Page 621
Assembly
1.
2.
3.
4.
Replace any worn, damaged or corroded parts.
In the case of the indirect piston, exchange the Oring on the push rod and the O-ring retainer at the
handbrake lever.
Mount the brake housing in a vice. Lubricate the
cylinder bore with brake fluid and fit new piston
seals.
Fit the anchor plate to the push rod and push the
latter into the hole in the indirect piston. Make
sure that the recess in the anchor plate comes immediately over the spring pin in the piston.
BRAKE HOUSING WITH PISTON
6.
In the same way push the direct piston into the
cylinder and, by means of tool 8996043, screw
together the piston and push r.od. Screw and push
in the two pistons until the edges of the dust cover
grooves are flush with the brake housing.
THE INDIRECT PISTON AND PUSH ROD
5.
Lubricate the indirect piston and insert it in the
brake housing so that the recess for the yoke is directly in line with the groove in the cylinder housing.
BRAKE HOUSING WITH PISTONS
Tool 8996043
•·
7.
8.
·r
S.1'11
.l.
Fit new dust covers and retaining rings.
Mount the spring and handbrake.lever to the yoke.
The green spring should be on the left and the red
on the right.
Page 622
Fitting
1. Check that the dust cover has not slipped out of position. Screw the complete brake assembly to the steering
knuckle housing or rear axle respectively. Use a new
locking plate.
2. Connect the brake lines.
3. Adjust the handbrake cable so that the distance between the lever and the yoke is 0.019 ± 0.003 in. (0.5
± 0.1 mm) when the handbrake is in the off position.
First apply the handbrake lever a few times to stretch
the cable. Adjustment is made at the lever. The cables
are crossed which means that adjustment of the left
handbrake mechanism is made by means of the right
adjustment nut and vice versa.
YOKE WITH YOKE SPRING AND HANDBRAKE
9.
10.
11.
12.
LEVER
Apply special grease No. 7990179 by means of a
brush to the sliding surfaces of the yoke. Also apply grease to the seating of the pad retaining disc
in the brake housing.
Align the yoke guide edges with the grooves in the
brake housing. Lift the handbrake lever and fit the
end of the axle pin into the hole in the indirect piston. At the same time, ensure that the yoke fits into
the recess in the indirect piston.
Fit the handbrake lever return spring.
Check the clearance between the sliding surfaces of
the yokes and the brake housing as shown in the
diagran,. Greater play can result in vibration and
noises on braking.
CLEARANCE BETWEEN LEVER AND YOKE
B
S 4336
CLEARANCE BRAKE HOUSING-BRAKE
WHEEL BRAKE
A ~
B •
0,006-0.012
in. (0.15-0.30
YOKE, FRONT
ADJUSTING THE HANDBRAKE'CABLE
mm)
No clearance
,. _523-4
SANI
Page 623
4. Fit the brake pads.
5. Top up the brake fluid, bleed the system and check
all connections for leakage.
2. Remove the yoke from the brake housing by lifting it
towards the bleeder screw. Remove the yoke spring.
3. Remove the retaining ring and dust cover.
4. Force out the indirect piston using compressed air.
CAUTION
Before the car can be driven the brake pads must be
brought out to the brake disc. This is achieved by
repeated pumping of the brake pedal until both the
footbrake and the handbrake function effectively.
REAR WHEEL BRAKE ASSEMBLY, GIRLING MAKE
Removal
1. Remove the brake pads. See Section 517.
2. Disconnect the brake pipes at the connection to the
brake housing. Insert a plastic stopper in the end of
the pipe to avoid spillage from the brake system.
3. Remove the two screws which hold the brake housing
to the rear axle.
FORCING OUT THE INDIRECT PISTON WITH COMPRESSED
AIR
Dismantling
5. Push out the direct piston by hand.
6. Remove the brake housing from the vice and carefully
remove the piston seals from the cylinder bore.
1. Clean the brake housing and mount it in a vice.
1·111·11
1111111
1111111
1111111
1111111
1111111
1111111
1111111
1111111
1111111
1111111
1111111
N.♦.'11•♦.'1
'Ut'.♦.'.♦.'i
B
10
T
13
12
S4339
REAR BRAKE HOUSING, EXPLODED VIEW
1. Dust cover holder
2. Dust cover
3. Piston (indirect)
4. Piston seal
5. Bleeder nipple
6. Brake housing
7. Piston (direct)
8. Yoke
SAAB
9. Brake pads
10. Spring (green-lef•, red-right)
11. Damper spring
12. Pad retaining pin
13. Pin retaining clip
523-5
Page 624
Assembly
1. Worn, damaged or corroded parts should be replaced.
2. Mount the brake housing in a vice. Lubricate the cylinder bore with brake fluid and fit new piston seals.
3. Push the pistons into the cylinder. Rotate the indirect
piston so that the recess for the yoke is in line with
the groove in the brake housing.
4. Fit a new dust cover and retaining ring.
5. Fit the yoke spring to the yoke and then align the
yoke so that it fits into the groove in the brake housing and into the recess in the indirect piston.
6. Check the clearance between the sliding surfaces of
the yoke and brake housing as shown in the diagram.
Greater clearance than that specified can result in vibrations and noise on braking.
.
.
B
1
S 4341
CLEARANCE BRAKE HOUSING-BRAKE
WHEEL BRAKE
A
B
0.006-0.012
=
in. (0.15-0.30
No clearance -
YOKE, REAR
mm)
Fitting
1. Check that the dust cover has not slipped out of position. Screw the complete brake assembly to the steering
knuckle housing or rear axle respectively. Use a new
locking plate.
2. Connect the brake lines.
3. Fit the brake pads.
4. Top up the brake fluid, bleed the system and check
all connections for leakage.
CAUTION
Before the car can be driven, the brake pads must be
brought out to the brake disc. This is achieved by
repeated pumping of the brake pedal with the engine
switched off until the foot brake and hand brake are
functioning properly.
Refrain from depressing the pedal after the hand
brake has started to operate, as this will cause overadjustment of the hand brake mechanism and may
cause the brakes to seize.
523-6
Page 625
REAR-WHEEL BRAKE ASSEMBLY, ATE MAKE
Assembly
Removal
1. Replace any worn, damaged or corroded parts.
2. Lubricate the cylinder bore with brake fluid and fit a
new seal.
3. Lubricate the piston with brake fluid and insert carefully into the cylinder.
4. Fit new dust covers and holders to the piston. Press in
the cylinder using clamp No. 7841323.
1. Remove the brake pads (see section 517).
2. Disconnect the brake pipe at the connection to the
brake housing. Plug the end of the pipe to prevent
fluid leaking from the brake system.
3. Remove the two screws securing the brake housing to
the end assembly of the rear axle.
6
5
REAR BRAKE HOUSING, EXPLODED VIEW
1. Brake housing
2. Damper spring
3. Lock pin
4. Piston seal
5. Rubber cap
6. Bleeder nipple
7. Piston
8. Twist stop
9. Brake pad
CAUTION
The two sections of the brake housing should never
be separated.
Dismantling
Hopsiittning
1. Clean the wheel brake assembly.
2. Secure clamp No. 7841323 to one of the pistons and
press out the other by means of compressed air blown
through the brake pipe connection.
3. Carefully remove the seals from the cylinder using a
screwdriver with a rounded blade. Take particular care
not to damage the sealing groove and cylinder bore.
4. After the seal and piston have been fitted (see assembly) the other piston can be removed. The method is
the same for both pistons.
1. Forslitna, skadade eller svart korrosionsangripna delar
SAMI
skall bytas.
2. Smorj cylinderloppet med bromsvatska och montera
nya tatningsringar.
3. Smorj kolvarna med bromsvatska och tryck in dem
forsiktigt i cylindern.
4. Montera nya dammskydd och tryck in kolvarna i
botten.
5. Vrid kolvarna med hjalp av kolvtang 89 98 367 sa att
urtagen i kolvarna kommer ratt. Kontrollera laget
med mall 89 95 :342. Se bild.
523-7
Page 626
1
•
L__
Page 627
BRAKE OPERATION
Assembly
BRAKE PEDAL
Assembly is carried out in the reverse order.
Removal
Adjustment of the position of the brake pedal in relation
to the clutch pedal is carried out by shortening or lengthening the pull rod from the brake pedal.
1. Remove the lower circlip on the pull rod and the return spring on the pedal.
2. Pull up the rubber bellows in the dash panel and remove the lock nut on the push rod. The rubber bellows
and lock nuts can be reached from the engine compartment.
3. Rotate the lower fork of the pull rod to obtain the required length.
4. After completed adjustment tighten the lock nut and
then reassemble the pull rod, circlip and return spring.
1. Remove the pedal-return spring.
2. Remove the lower circlip on the brake pedal pull rod.
3. Remove thP. lock nut from the end of the pedal pin
and push out the latter.
4. If the bushes are worn these can be pressed out and
replaced with new ones. New bushes must be carefully
greased with ball bearing grease.
5
111'♦'1♦
111111
111111
111111
1'.♦♦♦♦.'.♦.'.♦
tit
4
:11111
•:❖:•:•:
'.♦•♦.'.♦.'1
2
111111
U.♦.',1,
1
S1167
BRAKE PEDAL (WITH PEDAL AND PUSH ROD)
1. Brake pedal
2. Return spring
3. Circlip
4. Lock nut
5. Pull rod
6. Stop light switch
524-1
Page 629
VACUUM SERVO UNIT
The servo unit comprises one complete unit and cannot
be taken apart. Only the non-return valve, dust cover, filter and one seal ring can be removed and replaced.
REMOVAL
1. Remove the upper circlip on the brake pedal push rod.
(Reached from the engine compartment.) See illustration Section 524.
2. Pull off the two electric cables from the brake light
switch.
3. Remove the vacuum hose from the non-return valve
on the servo unit.
4. Disconnect the brake hoses and the electric cables for
the brake warning switch from the master cylinder
and also the hose to the clutch master cylinder from
the fluid reservoir. Insert plastic stoppers in the hoses
to avoid spillage of the brake fluid.
5. Remove the servo unit together with the master cylinder and bracket. The bracket is fitted to the dash
panel by means of four screws. Three of the nuts for
these are accessible from underneath in the passenger
compartment after removal of the screen section and
parts of the dash panel insulation felt below the instrument panel. The fourth nut is accessible from the engine compartment by the bracket.
6. Unscrew the master cylinder and bracket from the
servounit.
To fit new air filters these must be slit with a knife to
enable them to fit over the input push rod.
NOTE
The dome nut on the output push rod is correctly
set by the manufacturer and must never be adjusted.
ASSEMBLY
1. Screw the master cylinder and the bracket to the servo
unit.
2. Fit the servo unit together with the bracket and master
cylinder.
3. Connect the brake hose and the electric cable to the
master cylinder and connect the hose from the clutch
master cylinder to the brake fluid reservoir.
4. Connect the hose from the inlet manifold.
5. Connect the cable for the brake warning switch and
fit the circlip to the brake pedal push rod.
6. Bleed the brake system.
SERVO UNIT
I. Non-return valve
5. Diaphragm
2. Push rod (master cylinder)
3. Seal
6. Valve piston
7. Filter
4. Return spring
8. Dust cover
9. Push rod (brake pedal)
S.AB
541-1
Page 630
HANDBRAKE SYSTEM
HANDBRAKE CABLE
Removal
1. Remove the driver's seat and fold back the floor carpeting to expose the air ducts for the heating system.
2. Remove the gear lever cover. Observe the ignition
switch light and the cables for interior lighting.
3. Remove the plate over the air ducts and remove the
air ducts.
4. Disconnect the cable from the adjustment nut on the
handbrake lever.
5. Remove the clip holding the two cables to the floor.
6. Remove the rubber bush in the side of the wheel housing and disconnect the cable from the handbrake lever
at the brake cylinder housing.
7. Pull out the cable. The simplest method is to pull out
each cable and from underneath in the engine compart·
ment.
i
I
I
~
I--- 0.32 ± 0.08 in. (8 ± 2 mm)
S 3172
CHECKING MEASURE ON HANDBRAKE LEVER PAWL
BUTTON
--
Fitting
1. Fitting is carried out in the reverse order. The cables
should cross each other on the floor of the passenger
compartment.
2. After the cables have been fitted the handbrake lever
should be applied a few times, in order to stretch the
cables. The cables are then adjusted with the adjust·
ment nut at the handbrake lever and the yoke on the
brake housing so that the distance between the yoke
and the handbrake lever is 0.019 in.± 0.003 (0.5 mm
± 0.1) when the handbrake is in the off position. (See
illustration on page 523-4.)
HANDBRAKE LEVER
Removal
1. Disconnect the two cables from the adjustment nuts.
2. Remove the locking pin from the pivot pin and pull
out the latter.
Assembly
Assembly is carried out in the reverse order. If the pawl
button, pawl rod or any other part contained in the hand·
brake lever has been removed the position of the pawl
button must be checked. After the lever has been fitted
and the brake applied, the distance between the top edge
of the button and the handbrake lever should be 0.32"
± 0.08" (8 ± 2 mm). The pawl button can be adjusted by
screwing or unscrewing it on the push rod.
551-1
I
S.1'11
.L