Bosch Alternators 1974

Car Manufacturers Covered:

• Alfa Romeo
• Audi
• BMW
• Capri
• Fiat 128 & X1/9
• Mercedes-Benz
• Opel
• Porsche
• Saab
• Volkswagen
• Volvo 4 Cylinder

CHANGES, CAUTIONS, CORRECTIONS

BATTERY INSTALLATION, BATTERY CHARGING, OR USING A BOOSTER BATTERY TO START ENGINE - Reversed polarity or excessive voltage will result in damage to alternator system. Note the following to prevent damage:

Battery Installation - Negative battery terminal must be connected to ground. Positive terminal must be connected to starter lead. DO NOT reverse battery leads.

Battery Charging - If a Quick Charger is used, both battery cables must be disconnected from the battery. DO NOT use a Quick Charger to provide starting voltage.

Booster Battery (For Engine Start) - Booster battery must be connected with negative lead to negative terminal of battery and positive lead to positive terminal of battery. DO NOT reverse battery leads.

                                   APPLICATIONS

Model                             Type No.                          Part No.

Alfa Romeo ................ K1 14V 45A 22 ............. * 0 120 400 848

Audi .................................. ... ............................. ** 059 903 017D

BMW

     2002, 2002A .......... K1 14V 45A 22 ............. * 0 120 400 752

     2002 tii ................... K1 14V 45A 22 ............. * 0 120 400 794

     3.0 .......................... K1 14V 45A 20 ............. * 0 120 400 702

Capri

     4 Cyl. W/A.C ............... ... .............................. *** D4RY-C

     4 Cyl. All Others ......... ... .............................. *** D4RY-B

     V6 W/ A.C. .................. ... .............................. *** D4RY - D

     V6 All Others .............. ... .............................. ***D4RY-A

Fiat 128 & X1/9 ................ ... ............................. * 0120 300 568

Mercedes Benz

     230, 240D .................... ... .............................. **** 0041 546 902

     280 ........................ K1 14V 55A 20 .............. **** 0041 541 802

     450 ........................ K1 14V 55A 20 .............. **** 0031 545 602

Opel ................................ ... ................................ * 0 120 400 620

Porsche

     4 Cyl .......................... ... ................................ ***** 022 903 023

     6 Cyl .......................... ... ................................ *****911 603 118 00

Saab

     99 .............................. ... ................................. *0120 400 850

     V4 ............................. ... .................................  *0120 400 657

Volkswagen 

     Type 1 ........................ ... ................................ * 0120 400 836 or 862

     Type 2 & 4 ................. ... ................................ * 0120 400 721

     Dasher ........................ ... ................................ * 0120 489 532 or 535

Volvo 

     140 ............................. ... ................................ * 0120 400 756

     164 ............................. ... ................................ * 0190 601 011

* - Bosch Part No.

** - Audi Part No.

*** - Motorcraft Part No.

**** - Mercedes Benz Part No. 

***** - VW Part No.

DESCRIPTION

Bosche alternators are conventional three-phase, self-rectifying type alternators. Nine rectifier diodes are connected to the stator windings (three to each phase lead). The diodes change the alternator A.C. voltages to D.C. voltages coming out of the "B+" and "D+" terminals of the alternator.

                                  SPECIFICATIONS

Alternator*                     Amp Output @ RPM                     Max Current

G1 14V 33A 27 ...................  33 @ 5000 ................................... 40A

K1 14V 35A 20 ................... 23 @ 2000 .................................... 35A

K1 14V 45A 20 .................... 30 @ 2000 ................................... 45A

K1 14V 45A 20 .................... 30 @ 2200 ................................... 45A

K1 14V 50A 20 .................... 33 @ 2000 ................................... 50A

K1 14V 55A 20 .................... 36 @ 2000 ................................... 55A

K1 14V 55A 22 .................... 36 @ 2200 ................................... 55A

* - Charging voltage: 14.

Field Coil Resistance - 4.0 ohms + 10% measured at slip rings at normal ambient temperature.

Stator Windings Resistance - .2 ohms + 10% measured between the phase output terminals

ON VEHICLE TESTING

NOTE - Off vehicle testing is explained as part of Overhaul procedure in this article.

WIRING CONTINUITY TEST

Disconnect terminal plug from rear of alternator and connect a voltmeter negative terminal to ground. With Ignition "ON", connect positive lead to each of  the connector wires, in turn. Voltmeter should read battery voltage as each positive connection is made. If proper voltage is not read, trace each wire to find fault.

VOLTAGE DROP TEST - GROUND SIDE

Connect voltmeter between negative terminal of battery and alternator housing. Start engine and run at approximately 3000 RPM. If voltmeter reading exceeds .25 Volts, a high resistance in negatvie side of charging circuit is indicated. If so, check for loose, dirty, or corroded connections.

OUTPUT TEST

Disconnect terminal plug from rear of alternator and connect ammeter, in series between alternator center terminal and corresponding socket in terminal plug. Also connect a jumper lead between the "D+" terminal and its corresponding socket in terminal plug. Start engine and run at approximately 3000 RPM. Turn on headlights and leave on for five minutes. Ammeter should read maximum alternator amperage at normal operating temeperature.

REGULATOR CONTROL VOLTAGE TEST

Connect a voltmeter between main terminals of battery. Connect an ammeter, in series, between "B+" terminal of alternator and corresponding terminal of connector plug. Connect a jumper lead between alternator "D+" terminal and corresponding terminal of connector plug. Start engine and increase speed to approximately 3000 RPM. Run engine until charging rate falls below 10 amps. The voltmeter should then read 14.1 - 14.4 Volts. If these readings are not obtained, replace regulator.

NOTE - The test cables should not be removed or the load excessively reduced during the diodes. The control lamp should not go on at any time during the test.

BOSCH ALTERNATOR (TYPICAL)

OVERHAUL

DISASSEMBLY

NOTE - On 0 120 400 600 series alternators, lift carbon brushes with hook and secure them, prior to disassembly (see illustrations).

1) Remove nut, pulley, hub and key. Mark location of alternator in blower housing. Unscrew brush

LIFTING CARBON BRUSHES
(0 120 400 600 Series)

plate assembly and remove from alternator. Remove bolts from end frame, then remove frame and field rotor. Press rotor out of end frame. Press ball bearing off rotor. Remove insulating conduit from wires and cut wires as close to soldered joints as possible.

2) The diodes may be tested at this point, prior to further disassembly. Care should be exercised with insulating busings under positive diode carrier. To remove negative carrier, extract threaded studs. When one rectifying diode has been damaged due to short circuiting, the three complementing diodes must be replaced also. Unscrew nuts on both "B+" terminal bolts and lift positive diode carrier (heat sink) up and back.

TESTING & REPAIRING

Diode Assemblies - test diodes with a suitable alternator tester (EFAW 192) before dismantling slip ring end frame further. CAUTION - Do not lay positive diode carrier on housing or false reading will be obtained. Disconnect conductor from "D+" to the exciter diodes at the exciter diodes heat sink. Unscrew spring and brush holder and remove from alternator. Unsolder stator lead and negativediode connection. Unscrew exciter diodes heat sink  and remove together with positive diodes heat sink.

NOTE - Before further testing, lightly clean all components in gasoline or trichlorethylene, but do not soak.

Stator - Test stator for short circuits to ground, using suitable tester (EFAW 84). Test voltage should be 40V AC. Measure resistance of stator windings between phase connections. See specifications for proper value.

Rotor  - 1) Test claw pole rotor for short circuits to ground. Test voltage should be 40V AC. Measure resistance of exciter (field coil) in rotor with ohmmeter. See Specifications for proper value. Turn down slip rings on a lathe, using suitable tailstock chuck (EFAW 75 or GDF 85 R 3).

2) After turning, check concentricity of slip rings with dual gauge. Runout should not exceed .001" (.03 mm). Minimum diameter of slip rings may be 1.25" (31.5 mm). Maximum runout of pole wheel must not exceed .002" (.05 mm).

Diode Replacement - 1) On all except 0 120 400 600 series alternators, set diode plate on press die and force diodes out with plunger. Place diode plate (without diodes) onto suitable guide pilot (EFLJ 57/0/5) and set diode seat with suitable sleeve (EFLJ 57/0/3). Smear silicone oil on diode seat, place diode palte on press die and press diodes into position. After pressing in, test all diodes.

2)  On 0 120 400 600 series alternators, set slip ring end frame on press die and force out defective diode. Coat diode seat with silicone oil and press in new diode. Test all diodes after replacement.

Drive End Frame - Check ball bearings for wear and replace as necessary. Lubricate bearings on one side. Press ball bearing into drive end frame with shielded side downward. Screw on retainer plate. Press ball bearing onto rotor (slip ring end), then press drive end frame onto rotor.

Carbon Brushes - Unsolder and replace carbon brushes. Do not allow solder to run into copper stands of brush leads. Minimum brush length is .55" (14 mm). After installation of new brushes, test for free movement.

REASSEMBLY & TESTING

1) On all except 0 120 400 600 series alternators (steps 1 through 4), fit negative diodes heat sink and clamps. Screw in double end bolts (shorter threads outward). NOTE - Left clamp is longer than right. Replace insulating washers and bushings. Test terminal bolt "B+" for short circuit to ground. Test voltage should be 80V AC.

2) Position positive diodes heat sink (carrier) and secure with insulating and spring washers. NOTE -

INSTALLATION OF DIODES

Use insulating cap NO. 1 120 502 000 instead of insulating washer on bolt nest to terminal marked "D+/61". Tighten hex nuts.

3) Place stator in slip ring end frame. Draw positive and negative diode leads together and lip through an insulating sleeve. Push sleeve over lead of exciter diode and stator connections cable. Crimp a metal ring around end of leads and solder. Cut off any excess wire protruding through ring. Reposition wiring and attach in holding clamps.

4) Side insulating sleeve over exciter diode terminal. Insulating sleeves of stator connection lead must  project over edge of negative diodes heat sink. Clamp connections firmly. 

5) On 0 120 400 600 series alternators (step 5 through 7), test both "B+" terminal bolts for short circuit to ground. Test voltage should be 80V AC. Before fitting exciter diodes heat sink (carrier), solder three positive diode terminal leads onto heat sink from below.

6) After fitting exciter diodes heat sink, solder stator leads, negative and exciter diodes to the "COMB". NOTE - Use caution, do not overheat negative diodes. Install brush holder. Raise and secure carbon brushes before installing. Screw conductor "D+" onto exciter diodes heat sink.

7) Place wave spring washer into ball bearing fit. Rub ball bearing seat with suitable lubricant. Insert rotor with drive end bearing into slip ring end frame and secure. Springs are to be set onto carbon brushes by pressing on brush with a screwdriver. Brush spring pressure will seat brushes automatically.

8) Rub suitable lubricant into ball bearing seat of slip ring end frame. Install claw pole rotor with drive end frame. Check position of stator relative to end frame. Position brush holder plate. Tighten screws. Install fan belt pulley. Coat newly installed positive diodes with chlorinated rubber lacquer.

Audi 100LS 1977 Brake Repair Guide

DESCRIPTION

Brake system is hydraulically operated, utilizing a tandem master cylinder and power brake unit. Front disc brakes consist of rotors attached to wheel hub and drive shaft and two piston calipers attached to strut assembly. Disc pads are equipped with a ceramic transmitter-type wear sensor. Transmitter is mounted on cross spring and will break when contact is made with pad plates, interrupting control circuit and causing indicator light on instrument panel to be activated. All models are equipped with pressure regulator that is mounted to body and operated by a spring connected to rear axle. Rear brakes are leading-trailing shoe/drum type, using a dual piston wheel cylinder. Parking brake is cable actuated, operating secondary shoes of rear brake assemblies.

ADJUSTMENT

NOTE - Adjustments or readjustments should be carried out on cold brakes. However, brakes must be warm when testing. Instrument panel trim must be removed to adjust master cylinder push rod free play.

MASTER CYLINDER PUSH ROD FREE PLAY

Adjustment of piston rod play at master cylinder is made by loosening lock nut and turning piston rod until correct free play, measured at brake pedal, is obtained. When correct free play of .039" is obtained between push rod and piston, free play is measured at brake pedal will be approximately .2".

FRONT DISC BRAKES

Front disc brakes are self-adjusting, therefore, no adjustment in service is required.

REAR DRUM BRAKES

Raise and support rear of vehicle and release parking brake. Using a 17 mm wrench, tighten eccentric adjusters until wheels can no longer be turned by hand. Loosen eccentric adjusters until wheels are just fee to turn.

PARKING BRAKE

NOTE - Because of the residual pressure in brake regulator, the right rear brake shoes might not fully release from drum. Before adjustment, move lever on pressure regulator rearward.

Raise and support rear of vehicle and adjust rear brakes. Lift parking brake lever until it engages third ratchet stop. Adjust nut at equalizer until rear wheels are just free to turn. When parking brake lever is pulled up one additional notch (to fourth ratchet stop), rear wheels should be locked.

BRAKE PRESSURE REGULATOR

Fig. 1 Brake Pressure Regulator Adjustment Points

Checking & Adjusting - 1) Rock vehicle back and forth several times, then measure distance from top of rim to bottom of fender lip. Measurement must be made with trunk empty, gas tank full, and driver in vehicle

2) Raise vehicle on a hoist and make measurement again. If there is a difference in measurements, adjust by turning clamps. See Fig. 1.

3) Connect pressure gauges to left front and right rear wheels. Bleed pressure gauges. Apply pressure to foot pedal and note reading at gauge. Repeat procedure on right and left rear wheels.

                        Brake Pressure Values

Application                                    Pressure (psi)

Left Front.............................................  700

Right Rear............................................. 475-625

Right Front............................................ 1400

Left Rear............................................... 765-945

NOTE - DO NOT adjust brake pressure regulator when pressure is applied to brake pedal.

4) If pressure at rear wheels is to high, release spring and move spring support arm forward. If pressure at rear wheels is too low, move support arm rearward.

HYDRAULIC SYSTEM BLEEDING

Fill master cylinder reservoir with brake fluid and maintain level throughout bleeding operation. Attach a hose to bleeder screw, and immerse opposite end in a container partially full of brake fluid. Open bleeder screw, approximately one-half turn, depress brake pedal, close bleeder screw, and slowly return pedal. Continue operation until air bubbles are no longer seen in discharged fluid. Bleeding sequence is left-rear, right-rear, right-front, left-front.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal - Remove lock clips. Pull out retaining pins so they project into openings in side members. NOTE - Do not remove rubber grammets from side member holes. Using a suitable extractor tool (SB-3), remove disc pads from caliper.

NOTE - Disc pads can be removed on right side only after removing front exhaust pipe.

Installation - Press both pistons into caliper bores.

NOTE - Fluid level in master cylinder reservoir will rise. Siphon sufficient fluid to prevent reservoir from overflowing. Ensure pistons are in correct alignment in bores using suitable tool (B-5). Install disc pads in recesses of caliper, slide in retaining pins, and install lock clip. Pump brake pedal several times to position disc pads. Bleed hydraulic system if necessary.

Fig. 2 Audi 100LS Rear Brake Assembly

FRONT DISC BRAKE CALIPER

Removal - With wheel and tire removed, take out disc pads. Disconnect hydraulic line from caliper. Remove bolts securing caliper and take off caliper.

Installation - To install brake caliper, reverse removal procedure and bleed hydraulic system

FRONT DISC BRAKE ROTOR

Removal - With wheel and tire assembly removed, take off caliper. Do not disconnect hydraulic line unless necessary. Remove screw retaining rotor to wheel hub (if equipped) and withdraw rotor.

Installation - To install rotor assembly, reverse removal procedure and bleed hydraulic system.

REAR BRAKE DRUM

Removal - Raise and support vehicle, remove wheel and tire assembly. Pry off dust cap, remove cotter pin from hex nut, and remove nut. Remove brake drum making sure that retaining washer and wheel bearing do not fall out.

Installation - To install, reverse removal procedure, adjust brakes, and adjust wheel bearings. See Wheel Bearing Adjustment in WHEEL ALIGNMENT Section.

REAR BRAKE SHOES

Removal - With brake drum removed, remove retaining spring for brake shoes. Remove shoes as an assembly by disconnecting spring at bottom, pulling shoes back from wheel cylinder, and disconnecting parking brake cable.

Installation - To install, reverse removal procedure and note the following: Make sure long ends of retaining clip and spring are installed on secondary shoe and parking brake lever. Ensure brake shoes are correctly  positioned on wheel cylinder pistons.

REAR BRAKE WHEEL CYLINDER

Removal - With drum and shoes removed, depress pedal approximately 1.2" and hold in position using a suitable pedal support. Disconnect hydraulic line from rear of backing plate and plug line to prevent loss of fluid. Remove retaining screws and wheel cylinder.

Installation - To install, reverse removal procedure, adjust brakes and bleed hydraulic system.

MASTER CYLINDER

Removal - Disconnect hydraulic line at rear of master cylinder. Depress brake pedal 1.2-1.6" and hold in position using a suitable pedal support. Disconnect remaining hydraulic line and cylinder mounting nuts. Separate master cylinder from power unit taking care not to lose "O" ring installed betweend them.

Installation - To install, reverse removal procedure and bleed hydraulic system.

POWER BRAKE UNIT

Removal - Siphon brake fluid from master cylinder reservoir and disconnect hydraulic lines. Loosen hose clamp and disconnect vacuum hose from power unit. From inside vehicle remove trim below instrument panel as necessary. Disconnect push rod from brake pedal, remove power unit adapter attaching nuts, and remove power unit and master cylinder from engine compartment as an assembly. Separate master cylinder and adapter from power unit.

Installation - To install, reverse removal procedure and note the following: Be sure to install "O" ring between master cylinder and power unit. Install adaptor to power unit so that center punch mark on adaptor is located on lower right side facing engine. To complete installation, adjust pedal push rod free play and bleed hydraulic system.

Check Valve Replacement - A vacuum check valve is located in vacuum line between intake manifold and power unit. To remove, loosen hose clamps, separate vacuum hoses from check valve, and remove check valve. To install, reverse removal procedure and note the following: Check valve stamped with the word "MOTOR" and a arrow. End of  valve in which arrow points must be connected to shorter hose from intake manifold.

OVERHAUL

FRONT DISC BRAKE CALIPER

Fig. 3 Front Disc Brake Caliper Assembly

Disassembly - Remove disc pads. Pry out retaining ring and remove dust seal by hand. Place a small block of wood in caliper cavity, and remove piston by applying compressed air to fluid inlet. Remove remaining piston in same manner. Remove seal from caliper bore using a piece of wood or plastic. NOTE - Do not use hard or sharp tools for this purpose. Do not separate caliper halves.
Cleaning & Inspection - Clean all parts in alcohol only. Check cylinder bore and piston
 for damage. NOTE -  Do not machine caliper bore or piston. Parts are serviced by replacement only.

Fig. 4 Using a 20° Gauge to Position Caliper Piston

Reassembly - Coat all parts with ATE brake cylinder paste (or equivalent), reverse disassembly procedure, and note the following. Use new seals, dust boots, and retaining rings when reassembling. When installing piston, make sure machined surface of piston face makes a 20 degree angle to wall of caliper bore (see illustration). Install disc pads after caliper has been installed on vehicle.
REAR WHEEL CYLINDER
Disassembly - Thoroughly clean outside of cylinder. Remove end caps, piston and seal assemblies, and spring. Remove dust cap and bleeder screw.
Cleaning & Inspection - Clean all parts in alcohol only. Check all parts for rust, corrosion, or other damage. Check cylinder bore and piston for wear. Maximum allowable cylinder diameter is .6287; minimum allowable piston diameter .6197". Manufacturer recommends replacing rubber components each time cylinder is disassembled.

Reassembly - Reverse disassembly procedure and not the following: Apply a thin coat of ATE brake cylinder paste (or equivalent) to all parts during assembly.
MASTER CYLINDER
Disassembly - Thoroughly clean outside of master cylinder. Remove hydraulic fluid reservoir, remove retaining ring, and remove primary piston assembly. Loosen or remove (if necessary) piston stop screw and remove secondary piston assembly. Disassemble primary and secondary piston assemblies.
Cleaning & Inspection - Clean all parts in alcohol only. Dry all parts with compressed air and check that compensating parts of cylinder are free of obstructions. Check cylinder bore and pistons for rust, corrosion or other damage. Inspect cylinder bore and pinion for wear. Maximum allowable cylinder diameter is .817:; minimum allowable piston diameter is .807". Manufacturer recommends replacing all rubber parts whenever cylinder has been disassembled.
Reassembly - Reverse disassembly procedure and note the following: Do not apply grease to push rod as damage may result to rubber components.
POWER BRAKE UNIT
NOTE - Manufacturer does not recommend overhaul of power brake unit.

Fig. 5 Sectional View of Audi 100LS Tandem Master Cylinder

Audi S90 & 100 1970-73 Brake Repair Guide

Models Covered

• S90 (1970-72)
• 100 (1970-73)

DESCRIPTION

Brake system is hydraulically operated, utilizing a tandem master cylinder and Teves T 51/349 power brake unit. Front disc brakes consist of rotors attached to transmission output flanges, and two-piston calipers attached to transmission. Disc pads are equipped with a ceramic transmitter-type wear sensor. Transmitter is mounted on cross spring and will break when contact is made with pad plates, interrupting control circuit and causing indicator light on instrument panel to be activate. Rear brakes are leading-trailing shoe/drum type, using a dual piston wheel cylinder. Parking brake is cable actuated, operating secondary shoes of rear brake assemblies.

ADJUSTMENT

NOTE - Adjustments or readjustments should be carrier out on cold brakes. However, brakes must be warm when testing. Instrument panel trim must be removed to adjust master cylinder push rod free play.

MASTER CYLINDER PUSH ROD FREE PLAY

Check brake pedal free play by measuring distance between master cylinder push rod and master cylinder piston. This measurement should be .039" (1.0 mm), which would give free play of .20" (5.08 mm) at brake pedal. If necessary to adjust, loosen lock nut on push rod and turn push rod until correct clearance is obtained. Tighten lock nut and again measure pedal free play at brake pedal.

FRONT DISC BRAKES

Front disc brakes are self-adjusting, therefore, no adjustment in service is required.

REAR DRUM BRAKES

Raise and support rear of vehicle release parking brake. Using a 17 mm wrench, tighten eccentric adjusters until wheels can no longer be turned by hand. Loosen eccentric adjusters until wheels are just free to turn.

PARKING BRAKE

Raise and support rear of vehicle and adjust rear brakes. Lift parking brake lever until it engages third ratchet stop. Adjust nut at equalizer until rear wheels are just free to turn. When parking brake lever is pulled up one additional notch (to fourth ratchet stop), rear wheels should be locked.

HYDRAULIC SYSTEM BLEEDING

Fill master cylinder reservoir with brake fluid and maintain level throughout bleeding operation. Attach a hose to bleeder screw, and immerse opposite end in a container partially full of brake fluid. Open bleeder screw approximately one-half turn, depress brake pedal, close bleeder screw, and slowly return pedal. Continu operation until air bubbles are no longer seen in discharge fluid. Bleeding sequence is left-rear, right-rear, right-front, left-front.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal - Remove lock clips. Pull out retaining pins so they project into openings in side members. NOTE - Do not remove rubber grommets from side member holes. Using a suitable extractor tool (SB-3), remove disc pads from caliper.

NOTE - Disc pads can be removed on right side only after removing front exhaust pipe.

Installation - Press both pistons into caliper bores.

NOTE - Fluid level in master cylinder reservoir will rise.

Siphon sufficient fluid to prevent reservoir from overflowing. Ensure pistons are in correct alignment in bores using suitable tool (B-5). Install disc pads in recesses of caliper, slide in retaining pins, and install lock clip. Pump brake pedal several times to position disc pads. Bleed hydraulic system if necessary.

FRONT DISC BRAKE CALIPER & ROTOR

Removal - 1) On vehicles equipped with automatic transmission, disconnect steering damper from its bracket and move out of way. On all models, depress brake pedal approximately 1.2" (30.48 mm) and hold in this position by using suitable pedal support. Disconnect temperature transmitter wire from connector (near transmission)

2) On automatic transmission equipped vehicles, disconnect hydraulic line at union on transmission, EGR line at exhaust pipe, and exhaust pipe from hangers. On all models, disconnect and remove front exhaust pipe and shield from manifold, and drive shaft at stub axle.

3) Remove ball joint mounting bolts, pull wheel downward, and swing out steering knuckle after prying it off ball joint. Remove disc brake pads, leaving spring and wire in vehicle. Remove EGR filter from oil  pan. Remove caliper mounting nuts, then remove caliper and rotor from stub axle. NOTE - If necessary, pry engine assembly to one side to ease removal.

Installation - To install, reverse removal procedure, tighten caliper mounting bolts securely, and bleed hydraulic system.

REAR BRAKE DRUM

REAR BRAKE ASSEMBLY

Removal - Raise and support vehicle, remove wheel and tire assembly. Pry off dust cap, remove cotter pin from hex nut, and remove nut. Remove brake drum making sure that retaining washer and wheel bearing do not fall out.

Installation - To install, reverse removal procedure adjust brakes, and adjust wheel bearings. See Wheel Bearing Adjustment in WHEEL ALIGNMENT Section.

REAR BRAKE SHOES

Removal - With brake drum removed, remove retaining spring for brake shoes. Remove shoes as an assembly by disconnecting spring at bottom, pulling shoes back from wheel cylinder, and disconnecting parking brake cable.

Installation - To install, reverse removal procedure and not the following: Make sure long ends of retainin clip and spring are installed on secondary shoe and parking brake lever. Ensure brake shoes are correctly positioned on wheel cylinder pistons.

REAR BRAKE WHEEL CYLINDER

Removal - With drum and shoes removed, depress brake pedal approximately 1.4" (35.56 mm) and hold in this position by using suitable pedal support. Disconnect remaining hydraulic line and cylinder mounting nuts. Separate master cylinder from power unit, taking care not to lose "O" ring installed between units.

Installation - To install, reverse removal procedure, adjust brakes and bleed hydraulic system.

MASTER CYLINDER

Removal - Disconnect hydraulic line at rear of master cylinder. Depress brake pedal 1.2-1.6" and hold in position using a suitable pedal support. Disconnect remaining hydraulic line and cylinder mounting nuts. Separate master cylinder from power unit taking care not to lose "O" ring installed between them.

Installation - To install, reverse removal procedure and bleed hydraulic system.

POWER BRAKE UNIT

Removal - Siphon brake fluid from master cylinder reservoir and disconnect hydraulic lines. Loosen hose clamp and disconnect vacuum hose from power unit. From inside vehicle, remove trim below instrument panel as necessary. Disconnect push rod form brake pedal, remove power unit adapter attaching nuts, and remove power unit and master cylinder from engine compartment as an assembly. Separate master cylinder and adaptor from power unit.

Installation - To install, reverse removal procedure and note the following: Be sure to install "O" ring between master cylinder and power unit. Install adaptor to power unit so that center punch mark on adaptor is located on lower right hand side facing engine. To complete installation, adjust pedal push rod free play and bleed hydraulic system.

Check Valve Replacement - A vacuum check valve is locate in vacuum line between intake manifold and power it. To remove, loosen hose clamps, separate vacuum hoses from check valve, and remove check valve. To install, reverse removal procedure and not the following: Check valve is stamped with the word "MOTOR" and an arrow. End of valve in which arrow points must be connect to shorter hose from intake manifold.

OVERHAUL

FRONT DISC BRAKE CALIPER

FRONT DISC BRAKE CALIPER ASSEMBLY

Disassembly - Remove disc pads. Pry out retaining ring and remove dust seal by hand. Place a small block of wood in caliper cavity, and remove piston by applying compressed air to fluid inlet. Remove remaining piston in same manner. Remove seal from caliper bore using a piece of wood or plastic. NOTE - Do not use hard or sharp tools for this purpose. Do not separate caliper halves.

FRONT DISC BRAKE CALIPER ASSEMBLY

Cleaning & Inspection - Clean all parts in alcohol only. Check cylinder bore and piston for damage. NOTE - Do not machine caliper bore or piston. Parts are serviced by replacement only.

PINION INSTALLATION

Reassembly - Coat all parts with ATE brake cylinder paste (or equivalent), reverse  disassembly procedure, and note the following: Use new seals, dust boots, and retaining rings when reassembling. When installing piston, make sure machined surface of piston face makes a 20° angle to wall of caliper bore (see illustration). Install disc pads after caliper has been installed on vehicle.

REAR WHEEL CYLINDER

Disassembly - Thoroughly clean outside of cylinder. Remove end caps, piston and seal assemblies, and spring. Remove dust cap and bleeder screw.

AUDI MASTER CYLINDER
(COMPONENT PARTS)

Cleaning & Inspection - Clean all parts in alcohol only. Check all parts for rust, corrosion, and damage. Check cylinder bore and piston for wear or damage. Cylinder bore should not exceed .6287" (16.00 mm) and piston diameter should not be less than .619" (15.74 mm). NOTE - Manufacturer recommends replacing rubber components on each disassembly.

Reassembly - Reverse disassembly procedure and not the following: Apply a thin coat of ATE brake cylinder paste (or equivalent) to all parts during assembly.

MASTER CYLINDER

Disassembly - Remove reservoir, brake light switch, circlip and dismantle cylinder. To extract piston, unscrew stop screw.

Cleaning & Inspecting - Clean all parts in denatured alcohol. Inspect bore and piston for rust or wear and replace any parts out of tolerance. It is advisable to always replace rubber parts.

Reassembly - Preassemble pistons and coat cups with ATE brake cylinder paste (or equivalent). Insert assembly into cylinder bore, install stop screw and circlip. Install brake light switch and resrevoir.

NOTE - Models without power brake servo differ slightly. Primary piston desgin is somewhat varied. Piston is equipped with only on secondary boot. There is no air compensating bore. Brake light switch location is different.

Audi Fox 1973-77 Brake Repair Guide

DESCRIPTION

Brake system is hydraulically operated, utilizing a tandem master cylinder and a Teves power brake unit. Front disc brakes consist of rotors attached to wheel hubs, and single piston floating caliper assemblies attached to steering knuckles. The disc brake pads are equipped with wear indicators that create a pulsation in the brake pedal when the pads are worn. Rear brakes are leading trailing shoe/drum type, using a dual piston wheel cylinder. Parking brake cable actuated, operating secondary shoes of rear brake assemblies. Pressure regulator valves for rear wheels mount to power brake unit.

ADJUSTMENT

FRONT DISC BRAKE PADS

Front disc brakes are self-adjusting, therefore, no adjustment in service is required.

REAR DRUM BRAKE SHOES

Raise and support rear of vehicle, release parking brake. Use a brake spoon, tighten rear star adjuster until wheel can no longer be turned by hand. Loosen star until wheels are just free to turn.

PARKING BRAKE

With rear brake shoes properly adjusted, pull parking brake handle to second notch. Tighten parking brake adjusting nut rear wheels can just be turned by hand, then tighten lock nut. Release handle and ensure both rear wheels rotate freely.

PRESSURE REGULATOR VALVE

Operation Test - Place hand around pressure regulator. Depress brake pedal relatively hard. Release pedal; listen and feel for a slight "knock" in each regulator. This is the piston returning in regulator.

Pressure Test - 1) Use two pressure gauges that will record at least 1400 psi. Hook one gauge to left rear wheel cylinder. Attach other gauge to right front caliper cylinder. Bleed both hoses through bleeder gauges. Operate pedal vigorously several times.

2) Depress brake pedal until gauge on right front caliper reads 497 psi at the same time the gauge hooked to the left rear wheel cylinder should read 384 psi.

3) Continue depressing pedal and hold it in position when right front gauge reads 1400 psi, left rear wheel cylinder gauge should read between 768-862 psi. Repeat procedure to check other side. Replace any regulator that does not meet specifications outlined here.

HYDRAULIC SYSTEM BLEEDING

Fill master cylinder reservoir with brake fluid and maintain level throughout bleeding operation. Attach a hose to bleeder screw, and immerse end in a container partially full of brake fluid. Open bleeder screw approximately one-half turn, depress brake pedal, close bleeder screw, and slowly return pedal. Continue operation until air bubbles are no longer seen discharged fluid. Bleeding sequence is right-rear, left-rear, right-front, left-front.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal - Raise and support front of vehicle and remove wheel and tire assembly. Pull spring locks out of retaining pins, drive retaining pins out toward outside of vehicle, and remove cross spring. Use a suitable tool (P 86), remove inboard brake pad. Pull mounting frame and brake cylinder outwards until outboard pad can be removed

Installation - Press piston to bottom of travel in cylinder and floating frame. NOTE - Level in master cylinder reservoir will rise. Siphon off sufficient fluid to prevent overflowing. Ensure machined portion of piston face makes a 20° angle to lower caliper wall. Install disc pads by reversing removal procedure.

FRONT DISC BRAKE CALIPER

Removal - With wheel and tire assembly and disc brake pads removed, disconnect hydraulic line from caliper. Remove bolts securing caliper to steering knuckle and remove caliper.

Installation - Reverse removal procedure and  bleed hydraulic system.

FRONT DISC BRAKE ROTOR

Removal - With wheel and tire assembly removed, remove caliper. NOTE - Do not disconnect hydraulic line unless necessary. Remove screw securing rotor to wheel hub and withdraw rotor.

Installation - Reverse removal procedure and bleed hydraulic system if necessary.

REAR BRAKE DRUM

Removal - Pry off grease cap. Remove cotter pin, castle nut, hex nut, and washer. Pull off brake drum making sure that inner race of outer bearing is not lost.

REAR BRAKE SHOES

Fig. 1 Exploded View of Rear Brake Assembly

Removal - With brake drum removed, disconnect lower spring by removing from primary shoe. Remove shoe vibration cups, springs, and pins. Remove primary shoe from backing plate, disconnect parking brake cable from lever, and remove secondary shoe and parking brake lever assembly.

Installation - Reverse removal procedure and not the following: Before installing secondary brake shoe, make sure that rear wheel cylinder piston is positioned so that web face outward and opening inward. Ajust brakes and bleed hydraulic system if necessary.

REAR BRAKE WHEEL CYLINDER

Removal - Depress brake pedal approximately 1.2" to close compensator bore in master cylinder, and hold in position using a suitable pedal support. Disconnect hydraulic line from cylinder and plug with rubber cap from bleeder screw. Remove bolts attaching wheel cylinder to backing plate. Remove cylinder by maneuvering out of backing plate

Installation - Reverse removal procedure and not the following: Make sure that rear piston is installed in wheel cylinder so that web faces outward and opening inward. Bleed hydraulic system.

Fig. 2 Audi Fox Disc Brake Caliper Assembly

MASTER CYLINDER

Removal - Siphon brake fluid from master cylinder reservoir. Disconnect hydraulic lines at cylinder, remove nuts attaching master cylinder to power unit, and remove master cylinder.

Installation - Reverse removal procedure and not the following: Make sure "O" ring is installed between master cylinder and power unit. After installing master cylinder, bleed hydraulic system.

OVERHAUL

FRONT DISC BRAKE CALIPER

Disassembly - Remove disc pads and pry mounting frame and piston assembly off floating frame. Remove brake cylinder and guide spring from floating frame. Remove clamp and dust cap from brake cylinder, then withdraw piston. NOTE -If necessary, apply compressed are to fluid inlet. Remove seal from cylinder.

Cleaning & Inspection - Thoroughly clean all parts in alcohol. Check all parts for rust, corrosion, or other damage; replace parts as necessary. NOTE - Manufacturer recommends replacing rubber parts whenever caliper has been disassembled.

Reassembly - Apply a thin coat of ATE brake cylinder paste (or equivalent) to cylinder, piston and seal, and reassemble. Place guide spring in groove of brake cylinder, then drive cylinder on floating frame with a brass mandrel. Place mounting frame in guide spring, then slide it on floating frame.

REAR BRAKE WHEEL CYLINDER

Fig. 3 Exploded View of Rear Wheel Cylinder

Disassembly - Remove rubber dust caps, then withdraw front and rear piston and seal assemblies. Remove seals from pistons. Remove bleeder screw and dust cap.

Cleaning & Inspection - Thoroughly clean all components in alcohol. Inspect cylinder and pistons for rust, corrosion, or scoring; replace parts as necessary. NOTE - Manufacturer recommends replacing all rubber parts whenever cylinder has been disassembled.

Reassembly - Reverse disassembly procedure and note the following: Pistons are not interchangeable. Install notched piston in front of cylinder so that it will engage primary shoe when installed on backing plate.  

Fig. 4 Master Cylinder Pinion Assembly

MASTER CYLINDER

Disassembly - Remove "O" ring from master cylinder housing. Remove retaining ring and loosen piston stop screw, then remove both pistons from housing. Remove pressure valves and reservoir from master cylinder housing. Disassemble piston assemblies as necessary.

Cleaning & Inspection - Clean all parts in alcohol and check for rust, corrosion, or other damage; replace parts as necessary. Make sure compensating and filler holes are not plugged.

Reassembly - Reverse disassembly procedure and note the following: Make sure pressure and intermediate piston cups are installed correctly. See Fig. 4. Use new "O" ring on master cylinder between cylinder and power unit. 

POWER BRAKE UNIT

NOTE - No information available for Overhaul of power brake unit.

Audi A3 1997 Repair Manual

Manufacturer: Audi
Model: A3
Year: 1997

Contains the following information and repairs for:

• Electrical
• Starter
• Current Supply
• Windscreen Wiper and Wash System
• Lights, Lamps, Switches - Interior
• Lights, Lamps, Switches - Exterior
• Wiring 
• Interior Equipment
• Passenger Protection
• Trim/Insulation
• Seat Frames
• Seats - Upholstery, Covers
• Maintenance

DOWNLOAD

File Size: 45 MB

File Type: PDF, RAR

Audi Wheel Alignment Guide 1975 Models

AUDI SPECIFICATIONS AND ADJUSTMENTS

TIRE INFLATION (COLD)
Before attempting to check and adjust wheel alignment, ensure tires are properly inflated. Model 100 requires 26 psi in front and 28 psi in rear. Fox requires 24 psi in front and 27 psi in rear.

CASTER
Fox - Caster angle is not adjustable. However, if not to specifications, check suspension for wear or damage and repair or replace necessary components

Model 100 - Caster and camber adjustment must be made at the same time. See Camber adjustment procedure.

CAMBER
Fox - With vehicle loaded down or placed on blocks, measure camber angle. If not to specifications, adjust by loosening ball joint mounting bolts and moving ball joint sideways on control arm until correct camber is obtained. Tighten ball joint mounting bolts and recheck camber angle.

Model 100 - 1) With vehicle equipped with spare tire and full fuel tank, measure caster and camber angle. If not to specifications, remove inner ball joint-to-lower control arm mounting bolt and install camber adjusting tool (US 9020) as shown in Fig. 1. Install slightly tighten on 8mm bolt and washer in threaded hole between inner and outer ball joint mounting bolts on lower control arm, then loosen outer mounting bolt. Tighten tensioner bolt on adjusting tool to break loose ball joint, then tighten or loosen tensioner bolt until camber angle is set to specifications.

2) To adjust caster angle, leave camber adjusting tool installed to maintain adjusted camber angle, then install caster adjusting tool as shown in Fig. 1. Adjust caster angle to specifications by moving ball joint forward or backward by means of adjusting tool. Hold tool stationary and tighten outer ball joint mounting bolt to 80 ft. lbs. (11 mkg). Remove caster and camber adjusting tools and tighten inner bolt to 47 ft. lbs. (6.5 mkg), then remove 8 mm bolt and washer.

Fig. 1 Adjusting Caster and Camber on Audi 100

TOE-IN
All Models - Before checking toe-in, check wheel rim run-out and replace rim if necessary. If toe-in is not to specifications, adjust by loosening tie rod outer locking nut and clamp and turning tie rods until correct toe-in is obtained. Tighten lock nut and clamp and recheck toe-in.

1974 Audi Wheel Alignment Guide

AUDI SPECIFICATIONS AND ADJUSTMENT

TIRE INFLATION (COLD)
Before attempting to check and adjust wheel alignment, make sure tires are properly inflated. Model 100 requires 28 psi in front and 26 psi in rear. Fox requires 28 psi in front and 24 in rear

CASTER
Fox - Caster angle is not adjustable. However, if not to specifications, check suspension for wear or damage and repair or replace necessary components.

Model 100 - Caster is determined from difference in camber at 20 degrees left and 20 degrees right wheel lock. Caster is negative if the left wheel at right lock shows larger camber than at left lock. Caster is considered positive if left wheel at left lock shows a larger camber than at right lock. Adjust by loosening lock nut "D" and turning eccentric bolt "E". Be sure to adjust equally on both sides and retighten lock nut (see illustration).

CAMBER
Fox - With vehicle loaded down or placed on blocks, measure camber angle. If not to specifications, adjust by loosening ball joint mounting bolts and moving ball joint sideways on control arm until correct camber is obtained. Tighten ball joint mounting bolts and recheck camber angle.

Model 100 - With wheel in straight-ahead position, measure camber angle. If not to specifications adjust by loosening lock nut "B", and bolt "C", and turning eccentric nut "A"

CASTER AND CAMBER ADJUSTING POINTS 100LS

TOE-IN
All Models - Before checking toe-in, check wheel rim run-out and replace rim if necessary. If toe-in is not to specifications, adjust by loosening tie rod outer locking nut and clamp and turning tie rods until correct toe-in is obtained. Tighten lock nut and clamp and recheck toe-in.

Audi Wheel Alignment Guide 1970-73

1970-73 AUDI SPECIFICATIONS AND ADJUSTMENTS

TIRE INFLATION (COLD)
Before attempting to check or adjust wheel alignment, ensure that tires are properly inflated. Model 100 and 100 LS require 26 psi (1.827 kg/cm2) in front and rear tires. Model S90 and Fox require 24 psi (1.687 kg/cm2) in front and rear tires.

RIDING HEIGHT
S90 (Front) - With vehicle unloaded and on level ground, check front ground clearance from floor to center of lower wishbone bearing support. If measurement is not within specifications, turn adjusting screw on crossmember to correct height. Both sides must be adjusted to specifications.

S90 (Rear) - Rear riding height is nonadjustable. Measure at lower edge of frame cross tube to floor. If measurement is not within specifications, check for damage to suspension components.

100 and 100LS - With wheel in straight ahead position, measure camber angle. If not to specifications, adjust by loosening lock nut "B", bolt "C" and turning eccentric nut "A".

Fox - With vehicle loaded down or placed on blocks, measure camber angle. If not to specifications, adjust by loosening both mounting bolts use suitable tool (Audi 40-200).

Fox - Check wheel rims for runout and replace as necessary. Measure distance between front edges of front rims and rear edges of front rims. Difference in these two measurements is toe-in. If not within specifications, adjust tie-rod (located just behind steering rack).

100LS (Front) - With vehicle unloaded and on level ground, check front ground clearance from floor to front bearing shell of lower wishbone. If distance is lower than specifications, correct riding height. Remove coil spring assembly from vehicle and shock absorber from coil spring assembly. For removal and installation procedures see Coil Spring/Shock Absorber Assembly in Suspension Section. Install spaces in position on shock absorber shaft to adjust ground clearance. Each spacer gives .393" (9.98 mm) increase in clearance. Assemble and install coil spring assembly and shock absorber into vehicle.

100LS (Rear) - With vehicle unloaded and on level ground , check rear ground clearance at lower edge of frame cross tube to floor. If not within specifications, adjust torsion bar.

100 (Front) - Measure clearance from ground to lower edge of front engine platform mounting bolt head. If height is not to specifications, adjust by adding spacers to coil spring

Fox (Rear) - Measure clearance form ground to lower domed surface of body next to control arm bushing. If clearance is less than specified, install heavier springs.

All Models - With riding height correct and before checking or adjusting wheel alignment, wooden blocks or adjustable supports must be in place and vehicle loaded down. Front supports are placed under front bearing shell of lower wishbone. Rear supports are placed under mounting plates on rear cross tube. Load vehicle until it is resting on support stands.

CASTER
NOTE - Before checking or adjusting wheel alignment, vehicle must be under specified loaded conditions (see Riding Height, All Models).

S90 - To adjust, loosen nut on upper wishbone to mounting bracket screw. Turn eccentric to change caster angle. Eccentric moving rear wishbone joint forward increases caster and reverse movement decreases caster. Torque lock nut to 542 ft. lbs. (7.49 mkg) when caster is within specifications.

100 and 100LS - Caster is determined from difference in camber at 20 degrees left and 20 degrees right wheel lock. Caster is negative if lewft wheel at right lock shows larger camber than at left lock. Caster is considered positive if left wheel at left shows a larger camber than at right lock. Adjust by loosening lock nut "D" and turning eccentric bolt "E". Be sure to adjust equally on both sides and retighten lock nut (see illustration).

Fox - Caster angle is not adjustable. However, if not to specifications, check suspension for wear or damage. Repair or replace necessary components.

CAMBER
NOTE - Before checking or adjusting wheel alignment, vehicle must be under specified loaded conditions (see Riding Height, All Models).

S90 - To adjust, loosen nut on upper wishbone to mounting bracket screw. Rotate adjusting tube to change camber angle. When wishbone joint moves away from center of vehicle, camber increases and reverse movement decreases camber. Torque lock nut to 54.2 ft. lbs. (7.49 mkg) when camber within specifications.

TOE-IN

Caster and Camber Adjusting Points 100LS

All Others - Toe-in must be checked with front wheels presented together with a pressure of approx. 22.0 lbs. or the rear wheels apart. To adjust, loosen track rod bolt clamp and hose clip securing boot. Rotate track rod until toe-in with specifications. For large corrections both track rods must be turned approx some amount. If correction to be made is small adjustment can be made to only one side: Tighten clamp bolt and hose clip.

1965 Import Vehicles Jacking and Hoisting Guide

ALL MANUFACTURERS

NOTE - Information not available for Lancia models.

NOTE - These illustrations are not intended to represent exact structure of the manufacturer's frame, underbody, or body outline. These are presented only to give the mechanic some point of reference

FRAME AND UNDERBODY
The following illustrations indicate areas (parts) of the underbody and frame which may be used to raise and support the vehicle, using either floor jack or hoist. These points are indicated by shaded areas on the frame (see sample illustration).

OUTERBODY
Those points designated on the outline of the body were specifically designed to facilitate the use of the vehicle's own jack, but may also be used to raise and support the vehicle by means of floor jack or hoist. These jacking points are indicated by circular dots on the outline of the body (see sample illustration). If floor jack or hoist is employed, extreme care should be exercised to prevent damaging the outer body shell.

1965 Import Vehicles Ball Joint Checking Guide

ARROW / COLT

All Models - With components removed from control arm and ball joint still installed, check following: Horizontal and vertical free play (0"), and ball joint rotation starting torque 4-6 ft. lbs. (6-8Nm). Replace ball joints if correct specifications are not obtained

AUDI

Fox - Clearance of ball joint with pressure applied by leverage should be .04-.10" (1.0-2.5 mm). if not replace ball joints

BMW

All Models - With lower control arm removed, measure axial (up and down) movement of ball joint stud. If movement exceeds .0945", replace ball joint.

COURIER

All Models - Check working surfaces of ball joints and studs for wear or damage. End play should not exceed .031" (.8 mm), if end play is excessive, replace ball joint.

DATSUN

All Models (Exc. 620 Pickup) - Remove lower control arm. Use appropriate spring tension gauge and and attach it to top of ball joint stud nut. Measure force (INCH Lbs.) required to move ball joint stud laterally. If measurement is not within specifications, replace ball joint

FIAT

All Models - With vehicle raised and supported under lower control arms, grasp wheel at top and bottom and try to shake wheel. If any movement is noted, control arm must be removed for further inspection.

HONDA

All Models - Raise and support front of vehicle. Attach dial indicator onto lower control arm with indicator tip on steering knuckle near ball joint. Place pry bar between lower control arm and steering knuckle. NOTE - Take care not to damage ball joint rubber boot. Push on pry bar and observe movement on dial indicator. If movement is in excess of .020" (.5 mm), ball joint must be replaced.

JAGUAR

All Models - Upper ball joint must be replaced if signs of wear or play are evident. The lower ball joint is adjustable with shims if axial play exceeds .004-.006" (.10-.15 mm). Shims must not be removed to take excessive wear in ball pin and socket. If parts are excessively worn, replacement is required.

LANCIA

All Models - if ball joint shows excessive amounts of wear (play) replace ball joints.

LUV

With vehicle raised and supported under lower control arms, grasp wheel at top and bottom. Try to move wheel and replace ball joint if movement exceeds .06" (1.52 mm).

MAZDA

All Models - Check ball joint dust seal for wear or damage and if necessary, replace seal. Ball joint end play must not exceed .039" (1 mm). If end play exceeds specifications, replace ball joint

MERCEDES-BENZ

There should be no lateral movement of ball joint. Vertical movement is adjusted by adding or removing washers.

OPEL

All Models - Raise and support front of vehicle. Inspect ball joint rubber boots for damage and replace as necessary. If lower ball joint axial play exceeds .008" (2 mm), ball joint must be replaced.

PEUGEOT

All Models - When moving ball pin some friction torque should be felt. If ball pin can be moved without resistance end play is shown, replace ball joint.

RENAULT

All Models - Inspect ball joints for wear or excessive play. Replace ball joints as necessary.

SAAB

All Models - if ball joint exhibits excessive play, it must be replaced as a complete unit.

SUBARU

All Models - Check ball joint for excessive play by pushing and pulling on ball joint stud. Allowable looseness is less than .012". If play exceeds this specification, ball joint must be replaced.

TOYOTA

Corona and Pickup - To check lower ball joint, jack up lower suspension arm and check for ball joint looseness by moving wheel vertically and horizontally. Movement limit in vertical direction should be less than .04" (1 mm) Corona and .20" (5.0 mm) Pickup. Movement limit in horizontal direction should be less than .08" (2 mm). Corona and .09" (2.3 mm) Pickup.
NOTE -  Ensure other suspension parts are tight before checking ball joints. To check upper ball joints. disconnect upper suspension arm from steering knuckle. Turn ball stud and check for excessive looseness or tightness. Replace ball joint if it is excessively loose or tight.

All Other Models - Check for excessive looseness, proper operation and damaged ball stud. Replace as necessary.

TRIUMPH

All Models - Inspect ball joints for excessive wear or play. Replace ball joint as necessary.

VOLKSWAGEN

Type 1 - Raise front of behicle and turn steering to one side. Place pry bar tool over nut or bolt head mounting steering knucle to strut. Compress ball joint spring and place vernier caliper over top of ball joint and over bottom stud. Note caliper reading, then release lever and record caliper travel. Increase reading is ball joint play. Replace ball joints as necessary

Type 2 - Raise front of vehicle and turn steering to one side. Insert pry bar tool VW 281a (or equivalent) under lower control arm and over top of strut mounting. Fit a vernier caliper on lower or upper torsion arm and steering knuckle. Record measurement. Press down with lever and measure travel of vernier caliper. IF travel exceeds specifications, replace ball joint.

All Other Models - Raise and support, then turn steering to one side. Install suitable levering tool so that ball joint spirng may be compressed. With spring compressed, position a vernier caliper with lower jaw on ball joint stud and upper jaw on top of clamping bolt for ball joint stud. Note reading. Slowly release tension from spring and not travel of caliper. This reading indicates ball joint play. If specified play is exceeded replace ball joint.

VOLVO

All Models - Maximum permitted axial play for lower ball joint is 12" (3 mm). Check ball joint by prying back and forth with a bar. If specifications are exceeded, replace ball joints.