Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 46

Brakes

185

(6) Using a suitable pair of pliers, disengage the

upper and lower return springs from the leading shoe,
and then remove them from the trailing shoe.

(7) Using a pair of pliers, compress the leading

shoe retainer, turn through ninety degrees and remove
the retainer, spring and pin. Remove the leading shoe
from the backing plate.

(8) Using the same procedure, remove the trail-

ing shoe retainer.

(9) Lift the trailing shoe from the backing plate

and disconnect the handbrake cable from the hand-
brake lever. Remove the trailing shoe assembly from
the backing plate.

(10) If the brake shoes are to be renewed, remove

the C clip from the trailing shoe and remove the
handbrake lever assembly.

(11) If the wheel cylinder is to be overhauled,

proceed as follows:

(a) Disconnect the brake pipe from the rear of

the wheel cylinder and plug the pipe to prevent the
loss of fluid and the ingress of dirt.

(b) Remove the bolts retaining the wheel cylin-

der to the backing plate and withdraw the wheel
cylinder from the vehicle.

(c) Remove the rubber boots, pistons and spring

from the wheel cylinder bore. Remove the seals from
the pistons. Discard the rubber boots and seals.

(d) Remove the rubber boot and bleeder valve

from the wheel cylinder.

TO CLEAN AND INSPECT

(1) Thoroughly clean all the brake components,

except the brake shoes in methylated spirits.

(2) Inspect the brake shoe linings. If the thick-

ness of the lining on one or more of the shoes is less
than 1.5 mm thick or contaminated with fluid or
grease, the brake shoes must be renewed as a set.

(3) Inspect the wheel cylinder bore and piston

for pitting, wear or damage. Renew the wheel cylinder
assembly if any damage is evident.

(4) Check the brake drums for cracks, scoring or

out of round. Renew or machine the brake drums as
necessary.

(5) Inspect the springs and handbrake lever for

fatigue and distortion. Renew as required.

(6) Operate the handbrake lever and check for.

smooth operation of the handbrake cable. Renew as
required under the Handbrake Cable and Lever
Assembly heading.

(7) Check the bleeder valve for blockage.
(8) Clean and lubricate the adjuster rod.
(9) Clean and inspect the backing plate for

cracks, damage and wear. Renew as required.

TO ASSEMBLE AND INSTAL

(1) If the wheel cylinder was overhauled, pro-

ceed as follows:

(a) Lubricate the pistons and seats with brake

fluid and install the seals onto the pistons so that the
lip on the seals will be facing towards the centre of the
cylinder.

(b) Install the spring, pistons and rubber boots to

the wheel cylinder ensuring that the rubber boots are
securely located in the cylinder. If necessary, use a
clamp to hold the pistons in the cylinder.

(c) Position the wheel cylinder in the backing

plate and install the brake pipe to the cylinder. Do not
fully tighten the pipe at this stage.

(d) Install the wheel cylinder retaining bolts and

tighten the retaining bolts and brake pipe securely.
Install and tighten the bleeder valve. Install the
valve
boot.

Dismantled view of the right hand rear drum brake

components.

Dismantled view of the rear wheel cylinder.

(2) Sparingly lubricate the brake shoe moving

contact surfaces on the backing plate and the adjuster
assembly with a high melting point grease.

(3) If necessary, position the adjusting lever

on
the handbrake lever.

(4) If necessary, position the handbrake lever

assembly and washer on the trailing shoe and secure it
with the C clip.

(5) Ensure that the adjuster assembly is adjusted

to its shortest length.

(6) Install the adjusting lever return spring to

the
trailing shoe.

186

Brakes

(7) Using a pair of pliers, compress the hand-

brake cable spring and install the cable to the hand-
brake lever.

(8) Position the trailing shoe on the backing

plate with the upper end located on the wheel cylinder
piston and the lower end on the anchor plate.

(9) Install the adjuster assembly to the

trailing
shoe ensuring that the adjuster fork is correctly
located on the upper end of the shoe.

(10) Install the pin, spring and retainer to the

trailing shoe, turn the retainer through 90 degrees and
secure the brake shoe to the backing plate.

(11) Connect the upper and lower return springs

to the trailing shoe as noted on removal.

(12) Position the leading shoe on the backing

plate with the upper end located on the wheel cylinder
piston and the lower end on the anchor plate. Ensure
that the adjuster assembly is correctly located on the
upper end of the shoe.

(13) Install the pin, spring and retainer to the

leading shoe, turn the retainer through 90 degrees and
secure the shoe to the backing plate.

(14) Connect the upper and lower return springs

to the leading shoe.

(15) By alternatively adjusting the automatic ad-

juster manually and sliding the brake drum on and off
the brake shoe assembly, adjust the brakes until the
brake drum will just slide over the brake shoes. Ensure
that the adjuster lever contacts the adjuster star wheel.
Install the brake drum and operate the handbrake
several times to adjust the brake shoes.

(16) Install the rear wheels and rotate each wheel

to ensure that the brake shoe linings are not dragging.

(17) Bleed the hydraulic system as described

under the Hydraulic System heading.

(18) Adjust the handbrake as described under the

Brake Adjustments heading.

8. HANDBRAKE CABLE AND LEVER

ASSEMBLY

HANDBRAKE LEVER AND FRONT CABLE
ASSEMBLY

To Remove and Install

(1) Raise the vehicle and support it on chassis

stands. Release the handbrake.

(2) Working beneath the vehicle, remove the

exhaust pipe centre heat shield retaining bolts and
maneuver the shield from the vehicle.

(3) Remove the rear handbrake cable front

clamp retaining nuts and disconnect the rear hand-
brake cable from the equalizer.

(4) Working within the vehicle, remove the

carpet square from the rear of the console. Remove
the retaining screw from the front and rear of the rear
console section and maneuver the rear console from
the vehicle.

Dismantled view of the handbrake lever components.

(5) Disconnect the handbrake warning lamp

switch wiring.

(6) Remove the handbrake lever assembly re-

taining bolts and remove the handbrake lever and
front cable assembly.

(7) If necessary slide the boot and cover towards

the equalizer, straighten the tang on the lower edge of
the lever and remove the adjuster nut and washer.

(8) Withdraw the front cable from the lever and

remove the boot and cover. Inspect the cable for
chafing or broken strands. Renew the cable if damage
is evident.

(9) Check the handbrake lever ratchet and pawl

for wear and renew as necessary.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Apply lubricant to all the working parts prior

to installation.

(2) Ensure that the handbrake cable clamp is

correctly installed.

(3) Adjust the handbrake cable as described

under the Brake Adjustments heading.

REAR HANDBRAKE CABLES

T

O

Remove and Install

(1) Raise the rear of the vehicle and support it

on chassis stands. Remove the rear wheels and release
the handbrake.

(2) Working beneath the vehicle, remove the

exhaust pipe centre and rear heat shield retaining
bolts and maneuver the heat shields from the
vehicle.

(3) Remove the bolts and nuts retaining the

handbrake cable clamps to the underbody and discon-
nect the rear handbrake cable from the equalizer.

(4) On disc brake models, remove the handbrake

cable to bracket retaining clip on the rear of the
caliper and disconnect the handbrake cable from the
cam lever. Remove the cable from the vehicle.

(5) On drum brake models, proceed as follows:
(a) Remove and dismantle the rear brakes as

previously described.

Brakes

187

(b) Disengage the handbrake cable return spring

from the backing plate.

<c) Using a hammer and punch, carefully tap the

handbrake cable flange from the rear of the backing
plate and remove the cable from the vehicle.

(6) Inspect the rear handbrake cables for chafing

or broken strands. Renew the cables if damage is
evident.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Ensure that the handbrake cable clamps are

correctly installed.

(2) On drum brake models, install the

handbrake
cable to the backing plate by carefully tapping the
flange on the handbrake cable. Ensure that the cable is
not damaged.

(3) Adjust the handbrake cable as described

under the Brake Adjustments heading.

9. BRAKE ADJUSTMENTS

FRONT AND REAR DISC BRAKES

The disc brakes are self adjusting and no manual

adjustment is required or provided.

REAR DRUM BRAKES

Depress the handbrake lever button, apply and

release the handbrake lever several times to adjust the
rear brake shoes.

HANDBRAKE

(1) Raise the rear of the vehicle and support it

on chassis stands.

(2) Remove the carpet square from the rear of

the console. Remove the retaining screws from the
front and rear of the rear console section and manoeu-
vre the rear console from the vehicle.

(3) Tighten the adjusting nut until the hand-

brake lever pull is between 7-11 notches.

(4) Check that the rear wheels are not binding. If

the rear wheels do not rotate freely refer to the Brakes
Trouble Shooting for possible causes.

(5) With the ignition switched On, check that

the handbrake warning lamp is extinguished when the
lever is fully released.

(6) Lower the vehicle to the ground and test the

handbrake on an incline.

10. BRAKE PEDAL

TO REMOVE AND INSTAL

(1) Working inside the vehicle remove the re-

taining clip from the clevis pin and remove the clevis
pin connecting the brake pedal to the pushrod.

Dismantled view of the brake pedal components.

(2) Remove the nut from the pivot bolt and

withdraw the brake pedal pivot bolt.

(3) Maneuver the brake pedal from the mount-

ing bracket.

(4) Remove the spring from the brake pedal.
(5) Inspect the return spring for breakage or

fatigue. Renew as required.

(6) Inspect the pedal pivot bolt for damage or

wear. Renew as required.

(7) Inspect the brake pedal for wear, cracks or

fatigue. Renew as required.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Sparingly lubricate the pedal pivot bolt and

clevis pin with a suitable grease.

(2) Ensure that the brake pedal pivot bolt is

correctly located in the pedal bracket.

(3) Ensure that the clevis pin is inserted fully

through the clevis and the retaining clip is correctly
installed.

(4) Check and if necessary adjust the brake

pedal height and stop lamp switch as described below.

TO ADJUST PEDAL HEIGHT

The dimension for the pedal height is measured at

right angles from the floor, with the carpet pulled
back, to the centre of the pedal pad.

(1) Working inside the vehicle, disconnect the

wiring from the stop lamp switch.

(2) Loosen the stop lamp switch locknut and

position the switch away from the brake pedal.

(3) Loosen the locknut on the brake pedal push-

rod and adjust the pushrod to achieve a pedal height
of 155-165 mm on manual transaxle models or
164-174 mm on automatic transaxle models. Tighten
the locknut.

(4) Adjust the stop lamp switch as described

under the following heading.

188

Brakes

Illustration showing the brake pedal adjustments. Di-
mension H = brake pedal height, Dimension C = stop
lamp switch clearance, Dimension F - brake pedal free

play.

TO ADJUST STOP LAMP SWITCH

(1) Loosen the stop lamp switch locknut and

disconnect the wiring from the switch.

(2) Adjust the stop lamp switch to achieve a

clearance of 0.3-1.0 mm between the pedal stop and
the threaded end of the switch.

(3) Tighten the locknut and connect the wiring

to the switch. Ensure that the stop lamps are off when
the pedal is released.

(4) Ensure that the pedal free play is 1.0-3.00

mm after adjustments have been completed.

11. HYDRAULIC SYSTEM

TO BLEED

Bleeding the hydraulic system should only be

necessary when some portion of the hydraulic system
has been disconnected or fluid has been drained,
allowing air to enter the system.

The brake fluid in the hydraulic system should be

changed every 30 000 km or 18 months. The proce-
dure for changing the brake fluid and bleeding the
hydraulic system are similar with attention to the
notes in the text.

There are four points in the system where bleeder

valves are installed, one on each front caliper and one
on each rear wheel cylinder or rear caliper.

14. Fill the fluid reservoir with clean hydraulic

brake fluid and maintain at least one third full
throughout the entire operation.

15. Attach a transparent hose to the bleeder

valve on the left rear caliper and immerse the other

Bleeding the right hand rear brake caliper.

end of the hose in a small amount of clean brake fluid
contained in a clean glass jar held higher than the
bleeder valve.

14.

Unscrew the bleeder valve one

complete turn.

15.

Have an assistant depress the brake

pedal slowly to the full extent of its travel. Close
the bleeder valve and allow the brake pedal to
return without assistance.

16.

Repeat operations (3) and (4) until

a con stant stream of fluid, without any air
bubbles, is being discharged into the glass jar,
hold the brake pedal down and tighten the
bleeder valve.

Bleeding the right hand front brake caliper.