Online Guide and Manuals

• S90 (1970-72)
• 100 (1970-73)

REAR BRAKE ASSEMBLY

FRONT DISC BRAKE CALIPER ASSEMBLY

PINION INSTALLATION

AUDI MASTER CYLINDER (COMPONENT PARTS)

Manufacturer: Audi
Model: A3
Year: 1997

Contains the following information and repairs for:

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

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

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

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

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

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

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

Fig. 1 Adjusting Caster and Camber on Audi 100

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

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

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

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

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

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

CASTER AND CAMBER ADJUSTING POINTS 100LS

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

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

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

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

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

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

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

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

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

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

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

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



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

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

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

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

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

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

TOE-IN

Caster and Camber Adjusting Points 100LS

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

NOTE - Information not available for Lancia models.

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

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

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

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


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


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


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


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



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


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


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


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


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


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


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


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


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


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


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


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


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

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


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


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

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

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


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

All Models - Tighten adjusting nut to 14.5 ft. lbs. After seating bearing components, loosen nut to 0 ft. lbs. Now make final adjustment to 3.6 ft. lbs. After installing lock cap, insert cotter pin. NOTE - Do not loosen adjusting nut more than 15 degrees to align spindle holes

NOTE - The following procedure can only be performed using special tools indicated.

Model 100 (Front) - 1) Raise and support front of vehicle. Remove lower wheel bolt and replace with special wheel bolt adapter (V-104) and special dial indicator (G-43). By means of retaining screw on special tool (V-104), adjust dial indicator to pretensioned position of 1 millimeter.

2) Grasp wheel at front and rear. First push inward on front while pulling outward on rear, record dial indicator reading. Reverse this procedure and record dial indicator reading. Difference between these two readings is wheel bearing play. If play exceeds .04-.07 mm, adjustment will be necessary.

3) Remove cotter pin and castle nut. If there was too much play, tighten spindle nut until play is within specifications. If there was insufficient play, remove wheel, spindle nut and its shim. Replace and tighten spindle nut. Using 1 millimeter feeler gauge, loosen spindle nut until it is possible to insert feeler gauge between spindle nut and wheel hub. Attach special hub puller (V-26) and withdraw hub until it is firmly in contact with spindle nut. Remove puller and retighten spindle nut until it is within specifications.

Model 100 (Rear) - Raise and support rear of vehicle. Remove grease cup and one wheel bolt. Attach special dial indicator (30-43), using wheel bolt adapter (40-104) and attachment (10-22). Dial indicator actuator foot should be pretensioned to 1 millimeter against the stub axle. Grasp wheel at front and rear. Move wheel on horizontal axis. If reading on dial indicator is not .02-.04 mm, adjustment will be necessary. Adjust by loosening or tightening spindle nut.
NOTE - Fox front wheel bearing is not adjustable. Torque stub axle nut to 13 ft. lbs.

Fox (Rear) - Remove grease cup, cotter pin and castle nut. Tighten spindle nut and loosen for adjustment. Adjust by lightly tightening spindle nut until plain washer (beneath spindle nut) can just be moved from side to side, using screwdriver. This adjustment will correspond to .0012-.0027" (.03-.06 mm) wheel bearing play.


320i and 630CSi - While rotating wheel hub, tighten castle nut to 22-24 ft. lbs., then rotate hub at least two more times. Loosen castle nut until bearing end play is noticed. Tighten castle nut to a maximum of 2.2 ft. lbs., then loosen nut to nearest hole and install cotter key
NOTE - After adjustment, slotted washer should move easily without noticeable resistance.

530i Models - While rotating wheel hub, tighten castle nut to 7 ft. lbs. Loosen castle nut approximately 1/4 turn. Insert screwdriver in recess of bearing retainer washer and ensure washer can be rotated easily. Install suitable gauge holder (BMW 00 2500) on wheel hub and install dial indicator with tip touching front axle stub. Move wheel hub back and forth several times and check bearing end play. Adjust castle nut until bearing end play is .0008-.0024".


All Models - Rotate wheel, hub and drum assembly while turning adjusting nut to 17 - 25 ft. lbs. Back adjusting nut off 120". Install cotter pin and check front wheel rotation.


All Models - While rotating wheel, hub and drum assembly, tighten adjusting nut to 17-25 ft. lbs. Back adjusting nut off 1/4 turn and retighten nut where castellations on the lock nut are aligned with cotter pin hole in spindle. Install new cotter pin and check wheel rotations


All, Except F10 - Tighten spindle nut to torque specifications in table. Spin wheel and retorque spindle nut. Loosen nut according to specifications in table and then tighten to align cotter key hole. Insert cotter key.


F10 - Raise vehicle and place on safety stands. Remove tire and wheel. Make sure mounting nut is torqued to 87-145 ft. lbs. (12-20 mkg). Spin wheel hub several times in both directions to ensure free rotation. Measure bearing preload by attaching a spirng pull scale to lug stud and turning hub. It should take about 3-11 lb (1.4-4.9 kg) to turn hub.


Model 124 and 131 - While rotating hub, torque spindle nut to 14.5 ft. lbs. Completely loosen nut and retighten to 5 ft. lbs. Loosen nut 30 degrees and stake collar of spindle nut into machined slot on spindle. Attach dial indicator with magnetic base on brake drum and actuating foot on spindle. Hub end play should not exceed .004". NOTE - When ever spindle nut has been removed it must be replaced with a new nut.

Models 128 and X1 /9 - Tighten front and rear spindle nuts to 112 ft. lbs. When spindle nuts are properly tightened, stake collar of spindle nut into machined slot on spindle.

ADJUSTMENT


TIRE INLFLATION (COLD)
Before attempting to check or adjust wheel alignment, ensure that tires are properly inflated. Refer to specifications in owners handbook for proper inflation procedures.


CASTER
Generally caster is stated as non-adjustable, and that if not within specifications parts are to be replaced. However, in some instances when slight adjustment will alleviate the problem, adjustment of strut bar nut is permitted.

CAMBER 
Camber is nonadjustable. If not within specifications, check front suspension for damage. Repair or replace parts as necessary

TOE-IN
Position wheels in straight-ahead position. If toe-in is not within specifications, loosen locking nuts on tie rod turn buckles. Rotate buckles until toe-in is within specifications.  Tighten lock nuts. NOTE - Adjustment must be made equally to both sides of vehicle to maintain correct wheel lock angle; difference of tie rod length when adjusted should not exceed .20" (5.1 mm).



TIRE INFLATION (COLD)
Before attempting to check and adjust wheel alignment, ensure tires are properly inflated. Model 100LS requires 26 psi in front and 28 psi in rear. Fox requires 27 psi in front and rear, (31 psi in rear with maximum load).

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

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

CAMBER 
FOX - With vehicle loaded down or placed on blocks, measure camber angle. If not to specifications, loosen ball joint nuts and attach tool US 4471 (or equivalent). Tighten tool nut to break loose joint from control arm. NOTE - When tool nut is loosened weight of vehicle will move wheel to negative camber. After adjustment retorque ball joint nuts to 47 fit. lbs. (6.5 mkg).

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

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

Fig. 1 Adjusting Caster and Camber on Audi 100LS with  Special Tool. Fox Camber Adjusting Tool is Similar

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

ADJUSTMENT

TIRE INFLATION (COLD)
Before attempting to check or adjust wheel alignment, ensure that tires are properly inflated. Refer to specifications in owners handbook for proper inflation procedures.

CASTER
Generally caster is stated as nonadjustable, and that if not within specifications parts are to be replaced. However, in some instances when slight adjustment will alleviate the problem, adjustment of strut bar nut is permitted.

CAMBER
Camber is nonadjustable. If not within specifications, check front suspension for damage. Repair or replace parts as necessary.

TOE-IN
Position wheels in straight-ahead position. If toe-in is not within specifications, loosen locking nuts on tie rod turn buckles. Rotate buckles until toe-in is within specifications. Tighten lock nuts. NOTE - Adjustment must be made equally to both sides of vehicle to maintain correct wheel lock angles; difference of tie rod length when adjusted should not exceed .20" (5.1 mm).


ADJUSTMENT

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

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

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

CAMBER 
Fox - With vehicle loaded down or placed on blocks, measure camber angle. If not to specifications, loosen ball joint nuts and attach tool US 4471 (or equivalent). Tighten tool nut to break loose joint from control arm. NOTE - When tool nut is loosened weight of vehicle will move wheel to negative camber. After adjustment retorque ball joint nuts to 47 ft. lbs. (6.5 mkg).

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

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

Fig. 1  Adjusting Caster and Camber on Audi 100 with Special Tool. For Camber Adjusting Tool is Similar

TOE-IN

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

Click to Enlarge

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

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

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

Click to Enlarge Photo

Click to Enlarge Photo

Click to Enlarge Photo

All Models - While rotating hub, tighten spindle nut to 18 ft. lbs. Loosen nut, then retighten to 7 ft. lbs. Back off on nut 1/4 turn and install cotter key. If slot in spindle nut does not align with hole in spindle, tighten nut until it is possible to insert cotter key. After cotter key is installed, ensure that bearing retainer plate can be easily rotated by insterting a screwdriver in plate holes

NOTE - The following procedure can only be performed using special tools indicated.

Model 100 (Front) - 1) Raise and support front of vehicle. Remove lower wheel bolt and replace with special wheel bolt adapter (V-104) and special dial indicator (G-43). By means of retaining screw on special tool (V1-104), adjust dial indicator to pretensioned position of 1 millimeter.

2) Grasp wheel at front and rear. First push inward on front while pulling outward on rear, record dial indicator reading. Reverse this procedure and record dial indicator reading. Difference between these two readings is wheel bearing play. If play exceeds .04-.07 mm, adjustment will be necessary.

3.) Remove cotter pin and castle nut. If there was too much play, tighten spindle nut until play is within specifications. If there was insufficient play, remove wheel, spindle nut and its shim. Replace and tighten spindle nut. Using 1 millimeter feeler gauge, loosen spindle nut until it is possible to insert feeler gauge between spindle nut and wheel hub. Attach special hub puller (V-26) and withdraw hub until it is firmly in contact with spindle nut. Remove puller and retighten spindle nut until it is within specifications

Model 100 (Rear) - Raise and support rear of vehicle. Remove grease cup and one wheel bolt. Attach special dial indicator (30-43), using wheel bolt adapter (40-104) and attachment (10-22). Dial indicator activator foot should be pretensioned to 1 millimeter against the stub axle. Grasp wheel at front and rear. Move wheel on horizontal axis. If reading on dial indicator is not .02-.04mm, adjustment will be necessary. Adjust by loosening or tightening spindle nut

NOTE - Fox front wheel bearing is not adjustable. Torque stub axle nut to 13 ft. lbs.

Fox (Rear) - Remove grease cup, cotter pin and castle nut. Tighten spindle nut and loosen for adjustment. Adjust by lightly tightening spindle nut until plain washer (beneath spindle nut) can just be moved from side to side, using screwdriver. Thin adjustment will correspond to .0012-.0027" (.03-06 mm) wheel bearing play.

Austin Marina - Raise and support vehicle so that front wheel is not touching ground. Remove grease cup and attach suitable magnetic base dial indicator with base on brake drum and actuating foot touching spindle. Bearing wobble should be from .001-.005". If adjustment is required remove cotter pin and slacken castle nut. Torque castle nut to 5ft lb. while spinning wheel. Stop wheel, slacken castle nut, and retighten castle nut, finger tight only. Reinstall cotter pin. NOTE - At minimum end-float figure given a considerable amount of movement will  be felt in the front wheel. Do not reduce end-float below .001".

2002 Models - While rotating wheel hub, tighten castle nut to 22-24 ft. lbs., then rotate hub at least two more times. Loosen castle nut until bearing end play is noticed. Tighten castle nut to maximum of 2.2 ft. lbs., then loosen nut to nearest hole an install cotter key. NOTE - After adjustment, slotted washer should move easily, without noticeable resistance.

3.0 Si and 530 i Models - While rotating wheel hub, tighten castle nut to 7 ft. lbs. Loosen castle nut approximately 1/4 turn. Insert screwdriver in recess of bearing retainer washer and ensure washer can be rotated easily. Install suitable gauge holder (BMW 00 2 500) on wheel hub and install dial indicator with tip touching front axle stub. Move wheel hub back and forth several times and check bearing end play. Adjust castle nut until bearing end play is .0008-.0024". NOTE - Set bearing end play as close to lowest limit as possible. Install cotter key.

All Models - Rotate wheel, hub and drum assembly while turning adjusting nut to 17-25 ft. lbs. Back off nut one-half turn. Retighten adjusting nut to 10-15 INCH lbs. Reinstall cotter pin and check front wheel rotation

All Models - Tighten adjusting nut to 14.5 ft. lbs. After seating bearing components, loosen nut to 0 ft. lbs. Now make final adjustment to 3.6 ft. lbs. After installing lock cap, insert cotter pin. NOTE - Do not loosen adjusting nut more than 15 degrees to align spindle holes.

All models - While rotating wheel, hub and drum assembly, tighten adjusting nut to 17-25 ft. lbs. Back adjusting nut off 1/2 turn and retighten nut to 6-8 ft. lbs. Install new cotter key and check wheel rotation.

All models - Tighten spindle nut to torque specifications in following table. Spin wheel and retorque spindle nut. Loosen nut according to specifications in following table and then tighten to align cotter key hole. Insert cotter pin.

Application                        Torque                  Loosen
B210..................................22-25....................90 Degrees
Pickup................................22-25....................40 to 70 Degrees
All Other.............................18-22...................60 Degrees

Model 124 and 131 - While rotating hub, torque spindle nut to 14.5 ft. lbs. Completely loosen nut and retighten to 5 ft. lbs. Loosen nut 30 Degrees and stake collar of spindle nut into machined slot on spindle. Attach dial indicator with magnetic base on brake drum and actuating foot on spindle. Hub end play should not exceed .004". NOTE - When ever spindle nut has been removed it must be replaced with a new nut.

Models 128 and X 1/9 - Tighten front and rear spindle nuts to 112 ft. lbs. When spindle nuts are properly tightened, stake collar of spindle nut into machined slot on spindle.

All Models (Front) - Front wheel bearings are not adjustable. Torque front spindle nut to 87-130 ft. lbs. (Civic CVCC)

All Models - While rotating hub, tighten nut until no end play is evident. Loosen nut 1 or 2 flats to line up cotter key and install cotter key. End play should be measured with a dial indicator and should be .002-.006". If not within specifications, adjust axle nut to correct end play.

All Models - While rotating wheel, tighten spindle nut to 22 ft. lbs. Turn hub through two or three turns and loosen nut until just finger tight. Check free play. Using a pull scale attached to wheel stud, measure turning torque; adjust nut until pull recorded on scale is 1.1 to 1-2.6 lbs. when wheel begins to rotate.

All Models - With vehicle raised and supported under lower control arms, measure amount of bearing preload using a pull scale hooked on hub bolt. Preload should be 1.3-2.4 lbs. (81600) or .9-2.2 lbs. (all other models). If not to specifications, adjust by tightening spindle nut until correct bearing preload is obtained. Align slot of spindle nut with hole in spindle and install new cotter key.

All Models - While rotating hub, tighten clamping nut until hub can just be turned. Loosen clamping nut and release bearing tension by striking steering knuckle spindle with plastic hammer. Using a suitable dial indicator, check wheel bearing end play. End play should be .0004-.0008". Adjust clamping nut until end play is within limits. Tighten socket bolt of clamping nut. Washer between outer bearing and clamping nut should rotate with light pressure applied to it.

Midget - Raise front of vehicle and remove each wheel. Remove caliper assembly, but do not disconnect hydraulic brake hose. Support caliper to prevent damage to hose. Attach suitable dial indicator and measure runout of hub at outer edge of brake rotor. If runout exceeds .006" remove rotor and reposition on hub. Torque spindle nut to 46 ft lbs. and recheck runout.

MGB and MGB/GT - Raise front of vehicle and remove fron wheels. Using suitable dial indicator, measure hub end play. Correct end play is .002-.004". If not within specifications, remove spindle nut, washer and outer bearing. Add or remove shims behind outer bearing, until correct end play is obtained with spindle nut torqued to 40-70 ft. lbs.

All Models - Raise and support front of vehicle. While rotating wheel, torque spindle nut to 18 ft. lbs. Back off spindle nut 1/4 turn. If slot in spindle nut and hole in spindle do not align, back off nut until they are aligned and insert cotter pin. Properly adjusted wheel bearing will exhibit small amount of end play

All Models - While turning wheel tighten spindle nut to 22 ft. lbs. Loosen and retorque nut to 7 ft. lbs. Lock nut in this position by staking nut collar into slot of spindle.

All Models - Turn wheel and tighten clamping nut just enough to seat roller bearings. Loosen until tab washer can be easily moved in a lateral direction (by means of screwdriver) and no perceptible bearing play is felt when hub is moved axially. Tighten screw on clamping nut to specified torque and recheck adjustment.

All Models (Front) - Front wheel bearings are not adjustable. Torque front spindle nut to 145 ft. lbs.

All Models (Rear) - Install washer and lock nut. Tighten lock nut to 36 ft. lbs. (5 mkg) to seat bearings. Loosen lock nut completely, then tighten nut to 1.4-2.9 ft. lbs. (.2-.4 mkg) and lock nut in place by bending flange into slot of lock nut.

All Models (Front) - Front wheel bearing is not adjustable. Tighten spindle nut to 174 ft. lbs.

4WD Station Wagon (Rear) - Rear wheel bearings are not adjustable. Tighten spindle lock nut to 145 - 181 ft. lbs.