it. To remove, loosen hose clamps, separate vacuum hoses from check valve, and remove check valve. To install, reverse removal procedure and not the following: Check valve is stamped with the word "MOTOR" and an arrow. End of valve in which arrow points must be connect to shorter hose from intake manifold.

OVERHAUL

FRONT DISC BRAKE CALIPER

FRONT DISC BRAKE CALIPER ASSEMBLY

Disassembly - Remove disc pads. Pry out retaining ring and remove dust seal by hand. Place a small block of wood in caliper cavity, and remove piston by applying compressed air to fluid inlet. Remove remaining piston in same manner. Remove seal from caliper bore using a piece of wood or plastic. NOTE - Do not use hard or sharp tools for this purpose. Do not separate caliper halves.

FRONT DISC BRAKE CALIPER ASSEMBLY

Cleaning & Inspection - Clean all parts in alcohol only. Check cylinder bore and piston for damage. NOTE - Do not machine caliper bore or piston. Parts are serviced by replacement only.

PINION INSTALLATION

Reassembly - Coat all parts with ATE brake cylinder paste (or equivalent), reverse  disassembly procedure, and note the following: Use new seals, dust boots, and retaining rings when reassembling. When installing piston, make sure machined surface of piston face makes a 20° angle to wall of caliper bore (see illustration). Install disc pads after caliper has been installed on vehicle.

REAR WHEEL CYLINDER

Disassembly - Thoroughly clean outside of cylinder. Remove end caps, piston and seal assemblies, and spring. Remove dust cap and bleeder screw.

AUDI MASTER CYLINDER
(COMPONENT PARTS)

Cleaning & Inspection - Clean all parts in alcohol only. Check all parts for rust, corrosion, and damage. Check cylinder bore and piston for wear or damage. Cylinder bore should not exceed .6287" (16.00 mm) and piston diameter should not be less than .619" (15.74 mm). NOTE - Manufacturer recommends replacing rubber components on each disassembly.

Reassembly - Reverse disassembly procedure and not the following: Apply a thin coat of ATE brake cylinder paste (or equivalent) to all parts during assembly.

MASTER CYLINDER

Disassembly - Remove reservoir, brake light switch, circlip and dismantle cylinder. To extract piston, unscrew stop screw.

Cleaning & Inspecting - Clean all parts in denatured alcohol. Inspect bore and piston for rust or wear and replace any parts out of tolerance. It is advisable to always replace rubber parts.

Reassembly - Preassemble pistons and coat cups with ATE brake cylinder paste (or equivalent). Insert assembly into cylinder bore, install stop screw and circlip. Install brake light switch and resrevoir.

NOTE - Models without power brake servo differ slightly. Primary piston desgin is somewhat varied. Piston is equipped with only on secondary boot. There is no air compensating bore. Brake light switch location is different.

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