bombardier:caf:cfto:c-30-108-000_mp-001_part_4

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C-30-108-000/MP-001 - First, Second and Third Line Maintenance Instructions — Part 4

C-30-108-000/MP-001
1991-06-10 Ch 2695 Pages
PDF (12,573 KB)

   The following article has been extracted from the original CFTO document. For ease of use, some hyperlinks, reformatting, and minor modifications have been made. English only. Pour la version français, télécharger le document original.

For other Canadian Forces Technical Order (CFTO) documents, see Iltis-related Canadian Forces Technical Order Documents.


Canadian Department of National Defence logo

C-30-108-000/MP-001

First, Second and Third Line Maintenance Instructions — Part 4

Truck Utility, Light 4 x 4 Military Design Iltis Canadian Series
Issued on Authority of the Chief of the Defence Staff
OPI: DSVPM
1986-10-31
1991-06-10 Ch 2
Canada logo

   This article contains only Part 4 — Steering and Brakes.

Due to the length of this document, each of its six parts have a dedicated page. Other parts are available here:

Table of Contents



WARNING — With the exception of the alternator and some minor components (e.g. composite taillight assemblies), all parts on the Iltis Canadian Series are dimensioned in the metric system. During any maintenance procedures, all replacement fasteners must have the same measurement and strength as those removed. (Numbers on the heads of metric bolts and on the surfaces of metric nuts indicate their strength). Mismatched or incorrect fasteners may result in personal injury or engine damage or malfunction. Therefore, fasteners removed from the engine should be saved for re-use in the same location where possible. When fasteners are unsatisfactory for re-use, care should be taken to select a replacement that matches the original.

Part 4 — Steering and Brakes

Section 1 — Steering System

General

Description of the Steering System

1.The steering system consists of a steering wheel, steering shaft, steering column, rack and pinion steering gear, tie-rods, tie-rod ends, steering damper, steering arms and steering stops. Although not part of the steering system, the rear suspension also has tie-rods, tie-rod ends and steering arms.

Operation of the Steering System

2.Effort applied to the steering wheel is transmitted through the steering shaft and universal joint to the steering gear pinion. Rotation of the pinion moves the rack which draws the tie-rod guide with it. Movement of the guide moves the tie-rods, which are connected to the guide and the wheel hubs.

Description of Steering Wheel

3.The steering wheel consists of an impact absorber that improves safety. The steering wheel contains the horn plate and has a full lock to lock travel of three turns.

Description of Steering Shaft

4.The steering shaft, which is housed in the centre of the steering column, has a universal joint at its lower end that provides an angular drive to the steering gear. The universal joint diverts impact and eliminates mounting stress of the steering gear.

Description of Steering Column

5.The steering column surrounds the lower end of the steering shaft. The column provides the securing mounts and contains the clutch and brake mounting brackets. At its upper end are the directional signal control/headlight high and low beam lever and the windshield wiper/washer lever and starter button bracket which are encased in an upper and lower cover.

Description of Rack and Pinion Steering Rack

6.The steering rack, which is mounted horizontally and parallel to the firewall in the engine compartment, consists of a pinion gear and rack. The rack is a long shaft with teeth cut on one side to mesh with the rotating pinion gear and V-shaped flats on the reverse side to contact the adjustment thrust pads. Connected to the rack at its right end is a tie-rod guide. The complete system is kept free of foriegn matter by two dust boots which surround the rack and are connected to the gear housing at thier outer ends and to the tie-rod guide at their inner ends. A removable end plug and rubber bumper at the right end prevent disengagement of the rack from the pinion on full right travel and allows for removal of the rack from the housing. The steering gear is vented to the atmosphere through the transaxle vent tube.

Description of Steering Damper

7.A steering damper is attached to the tie-rod guide mounting bracket at one end and the steering gear housing at the other. The damper acts as a shock absorber that absorbs road shock. The action of the damper reduces strain on the steering gear and creates smoother handling of the steering wheel.

Description of Tie-rods and Tie-rod Ends

8.The tie-rods and tie-rod ends transmit the linear motion of the steering rack to the steering arms. The right tie-rod has an adjustable sleeve to permit toe-in adjustment.

Description of Steering Arms

9.Attached to the top of each hub carrier is a steering arm. The steering arms connect the wheels to the steering gear through the tie-rods.

Description of Steering Stops

10.Both front wheels have a steering stop secured to the hub carrier. The steering stops prevent the wheels from turning at too great an angle and provide a turning radius of 11 meters in both directions.

Specifications

11.The vehicle has a wheelbase of 2017 mm and an unladen front and rear track of 1230 mm with a permissible rear-wheel track of 1260 mm at total allowable weight.

12.There is no permissible free play at the steering wheel. The only adjustments that can be carried out on the steering system are steering gear free play and toe-in of both front and rear wheels. The vehicle has a front wheel camber of -2°10 minutes to -10 minutes and a rear wheel camber of -2°15 minutes to -15 minutes. Camber angles are not adjustable.

Component Removal and Installation

WARNING — Do not replace metric bolts with standard bolts. See the WARNING page at front of the manual.

Steering Wheel

13.Removal — To remove, proceed as follows:

  1. Turn the battery master switch off.
  2. Ensure the front wheels are in the straight-ahead position.
  3. Pull out on the horn plate until it is disengaged from the snap clips and turn one-quarter turn counter-clockwise to disengage from the steering wheel.
  4. Disconnect the electrical connector from the back of the horn plate and remove the plate.
  5. Remove the steering wheel retaining nut and washer.
  6. Pull the steering wheel from the shaft.

14.Installation — To install, proceed as follows:

  1. Install the steering wheel on the shaft, ensuring the straight spoke of the steering wheel is in the horizontal position and the turn signal lever is in the centre position.
  2. Install the flat washer and retaining nut and torque the nut to 50 N•m (37 ft lb).
  3. Connect the electrical connector to the back of the horn plate.

Figure 4-1-1 — Positioning Horn Plate
Figure 4-1-1 — Positioning Horn PlateClick image to enlarge.

  1. Install the horn plate, ensuring the top of the plate is in a vertical position, see Figure 4-1-1.
  2. Turn the horn plate one-quarter turn so that the plate is aligned with the spokes of the steering wheel.
  3. Press on the top and bottom of the horn plate until the plate snaps into place.
  4. Turn the battery master switch on and test the horn.
Steering Shaft

15.Removal — To remove, proceed as follows:

Figure 4-1-2 — Inner Dust Cover
Figure 4-1-2 — Inner Dust CoverClick image to enlarge.

  1. Remove the steering wheel.
  2. Remove the inner dust cover, see Figure 4-1-2.
  3. Remove the two retaining screws from the lower steering column cover and remove the cover.
  4. Remove the lock nut from the top of the starter button and remove the button from the bracket.
  5. Disconnect the electrical connectors from the windshield wiper control, signal light control and hi/lo beam and horn terminals.
  1. Remove the three screws and remove the signal light control and windshield wiper control.
  2. Remove the upper bolt and nut from the steering shaft universal joint.
  3. Remove the socket head cap screw from the starter button bracket.
  4. Place the steering wheel on the shaft and install the retaining nut.
  5. Pull up on the steering wheel to remove the shaft from the column.
  6. Remove the wheel and retaining nut from the shaft.

16.Installation — To install, proceed as follows:

  1. Insert the steering shaft into the steering column, ensuring the cutaway portion at the bottom of the shaft is aligned with the upper bolt holes of the universal joint and the starter button bracket is aligned with the flange on the column.
  2. Install a bolt and nut in the universal joint and torque to 25 N●m (18 ft lb).
  3. Install the socket head cap screw to secure the starter button bracket to the column.
  4. Install the windshield wiper control and signal light control and install the three screws.
  5. Connect the electrical connectors to the corresponding wiper control, signal control, and hi/lo beam and horn terminals.
  6. Install the starter button into the bracket and install the lock nut.
  7. Install the lower steering column cover.
  8. Install the inner dust cover.
  9. Install the steering wheel.
Steering Column Assembly

17.Removal — The assembly consists of the following main components: steering wheel, steering shaft, steering column, clutch pedal and brake pedal. To remove the assembly, proceed as follows:

  1. Turn the battery master switch off.
  2. Position the front wheels in the straightahead position.
  3. Disconnect the return spring from the clutch pedal arm and the return spring from the brake pedal arm.
  4. Remove the clutch cable from the arm of the clutch pedal.
  5. Remove the lock clip from the clevis pin that secures the yoke of the brake push rod to the arm of the brake pedal and remove the clevis pin.
  6. Remove the upper and lower steering column covers.
  7. Disconnect the three electrical connectors from the column assembly.
  8. Remove the locking nut from the top of the starter button and slide the button out of the bracket.
  9. Remove the retaining nuts and bolts that secure the column bracket to the firewall.
  10. Remove the two retaining nuts from the bracket under the dash.
  11. Remove the top nut and bolt from the universal joint and remove the column assembly.

18.Installation — To install, proceed as follows:

  1. Insert the end of the steering shaft into the universal joint, ensuring the horn plate is in a horizontal position and the arm of the brake pedal is in the yoke of the brake push rod.
  2. Install the bolt and nut in the universal joint and torque to 25 N•m (18 ft lb).
  3. Install the column bracket on the firewall with a cap screw on both sides of the brake push rod but do not tighten.
  4. Install the bolts and nuts to the underside of the dash but do not tighten.
  5. Insert the starter button into the bracket on the columm housing.
  6. Install the starter button locking nut.
  7. Connect the three electrical connectors into the corresponding terminals.
  8. Install the column covers.
  9. Tighten the bolts and nuts on the firewall and under the dash.
  10. Install the clutch cable and return spring to the arm of the clutch pedal.
  11. Install the clevis pin through the yoke of the brake push rod and the arm of the brake pedal and install a lock clip.
  12. Connect the brake return spring to the pedal arm.
  13. Turn the battery master switch on.
Starter Button Bracket

19.Removal — To remove, proceed as follows:

  1. Remove the steering wheel.
  2. Remove the inner dust cover, see Figure 4-1-2.
  3. Remove the steering column covers.
  4. Remove the socket head screw from the starter button bracket.

Figure 4-1-3 — Removal of Starter Button Bracket
Figure 4-1-3 — Removal of Starter Button BracketClick image to enlarge.

  1. Remove the three retaining screws from the turn signal control.
  2. Disconnect the electrical connectors from the windshield wiper control, signal light control and hi/lo beam and horn terminals.
  3. Remove the lock nut from the starter button and remove the starter button.
  4. Install puller tool KUKKO 44-2 and remove the bracket, see Figure 4-1-3.
  5. Pry the bearing sleeve from the steering shaft.

20.Inspection — Inspect the splines and threads of the steering shaft for damage and replace if necessary.

21.Installation — To install, proceed as follows:

  1. Lightly coat a new bearing sleeve with lubricant and install on the steering shaft.
  2. Coat the inside of the bracket with lubricant and install the bracket on the steering shaft.
  3. Tap the bracket down until it is flush with the housing.
  4. Install the socket head screw.
  5. Connect the electrical connectors to the corresponding wiper control, signal control, and hi/lo beam and horn terminals.
  6. Install the three retaining screws in the turn signal control.
  7. Insert the starter button into the bracket and secure with the locking nut.
  8. Install the steering column covers.
  9. Install the inner dust cover.
  10. Install the steering wheel.
Steering Rack Assembly

Figure 4-1-4 — Clamp on Lower Steering Shaft
Figure 4-1-4 — Clamp on Lower Steering ShaftClick image to enlarge.

Figure 4-1-5 — Steering Rack Vent Hose
Figure 4-1-5 — Steering Rack Vent HoseClick image to enlarge.

22.Removal — To remove, proceed as follows:

  1. For easier access to the steering rack assembly, place the vehicle on axle stands and remove both front wheels.
  2. Turn the steering column upper boot inside out for access to the clamp on the lower steering shaft.
  3. Remove the socket head bolt and nut from the lower steering shaft, see Figure 4-1-4. Spread the clamp slightly and remove the clamp from the shaft.
  4. Using a tie-rod end puller GA 390, remove both tie-rod ends from the steering arms.
  5. Remove the steering rack vent hose, see Figure 4-1-5.
  6. Remove the four locking nuts from the rack assembly mounting studs.

CAUTION — To prevent damage to the threads of the mounting studs, remove the steering rack with care.

  1. With assistance, remove the rack assembly from the left side of the vehicle.

23.Installation — To install, proceed as follows:

CAUTION — To prevent damage to the threads of the mounting studs, install the steering rack with care.

  1. Insert the rack assembly from the left side.
  2. Install the assembly on the two mounting studs on the right side and install two new locking nuts and washers. Do not tighten.
  3. Install the lower shaft onto the pinion, ensuring the flat of the pinion shaft is aligned with the opening of the clamp.
  4. Install the socket head bolt and nut into the steering shaft clamp. Do not tighten.
  5. Install the assembly on the two mounting studs on the left side and install two new locking nuts and washers. Do not tighten.
  6. Press the lower dust boot into the groove on the underside of the floor.
  7. Torque the four rack assembly locking nuts to 25 N•m (18 ft lb).
  8. Ensure the front wheel hubs are in the straight-ahead position.
  9. Install the tie-rod ends on the steering arms.
  10. Install a castellated nut on each tie-rod end and torque to 40 N•m (30 ft lb). Install a cotter pin.
  11. Adjust the lower clamp so that the steering shaft U-joint turns freely.
  12. Tighten the socket head bolt and nut of the shaft clamp and torque to 40 N•m (30 ft lb).
  13. Turn the column upper boot right side out and push down until it snaps into place in the floor.Install the vent hose.
  14. Install the front wheels and remove the axle stands. Torque wheel bolts to 175 N●m (129 ft lb).
  15. Check front wheel toe-in and adjust, if necessary (refer to Section 3).
  16. Adjust the steering rack, if necessary (refer to Section 3).
  17. Reposition the steering wheel, if necessary.
Steering Damper and Front Tie-rods

24.Removal — To remove, proceed as follows:

Figure 4-1-6 — Locking Plate on Tie-Rod Bracket
Figure 4-1-6 — Locking Plate on Tie-Rod BracketClick image to enlarge.

  1. Remove the steering rack assembly and place in a vise.
  2. Remove the two damper bolts and remove the damper.
  3. Remove the two nuts from the outer tie-rod bracket.
  4. Using a punch, flatten the locking plate for the two bracket retaining cap screws, see Figure 4-1-6.
  5. Remove the two retaining cap screws.
  6. Remove the locking plate and outer tierod bracket.
  1. Remove both tie-rods from the mounting bolts of the inner bracket.
  2. Remove the inner bracket from the guide.

25.Installation — To install, proceed as follows:

  1. Position the steering rack assembly in a vise.
  2. Install the inner bracket on the guide, ensuring the steering damper portion of the bracket is toward the bottom portion of the steering gear.
  3. Install both tie-rods on the mounting bolts of the inner bracket, ensuring the tie-rod with the adjusting sleeve is on the steering damper side of the rack assembly.
  4. Install the outer bracket on the mounting bolts of the inner bracket and place the locking plate in the outer bracket.
  5. Install both bracket retaining cap screws and torque to 60 N•m (44 ft lb).
  6. Bend the locking plate over the bracket retaining cap screws.
  7. Install two nuts on the outer bracket and torque to 60 N•m (44 ft lb).

Figure 4-1-7 — Measurement of Left Front Tie-Rod
Figure 4-1-7 — Measurement of Left Front Tie-RodClick image to enlarge.

  1. Measure the length of the left tie-rod from the centre of the tie-rod end to the centre of retaining bolt. The tie-rod should be 358 mm (14 7/64 in) long, see Figure 4-1-7. Adjust the length of the tie-rod, if necessary.
  2. Install the piston end of the steering damper in the inner bracket and the other end in the housing bracket. Install the two steering damper bolts and torque to 40 N•m (30 ft lb).
  3. Install the steering rack in the vehicle.
  1. Check and adjust front wheel toe-in (refer to Section 3).

Figure 4-1-8 — Steering Rack Assembly 1. Snap ring
2. Rack stop plug
3. Rack
4. Needle bearing
5. Pinion
6. Thrust pads
7. Thrust disc
8. Spring
9. O-ring
10. Adjusting screw cover plate
11. Lock nut
12. Adjusting screw
13. Cap screw
14. Housing
15. Ball bearing
16. Self-locking nut
17. Lower cover
18. Dust boots
19. Tie-rod guide
20. Self-locking nut
21. Flat washers
22. Bolt

Figure 4-1-8 — Steering Rack AssemblyClick image to enlarge.

Steering Rack Dust Boots

26.Removal — Replace the steering rack dust boots if torn or leaking grease. To remove, see Figure 4-1-8 and proceed as follows:

  1. Remove the steering rack assembly.
  2. Remove the tie-rods and damper from the rack assembly.
  3. Remove the two cap screws (13) from the adjusting screw cover plate (10). The cover plate is under spring tension.
  4. Loosen the lock nut (11) and remove the adjusting screw (12), cover plate, spring (8), two thrust pads (6), thrust disc (7) and “O” ring (9) from the housing (14).
  5. Remove the self-locking nut (20), bolt (22) and flat washers (21) at the rack stop plug (2).
  6. Turn the pinion (5) to move the rack (3) away from the rack stop plug.
  7. Tap the stop plug into the housing and remove the snap ring (1).
  8. Turn the pinion to move the rack and push the plug to the end of the housing and remove the plug.
  9. Inspect the rubber bumper on the plug and replace if damaged.
  10. Disconnect the outer ends of both dust boots (18) from the housing.
  11. Remove the rack from the housing and remove both boots and the tie-rod guide (19).
  12. Remove the boots from the guide.
  13. Ensure the rack is clean and coat with Molykote grease.
  14. Ensure the pinion turns freely. Replace the rack assembly if there are signs of bearing failure or wear to the pinion shaft.

27.Installation — To install, see Figure 4-1-8 and proceed as follows:

Figure 4-1-9 — Installation of Dust Boots and Tie-Rod Guide
Figure 4-1-9 — Installation of Dust Boots and Tie-Rod GuideClick image to enlarge.

Figure 4-1-10 — Installation of Steering Rack Stop Plug
Figure 4-1-10 — Installation of Steering Rack Stop PlugClick image to enlarge.

  1. Partially slide the rack (3) into the housing (14), ensuring the teeth of the rack face up.
  2. Install the boots (18) on the guide (19), ensuring the boots are seated in the groove at each end of the guide.
  3. Ensure the pinion (5) is greased with Molykote grease.
  4. Install the boots and tie-rod guide in the housing, ensuring the vent tube of the tie-rod guide faces up, see Figure 4-1-9.
  5. Install the boot that is farthest from the pinion into the groove in the housing and slide the rack through the boot and guide.
  6. Install the remaining boot in the groove in the housing and slide the rack in as far as it will go.
  7. Turn the pinion until the teeth of the rack contact the splines of the pinion and then turn the pinion until the rack is in as far as possible.
  8. Install the stop plug into the housing, ensuring the bolt hole in the plug is aligned with the holes in the end of the housing, see Figure 4-1-10. Ensure the plug goes in straight so that it is not damaged.
  1. Tap the plug into the housing so that the snap ring (1) can be installed and install the snap ring.
  2. Pry the plug toward the end of the housing until the plug contacts the snap ring.
  3. Install the bolt (22), flat washers (21) and a new self-locking nut (20) to secure the plug in the housing and torque the nut to 25 N•m (18 ft lb).
  4. Install a new “O” ring (9) in the pinion housing.
  5. Grease the thrust pads (6) and the inside of the pinion housing with Molykote grease.
  6. Install the thrust pads, thrust disc (7) and spring (8).
  7. Install the cover plate (10) on the housing with the pointed end facing away from the pinion. Secure the cover in place with two cap screws (13). Torque the cap screws to 20 N•m (15 ft lb). Install the adjusting screw (12).
  8. Turn the adjusting screw until it contacts the rack and torque the lock nut (11) to 15 N•m (11 ft lb).
  9. Install the tie-rods and damper to the rack assembly.
  10. Install the rack assembly in the vehicle and adjust the steering to eliminate free play (refer to Section 3).
Steering Rack Vent Hose

28.Removal — To remove, proceed as follows:

  1. Loosen the clamp and remove the vent hose from the tie-rod guide on the rack assembly.
  2. Loosen the clamp and remove the vent hose from the “T” junction on the transaxle breather tube at the firewall.

29.Installation — To install, proceed as follows:

  1. Install the vent hose to the transaxle breather tube at the firewall and tighten the clamp.
  2. Install the vent hose to the tie-rod guide on the rack assembly and tighten the clamp.
Tie-rod Ends

30.Removal — To remove, proceed as follows:

  1. Hold the tie-rod end and loosen the lock nut.
  2. Remove the tie-rod end from the steering arm, using tie-rod end puller GA 390.
  3. Unscrew the tie-rod end, counting the number of turns required to remove it.

31.Installation — To install, proceed as follows:

  1. Install the new tie-rod end onto the tierod, ensuring the same number of turns are made as were required for removal.
  2. Install the tie-rod end into the steering arm and torque the nut to 40 N•m (30 ft lb).
  3. Tighten the lock nut against the tie-rod end.
  4. Check toe-in and adjust, if necessary (refer to Section 3).
Steering Arm Stops

32.Removal — Remove the two socket head screws and remove the stop from the hub carrier.

33.Installation — Install the steering arm stop to the hub carrier with two socket head screws and torque to 25 N•m (18 ft lb).

Ball Joints (Lower)

34.Inspection — To inspect, proceed as follows:

  1. Raise the vehicle so that the suspen- sion hangs unsupported with the wheel off the ground.
  2. Place a bar between the wheel and the ground and force the wheel upwards.
  3. If there is any movement in the ball joint, replace it.
  4. If the ball joint seal is punctured, replace the ball joint.

35.Removal — To remove, proceed as follows:

  1. Place an axle stand under the vehicle and remove the wheel.
  2. Remove the mounting bolts and selflocking nuts from the shock absorber and wishbone arms at the ball joint.
  3. Remove the nut from the ball joint at the hub carrier.

WARNING — To prevent injury, stand to the side of the ball joint when closing the jaws of the ball joint remover. There may be a build-up in pressure before the ball joint releases from the carrier, causing the ball joint to fly off the carrier with considerable force.

  1. Install remover VW 267A so that it is over the ball joint and under the housing and remove the ball joint.

36.Installation — To install, proceed as follows:

  1. Insert the ball joint into the hub carrier. Install the nut and torque to 100 N•m (74 ft lb). Retorque the nut every 7500 km or once a year.
  2. Install the bottom shock absorber/wishbone arms mounting bolt, flat washer and a new self-locking nut and torque to 200 N•m (148 ft lb).
  3. Install the wishbone arms to the ball joint with a mounting bolt and new self-locking nut and torque to 200 N•m (148 ft lb).
  4. Install the wheel and remove the axle stand. Torque the wheel bolts to 175 N•m (129 ft lb).
Trunnion Pivots

37.Inspection — To inspect the trunnion pivots, both the Radial and the Axial tolerance checks must be performed. Proceed as follows:

  1. Axial tolerance is checked as follows:
  1. Raise the vehicle so that the suspension hangs unsupported with the wheel off the ground.
  2. Mount a dial indicator on the hub carrier so that the axial movement of the trunnion pivot can be read.
  3. Place a bar between the steering arm and trunnion pivot. Force the trunnion pivot upwards.
  4. If the axial play is more than 2.5 mm, repair the trunnion pivot (refer to Part 3, Section 4).

NOTE — On new or rebuilt trunnion pivots, the allowable axial play is 0 to 1.3 mm.

  1. Radial tolerance is checked as follows:
  1. Raise the vehicle so that the suspension hangs unsupported with the wheel off the ground.
  2. Mount a dial indicator on the trunnion pivot so that the radial movement between the trunnion and the hub carrier can be read.
  3. Grasp the tire and wheel assembly at the top and force inwards and outwards to check for radial movement.
  4. If the radial movement, indicated on the dial gauge, is greater than 0.51 mm, repair the trunnion pivot (refer to Part 3, Section 4).

38.Removal — Refer to Part 3, Section 4.

39.Installation — Refer to Part 3, Section 4.

Section 2 — Service Brakes and Hand Brake

General

Description of Service Brakes

1.The service brakes, which are energized in forward and reverse, are a diagonal, dual-circuit hydraulic system with full braking action at all four wheels. The system consists of:

  1. A master cylinder with two separate chambers and two reservoirs. The front chamber operates the left front and right rear brakes. The rear chamber operates the right front and left rear brakes.
  2. A vacuum-operated brake servo is bolted to the firewall, with the servo piston attached to the brake pedal. The master cylinder is secured to the servo.
  3. The front wheels each have two brake cylinders with a piston on one end and an adjuster on the other. The rear wheels have a double-acting cylinder and a double-acting adjuster in each wheel.
  4. There are two shoes on each brake backing plate. The brake linings are riveted to the shoes, and can be replaced.
  5. Reservoirs on the master cylinder have separate warning light sending units which are operated by floats in the reservoirs. The warning light will come on if the fluid is below the minimum level in either reservoir.
Description of Hand Brake

2.The hand brake is a mechanical type brake, that works on the rear brake drums only. When the hand brake lever is pulled to the over-centre position, a cable which is attached to the lever and cable equalizer, pulls two cables that are attached to the brake lever of each rear brake assembly. The lever pushes out on the shoe to which it is attached and, through an equalizing rod, pushes the other shoe out so that both shoes contact the brake drums. When the hand brake lever is released, springs on the brake shoes and the cables return the system to the released position. A switch beneath the hand brake lever will activate a brake warning light on the dash when the hand brake is applied. Minor adjustments are made with a knob on the hand brake lever.

Component Removal and Installation

WARNING — Do not replace metric bolts with standard bolts. See the WARNING page at front of the manual.

Master Cylinder

3.Removal — To remove, proceed as follows:

  1. Turn off the battery master switch.
  2. Disconnect the brake warning light electrical terminal from the switch on the cylinder housing.
  3. Disconnect the electrical connectors from the terminals of the reservoir caps.
  4. Disconnect both brake lines from the residual check valves at the cylinder housing.
  5. Remove the two locking nuts from the cylinder at the brake servo and remove the bracket and cylinder.

4.Disassembly — To disassemble, see Figure 4-2-1 and proceed as follows:

  1. Remove the caps from the reservoirs and empty the fluid into a container.
  2. Clamp the cylinder (2) in a vise.
  3. Loosen the nut at the base of each reservoir.
  4. Remove both reservoirs and washers (1) from the housing.
  5. If necessary, empty the fluid from the cylinder into a container.
  6. Remove the brake light switch (9) from the cylinder.
  7. Remove the two residual check valves (8) from the cylinder.
  8. Remove the two bleeder valves (10) from the cylinder.
  9. Slightly push the primary piston (6) into the cylinder and remove the stop screw and washer (3) from the cylinder.
  10. Using circlip pliers, remove the circlip (7) from the primary piston.
  11. Remove the primary piston from the cylinder.
  12. Tap the open end of the cylinder against a piece of wood or use compressed air to remove the secondary piston (5) from the cylinder.

5.Inspection — To inspect, proceed as follows:

  1. Inspect the bore of the cylinder for scoring, corrosion and damage and replace, if necessary.
  2. Inspect the bore of the cylinder for minor scratches and hardened deposits and remove by honing. After honing, insert a new piston into the bore and measure the clearance between the piston assembly and the inside surface of the cylinder. If the clearance is greater than 0.10 mm, replace the master cylinder.

Figure 4-2-1 — Master Cylinder 1. Washer
2. Master cylinder
3. Stop screw and washer
4. Spring
5. Secondary piston
6. Primary piston
7. Circlip
8. Residual check valve
9. Brake light switch
10. Bleeder valve

Figure 4-2-1 — Master CylinderClick image to enlarge.

6.Assembly — To assemble, see Figure 4-2-1 and proceed as follows:

  1. Clean all piston components in clean brake fluid.
  2. Using a piston fitting sleeve, insert the secondary piston (5) into the bore of the cylinder (2), ensuring the spring (4) enters the cylinder first.
  3. Press down on the secondary piston and install the stop screw and washer (3).
  4. Ensure the secondary piston is past the stop screw and then torque the screw to 7 N•m (5 ft lb).
  5. Place the cylinder in a vise.
  6. Insert the primary piston assembly (6) into the bore of the cylinder.
  7. Using circlip pliers, install a circlip (7) on the primary piston.
  8. Install the two residual check valves (8) and torque to 19 N•m (14 ft lb).
  9. Install the two bleeder valves (10) and torque to 7 N•m (5 ft lb).
  10. Install the brake light switch (9) and torque to 19 N•m (14 ft lb).
  11. Install the reservoirs and new washers (1) on the cylinder and tighten the nut at the base of each reservoir.

7.Installation — To install, proceed as follows:

  1. Install the cylinder and bracket on the brake servo ensuring that the brake push rod fits into the primary piston and secure with two nuts and washers.
  2. Connect the brake lines to the residual check valves at the cylinder housing.
  3. Connect the electrical terminal to the brake light switch on the cylinder.
  4. Fill the reservoirs with brake fluid to the maximum level.
  5. Install the reservoir caps.
  6. Connect the reservoir electrical connectors to the terminals of the reservoir caps.
  7. Bleed the brakes (refer to Section 3).
  8. Turn on the battery master switch.
  9. Check brake pedal free play (refer to Section 3).
Brake Servo Assembly

8.Removal — To remove, proceed as follows:

  1. Remove the master cylinder.
  2. Remove the vacuum line from the servo unit.
  3. Remove the clip and clevis pin from the push rod yoke at the brake pedal arm.
  4. Remove the brake servo and adapter from the firewall by removing the two nuts under the dash.
  5. Pull the brake servo unit forward until the push rod is clear of the firewall.

Figure 4-2-2 — Components of Brake Servo Assembly 1. Vacuum hose grommet
2. Vacuum hose
3. Check valve
4. Spacer
5. Seal
6. Sealing sleeve
7. Sliding bushing
8. Yoke
9. Locking nut
10. Seal
11. Adapter
12. Filter
13. Servo unit

Figure 4-2-2 — Components of Brake Servo AssemblyClick image to enlarge.

9.Disassembly — To disassemble, see Figure 4-2-2 and proceed as follows:

  1. Remove the vacuum hose grommet (1) from the servo unit (13).
  2. Scribe match marks on the adapter and servo unit so that the adapter and unit can be aligned during assembly.
  3. Clamp the servo in a vise and remove the adapter (11) cover from the servo unit by removing the four nuts and washers.
  4. Remove the seal (10) from the rear of the adapter assembly.
  5. Remove the filter (12) from the push rod.
  6. Loosen the push rod locking nut from the yoke (8) and remove the yoke and locking nut (9) from the rod.
  7. Remove the sliding bushing (7) from the rod.
  8. Remove the sealing sleeve (6) from the rod.

10.Assembly — To assemble, see Figure 4-2-2 and proceed as follows:

  1. Install the sealing sleeve (6) on the push rod until it rests against the servo unit.
  2. Install the small end of the bushing (7) in the sealing sleeve.
  3. Install the push rod locking nut (9).
  4. Install the yoke (8) on the push rod and then unscrew the locking nut until it is tight against the yoke.
  5. Install the filter (12) on the push rod and over the sealing sleeve.
  6. Install the seal (10) in the hole in the adapter, ensuring the shoulder of the seal is aligned with the mounting bolts.
  7. Ensure the seal mates with the bushing and the scribe marks on the adapter and servo unit are aligned.
  8. Install the adapter (11) to the servo unit with four nuts and washers and torque the nuts to 25 N•m (18 ft lb).
  9. Install the vacuum hose grommet (1) into the housing.

11.Installation — To install, proceed as follows:

  1. Insert the push rod through the firewall and into the passenger compartment. Ensure the brake pedal arm is positioned between the arms of the push rod yoke, and the mounting bolts of the adapter protrude through the firewall, into the passenger compartment.
  2. Install a locking nut on each servo mounting bolt at the firewall.
  3. Install a clevis pin through the push rod yoke and brake pedal arm and secure with clip.
  4. Ensure the vacuum hose check valve is operating correctly. The check valve must hold suction applied to the servo side. It must not hold suction applied to the vacuum hose side. Replace the valve, if necessary.
  5. Connect the vacuum hose to the check valve.
  6. Install the vacuum hose to the brake servo check valve.
  7. Install the master cylinder.
  8. Adjust the brake pedal free play (refer to Section 3).
Brake Drums

12.Removal — To remove, proceed as follows:

Figure 4-2-3 — Removal of Brake Drum
Figure 4-2-3 — Removal of Brake DrumClick image to enlarge.

  1. Remove the wheel.
  2. Turn the brake shoe adjusters all the way counter-clockwise.

CAUTION — If the adjusters are not loosened all the way, the drum will catch on the brake shoes causing the brake cylinder tangs to break.

  1. Install three 8 x 40 mm cap screws in the threaded hole of the drum and evenly tighten the cap screws to pull the drum away from the hub, see Figure 4-2-3.
  2. Remove the drum.

13.Inspection — To inspect, proceed as follows:

  1. Inspect the brake drum for grooving, cracks and discoloration.
  2. Measure the internal diameter of the drum:
  1. A new drum has a diameter of 280.2 mm (11.04 in).
  2. If it was scored and required turning, a maximum of 0.5 mm (0.020 in) can be taken off to bring the new diameter to 280.7 mm (11.06 in).
  3. If more than 0.5 mm (0.020 in) must be removed to restore the drum, replace it.
  4. Once turned, the drum can be reused until the inside diameter has worn to 281.2 mm (11.08 in).

14.Installation — To install, proceed as follows:

  1. Install the drum over the brake shoes and ensure the wheel bolt holes of the drum and hub are aligned.
  2. Install the wheel bolt pilot and install the wheel and four mounting bolts.
  3. Remove the pilot bolt. Install the remaining bolt and snug the bolts in a diagonal sequence.
  4. Adjust the brakes (refer to Section 3).
  5. Remove the axle stand and torque the wheel mounting bolts to 175 N•m (129 ft lb).
Front Brake Shoes

15.Removal — To remove, see Figure 4-2-4 and proceed as follows:

Figure 4-2-4 — Front Brake Shoe Assembly (R/H Side)
Figure 4-2-4 — Front Brake Shoe Assembly (RH Side)Click image to enlarge.

NOTE — Always replace all linings on one axle at the same time. Use brake linings of the same quality.

  1. Remove the brake drum.
  2. Clean the brake shoes with a wire brush.
  3. Using a micrometer or Vernier caliper, measure the thickness of the brake shoe and lining. The linings should conform to the following specifications:
New shoes and linings 7.28 mm
(0.287 in)
New lining thickness 4.76 mm
(0.186 in)
Lining thickness over rivets 270 mm
(0.106 in)
Shoe thickness 2.52 mm
(0.099 in)
Minimum lining thickness 2.80 mm
(0.110 in)

If the combined thickness of the shoe and lining is 5.32 mm (0.210 in) or less, replace the linings. If shoes require replacement, replace both sides.

  1. Using brake spring pliers, remove both return springs.
  2. Using pliers, push in on each spring retainer and spring and turn one-quarter turn to remove the spring and retainer from each brake shoe.
  3. Remove the shoes from the backing plate.

16.Installation — To install, proceed as follows:

  1. Ensure the receiving groove of each wheel cylinder piston is correctly aligned to receive a shoe.
  2. Install a shoe on the backing plate, ensuring the bottom of the shoe fits into the adjuster and the top into the groove in the wheel cylinder piston.
  3. Install the spring and retainer on the shoe and, using pliers, push in and turn one-quarter turn to secure the retainer to the retaining pin.
  4. Repeat steps b. and c. for the remaining shoe.
  5. Install the return springs, ensuring the ends of the springs are hooked into the long grooves of the shoes.
  6. Install the brake drum and adjust the brake shoes (refer to Section 3).

Figure 4-2-5 — Rear Brake Shoe Assembly (R/H Side) 1. Upper return spring
2. Wheel cylinder
3. Brake shoe
4. Equalizer rod
5. Hand brake lever
6. Lower return strings
7. Adjuster assembly
8. Retaining pin
9. Spring retainer
10. Spring
11. Backing plate

Figure 4-2-5 — Rear Brake Shoe Assembly (RH Side)Click image to enlarge.

Rear Brake Shoes

17.Removal — To remove, see Figure 4-2-5 and proceed as follows:</wrap>

  1. Remove the brake drum.
  2. Clean the brake shoes with a wire brush.
  3. Measure the thickness of each brake shoe. When newly installed the combined thickness of the shoe and lining is 7.28 mm (0.287 in). The wear limit is 5.32 mm (0.210 in). Replace the brake lining, if necessary.
  4. Remove the upper return -spring (1) from the shoes and pull the shoes away from the wheel cylinder (2).
  5. Remove the lower return springs (6) from the shoes and backing plate.
  6. Using pliers, push in on a spring retainer (9) and spring (10), turn onequarter turn to release the retainer from the shoe guide pin and remove the retainer, spring and guide pin (8).
  7. Repeat step f. for the retainer, spring and guide pin of the other shoe. h. Remove the shoe from the backing plate (11).
  8. Disconnect the hand brake cable from the lever of the front shoe and remove the shoe and equalizer rod (4) from the backing plate.

18.Installation — To install, see Figure 4-2-5 and proceed as follows:

  1. Ensure the hand brake lever (5) moves freely and lubricate it. Connect the hand brake cable to the lever of the front shoe.
  2. Install the bottom end of the front shoe in the adjuster (7) and the top end in the wheel cylinder (2).
  3. Insert the guide pin (8) through the backing plate and shoe.
  4. Install a spring (10) and retainer (9) over the guide pin, push in the spring and retainer and turn one-quarter turn to secure the retainer to the guide pin.

Figure 4-2-6 — Equalizer Rod
Figure 4-2-6 — Equalizer RodClick image to enlarge.

  1. Install the equalizer rod (4) with the long tang of the rod toward the front shoe and in front of the shoe. Ensure the equalizer rod also engages the lever of the front shoe, see Figure 4-2-6.
  2. Install the bottom end of the rear shoe in the adjuster and the top end in the wheel cylinder, ensuring the shoe engages the equalizer rod.
  3. Repeat steps c. and d. for the rear shoe.
  4. Attach the upper return spring (1) to the front and rear shoes, see Figure 4-2-5.
  1. Attach the lower return springs (6) to the shoes and the backing plate (11).
  2. Install the brake drum and adjust the brake shoes (refer to Section 3).
Front Wheel Cylinders

19.Removal — To remove, proceed as follows:

  1. Remove both brake shoes from the backing plate.
  2. Remove the drive axle dust boot guard from the hub carrier.
  3. Disconnect the brake line from the cylinder at the rear of the backing plate.
  4. Disconnect the interconnecting brake line from both cylinders and remove the line.
  5. Remove the bleeder valve from the rear cylinder.
  6. Remove the three cap screws and lock washers from each cylinder and remove the cylinders from the backing plate.

20.Disassembly — To disassemble, see Figure 4-2-7 and proceed as follows:

  1. Remove the adjuster (1) from the cylinder (2).
  2. Remove the retaining clip (6) from the cylinder dust boot (5) and pull the boot from the cylinder.
  3. Pull the piston (4) from the cylinder and clean the piston and cylinder bore.
  4. Remove the cup (3) from the piston.

NOTE — Ensure the cups and pistons are submerged and cleaned in brake fluid before installing.

21.Inspection — To inspect, proceed as follows:

  1. Inspect the cylinder bore for rust and scoring and replace, if necessary.
  2. Inspect the piston for pitting and scoring and replace the piston, if necessary.
  3. Inspect the adjuster sleeve and screw threads for rusting. Clean and remove all signs of rust.

Figure 4-2-7 — Components of Front Wheel Cylinder 1. Adjuster
2. Cylinder
3. Cup
4. Piston
5. Dust boot
6. Retaining clip

Figure 4-2-7 — Components of Front Wheel CylinderClick image to enlarge.

22.Assembly — To assemble see Figure 4-2-7 and proceed as follows:

  1. Carefully install the cup (3) on the piston (4), ensuring the lip of the cup faces toward the inner end of the piston.
  2. Install the piston in the cylinder (2), ensuring the lip of the cup does not fold outward.
  3. Install a new boot (5) over the piston end of the cylinder and install a retaining clip (6), ensuring the tangs of the clip will face away from the backing plate when the cylinder is installed on the backing plate.
  4. Apply a coating of Molykote G (NSN 9150-21-872-3378) to the adjuster sleeve and screw threads to prevent seizing. Make sure the adjuster turns freely.
  5. Clean the cylinder bore for the adjuster and install the adjuster.

23.Installation — To install, proceed as follows:

NOTE — If teeth are broken or damaged on the adjusting pinion, a new adjusting pinion must be installed on the backing plate.

  1. Install each cylinder on the backing plate and loosely install the three cap screws and lock washers.
  2. Connect the interconnecting brake line to the cylinders, ensuring the rubber collar on the brake line fits under the clip on the backing plate.
  3. Connect the brake line to the cylinder at the rear of the backing plate.
  4. Install the adjuster, ensuring the teeth of the adjuster engage the teeth of the adjuster nut on the backing plate.
  5. Torque the cylinder cap screws to 25 N•m (18 ft lb).
  6. Install the bleeder valve in the rear cylinder.
  7. Install the dust boot guard on the hub carrier and install the two socket head screws and lock washers.
  8. Install the brake shoes.
  9. Install the brake drum. Adjust brake shoes and bleed brakes (refer to Section 3).
Rear Wheel Cylinders

24.Removal — The procedure for removing either rear wheel cylinder is the same. To remove, proceed as follows:

  1. Remove the rear wheel.
  2. Remove the brake drum.
  3. Remove the brake shoes.
  4. Remove the bleeder valve and brake line.
  5. Remove the two cap screws from the cylinder at the backing plate and remove the cylinder.

Figure 4-2-8 — Components of Rear Wheel Cylinder 1. Retaining Clip
2. Dust boot
3. Piston
4. Cup
5. Bleeder valve dust boot
6. Bleeder valve

Figure 4-2-8 — Components of Rear Wheel CylinderClick image to enlarge.

25.Disassembly — To disassemble, see Figure 4-2-8 and proceed as follows:

  1. Remove the retaining clip (1) from each cylinder dust boot (2).
  2. Remove the two pistons (3) from the cylinder and remove the dust boots from the pistons.
  3. Remove the cups (4) from both pistons.
  4. Clean the pistons and the inside surface of the cylinder with a clean cloth.

NOTE — Ensure the cups and pistons are submerged and cleaned in brake fluid before installing.

26.Inspection — To inspect, proceed as follows:

  1. Inspect the inside surface of the cylinder for rust and scoring and replace, if necessary.
  2. Inspect the pistons for rust and scoring and replace, if necessary.

27.Assembly — To assemble see Figure 4-2-8 and proceed as follows:

  1. Install a new cup (4) on each piston (3), ensuring the lip of the cup faces toward the inner end of the piston.
  2. Install a piston in each end of the cylinder, ensuring the lip of the piston cup does not fold back toward the cylinder opening.
  3. Install new dust boots (2) over each end of the cylinder, ensuring the boot retaining clip lip is over the groove at the ends of the cylinder and the raised lip in the hole of the boot sits in the recessed portion of the piston push rod.
  4. Install boot retaining clips. Ensure the tangs of the clamps are on the side of the cylinder that will face away from the backing plate.

28.Installation — To install, proceed as follows:

  1. Install the cylinder on the backing plate and install two socket head cap screws and lock washers. Torque the cap screws to 10 N•m (7 ft lb).
  2. Install a new bleeder valve (6) if necessary and connect the brake line to the cylinder at the rear of the backing plate.
  3. Install the brake shoes.
  4. Install the brake drum.
  5. Adjust the brake shoes (refer to Section 3).
  6. Install the wheel.
  7. Bleed the brakes (refer to Section 3).
  8. Remove the axle stand.
  9. Torque the wheel mounting bolts to 175 N•m (129 ft lb).
Rear Brake Shoe Adjuster Assemblies

29.Removal — To remove, proceed as follows:

  1. Remove the rear wheel.
  2. Remove the brake drum.
  3. Using brake spring pliers, remove the bottom springs and pull the shoes away from the adjuster assembly.
  4. Remove the three cap screws and internal lock washers.
  5. Remove the adjuster assembly from the backing plate.

30.Inspection — Check adjusters for broken teeth and clean all rust from adjuster sleeve and screw threads. Replace broken or severely seized adjusters.

31.Installation — To install, proceed as follows:

  1. Before installing, apply a coating of Molykote G (NSN 9150-21-872-3378) to the adjuster sleeve and screw threads, to prevent seizing. Make sure the adjuster turns freely.
  2. Lightly lubricate the adjusting pinions and ensure the pinions turn freely.

NOTE — If teeth are broken or damaged on the adjusting pinion, a new adjusting pinion must be installed on the backing plate.

  1. Install the adjuster assembly on the backing plate using riveting tool B183012371. Ensure the teeth of the adjusters mesh with the teeth of the adjusting pinions.
  2. Install the three cap screws and internal lock washers. Torque the cap screws to 25 N•m (18 ft lb).
  3. Fit the shoes into the adjusters.
  4. Install the bottom springs.
  5. Install the brake drum and adjust the brakes (refer to Section 3).
  6. Install the wheel and torque to 175 N•m (129 ft lb).
Brake Backing Plates

32.Removal — To remove, proceed as follows:

  1. Remove the hub assembly (refer to Part 3, Section 4).
  2. Remove the wheel hub from the hub carrier (refer to Part 3, Section 4).
  3. Remove the brake shoes.
  4. Remove the wheel cylinders and adjuster assemblies.
  5. Remove the steering arm stop (front wheels only).
  6. Remove the drive axle dust boot guard.
  7. Place the hub assembly in a vise.
  8. Scribe match marks on the backing plate and hub carrier.
  9. Remove the socket head screws.
  10. Support the backing plate and press the hub carrier from the backing plate.

33.Installation — To install, proceed as follows:

  1. Place the hub carrier in a vise.
  2. Ensure the adjusting pinions in the backing plate turn freely.
  3. Install the backing plate on the hub carrier ensuring the scribe marks of the carrier and backing plate are aligned.
  4. Install the twelve socket head screws, and torque to 35 N•m (26 ft lb) in a diagonally opposite sequence.
  5. Install the drive axle dust boot guard on the carrier with the two socket head screws and lock washers. Torque to 25 N•m (18 ft lb).
  6. Install the steering arm stop on the hub carrier with the two socket head screws (front wheels only). Torque the screws to 25 N•m (18 ft lb).
  7. Install the wheel cylinders and adjuster assemblies on the backing plate.
  8. Install the brake shoes.
  9. Install the wheel hub in the hub carrier (refer to Part 3, Section 4).
  10. Install the hub assembly (refer to Part 3, Section 4).
Hand Brake Lever and Front Hand Brake Cable

34.Removal — To remove, proceed as follows:

  1. Disconnect the front hand brake cable from the equalizer.
  2. Force the retaining clip on the cable up through the hole in the vehicle floor panel.
  3. Remove the four cap screws and lock washers from the hand brake bracket at the vehicle frame.
  4. Remove the lever and front cable.
  5. Remove the cotter pin, washer and clevis pin from the cable at the lever bracket.
  6. Remove the two nuts and bolts holding the cable and the brake warning lightswitch to the bracket.
  7. Slide the cable along the slot and away from the bracket.

35.Installation — To install, proceed as follows:

  1. Slide the yoke and cable into the bracket until the yoke is aligned with the hole in the bracket.
  2. Install a clevis pin in the hole and install a washer and cotter pin.
  3. Install the cable clip and brake light warning switch on the bottom of the bracket.

Figure 4-2-9 — Location of Brake Warning Light Switch
Figure 4-2-9 — Location of Brake Warning Light SwitchClick image to enlarge.

  1. Insert the cable through the hole in the vehicle floor panel until the securing clip passes through the hole and secures the cable.
  2. Install the bracket on the mounting frame and ensure the brake warning light switch lever is under the yoke pin, see Figure 4-2-9.
  3. Install the four cap screws and lock washers.
  4. Install the cable to the cable equalizer.
  5. Adjust the hand brake so that the rear brake assemblies will hold the vehicle stationary when the hand brake lever is applied.
Hand Brake Cables

36.Removal — The removal procedure for either hand brake cable is the same. To remove a rear hand brake cable, proceed as follows:

  1. Remove the rear wheel.
  2. Remove the brake drum.
  3. Remove the brake shoes.

Figure 4-2-10 — Hand Brake Cable Bracket
Figure 4-2-10 — Hand Brake Cable BracketClick image to enlarge.

  1. Unhook the cable from the front shoe.
  2. Using needle nose pliers, squeeze the cable locking collar and pull the cable out through the rear of the backing plate.
  3. Remove the cable from the cable bracket at the rear of the vehicle frame, see Figure 4-2-10. Remove the spring attaching the cable to the shock absorber.
  4. Remove the retaining nut from the cable at the cable equalizer and remove the cable from the equalizer.
  5. Remove the cable.

37.Installation — The installation procedure for either rear handbrake cable is the same. To install a cable, proceed as follows:

  1. Before installing the hand brake cable, ensure it moves freely in the casing.
  2. If the new cable is not equipped with securing clips, remove the clips from the used cable and install on the new cable.
  3. Feed the cable over the rear differential and through the holes in the cable bracket until the cable clip clamps into place.
  4. Insert the other end of the cable through the cable equalizer and install a nut on the end of the cable.
  5. Install a new self-locking nut on the cable clip at the outer cable bracket.
  6. Insert the cable through the rear of the backing plate and pull the cable through until the cable anchor locks in place.
  7. Install the outer cable clip to the frame bracket.
  8. Install the end of the cable onto the hook of the front shoe.
  9. Install the brake shoes on the backing plate.
  10. Install the spring attaching the cable to the shock absorber.
  11. Install the brake drum and adjust the brake shoes (refer to Section 3).
  12. Completely slacken the hand brake cable by turning the adjusting knob on the hand brake lever.
  13. Adjust the cable at the equalizer so that both cables are pulled evenly when the hand brake lever is applied.
  14. Adjust the hand brake.

Section 3 — Maintenance and Adjustments

Steering System

Steering Adjustment

1.General — Check the steering for play and adjust the steering rack to remove play.

2.Adjustment — To adjust, proceed as follows:

  1. Place the front of the vehicle on axle stands so that the wheels are off the ground.
  2. Ensure the front wheels are in the straight ahead position.

Figure 4-3-1 — Steering Rack Adjusting Screw and Lock Nut
Figure 4-3-1 — Steering Rack Adjusting Screw and Lock NutClick image to enlarge.

  1. Loosen the lock nut on the steering rack adjusting screw, see Figure 4-3-1.
  2. Turn the adjusting screw until it contacts the rack.
  3. Hold the adjusting screw in place and tighten the lock nut.
  4. Check the steering for play. If necessary, tighten the screw a little more or, if the steering binds, loosen the screw until the steering binds, loosen the screw until the steering does not bind and tighten the lock nut.
  5. Remove the axle stands
Front Wheel Toe-in

3.Checking Front Wheel Toe-In — To check, proceed as follows:

  1. Ensure the tire pressure in the front wheels is correct and the vehicle is unladen.
  2. Place the vehicle on a smooth, level surface.
  3. Ensure the steering gear is correctly adjusted and there is no play in the steering linkage and front suspension.
  4. Check toe-in. The toe-in should be -10 minutes to 0 degrees (-1.2 to 0 mm) (-3/64 to 0 in).
  5. Adjust toe-in, if necessary.

Figure 4-3-2 — Tie-Rod Adjusting Sleeve
Figure 4-3-2 — Tie-Rod Adjusting SleeveClick image to enlarge.

4.Adjusting Front Wheel Toe-In — To adjust toe-in, proceed as follows:

  1. Loosen both adjusting sleeve lock nuts on the right tie-rod, see Figure 4-3-2, and turn the adjusting sleeve to adjust toe-in.
  2. Tighten the lock nuts and check toe-in.
Rear Wheel Toe-in

5.Checking Rear Wheel Toe-In — To check, proceed as follows:

  1. Ensure the tire pressure in the rear wheels is correct and the vehicle is unladen.
  1. Place the vehicle on a smooth, level surface.
  2. Ensure there is no play in the rear tierods and rear suspension.
  3. Measure the length of each rear tie-rod:

Figure 4-3-3 — Measurement of Rear Tie-Rod
Figure 4-3-3 — Measurement of Rear Tie-RodClick image to enlarge.

  1. Place a steel tape on a tie-rod securing bolt and to a reference point at the centre of the corresponding tie-rod end to measure the length of the tie-rod, see Figure 4-3-3. The distance between the centre of the tie-rod end and centre of the securing bolt should be 370 mm (14 9/16 in.).
  2. If the length of a tie-rod is incorrect, loosen the tie-rod lock nut and turn the tie-rod sleeve until the tie-rod is the correct length.
  3. Tighten the tie-rod lock nut.
  1. Measure the length of the other tie-rod following steps (1), (2) and (3). Ensure the reference points that are used to measure the second tie-rod are similar to those that were used to measure the length of the first tie-rod.
  2. If necessary, loosen the lock nut of the second tie-rod, turn the tierod sleeve until the tie-rod is the correct length and then tighten the lock nut.
  1. Check toe-in. The toe-in should be -15 minutes to -10 minutes (-1.8 to -1.2 mm) (-5/64 to -3/64 in).
  2. Adjust toe-in, if necessary.

6.Adjusting Rear Wheel Toe-In — If toe-in is incorrect, proceed as follows:

  1. Loosen both tie-rod lock nuts and turn the sleeve on each tie-rod equal amounts until the toe-in is correct.
  2. Tighten the tie-rod lock nuts and check the toe-in.
Front and Rear Wheel Camber

7.General — Camber is not adjustable. If camber is not within the specific limits, examine steering and suspension components for wear and replace as required.

8.Inspection — To inspect, proceed as follows:

  1. Ensure tire pressure is correct.
  2. Place the vehicle on a smooth, level surface with the front wheels in the straight-ahead position.
  3. Check the camber with a camber gauge. The camber of the front wheels should be -2°10 minutes to -10 minutes with a maximum difference of 1° between each front wheel. The camber of the rear wheels should be -2°15 minutes to -15 minutes with a maximum difference of 1° between each rear wheel.

Brake System

Brake Shoes Adjustment

9.General — Total pedal travel is 150 mm (5.9 in). When brake pedal free travel is greater than 1/3 of total pedal travel, the brake shoes require adjustment. Prior to adjusting the shoes, remove the brake drums and inspect the thickness of each brake shoe lining. If the combined thickness of the lining and shoe is less than 5.32 mm (0.21 in), the lining must be changed.

NOTE — Brake shoes should be inspected and adjusted every 5,000 km or sooner under dusty conditions.

10.Adjustment — To adjust, proceed as follows:

  1. Ensure the transmission is in neutral and the rear differential lock and four wheel drive are disengaged. When adjusting the rear brake shoes, ensure the hand brake is disengaged.
  2. Place an axle stand under the vehicle frame so that one wheel is off the ground.
  3. Turn the adjusting nut for each brake shoe counter-clockwise until the wheel turns freely and then turn the adjusting nut clockwise until the brake shoe contacts the brake drum and the wheel will not turn.
  4. Turn the adjusting nut counter-clockwise just enough to allow the wheel to turn freely.
  5. Repeat steps a. through d. for all brake shoes and then test the brakes.
Bleeding the Hydraulic Brake System (Bleeder Ball Method)

11.If air is present in the hydraulic brake system, bleed the system to eliminate the air. If installing a new master cylinder or flushing the system, bleed the master cylinder before bleeding the rest of the system. To bleed each bleeder valve, follow the bleeding sequence and proceed as follows:

  1. Ensure the bleeder ball contains sufficient brake fluid and the air pressure in the ball is about 173 kPa (25 psi).
  2. Remove the cap from the front brake fluid reservoir when bleeding right rear and left front wheels. Remove the cap from the rear brake fluid reservoir when bleeding left rear and right front wheels. Connect the bleeder ball to the reservoir.
  3. Open the bleeder ball tap.
  4. Remove the rubber dust cap from the bleeder valve.
  5. Attach a rubber hose to the bleeder valve and place the end of the hose in a glass jar that is partially filled with brake fluid. Ensure the end of the hose is submerged in the brake fluid.
  6. Open the bleeder valve by turning it about 3/4 of a turn and observe the end of the hose submerged in the brake fluid. When air bubbles no longer emerge from the end of the hose, close the bleeder valve.
  7. Disconnect the hose from the bleeder valve and place the dust cap on the bleeder valve.
  8. Repeat the above steps for each bleeder valve and follow this bleeding sequence:
  1. front brake fluid reservoir
  2. right rear wheel
  3. left front wheel
  4. rear brake fluid reservoir
  5. left rear wheel
  6. right front wheel

NOTE — If a bleeder ball is not available, bleed the brake cylinders in the order described above. Connect a rubber hose to the bleeder valve and place the end of the hose in brake fluid in a glass jar. With assistance, pump the brake pedal to create pressure, hold the brake pedal down and open the bleeder valve. Close the bleeder valve after eliminating all air from the brake cylinder and top up the corresponding brake fluid reservoir before bleeding the next brake cylinder.

Brake Pedal Free Play

12.General — Check the brake pedal free play after installing a master cylinder. The free play should be 5 to 10 mm (0.2 to 0.4 in). Adjust the free play, if necessary.

13.Adjustment — To adjust, proceed as follows:

  1. Remove the clip from the clevis pin in the yoke of the brake push rod at the arm of the brake pedal- and withdraw the clevis pin.
  2. Loosen the lock nut on the push rod and turn the yoke to either lengthen or shorten the rod to adjust the free play.
  3. Insert the clevis pin through the yoke and arm of the brake pedal.
  4. Check the brake pedal free play and continue to adjust the length of the push rod until the free play is correct.
  5. Install the clip on the clevis pin.
  6. Tighten the lock nut.

Section 4 — Troubleshooting

General

1.The following figures contain troubleshooting instructions on steering and brakes.

2.For steering system troubleshooting instructions, see Figure 4-4-1.

3.For brake system troubleshooting instructions, see Figure 4-4-2.



Item
No 		Malfunction Probable Cause/Test Corrective Action
1. Hard steering a. Low or uneven tire pressure. a. Inflate to proper pressure.
b. Steering rack improperly adjusted. b. Adjust steering rack.
c. Steering gear dry. c. Lubricate rack and pinion.
d. Steering shaft universal joint binding. d. Inspect, lubricate or replace U-joint.
e. Spring trunnion worn or dry. e. Inspect, lubricate or replace bushing.
f. Ball joint worn or dry. f. Inspect and lubricate or replace if necessary.
g. Worn or damaged parts causing excessive caster. g. Inspect, check caster replace damaged parts.
h. Wishbone bent or twisted. h. Check camber, replace wishbone.
j. Weak or broken front springs. j. Replace broken leaves or spring.
k. Bent or twisted frame. k. Check vehicle tracking, repair or replace frame.
m. Loose spring U-bolts or broken centre bolt. m. Tighten U-bolts, replace centre bolt.
n. CV joints dry or binding. n. Clean and lubricate or replace.
2. Excessive play or looseness in steering a. Steering rack improperly adjusted. a. Adjust steering rack.
b. Steering rack mounting bolts loose. b. Tighten mounting bolts.
c. Worn tie-rod ends. c. Replace tie-rod ends.
d. Worn ball joint. d. Replace ball joint.
e. Worn bushings in springs, steering arms or wishbone arms. e. Inspect and replace worn bushings.
f. Wheel bearing worn or collapsed. f. Replace wheel bearing.
3. Erratic steering when brakes applied a. Low or uneven tire pressure. a. Inflate to proper pressure.
b. Brakes incorrectly or unevenly adjusted. b. Adjust brakes.
c. Oil or grease on brake linings. c. Replace linings and seals. Clean drum.
d. Front wheel bearings worn. d. Replace wheel bearings.
e. Front springs or shock absorbers weak. e. Replace springs, shocks, or both.
f. Excessive caster. f. Inspect for worn or damaged parts and replace.
g. Spring U-bolts loose or broken. g. Tighten or replace U-bolts.
h. Spring centre bolt broken. h. Replace centre bolt.
4. Vehicle pulls to one side a. Low or uneven tire pressure. a. Inflate to proper pressure.
b. Brakes incorrectly or unevenly adjusted. b. Adjust brakes.
c. Oil or grease on linings. c. Replace linings and seals. Clean drum.
d. Excessive or unequal camber. d. Inspect for worn parts, repair or replace as necessary.
e. Toe-in incorrect. e. Repair or replace worn or damaged parts. Adjust toe-in.
f. Rear wheels shifted. f. Inspect for loose or broken U-bolts or centre bolt. Check length of rear tie rods. Repair as necessary.
g. Bent frame. g. Check vehicle tracking. Repair or replace frame.
5. Scuffed tires a. Tires improperly inflated. a. Inflate to proper pressure.
b. Toe-in incorrect. b. Repair or replace worn or damaged parts. Adjust toe-in.
c. Wheel out of true due to loose wheel bolts, bent rim or hub, or dirt between rim and hub. c. Check for loose wheel bolts and tighten to proper torque. Check for bent rim or hub. Replace as necessary. Clean dirt from between rim and hub.
d. Worn steering arm, spring, or wishbone bushings, or worn lower ball joint. d. Replace worn parts as necessary.
e. Incorrect toe-out on turns. e. Check for bent steering arm.
f. Wheel bearings worn. f. Replace wheel bearings.
g. Wishbone bent or worn bushings. g. Replace wishbone or bushings.
6. Scuffed rear tires a. Excessive driving on hard surface with differential lock engaged. a. Caution drivers on proper use of differential lock.
7. Cupped tires a. Tires improperly inflated. a. Inflate to proper pressure.
b. Wheels, tires or brake drums out of balance. b. Balance wheels, check for excentric drums, wheels and tires. Replace as necessary.
c. Brake shoes dragging. c. Adjust brakes.
d. Wheel bearings worn. d. Replace wheel bearings.
e. Incorrect camber. e. Check camber. Replace worn or damaged parts.
f. Worn or loose tie-rod ends, steering gear, lower ball joint, spring or wishbone bushings. f. Replace worn parts as necessary.
g. Worn shock absorbers. g. Replace shocks.
8. Front wheel shimmy a. Low or uneven tire pressure. a. Inflate to proper pressure.
b. Worn or loose components in steering or suspension systems. b. Replace components or bushings as necessary.
c. Loose steering rack mountings. c. Tighten to proper torque.
d. Steering rack improperly adjusted. d. Adjust steering rack.
e. Wheel bearings worn. e. Replace wheel bearings.
f. Wheels or tires out of true. f. Check for wheel wobble.
g. Weak shock absorbers. g. Replace shocks.
h. Incorrect toe-in. h. Adjust toe-in.
j. Worn axle CV joints. j. Replace CV joints.
k. Bent stub axle. k. Replace stub axle.
9. Front wheel shimmy a. Wheels, tires or brake drums out of balance. a. Balance wheels. Check for eccentric wheels, tires or drums. Replace as necessary.
b. Weak or broken springs. b. Replace broken leaves or springs.
c. Weak shock absorbers. c. Replace shock absorbers.
10. Vehicle has tendency to wander a. Low or uneven tire pressure. a. Inflate to proper pressure.
b. Loose steering rack mountings. b. Tighten steering rack mountings.
c. Steering rack adjusted incorrectly. c. Adjust steering rack.
d. Dry steering rack, tie-rod ends, ball joints or steering arm bushings. d. Lubricate or replace components as necessary.
e. Incorrect toe-in. e. Adjust toe-in.
f. Incorrect caster. f. Check for worn or bent components and replace as necessary.
g. Rear wheels shifted. g. Check for loose U-bolts, broken centre bolt, worn spring bushings, bent rear tie-rod. Repair or replace as necessary.
11. Road shocks a. Low tire pressure. a. Inflate to proper pressure, see Figure 1-2-5.
b. Steering rack incorrectly adjusted. b. Adjust steering rack.
c. Weak shock absorbers. c. Replace shock absorbers.
d. Weak or broken springs. d. Replace springs or leaves.
e. Weak or broken steering damper. e. Replace steering damper.
12. Groaning noise a. Steering rack requires lubrication. a. Clean old grease from rack and lubricate with Dow Corning Molykote #321. Allow 10 minutes before moving the steering wheel.

Figure 4-4-1 — Steering System Troubleshooting



Item
No 		Malfunction Probable Cause/Test Corrective Action
1. Pedal goes all the way to the floor when braking a. Low or no fluid. a. Check for leaks. Fill and bleed system.
b. Worn linings. b. Check lining thickness. Adjust shoes if linings serviceable. Replace linings if below allowable tolerance.
2. Low pedal after adjusting and bleeding a. Master cylinder faulty. a. Replace or rebuild master cylinder.
3. Pedal spongy or brakes work only after pedal is pumped a. Insufficient fluid in reservoirs. a. Check for leaks and top up fluid.
b. Air in system. b. Bleed system.
c. Weak springs in master cylinder. c. Replace or rebuild master cylinder.
d. Shoes require adjusting. d. Adjust shoes.
4. Braking action descreases after shoes have been adjusted a. Brake lines leaking. a. Tighten connections or install new lines.
b. Faulty master or wheel cylinder. b. Replace or rebuild faulty cylinder.
5. Brakes overheat a. Compensating port blocked. a. Clean master cylinder.
b. Push rod adjusted incorrectly. b. Adjust to proper length.
c. Brake shoe return spring weak. c. Replace springs.
d. Rubber cups swollen. d. Flush system, replace rubber cups and fluid.
6. Brakes inefficient desite high pedal pressure a. Oil on linings. a. Clean drums. Replace lining and seals.
b. Leaking vacuum hose. b. Replace hose or tighten clamp.
c. Servo diaphragm leaking. c. Replace servo.
d. Poor seal between servo and master cylinder. d. Replace seal. Check piston rod and replace if necessary.
e. Faulty check valve in servo vacuum line. e. Replace valve.
7. Brakes bind while vehicle is in motion a. Compensating port blocked. a. Clean master cylinder.
b. Brake fluid contaminated. b. Flush system and refill.
c. Push rod maladjusted. c. Adjust push rod free play.
d. Handbrake adjusted too tightly. d. Loosen adjustment.
8. Brakes chatter and tend to grab a. Linings oil soaked or worn. a. Replace linings.
b. Drums out of round. b. Recondition brake drums.
c. Brake backing plate loose. c. Tighten backing plate cap screws.
9. Brakes squeak a. Linings loose. a. Replace linings or rivets.
b. Linings dirty. b. Clean linings.
c. Brake backing plate warped. c. Replace brake backing plate.
d. Shoe return springs weak. d. Replace springs.
e. Poor lining contact. e. Replace worn parts. Realign and adjust shoes.
10. Brakes give uneven braking a. Oil or grease on linings. a. Clean drums. Replace linings and seals.
b. Incorrect or uneven tire pressure or unevenly worn tires. b. Correct pressure or replace tires.
c. Drums out of round or scored. c. Recondition or replace drums.
d. Brake shoes not in alignment with brake drum. d. Replace worn parts, realign shoes and adjust.
e. Pistons seizing in cylinder. e. Free up or replace pistons.
f. Dirt in brake lines. f. Flush system and refill.
g. Worn suspension components. g. Check suspension and replace parts as necessary.
h. One half of system not operating. h. Check for leaks or faulty master cylinder. Repair as necessary.
11. Brakes pulsate a. Drums out of round. a. Recondition or replace drums.
b. Mating surface between drum and hub dirt. b. Clean surfaces.
12. Foot pressure on pedal must be increased when pedal reaches a certain position a. Groove worn in piston rod that allows air from ventilation drilling to enter servo as groove passes sealing cup. a. Rebuild or replace master cylinder.
b. Failure of one system. b. Check both systems and repair as necessary.
13. Hand brake does not hold vehicle on incline a. Insufficient adjustment. a. Tighten adjustment.
b. Broken or seized cables. b. Free up or replace cables.
c. Dirt, grease or oil on rear linings. c. Replace linings. Clean drums.
14. Hand brake has no further adjustment a. Rear linings excessively worn. a. Replace linings.
b. Cables stretched. b. Replace cables.

Figure 4-4-2 — Brake System Troubleshooting

Section 5 — Specifications and Special Tools

1.Figure 4-5-1 lists the torque specifications for all components in Part 4.

2.Figure 4-5-2 lists the special tools used in Part 4.



Item
No 		Item or Component N•m ft lb
1. Ball Joint to Hub Carrier 100 N•m 74 ft lb
2. Brake Master Cylinder Secondary Piston Stop Screw 7 N•m 5 ft lb
3. Brake Master Cylinder Residual Check Valves 19 N•m 14 ft lb
4. Brake Master Cylinder Bleeder Valve 7 N•m 5 ft lb
5. Brake Warning Light Switch to Master Cylinder 19 N•m 14 ft lb
6. Brake Servo Adapter to Housing 25 N•m 18 ft lb
7. Brake Wheel Cylinder to Backing Plate (Front) 25 N•m 18 ft lb
8. Brake Wheel Cylinder to Backing Plate (Rear) 10 N•m 7 ft lb
9. Brake Adjuster to Backing Plate 25 N•m 18 ft lb
10. Brake Backing Plate to Hub Carrier 35 N•m 26 ft lb
11. Drive Axle Dust Boot Guard to Hub Carrier 25 N•m 18 ft lb
12. Steering Wheel to Shaft 50 N•m 37 ft lb
13. Steering Shaft Universal Joint 25 N•m 18 ft lb
14. Steering Rack Mounts 25 N•m 18 ft lb
15. Steering Shaft Clamp 40 N•m 30 ft lb
16. Steering Damper to Steering Rack Housing 40 N•m 30 ft lb
17. Steering Rack End Plug to Housing 25 N•m 18 ft lb
18. Steering Rack Adjuster Screw Cover to Housing 20 N•m 15 ft lb
19. Steering Rack Adjuster Lock Nut 15 N•m 11 ft lb
20. Steering Stop to Hub Carrier 25 N•m 18 ft lb
21. Tie-Rod End to Steering Arm 40 N•m 30 ft lb
22. Tie-Rod Bracket to Steering Rack 60 N•m 44 ft lb
23. Tie-Rod to Tie-Rod Bracket 60 N•m 44 ft lb
24. Wheel Bolts 175 N•m 129 ft lb
25. Wishbone Arm to Ball Joint 200 N•m 148 ft lb

Figure 4-5-1 — Steering and Brake Torque Specifications



Item
No 		Tool No Nomenclature NATO Stock No.
1. KUKKO 44-2 Two-Jar Puller 5120-21-896-7695
2. VW 267A Ball Joint Remover 5120-12-176-1090
3. B183012371 Riveting Tool 5120-21-899-4915

Figure 4-5-2 — Special Tools





   This article contains only Part 4 — Steering and Brakes.

Due to the length of this document, each of its six parts have a dedicated page. Other parts are available here:

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