Page 521
WHEEL CYLINDERS AND BRAKE HOUSINGS
Removing brake pistons and seals
IMPORTANT
The two halves of the brake housing are not to be
separated. All normal servicing can be carried out
with the two halves bolted together.
1. Jack up the front or rear end and take off the wheel.
2. Remove the guard plate with a screw driver. Knock
out the locking pins with a drift and remove the re-
taining spring and brake pads.
3. Unscrew the brake housing from the steering knuckle
housing and disconnect the brake line from the hous-
ing.
4. Lift the housing off the brake disc.
5. Clean the outside of the housing and wipe it thorough-
ly dry afterwards.
6. Apply screw clamp 786043 to one brake piston and
force out the other piston by supplying compressed
air to the brake line connection. Take care that the
piston does not fall out and suffer damage.
NOTE
When the piston has been removed, great care must
be taken to insure that no dirt or oil gets into the
brake system.
7. Use a blunt tool to prize the seal out of the cylinder.
Be careful not to damage the seal groove or the cylin-
der itself (see fig.).
IMPORTANT
Use only brake fluid or denatured spirit for clean-
ing a brake cylinder, as the seal between the two
halves of the housing may otherwise be destroyed.
REMOVING THE PISTON SEAL
8. After refitting the seals and piston (see Assembling),
the other piston can be removed. The operation is the
same for both.
NOTE
Honing or grinding the wheel cylinders is not recom-
mended because the cylinder walls are treated against
corrosion. If the surface is ground or in some other
way damaged, there will be the risk that the pistons
are jammed in the cylinders because of corrosion.
$1740
BRAKE HOUSING WITH COMPONENT PARTS
- Brake housing
. Guard plate
Retaining spring
Locking pins
Brake pads
Piston
. Dust gasket
Seal retainer
Piston seal
CONagsuna
Dec. 1975 SAAB 523-1
Page 522
Assembling
Check that all parts are clean and in perfect condition.
1. Coat a new seal with a special lubricant, e.g. Lockheed
Disc Brake Lubricant. The seal must be dry before the
lubricant is applied. Locate the seal carefully in its
groove in the cylinder and rotate it with the fingers to
seat it properly.
2. Coat the piston with the same grade of lubricant and
locate it so that the recess in the contact surface with
the brake pad is turned the right way. Use the template,
tool 899534 (see fig.). If the piston must be rotated
Saez
CHECKING BRAKE PISTON POSITIONS
Too! 899534
Wheel rotation when driving forward
tated after insertion, use the grippers, tool 899536.
Push the piston carefully into the cylinder and check
that it does not jam.
ROTATING THE PISTON
Tool 899536
523-2 SAAB
3. Take a new dust gasket and coat it with the special
lubricant. The gasket must be dry before the lubricant
is applied. Press home the gasket retainer and brake
piston using screw clamp 786043 (see fig.). Fit
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a
PUSHING THE BRAKE PISTON INTO THE CYLINDER
Tool 786043
the piston and dust gasket in the other cylinder in the
same manner.
4. Connect the brake line to the housing and screw the
brake housing to the steering knuckle housing. Apply
a new locking plate. Wash the brake disc with trichlo-
roethylene.
5. Fit the brake pads.
NOTE
On the rear wheel brakes a washer is placed between
the brake piston and the pad. The washer has a re-
cess and prevents the piston from turning.
IMPORTANT
If you have to rotate the piston, make sure that the
sealing surface is not damaged in the process.
6. Bleed the system. Pump the brake pedal to advance
the pistons and top off the container with brake fluid.
Dec. 1975
Page 523
BRAKE CONTROL
Brake pedal
The brake pedal is journaled in self-lubricated bushings
on the same shaft as the clutch pedal and mounted in a
bracket.
Removing and fitting
1. Disconnect the electric wiring and remove the brake
light contact and brake warning contact holder. The
holder is fixed to the pedal bracket by two screws.
2. Remove the eccentric shaft where the pedal is con-
nected to the vacuum power assist Push rod.
3. Pull the split pin from the right-hand end of the pedal
shaft and push out the shaft.
. Take out the pedal.
5. Reassemble in the reverse order.
+
Adjusting the position of the pedal
The position of the brake pedal in relation to the clutch
pedal can be adjusted by means of an eccentric pin where
the brake pedal is connected to the vacuum power assist
push rod.
April 1969 SAAB 524-1
Page 524
HANDBRAKE SYSTEM
Removing the handbrake cable for exchange
1. Remove the front seats and take up the carpet.
2. Remove the front branching duct of the heating sys-
tem and the valve house assembly.
3. Remove the knob from the free wheel control lever.
4. Engage reverse gear and take out the ignition key. Un-
screw the gear lever cover and lift it off.
(NOTE! Ignition switch light.)
5. Detach the handbrake lever cover and unscrew the
2
wire adjusting screws completely. Pull the handbrake
lever straight up so that the wires can be freed. Remove
the rear duct with the heater control.
Remove the wire clamp from the floor tunnel.
7. Remove the front wheel. Unscrew the wire retainers
from the wheel housings.and undo the retainer straps
on the steering gear.
8. Pull out the wire from the wheel end.
nstalling brake cables
1. Proceed in the reverse order to the above. Make sure
that the rubber grommet in the dash panel bulkhead
is not damaged.
NOTE! The crossover of the wires. Make sure they are
installed this way.
2. After installing, adjust the parking brake shoes first
H
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and then the wires.
jandbrake lever
emoving
. Remove the left front seat.
. Detach the handbrake lever cover.
. Unscrew the wire adjusting screws completely and
remove them.
. Free the shaft lock ring and pull out the shaft until it
clears the ratchet.
. Remove the lock ring from the lower shaft bolt and
pull the bolt right out. Lift off the lever.
itting the handbrake lever
Install in the reverse order.
Disassembling the handbrake lever up to and incl. model
1970
1. Remove the pawl pivot split pin and take out the pivot.
2. Push the pawl rod out towards the handle.
3. Undo the lock nut and remove the catch button, lock
nut and return spring.
4. Remove the pawl rod with the pawl.
551-1
Assembling
1. Check that all parts are in good condition before assem-
bling.
2. Fit the pawl mechanism in the lever and screw the lock
nut right home. Fix the correct position of the lever
by mounting it in position. The paw! button should pro-
ject 0.4” (10.5 mm) beyond the handle when the pawl
is engaged in the ratchet. When this has been done, re-
move the lever again to lock the paw! button and fit in
place once more.
3. Insert and pin the shaft and connect the wires to the
lever.
4. Adjust the handbrake.
Disassembling the handbrake lever as from model 1971
1. Remove the pawl pivot split pin.
Undo inner paw! and both spring.
2. Push the pawl rod upwards so that the knob can be
unscrewed.
3. Pull out the pawl rod with outer pawl, washer and
return spring.
Assembling
1. Check that all parts are in good condition before
assembling.
2. Fit washer, return spring and outer pawl on the pawl
rod,
ia 0.32 + 0.08 in. (8 + 2 mm)
CHECKING MEASURE ON THE HANDBRAKE KNOB WHEN
THE OUTER PAWL IS ENGAGED
$ 3172
3. Place the pawl rod in the lever. Screw on the knob to
the bottom of the thread and if necessary to obtain
correct position for the knob, further not more than
one turn,
When the lever has been fitted in the car, check that
the measure from the outer end of the knob to the
lever is 8+ 2 mm (0.32 + 0,08 in.). See fig.
4. Fit pawl springs, inner pawl and the shaft bolt. Check
that the springs are correct placed. Lock with a split pin,
Jan. 1971
Page 525
Disassembling the brake drum and shoes
1. Apply the handbrake, remove the front wheel hub caps
and slacken the wheel nuts slightly.
2. Jack up the front end and take off the wheel. Release
the handbrake.
3. Unscrew the brake housing from the steering knuckle
housing and lift it off the brake disc.
NOTE
The brake housing must not be left hanging from the
brake line but must be supported to relieve the brake
hose.
4. Undo the brake drum retaining screws and pull off
the drum.
If the brake drum is difficult to remove, use ring
899579 and puller 899518.
Place the ring so that the raised part fits in the recess
on the brake drum and tighten the screws.
Fasten the puller at the ring with the aid of two spacer
screws, tool number 899524, and pull off the brake
drum. See fig.
REMOVING THE BRAKE DRUM
Tools 899518, 899524 and 899579
5. Unhook the upper return spring using tool 899560.
S$ i742
REMOVING THE RETURN SPRING
Tool 899560
6. Release the two retaining springs and remove the shoes
by pulling them down.
REMOVING THE BRAKE SHOES
Dec. 1975 SAAB 551-2
Page 526
Assembling
NOTE
When fitting new linings, replace both brake shoes
at the same time. They are ground in matching pairs
and must not on any account be changed separately.
The brake shoes should be replaced when the thick-
ness of the very lining is less than 0.02” (0.5 mm).
1. Before fitting new linings or a new drum, slacken
the wire adjustment to avoid straining the wire.
2. Coat the three sliding studs on the shield as well as
the lever arm joint and the adjusting screw with
special grease. Grease sparingly.
3. Assemble the shoes and adjustment. The short
sleeve should face forward on the right-hand side
and backward on the left-hand side. Hook on the
lower tension spring so that it lies inside the shoes
after mounting.
4. Insert the shoes from below between the brake
shield and the wheel hub to their location against
the support piece and fit them in the groove on the
lever arm and link.
5. Mount the compression springs and upper tension
spring.
6. Check operation by pushing on the wire end of the
lever arm. Make sure that the adjustment device is
screwed in.
7. Mount the brake drum. If it will not slip straight
over the shoes, this is probably because the shoes
are not centered.
8. Fit the retaining screws and the brake housing.
Make sure that the brake hose is not twisted.
9. Check that the brake pads clear the disc. Adjust
the handbrake (see Adjustment of handbrake).
10. Mount the wheel and hub cap.
Adjusting the handbrake
Check the adjustment of the handbrake by jacking up the
front end of the car and rotating the front wheels by hand.
When correctly adjusted, the handbrake should, in model
1969 and 1970, begin to take hold at the second ratchet
notch and lock the wheels at the third notch. As from mo-
del 1971 the brake should begin to take hold at the fourth
notch and lock the wheels fully at the sixth or seventh notch.
If not, the brake must be adjusted. To do this, adjust the
brake shoes first and after that, if necessary, adjust the wire.
1. Apply the handbrake, remove the front wheel hub
caps and slacken the wheel nuts slightly.
2. Jack up the front end, place trestles under the front
suspension arms, release the handbrake and take the
wheel off.
3. Check that the brake pads clear the disc and that the
lever arm does not influence the position of the shoes
on adjustment to give misleading results, It is best to
release the wire adjustment at the handbrake lever end.
$51-3 SAAB
4. Line up the hole in the drum with the teeth of the
adjusting screw, Insert a screwdriver into the hole, placing
its point between the teeth of the screw. Apply the
shoes to the drum by turning the screw until the drum
can only just be turned. Then stop tightening and back
off again 1—2 teeth. Apply and release the handbrake
lever to center the shoes.
rs
nl
3427
PARKING BRAKE, COMPONENTS
Support piece
. Lever arm
. Upper tension screw
. Holding spring
Primary brake shoe
Adjustment
. Lower tension spring
. Brake drum
. Brake lining
10. Compression spring and locking pin
11. Secondary brake shoe
12. Pressure rod
WOONAMSWNH>
Jan. 1973
Page 527
5. Check that the shoes are not binding by rotating the
drum in its normal direction. A very light contact can
be accepted. If the drum does not turn easily, back off
the screw another 1—2 teeth.
6. Repeat the adjustment on the other front wheel.
7. Pull up the handbrake lever, checking that the brake, in
model 1969 and 1970, begins to take hold at the second
notch and is fully applied at the third notch. As from
model 1971 the brake should begin to take hold at the
fourth notch and lock the wheels fully at the sixth or
seventh notch. Check also that the brakes act with the
same force on both front wheels.
8. Mount the wheels, after first cleaning all sand and dirt
off the contact surfaces, and tighten the nuts until the
wheel is immobilized on its hub. Then lower the front
end of the car and tighten the wheel nuts to a torque
on of 65—80 ft.lb. (90-110 Nm, 9—11 kpm); tighten
J each nut in turn a little at a time, following a criss-
cross pattern. Fit the hub caps.
ADJUSTING THE BRAKE SHOES
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Jan. 1973 Sues 551-4
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Page 528
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Page 529
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Sept. 1973
CONTENTS
600 General
601 Wheel alignment
631 Ball joints
632 Control arms
641 Steering wheel, steering column tube
with support and steering column
642 Steering gear
643 Tie-rod assemblies
644 Power steering