Page 461
1, Remove the friction pads as described previously
2. Bend up the retaining plates and remove the two re
taining bolts which hold the brake housing to the
steering knuckle housing, Lift the brake housing away
from the brake disc. Do not disconnect the brake
hose, but place the brake housing
does not get stretched,
$0 that the hose
NOTE
Never allow the brake housing to hang from the
brake hose, Collect the brake fluid when the piston
is removed,
3. Press the brake pedal down carefully, thus forcing the
piston out for enough for it to be taken off by hand,
Keep a clean container handy, so that you will be able
to collect the brake fluid when the piston is removed.
4, Disconnect the brake hose from the brake cylinder,
Insert a plug in the hose to prevent the escape of the
brake fluid and also to prevent the entry of impurities
into the system.
5. Remove the two springs which hold the cylinder in
place and remove the cylinder.
6. If the piston seal needs replacing, it can now be re-
moved from its groove in the cylinder.
7. If it is necessary to remove the wiper seal, it can now
be taken out with the aid of a screwdriver.
IMPORTANT
Always use either brake fluid or denatured alcohol
(methylated spirit) for cleaning.
Reassembly of brake piston and seals
1. Coat a new, dry seal with special lubricant (Lockheed
Disc Brake Lubricant) and place it carefully in its
groove in the cylinder, making sure that it is prolerly
seated,
2. Check that the piston and cylinder are thoroughly
clean and coat them with the special lubricant. Press
the piston into the cylinder, making sure that the re-
cess in the contact surface facing the friction pad is
pointing downwards. The brake piston of the latest de-
sign has a face ground contact surface facing the fric-
tion pad. In this connection the damping shim has
been altered in such a way that the piston has the cor-
responding fit-up facing the friction pad. To facilitate
refitting of the wiper seal, do not press the piston fully
home, but leave about 0.4 in. (10 mm) outside the cyl-
inder.
Febr 1977
5 1286
FITTING THE WIPER SEAL
1
2.
3.
4,
. Piston
Piston seal
Seal retainer, wiper seal
Wiper seal
. If the wiper seal has been removed previously, smear
a new, dry seal with the special lubricant and place it
in the retainer with its groove turned towards the pis-
ton.
. Press the retainer and seal home with the aid of screw
vise 78 60 430 and distance piece.
. Replace the brake cylinder in the brake body assem-
bly and refit the springs.
. Remove the plug from the brake hose, fit a new cop-
per washer and tighten the hose securely in the cy!-
inder.
. Put the brake in place and tighten the retaining bolts.
Remember to secure the bolts with the retaining plate. _i!
WARNING
Make quite sure that the brake hose is not twisted.
If it is not mounted in a neutral position, slacken its
attachment at the wheel housing and then retighten
it in the correct position.
. Refit the friction pads, spring and new cotter pins as
described earlier.
NOTE
Fit a new spring if the old one seems to be exhausted.
. Bleed the brake system and pump repeatedly up and
down with the brake pedal in order to adjust the fric-
tion pads in against the disc. Top up with brake fluid
in the reservoir.
WARNING
Do not forget to pump repeatedly with the brake
pedal, as otherwise the pedal will go all the way
down when the brakes are applied.
523-3
Page 462
Replacement of complete brake cylinder
Disassembly
1.
2,
Remove the friction pads as described earlier.
Bend up the retaining plate and remove the two brake
retaining bolts from the steering knuckle housing.
Lift the brake away from the brake disc.
Disconnect the hose from the brake cylinder. Insert a
plug in the hose to prevent the escape of brake fluid
and also prevent the entry of impurities into the sys-
tem.
. Remove the two springs which hold the cylinder in
place and remove the cylinder.
. Clean the entire brake housing thoroughly.
NOTE
Take the opportunity to check for brake wear, es-
pecially on the hinge pin.
Reassembly
1
Insert the new brake cylinder in the brake body as-
sembly and refit the springs.
. Remove the plug from the brake hose, fit a new cop-
per washer and tighten the hose securely in the cyl-
inder.
. Put the brake housing in place and tighten the retain-
ing bolts. Remember to secure the bolts with the re-
taining plate.
WARNING
Make quite sure that the brake hose is not twisted.
\f it is not mounted in a neutral position, slacken its
attachment at the wheel housing and then retighten
it in the correct position.
. Refit the friction pads, spring and new cotter pins as
described earlier,
NOTE
Fit a new spring if the old one seems to be exhausted.
. Bleed the brake system and pump repeatedly up and
down with the brake pedal in order to adjust the fric-
tion pads in against the disc. Top up with brake fluid
in the reservoir.
WARNING
Do not forget to pump repeatedly with the brake
pedal, as otherwise the pedal will go all the way
down when the brakes are applied.
523-4
y assembly and support bracket
Dismantling of brake bod
replace the brake body assem-
necessary tO ’
pan these items can be disassem-
it shoul
if its cket,
bly or the support bra
bled as ee aks from the steering knuckle housing
1, Remove
ibed earlier. ; ’
7 iil? the spring on the hinge pin and take away
2. Com
k washer and spacer.
3 pd the spring and lift the support bracket away
, Re
from the hinge-
4. Reassembly takes place in the reverse order.
S 1284
DISC BRAKE COMPONENTS
1. Brake body assembly
2. Spring loaded steady pin
3. Support bracket
4. Hinge pin
Febr 1977
Page 463
BRAKE OPERATION
Up to and incl. model 1968
BRAKE PEDAL
The brake pedal is carried on the same shaft as the clutch
pedal and is fitted with self-lubricating bushings.
PEDAL STAND WITH PENDANT PEDALS
1. Stop light switch
2. Brake warning contact
Removal and installation
1. Remove the steering column and gear shift shaft.
2. Detach the fork for the clutch cylinder from the clutch
pedal.
3. Remove the cotter pins from both ends of the shaft.
4. Remove the clutch pedal and return spring from the
shaft.
5. Unscrew the master cylinder push rod att
nut.
6. Pull out the shaft leftwards and remove the br
he adjusting
ake ped-
al.
7. Check the bearing for wear and fit new bus
necessary.
hings if
Reinstall in the reverse order, and then adjust the brake
pedal free movement.
Adjustment
In order to ensure that the piston in the master cylinder
will return fully every time the brake pedal is released,
there must always be a clearance between the master cyl-
inder piston and the brake pedal push rod when the ped-
al is at rest. This clearance, measured at the tip o
al, should be 0.12—0.24 in. (3-6 mm). Measured between
the push rod and the piston, the clearance should amount
to 0.024—0.047 in. (0.6—1.2 mm).
a=
or
ADJUSTMENT OF BRAKE PEDAL CLEARANCE
A =0.12—0.24 in. (3—6 mm)
Adjust as follows:
1. Back off the locking nut.
2. Turn the hexagonal part of the push rod until the cor-
rect clearance is obtained at the tip of the pedal.
3. Tighten the locking nut.
SAAB —
Febr 1977
f the ped-
Page 464
As from model 1969
BRAKE PEDAL
The brake pedal is carried on the same shaft as the clutch
pedal and is equipped with self-lubricating bushings.
Removal and installation
1. Remove the protective cover of the steering wheel
shaft.
2. Remove the bracket of the brake light and the brake
warning contacts.
REMOVAL OF COTTER PIN
4. Loosen the clutch pedal spring.
5. Remove the cotter pin from the R.H. end of the pedal
shaft.
6. Pull the shaft out to the left, and remove brake pedal.
7. Check the bearing for wear, renew bushings as neces-
sary.
Installation is made in the reverse order.
3. Loosen the brake cylinder push rod, by removing cot-
ter pin and shaft bolt.
524~2 SAAB
Febr 1977
Page 465
>
HANDBRAKE SYSTEM
GENERAL
The mechanical handbrake acts on the rear wheels only
When the handbrake lever is pulled, the movement is
transmitted by the handbrake cables to levers on the rear
wheel brakes. These actuate the brake shoes mechanically
and press them against the brake drums.
HANDBRAKE CABLES
The permanently lubricated handbrake cables comprise
inner steel wires in plastic coated spiral sheathing, led
through a sleeve under the backrest cushion of the rear
seat. The cables are fitted with protective grommets where
they pass through panels. The cables are clamped to the
rear axle, the inner wires being attached to the back plate
levers by means of clevis-and-pin connections. A return
spring is fitted between the clevis and the spiral sheathing.
Up to and incl. model 1970
As from model 1971
od
Removal
1. Remove one of the front seats and the rear seat cush-
ions, Jack up the car.
2. Remove the rear wheel.
3. Back off and remove the adjusting nut under the ‘
brake lever.
4. Pull the cable sheathing out of the sleeve under the
rear seat cushion.
5. Remove the clamps used to hold the cable to the rear
axle.
6. Remove the pin holding the clevis on the brake lever.
7. Ease the grommet out of the inclined panel in the rear
axle tunnel.
8. Pull out the entire brake cable rearwards.
and-
Installation
1, If the grommet in the rear axle tunnel has been re-
moved, ease it on to the cable.
2. Pass the cable, threaded end first, up through the in-
clined panel in the rear axle tunnel and on through
the sleeve under the rear seat to the handbrake lever.
Make sure that the grommet in the front inclined pan-
6 89 1011 12
S$ 2950
HANDBRAKE LEVER COMPONENTS
1. Release button
2. Nut
3. Return spring
4, Washer
5. Handbrake lever
6. Paw!
7. Spacer sleeves
8. Cotter pin or circlip
9. Pin
10. Adjusting nut
11. Cable pin
12. Threaded wire rods
13. Pawl rod
14, Ratchet
Febr 1977 SAAB
551-1
Page 466
el has not been dislocated.
3. Refit the adjusting nut.
4. Reconnect the clevis to the brake lever and secure the
pin.
7 5. 5 4. 5352 1
REVERSE SIDE OF REAR, LEFT BACKPLATE
1. Handbrake wire 7. Pin
2. Coil spring 8. Cotter pin
3. Clevis 9. Washer
4. Brake pipe connection 10. Rubber boot
11. Brake lever
12, Adjustment device
5. Bleed nipple
6. Locking washer
5. Fit the grommet in the inclined panel in the rear axle
tunnel and secure the cable to the rear axle with two
clamps.
NOTE
Make sure that the spiral sheathing does not touch
the brake pipe.
6. Refit the wheel.
7. Put back the cushions and seats and adjust the hand-
brake.
8. Lower the car to the floor. Finally tighten the wheel
bolts and refit the hub caps.
Instructions for fitting the brake shoe lever in the back-
plate are given in section 511.
551-2 Shan
HANDBRAKE LEVER
tion, which shows the handbrake lever
stration,
See the illu
and its component parts.
Removal
ck the front seats, possibly removing one of
ter accessibility.
boot from the handbrake lever.
e adjusting nuts.
her and the lever bearing pin
pacer sleeves.
1. Push ba
them to provide bet
Remove the rubber
Back off and remove th
4. Remove the locking was'
from the ratchet. Collect the s
ndbrake lever.
wn
5. Remove the ha
Disassembly, up to and incl. model 1970
Remove the cotter pin and the pin for the pawl.
2. Slide the pawl lever out towards the handgrip.
3. Back off the locking nut and remove the release but-
ton, locking nut, spring and washer.
4. Remove the pawl rod, the pawl and the washer by the
pawl.
—_
Reassembly, up to and incl. model 1970
1. Check that the spring, pawl, ratchet and pins are flaw-
less.
2. Refit the ratchet mechanism in the lever. The release
button should project about 0.4 in. (10 mm) beyond
the brake lever handgrip when the pawl engages with
the ratchet.
Disassembly, as from model 1971
1. Remove the cotter pin and the shaft bolt for the pawl.
Collect the washer.
2. Slide the pawl lever out and unscrew the button. Re-
move the return spring.
3. Remove the pawl rod and the pawl.
Febr 1977
|
Page 467
| Febr 1977
reassembly, as from model 1971
Before reassembling, check that all the parts are in per-
fect condition.
Mount the pawl on the pawl rod and insert the rod in
the lever.
3, Refit the return spring. Screw the button on until it
bottoms in the thread and then, to ensure correct po-
sitioning, not more than one additional turn. Check
the position of the button after having fitted the brake
lever in the car.
4, Refit the washer, the shaft bolt and the cotter pin.
Installation
1. Refit the lever to the ratchet with spacers, pin and cir-
clip.
2, Reconnect the brake wires to the lever.
Adjust the handbrake.
4. Refit the rubber boot.
~
ADJUSTMENT OF HANDBRAKE
Adjustment of handbrake lever travel or of the brake ca-
bles, which may be necessary after the car has been driven
for a lengthy period or after removal of the handbrake
lever, should always be preceded by adjustment of the
footbrake, If the handbrake still requires adjustment, this
can be done in the manner described below with the ad-
justing nuts, which are accessible from the driver’s seat.
NOTE
Always adjust the brake shoes before adjusting the
handbrake.
HANDBRAKE LEVER AND ADJUSTING NUTS
1, Adjusting nuts
on
. Jack up the rear part of the car so that both rear wheels
are clear of the floor.
. Remove the right front seat and move the handbrake
lever to its bottom position.
. Tighten the left adjusting nut until the brake shoe pres-
ses against the left drum. Use a suitable hex. socket
wrench to tighten the nut.
. Back off the nut enough to allow the wheel to rotate
freely and then back off one more full turn.
. Repeat this procedure with the right adjusting nut.
. Test by pulling the handbrake lever firmly and then
returning it to the bottom position. The wheels should
turn freely when the lever has been pulled up two cogs
from the off position, but should be locked at the third
cog.
. Check that the braking effect is equal on both wheels.
551~3
aneene
Page 469
sENERAL ant
GENE oughly the medium of ball joints in two vee shaped, ans
- n
verse control arms, The inner ands of these are carried |
All four wheels have coll springs, Each front wheel |i at rubber-clad bearings on the body, The vertical spring
tached to the steering knuckle, which Is suspended thot travel of the wheels is limited by rubber bumpers,
S 2488
FRONT SUSPENSION
Febr 1977
Page 470
ee eS & & ee ee te
ee ee ee Sr |
aR agente. Mt
a
tame oat. 7s seeree ecucxis forms 2 sae 4
a ort ee Stace Se Se rg muse as.
eee Sey orc Sexbie cocrectocs for Ge orcs of
Se contd ams The steering am, to whieh the tera
& COMmeses, & locates on re upper Steeies merck
= a7 é
= 5.
— —J -
a4 3
aa ’
- "23>
5
4
=
§
od
.
=
FRONT AXLE UNIT
1. Protective shield
2. Brake disc
3. Wheel hub
4. Ball bearing
5. Nut
een ie sae re secmaiiecs
an ag S ciested rebbe boot
sores Gage aes:
scter fromm ectering th outer
sane jort smc S
a! OT SSS
l< .
eee
h
4678 9 4
5. Lock ring
7. Ball
8. Hub 12. Ball joint
10. Rubber bellows 14. Outer universal joint
600-2 SAAB
Febr 1977