lock DATSUN 210 1979 Owners Manual

Automatic
Transmission

Oil
strainer

to
lower

valve

body

Governor
valve

body
to
oil
distributor

Oil

pump
housing
to

9il

pump
cover

Inhibitor
switch
to
transmission
case

Manual
shaft
lock
nut

Oil
cooler

pipe
to
transmission
case

Test

plug
oil

pressure
inspection
hole

Support
actuator

parking
rod

inserting
position
to

rear
extension

Turn
back
two

turns
after

tightening
0
3
to
0
4

0

5
100
7

0
6
100
8

0
5
to

0
7

3
0
10
4
0

3
0105
0

14102
1

0
810
I
I

SPECIAL
SERVICE
TOOLS

Kent
Moore

No

Tool
number

tool
name
Reference

page
or

Fig
No

ST07870000
Transmission
case
stand

ST07860000
J

25607

Fig
AT
26

ST25850000

Sliding
hammer
J
25721

Fig
AT
30

HT69860000

Snap
ring
remover

Fig
AT
33

AT
53
Tool
number

tool
name

GG930
I
0000

Torque
wrench

ST25420001
Clutch

spring
compressor

ST25420000

ST25320001

Snap
ring
remover
2

2
to
2
9

3
6

to
5

1

4
3

to
5
8

3
6
to
5
1

22
to
29

22
to
36

10
to

IS

5
8

to
g

O

Kent
Moore
No

Reference

page
or

Fig
No

J
25703

Fig
AT
43

J
26063

Fig
AT

53

Fig
AT
60

125710

Fig
AT
53

Fig
AT

60

Propeller
Shaft
Differential
Carrier

DIFFERENTIAL
CARRIER

fQ

@

1

11
Thrust
washer

12

Ring
gear

13
Differential
case

14
Lock
strap

15
Drive

pinion

16
Pinion
height
adjusting
washer

17
Pinion
rear

bearing

18

Collapsible
spacer

19
Side

bearing
cap

20
Gear
carrier
1

Companion
flange

2
Oil
seal

3
Pinion
front

bearing

4
Sidebearing

5
Side

bearing
adjusting
shim

6
Thrust
walher

1
Side

gear

8

Lock

pin

9
Pinion
mate
shaft

10
Pinion
mate
Tightening
torque
kg
rn

ft
lb

@
14
to
30

101
to

211

@
6
0101
0
43
to
51

@
5
0
to
5
0
36
to
43

@
1

6
to
2
4

12
to
11

PD446

Fig
PD

3
Differential
Carrier

2

Visuany
inspect
parts
for
wear

of

damage

3

Rotate

gears
to
see
that
there
is

any

roughness
which

would
indicate

damaged

bearings
or

chipped
gears

Check
the

gear
teeth
for

scoring
or

signs
of
abnonnal

wear
Measure

pre

load
of
drive

pinion

4

Set

up
a
dial
indicator
and
check

the
backlash
at
several

points
around

ring

gear
Backlash
should
be

specified

value

Ring
gear
to
drive

pinion
backlash

0
10

to
0
15

mm

0

0039
to
0

0059
inl
spected
before

any

parts
are
removed

from
it

These

inspections
are

helpful
in

fmding
the
cause
of
a

problem
and
in

detennining
the

corrections
needed

Mount
carrier
on
Differential

Carrier
Attachment
ST06320000
REMOVAL

I

Jack

up
rear
of

car
and

sup

port
it

by

placing
a

safety
stand
under

rear
axle

case
Drain

gear
oil

2
Remove

propener
shaft
and
rear

axle
shafts

These
works
can
be
done

by

referring
to
Rear

Axle
and
Rear

Suspensionu

3
Loosen
off
bolts

securing
differ

ell
tial
carrier

to
rear
axle
ca
se
and

take
out
differential

gear
carrier

as

sembly

PRE

DISASSEMBI
Y

INSPE
CTION

Differential
carrier
should
be
in
5

Check
the

gear
tooth
contact

with
a
mixture

of
recommended

Fig
PD
4

Holding
Differential
Carrier

PD

3

I

powder
and
oil

applied
sp
hingly
to

all

ring
gear
teeth

For
the
tooth

contact

pattern
see

paragraph
dealing
with
tooth
contact

pattern
adjustl1ll
nt

DISASSEMBLY

FINAL
DRIVE
ASSEMBLY

I
Put

match
marks

on
side

bearing

caps
and

carrier
and
remove
side

bearing
caps
and

take
out
differential

case

assembly

using
Slide
Hammer

HTI2400000

PD266

Fig
PD

5

Removing

Diffe
ntial

Ca
e

A
embly

Note
Care
should
be
taken

not
to

confWle
the

left
end

right
hand

bearing
caps
and

bearing
outer

races

so
that

reassembly
will
be

easily

carried
out
with
the
same

parts
in

the

original
position

2

Rel
love
drive

pinion
nut

using

Drive
Pinion

Flange
Wrench

ST31530000
and

pull
off

companion

flange
using
a
standard

puller

Fig
PD

6
Removing
Drive
Pinion

Nut

3
Extract
drive

pinion
assembly
to

the
rearwards

by

tapping
the

front
end
Propeller
Shaft
Differential
Carrier

of

drive

pinion
with
a
soft
baminet

Drive

pinion
can
be
taken
out

together

with
rear

bearing
inner

race

collapsi

ble

spacer
and
washer

4

Remove
oil
seal
and
take
out

front

bearing
inner

race

Note

Oil
seal

must
not
be
reused

5

Hold
rear

bearing
inner

race
with

Drive

Pinion
Rear

Bearing
Inner
Race

Puller
ST30031000
and
extract
from

drive

pinion
with

a

press

STJ0031000

r

1

i
9

PD205

Fig
PD
7

Removing
Pinion

Rear

Bearing
I
nfUr
Race

6

To
remove
outer
races

of
both

front

and
rear

bearings
apply
a
brass

drift
to

race
side
surface
and

with

draw

them

by
tapping
the

top
of

drift

with

a
hammer

PD268

Fig
PD

B
Removing
Pinion
Front

and
Rear

Bearing
Outer
Race

DIFFERENTIAL
CASE

I

When

replacing
side

Wle
Differenliai

Side

Puller
ST3305
1001

and

ST33052000
bearing

Bearing

Adapter

PD
4
Fig
PD
9
Removing
Side

Bearing

Note

a

Puller
should
be
bandlOd
with
care

in

catching
the

edge
of

bearing

inner
race

b
Be
careful
not
to
confuse
left
and

right
band

parts

2

Rel
love
ring
gear
by
sp
readJ
lg

out
lock

straps
and

loosening

ring
gear

bolts
in

diagonally

3

Punch
off

pinion
mate
shaft
lock

pin
from

ring
gear
side

using
Solid

Punch
KV3810Ig00

KV3810I800

PD319

Fig
PD
I0
Removing
Lock
Pin

Note
Lock

pin
is
slaked
et

pin
hole

mouth
on
differential

case
Do
not

punch
it
off

forcibly
without

checking
how
it
is

staked

4

Draw
out

pinion
mate
shaft
and

remove

pinion
ID3
tes
side

gears
and

thrust
washers

Note

Put
mams
on

gear
end
thrust

waaher
so
that

they
can
be
re

installed
in
their

origiital
positions

from
which

they
were
removed

INSPECTION

Thoroughly
clean
all
disassembled

parts
and

examine
them
to
see

that

they
are
worn

damaged
or
otherwise

faulty
and
how

they
are
affected
Re

pair
or

replace
all

faulty

parts
which

ever
is

necessary

1
Check

gear
teeth

for

scoring

cracking
or

chipping
and
make
sure

that

tooth
contact

pattern
indicates

correct

meshing
depth
If

any
fault

is
evident

replace

parts
as

required

Note
Drive

pinion
and

ring
gear
are

supplied
for

replacement
as
a

set

therefore
should
either

part
be

damaged

replece
as
a
set

2
Check

pinion
shaft
and

pinion

mates
for
scores
and

signs
of
wear

and

replace
as

required

F
oUow
the
same

procedure
for
side

gear
and
their
seats
on
differential

case

3

Inspect
all

bearing
races
and
roU

ers
for

scoring
chipping
or
evidence
of

excessive
wear

They
should
be
in

tiptop
condition
such
as
not
worn
and

with
mirror

like
surfaces

Replace
if

there
is
a

shadow
of

doubt
on
their

efficiency
as
an

incorrect

bearing
op

eration

may
result
in
noises
and

gear

seizure

4

Inspect
thrust
washer
faces
SmaU

faults
can
be

corrected
with

sand

paper
If

pinion
mate
to
de

gear

backlash
exceeds

specified
value
re

place
thrust

washers

Pinion

mate
to
side

gear
backlash

0
10
to
0
20
mm

0
0039
to
0
0079
in

5

Inspect
gear
carrier
and
differ

ential
case
for
cracks
or
distortion
If

either

condition
is
evident

replace

Jaulty

parts

6
As
a

general
rule
oil
seal
should

be

replaced
at
each

disassembly

ASSEMBLY
AND

ADJUSTMENT

Assembly
can
be
done
in
the

reverse
order
of

disassembly
The

foUowing
directions
for

adjustment

and

usage
of

special
tools
enable
to

obtain
a

perfect
differential

operation
Propeller
Shaft
Differential
Carrier

PRECAUTIONS
IN

REASSEMBLY

I

Arrange
shims
washers
and

the

like
to
install
them

correctly

2

Thoroughly
clean
the

surfaces
on

which
shims

washers

bearings
and

bearing
caps
are
installed

3

Apply
gear
oil
when

installing

bearings

4

Pack

grease
cavity
between

lips

when

fitting
oil
seal

ASSEMBLY
OF

DIFFERENTIAL
CASE

1

Assemble

pinion
mates
side

gears

and
thrust
washers
in
differential
case

2
Fit

pinion
shaft
to
differential

case

so
that
it

meets
lock

pin
hole

3

Adjust
pinion
mate

to
ide

gear

backlash
or
the
clearance
between
the

rear
face
of
side

gear
and

thrust

washer
to
the

specified
value

by

selecting
side

gear
thrust
washer

Pinion
mate
to
side

gear
backlash

0
10
to
0
20

mm

10
0039
to
0
0079
in

PD023

Fig
PD

l1
Measuring
Clearance

Side

gear
thrust

washer

Thickness
mm
in

0
785
0
0309

0
835
0

0329

0

885
0
0348

4

Lock

pinion
shaft
lock

pin
using
a

punch
after
it
is

secured
into

place

5

Apply
oil

to

gear
tooth
surfaces

and
thrust
surfaces
and
check
if

they

turn

properly

6

Place

ring

gear
on
differential
case

and
install
bolts
and
lock

straps
Tor

que
bolts
to

specification
and
bend

up

lock

straps

PO
5
tiJ
Tightening
torque

Ring
gear
bolt

6
0
to
7
0

kg
m

43
to
51
ft
Ib

CAUTION

e
Use

only
genuine
ring
gear
bolts

end
new
lock

straps

b

Tighten
bolts
in
criss
crilss
fashion

lightly

tapping
around
bolt
heads

with
a
hammer

7

When

replacing
side

bearing

measure

bearing
width

using
Side
Bear

ing
Adjust
Weight
ST3250S000

Weight
mock
ST3250
I

000
and

Master

Gauge
ST325020oo
or
suit

able

standard

gauge
17
5
nun
0
689

in

thickness
and

a

weight
block
2
5

kg
5
5
Ib

prior
to
installation

Standald

bearing
width

17
5
mm
10
689
in

y

ST32501000

8
Select
side

bearing
shims
re

ferring
to

Adjustment
of
Side

Bearing

Shims

9
Press
fit
side

bearing
cone
into

differential
case

using
Gear
Carrier

Side

Bearing
Drift
ST33220oo0
and

Adapter
ST33052000

w

I
ST33220000

PD244
1000

ST33052000

Fig
PD
13

lnatalling
Side

Bearing

Cone

Propeller
Shaft
Differential
Carrier

SPECIAL
SERVICE
TOOLS

Tool
number

tool
name
IKent
Moore
No

I
Reference

page
or

Fig
No

Unit

application

Drive

pinion
flange
wrench
J

25774

Fig
PD
6

Page
PD
7
ST31530000

ST0632001i0
Differential
carrier

attachment

ST3003S000
Drive

pinion
rear
inner

race

puller
set

Puller

Base
CD
ST30031000

00
ST30032000

ST33051001
Differential
sIde

bearing

puller

oiij

9
J

25601

Fig
PD4

Page
PD
9

J
25733

CD

J
25733
1

00

J
25733
2

Fig
PD
7

Fig
PD
9
Tool
number
tool
name

ST33052000

Adapter

@

KV38101800
Solid

punch

ST3250SOO0

CD
ST32501000

00
ST32502000
Side

bearing
adjust
weight

Weight
block

Master

gauge

Er

ST33220000
Differential
side

bearing

drift

ST30611000
Drive

pinion
outer
race

drift
bar

i
IM
I
UI
r
l
JM
M

Md
Kent
Moore
No

Reference

or

Fig
No

Unit

application

J
25797
1

Fig
PD
9

Page
PD
g

FiJi
PD
IO

J
25407
3

CD

J

25407
3

00

J

25407
1

Fig
PD
12

J
25804
D1

Fig
PD
13

Page
PD
g

J

25742
1

Page
PD
6

PD

15
Applicable
to
all
B310
series

models

Front
Axle

Front

Suspension

INSPECTION
AND
ADJUSTIVIENT

INSPECTION

Inspect
in
accordance
with

periodic

maintenance
schedule

Block
rear
wheels
with
chocks

2

Jack

up
the
front

of

car
and

support
it
with

safety
stands

Refer
to

Section
GI
for

lifting

points
and

towing

3

Shaking
each
fiont
wheel

by

grasping
the

upper
and

lower
surfaces

of
the
tires
check

suspension
parts
for

looseness
wear
or

damage
Tighten
aU

loose
bolts
and

nuts
to
the

specified

torque
Replace
all
worn

parts
as

described
under
Front

Suspension

4

Check
wheel

bearings
If

there
is

any
axial
end

play
adjust

bearings
to

specifications

Replace
worn
or

damaged
bearings

as
described
under
Front

Axle

S
Check

strut
for
oil

leakage
or

damage

ADJUSTMENT

WHEEL

BEARING

Block

rear
wheels
with
chocks

2

Jack

up
the
front
of
car
and

support
it

with

safety
stands

3

Remove
brake

pads
Refer
to

Section
BR
for

pad
replacement

4

Remove
hub

cap
cotter

pin
ad

justing

cap
and
wheel

bearing
nut

S

Sparingly
apply
recommended

multi

purpose

grease
to
threaded

por

tion

of

spindle
and

contact
surface

between
wheel

bearing
washer
and

outer
wheel

bearing

6

Tighten
wheel

bearing
nut

using

a
suitable

torque
wrench

P
Tightening

torque

Wheel

bearing
nut

3
0
to
3
5

kll
m

22

to
25
ft

Ibl
Fig
FA

Tighlening
Wheel

Bearing

Nul

7
Turn

wheel
hub
several
times
in

both
directions
to

seat
wheel

bearing

correctly

again
tighten
wheel

bearing

nut
to
the
above

torque

8
Turn
back
wheel

bearing
nut
A

degrees

Return

engle
AU

900

Install

adjusting
cap
and

align
any

of
its
slots
with
hole
in

spindle
If
the

above

procedure
fails
to

align
hole
and

slot

together
then

tighten
lock

nut
as

much
as
I

S

degrees
until
hole
in

spindle
is

aligned
with

eny
slot

CAUTION

00
not

overtighten
wheel

bearing
nuts

as
this

can
cause
wheel

bearing
seizure

9
Turn

hub
in
both

directions
two

or
three
times

measuring
its

turning

torque
and

axial

play
to

ee
if

they
are

within
the

specified
range
If

they
are

not

adjust

Axial

play

Omm

Din

Wheel

bealing
starting
torque

With

new

gleaS8
l8al

A

measured
et

wheel

bearing

nut

less
than
7

kg
cm

G
1
in
Ibl

FA
2
AJ
measuled
et
wheel
hub

bolt

Less
then
1
2

kg
12
G
Ibl

With
u
ed

gr
seal

AJ
measured

at
wheel

bealing

nut

1
0
to
4
5

kg
cm

0
9
to
3
9
in
b

AJ
measuled
at

wheel
hub

bolt

0

17
to
0
79

kg

0
37
to
1
741bl

FA413

Fig
FA
2
Metr

uring
Bearing
Starting

Torq
ue

Repeat
above

procedures
until
cor

rect

starting
torque
is

obtained

Note

a

Correctly
meas
e
rotation

slar
ting

force

toward

tangential
direction

against
hub
bolt

b

Above

figures
do
not

include

dragging
resistance
with

pads
re

moved
on
disc
brake
models

c

Any

slightest
wheel

bearing
axial

play
cannot
be
tolerated

10
Insert
new
cotter

pin
with
the

legs
through
hese
two

parts
spread

legs
away
from
each
other

against
sides

of
wheel

bearing
nut

Fig
FA
3

Installing
Coller
Pin

II
Install
hub

cap
with
new
Q

ring

and
wheel

WHEEL
ALIGNMENT

Correct
front
wheel

alignment
as

sures

proper
car

handling
characteris

tics

and
minimum

steering
effort
with

the
least

amount
of
tire

wear
Before

adjusting
front
wheel

alignment
be

sure
to
make

preliminary
inspection
of

front
end

parts

Tire

pressure
and
balance

Wheel

bearings
and
wheel

bearing

nuts

Steering
gear

play

Steering
gear
housing
loose
at
frame

Steering
linkage
and
connections

Shock
absorber

operation

If

wrong
repair
or

replace
the

damaged
portion
or

parts

When

using
equipment
for
front

wheel

alignment
inspection
follow
the

instructions
furnished
with

equipment

Note

Inspection
should
be

made
with

the
car
set
Ievel
and
at
curb

weight

Cember
end
caster

Camber
and
caster
are

preset
at

factory
and

cannot
be

adjusted

The

car

requires
only
toe
in

and
car

posture
adjustment

Note
If
camber

or
caster

alignment
is

not
within

specifications
check
as

sociated

parts
Repair
or

replace
as

necessary
Front
Axle
Front

Suspension

Toe
In

Measure
toe
in
and

adjust
as
neces

sary
For

adjustment
carry
out
the

following
procedure

1

With

steering
wheel
at

its

straight

ahead

position
check
front
wheels
to

see
if

they
are
set
in

straight
ahead

positions

2
Toe
in

can
be

adjusted
by

varying

length
of

steering
side
rods

Note

a
Loosen

lock
nuts
and

turn
left
and

right
side

rods

equally

b

Turning
side
rods
in
forward
direc

tion
of

car
inaeases
toe
in

c
If
side
rods
have
been

disassembled

set
at

specified
distance
A

be

forehand
when

reassembling

d
Be
sure
to
s
w
side
rods
into
ball

joint
sockets

more
than
20
mm

0
79
in

A
315
mm
12
40
in

EfJK

Toe
in
Unladen

1
to
3
mm

0

04
to
0
12
in

Unladen
means

the

following

conditions

Tankful
of
fuel
radiator
filled
and

engine
oil
full

Spare
tire

jack
hand
tools
mats
in

design
position

All

tires
inflated
to

specified

pres

sure

All
excessive
mud
dirt
and
road

deposit
accumulations

away
from

chassis
and

underbody

3
After
correct
toe
in
is

obtained

tighten
side
rod

adjusting
nuts

FA
J
Toe
in

A
B

Toe
in

28
Lines

parallel
to

center
line
of

body

8

F

A696

FA724

Fig
FA
4

Adj
ting
Toe
in

r

II
Li
1
t

Fig
FA

5
Side
Rod
T

Side
lod

edjusting
nl

8

to
10
0

kg

58
to
72
ft

1
Drive

caf
r

whet
ls
ride

01
properly

2

Gauge
sh

steenng
whe

tion

3
Rota

right
an

on
lOner

Tu

corre

i
I

rf

c

Ji
1

A

JI
U

2

7181

JOck

CL

C

6

Pry
off
cotter

pin
take
out
ad

justing
cap
and

wheel

bearing
lock
nut

7

Remove
wheel
hub
with
disc

brake
rotor
from

spindle
with

bearing

installed

FA199

Fig
FA
10

Removing
Wheel
Hub

Note
Be
careful

not
to

drop
outer

bearing
DOne
out
of
hub
when

removing
hub
from
knuckle

spin

dle

8
Remove
outer

bearing
cone

9
Loosen
four

bolts

securing
brake

disc
remove

disc
brake

rotor
from

wheel
hub

assembly

Fig
FA
11

Removing
Due
Broke

Rotor

Loosen
screws

securing
baffle

plate

take
out
baffle

plate

10
Remove
inner

earing
cone
after

prying
out

grease
seaL
Discard

grease

seaL

11

If
it
is

necessary
to

replace

earing
outer
race
drive
it
out
from

hub
with

a
brass
drift
and
mallet

Evenly

tap
bearing
outer
race
through

two

grooves
inside
hub
Front
Axle

Front

Suspension

Fig
FA

12
Removing
Bearing
Outer

Race

INSPECTION

WHEEL
BEARING

Thoroughly
clean

grease
and
dirt

from
wheel

bearing
with

cleaning
sol

vent
and

dry
with

compressed
air
free

from
moisture
Check
wheel

bearing
to

see
that
it

rolls
freely
and
is
free
from

noise
crack

pitting
or
wear

WHEEL
HUB

Check
wheel
hub
for

crack

by

means
of

a

magnetic
exploration
or

dyeing
test
and

replace
if
cracked

INSTALLATION

Install
front
axle
in
the

reverse

order
of
removal

noting
the
fol

lowing

I
Install

bearing
outer
race
with

Front
Wheel

Bearing
Drift

Inner
ST35321000
Front
wheel

Bearing
Drift
Outer
ST35322000

and

Drift
Bar
ST35325000

until
they

seat
in

hub

2

Pack
hub
and
hub

cap
with

re

commended
multi

purpose
grease
up

to

shaded

portions

fA261

Fig
FA
13

LubriCating
Points

of

Wheel

Hub

FA
5
3
Coat
each

bearing
DOne
with
rec

ommended
multi

purpose
grease

FA781

Fig
FA

14

Coating
Bearing
Cone

with
Grease

4

Place
inner

bearing
cone
in
hub

and
install

a
new

grease
seal

coating

sealing
lips
with
recommended
multi

purpose
grease

5

Concerning
installation
of

brake

parts
refer
to

Section
BR

i
l
Tightening
tOlque

Disc
brake

Rotor
to

hub

3
9
to
5
3

kg
m

28
to
38
ft

lbl

6

Install
hub
with
rotor
and
outer

bearing
cone

7

Sparingly
apply
recommended

multi

purpose
grease
to
threaded

por

tion
of

spindle
and

bearing
washer
to

bearing
contacting
face
Then

install

washer
and
wheel

bearing
nut

Adjust
wheel

bearing
nut
as
de

scribed
in

Adjustment
in
this
section

Note

a
In

order
to
assure
DOrrect

bearing

starting

torque
and

to
extend
serv

ice

nfe
of
wheel

bearings
be
sure

to

avoid
dirt
and

foreign
particles
get

ting
iIi

bearings
grease
seal
Washer

bearing
nut
etc

b

Grease
should
be

changed
at
each

disassembly
end
in

aa
ordance
with

Periodic

Maintenance
Schedule

8

Install
O

ring
on

hub

cap
and

install
hub

cap
on
hub

9
Install
brake

caliper
assembly
re

ferring
to

Section
BR

10
Install
wheel
and
lire

S

Support
strut

assembly
with
a

jack
or
suitable
stand
and
remove

three
nuts

securing
strut
to

hoodledge

Strut
assembly
and

spring
can
then
be

removed
as
a
unit

DISASSEMBLY

When

disassembling
a

strut
extra

caution
should
be
exercised
to
avoid

dirt
and
dust

getting
inside
strut
This

dirt
and
dust
is
loaded
with
abrasive

which
if
enters
strut
causes
internal

leak
and

premature
wear
of

moving

parts

I
Secure
Strut

Steering
Gear

Housing
Attachment
KV48100300
in

a
vise
and
install
strut
on
attachment

2

Set

up
Spring
Compressor

ST3S6S
100
I

on

spring
Compress

spring
just
far

enough
to

permit
turn

ing
of
strut

mounting
insulator

by

hand
Remove

self

locking
nut

FA658

Fig
FA
18

Comprt
ingSpring

3
Remove

lock
nut

on

top
of

piston

rod
remove

mounting
insulator
strut

mounting
bearing
dust

seal

spring

seat

spring
and

bumper
rubber

CAUTION

Be

sure
to
hook

special
tool

8135651001

evenly
on
a

minimum

of
three
coils

Paying
attention
not
to

damage
piston
lod
Front
Axle
Front

Suspension

AJ

r

ST3565S001

F

A059
k

j

h

Fig
FA
19

Removing
Mounting

Insulator

4

Retract

piston
rod

by
pushing
it

down
until
it
bottoms
Remove

gland

packing
with
Gland

Packing
Wrench

ST3SS00001

A

ST35500001

1J

FA209
KV48
100300

Fig
FA

20
Removing
Gland

Packing

Note

Clean

gland

pecking
of

mud

and
other

foreign
perticles
accumu

lated

5
Remove

O

ring
from

top
of

pis

ton
rod

guide
bushing

6
Lift
out

piston
rod

together
with

cylinder

Note
Do
not
remove

pistion
rod

quickly
as
this
will
cause
oil
to

spurt
out

FA275

Fig
FA

21

Removing
Pi
ton
Rod

and

Cyliilder

FA
7
Note

Piston
rod

piston
rod

guide

and

cylinder
are

adjusted
to

provide

precision
mating
sutfeces
and

should
be
handled
as
a

matched
set

7
Drain

fluid

thoroughly
from
inner

cylinder
and
discard

8

Wash
aU

parts
in

suitable
solvent

9
Drain
fluid

thoroughly
from

outer

casing

Note
This

operation
is

very
im

portant
since

performance
of
strut

varies
with
amount
of
fluid
filled

within
strut

INSPECTION

I

Replace
gland
packing
O

ring
and

fluid
whenever

strut
is
disassembled

2

Wash
aU

perts
except
for
non

metallic

parts
with
suitable
solvent

and

dry
with

compressed
air

3
Blow
dirt
and
dust

off
of
non

metallic

parts
using
compressed
air

Note

a

Oil

oozing
out
at
and
around

gland

pecking
does
not
call

for
strut

maintenance
If
oil
leaks

past
pring

sest

check

piston
rod
and

gland

pecking
to
cxirrect
the
cause
of

problem
If
oil

leakage
occurs

on

welded

portion
of
outer
strut

casing

replace
strut
outer

casing

essembly

b
If
hock
absorber
itself
is

malfunc

tioning
replace
as
an

assembly
in

cluding

piston
rod

cylinder
bot

tom
valve
and

guide
bushing

Outer
ce
in

Check
outer

casing
for
evidences
of

deformation

cracking
or
other
dam

age
If

necessary
discard

Strut
mountln
In
uletor

Replace
if
cemented
rubber
to

metal

joints
are
melted
or
cracked

Rubber

parts
should
also
be

replaced

if
deteriorated

Strut
mountln
beerln

Replace
if

inspection
reveals
abnor

mal
noise
or
excessive
rattle
in
axial

direction

FA070

FA071

Fig
FA

26
Air
Bleeding
from
Strul

9
Place
Strut

Steering
Gear

Housing
Attachment
KV48100300
in

jaws
of
a
vise

10

Before

proceeding
with
further

steps
pull
piston
rod
all

the

way
out

to
the
limit
of

its
stroke
install
bound

bumper
rubber
in

place
to

prevent

piston
rod

from
falling

by
its

own

weight

11

Compress
spring
with

Spring

Compressor
ST35651001

ST35651001

r
l

I

FA665

Fig
FA

27
Compressing
Spring

Note
To

prevent
interference
be

tween

upper
spring
seat
and

special

tool
leave

upper
2
5
to
3
turns
of

spring
coils
free

compress
spring

and
assemble
to
strut

12
Lubricate
dust
seal
indicated

by

arrow
in

Fig
FA
28

with
recommend

ed
multi

purpose
grease
Front
Axle
Front

Suspension

I

1

i
I
FA671

Fig
FA
28
Grea

ing
Point

13
Install
dust

cover

upper
spring

seat

dust
seal

mounting
bearing
and

insulator
in
this
written

order

Note

a
Be

careful
to
avoid

damaging
piston

rod

during
disassembly
and
assem

bly
Do

not
use

pliers
or
the
like
in

an
effort
to
extract

piston
rod

b
InstaU
thrust

bearing
so
that
it

points
in
correct

direction

Fig

FA

28

14

Tighten
new

piston
rod

self

locking
nut

fil
Tightening
torque

Pi
ton
rod
elf

Iocking
nut

6
0
to
7
5

kg
m

43
to
54

ft
lbl

Note

a

Temporarily
tighten
self

locking

nut
on

tip
of

piston
rod
After

installing
piston
rod
on
car

tighten

self

locking
nut
to

specification

b

Replace
self

locking
nut
whenever

strut

is
disassembled

15
To

prevent
entry
of

water
and

dust

apply
a
thick

coat
of

recom

mended

multi

purpose
grease
to

points

indicated

by
arrows
in

Fig
F
A

28

16
After

placing

spring
in

position

between

upper
and

lo
er

spring
seats

release

compressor
graduaUy

I
J

k

1
jt
r
end

FA074

Fig
FA
29

talling
Front

Spring

FA
9
17

Raise
bound

bumper
rubber

10

u

per
spring
seal

I

STALLATION

Install
strut
and

spring
assembly
in

reverse
order
of
removaL

fil

Tightening
torque

Strut

to

hoodledge

2
5
to
3
5

kg
m

18

to
25

ft
Ib

Steering
knuckle

arm
to
strut

7
3
to
9
9

kg
m

53

to
72
ft
lb

Note

a

Make
sure
brake
hose
is

secure
and

not
tw

ted

b
When

installing
steering
knuckle

ann
to
the
bottom

of
strut
as

sembly

epply
the
suitable

sealing

material
to
the
indicated

portion
so

as
to

prevent
ball
stud
from
rust

FA660

Fig
FA
30
Applying
Sealant

TENSION
ROD
AND

STABILIZER
BAR

REMOVAL

I

Jack

up
the
front
of
car
and

support
it
with

safety
stands
remove