Brakes DATSUN F10, 200SX, B210 Fo. 2008x 8210 DESCRIPTION Brake system is hydraulically operated, utilizing @ tandem ‘master eyinder ond a Master-Vac power brake unit. Front dise brakes consist of rotors attached to wheel hubs, ond single cylinder, dual-piston, floating-colipers attached to steering Knuckles. Rear Brakes are leading trailing shoe/drum type, us- ing © single piston sliding wheel cylinder. Parking brake is coble ecvoted, operating wheel cylinders of reor broke ADJUSTMENT PEDAL HEIGHT & FREEPLAY F10 — Adjust pedal height to 6.8-7.0" (172-178 mm) by turning nut'on master cylinder push rod. Adjust stop light ‘witch s0 pedal just touches end of stop light switch; tighten lock nut. KISH ~ Brake pedo should be checked for travel and smooth peraion. roe should be $-5.25¢ (127-198 2008X ~ Adjust pedal height to about 6,9" (175.5 mm) vsing stop light switch. Lock switch in place with retaining nut. AHter pedal height is adjusted, loosen push rod lock nut and adjust pedal free play to .039..118" ( 1-3 mm), 8210 ~ Adjust pedol height to specifications by moving stop lamp switch. Pedal height should be 6.14" (156 mm) on vehi cles equipped with manual transmission and 6.22" (158 mm) fon vehicles with automatic transmission. After pedal height is adjusted, loosen push rod lock nut and adjust pedal free ploy 0 -039-.197" (1-5 mm). FRONT DISC BRAKE PADS Front disc brakes are self-adjusting, therefore, no adjustment in service is required REAR BRAKE SHOES F10 ~ Reise and support vehicle. Pump brake pedol several times to center brake shoes. Using o screwdriver, turn adjuster star until considerable drag is evident. Back off adjuster five or six notches and make sure drum rotates freely. 2008X — No adjustment required. 18210 ~ Roise and support vehicle. Using o suitable brake ad- ivsting tool, tighten adjuster eccentric clockwise until brake shoe contacts drum. Return odjuster eccentric until shoe is slightly separoted from drum. Check operation by turning drum and applying brakes; if shoe interferes with drum rota: ion, readivt, PARKING BRAKE With rear brakes properly adjusted, adjust porking brake cable turnbuckle until rear brakes are locked when parking brake lever is pulled to sixth or seventh ratchet stop. Release parking broke lever ond ensure rear wheels turn freely and thot all parts are returned to their original postion COMBINATION VALVE Function Test, All Models ~ Accelerate engine 1o 30 mph ‘ond rapidly apply brakes. if rear wheels lock before front ‘wheels, malfunction of combination valve assembly (200SK & 8210), oF of separate proportioning valve (F10) is indicated. HYDRAULIC SYSTEM BLEEDING ‘Attach @ bleed tube to bleeder screw and immerse opposite ‘end of tube in o container partially filled with brake fluid Pump broke pedal two or three times, keep pedol fully depressed, open bleeder screw and exhaust oir, close bleeder screw, and return brake pedal. Repeot operation uatil air bubbles are no longer seen in discharged fluid. Repeat procedure on remaining brake lines. Bleed rear wheels firs, then front wheels. REMOVAL & INSTALLATION FRONT DISC BRAKE PADS Removal — Raise front of vehicle and support in place, then remove front wheels, Remove clips from retaining pins ond pull ‘out pins, coil springs ond pad springs, Remove pads from coliper assembly using a suitable pair of pliers Inspection — With friction pods removed, measure their thickness, Replace any pod that is worn to less than 063" (1.6 ‘mm) in thickness (not including metal backing plate). It is recommended that friction pods be replaced as 0 set fo pre- vent any possibilty of uneven broking. — Replace all pods at same time, Installation ~ Cleon ond apply PBC. grease (or equivalent) on yoke guide groove of cylinder body, sliding contact portions of yoke and end surface of piston. Loosen bleeder serew and push outer piston in eyinder until end sur- face of piston coinsides with end surface of retaining ring on boot, Install inner brake pad. Push inner piston in cylinder by pulling on yoke, then install outer broke pad. After installing ads, depress broke pedal several mes 10 seat pads, FRONT DISC BRAKE CALIPER Removal — Roise vehicle and suitably suppor on solely stands: remove tire and wheel. Remove brake friction pads as previously described. Disconnect brake line from wheel Cylinder, To ease removal of caliper, remove strut assembly ‘ond knuckle arm mounting bolt. Withdraw caliper mounting bolt and separate it from strut assembly. ‘ipo 200 Rapa ema CampaBrakes DATSUN F10, 200SX, B210 (Cont. Installation — To install brake caliper assembly, reverse removal procedures, noting the following: Bleed hydraulic system. FRONT DISC BRAKE ROTOR Removal (2008X & B210) ~ With caliper removed, remove hub dust cop, cotter pin and nut. Remove hub and rotor ‘assembly with wheel bearing and washer in place. Remove bolts attaching rotor to wheel hub and separate rotor from hub, Installation — Reverse removal procedure, tighten rotor: hub bolts securly, and adjust wheel bearings. See Whee! Bearing Adjustment in WHEEL ALIGNMENT Section. Use o dial indicator to measure rotor runout. Resurface rotor if runout exceeds .0047" (.12 mm) Removal (F10) — With coliper removed, remove stub axle cotter pin, washer ond mounting nut. Using @ puller, withdraw stub axle ond brake rotor as an assembly. Rotor can now be separated from stub axle. Installation ~ To instoll stub axle and rotor assembly, reverse removel procedure and tighten stub oxle mounting nut t0 87. 145 ft Ibs, (12-20 mig). Rajser chon Anti-Rattle Pin m Wheel Cylinder ‘Assent Retainer, : Ge Spring Seot ae \ Peon Jasisone ode Shoe Sores Return Spring Fig. 1 Exploded View of Datsun 200X Rear Broke Assembly REAR BRAKE ASSEMBLY Removal (Rear) ~ Rose vehicle ond witably support on safe fy ends! remove te and wheel Looien porking broke Thkage et cleus pin end place ovt of woy. Remove broke chum Remove shse retcner ond return spring, en Uo shoe ossembly. Disconnect brake line from wheel cylinder necesory, wheel cyinder con now be removed by Yoking out mounting bolt Inspecting — Inspect all broke components for damoge ot tncessve wear and replace thote found defective. Reploce troke lining i ti of soaked or ining it Tess thon "059" (15mm) thick Installation ~ To install reor broke lining, reverse removal procedures, noting the following: Readjust.shoe-to-drum Clearance ond, if necessary, bleed hydraulic system ‘Adjusting Sfar © Pistor Piston—pp SD / % { Y Wheel | Cylinder “S tien Dust Cover Return Spring Fig. 2. Exploded View of F10 and B210 Rear Brake Assembly (MASTER CYLINDER Removal ~ Disconnect any electrical leads attached to cylin- der reservoir. Disconnect front and rear brake lines from master cylinder outlet ports. On models equipped without ower brokes, separate master cylinder push rod from pedal Remove cylinder mounting nuts and slide unit off studs. Moke sure brake fluid does not drop on paint. ISIE — On F10 models, fluid reservoir can be removed ot tached to cylinder. Installation ~ To install master cylinder, reverse removal procedures, noting the following: Bleed hydraulic system and Check pedal height. POWER BRAKE UNIT Removal ~ Disconnect power vnit push rod from brake pedal by removing clevis pin. Disconnect hydraulic lines from moster eylinder and vacuum line from power unit, remove moster ‘ylinder attaching nuts, and remove master cylinder. Remove ‘nuts attaching power unit to firewall, and remove power unit from engine compartment Installation ~ Reverse removal procedure, adjust broke pedel height, and bleed hydraulic system. Check Valve Removal ~ Check valve is located in vacuum line between intake manifold and power unit on firewall. To remove, disconnect retaining clip from firewall, remove hose clamps, separate hoses from valve, and remove check valve, To install, reverse removal procedure, OVERHAUL FRONT DISC BRAKE CALIPER Disassembly — With caliper removed, drain broke flvid and remove bleeder screw. Push both pistons into cylinder bore, then place yoke in a vise and tap the top of yoke lightly with o ‘opt 6 200 ib Reps emai CapBrakes DATSUN F10, 200SX, B210 (Cont.) Bias Spring Retaining Ring Piston Seal Bleeder Scrow Yoke Springs Retaining Ring Cylinder Pad Springs Fig. 3 Exploded View of Front Disc Brake Caliper hammer to separate cylinder from yoke. Remove bias ring from outer piston, then remove retaining rings and boots. Push both pistons out in one direction. Remove piston seals from cylinder and yoke spring from yoke. Inspecting — Thoroughly clean all internal ports and check ‘each component for excessive Wear or damage. If caliper bore is domoged or excessively rusted, it must be replaced. I, however, slight imperfections are evident, honing will eliminote them. tis recommended to replace all seals when overhauling Reassembly ~ Before assembling components, lightly coot with suitable brake grease. Insert bios ring into piston so round portion of ring fis to bottom of piston. Insert piston inte Cylinder. Do not fully seat piston. Install dust boot and retain ing ring, Install yoke bias ring so it coincides with yoke groove ‘of cylinder. Fit bias spring to yoke so bios spring faces bleeder side of cylinder. With yoke spring inserted in cylinder groove, properly align position of bias spring 40 groove of spring ‘ligne with yoke. Assemble body to-yoke, tapping lightly it necessary (Overhaul CAN BE Performed th Cylinder Installed Piston 8 Bleeder Cop Dust Cover Piston Cup Pistgn Dy BP rohan : Dust Cover 006" (.15 mm) Maximum Fig. 4 Exploded View of Datsun Wheel Cylinder Used on F10, 200SX and 8210 Models MASTER CYLINDER — On F10 models, separate reservoir tank assembly. Disassembly — Remove master cylinder reservoir caps and filters ond drain brake fluid, Using @ screwdriver, pry off stopper ring. Remove stopper screw and pull out primary piston ossembly, spring ond. secondary piston assembly, Remove plugs ond pull out front and rear check valves = On all except F10 models, do not remove reservoir fanks. IF fonks are removed for any reason, diseard and install Secondary Piston Aus, Rem spring | is ge Fig. 5 Exploded View of Datsun 200SX and 8210 ‘Master Cylinder ~ F10 Models Have Different Reservoir Arrangement ‘ipo 200 Rapa ema CampaBrakes DATSUN F10, 200SX, B210 (Cont.) Inspecting ~ Thoroughly cleon all components in opproved grade broke fluid. Inspect all components for excessive wear ‘or domage ond replace parts as necessory. Reassembly ~ Reverse disassembly procedure and note the following: Coot oll ports with brake fluid (rubber parts with broke grease) when assembling. POWER BRAKE UNIT Disassembly ~ 1) Place power unit in @ soft jaw vse with ‘operating rad pointing up. Scribe an alignment mark on front ‘and rear shell o assure reossembly in original position, then remove lock nut, clevis and dust boot from reor shel 2) Place suitable wrench (ST08080000) over reor shell mounting studs. Press down on wrench while rotating counterclockwise and remove rear shell, then lift out diaphragm plate assembly, diophragm spring and push rod ‘ottembly. Pry off retainer and remove bearing and valve body seai assembly 3) Remove diaphragm from diaphragm plate assembly, then pry off oir silencer retainer ond remove silencer and filter, Rotate diaphragm plate assembly until valve plunger key slot is down, then press in on plunger and shake out sop key, Remove reaction disc from plate assembly. Detach flange from front shell nd cemove front seal assembly, Cleaning & Inspection — Clean oll ports in denatured clcohol and blow dry with compressed cir. Inspect front ond ‘ear shells for wear or damage. If slight rust is found on inside surface of shells, polish clean with fine emery cloth. Inspect oll part for cracks, nicks, distortion or other damage ond reploce bs necessary. Reastembly ~ Reverse disassembly procedure and note the following: Apply a thin coat of slicone grease to parts before installation. When assembling front shell to rear shell ensure marks made during disassembly are ligned, After reassembly, measure distance from master cylinder mounting surface of power unit to end of power unit push rod: distance should be’ -38-.39" (9,810.0 mm). If distance is not to specifications, correct by adjusting end of push rod, TIGHTENING SPECIFICATIONS Ft Lbs. (mkg) 6.9(8-1.2) 11-13 (1.5-1.8) Application Master Cylinder Attaching Nuts Hydrovlie Lines Rotor-to-Hub 208K & 8210 Fio, Caliper Mounting Bolts 208K & 6210 Fo 28-38 (3.9-5.3) 18-25 (2.5.3.4) 53.72(7.3.99) 40-47 (5.56.5) Diophragm Plate ‘ond Valve Body Plate ong Seal AS: oy shal Diaphragm Reaction ise Return Spring Plunger Assy. Valve Plunger Stop Key Valve Bods Cover” Retainer Bearing Volve Bods Spot” Valve Push Rod Silencer Retainer Silenter Filter Silencer Rubber Fig. 6 Sectional View of Datsun Master Vac ‘ley 200 Mee Rep emai angryBrakes 7-38 DATSUN F10, 200SX, B210 (Cont.) DISC BRAKE ROTOR SPECIFICATIONS. Minimum dise | Lateral Original | Refinish | Discard Application Diameter | Runout | Paroltelism | Thickness | Thickness } Thickness tos (mma) | tnctomm) | tno(mm). | tn.(mm) | tn.(mm) | _tn.(mm) Fo 94s | 0050 339 ® gaa) | a3) es) 8210 965 | 00470 a74 331 ® (245) | (12) (3) (e4) 2008x 965 | 00470 394 331 ® 245) | 02) (10.9) ie) © = Moximum © = Less than minimum refinish thickness. BRAKE LINING SPECIFICATION : Width Length Thickness Application Bia | Front Rear Primary | Secondary | Primary | Seondary In. (mm)fin. (mm) | tn. (mm) In. (mm) In. (mm) In. (mm) In, (mm) F108 8210 20 | o 1.378 7.68 7.468 189 189 (203) (35), (195) (195) (4.8) (4.8) 2008x 900 | o 1375 8.64 3.64 177 7 (228.6) (40) 29.5) | (219.5) ia) i435) © — Front disc equipped. BRAKE DRUM SPECIFICATIONS | Drum ‘Original ‘Maximum Refinish | Discord Application Diameter Diameter Diameter Diameter In.) In (men) Inc) fn.) Fi0 & 8210 8.00 8.00 8.051 Q (203) (203) (204) 208% 9.00 9.00 9.055 ° (228.6) (2286) (230) © ~ More thon Maximum Refinish Diameter. BRAKE SYSTEM SPECIFICATIONS = Wheel Cylinder Diameter Master Cylinder Application Diam. Front Rear Diameter tn (mem) In. (mam) tn. (mm) In. (ram) a 3.00 7 87 750 (203) (48.1) (17.46) (39.05) 8210 8.00 2.0120 813 750 (203) (51.1) (20.64) (19.05) 2008x 9.00 2012 813 750 (228) (51.1) (20.64) (19.05 © ~ Coliper cylinder diameter. ‘ipo 200 Rapa ema Campa