TRANSMISSION· SUSPENSIONVEHICLE HEIGHT AND GEOMETRYSTEERING GEAR· BRAKES
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Alfawiki.nl

--8-This publication is intended
for the use by the ALFA ROMEO Service Organisationand contains instructions for adjusting, repairing andoverhauling the transmission, suspension, brakes and steering.
The operations are fully illustrated in orderto facilitate the identification of the parts or units in question,of the tool or jig to use, and the correct way to proceed.
The replacement of separate units or parts must be carriedout using only genuine ALFA ROMEO components. Only by this means
can the complete interchangeability and perfect performanceof the various parts be ensured.
When ordering please specify not oniy
the type of car and the part number from the Spare Parts Catalogue,
but also the chassis and engine serial numbers.
When repairing and overhauling we also recommend strongly theuse of special tools. Finally, this Manual should always be kept
up-to-date with the data and information received through the'Service Information Sheets' and the 'Up-dating Instructions'which are issued periodically by the Technical Service Department.

Alta Romeo Service Department

Public. n° 2064·Workshop Manual

Alfawiki.nl

November 1975

--.-CONTENTS
3

4
6
8
12
13
15
18
21
22

Workshop standards

TRANSMISSION
To remove propeller shaft from the car

To check vehicle height
To adjust vehicle height
To check geometryTools

To reassemble propeller shaft
Refitting propeller shaft to car
To overhaul the half shafts
Tools
Tightening torques
Lubricants and sealants

67
68
69
70
73
73

STEERING GEAR74

To dismantle and reassemble the steeringcolumn tube

75
76
80
83
83

To refit steering column to car
Partial operations

To remove the ZF steering rack from car
To dismantle the steering rack
To reassemble the steering rack
To refit steering rack to the car
To remove the steering column from the
car

Tools
Tightening torques
Lubricants and sealants

Lubricants and anti-seizing compounds

85
86
87
88
89
90
92
93
96
100
102
106
107
107

November 1975

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REAR SUSPENSION
To remove the rear suspension
DismantlingRe-assembling
To reconnect the suspension
Partial operations
Rating data for calibrating and matching
front & rear shock absorbers

54

Tools

57
57

Tightening torques

2

VEHICLE HEIGHT AND GEOMETRY

To dismantle propeller shaft

23 FRONT SUSPENSION
2.4 To remove the front suspension
26 Dismantling
29 Re-building
31 Re-fitting the suspension
32 Partial operations
36 Tools
40 Tightening torques
40 Lubricants, anti-seizing compounds

41
42
45
48
48
49
52

58
58
60
62
66

BRAKI NG SYSTEM
To dismantle the front brakes
Tests and checks
To refit the front brakes
To dismantle rear brakes
Tests and checks
To refit the rear brakes
To remove and refit the servo assembly
Brake pipes
To bleed brake system
To overhaul the handbrake assembly
Tools
Tightening torques
Lubricants, fluids and sealants

Public. nO 2064-Workshop Manual

--8-WORKSHOP STANDARDSWhen dismantling and reassemblying, always use appropriate spanners, extractors and tools (bothgeneral and special tools) and not improvised devices, so as to prevent damaging the parts.
To release tight components, tap lightly using only a copper or aluminium hammer, if the parts
concerned are made of ferrous materials, or a wood or plastic head mallet, if the parts are madeof light alloy (covers, housings, etc.).
Neatly separate the parts belonging to the various units and partially screw the nuts on theircorresponding studs or screws.
When dismantling, check that the parts that are to be aligned have a reference'< number or a
distinctive mark on them. If it is discovered that a pr'lviously replaced part has not been alignedwith such a mark, one should be applied.
Before washing the parts, remove all dirt with a brush and rags (to avoid excessive contaminationof the cleaning fluid). Then wash the parts with paraffin or a suitable fluid. Remove any surplus
with a compressed air jet. Dry the parts immediately after washing, to avoid corrosion.
After sandblasting or grinding with abrasive discs, etc., wash the parts thoroughly and blow off
with compressed air to remove completely all traces of abrasive material. When reassembling, usecompressed air or a dry clean brush to clean the parts (especially those that have been machinedor ground).
When re-assembling, lubricate the parts adequately (except graphited bushes) to avoid seizure
during the initial running period.
When coating parts with a lubricant use specially clean brushes and oil. Protect the containers
from dust and use them exclusively for this purpose.
When re-assembling, replace seals, oil seals, gaskets, flexible washers, lock washers and lock plates,"Palmutter" locknuts and any other parts that appear to be in a doubtful condition.

Use exclusively genuine ALFA ROMEO spare parts

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_ _ _ _ _ _o_VE_RH_AU_L_ _ _ _ _~------TRA-NS-MI-SS-ION-----

B

A

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_____________O_V_E_R_H_A_U_L___________~-----------T-R-A-N-SM--IS-S-IO_N____________

TRANSMISSION
A peculiarity of the Alfetta is thelayout of the transmission.
This car differs from conventional cars
as it has the clutch and gearbox unit
mounted in unit with the rear axle.
This assembly is connected with theengine by means of a two-piece propeller shaft. The connection at either end isachieved by means of a flexible coupling.
The location on the body is by meansof a central support fitted with ballbearings.
The drive from the differential unit,tothe rear wheels is by means of half
shafts with constant velocity joints.
These shafts are necessary owing to the
De Dion type rear axle layout chosen
for this car.
This type of axle achieves a reductionof the unsprung weight and improves
therefore the stability under any driving condition.

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_____________R_ E_M__
O_V_A_L_____________~-----------T-R-A-N-S-M-IS-S-I-O_N____________TO REMOVE PROPELLERSHAFT FROM THE CAR
Place the car on a ramp.
- Slacken clip 2 connecting the front pipe tothe rear pipe;- unhook the flexible supports 3 from thefront crossmember supporting the rear axle
assembly;- slacken and remove the bolts connecting theflanges 4 which retain the exhaust pipe 5
against the manifold;- slacken and remove bolt 6 fixing theexhaust pipe to the bracket situated on therear engine mounting and lower the pipe after
separating it from the rear section.

- Remove gaiters 7 from the gearlever support.
- Slacken and remove the screw and washer 8 retaining shaft 9 against the selector lever. Slacken
and remove the nuts and washers 10 of the flexible coupling connecting the rod to the lever on the
clutch housing. Lower shaft.

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_______________R_E_M_O_V_A_L_____________~------------T-R-A-N-S-M-I-S-S_IO_N

Rotate propeller shaft in order to be able tounscrew both one of the set bolts fixing theshaft to the flywheel and one of the set bolts
fixing shaft to the clutch .
Remove the small flywheel cover from therear engine housing.

____________

Remove the flywheel locking tool and unscrew
the remaining fixing bolts on the propeller
shaft, using the same procedure.
Unlock and remove the nuts and washers fixing the propeller shaft centre support to thestuds .

Lock the flywheel by means of tool no.
A.2.0290 which is fitted in place of the cover.
Release and remove the above mentioned fixing bolts using spanner no A.5.0192 (1).

Disconnect the rear engine mounting from thebody by unscrewing the retaining nuts. The
washers should be retained as they are used on
assembly to determine the distance of 7 ± 1
mm between the propeller shaft and the topof the support. This clearance is required toprevent any fouling. Withdraw the propeller
shaft from the clutch.
Proceed with care in order not to damage thegrease-retaining rubber cup 2 between theflexible coupling and the clutch fork.

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D_s_M_A_N_T_L_N_G_________________________~-----------T-R-A-N-S-M-IS_S_I_O_N

Withdraw the propeller shaft from the tunnel,
working from the rear of 'the car, disconnecting the centre support from the studs and thefront bush from the flywheel spigot simulta~
neously with the front flexible coupling.

____________

between shaft and flexible coupling andremove them with their washers.
- Separate the two shaft halves.

Front flexible coupling- Clamp the front shaft in a vice. Fit tool no.
A .2.0263 to the flexible coupling and remove
the protective rubber cap. Disconnect the
coupling from the flange unscrewing andremoving the fixing screws and washers.

- Remove the circlip 1 using the special pliers.
Extract the washer 2 and the spring 3.

TO DISMANTLE ,PROPELLER SHAFT
Disconnect the front section of the shaft fromthe rear portion. Proceed as follows :- Suitably mark the respective positions of
the front and rear shaft. Fit tool no. A.2.0263
to the flexible coupling. Release the bolts

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_dJa\I]JJ _ __DISMANTLING

TRANSMISSION- Extract the spherical seat and the bush fromthe flange on the front propeller shaft, using
extractor no. A.3.0361.

with the centering pivots. Tighten the fixing
bolts to 4.9 to 5.3 kgm; if the transmission isof the type with interference mounted bolts,
fixing nuts must be tightened to 4.4 to 4.9
kg.m.
Remove tool no. A.2.0263.
Fit protective cap and fill the front bush withapprox. 5 cm 3 of Molykote BR 2 grease,lubricating also its external surface.
Warning: The front bush may also be dismantled when the flexible coupling is mounted on
the shaft flange. It is sufficient to remove theprotective rubber cap.

Centre support
Replace the spherical seat and front bush,proceeding as follows:

Remove flange 1 and centre support 2 fromthe shaft, using a press. Proceed as follows:

Using Molykote paste G Rapid, lubricate theworking surfaces of the new spherical seat andthe new bush.

- Mark flange and front shaft in order to facilitate the assembly.

Place the spherical seat inside the bush andinsert them together in the flange, using
special tool no. A.3.0246.

- Remove spherical seat 3. This is provided
with a slot for the use of general tools.
Proceed with care. If there is no slot, use tool
no. A.3.0261.
- Unlock and remove fixing nuts 4 on theflange crnd support, using a ratchet and hexagon socket spanner.

•g

Locate in the front bush: spring, spring
seating washer and circlip.
Re-assemble the flexible coupling to the front
propeller shaft. Ensure that the holes alignPublic. nO 2064-Workshop Manual

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March 19789

D_s_MA_N_T_L_N_G____________________________~------------T-R-A--N-S-M-IS_S- Remove the flange from the shaft, .using apress and semi-circular plates no. A.2.0248.
NOTE: Great care should be taken. in order to prevent any
damage to the flange which cannot be replaced without affecting the balance of the complete shaft.

- Remove centrifugal cap.
- Remove the centre support, using a press andthe semi-circular plates, no. A.2.0247 at thisstage the other centrifugal cap is damaged andmust be replaced when re-assembling.

__
IO_N____________

Replace the centre support bearing as follows:- Remove bearing
special pliers.

retaining circlip, using- Extract the ball bearing, using a press, andspecial base, tool no. A.3.0265/2 (1) and tool
A.3.0401 (2).

2 - - -...

- Fit the bearing in the centre support, using
fitting tool no. A.3.0401. Retain with circlip.

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Public. nO 2064·Workshop ManualD_s_MA_N_T_L_N_G___________________________~-----------T-R-A-N-S-M--IS_S_I_O_N

Apply sealant Loctite 242 to the seat of thecentre support and the seat of the flange.
WARNING : Before applying the sealant, all traces of oldsealant should be removed by scraping and blowing the surfaces clean. Degrease the surfaces using trichloroethylene orchlorothene.

Fit a centrifugal cap on the front shaft andinsert the centre support with the othercentrifugal cap.
Refit the flange ensuring that the previously
applied alignment marks are correctly positioned.
Fit the nut retaining the flange on the shaft.
Tighten to 9.5 to 10.5 kg.m and fit locknut.
Check that the spherical seat on the rearflange is in good condition. If necessary,
replace as follows:- Remove circlip (where fitted), using special
pliers, and extract the spherical seat from theflange.

____________

Remove the protecting rubber cap from thefront bush of the rear shaft, after having
removed the retaining ring.
Fit tool no. A.2.0263 to the coupling.
Remove the centre flexible coupling from therear shaft by unscrewing and removing theretaining bolts and washers.
Refit the centre flexible coupling, and ensurethat the housing holes are aligned with thecentering doWels on the flange of the rearshaft.
Fit the retaining screws · and washers andtighten to 4.9 to 5.3 kg.m; stop nuts must be
tightened to 4.4 to 4.9 kg.m.
Refit the rubber protection cap to the bushon the rear shaft and secure by means of thesealing ring. Lubricate the cap and the bushwith approx. 7 cm 3 of Molykote B R 2 grease.
Remove tool no. A.2.0263.

- Fit a new spherical seat, using tool no.
A.3.0244 and retain with circlip.
Complete the assembly of the front propeller
shaft by refitting the sphericaJ seat after
lubrication of the working surfaces with
Molykote paste G Rapid.

Rear coupling on rear propeller shaft
Check the condition of the flexible couplingand dismantle it as follows :- Mark the position of the flexible coupling in
relation to the flange on the rear shaft, inorder to facilitate the re-assembly.

Centre coupling on rear shaft
Clamp the rear shaft in a vice.
Mark the position of the coupling in relation
to the shaft.

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Alfawiki.nl- Fit tool no. A.2.0263 as previously described and disconnect the coupling from theflange by removing the fixing bolts andwashers.

March 197811

____________D_'_s_M_A_N_T_L_'N_G____________~-----------T-R-A-N-S-M-'_SS_'_O_N- Remove the rubber protection cap 1 fromthe flexible coupling, after having previously
removed the retaining ring.

____________- Fit the spherical bearing complete with seat

3 on the spider, using special tool no.
A.3.0244, (2) and secure with circlip.

- Fit the rubber sealing cap to the bush of therear flexible coupling and secure by means of
the special ring.
Check the condition of the spherical bearing
and if necessary, replace it together with thecorresponding spherical seat. Proceed asfollows:- Where fitted, remove the circlip that remains in the spherical bearing, using thespecial pliers.
- Extract the spherical bearing together withthe spherical seat, using extractor no.
A.3.0261. If the spherical seat is provided
with a slot, use general tools.

- Re-assemble the flexible coupling; align themarks previously made and ensure that thelocating holes are aligned with the centeringpins on th.e flange.
- Fit the bolts, flexible coupling to flange,
and tighten to 4.9 to 5.3 kgm (for stop nuts,
4.4 to 4.9 kgm).
- Lubricate the bush and the grease cap of theflexible coupling, using approx. 7 cm 3 of
Molykote B R 2 grease, and fit the grease
retaining cap (which will remain interposed
between the gearbox spider and the rearcoupling), locating its lip over the bush of thecoupling itself.

TO REASSEMBLE
PROPELLER SHAFT- Insert the spherical bearing in the sphericalseat, after having previously lubricated theworking surfaces with Molykote G Rapid
compound.

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March 1978

Re-assemble propeller shaft by aligning themarks on the flexible coupling and the centre
spider. Connect the front propeller shaft tothe .rear shaft and tighten the bolts, using
spanner no. A.5.0192 and a torque wrench(300 to 400 mm) to 4.1 to 4.5 kg.m.
The lock nuts on the propeller shafts and thefitted bolts must be replaced and tightened,using the above spanner, to 3.8 to 4.2 kg.m.

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__

R_EFITTING_~
\(jJJ

_ _
_
TRANSMISSIONREFITTING PROPELLERSHAFT TO CAR
To refit the propeller shaft, proceed in thereverse order, noting the following:

To check tightness of flexible couplings

Lubricate, if this was not carried out during
the overhaul, front bush and spherical seat of
the rear coupling provided with grommet, byapplying 5 and 7 cm 3 respectively of Molykote BR 2 grease; if necessary, add 2 cm 3 ofthe above mentioned grease to the bush of theengine flywheel.

This is the only operation required to be
carried out when servicing the car, with noneed to disconnect the propeller shaft. This
check is not required on propeller shafts using
safety locking nuts.

Lock the engine flywheel, using tool no.
A.2.0290, as for the dismantling, and insert
the bolts fixing the propeller shaft to theflywheel and the spider on the clutch end.
Tighten the bolts, using spanner no. A.5.0192
and a 3000 mm. torque wrench, to 4.1 to 4.5
kg.m.
Clean the thread of the studs fixing thecoupling to the gear control rod and fit thenuts and tighten to 2 to 3.25 kg.m.
The above operation applies to flexible couplings. For solid couplings, proceed as follows:
fit loosely the gear control rod and the fixing
nuts of the coupling. Engage 5th gear andtighten the nuts to the above mentioned
torque.

Check tightening torque of all coupling securing bolts, which must be within 4.1 to 4.5
kg.m using the appropriate special tool.
Proceed as follows:
Disconnect the exhaust pipe, as described onPage 6.
Remove the small cover plate from theflywheel housing and fit in its place tool no.
A.2.0290 which locks the flywheel. Secure thetool with small bolts.

- Check the tightening torque of the rear andfront bolts on the rear coupling, using spanner
no. A.5.0192 (1) and a torque wrench.

Remove tool no. A.2.0290 and fit in its place
the small cover plate on the flywheel housing.
Reconnect the rear engine mounting, using
the displaced washers to ensure the correct
distance between shaft and top of support,
i.e. 7 ± 1 mm.
Refit the exhaust pipe by reversing the removal operation.

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_____________

R_E_F__TT__N_G_____________~-----------T-R-A-N-S-M-I-S-S_IO_N- Check tightening torque of bolts on central
coupling.
- Front bolts, use special tool no. 2(A.5.0190) and torque wrench.

____________- To check tightening torque of bolts onfront coupling.
- Front bolts, use special tool no. 1(A.5.0191) and torque wrench.

- Rear bolts, use special tool no. 2 (A.5.0192)
and torque wrench.
- Rear: bolts, use special tool no. 3 (A.5.0191)
and torque wrench.

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OVERHAUL

-

~f)

.

TRANSMISSION--TO OVERHAUL THE
HALF SHAFTS
INTRODUCTION
It should be noted that any damage to therubber boots means the loss of the lubricant
and ingress of foreign matter, which will
prevent the constant velocity joints fromworking correctly.

Remove the joint from the shaft, using a press
and semi-circular plates A.2.0247 (1), thebase, tool no. A.3.0487 (2) and tool no.
A.3.0479 (3).

To replace constant velocity joint boots

Place the car on a ramp and raise the rear
wheels by means of a suitable jack.

Slacken the bolts securing the half shaft tothe brake disc spacer and to the hub shaft.
Remove the half shaft, retaining the fixing
bolts, washers and plates.

Clamp the half shaft in a vice, remove theboot by separating it from the retaining clips
and pushing it back along the shaft, to enable
the constant velocity joint to be dismantled.
Finally, remove the cup spring and the boot.
Remove the outer cover from the joint andcarefully clean the external part of the joint
with rags. Do not use solvents.

Replace the boot, taking care not to damage
it when pushing it over the splines of the half
shaft. Tape the splines to provide the necessary protection.
Fit the cup spring to the half shaft.

Remove the circlip retaining the constantvelocity joint, using suitable pliers.

Refit the joint to the half shaft, aligning themarks made prior to dismantling it. Place theassembly under a press, and using the semi-Mark the joint in respect of the shaft.

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Fill the inner and outer chambers of the joint
with 70 g. of Molykote VN 2461 C grease or
Optimol Olistamoly 2 LN 584.

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______________
O_V_E_R_H_A_U_l_____________~------------T-R-A-N-S-M-I-S-S_IO_N

circular plates, No. A.2.0247 (1), the base,
tool no. A.3.0487 (2) and the inserter, no.
A.3.0386 (3) as illustrated.

____________

Place the boot on the joint and in the seat provided on the inner cover and on the shaft inthe space between the ribs. Position the retaining clips and tighten with special pliers no.
A.2.0288/0035 and A.2.0288/0062, taking
care not to damage the boot.
Reconnect the half shaft and lubricate thethread of the retaining bolts with Molykote
BR 2 grease. Tighten bolts to 2.8 to 3 kg.m . .

0<'

The half shafts are symmetrical and therefore
interchangeable. The above operation thus
applies to all the constant velocity joints ofboth half shafts.

Refit the circlip, ensuring that it is seatingcorrectly in its seat on the shaft.
Ensure that the grease-retaining rubber seal ison the outer ring of the joint; apply Curil K2
sealant and fit the outer cover.
Apply some Bostik 475 or U.S.M. 475 to thesurface between the boot and the inner coverof the constant velocity joint.
WARNING: It is recommended to apply the boot sealantuni formly and in sufficient quantity, to prevent, i n time, lossof grease. It is also recommended that only the clamping clipsof the type supplied by our Part Department be used, inorder to prevent any out-of-balance condi tion of the half
shafts.

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TOOLSTIGHTENING TORQUES

LUBRICANTS AND SEALANTS

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______________T_o_o_L_s_______________~-----------T-R-A-N-S-M-IS-S-I-O-N____________TOOLS
A'. 5.0190
SPANNER
17 mm Bi -hexagon spanner, L-shaped, forfront bolts of centre coupling

A.5.0191
SPANNER
17 mm Bi-hexagon spanner, L-shaped, forfront bolts of front coupling and rear bolts ofcentre coupling,

A.5.0192
SPANNER
17 mm Bi-hexagon spanner, L-shaped, forfront bolts of rear coupling and rear bolts offront coupling

A.2.0247 *

~

~
.. .

~

.--;:--.

_ .

___ .1_...I L. _.

-1-__ -"-

_

~ _

_

SEMI-CIRCULAR PLATES
for removing the centre support of the front
propeller shaft and for extracting and inserting constant velocity joints on the half shafts,_

A.2.0248 *SEMI-CIRCULAR PLATES
for removing spider from front propeller
shaft ,

A.2.0315 'iF

CLAMP
For fitting front, centre and rear couplings

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______________
To_ o_L_s_____________~-----------TR-A-N-S-M-I-S-S-IO-N----______

A.2.0290
TOOL
for locking flywheel (on the car)A.3.0244 *TOOL
for inserting rear spherical bearing of front
shaft and rear spherical bearing of rear propeller shaft.

A.3.0246=~' -iI- --1

FITTING TOOL
for the front spherical bearing of the front
propeller shaft.

A.3.0261 *EXTRACTOR
for rear spherical bearing and spherical seat of
the front propeller shaft and spherical bearingof the rear propeller shaft

A.3.026S/2 *BASEfor extracting the bearing of the centre
support of the propeller shaft (use with
A.3.0401 )-.;;-':=:=I

01.•t::.":.=.-:l

A.3.0361
EXTRACTOR
for the front spherical bearing and bush of thefront propeller shaft

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______________T_o_o_Ls_____________

Jdb~----------T-R-A-N-S-M-I-SS-I-O-N----______

A.3.0386 *FITTING TOOL
for fitting constant velocity joint into half
shaft (use with A.3.0487 and A.2.0247)

4-!

A.3.0401 *F:='-,~.:::>

10"';0::;'='-:-101

t::::~:~~--JI':"='=='I- c..:-,"::'= :::i

EXTRACTOR-FITTING TOOL
for bearing of centre support for propeller
shaft

A.3.0479
EXTRACTOR
for extracting half shaft from constant velocity joint (use with A.3.0487 and A.2.0247)

A.3.0487
BASE
for extracting and fitting constant velocity
joints on half shafts (use with A.3.0479,
A.3.0386 and A.2.0247). ---...,~

A.2.0288/0035-0062
PLIERS
for fitting retaining clips for constant velocity
joint boots on half shafts

Tools marked thus:1\: are also used on other types of cars.

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Public. nO 2064-Workshop ManualH_TE_N_I_N_G_T~O_R_Q_U_E_S_________T_IG___________~------------T-RA--N_S_M_IS_S_I_O_N___________

TIGHTENING TORQUES

Kg.m.

METHOD OF
TIGHTENING

2 · 3.25

Sealant

Nut on propeller shaft spider

9.5 . 10.5

Dry

Bolts securing half shafts to brake disc spacer and hub shaft

2.8 - 3

With grease

Fixing bolts for propeller shaft (with torque w rench directly applied)

4.9 - 5.3

Dry

Fixing nuts for propeller shaft, with use of special spanner and 300 or
400 mm torque wrench

4.1 - 4.5

Dry

Locking nuts for fitted bolts (with use of special spanner and 300 or
400 mm torque wrench)

3.8 - 4.2

Dry

Locki ng nuts for fitted bolts (with torque wrench directly applied)

4.4 - 4.9

Dry

DESCRIPTION

Nuts, fix ing selector rod to flexible joint

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_______L_U_B_R_'C_A__
N_TS__A_N_D_S_E_A_._LA_N_T_S_______~--------____T_R_A_N_S_M_'S_S_'_O_N____________

LUBRICANTS AND SEALANTS

DESCRIPTIONCOMMERCIAL EQUIVALENT

Grease for :- Bol t th reads securing half shafts to brake discspacers and to hub shaft- Bush and grease cap on rear coupling of propel ler
shaft- I nner and outer surfaces of front bush (5 cm 3 )ISECO MOL YKOTE BR 2

- Bush of propeller shaft and rubber cap on centre
coupling- Bush of engine flywhee l .
Grease for :- Working surfaces of spherical bearing and bushfor taking up front clearance of propeller shaft

ISECO MOL YKOTE COMPOUND G RAPID- Working surfaces of spherical bearing and centre
and rear spherical seat of propeller shaft.
Sealant liquid for :- Spl ines of spider and centre propeller shaft support and seat on shaft for centre support bearing
Grease for :- Constant velocity joint on half shafts (70 g)

lOCTITE 242

ISECO MOL YKOT E VN 2461 C
OPTIMOl OLiSTAMOL Y 2 LN 584

Compound for :- Surface connect ing outer cover of constant velocity joint on half shaft

CURIL K2

Compound for :- Surface connecting boots to inner cover of
constant velocity joint on half shaft

BOSTIK475
U.S.M.475

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______________o_V_E_R_H_.A_u_L_____________~----------F-R-O-N-T-S--U-S-p_E_N_S_IO_N__________

1 - Torsion bar
2 - Upper wishbone
3 - Lower wishbone
4 - Caster rod
5 - Anti-roll bar
6 - Shock absorber

FRONT SUSPENSION
The front suspension is independent, bymeans of wishbones. The flexible element isprovided by two longitudinal torsion bars inplace of coil'springs. The torsion bars are attached at the front to the lower wishbones
and at the rear to the body.

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The suspension also comprises hydraulicdouble-acting shock -absorbers, passing
through . the upper wishbone and locatedbetween the body and the lower wishbone.
Cornering is improved by an anti-roll bar. The
upward and downward movement of thewishbones is restricted by the rebound stop
secured to the chassis cross-member.
This new front suspension design, together
with an even distribution of the weight, results in an exceptionally light steering.

November 197523

______________R_E_M_o_V_A_L_____________~---------F-R-O-NT---S-U-S-PE-N-S_I_O_N__________TO REMOVE THE
FRONT SUSPENSION
Place the car on a ramp. Load the car statically and slacken the road wheel nuts.
Raise the car and support it on stands.
Remove the road wheels. Remove the front
valance by removing the securing screws.
Remove anti -roll bar 1, complete with links,
separating it from its fixing points on the
body and from the pivot points of the lower
wishbones by removing bolts 2 and nuts 3.

Disconnect the shock absorbers from thelower wishbones by removing the retaining
bolts.

To remove the lower wishbone and torsion
bar
Fit to the lower wishbone special tool no.
A.2.0265 (4) locating it in the two registers
which are provided near the shock absorberlocating point.
Raise the lower joint, using tool no. A.2.0069(5) and jack no. R.7.0010, in order to movethe upper wiShbone away from the reboundstop.
Disconnect the lower wishbone from the stubaxle, by tool no. A.3.0377 (6) freeing theswivel pin, after first removing the retaining
nut. Lower the wishbone to release the loadfrom the torsion bar.

From the engine compartment, disconnect
the shock absorbers from the body anchorage
points, by removing the locknuts, retaining
nuts, washer, and the appropriate rubber
buffer.
For the latter operation, and when working
on the LH side of the car, it is necessary to
disconnect the expansion tank.

Remove the small cover over the torsion baron the rear crossmember. Mark the alignment
components if not already marked. Fit extractor no. A.3.0374 and extract the torsion bar
from its seat.

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November 1975

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REMOVALd8 _ _~

Remove the lower wishbone by withdrawing
the bolts, associated spacers and washers
which secure the wishbone mounting bracket
to the body.

FRONT SUSpeNSION

Disconnect the steering linkage from the stubaxle by using tool no. A.3.0376 after removing
the castellated nut and split pin.
Disconnect the stub axle from the upper
wishbone after removal of the retaining nut
by freeing the swivel pin using tool no.
A.3.0377.

To remove upper link
From inside the engine compartment, remove
lock nut 1 securing the caster adjustment
rod to the body and remove it together with
washer 2 and rubber pad 3.
Remove the upper wishbone by disconnecting
the appropriate securing bolt 4.

Remove the torsion bar from the rear crossmember by extracting it from the front.
Proceed as detailed above for the other side of
the car.

To remove the stub axle from the upper link

Proceed as detailed above for the opposite
side. When working on the LH side of the car,remove the battery, and where fitted, thealternator air intake shield.
Finally, disconnect the rear crossmember
supporting the torsion bars, by removing thesecuring bolts, thus completing the dismantling operation of the front suspension.

Remove the brake pads, extracting the retain ing pins and cross-shaped spring.
Remove the brake caliper from the brake discby unscrewing the retaining bolts, and attach
it to the bracket for the brake fluid pipe
connection, using a wire or string.

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November 197525

____________D_I_s_M_A_N_T_LI_N_G____________~~---------F-R-O-N-T- S-U_S_P_EN_S_I_O_N__________DISMANTLING
To dismantle the wheel hub and stub axle
assembly on the bench

Check bearings for signs of wear or seizure.

Dismantle the assen:!bly as follows:

Check condition of hub and stub axle andreplace these if necessary.

- Remove hub cover cap. Withdraw split pin
and remove hub securing nut.

Upper link

- Extract wheel hub from the stub axle, together with brake disc, retaining the innerrace of the outer bearing.

Check that the upper link, caster adjustment
rod and swivel pin are in good condition andnot distorted. Replace these parts as required.

- Remove the splash shield by removing thethree retaining nuts.

Check 'condition of caster adjustment rod
mounting pads and upper link rubber mountings. Replace these as required.

- Remove wheel hub from the brake disc byremoving the two retaining screws.

To remove the hub bearings

When replacing rubber mountings, use tool
no. A.3.0367 (1) (outer part only) and tool
A.3.0368 (3) for extracting purposes. Usetool A.3.0367 (complete with inner part andtaper bush 2) and tool A.3.0368 for inserting.
Insert the mounting from the chamfered end .

Extract the outer bearing outer race fromthe hub, using tool A.3.0378 and a press or avice, as illustrated.

Rear cross member
Extract the oil seal with outer race of innerbearing from the hub, using tool no. A.3.0379
and a press or vice, as illustrated.

26

November 1975

Check condition of the rear crossmember
rubber mountings, and replace these as required, using tools A.3.0422 and A.3.0423. It

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should be noted that for extracting the rubber
mounting the base of tool A.3.0423 must be
used. When fitting the mounting, use the same
tool in the opposite way, in order to determine the fitted depth of the mounting.

__________- Fit tool (5) A.3.0372 to the front of thewishbone, using the threaded mounting
bracket, and extract the bushes.

Lower wishbone
Check conditions of lower wishbones, swivel
pins and bushes.

If necessary, replace the bushes as follows:- Clamp the lower wishbone in a vice andremove the protruding washer from thetorsion bar seat.
- Remove palmutter nut 1 and threaded cap 2
from the front end of the wishbone andremove nuts 3 with corresponding washers,
securing the bushes to the wishbone mounting

4.

Remove tool A.3.0373 and withdraw the rear
bush; withdraw wishbone mounting and front
bush by removing tool A.3.0372.
To reassemble, operate in the reverse order.
Make sure that:- the protected side of the bushes are turned
towards the wishbone support;- front bush is locked by means of tool
A.3.0373; tool A.3.0372 must be at torsion
bar side.

Insert in the torsion bar seat the serrated ring
tool no. A.3.0373, and secure to the threaded
pin of the mounting bracket, by means of any
type of nut, except a thin one.

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November 1975'27

____________D_I_s_M_A_N_T_L_IN_G____________~----------F-R-O-N-T-S-U-S_P_E_N_S_IO_N- Lubricate the inner cavity between bushes
and lower wishbone with Molykote LONG TERM No.2 grease (6 grs).
- Secure the wishbone mounting by tightening the respective nuts and washers to 3 to 3.5
kg.m.
- Tighten the threaded cap to the front of thelower wishbone to 2 to 3.5 ~g.m.
- Retighten the palmutter nut to 6 to 7.2
kg.m.
To replace the ball swivel on the lower
wishbone
Replace the ball swivel on the lower wishbone. To extract it, use a press, tool A.3.0441(A) and part (8) of tool A.3.0435.

__________At this stage ensure that the alignment markon the ball joint coincides with that on theseat of the wishbone to prevent misalignment
damage which would adversely affect theperformance of the ball joint.
Fit the connecting nut to the wishbone
without tightening it.
Shock absorbers- Check the condition of the stem and cylindrical body of the damper and ensure thatthey have not been distorted.
- Check that the boots are intact and thatthey are no fluid leaks from the cylindricalbody.
- Check the efficiency of the shock absorbers
by mea\uring on a special test rig, their
damping capacity at low and high speeds.
The readings should meet the data given on
page 52.
- The front and rear shock absorbers of eachcar should be matched together as shown by
the table con page 52.

To insert, use tool A.3.0442 (D) together
with parts C of tool A.3.0440 and E of tool
A.3.0435.

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___________R_E_-_A_s_s_E_M_B_L_IN_G___________~---------F-R-O-N-T-S_U_S_P_E_N_S_I_O_N__________RE-BUILDING
Anti-roll bar and links

To re-assemble wheel hub

Check the condition of the rubber mountings,
bushes, links and antiroll bar.

Fit the hub bearings as follows:

Should one or more of the above parts needreplacing, proceed as follows:- Insert the outer bearing outer race in thehub, using tool A.3.0328 (1) and a press or avice, as illustrated.

- Apply markings on the bar and link.
- Separate the link from the anti -roll bar,using a press.
- Using a press remove the rubber bush andfit replacement.

- Before fitting the links, slide off th~cmtirollbar the worn rubber mountings and fit new
ones. Prior to fitting them, lubricate theirinternal surfaces with :-ERGON RUBBER GREASE NO. 3 ISEeOSFERUL B2 AR - REINACH OLEOBLITZ.

- Fit the inner bearing outer race by means oftool A.3.0329 (2), using a press or vice, as illustrated.

- Apply similar markings on the new components as on the discarded ones. Clamp theanti-roll bar in a vice and insert the link on
the bar's pin , using tool A.3.0346. Ensure thatthe previously applied markings are aligned.

At this stage of assembly, apply some greaseat the rate of 55 grs. per hub, spreading it
uniformly inside and on the sides of the bearings.
Do not exceed this quantity, to prevent thebearing from being overloaded, thus causing
overheating, loss of grease etc.

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March 197829

___________R__
E._A_S_S_E_M_B_L_I_N_G___________~----------F-R-O-N-T-S_U_S_P_E_N_S_IO- Fit the inner bearing inner race. Fit the oilseal after lubricating it with differential oil.
Fit race by means of tool A.3.0459 (1) and apress or vice.

__
N__________- Improve the seating of the bearings by tapping with a mallet on the end of the stub axle.
- Check that the retaining washer of the bearing is not locked. This is done by inserting ascrewdriver in one of the radial holes to checkthe clearance.
- Should the washer be locked, slacken the
nut by one notch and tap again lightly with amallet on the end of the stub axle.

To fit the hub to the stub axle
Fit the splash shield to the stub axle, andsecure it by means of the nuts. Carefully clean
the brake disc and fit it to the hub.
Carefully clean the stub axle and lubricate itwith Molykote B R2 grease, also the lip of theoil seal.
Fit the hub-disc assembly to the stub axle,
noting the following:- Tighten the hub retaining nut to 2 to 2.5
kgm. At the same time rotate the hub to assist
the seating of the bearings in their seats, andto prevent the rollers causing damage to theraces.
- Slacken the nut and tighten it again, using atorque wrench, to 0.5 to 1 kg.m.
- Slacken the nut by 90° and fit the split pin,
if the hole on the shaft aligns. If it does not,turn the nut as little as possible, until theholes align.

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______________R_E_F_'TT__'N_G______________~----------F-R-O-N-T-S-U-S-P-E_N_S_'_O_N__________RE-FITTING THE SUSPENSION
Reassemble the front suspension
reverse order, noting the following:in theUpper link
If previously removed, refit the caster adjustment rod. Position the rubber mounting andwasher on the rod.
Position the upper link on the body and insert
the securing bolt in its seat, having previously
lubricated it with 'Never Seez' grease, manufactured by R. Gori.

9.2 kg.m. Ensure that the protective plastic
washer is located in the seat of the torsion
bar, smear the splines with the anti-seizing
compound used for the rear splines, and insert
the torsion bar into its seat aligning the marks
previously applied.
NOTE: On the lower wishbone, the anchoring points of theanti-roll bar links must be lubricated with Never Seez compound, manufactured by R. Gori.

Stub axle

Position the rubber mounting and the washer
for the engine compartment and offer theretaining nut to the body panel.

Layout the tools A.2.0265 and A.2.0069,
as detailed on page 24 and load the torsion
bar in such a way that both the lower wishbone and the upper link can be connected tothe stub axle.

Lift the upper link 1 to 2 mm. from the bumprubber, thus bringing it into its datum
position. Tighten the link retaining bolt andthe camber adjustment rod securing nut to 4
to 4.5 kg.in.

Tighten the nuts on the ball joints; torque to
8.2 to 9.2 kg.m. for the upper ball joint nut.

Rear crossmember and torsion bars
Fit the rear crossmember supporting thetorsion bars and tighten the securing nuts to
8.2 to 9.2 kg.m.
Apply Never Seez compound, made by R.
Gori, to the torsion bar seats. Fit the torsion
bars. It should be noted that these have 35
splines at the front and 34 at the rear. The
following identification marks are used:
RH bar
LH barBlue mark and letter 0 or R at
front of bar
Yellow mark and letter S or L
on front of bar.

Separate the lower wishbone from the tools
and tighten the nut securing the lower balljoint to the wishbone to 1.5 to 2 kg.m.
Proceed similarly on the opposite side of thecar.
Complete the assembly, noting the follovying:
The brake caliper securing bolts should betightened to 7.5 to 8.5 kg.m.
Ensure that the working surfaces of the brakediscs are clean, before fitting the pads to thecaliper.
Check vehicle suspension height.
Check the front suspension geometry.

Lower wishbone
Position the lower wishbone against the body,
locating the respective spacers between thelongitudinal member and the mounting pin of
the wishbone, in line with the retaining bolt
holes. Insert the bolts and tighten to 8.2 to

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November 197531

__________P_A_R_T_IA__
L_o_P_E_R_A_T_Io_N_S_________~----------F-R-O-NT__S_U_S_P_E_N_S_I_O_N__________PARTIAL OPERATIONS
To disconnect anti-roll bar
Proceed as detailed on page 24 noting the fol lowing:- It is not necessary to load the car statically.
- It is not necessary to remove the roadwheels.

- It is not necessary to weight the car statically.
- It is sufficient to slacken and remove bolts 1
securing the brake disc to the hub.
- It is not necessary to remove the stub axle
from the wishbone.

To disconnect the shockabsorbers
Proceed as described on page 24 noting thefollowing :- It is not necessary to load the car statically.
- It is not necessary to remove the anti-rollbar.
- Road wheel removal is optional.

To remove the caster adjustment rod mountings
To remove and refit the mountings for thecamber adjustment rod, proceed as follows:- Jack up the car and remove the wheel.

To disconnect the hub from the stub axle
Carry out the operations detailed on pages 25
and 26 noting the followin g:- Slacken and remove the nut retaining therod to the body . Remove the washer andcorresponding mounting.
- Slacken the locknuts on the adjuster.

- It is necessary to remove the road wheel on
the side of the car in question .
- It is not necessary to re move the brakecaliper.

32

Nove mbe r 19 75- Mark the position of the adjuster and screw
it down completely to enable the inner
mounting pad to be removed . If necessary,
push the upper link backwards.

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__________
P_A_R_T_IA_L_o_P_E_R_A__
TI_o_N_S_________~----------F-R-O-N_T_S_U_S_P_E_N_S_I_O_N__________- Fit the new mounting pads. Bring theadjuster to its original position. Move theupper link 1 to 2 mm. away from the reboundpad thus bringing it to its nominal position
and tighten the nut securing the rod to thebody.

- Disconnect the shock absorber completely.

- Fit the road wheel and check the front
suspension geometry. (see section on vehicle
height).

- Finally, remove the upper link by withdrawing the bolt securing it to the body, and by
removing the caster adjusting rod .

- Disconnect the brake caliper.
Disconnect the steering linkage,proceed as detailed on page 25.

and- Tighten the locknuts on the adjuster.
To remove stub axle
To remove lower wishbone
Carry out the operations detailed on page 24
noting that it is not necessary to remove theshockabsorber from the body.

To remove the ball joint from the lower
wishboneThe lower ball joint can be replaced without
disconnecting the wishbone from the bodyand without removing the anti-roll bar.
Disconnect the lower wishbone from the stubaxle. Replace the ball joint as follows:- Extract ball joint using tools A.3.0440 and
A.3.0441.
- Fit a new ball joint, using tools A.3.0440
and A.3.0442.

To remove upper link
To remove the upper link, carry out theremoval operations as for the lower wishbone,noting the following:- Disconnect the top ball joint from the stubaxle.
- Release the bottom wishbone as detailed on
page 24.

Public. nO 2064-Workshop Manual

Alfawiki.nl- Disconnect the stub axle from the wishbone
and upper link. Proceed as for the disconnecting of the upper link.
- Remove the ball joints from the lower wishbone and upper link. Proceed as detailed on
pages 24 and 25.
- Dismantle the stub axle as detailed on page25.

To remove the crossmember and torsion bars
To remove the crossmember, carry out theoperations for disconnecting the lower wishbone, noting the following:- Do not detach the lower wishbone from thebody.
- The same procedure applies to both sides of
the car.
Remove the crossmember by withdrawing thetorsion bars from their seats and by removing
the crossmember retaining bolts from thebody.
WARNING: Check the front suspension geometry (seeChapter on suspension/ vehicle height) after each partial operation, which includes the removal of the wishbones, torsion
bars or the stub axle.

To reconnect parts disconnected during thepartial operations described above, proceed in
the reverse order.

November 1975

33

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TOOLSTIGHTENING TORQUES
LUBRICANTS
ANTI-SEIZING COMPOUNDS

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_____________T_o_o_L_s__~_________~---------F-R-O-NT--S-U-SP-E-N-S-IO_N_________

TOOLS
A.2.0069
SUPPORT TOOL
for A.2.0265 for tightening and releasing
torsion bars.

A.2.0265
TOOL
for tightening and releasing torsion bars (to be
used together with A.2.0069)

A.3.0328 *FITTING TOOL
for front hub outer taper bearing outer race

A.3.0329 *FITTING TOOL
for front hub inner taper bearing outer race

A.3.0346

FITTING TOOL
for link on anti-roll bar pivot

A.3.0367
BASE
for extracting and fitting rubber mountings
for upper link. (To be used with A.3.0368)

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_______________T_o_o_Ls_____________~---------FR-O-N-T--SU-S-P-E-N-S-IO__
N_________

A.3.0368
EXTRACTOR-FITTING TOOL
for rubber mountings on upper link (to be
used with A.3.0367)

A.3.0372
EXTRACTOR-FITTING TOOL
for lower wishbone bush (to be used with
A.3.0373)

A.3.0373
RING
serrated ring for extracting the bushes fromthe lower wishbone (to be used with
A.3.0372)

A.3.0374
EXTRACTOR
for torsion bar

A.3.0376 *-----1- \ ---- ~\-'~

r~."r-\

II

\

\

I

L------ -~ - - -\'_ . . . - I. .r---=-Ji!!l'!!!!!!I!~EXTRACTOR.

for ball joint on steering arm

A.3.0377
EXTRACTOR
for upper and lower ball joints on stub axle

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November 197537

_______________
To_o__
Ls_______________~][~---------F-R-O-N-T-S-U-S-P-E-N-S_I_O_N__________

A.3.0378

EXTRACTOR
for front hub outer bearing outer race

A.3.0568
EXTRACTOR
for front hub inner bearing outer race

A.3.0422
PUNCH
for extracting rubber mountings for crossmember (to be used with A.3.0423)

A.3.0423
BASE
for extracting and fitting crossmember rubber
mountings (to be used with A.3.0422)

A.3.0435
FUNNEL(Part of tool) for extracting/fitting ball joint
on lower wishbone, on the bench

A.3.0440

EXTRACTOR-FiniNG TOOL
for ball joint on lower wishbone on car

38

M arc h 1978

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Public. nO 2064 -Workshop Manual---~--TOOLS~FRONT SUSPENSION

A.3.0441

RING
for extracting ball joint on lower wishbone

A.3.0442

RING
for extracting ball joint on lower wishbone

A.3.0459

FITTING TOOL
for front hub oil seal

R.7.0010 *JACKcolumn type for car hoisting,ifTools marked with an asterisk are also used on other models.

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November 197539

_ _ _a\(]JJ_ __DATA

FRONT SUSPENSIONTIGHTENING TORQUES
kgm

METHOD OF
TIGHTENING

Nuts at end of lower wishbone mounting bracket

3 to 3.5

Dry

Threaded cap on lower wishbone

2 to 3 .5

With sealant

Locknut for ring nut on lower wishbone

6 to 7 .2

Dry

Securing nut for ball jOint to lower wishbone

1.5 to 2

Dry

Nuts fixing lower wishbone mounting bracket to body

8.2 to 9.2

Dry

Nuts fixing upper link to stub axle

8.2 to 9 .2

Dry

Nut fixing camber adjusting rod to body

4 to 4.5

Dry

Bolt fixing upper link to body

4 to 4.5

With anti-seizure
compoundBolts f i x ing crossmember to body

8.2 to 9 .2

Dry

Bolts fixing brake calipers to stub axl e

7.5 to 8.5

Dry

DESCRIPTIONLUBRICANTS AND ANTI-SEIZING COMPOUNDSDESCRIPTION

Grease for:I nternal cavity of hub
Grease for:Lip of oil seal for hub and working area
on stub axle.

QUANTITYCOMMERCIAL EQUIVALENTS

50 g

AGIP FI GREASE 33 FDSHELL RETINAX AX
IP AUTO GREASE FDISECO MOL YKOTE BR 2
Suffici ent
quantity
AGIP F1 ROTRA MP SAE 85 W /90
SHELL SPIRAX HD 90
IP PONTIAX HD 85 W 90

NOTE : Before fitting it to the hUb. moisten
the outer surface of the oil seal.
Grease for:- In terna l surface of rubber bushes on antiroll bar supports.
Grease for:- Inner space
wishbone

between

bush

and

lower

Anti-seizure compou n d for:- Upper link sec uring bolts- Small mounting on lower wishbone foranti -roll bar l ink- Torsion bar spli nes

AP I - American Petroleum Institute40

Marc h 1978

Sufficientquanti ty

ISECO ERGON RUBBER GREASE N . 3
REINACH OLEOBLITZ SFERUL B2 AR

6g

MOLYKOTE LONG TERM N o.2

Sufficientquantity

R . GORI NEVER SEEZNLGI - N atio nal Lubricating Grease Institute

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SAE - Society of Automotive Engineers

Publ ic. n° 2064-Workshop Manual__ _ dJ1)\(]J! _ __OVERHAULREAR SUSPENSION

6

1 - De Dion axle
2 - Transverse link
3 - Anti-roll bar
4 - Bump rubber
5 - Spring
6 - Shock-absorber

REAR SUSPENSION
The rear suspension features a De Dion typeaxle.
This design which combines the advantages of
the rigid rear axle with those of the independent axle, allows a reduction of unsprungweight together with an improved rear wheel
geometry which ensures that the wheels
always remain parallel to each other, providing thus excellent adhesion on corners anduneven surfaces.
The De Dion axle, which is of tubular construction and triangular shape, is connected at
the front to a crossmember by means ofrubber mountings. This crossmember in turnis bolted to the body.

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The De Dion axle is controlled by a Watts
linkage which is anchored on the body by abalance lever, which is in turn linked to thebody by means of two crossmembers.
The bars of the Watt's linkage, by acting as
struts or tie rods with forces equal to thosetransmitted by the wheels to the axle, prevent
any lateral movement of the body.
The rear suspension comprises also variable
rate coil spring, covered with a sound-absorbing plastic material, telescopic hydraulic shock
absorbers, and an anti-roll bar.

November 197541

---~---REMOVAL~REAR SUSPENSIONTO REMOVE THE REARSUSPENSION
Preliminary operations

To remove the rear axle

- Place the car on a ramp and slacken the rearroad wheel nuts.

Disconnect the half shaft on the hub side byslackening and removing the bolts 3, also associated washers and plates. Take care not todamage the boot on the constant velocity
joints 4.

- Fit tool no. A.2.0075 (1) to jack no.
R.7.0010 (2); then raise the car and place on
stands approx 40 cm. high.
Remove road wheels and retain wheel nuts.
Lower the jack.

Support the axle .

Remove exhaust pipe as detailed on page 6 .

Disconnect the anti-roll bar from the axle byslackening and removing the retaining nuts 5,
together with the rubber bushes and washers.

Disconnect gear selector rod from the selector lever and from the lever on the clutch
cover, proceeding as detailed on page 6.

Disconnect shock absorbers 6 from the mounting brackets by removing the nuts, locknuts
and rubbe r bushes.

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November 1975

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\(]JJ--~-REMOVALREAR SUSPENSION

Disconnect the transverse links of the Wattlinkage 1 from the body by removing the fixing bolts 2.

Fit tool R.4.0150 (6) to the gearbox/rear axle
unit. Support the assembly by means of acolumn-type jack and proceed as follows:- Disconnect the propeller shaft from theclutch spider by slackening and removing theretaining bolts 7 from the flexible coupling.
- Slacken the securing bolts 8 between axle
and front crossmember.
- Detach the front cross member from thebody by slackening and removing retaining
bolts 9.

Lower the axle by means of the jack, until thesprings 3 are completely free and remove
them from their seats together with the rings
4 and rubber pads 5.

Detach the front cross member from thegearbox/rear axle unit by slackening andremoving the retaining bolts 10. At this stageof the operation it becomes necessary tomomentarily support the rear axle.

Disconnect the speedometer drive cable fromthe drive shaft.
Disconnect the electric cables from the reverse light switch.

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November 197543

______________R_E_M_O_V_A_L_____________~----------R-E-A-R-S-U-S-P-E-N-S_I_O_N

Place the removed items on the ramp. Separate the axle from the crossmember by removing the anchoring bolt 1.

__________To disconnect anti-roll bar
Disconnect the links from the anti-roll bar byremoving the securing bolts.
Slacken and remove the bolt securing the antiroll bar mountings to the body. Withdraw
mountings.
Disconnect the handbrake cable from thebrake caliper levers.
Fit the column-type jack to tool R.4.0150
and raise the gearbox/differential unit, inorder to allow the removal of the bolt securing it to the body.
Finally, lower the assembly to enable the antiroll bar to be withdrawn.

Refit temporarily the front crossmember tothe body, in order to support the gearbox/
rear axle unit when removing the jack, toallow the complete withdrawal of the axle
assembly.

To disconnect the shock absorbers from thebody
Disconnect the shock absorbers from theiranchoring points on the body, proceeding asfollows:
From inside the boot, remove the wing nuts
retaining the rear squabs.

44

November 1975

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Public. nO 2064 -Workshop Manual

____________D_Is_M__A_NT__
LI_N_G____________~----------R-E-A-R-S-U-S-P-E_N_S_IO__
N__________DISMANTLING
Move the rear seat and remove the squab byunscrewing the bolts which secure it to thewheel arch.

To dismantle rear axle
Secure the axle assembly to the bench andremove the Watts linkage from the pivot by
removing the securing nut for the balance
lever, after breaking the caulking. Where
fitted, remove also the washer.
Disconnect the Watts linkage from the balance
lever by removing the securing nuts.
Remove hub and half shaft from the axle.
Proceed as follows:
Withdraw split pin and remove locknut fromthe half shaft securing nut.
Fit tool A.2.0131 (2) to half shaft flange.
Slacken the nut securing the hub to the half
shaft, using tool A.5.0163 (3).

Disconnect the shock absorbers by removing
the locknuts and securing nuts.
Remove the cups together with the rubber
bushes 1.

Extract the hub, using tools A.3.0327,
A.2.0281 and A.2.0131 (the latter having
been fitted previously), proceeding as follows :Public. nO 2064·Workshop Manual

Alfawiki.nl

November 197545

____________D_I_s _M_A_N_T_Ll_N_G____________~----------R-E-A-R-S-U-S-p_E_N_S_I_O_N

Fit tool A.3.0327 (1) to the hub. Interpose
tool A.2.0281 (2) between axle and half shaft
flange . Rotate the hub until it is locked bytool A.2.0131. At this poi nt, proceed to
extract the hub by operating tool A.3.0327.

__________

Check condition of De Dion axle, Watts linkage, balance lever and all rubber mountings.
If necessary, replace the rubber mountings at
the anchoring points between axle and crossmember. Proceed as follows:
Extract the rubber mounting from its seat
together with upper and lower washer, using
tool A.3.0435 operated by a spanner.
Place the lower washer in its seat. Insert the
new rubber mounting using tool A.3.0435
complete with guide tunnel.
Fit the upper washer. Caulk the .edge of theseat of the rubber mounting, using tool
A.2.0269.

To replace rubber bushes for Watts linkage
and balance lever
Remove the tools and half shaft.
Remove the caulking from the ring nut securing the hub bearing. Unscrew the ring nut,
using spanner no. A.5.0187 (3).

Extract the bushes from the Watts linkage using tools A.3.0443 and A.4.0444 and a press.
Replace bushes, using the identical tools, butinserting them from the chamfered side.
Extract the balance lever bush, using tools
A.3.0445 and A.3.0446 and a press. Fit thebush, using the same tools, but inserted fromthe chamfered side.
Anti-roll bar
Check the condition of the rubber pads 1 on
the links connecting the anti-roll bar to the
De-Dion axle; replace the pads, if damaged.
Check that the rubber mountings 2 securing
the anti-roll bar to the body are in good condition. If necessary, replace the mountings.
Before fitting new mountings these should be
lubricated on their internal surface with:It should be noted that the ring nut has aleft-hand thread on the LH side and a R H
thread on the R H side.
Extract the bearing from the hub by means oftool A.3.0432 operated by a spanner.

46

Marc h 1978

- SPAGRAPH by RN RENAULT- ERGON RUBBER GREASE NO. 3 by
ISECO
- SFERUL B2 AR REINACH OLEOBLITZ

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Public. nO 2064 -Workshop Manual

\I]JJ---~--DISMANTLINGREAR SUSPENSION

Check the condition of the rubber bushes 3
seated in the eye of the anti-roll bar. If necessary, replace them as follows:- take away the stakings from the distancepieces and remove the worn parts;- fit the new rubber bushes, the washers andthe distance pieces; then, stake again the
distance pieces in place with tool A.2.0298.

Road springs
To check the efficiency of the springs, measure, under static load, the distance between
the spring cup and the bump rubber pad (seepage 59).
If spring replacement is necessary, fit springsof the same grade to each axle. Furthermore,
the variable rating coil springs (A) must be
fitted with the variable coils pointing toward
the axle.

Check the shock absorbers by measuring their
damping capacity at high and low speeds.
The readings should meet the data given on
page 52.
- The front and rear shock absorbers of eachcar should be matched together as shown by
the table on page 52.

For tables stating spring grade, loads and partnumbers, refer to the "Inspection Specs".

Wheel hub bearings
Check the hub bearings for signs of excessive
wear and or seizure.

Rebound rubbers
Check the condition of the rubbers which
determine the end of the compression strokeof the springs. Replace rubbers if required.
To facilitate the replacement, lubricate thespherical head of the rubber, and fit it underpressure in its locating hole on the body.

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March 197847

______R_E_-_A_S_S_EM__
B_LI_N_G_A_N_D__R_E_FI_TT__
IN_G_____~------____R_E_A_R_S_U_S_P_E_N_S_I_O_N__________

RE-ASSEMBLINGTO RECONNECT
THE SUSPENSION

To fit wheel hub

To re-connect anti-roll bar

Fit hub bearing, after previously cleaning andlubricating its seat. Use fitting tool A.3.0432.

Place the anti-roll bar, complete with rubber
mountings and bushes, in position, and secure
to body.

Fit ring nut to lock the bearing, using tool
A.5.0187 and tighten to 23 to 27 kgm. Lockby caulking on diametrically opposed sides.
Fit hub, using tool no. A.3.0432.
Insert the drive flange and fit tool A.2.0131(1) to flange. Fit the nut securing the hub tothe drive flange, using tool A.5.0163 (2) andtighten to 27 to 33 kgm.
After tightening the hub securing nut, apply
the RUST VETO 1064 greasy-film compoundby HOUGHTON to the drive flange threads
with a brusch.

Raise the gearbox/differential unit, using acolumn type jack in conjunction with tool
R.4.0150, previously fitted, and secure to
body. Tighten the fixing bolts to 4.5 to 5.5
kgm.
Reconnect the links to the anti-roll bar andtighten the fixing bolts.

To re-connect the shockabsorbers to the bodyReconnect the shockabsorbers to the body inthe reverse order.

Fit lock nut and secure with split pin.
To reconnect the axle
Reconnect the axle in the reverse order, noting the following:- Tighten the crossmember securing bolts to 4
to 4.5 kgm.
- Tighten the bolt securing the front axle
mounting to the crossmember to 9 to 11 kgm.
- Tighten the bolt securing the flexible coupling to the clutch spider using tool A.5.0192 inconjunction with a 300 or 400 mm. torquewrench. Torque: 4.1 to 4.5 kgm. At thisstage, and before proceeding with the tightening, lubricate the centralising seat and theretaining rubber cap, using approx. 7 cm 3 of
MOL YKOTE BR 2 grease.
To refit Watts linkage
Connect the Watts linkage to the balance
lever. Fit the bolts without locking them. It
should be noted that the lower bolt of the R Hlink must have its head turned towards theaxle to prevent fouling.

48

March 1978

Position the road springs, complete with cups
and rubber pads and raise the axle. Connect
the shock absorbers after having previously
coated the stems with NEVER SEEZ
compound manufactured by R. GORI.
Also reconnect to the axle:

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_________P_A_R_T_IA__
L_O_P_E_R_A_T_IO__
N_S_________~----------R-E-A-R__S_U_S_P_E_N_S_IO_N___________PARTIAL OPERATIONS- Anti-roll bar links,- Watts linkage, securing it to the pivot on theaxle, using a retaining bolt and the abutment
washer. Do not lock at this stage.

For refitting the parts disconnected or
removed during the partial operations,proceed jn the reverse order.
To disconnect the rear shock absorbers

Connect the Watts linkage to the body. Fit
the bolts which should also be coated with
NEVER SEEZ compound, manufactured by
R. GOR I, but do not tighten at this stage.
Reconnect the half shafts to the stub shafts.
Lubricate the retaining bolts with MOL YKOTE BR 2 paste and tighten to 2.8 to 3
kgm.
Fit the road wheels. Establish the correct
vehicle/suspension height and tighten:- Nut securing balance lever to axle andcaulk.
- Bolts securing the Watts linkage to the bodyand balance lever.

Place the car on a ramp.
Remove rear seat. Release the squab byunscrewing the retaining bolts securing it to
the wheel arch and releasing the wing nuts
accessible through the boot.
Disconnect the shock absorbers from theiranchoring points on the body by unscrewing
the locknuts, ~retaining nuts and removing
these together with the rubber bushes and cup
washers.
(See illustrations on page 44 and 45).
Raise the car and disconnect the shock absorbers from the De Dion axle, by unscrewing
the locknuts and retaining nuts and removing
the rubber bushes 1 and cup washers 2.

- Anti-roll bar bushes, near the rubber caps,
to prevent any possible lateral movement of
the bar.
Reconnect the speedometer drive cable, theelectric wires and adjust the hand-brake cable.
Check the correct vehicle/suspension height.
Check rear wheels geometry.

To disconnect the anti-roll bar
Raise the car on a ramp:- Disconnect the speedometer drive cablefrom the drive spindle.

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November 197549

_________P_A_R_T_I_A_L_O_P_E_R_A_T_I_O_N_S_________~~-----------RE_A- Disconnect the handbrake cable.

__
R_S_U_S_P_E_N_S_I_O_N__________- Disconnect the electric cables from thereverse light switch.

Disconnect the balance lever from the axle byremoving the fixing bolt, after having previously removed the caulking, and where fitted, the washer.

Disconnect the bar links, retaining the rubber
mountings, cups and fixing nuts.

Remove the bolts securing the Watts linkage
to the balance lever and withdraw the linkage.
Replace the rubber bushes on the bench, asdetailed on page 46.
Reassemble the Watts linkage by connecting
the linkage to the balance lever and inserting
the retaining bolts, but without tightening
these. Fit the lower bolt securing the R H
linkage with its head turned towards the axle,
in order to avoid any fouling the axle.
Connect the Watts linkage to the axle byinserting the bolts securing the linkage to thebody and fitting the nut securing the balance
lever to the pivot bolt and all remaining bolts.
Do not tighten fixings at this stage.

Remove the supports securing the anti-roll bar
to the body.

Place the car in its normal height position.
Tighten the linkage securing bolts. Tighten
the nut securing the balance lever to the axle
and caulk.

Remove the anti -roll bar links from the bar by
unscrewing the fixing bolt.
Support the gearbox/ differential unit bymeans of a column type jack. Release thisassembly from the body anchoring point by
removing the fixing bolt.
Lower the jack and gearbox/ differential
assembly sufficiently to allow the anti-roll bar
to be withdrawn.

To replace the Watts linkage rubber mountings
Raise the car on a ramp .
Disconnect the Watts linkage from the bodyby removing the relevant fixing bolts.

50

November 1975

To replace a stub shaft, hub and bearing
Place the car on a ramp. Slacken the roadwheel nuts on the wheel in question.
Support the car on a stand and remove thewheel.
Remove the bolts 3 retaining the half shaft tothe stub shaft and to the brake disc spacer.
Take care not to damage the boots 4 on theconstant velocity joints and remove the half
shaft. (see illustration on page 42).

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__________
PA__R_TI_A_L_O_ P_E_R_A_T_I_O_N_S_________~----------R-E-A-R

Remove the split pin and remove the locknut
1 -from the retaining nut fixing the half shaft
to the hub.

__
S_U_S_P_E_N_S_IO_N___________

Replace the parts affected as detailed on
pages 45 and 46. It should be noted that for
the removal of stub shaft and hub it is only
necessary to carry out the first sequence of
operations, whereas it is necessary to carryout the complete sequence of operations if
the hub bearing is to be replaced.
The fitment of the hub to the axle is detailedon page 48.

To remove road springs and bump rubber
The operations for the removal of the roadsprings and bump rubbers are detailed on
pages 42 and 43. This operation may berequ ired for a possible correction of thevehicle height, which can be achieved byshimming the springs.

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Novembe r 197551

_________S_H_o_C_K__
A_B_S_o_R_B_E_R_S__________~------F-R-O-N-T-&__R_E_A_R__S_U_S_P_E_N_S_I_O_N_S_____RATII'IG DATA FOR CALIBRATING AND MATCHING FRONT & REAR SHOCK ABSORBERS

The front and rear shock absorbers of each car should be matched together as shown by the tablebelow:

116.08 - 116.09

CAR'S MODEL

116.42r
SHOCK ABSORBER

LOW : COMPR ESSION

I-

z

0

a:

u.

SPEED
RATINGkgt-------: EXTENSION

11600.21070.01
11600.21070.07
6 · 15116.10 - 116.11 - 116.36 - 116.37 - 116.54*

11600.21070.13
11600.21070.06 ---- -- - 11604.21070.01 11655.21070.01

5 - 16EXTENSION-- - - - -

LOW

w

a:
RATING
kg

.,

'\.

7 ·17

9 -19

BLACK

10 - 21

14 - 26-- -- - --------

12 - 33

37 -64 24 ·43

35 - 5943-70

157 - 205

84 - 127

83 - 118 98 - 135

94 - 130

145 - 190------- --- - -- -- - ------

11600.25070.11 11600.25070.10*"11655.25070.01-------- 11604. 25070.01

11600.25070.22

GREEN

BLUE

BLACK

5 -16

6 - 16

9 - 1913 - 25

19 - 37

21 - 35 26 - 45

11600.25070.06
SHOCK ABSORBER

«

BLUE

- --- ---53-72
47 -6632 - 45
20 - 32 47 - 65
19 - 35:COMPRESSION
HIGH
1-- - - - - - - -- --- - - - 1 - - - - - - - - -- - - - - - - --- -SPEED I~----+-------

I

a:

GREEN

------ ------- --- f - - 28 - 50

116.10 - 116.11
116.36 - 116.37
116.54 - 11 6.55
116.56:COMPRESSION+- -- - - - -HIGH :COMPRESSION
SPEED i~X-:;:E~S~O~ -22·50------29 -45-------- -- ------ - - - / - - 112-155

6 -16- - -- - - - -----24- 54
12"- 39
15 - 38 21 - 54
22·54------ --- - - ----- - - - - -- ---r------- - - ----- - - - - - -SPEED I EXTENSION
1-- - -

6 - 1511600.25070.17

86·14483 - 127 92 - 14~

44 - 67-- --93 - 144

23 -42- -- --93 - 140* Shock absorbers to be fitted at option to get stiffer suspensions.
These figures are to be achieved on a test rig and with the shock absorbers at a temperature of 20° ±2°C. Prior to perform the tests, pump the shock absorbers through few complete cycles to settle
them, particularly when they have been out of use for a long time.

52

March 1978

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Public. nO 2064-Workshop Manual

TOOLSTIGHTENING TORQUES

LUBRICANTS AND
ANTI-SEIZING COMPOUNDS

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_____________T_o_o_L_s _____________~---------R-EA-R--S-U-SP-E-N-S-IO-N__________

TOOLS

A.2.0075 *SUPPORT
for raising car

A.2.0131
STOP
Wheel hub tool

A.2.0269
CAULKING TOOL
for caulking upper washer on rear axle rubber
mounting

A.2.0281

SPACERfor extracting rear wheel hubs

A.3.0327 *
\

\

-\

EXTRACTOR
for rear hubs

A.3.0432

EXTRACTOR-FITTING TOOL
for rear hub bearing

54

November 1975

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Pub lic. nO 2064 -Workshop Manual

_____________ T_O_O_L_s_____________~~---------R-E-A-R-S-U-S-P-E-N-S-IO_N_________

A.3.0435
EXTRACTOR-FITTING TOOL
for rear axle rubber bush

A.3.0443
BASE
for extracting and fitting rubber bush ontransverse linkage for rear axle

A.3.0444
EXTRACTOR -FITTING TOOL
for rubber bushes on transverse linkage forrear axle

A.3.0445
EXTRACTOR-FITTING TOOL
for balance lever rubber bush, connecting
Watts linkage to the axle

A.3.0446
BASE
for extracting and fitting rubber bushes onbalance lever

A.5.0163I
SPANNER
36 mm. spanner for rear hub nut

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November 197555

______________T_O_O_L_s______________~---------R-E-A-R--S-US-P-E-N-S-I-O_N

1-.

_~-~T!

!
I!
I__________

A.5.0187

I
1

TOOTHEO SPANNER
for ring nut on rear wheel bearings

Ii

Ii

;:

A.5.0192
SPANNER
17 mm. hexagon spanner for propeller shaft
flexible coupling retaining bolts

R.4.0150
SUPPORT
for fitting and removing clutch unit to
gearbox/differential unit

R~7.0010*

ELEVATOR
column type for fitting
gearbox/differential unit

andremoving

A.2.0298
CAULKING TOOL
for caulking antiroll bar mountings

Tools marked thus

56"* are also used on other models.

Ma rch 1978

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Publ ic. nO 2064-Workshop Manual

______________O_V_E_R_H_A_u_L_____________~----------R-E-A-R--S-U-S-P-E-N_S_IO__
N__________

TIGHTENING TORQUES
kgm

METHOD OF
TIGHTENING

Bolt, axle to crossmember

9 to 11Dry

Bolt, gearbox crossmember to body

4.5 to 5.5

Dry

Nut, shaft to hub

27 to 33

Dry

Ring nut on hub beari ng

23 to 27

Dry

Bolts, half shaft to stub shaft

2.8 to 3With grease

Bolts, di fferential drive shaft to spacer

2.8 to 3With grease

Bolts, retaining propeller shaft (with 200 to 400 mm torque spannerand tool spanner)

4 .1 to 4.5

Dry

Bolts , retaining axle crossmember

4 to 4 .5

Dry

DESCRIPTIONLUBRICANTS AND ANTI-SEIZING COMPOUNDSRECOMMENDED COMMERCIAL
EQUIVALENTSDESCRIPTION

Grease for :- Internal surface of rubber mounti ngs for anti-roll bar

Grease for :Bolts, half shaft to stub shaft

ISECO - ERGON RUBBER GREASE N. 3
REINACH-OLEOBLITZ - SFERUL B2 AR

ISECO MOL YKOTE BR 2

Anti-seizure compound for :Lower shoc kabsorber pin

R. GORI - NEVER SEEZ

Bolts, Watts linkage to bodyProtective compound for :- Drive flange threaded end

Public. n° 2064-Workshop Manual

HOUGHTON RUST VETO 1064

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March 197857

_______________
C_H_E_C_K______________~--------H-E-IG-H-T--A-N-D-G-E-O-M__
ET_R_y_________TO CHECK VEHICLE HEIGHT
Preliminary operations

To check front vehicle height

Place the car on a 4 column lift or over a
suitable, level pit.

Measure dimension A from the lower wishbone mounting and distance B from the endof the ball joint on the stub axle to theground.

Ensure that the tyre pressure is a recommended and check, using the appropriate gauge,that the tyre tread depth is the same on all
four wheels.
Put the car in running order, filling up thetank completely.
Weigh the car statically as shown below.

Calculate the difference of the two dimensions. This should be between 39 and 49 mm.
and the values should be the same on eachside of the car.
If the torsion bars have been replaced, theabove value should be 44 to 54 mm., but still
the same on both sides of the car.
Raise the car, disconnect the anti-roll bars,
front and rear; disconnect front and rear shock
absorbers and slacken the bolts securing theWatts linkage to the body.
Bounce the car a few times to settle thesuspension.

58

November 1975

Measure dimensions A and B using the following tools:- Ruler A.4.0146- Bar, graduated in mm., and base A.4.0149
Pointer A.4.0151.

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_______________C_H_E_C_K______________~---------H-EI-G-H-T-A-N-D- G-E-O_M_E_T_R_y

Place ruler against the lower joint.
Fit pointer 1 to the upper hole on head 2 oftool A.4.0149.
Slacken bolts A and B and tighten Bolt C.
Place tool on the outer face of the ruler andbring the upper part of the pointer lightly incontact with the end of the ball joint, as
illustrated.

________

Read the actual value of the front suspension
height E off the calibrated rod, at points asshown below.

A

To check rear vehicle height
Tighten bolts A and B. The tool is now
zeroed.
Move tool A.4.0149 along the inner surface ofthe ruler and, after removing the pointer andslackening bolt C, withdraw graduated rod
until the head of screw D lightly touches thelower part of the wishbone mounting, as
illustrated, and tighten setscrew C.

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With the car laden statically, measure thedistance between the spring locating cup andthe bump rubber pad.
The value F thus obtained must be between
39 and 49 mm., and must be identical on
both sides.

Ma rch 197859

______________A_D_JU_S_T_M__E_N_T___________~--------H-E-IG--H-T-A-N-D-G__E_O_M_E_T_R_y_________TO ADJUST VEHICLE HEIGHT

\\~\

\~I

The front suspension height is adjusted byrotating the torsion bars.
The different number of splines at the ends ofthe torsion bars, i.e. 35 at the front and 34 at
the rear, allows a minimum correction of 1.5mm., which corresponds to the rotation by
one spline.

VALUES FOR CORRECTING SUSPENSION HEIGHT
Error ofsuspension
heightmm

I. .'Torsion bar

left-handright-handSuspension height highTorsion bar
left-handright-hand

Z=1

Z= 1

Z= 1

'.

3.0

Z=2

Z=2

Z=2

Z=2

4.5

Z =3

Z=3

Z=3

Z=3

DIRECTION OF ROTATION OF TORSIONBARS FOR SUSPENSION HEIGHT
ADJUSTMENT

6.0

Z=4

Z=4

Z=4

Z=4

7.5

Z=5

Z=5

Z=5

Z=5

Suspension height low

9.0

Z=6

Z=6

Z=6

Z =6

Correct the suspension height as shown in theillustration, and detailed in the chart listing
the relevant corrective values. It should be
noted that the instructions refer to the suspension when this is viewed from the rear.

('.

(The car is raised)

.'

.'(.

Clockwise

Anti-clockwise
Suspension height high(Car is lowered)

1.5

.\ !

Z=1

Z = Number of splines by which the torsion
bars must be rotated, either clock-or anti-clockwise, with reference to the front and rear markings on the seats, in order to correct thesuspension height of the car.

Anti-clockwise

Clockwise60

Suspension height low

November 1975

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____________A_D_J_U_S_T_M_E_N_T____________~--------H-E-IG-H-T--A-N-D_G_E_O_M__
ET_R_y_________In the case of replacements or completely
dismantling the torsion bars, care should betaken, not to transpose them and not to overlook the following marks when refitting thebars.

Rotate the lower wishbone and insert it on
the torsion bar. Ensure that the assembly
notch lines up with the new mark.

LH torsion bar

Yellow mark and letter S(or L) on front face

The rear suspension height is adjusted byshimming the springs. Proceed as follows:

RH torsion bar

Blue mark and letter D(or R) on front face.

Disconnect the half shafts on the outer end.
Disconnect the Watts linkage from the body.
Raise the car, using jack R.7.0010 fitted withtool A.2.0075 and support the car on stands.
Remove road wheels.

Refit all parts previously removed.

Lower the jack and the axle until the springs
are free.

Example of adjustment
Assuming the suspension height is 8 mm. too
low on the R H side.
The height is adjusted by rotating the torsion
bar. In this particular case reference to the
CHART showing the VALUES FOR CORRECTING THE SUSPENSION HEIGHT
shows that the rotation must amount to 5
splines (the difference of 0.5 mm. cannot be'accommodated) in a clockwise direction.

Restore vehicle height values inserting thenecessary spacers 1 between the bump rubberand body. The spacers are obtainable fromour Parts Department in the following sizes:
7, 14 and 21 mm.

Proceed as follows:
Raise the car and place on stands. Remove theroad wheel.
Disconnect the lower wishbone as describedin the front suspension section.
Remove the torsion bar cover from the rearcrossmember.
Starting from the assembly notch, and moving
in an ANTI-CLOCKWISE DI RECTION, markoff the 5th spline on the rear face of thetorsion bar. Repeat the same operation for
the front end.

If the required correction exceeds 21 mm.,the replacement of the springs is recommended. Ensure that the new springs are of thesame type (see page 47).

Using tool A.3.0374, remove the torsion bar
from its seat, rotate it in a CLOCKWISE
direction, and locate it again in its rear seat.
Ensure that the marked spline lines up withthe assembly notch.

Refit all parts previously disconnected byproceeding in the reverse order. At this stage
the bolts securing the Watts linkage to thebody should be tightened with the suspension
height adjusted to the correct value.

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November 197561

_______________C_H_E_C_K_______________~-------H-E-I-G-H-T-A-N-D--G-E-O_M_E_T_R_y__________TO CHECK GEOMETRY
Check for possible damage to the wheel rims
ard replace these if the distortion exceeds 3
to 4 mm.
Turn the steering wheel to its central position
so that it is symmetrical in the vertical plane.
Check that the front wheels are in the straightahead position.

Where the caster angle is outside the specified
value, slacken nuts and rotate adjuster on therod.
NOTE : Small variations of the caster angle within the previously mentioned tolerance are permitted to accommodate
small corrections to the car's stability.

Lock the brake pedal in the depressed
position to prevent the wheels from turningwhen turning them from lock to lock on
rotating plates.

To check and adjust front camber angle
Check camber angle on both sides, whichshould be :{3 = 0° 20' ± 30'

To check and adjust caster angle

whilst the maximum difference
between the two sides is 0° 40'.

allowedCheck the caster angle on both front wheels,
which should be:
ex = 4° 30' ± 30'
H

The maximum difference between the twosides is 0° 20'.

H+Smm
-1 mm

If camber value is taken in linear measure,
follow dimensions as illustrated.

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_______________C_H_E_C_K_______________~--------H-E-I-G-H-T-A-N-D--G-E-O_M_E_T_R_y

If the camber angle exceeds the specified
values, adjust by fitting shims between thespacer and the longitudinal side member towhich the lower wishbone is secured (eachshim allows a variation of 15' approx.).
NOTE : Adjustments can only be carried out in a negative
direction.

_________

Before refitting it, check that the notch
controlling the cancellation of the direction
indicator lever is in line with the pawl of thislever. If this condition is not correct, disconnect the steering column from the universal
joint and rotate it sufficiently to restore thealignment.
Refit the steering wheel in the central position.

To check steering lockWith the front wheel on full LH or RH lock,the maximum angle, measured at the outerwheel, must be 30° .

To check and adjust front wheel toe-out
Check front wheel toe-out, which should be:'Y = 0° 9'
The toe-out is adjusted by equalizing thelength of the tie-rods G and H until for eachwheel a toe-out of 1 mm is obtained.
Toe-out varies by 35' approx. on one wheel(3.5 mm. on dimension O-E) rotating one
steering tie-rod by 1 rev.

To check toe-in on rear wheels
Check the chassis serial number, as there are
two different values, according to the type ofcar.
VALUE A, Applicable to cars up to chassis
serial number 2034000
VALUE B,The latter cars are also identified by a whitepaint mark on the axle.

oCheck toe-in on both sides, noting that thevalue {j for each wheel must be as follows:E

If the steering wheel is not central, reposition
it on the steering column splines.

Public. nO 2064 -Workshop Manual

Applicable to cars from chassis
serial number 2034001 onwards.

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For type A{j =0° 30' ± 15'

For type B{j = 0° ±10'.

The maximum difference in toe-in between
LH and RH side must not exceed 0° 10'.

March 197863

_______________C_H_E_C_K_______________~----~--H-E-I-G-H-T-A-N-D--G-E-O_M_E_T_R_y_________

4-

To check rear wheel camber angle

\',I

.~. ~
-

Check the camber angle on the LH and RH
rear wheel. This angle, which is not adjustable, should be:{3 = 0° ± 30'

I,'\

whilst the maximum difference between thetwo sides should not exceed 0° 20'.

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TOOLS

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______________T_O_O_L_S______________~-------H-E-IG-Kr--A-N-D-G-E-O-M-ET_R_y___________

TOOLS
A.2.007S *SUPPORT
for raising car

A.3.0374

EXTRACTOR
for torsion bar

A.4.0146 *

r1
I~

n

g

II

I!

I'='j

/c=\

iJ

! I

'W'II .~
...~
'.

RULER
for checking car suspension height

A.4.0149 *TOOL
for checking car suspension height

A.4.01S1 *
,I

,

I,

'-~'=~II

I, , Iill,----'- J.-- i~<LYI!

r--'-' , _,_,----"
L...... _J

POINTERfor checking car suspension height

R.7.0010 *ELEVATOR
column type for car hoistingTools marked thus

66

* are also common to other models.
November 1975

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Public. nO 2064-Workshop Manual

______________
O_V_E_R_H_A_U_L_____________~-------------S-T-E-E-R-I-N-G--____________STEERING GEAR
The steering is of the rack and pinion type.
Neither the ZF type steering rack, nor the balljoints require any lubrication.

For the same reason a two-piece steeringcolumn is used, which is connected by auniversal joint.

In order to afford the driver increased ·protection in the event of a frontal impact, thesteering rack has been mounted in a rearward
position.

The steering wheel is dished and provision ismade for adjusting it in the vertical plane
using a lever whicli makes the adjustment easy
and rapid.

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_____________O_V_E_R_H_A_U_L_____________~-------------S-T-E-E-R-IN-G----______~__TO REMOVE THE ZF STEERINGRACK FROM CAR
IMPORTANT WARNING
The overhauling operations outlined below are to be carried out exclusively on the ZF steering box.
Never perform them on BURMAN (SPICA) steering box. Use only exchange scheme units available
from SPICA.
Place the car on a ramp. Before raising it,
carry out the following operations:- Remove the lower half of the shroud fromthe steering column tube by unscrewing theretaining bolts.

- Finally, disconnect the steering column
tube from the lower mounting by removing
retaining bolt 4.
Open the bonnet and remove the steering rack
protection panel by unscrewing the fixing
bolts.
Raise the car and disconnect the steering
5 from the stub axles and withdraw
the ball joints by means of tool A.3.0376 (6).
t~e- rods- Disconnect the steering column tube 1 fromthe top mounting 2 by removing the adjustinglever 3 after unscrewing the retaining nut andwasher.

Remove bolt 7 connecting the lower steeringcolumn to the pinion.

- Extract the upper half of the shroud fromits location on the scuttle.

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______________O_V_E_R_H_A_U_L____________~-------------S-T-E-E-R-IN-G----

Disconnect the steering rack from the bodycrossmember by removing the securing bolts
from the mounting strips.

__________- Slacken the locknut fixing the ball joints. If
necessary, hold the tie rods, using a spanner
applied on the flats provided on the rods.

Pull the steering wheel upwards and disconnect the steering column from the steeringrack.
Turn the LH road wheel to a suitable posi tion. Withdraw the steering rack through thehole on the valance panel, manoeuvring therack to facilitate its removal.

- Extract the ball joints and remove the bootsby removing the securing clips.
- Withdraw ~he rack sufficiently to hold itwith suitable pliers. Protect the rack toprevent any damage being caused.
- Disconnect the steering tie rods, using tool
A.5.0202 in conjunction with a ratchet
spanner.

TO DISMANTLE
THE STEERING RACK
Clamp the steering rack in a vice . Remove theball joints from the steering tie rods asfollows:

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November 197569

______________O_V_E_R_H_A_U_L____________~-------------S-T-E-E-R-ING--------- Remove the cover over the rack pressure
bush by removing the retaining bolts. Remove
the shim and withdraw the spring and thebush itself.
- Remove the pinion cover by unscrewing theretaining bolts. Remove the shim and driveout the pinion, using a plastic or leadhammer.

_______

I nspection and checks
Carefully clean all dismantled parts, checking
that:- The piniOn, the rack and bearings do notshow any signs of excessive wear or seizure.
- The boots on the tie rods and the dust
covers on the ball joints are intact.

- Withdraw the steering rack.
- The ball joints have not seized.
To dismantle the pinion, proceed as follows:- Remove the circlip securing the bearing,using suitable"pliers, and retain the shim.

,; .

- The pressure bush and rack guide bush do
not show any signs of excessive wear or seizure on their working surfaces.

- Extract the ball bearing, using tool no.
A.2.0239 in conjunction with A.3.0353.

TO REASSEMBLE
THE STEERING RACK
Carefully clean the seat of the rack guide bushand the outer surface of the guide bush.
Apply Loctite 601, manufactured by R. Gorion the outer surface of the bush.

I nsert the guide bush on its seat, using tool
A.3.0346.
Fit the ball bearing on the rack pinion, using apress and the base tool A.3.0397 (1).

Extract the needle bearing from the housing,using tool A.3.0455 after having removed thesealing ring.
Extract the guide bush from the rack fromthe far end of the housing, using tool
A.3.0291.

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L____________~

Fit to the rack pinion the shim previously
removed and secure with the circlip, placing it
squarely in its seat. Check with a feeler gauge
the clearance between the circlip and thespacer. The clearance must not exceed 0.05mm.

______________
ST_E_E_R_I_N_G______________

Prepare approx. 90 g. of BP Energrease
HT-EP-OO grease and lubricate the rack, therack pinion, bearings and all working surfaces.
Insert the rack in the housing and turn it sothat its teeth are towards the pinion seat.
Fit the rack pinion, locating it correctly, bymeans of tool A.3.0397 and A.3.0393.

If this condition is not fulfilled, alter theshim. These are available from our Spares
Department in various thicknesses.
Fit the needle roller bearing to the housing,using tool A.3.0456. Fit the rubber ring in its
seat.
Using a suitable gauge, measure the distancefrom the edge of the bearing to the bearing
surface of the cover.

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______________
O_V_E_R_H_A_U_L_____________~--------------S-TE-E-R-I-NG----------

Check that the previously removed shim issufficient to cancel the distance measured. Fit
the shim.

_____

Fit the boots to the steering rack and securewith a clip. Ensure that the boots are nottwisted.
Position the steering rack as shown below.

Where this condition is not met, replace theshim, which is available in various thicknesses
from our Spare Division.
Fit the cover after previously applying CU R I L
K 2 sealant to the bearing surface. Tighten the
securing bolts to 1.5 kgm.
Fit the rack pressure bush without sealing
ring, after having previously lubricated it. .
Fit the previously removed shi m between thepressure bush and the cover. Fit the cover andtighten the securing bolts to 1.5 kgm.
Check manually that the rack can slide freely
without end float or binding.

Fit the ball joints. Position the lock nuts tothe dimension shown at the illustration
below.

Where this condition is not met, rectify byreplacing the shim, which are available fromour Spare Division in various thicknesses.
Remove again the cover, spacers and the bush.
Fit sealing ring to the bush.
31 mm

Refit the bush, spring and spacers. Apply
CU RILK 2 to the cover and fit. Tighten the
securing bolts to 1.5 kgm.

WARNING
Lock the ball joint locknuts, after having checked the toe-out
and the steering rack having been assembled.

Fit the steering tie rods and tighten these to
4,2 kgm. using spanner no. A.5.0202 in
conjunction with a 300 to 400 mm. torquewrench.

Secure with lock plate.

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_____________O_V_E_R_H_A_U_L_____________~-------------S-T-E-E-R-IN-G----__________TO REFIT STEERINGRACK TO THE CAR
Refit the steering rack in the reverse order,
noting the following:

Disconnect from the steering column tube thelower shroud and steering assembly by removing the retaining screws ..

- The steering wheel spokes should be arranged symmetrically in the vertical plane before
refitting the rack pinion to the steering rack.
- Coat the upper steering column retaining
bracket with Molykote G compound.
- Adjust front wheel toe-out as detailed in thea ppropriate Section, after refitting thesteering rack.
- Fit the flexible joint to the facia side of thescuttle, after having previously applied
SIGIFLEX FR sealant, manufactured by
ICIR.

TO REMOVE THE STEERINGCOLUMN FROM THE CAR

Disconnect the steering column tube from theupper retaining bracket, removing the steering
wheel adjusting lever after withdrawing thesecuring nut and washer.
Separate the upper shroud from the dash.

Disconnect the battery earth cable.
Remove the steering wheel hub trim cover.
Unlock and unscrew nut retaining steering
wheel to column.
Extract the steering wheel from the splines,
using tool A.3.0451.

Disconnect
cables.

ignition steering column

lockDisconnect the steering column tube from thelower mounting by removing the retaining
bolt.
Finally disconnect the steering column fromthe universal joint connecting the steeringcolumn to the intermediate steering column.
Remove the vulcollan washer between theuniversal joint and the steering column tube.

To disconnect the lower steering column
Remove the cover from the steering rack fromthe engine compartment, by removing therelevant bolts.

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_____________O_V_E_R_H_A_U_L_____________~-------------S-T-E-E-RI-NG--------_______TO DISMANTLE ANDREASSEMBLE THE STEERINGCOLUMN TUBE
Disconnect the lower steering column fromthe steering column tube and rack pinion byuncrewing the universal joint bolts.

Clamp the steering column tube in a vice.
Drive out the steering column, as illustrated,using a lead or plastic hammer.

Withdraw the steering column from the boots,working under the car. If necessary, remove
the boots.
Early cars were fitted with a type of lower
steering column illustrated below.
To di~connect this type of steering column,
proceed as follows:
Remove the steering rack cover.
Disconnect the lower steering column 1 fromthe upper flange of the flexible coupling.
Extract the bushes and the cover from theends of the tube, using tool A.3.0402.

Withdraw the column from this flange,
working from the passenger compartment of
the car. Extract the flange from the boots. If
necessary, remove boots.
Raise the car and disconnect the flexible
coupling by unscrewing the retaining bolts.

74

November 1975

Extract the rubber bush from the lower lug,using tool A.3.0501, base A.3.0492 and apress.

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_____________O_V_E_R_H_A_U_L_____________~-------------S-T-E-E-R-IN-G----~

Check that the steering column bushes working surfaces do not show any signs of seizure.
Replace elastic type bushes with roller bushes
obtainable from our Spares Department.
Check that the universal joints have no excessive play nor signs of roughness.
Check that the steering column and tube arein good condition. Ensure that their working
surfaces show no signs of scoring or seizure.
Check operation of steering column lock. If
necessary, replace as follows:- Clamp the steering column tube in a vice.
Drill out the steering column lock securingbolt.

________

Fit the rubber bush to the lower lug, using apress, tool A.3.0501 and base A.3.0492.
Prior to fit the roller cages to the steeringcolumn, lubricate their seats in column tube
with grease:- ERGON RUBBER GREASE NO. 3 by
ISECO
- SFERUL B2 AR by REINACH
Clamp the steering column tube in a vice andfit one of the cages in the lower seat of thetube, using tool A.3.0383.
Insert the steering column in the tube and fit
the second bush in the upper seat of the tube,
using tool A.3.0493 minus lower cup.

TO REFIT STEERINGCOLUMN TO CAR
Refit the steering column in the reverse order,
noting the following:- Place the front wheels in the straight ahead
position.

- Remove the steering column lock from its
housing. Take care not to damage the switch
leads.
- Fit a new steering column lock. Tighten theshear bolt until the head shears.

Publ ic. nO 2064 -Wo rkshop Manual

Alfawiki.nl- I nsert the Vulcollan washers, previously
removed, between the universal joint and thesteering column tube.
- Position the steering column and check thatthe notch that operates the direction indicator lever is aligned with the pawl of theself-effacing device.

Ma rc h 19 78

75

_____________O_V_E_R_H_A_U_L_____________~-------------S-TE--E-R-IN-G--------______PARTIAL OPERATIONS- Fit the steering wheel, arranging the spokes
symmetrically.
- Refit the steering rack cover, after applying
SIGIFLEX FR sealant, manufactured by
ICIR.
- When carrying out work on the flexible
coupling, turn the lower steering column until
the clamping bolt can be fitted.
Should the Vulcollan washers be mlssmg
between universal joint and steering column
tube, check, after the assembly has been
completed, that the endfloat of the steeringcolumn does not exceed 5 mm. The dimension is measured between the lower face ofthe tube and the upper edge of the universal
joint.
If this condition is not fulfilled, take up theendfloat by unscrewing the fixing bolts 1 and
2 and moving the universal joint upwards.
Take care not to move the steering column.
If this operation is not sufficient, it is necessary to remove the steering colurTIn tube, inorder to fit suitable Vulcollan washers,
obtainable from our Parts Department, toovercome the excessive endfloat.

In the event of repairs being required, it ispossible to work on the steering rack and thesteering, without completely removing anddismantling the units concerned.
Partial operations that can be carried out, are:
- Removal of steering wheel. Details on page73.
- Removal of steering column assembly, as
detailed on page 73. It is also necessary to
disconnect the electric leads.
- Removal of steering column lock, as detailed and illustrated on page 75.
- Removal of steering column tube, as detailed on page 73.
- Removal of lower steering column, as detailed and illustrated on page 73, after having
previously removed the steering column tube.
- Removal of gaiters on lower steeringcolumn shaft, after removal of shaft.
The fitment of the parts removed during theabove operations is usually effected in thereverse order.

To remove and replace the flexible couplingon the lower steering column
On cars fitted with a lower steering column
comprising a flexible coupling, this coupling
can be removed as follows:- Place the car on a lift.
- Raise bonnet and remove steering rackcover by removing the appropriate fixing
bolts.

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____________~O~V_E_R_H_A_U_L_____________~----------~-S-T-E-E-RI-NG--------_______- Raise the lift. Unscrew the 4 bolts securing
the coupling to the steering rack flange andthe lower steering column flange.

To disconnect steering tie rods

- Remove flexible coupling together withmetal housing.

- Disconnect the ball joint from the stub axle
as detailed on page 68.

- Remove the earth cable from the centre
hole of the coupling and extract the couplingfrom its housing.

- Remove the retaining clips and move theboots.

- Refit flexible coupling to its housing. Insert
the earth cable in the centre hole. Refit theassembly between the two flanges. Insert theterminals of the earth cable. One terminal in
one of the lower retaining screw and the otherin one of the upper retaining screws.

Dis.connect the steering tie rods as follows:- Unlock the steering tie rods, using tool
A.5.0202 (1) in conjunction with a ratchet
spanner, and locking the rack rod with a grip
spanner 2, to avoid transmitting the load tothe rack pinion.
Assemble in the reverse order, using the same
tools as for the removal.

- Tighten the bolts securing the flanges to theflexible coupling.
- Refit the steering rack cover, after previously applying SIGIFLEX FR sealant,
manufactured by lei R.

To replace steering tie rod ball joints
Disconnect the ball joints from the stub axle,
as detailed on page 68.
Unscrew the locknuts. If necessary, use aspanner on the flats of the tie rods.

To replace the boots on the steering tie rods
In order to replace the boots on the tie rods it
is necessary to remove the ball joints from thestub axle.
The boots can then be withdrawn after removal of the retaining clips.

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WARNING: After every operation that involves the removal of parts from the steering rackand the remaining steering units, the toe-outof the front wheels should be checked.

November 1975

77

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TOOLSTIGHTENING TORQUES

LUBRICANTS AND SEALANTS

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____________~T_O_O_LS' ~--------~--S-T-E-ER-I-N-G------------_____________

TOOLS

n
_~
..IT.. _--~I
I-"1----<

A.2.0239 *PLATE
for extracting ball bearing from steering rack
pinion. (use with tool A.3.0353)'-----

A.3.0291
EXTRACTOR
for rack bush

A.3.0353 *EXTRACTOR
for ball bearing on steering rack pinion (usewith tool no. A.2.0239)

A.3.0376 *EXTRACTOR
for ball joint on steering lever

A.3.0393
FITTING TOOL
for pinion complete, with bearing (use withtool A.3.0397)

A.3.0397
BASE
for fitting steering rack pinion complete withbearing (use with tool A.3.0393)

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______________
TO_O__
Ls_____________~------------S-T-E-E-RI-N-G------------

A.3.0402 *EXTRACTOR
for bushes from ends of steering column tube

n
r
r
I

A.3.0451 *I"};-=~'"' ...~

I
.

I

Llr~
' -, --- l

EXTRACTOR
for steering wheel

A.3.0455
EXTRACTOR
for needle roller bearing on steering rack
pinionA.3.0456
FITTING TOOL
for needle roller bearing on steering rack
pinion

rr~'
l )\
t(j

0

:'---

~~~,

,( i )~\'

0

A.3.0492/

tf--e b/BASE
for fitting and extracting steering column bush

A.3.0342
FITTING TOOL
for steering column roller cage, top side

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March 197881

______________T_O_O_Ls_____________~------------S-T-E-E-RI-N-G------------

A.3.0383
FITTING TOOL
for steering column roller cage, bottom side

A.3.0501
EXTRACTOR-FiniNG TOOL
for rubber bush for steering column tube. (tobe used with tool A.3.0492)

A.5.0202

SPANNERfor steering tie rods

A.3.0346

FITTING TOOL
for rack guide bush

Tools marked thus ,,\: are also common to other models

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--~-~DATASTEERING

TIGHTENING TORQUES
kgm

METHOD OF
TIGHTENING

Fixing bolt for steering rack end float adjustment plate, ZF steering

1.5

Dry

Fixing bolt for rack pinion end float, ZF steering

1.b

Dry

Nut, fixing steering tie rod to rack, ZF steering (with spanner A.5.0202)

4.2

Dry

DESCRIPTIONLUBRICANTS AND SEALANTSCOMMERCIAL PRODUCTS

DESCRIPTION

Grease for- ZF steering box : 90 g

BP ENERGREASE HT-EP-OO

ERGON RUBBER GREASE N. 3 - ISECOSFERUL B2 AR-REINACH

Oil for:- Steering column roller cages
Lubricant for :- Top support brackets fixing the pivot and steering column
adjustment lever
Sealant for:ISECO MOL YKOTE COMPOUND GLOCTITE 601- Outer surfaces of steering rack support bush

ICIR SIGIFLEX FR

Contact faces of top cover and dash
Pinion adjusting covers

CURIL K2

- Steering rack adjusting cover

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March 197883

Alfawiki.nl

______________O_V_E_R_H_A_U_L_____________

1 - Hand brake pads control levers
2 - Hand brake cable
3 - Hand brake cable sheath
4 - Stop lights
5 - Air bleed screws
6 - Pads
7 - Pistons
8 - Discs
9 - Vacuum port and check valve~-----------B-R-A-K--E-S-Y-S-T_E_M____________

10 - Pipe connecting vacuum port toservobrake
11 - Brake master cylinder
12 - Brake fluid reservoi r with switches
for minimum level warning light
13 - Hand brake lever
14 - Warning light for hand brake andbrake fluid minimun level

15 - Switch for hand brake warninglight
16 - Servo brake unit
17 - Pedal
18 - Switch for stop lights
19 - Braking effort valve on rear wheels
20 - Hand brake pads push rods
21 - Hand brake adjusting screws_

BRAKING SYSTEM
The brakes are hydraulic and servo assisted_
Disc brakes are fitted to all four wheels.
The hydraulic circuit is fed by a tandem brakemaster cylinder, mounted co-axially on thevacuum brake servo unit.
The circuit is of the dual line tipe, i.e. it con sists of two independent circuits, one front
and one rear, which feed the four brake cal ipers.
The front brake circuit consists of two pipes
which are connected to the front body of themaster cylinder and feed independently thefront brake calipers.

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The rear brake circuit consists of a single pipe
which comprises a pressure limiting valve toprovide increased stability under braking.
From this pressure limiting valve the circl1lit
continues to a three-way union which distributes the brake fluid to the rear brakecalipers.

Parking (hand) brake

The hand brake acts on the rear brake calipers, which are of the mixed type, i.e. they
comprise a hydraulic and a mechanical control. The hand brake lever is connected to themechanical control by means of a flexible
cable.

November 197585

_____________D_IS_M_A__
NT_L_I_N_G___________~-----------F-R-O-N-T-B-R-A_K_E_S____________TO DISMANTLE
THE FRONT BRAKES
To remove brake pads

Push back the brake cylinders, using tool

A.2.0147.
Raise the front of the car and place it on
stands. Remove the road wheels.
Extract the cross-shaped spring from thebrake caliper, removing the retaining pins bymeans of a centre punch.

To remove brake disc
Remove the hub cover. Withdraw the split pin
and unscrew the wheel hub castellated nut.
Disconnect and remove the wheel hub after
removal of the bolts securing it to the brake
disc.
Withdraw the brake pads. If necessary, usepliers. Mark the assembly position of thepads.

Withdraw the brake disc from the stub axle,
withdrawing it from the caliper.

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__________T_E_ST_S__
A_N_D_C_H_E_C_K_S__________~-----------F-R-O-N-T_B_R_A_K_E_S____________TESTS AND CHECKS- Disconnect the caliper from the stub axle
by removing the retaining bolts 3.

Brake pads
Check brake pads for wear. The pad thickness, including the metal backing, should be
as follows :
New
Worn

15 mm.
7 mm. (minimum thickness)

Front brake calipers
The front brake calipers are of the type with
automatic adjustment to compensate for pad
wear. Therefore no provision is made foradjustments.
Check that the position of the cylinders is asrequired, using tool A.2.0149.
If necessary, re-set, using tool A.2.0355.

- Refit the brake caliper to the stub axle byreversing the removal operations, noting thefollowing:- Tighten the bolts securing the caliper to thestub axle to 7.5 to 8.5 kg.m.
- Tighten the caliper feed pipe adaptor to anindicated torque of 0.8 to 1.0 kg.m.
On completion of the operation, bleed thesystem as detailed on page 100.

Front brake discs
To replace brake calipers
Test operation of brake caliper. Replace it ifnecessary. Proceed as follows :Carefully clean the front brake discs andensure that the working surfaces are notscored or porous.

- Unscrew the adaptor 1 of the metal pipe
connecting it to the caliper. Unscrew the adaptor 2 and remove the connecting pipe.

Should the working surfaces require machining, the following instructions should be
noted:

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____________R_E_-_A_S_S_E_M_B_L_IN_G___________~-----------F-R-O- NT- B_R_A_K_E_S- Always machine the complete working
surface on both front brake discs.
- The amount of metal removed must always
be the same on both surfaces of each disc, andmust not exceed 0.5 mm. on each side. Aftermachining, the disc thickness must not be lessthat 10 mm.
- The machining must be carried out within
the following tolerances:- Parallelism in respect of plane A- Flatness, measured in a radial
direction . . . . . . . . .
- Flatness, measured in a circumferentiaJ direction. . .
- Parallelism, measured in aradial direction . . . . . .
- Parallelism, measured in a circumferential direction . . . .

____________To replace brake caliper dust covers
Disconnect the brake caliper from the stubaxle by removing the appropriate retaining
screws.
With the caliper connected to the brake pipes,
remove the dust covers 1 from their respective
seats, together with their flexible retaining
rings 2.

0.030 mm.
0.025 mm.
0.015 mm.
0.038 mm.
0.015 mm.

The surface finish of the disc must be as fol lows:
0.4 to 0.9 J.I. measured in a circumferential
direction
0.5 to 1.2 J.I. measured in a radial direction.
Replace the dust covers in the reverse order,
noting the following :- The dust covers must be lubricated prior toassembly, using ATE Bremszylinder grease.
- Tighten the bolts securing the brake caliper
to the stub axle to 7.5 to 8.5 kg.m.

TO REFIT THE FRONT BRAKES
Refit the front brakes in the reverse order,
noting the following:- Clean the brake discs carefully and check aspreviously described.

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_____________D_I_S_M_A_N_T_LI_N_G___________~------------R-EA--R-B-R-A-K_E_S____________TO DISMANTLEREAR BRAKES- Lubricate the stub axle and the working lipof the hub oil seals with Molykote BR 2
grease.
- The amount of grease required for thecorrect functioning of the hub bearings must,
if necessary, be replenished as described in the
Section dealing with the front suspension.

To remove the rear brake pads
Raise car on a lift sufficiently to be able towork comfortably on the rear brakes.
Remove the retaining springs 1, the padretaining pins 2 and the cross-shaped spring 3.

- Before fixing the hub to the brake disc,secure it to the stub axle as detailed in the
Section dealing with the front suspension.
- Refit the brake pads in accordance with themarks previously applied, providing they are
not replaced and no rectification work is
required on the brake disc.
- On completion of the assembly, pump thebrake pedal repeatedly, in order to re-establish the correct braking conditions.

Push back the cylinders, using adjustment
screw.
Withdraw the brake pads upwards.

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_

_

TESTS AND CHECKS

d4\(]J! _ _To remove rear brake discs
Remove the bolts 1 securing the spacer 2 andbrake disc 3to the differential drive shaft
and remove the brake disc.

REAR BRAKES- Always machine the working surfaces ofboth brake discs.
- The amount of metal removed, which must
be the same on both surfaces of each disc,must not exceed 0.5 mm. on each side. Aftermachining, the thickness of the rear discs
must not be less than 9 mm.
- The machining must always be carried out
within the following tolerances :- Parallelism in respect of plane 8 0.050 mm.
- Parallelism measured in a radial
0.038 mm.
direction. .. . . .. .
- Parallelism measured in a cir0.025 mm.
cumferential direction. . . .
- Flatness, measured in both aradial and circumferential direction. . . . . . . . . . .
0.025 mm.
The finish of the brake disc surface must be as
follows:
0.4 to 0.9 f.1 when measured in a circumferential direction
0.5 to 1.2 f.1 when measured in a radial direction .

TESTS AND CHECKS
O,9 +0,4A

Brake pads

1,2 + 0 ,5"'«Check brake pads for wear. The pad thickness, including the metal backing, should be
as follows:
New
Worn

15 mm .
7 mm. (minimum thickness)

Rear brake discs
Carefully clean the rear brake discs and ensurethat the working surfaces are not scored or
porous.
Where these surfaces are to be machined, notethe following :90

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___________
TE_S_T_S__
A_N_D_C_H_E_C_K_S__________~------------R-E-A-R--B_R_A_K_E_S____________

Rear brake calipers

To replace the dirt excluders

Test the operation of the rear brake calipers
and, if necessary, replace them. Remove thebrake calipers as follows:

The dirt excluders for the rear caliper cylinders can be replaced as follows:- Disconnect the feed pipe adaptor 1 fromthe three-way adaptor 2.
- Remove the retaining nuts 3 and the handbrake adjustment. Disconnect the cable 4
from the caliper levers 5.

- Remove the brake pads and discs. Push in
the cylinders by acting on the caliper adjusting screws.
- Remove the dirt excluders 7 and associatedretaining rings from the caliper pistons.

- Remove the caliper, unscrewing the nut 6
securing it to the differential/rear axle casing.

Re-assemble the dirt excluders in the reverse
order and lubricate them , using ATE Bremszylinder grease before fitting.
Refit the brake caliper in the reverse order,
noting the following:- Tighten the bolts securing the caliper to thedifferential/rear axle casing to 4.7 to 5.4 kgm.
Braking effort limiting valve- Fit the caliper feed pipe adaptor Ut -thethree-way adaptor and tighten to 0:8 to 1
..:;
kg.m.
- Bleed the brakes as detailed on page 100 oncompletion of the assembly.

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The braking effort limiting valve cannot be
serviced and must be replaced in the event ofmalfunctioning. Disconnect the feed pipes
and remove the screw securing the valve tothe body.

November 197591

___________R_E_-A_S_S_E_M__
B_LI_N_G___________~------------R-E-A-R-B-R_A_K_E_S____________TO REFIT REAR BRAKES
Refit the rear brake in reverse order, noting
the following:- Tighten the bolts securing the spacer andbrake disc to the differential drive shaft to 5.2
to 5.7 kg.m. Use tool A.5.0201.

I nner brake pads
Turn the adjusting screw 2 until the required
end-float of 0.1 -0.15 mm. between disc andpad (measured with a feeler gauge) is obtained.
Refit dirt excluders previously removed.

- The brake pads, either the original ones or
new ones, must be fitted with the referencemarks pointing in the direction of the movement of the car.

Pump the brake pedal repeatedly to restore
the normal braking action.

- Adfust the brake pad end-float as follows:
Outer pads
Remove dirt excluders.
Unscrew the locknut 1 using tool A.5.0194.
Turn the adjusting pin clockwise or anticlockwise, until the required endfloat of
0.1-0.15 mm. between brake disc and pad,measured with a feeler gauge, is obtained.

To re-connect and adjust the handbrake cable
Check that the handbrake lever is in its inoperative position.
Re-connect the hand brake cable to the leverson the calipers, screwing the retaining nut 3
on the threaded terminal 4 until the end-floatof the cable is completely ta~en up without
loading the caliper levers. Failure to observe
this condition will reduce the end-float
between the inner pad and the disc, which has
previously been adjusted, thus c using friction
with the handbrake lever in the inoperative
position.
Finally tighten the locknut 5.

Tighten the locknut to a nominal torque of
0.7 to 1 kg.m. using tool A.S.0194.

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_ _D_I_S_M_A_NT_ Ll_N_G_A_N_D_ R_E_A_S_S_E_M_B_L_IN_G_ _~f)When the adjustment is completed, check thatthe rear wheels are locked when the handbrake lever is pulled up to between the 4th
and 6th notch.
Check that the level in the brake fluid reservoir is as required. If not, replenish it, using
exclusively one of the following products:- ALFA ROMEO Standard 3881-69905
AGIP F1 BRAKE FLUID SUPER HD- ATE "s"_____S_E_R_V_O_B_R_A_K_E_S_y_S_T_E_M_ _ __Disconnect the brake master cylinder fromthe brake servo by removing the associatedretaining nuts.
Refit in the reserve order, noting the following:
Check the seals 4 for wear. Replace the seals
if necessary.
"

Ensure that the sealing ring is fitted between
the brake master cylinder and the brake servo
unit.
Tighten the nuts to 0.8 to 1.0 kg.m.

To disconnect and reconnect the brake mastercylinder and reservoir

Fill the braking system and bleed. Use only
one of the recommended products. Bleed as
described on page 100.

Remove cover 1. Remove gauze 2 and, using asyringe, remove the fluid from the twochambers of the reservoir 3.
Separate the reservoir from its connections on
the master cylinder an.d collect the seals 4.

'G -__e--

TO REMOVE AND REFITTHE SERVO ASSEMBLY
To remove and dismantle the brake mastercyl inder-servo-pedal assembly12

Empty the chamber of the braking systemand the reservoir of the clutch system, withdrawing the fluid by means of a syringe.
Disconnect the flexible vacuum pipe from theadaptor on the brake servo by slackening thesecuring clip.
Disconnect the adaptors for the feed pipesfrom the brake and clutch master cylinders.
Working as described and illustrated in the"STEERING'Section".
Remove the lower half of the shroud from thesteering column tube. Disconnect the steeringcolumn tube from the top mounting bracket.
Remove the lever for the steering wheel
adjustment and remove the upper half of the
shroud from the facia .

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_ _ _D_I_S_M_A_N_T_L_IN_G_A_N_D_R_E_A_S_S_E_M_B_Ll_N_G_ _8 _____

S_E_R_v_O_B_RA_K_E_S_y_S_T_E_M_ _ _ __Lift the carpets and unscrew the five nuts fixing the pedal box to the scuttle.

- Remove the pivot pin securing the fork of
the clutch master cylinder to the pedal.

At this stage, collect the plates secured by thetwo lower nuts corresponding to the clutch
pedal. These determine the stroke of the
clutch pedal.

- Remove the anchorage plate for the pedal
return spring and remove the spring.

Remove the brake master cylinder and brakeservo unit complete with mounting andpedals.
Remove the gasket from the pedal support
bracket or from the dash.
Disconnect the servo rod from the brake
pedal, removing the flexible ring and the pivot
1. Remove the spri ng anchorage plate 2 andthe spring itself.
Disconnect the master cylinder-brake servo
assembly from the pedal bracket by removing
the fixing nuts 3.

- Remove the clutch master cylinder from thepedal bracket by unscrewing the fixing nuts.
- Withdraw the pedal shaft from the bracket,
after having removed the retaining pin.
Remove the pedals.
- Remove the bushes from the pedals.
When the dismantling is-oompleted, check thepedal bushes and shafts for excessive wear.
To assemble and refit pedal-master cylinderand servo assembly
Refit the assembly in the reverse order, noting
the following:- Lubricate the pedal shaft with LONGTERM
MOL YKOTE No.2.
- Check that the clutch master cylinder push
rod and fork are adjusted to the required
length of 99.5 mm.

Dismantle the pedal assembly as follows :94

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~ ~---------S!~'!~~~~!-~~~T-E~---------DISMANTLING AND REASSEMBLIN________________________________- Apply LOWAC Perfect Seal to the contact
faces of the pedal assembly and the brakeservo. Tighten the retaining screw to 1.2 to
1.5 kg.m.

- Disconnect the flexible pipe 1, slackening
its retaining clip 2.

- Replace the gasket between the seating faceof the pedal assembly and the dash, after having thoroughly cleaned the contact areas.
- Tighten the feed pipe adaptors for the brakeand clutch master cylinders to 0.8 to 1 kg.m.
- Replenish the brake and clutch fluid reservoirs with the recommended fluid and bleed
the systems as detailed on page 100.
- Fit the previously removed plates for the
clutch pedal adjustment. Check that thestroke of the slave cylinder operating the fork
is 10.6 to 12.2 mm. If necessary, the stroke
can be adjusted by varying the number ofadjustment plates.
- Unscrew the non -return valve 3 and remove
the gasket.
- Check the non-return valve for correct operation and replace it, if necessary, proceedingin the reverse order. Fit new gasket to thevalve.
- Check the condition of the flexible pipe
connecting the non-return valve with thebrake servo unit, and replace it, if necessary.
- Refit the air cleaner.

Vacuum system

The vacuum system consists of a non-return
valve fitted to the inlet manifold and connected to the brake servo by means of a flexible
pipe.
Dismantle the non -return valve as follows:- Remove the air cleaner by releasing theretaining clips.

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______________O_V_E_R_H_A_U_L_____________~------------B-R-A-K-E-~--P-IN-G_____________BRAKE PIPES
When removing brakes pipes, either rigid or flexible, take care to prevent the loss of fluid bysuitably plugging the ends.
Refit the pipes in the reverse order and tighten the unions to 0.8 to 1 kg.m.
It is necessary to bleed the brakes as detailed on page 100, even in the case of a partial removal of
the brake pipes.

Front circuit
To remove brake pipe A
Raise the car. Remove the front LH roadwheel and unscrew the union 1.

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November 1975

Disconnect the union 2 on the brake mastercylinder. Remove the brake pipe from its
retaining clip and remove it from the engine
compartment by passing its lower end
through the aperture in the valance and retain ing the rubber grommet.

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______________O__
V_E_R_H_A_U_L____________~------------B-R-A-K--E-P-IP-I-N_G

To remove brake pipe B
Working in the engine compartment, remove
air cleaner from its seat by releasing it fromits retaining clips.
Disconnect link 1 of the accelerator control
linkage by unhooking the socket 2 from theball joint. Remove the brake pipe 3 from theretaining clips.

____________

Raise the car. Remove the front RH roadwheel and disconnect the union between
brake pipe B and the flexible pipe D.
Feed again into the engine compartment theend of the pipe that has just peen disconnected. Retain the rubber bush and finally remove
the pipe complete by withdrawing it from theR H side of the car.

To remove brake pipes C and flexible pipes D
Raise the car and remove the front wheels.
Unscrew the union 5 from the brake caliper.
Disconnect the union 6 for the flexible pipeand remove the pipe.
Remove flexible pipe by disconnecting union
7 and locknuts 8.

Unscrew the union 4 from the brake mastercylinder.

Operate in a similar manner on the opposite
side of the car.

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______________O_V_E_R_H_A_U_L_____________~------------B-R-A-K-E--P-IP-I-N_G

Rear braking circuit
To remove pipe E____________

completely. This allows the crossmember tobe lowered sufficiently for the pipe to passthrough.

Place the car on a lift. Disconnect the union 1
at the brake master cylinder.

Raise the car and unscrew the union 2 on thebraking effort limiting valve.

From underneath the car, remove the metal
brake pipe E, withdrawing it towards the rearand simultaneously guiding it from the side ofthe engine compartment, to avoid it becoming
entangled, thus causing possible damage.
When refitting, tighten the securing bolts ofthe crossmemb~r to 4 to 4.5 kg.m.
To remove brake pipe F
Raise the car by means of a lift. Disconnect
the brake pipe F from the braking effort
limiting valve by unscrewing the union 4.
Unscrew the union 5 to the rear flexible brakepipe.

Free the brake pipe from the retaining clips.
Partially unscrew the bolts fixing the De Dionaxle crossmember to the body, with the
exception of bolt 3 which must be removed98

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______________
O_V_E_R_H_A_U_L_____________~------------B-R-A-K-E--P-IP-I-N_G

Separate the pipe from the support clip andremove it.

To remove brake pipes G
Unscrew union 1 connecting brake pipe 2 tothe three-way connector.

____________To remove flexible pipe H
Raise the car. Disconnect the union 3
between the brake pipe F and the flexible
pipe. Unscrew locknut 4 and withdraw theflexible pipe union from the mounting
bracket.

Unscrew union 5 from the three-way connector on the differential housing and remove
the flexible pipe, retaining the gasket.

Remove the rear brake caliper as detailed on
page 91.
Remove the brake pipe by unscrewing theadaptor, connecting it to the brake caliper.
Proceed in a similar manner for the oppos ite
side of the car.

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______________O_V_E_R_H_A_U_L____________~--------B-R-A-K-E-S-Y-S-T-E_M_B_L_E_E_D_IN_G________TO BLEED BRAKE SYSTEM
The brakes can be bled in two different ways:
conventional method, and the method involving the use of tool R.2.0105.

- On completion of this operation on the one
pair of calipers, refit the dust caps. If necessary, restore the level of brake fluid in thereservoir.

Conventional method

If the bleeding has been carried out carefully,
after an initial empty stroke the pedal operation should be without any trace of sponginess. If not, continue with the bleeding.

Place the car on a lift.
If necessary, replenish the reservoirs with therecommended fluid from sealed tins. Theseshould be opened only immediately before
use.
Raise car and remove the dust caps from thebleed screws on the calipers.
Bleed brakes, adhering strictly to the following instructions. It should be noted that thefront and rear calipers must be bled simultaneously, first on one side of the car, then or
the other.
- Attach flexible tubings to the bleed screws
1 and 2 on the calipers in question and put
the other end in transparent containers
containing brake fluid of the recommended
type.

Method involving the use of tool R. 2.0105
The set, which is supplied complete with allaccessories, comprises:
Pump complete 3, connecting plug 4, flexible
tubing and two transparent bottles 5 forcollecting the fluid.

- Slacken the bleed screws and operate repeatedly the brake pedal; allow the brake pedal
to return slowly and pause a few seconds
between each stroke. Continue with thisoperation until the fluid emerging is free fromair bubbles. Depress the brake pedal fully.
Tighten the bleed screws and remove thetubings.

.,
4

Place the car on a lift and fit the equipment asfollows:- Replenish the master cylinder reservoir byabt. three quarters, using the recommended
fluid from sealed tins.

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_____________O__V_E_R_H_A_U_L_____________~--------B-R-A-K-E- S-Y-S-T-E_M_B_L_E_E_D_I_N_G- Fit the plug contained in the kit in place ofthe reservoir cap. Connect the pump's flexible
pipe and fit a collecting bottle to the bleed
valve.

_______- Attach the transparent collecting bottles,
which should be partially filled with fluid, tothe bleed screws or the calipers in question.
Ensure that the flexible tubes are immersed in
the fluid.
- Raise the pressure to the level previously
indicated.
- Open the bleed screws. Maintain thesystem's pressure at 2.8 kg/cm2 and allow thefluid to escape until all air bubbles have disappeared completely. Close the bleed screws in
the sequence illustrated, whilst still maintaining the pressure at a constant level.
- front caliper- rear caliper inner screw- rear caliper outer screw- Repeat the above operation on the opposite
side of the car and, when the bleeding iscompleted, and prior to releasing the pressure,ensure that there are no fluid losses from thetubings.
- Release the pressure.

Bleed the air from the reservoirs, operating asfollows:- Pressurize the circuit by operating the pumplever. Do not exceed a pressure of 3 kg/cm 2 ,as indicated on the pressure gauge .
- Open the valve on the adaptor plug andallow the fluid to flow until all air bubbles
have disappeared.
- Maintaining the pressure, close the bleed
valve. Release the pressure by means of thevalve on the pump reservoir.

- Check that the brakes have been bled carefully by operating tbebrake pedal. This should
show no sign of sponginess, otherwise theabove operation should be repeated.
- Disconnect the pump from the adaptor plugand from the valve on the pump. Remove any
excess fluid from the reservoirs, until the
maximum permissible level is restored.
Remove the adaptor plug and fit the reservo ir
caps.

At this stage bleed the system as detailed
below, taking into account that the front andrear calipers must be bled simultaneously,
first on one side, (we recommend the RHside), then on the other.
- Raise the car and remove the dust caps fromthe bleed screws on the calipers.

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______________O_V_E_R_H_A_U_L____________~------------H-A-N-D-B-R-A-K-E_____________TO OVERHAUL THE
HANDBRAKE ASSEMBLY
To bleed clutch system

To remove the handbrake cable

Proceed in a similar manner as for the con ventional bleeding of the brakes.

Raise the car and, working below it, discon nect the front part of the exhaust pipe as
detailed below:

Attach the tubing to the only bleed nipple 1of the system located on the clutch slave
cylinder.

Slacken the clamp 2 securing the front pipe tothe tail pipe and disconnect the flexible
mountings 3 from the crossmember.

Remove the front exhaust pipe by unscrewing
the nuts 4 and the bolt 5 which secures it to
the exhaust manifold and the mounting
bracket respectively, and withdrawing it fromthe rear tail pipe adaptor.

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______________
O_V_E_R_H_A_U_L_____________~-------------H-A-N-D-B-R-A-K-E

Disconnect the handbrake cable 1 from therear brake calipers by unscrewing locknut 2'
and adjusting nut 3. Withdraw handbrake
cable from the levers, complete with outer
cable.

_____________

Separate the cable from the anchoring plates.
Withdraw the handbrake outer cable from themounting plate near the rear flexible propeller
shaft coupling.

To remove hand brake lever
Remove the console from the tunnel asfollows:· Remove gear lever knob.
· Remove ashtray by unscrewing retaining
screws.
· From the aperture of the rear ashtray,
remove the screw fixing the console to thetunnel.

Disconnect the gear selector linkage 4 fromthe studs by removing the securing nuts andmove it sufficiently to provide access to theconnection between cable and handbrake
control lever as illustrated.

· Remove the securing nut for the console,
located at the front .
· Unscrew the lateral fixing screws.
Raise the back of the console. Disconnect theelectric wiring of the cigar lighter, and remove
the console.

Remove the screws 1 fixing the handbrake
mounting bracket to the console.

Disconnect the cab le from the lever byremoving the split pin and washer from thepin.

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______________O__
V_E_R_H_A_U_L____________~------------H-A--N-D-B-R-A-K-E_____________

Raise the lever and disconnect the electric
cables from the handbrake warning lightswitch.

~ Tighten the securing nuts, selector linkage
to joint, to 2 to 3.25 kg.m.

Disconnect the hand brake lever from its
mounting bracket by removing the split pin
and retaining washer from the pivot pin.

To replace spring for handbrake releasebuttonUnscrew the push button from the control
rod. Remove the washer and remove thespring.
Replace the spring, proceeding in the reverse
order.

€_.~
.
~

'8

tJ

fJ

Remove handbrake warning light switch,using pliers, withdrawing it from its seat located at the rear of the handbrake lever mounting bracket.
Check the components removed and replacethem as required. Assemble the lever in thereverse order, noting the following :Adjust the handbrake lever travel by reconnecting the flexible cable to the rear calipers,
as detailed on page 92.
Reconnect the gear selector linkage to thejoint, noting the following:- Select 5th gear, by means of the rear
selector lever on the gearbox.

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TOOLSTIGHTENING TORQUES

LUBRICANTSFLUIDS ANDSEALANTS

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______________T_O_O_L_s__------------~-----------B-R-A-K-E-S-Y-S-T-EM----________

TOOLS

A.2.0147 *EXPANDER
for brake cali'per pistons

A.2.0355' *PLIERSfor extracting front caliper pistons

A.2.0149*
GAUGE
for checking front caliper piston position

A.5.0194 *SPANNERfor rear caliper endfloat adjustment

A.5.0201

SPANNERfor rear brake disc retaining bolts

R.2.0105 *PUMP AND ACCESSORIES
foor bleeding brake system
Tools marked thus

106

* are also used for other models.
March 1978

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Public. nO 2064-Workshop ManualDIREZIONE ASSISTENZA TECNICA
Centro Direzionale
20020 - ARESE (Milano)
Publ ie. 2064 R '·5/78·'.000
Printed in Italy
All rights reserved . This book, or parts thereof,
may not be reproduced in any form without
permission of ALFA ROMEO S.p.A.

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