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. 

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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.