Online Guide and Manuals

Manufacturers: Toyota, Porsche, Triumph, Renault, Volkswagen, Saab, Subaru, Volvo
Models Covered: 911SC and Turbo, Land Cruiser, R-5, TR7 and Splitfire, 99, VW Type I, Volvo 240, 260
Year: 1978

TIRE INFLATION (COLD)
Before attempting to check or adjust wheel alignment, make sure tires are properly inflated. Refer to manufacturer's specifications given in owner's manual.

NOTE - Riding height should be set with full tanks of gasoline and spare tire included.

All Models (Front) - Checking or adjusting riding height can only be performed with vehicle on level surface. Mark center of front wheel hub cap (grease retainer cup). Bounce vehicle several times to settle suspension. Measure distance "a" as shown in illustrations, then measure distance "b". Difference "a" and "b" should be to specifications. If necessary to adjust, loosen or tighten torsion bar adjusting bolt until correct height is obtained. Bounce vehicle several times and recheck height. NOTE - Difference between right and left measurement must not exceed .20".


911 Series (Rear) - Checking or adjusting riding height can only be performed with vehicle on level surface. Mark center of rear wheel. Bounce vehicle on level surface. Mark center of rear wheel. Measure distance "a" as shown in illustrations. Distance "a" plus .468" euals "b"; however, distance "b" is difficult to measure because the torsion bar is mounted off center in its rubber bushing. Therefore, it is necessary to measure distance "b 1" and add .585" (radius of bushing). This total should be equal to "b" should be .468±.20". Difference in height from left to right should not exceed .197". If values are not within specifications, check front height and rear torsion bar adjustment. Correct as required.

All Models - If caster angle is not to specifications, it will be necessary to move adjuster plate which attaches to front shock absorber. Remove enough front compartment carpet to allow access to top of each shock absorber. Mark position of each movable plate, located below each Allen screw. Loosen each screw and upper shock absorber nut. Move assembly lengthwise to obtain correct caster angle. Tighten all three screws and shock absorber nut. NOTE - Movement of adjuster plate from side to side will affect camber angle.


911 Series (Rear) - Mandatory prerequisite, for obtaining permissible camber values at rear wheels, is proper adjustment of rear torsion bars. See Torsion Bar Adjustment. Loosen nuts on retaining bolts and nuts on eccentric bolt at rear axle flange. Turn camber eccentric until camber angle is within specifications. Tighten retaining nuts and eccentric bolt nuts.

914 Series (Rear) - Mark position of rear axle control arm on base plate and remove center bolt. Loosen remaining bolts. Change shims between control arm bushing and body. Shims are available in .039" thicknesses. Addition or removal of one shim changes camber angle by 10'. With camber angle to specifications tighten all bolts.

All Models - Place wheel in straight-ahead position. Adjust left and right steering links (tie rods) equally to obtain specified setting. Coat each steering link with anti-corrosive compound after adjustment.

911 Series (Rear) - Place torsion bar into transverse tube with inner end splines first. Slip radius arm onto outer end splines of torsion bar. Place suitable leveling tool (VW 261) on lower edge of door opening and adjust level so bubble is in center of glass. Check adjustment (degrees) of free hanging radius arm with some leveling tool. If not to specifications, adjust by turning torsion bar and radius arm in opposite directions. Adjustment of both radius arms must each equal 36°45'±15.

TIRE INFLATION (COLD)
Before attempting to check or adjust wheel alignment, ensure that tires are properly inflated.


NOTE -  Riding height should be set with a full tank of gas and spare tire in proper position.
All Models (Exc. 356B/C and 911E) Front - Check or adjust riding height with vehicle on level ground. Mark center of front wheel hub cap. Bounce vehicle several times to settle front suspension. Measure dimension "a" as shown in illustration. When riding height is properly set, dimension "b" is 4.25" (911 & 912) or 3.54" (914) less than dimension "a" ± .2". To adjust riding height, if not properly set, loosen or tighten adjusting screw on torsion bar until correct dimension is obtained. Bounce vehicle several times and recheck. Difference between right hand and left hand measurement may not be more than .2".
911E (1969-72) - These models equipped with self-leveling hydropneumatic suspension system. Spring struts must be brought to correct height before proceeding with wheel alignment checks. Insert the measuring pins of suitable tool (P 1036),  through the hollow of sub frame until they make contact with the left and right wishbones. Attach the measuring pins with a small amount of grease. Lift car at the front center with a car jack until dimension "b", shown in illustration, is 4.252. Carry out normal wheel alignment procedures. NOTE - If hydraulic car jack is used, make sure that the hack does not sink while checking alignment.

FRONT RIDING HEIGHT DIMENSIONS

REAR AXLE RIDING HEIGHT DIMENSIONS

911 & 912 Rear (1965-72) - Check rear axle height with vehicle on level ground. Bounce vehicle several times to set suspension at proper attitude. Mark center of rear wheel and measure dimension "a" as shown in illustration. To calculate "b1", add .472 in. to dimension "a" less radius of the bushing cover on torsion bar. Measure "b1". Calculated value should not differ from actual measurement by more than .197 in. The height difference between left and right side should not be more than .315 in. If values are not within limits, check height adjustment of front suspension and rear torsion bar adjustment. Correct if necessary.

All Models Exc. 356B/C - Remove sealing compound on pressure plates and supporting bearings. Mark position of single hole and double hole pressure plates . Loosen pressure plate bolts. Shift supporting bearing with shock absorber strut in vehicle lengthwise direction until caster is within specifications. NOTE - Any shifting of shock absorber strut in crosswise direction will change the camber adjustment. Tighten pressure plate bolts.
356B/C - If caster is not within specifications check torsion bar angle and correct if necessary. See Torsion Bar installation in SUSPENSION Section. If caster still not within specifications with torsion bar adjustment correct, remove and check suspension arms and the stub axles separately.

All Models Front Exc. 356B/C - To adjust camber, refer to Caster adjustment procedure and not the following. Shift supporting bearing with shock absorber strut in vehicle crosswise direction to adjust camber to specifications. Tighten pressure plate bolts and reseal supporting bearings and pressure plates with a permanent elastic sealing compound
356B/C Front - if camber not within specifications check torsion bar angle and correct if necessary. See Torsion Bar Installation in SUSPENSION Section. If camber still not within specifications with torsion bar adjustment correct, check suspension arm offset, suspension arm and stub axles. Replace as necessary.
911 & 912 Rear (1965-72) - Mandatory prerequisite for obtaining permissible camber values at rear wheels is proper adjustment of torsion bars. See Torsion Bar Adjustment. Loosen retaining bolt nuts and eccentric bolt nuts at the rear axle flange. Turn camber eccentric so camber angle within specifications. Tighten retaining bolt nuts and eccentric bolt nuts.
914 Rear (1970-72) - Mark position of rear axle control arm on base plate and remove center bolt. Loosen remaining bolts only slightly. Change shims between control arm bearing and body to change camber angle. A 1mm shim results in approx. 10" change of camber. With camber to correct specifications tighten bolts, install center bolt and tighten.
356B/C Rear (1963-65) - The camber adjustment depends on the setting of the radius arms. If camber not within specifications, See Torsion Bar Adjustments.

All Models Front Exc. 356B/C - Turn steering wheel to center position (wheels straight ahead). Adjust left hand and right hand tie rods to bring each wheel to a 20" toe-in. Wheels should be pressed with a preload of 33lbs. NOTE - Coat the threaded part of the tie rod with an anti-corrosion compound upon completion of front axle adjusting.
356B/C Front - Turn steering wheel to center position (wheel straight ahead). Adjust short tie rod so left wheel shows + 10' toe-in (pressed). Adjust long tie rod so right wheel shows +10' toe-in (pressed)
911 & 912 Rear (1965-72) - Loosen retaining bolt nuts and eccentric bolt nuts at the rear axle flange. Turn toe eccentric so that specifications are within limits. If in cases requiring extreme adjustment the camber eccentric is in the extreme left or right of the oblong cavity in the radius arm then the camber eccentric should be turned around by 180 degrees to preclude possible binding. NOTE - The camber eccentric must always point down at the time of installation to preclude binding when toe-in adjustments are made. Tighten retaining bolt nuts and eccentric bolt nuts. Recheck rear wheel camber and toe.
914 Rear (1970-72) - Slightly loosen control arm bearing bolts and push control arm outside (back or forth) as required. Move until specifications are within limits. Tighten bolts.
356B/C Rear (1963-65) - Loosen bolts on bearing flange of axle tube and strap screw. More axle tube until specifications are within limits. Tighten stop screw and screws on bearing flange.

911 and 912 Rear (1965-72) - Place torsion bar into transverse tube with inner end splines first. Slip radius arm onto outer end splines of torsion bar. Place suitable tool (VW 261) onto the lower edge of door cavity in body and adjust clinometer so bubble in glass tube is in center. Check adjustment of free hanging radius arm using suitable tool (VW 261). If not within specifications adjust by turning torsion bar and radius arm in opposite directions to change angle. Adjustments of both radius arms must be the same if camber specifications are to be within limits.
356B/C Rear (1963-65) - Using suitable tool (VW 245o) check horizontal position of vehicle on floor tunnel and more reading to be taken into account in setting radius arm. Install torsion bar so that splines engage socket in frame. Install radius arm on outer end of torsion bar. Place suitable tool (VW 245o) on unloaded radius arm. Adjust pendulum on tool so that level is horizontal. If actual angle of radius arm  is not within specifications, adjust by moving torsion bar and radius arm in opposite directions to change angle. The adjustment of both radius arms should be identical. When adjusting one side, always check other side. Correct if necessary.

All Models - Check working surfaces of ball pins and their seats, and ball joint studs for damage or wear. Axial play should not exceed specifications (.04"). Replace complete ball joint unit when indicated

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 - With components removed from control arm and ball joint still installed, check the following: Horizontal and vertical free play (0") and ball joint rotation starting torque 4-7 ft. lbs. (.6-1.0 mkg). Replace ball joints if correct specifications are not obtained

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

All Models (Exc. 620 Pickup) - Remove lower control arm. Measure axial movement by lifting and depressing ball joint stud. Difference between these two measurements is axial movement. Using suitable spring tension gauge attached to top of ball joint stud measure force (INCH lbs.) required to move ball joint stud laterally. If either 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.

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 up excessive wear in ball pin and socket. If parts are excessively worn, replacement is required.

With vehicle raised and supported under lower control arms, grasp wheel at top and bottom. Try to shake wheel and if any movement is noted, inspect front suspension for wear or damage.

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.

All Models - Raise and support front of vehicle. Inspect ball joint rubber boots for damage and replace as necessary. Using suitable gauge (J-23745) measure axial play. If axial play is more than .080" (2 mm), ball joint must be replaced.

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

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

All Models - Inspect ball joints for wear or excessive play. Replace ball joint 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. Allowance loosness is less than .012". If play exceeds this specification, ball joint must be replaced.

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.