Transmission DATSUN 210 1979 Workshop Manual

DATSUN

210
Model
8310
Series

MANUAL
TRANSMISSION

CONTENTS

4
SPEED
TRANSMISSION

Model
F4W60L

REMOVAL

INSTALLATION

DISASSEMBL
Y

TRANSMISSION
CASE
DISASSEMBLY

DISASSEMBLY
OF
GEAR
ASSEMBLY

ADAPTER
PLATE
DISASSEMBLY

REAR
EXTENSION
DISASSEMBLY

INSPECTION

TRANSMISSION
CASE
AND
REAR

EXTENSION

BEARING

GEARS
AND
SHAFTS

BAULK
RING

SHIFTING
INSERT

01
L
SEAL

REAR

ENGINE
MOUNTING

INSULATOR

ASSEMBL
Y

FRONT
COVER

ASSEMBLY

TRANSMISSION

CASE
ASSEMBLY

REAR
EXTENSION
ASSEMBLY

ADAPTER
PLATE

ASSEMBLY

ASSEMBLY
OF
GEAR
ASSEMBLY

TRANSMISSION

ASSEMBLY

S
SPEED
TRANSMISSION

Model
fSSW60L

REMOVAL

INSTALLATION
MT
2

MT
3

MT
4

MT
5

MT
5

MT
5

MT
9

MT
9

MT
9

MT
9

MT
9

MT
9

MT10

MT10

MT10

MT10

MT10

MT10

MT10

MT10

MTll

MT
1
1

MT14

MT

16

MT17

MT18
DISASSEMBL
Y

TRANSMISSION
CASE

DISASSEMBLY

DISASSEMBLY
OF
GEAR
ASSEMBLY

ADAPTER
PLATE
DISASSEMBLY

REAR

EXTENSION
DISASSEMBLY

INSPECTION

TRANSMISSION
CASE
AND

REAR
EXTENSION

BEARING

GEARS
AND

SHAFTS

BAULK
RING

SHIFTING
INSERT

01
L
SEAL

REAR
ENGINE

MOUNTING

INSULATOR

ASSEMBLY

FRONT
COVER
ASSEMBLY

TRANSMISSION
CASE
ASSEMBLY

REAR
EXTENSION
ASSEMBLY

ADAPTER
PLATE
ASSEMBLY

ASSEMBLY

OF
GEAR

ASSEMBLY

TRANSMISSION
ASSEMBLY

SERVICE

DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

INSPECTION
AND
ADJUSTMENT

TIGHTENING
TORQUE

TROUBLE
DIAGNOSES
AND

CORRECTIONS

SPECIAL
SERVICE

TOOLS
MT19

MT19

MT19

MT
22

MT
22

MT
23

MT
23

MT
23

MT
23

MT
23

MT
24

MT
24

MT
24

MT
24

MT
24

MT
24

MT
24

MT
24

MT
25

MT

29

MT31

MT31

MT32

MT

33

MT

34

MT

35

Manual

Transmission

4
SPEED
TRANSMISSION
Model

F4W60L

t

f

@

4

Y

0

f

@
@

jj
J
QW

i

6

i

l

16
Rear
cxtension
dust
cover

with
oil
seal

17

Top
detecting
switch
TM281A

6
Tran
smi
sion
case
a

mbly

7
Filler

plug

8

Adapter
plate

9
Breather

10

Bearing
retainer

11

Rear
extension
dowel

pin

12
Reverse

lamp
sWitch

13
Rear
extension

assembly

14
Drain

plug

15
Retum

spring
bushing

Fig
MT
l

F4W60L

TrarwniuionClOMJ
Components
Tighteni
torque
kg
m
ft
lb

@
1
0
0

1
6

7
to
12

@
2
0
to
3
0

14
to
22

@
0
1
to
1
0

5
1

to
1

2

@
1

6102
2

12
to
16

@
2
5
to
4

0
18
to
29

itJ
2
0
to
3
5

141025

@
2
5
to
4

0
18
to
29

I8i
2
0

to
3
5

14
to
25
1
Front

cover

2
Front
cover
oil

seal

3
Front
cover
O

ring

4
Front

cover

adjusting
shim

5

Welch

plug

c

@

r

TM093A

1

Main
drive

bearing

2
Main
drive

gear

3
3rd

top
synchronizer

4

3rd

gear
mainshaft

5
Mainshaft

6
2nd

gear
mainmaft

7
ht

2nd
synchronizer

8
1

It

gear
mainshaft

9
Mainshaft
bearing

10
Reverse
gear
mainshaft

11
Counter

gear
assembly

12
Idler
gear
assembly

Fig
MT
2
F4W60L
Transmi8aion

G
CompoMnla
I

I

I

MT
2

I
ht
2nd

fork
r

2

3rd

top
fork
rod

3
Reverse
fork
rod

4

Retaining

pin

5
I
t

2nd
shift

fork

6
3rd

top
shift
fork

7

Checking
ball

plug

8

Check
ban

spring

9
Check
ball

10
Interlock

plunger

11

S

topper
ring

12

Shift
rod
A
bracket

13
Reverse

shift
fork

14
Lock

pin

15

Striking
lever
Manual
Transmission

16

Striking
rod

17
Return

spring
plug

18
Reverse

check

spring

19
Return

pring

20

Plunger

21
D

ring

22
Stopper
pin
bolt

23

Striking
guide
assembly

24

Striking
guide
oil
seal

REMOVAL

To

dismount
transmission

from
the

car

proceed
as
follows

Disconnect

battery
ground
cable

2

Remove
console
box

and
detach

rubber
boots
if

so

equipped

3

Place
transmission
control
lever

in

neutral

position
and
remove
it

m

TM781

Fig
MT
4

Removing
Control
Lever
@

@

25
Control
lever

bushing

26

Expansion
plug

27
Control

pin
bushing

28
Control
arm

pin

29
Control
lever
o

Tightening
torque
kg
m
ft
lb

@
0
5
to

0
8
3

6
tn
5
8

@
1
3
to
1
7

9
to
12

Fig
MT
3
F4W60L
Tra11lmiBSion

Shift
Control

Components
TM094A

4
Jack

up
the

car
and

support
its

weight
on

safety
stands
Use
a

hy

draulic
hoist
or

open
pit
if
available

Make

sure
that

safety
is

insured

5

Disconnect
front
exhaust
tube

and

remove
bolt

securing
exhaust

mounting
bracket
from

exhaust
front

tube

side

6

Disconnect
wires
from

reverse

back

up
lamp
switch

7

Disconnect

speedometer
cable

from
rear
extension
At

the
same
time

removey

top
detecting
switch
if
so

equipped

8
Remove

propeller
shaft

Refer
to
Removal
Section
PO

Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from
flow

ing
out

MT
3
9

Remove
clutch

operating
cylinder

from
transmission
case

10

Support
engine
by
placing
a

jack

under
oil

pan
with
a
wooden

block

used
between
oil

pan
and

jack

CAUTION

00
not

place
the

jack
under
the

oil

pan
drain

plug

11

Support
transmission
with
a

transmission

jack

12

Loosen
rear

engine
mount
se

curing
bolts

CD

temporarily
and
re

move
crossmember

mounting
bolts

V

Fig
MT
5

Removing
Rear

1IIline

Mounting
Croamember
Manual

Transmission

13

Remove

starling
motor

14
Remove
bolts

securing
transmis

sion
to

engine
and

gusset

Then

support
the

engine
and

trans

mission
with

jacks
and
slide
trans
is

sion
rearward

away
from

engine
and

remove
from
the
car

CAUTION

Take
care
in

dismounting
trammission

not
to
strike

any
adjacent
parts
and

main
drive

gear

INSTAUATION

Install
the
transmission
in
the

re

verse
order
of

removal

paying
atten

tion
to
the

following
points

MT
4
I

Before

installing
cJean

mating

surfaces
of

engine
rear

plate
and

trans

mission
case

2

Before

installing
lightly

apply

grease
to

spline

parts
of

clutch
disc

and

main
drive

gear
And
also

apply

grease
to

moving
surfaces
of

control

lever

and

striking
rod

3
Remove
filler

plug
and
fill
trans

mission
with

recommended

gear
oil
to

the

level
of
the

plug
hole

Oil

capacity

1
3
liter

2
US

pt
2

Y

Imp
ptl

4

Apply
sealant
to
threads
of
filler

plug
and

install
fdler

plug
to
transmis

sion

case

IiJ
Tightening
torque

Filler

plug

2
5
to
4
0

klt
fll

18
to
29
ft

Ib

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

I

Prior
to
disassembling
traiIsmis

sian

thoroughly
wipe
off
dirt

and

grease
from
it

2
Drain

oil

thoroughly

3

Remove
dust
cover
from
trans

mission

case

Remove
release

bearing
and
with

drawallever

4

Remove
reverse

lamp
switch
and

top
detecting
switch
if

equipped

5
Remove

speedometer

pinion
as

sembly

6
Remove

nut
and

stopper
pin
bolt

from
rear
end
of
rear
extension

TM783

Fig
MT
6

Removing
Nut
and

Stopper
Pin
Bolt

7

Remove
return

spring
plug
return

spring
reverse
check

spring
and

plunger
from
rear
extension

@

@

j

TM784

Fig
MT

7
Rt

moving
Return

Spring
Plug

8
Remove
front
cover
Detach

0

ring
and
front
cover

adjusting
shim

TM785

Fig
MT
B

Removing
Front
Cover

a

Ring
and

Adju

ting
Shim
Manual
Transmission

9
Remove
main

drive

bearing
snap

ring
with

snap
ring

pliers

o

TM188

Fig
MT

9
Rt

mouing
Main
Drive

BNring
Snap
Ring

10
Remove

rear
extenSion

secUring

baits
and
turn
the

striliing
rod

clock

wise

Drive
out
rear
extension

backward

by
lightly
ta

pping
around
it

with
a

soft

hammer

TM787

Fig
MT
10

Removing
Rear
Extemion

11

Separate
transmission
case
from

adapter
plate
by
evenly
tapping

around
it

with
a
soft
hammer

CAUTION

Do
not

pry
transmission
case
or
rear

extension
from

edapter
plate
with

screwdriver

TM788

Fig
MT
II

Removing
Tronsmiuion

COSf

MT

5
12

Set

up
Adapter
Setting
Plate

KV32100300

on

adapter
plate

Place
the
above

assembly
in

a
vise

TM789

Fig
MT
12
A

ttaching
Gear

A
mbly

to

Special
Tool

13
Detach
counter

gear
thrust

washer

DISASSEMBLY
OF

GEAR

ASSEMBLY

Shift

forks
and
fork
rods

I

Drive

out

retaining

pins
from

each
fork

rod
with
Fork

Rod
Pin

Punch

ST23540000

TM790

Fig
MT
13
Drive
Out

Retaining
Pim

2

Drive
out
reverse

gear
shift
fork

and
reverse
idief

gea

TM791

Fig
MT
14

Driving
Out
Re
1dkr

Gear
and

Shift
Fork

3

Remove
three
3
chick

ball

plugs

TM792

Fig
MT
15

Removing
Check
Ball

Plug

4

Drive
out
fork
rods
from

adapter

plate
by
lightly
tapping
on

the
front

end

Detach
shift
forks

Note

a
Be

careful
not
to
lose

three
3

check
balls
and

two
2
interlock

pluDgl
rs

b
Each

gear
and
sbaft
can
be
de

tached
from

adapter
plate
without

removing
each
fork
rod

D

t

@

@
6

@

1

q
eck
ball

ptug

2
Fork
Tod
1st
2nd

3
InterJock

plunger

4

Fork
rod
3rd
4th

5

Fork
rod
reverse

6
Check
ball
TM793

Fig
MT
16
Check
Ball
and

Interlock

Plunger

Gear

assembly

Note
It

is

necessary
to
measure
end

play
before

disassembling
main

sbaft
and
after

reassembling
main

shaft
Refer
to

Inspection
for
Gears

and
Shafts

1
Remove
reverse

gear

snap
ring

from
the

rear
of
mainshaft

using

snap

ring

pliers
and
remove
thrust
washer

and
mainshaft
reverse

gear
Manual

Transmission

TM794

Fig
MT

17
R

molJing
Reuerse
Gear

SfUJpRing

2

Remove
four
4

bearing
retainer

attaching
screws
with

an

impact
driver

and
remove

bearing
retainer

TM79S

Fif
MT

18

RemouingBcrews

3

Remove

snap

ring
from

mainshaft

rear

bearing
using

snap
ring
pliers

TM796

Fig
MT
19

Removing
Mainshaft
Rear

Bearing

Snap
Ring

4
Drive

out
mainshaft

gear
as

sembly
together
with
counter

gear

assembly
by
lightly
tapping
the
rea

end
with
a

soft
hammer
while

holding

the
front
of
mainshaft

gear
assembly

and
counter

gear
assembly
by
hand

MT
6
Remove

counter

g
ar

main

dfN

gear
and

mainshaft

assembly
in
that

order

CAUTION

Be
careful
not
to

drop
gears

TM797

Fig
MT
20

Removing
Gear

AlSembly

Malnshaft

Disassemble
mainsltaft

gear
assem

bly
as
follows

1
R

emove

snap
ring
from

l
l
Iinshaft

front
end

Remove
3rd

4th

synchronizer

assembly
baulk

rings
3r

gear
and

mainshaft
needle

bearing
toward
the

front
side

Fig
MT
21

Removing

Snap
Ring

2

Press

out
mainsltaft

bearing
using

Bearing
Puller

ST3003Iooo
See

Fig

MT
23

CAUTION

When

pressing
out

bearing
hold

main

shaft

by
hand
so
as
not
to

drop
it

Manual

Transmission

3
Remove
thrust
washer
1
st

gear

needle

bearing
bushing
1st
2nd

synchronizer
assembly
baulk

rings

2nd

gear
and
needle

bearing
from

mains
haft

ST30031000

l
l

TM693

Fig
MT
22

RemotJing
Mainshaft

Bearing

fJ

I

@

00
1

Snap
ring

2

Baulk

ring

3

Shifting
imcrt

4

Coupling
sleeve

5

3rd

gear
mainshaft

6
Needle

bearing

7

Mainshaft

8

Spread
spring

9

Synchronil
er
hub

10

3rd
4th

synchroniz
er
assembly
II
2nd

gear
mainshat
t

12
ht
2nd

synchronizer

assembly

13
Mainshaft

bearing

14
1st

gear
mainshaft

15

Bushing
ht

speed
gear

16
Thrust
washer
mainshaft

11
Reverse

gear
mainshaCt

18
Thrust
washer

19

Snap
ring

TM799

Fig
MT
23

Mainshaft

A
mbly

Remove

sna

p
ring
and

spacer
with

snap

ring
pliers

2
Press
out

main
drive

bearing
with

Bearing
Puller
ST22730000
and
a

suitable

press
CAUTION

When

pressing
oul

bearing
hold

gear

by
hand
so
as
not
to

drop
it

1
Mein
drive

geer

ST22730000

TM

695

Fig
MT
24

Removing
Main
Drive

Bearing

MT7

Manual
Transmission

1
Snap
ring

2

Spacer

3

MaiJl4rive
be

ng

4

Main
drive
gear

5
Pilot

bearing

TM696

Fig
MT
25
Main
Drive
Gear

Counter

gear

1
Remove

snap
ring
from
the

rear

of
counter

gear
using
snap
ring
pliers
2

Press
out

counter
reverse

gear

using
Bearing
Puller
ST22730000
and

suitable
bar

CAUTION

When

pressing
out
coiinter
reverse

gear
hold

gear
by
hand
so
as
not
to

drop
it

TM697

Fig
MT

26
Removing
Snap
Ring

@

5

i

MT
8
H

J

TM698

Fig
MT
27

Removing
Counter

Reverse
Gear

3
Press
out

counter

gear
rear
bear

ing
using
Bearing
Puller
ST22730000

CAUTION

Be
careful
01
to

drop
counter

gear

9

iL

TM699

Fig
MT
28

Removing
Counter
Gear

Rear

Bering

1
Needle

bearing

2

Thrust
washer

3

Counter

gear

4

Bearing

5

Counter
reverse

gear

6

Snap
ring

TM800

Fig
MT
29
Counter

Gear

Synchronizers

I
Remove

spread

springs

j
and

take

out

shifting

inserts@

2

Separate
coupling
sleeve

@
from

synchro
hub

@

0
t
j

@

O
LJ

J
1

ID

4

Synchro
hub

S
Baulk

ring
1

Spread

spring

2

Shifting
insert

3

Coupling
sleeve

TMSOl

Fig
MT
30
Synchronjzer

Assembly

ADAPTER
PLATE

DISASSEMBLY

1
Remove
reverse
idler
shaft

snap

ring
using
snap

ri
1g
pliers
and

draw

out
reverse
idler
shaft

by
lightly

tap

ping
the
shaft

end
with
a

soft
hammer

k

Fig
MT
31

Removing
Reverse

Idler

Shaft
Snap

Ring

REAR

EXTENSION

DISASSEMBLY

I

Remove
lock

pin
nut
and

lock

pin

from

striking
1

lever

Remov

str

iking

lever

TM803

Fig
MT
32

Removing
Lock
Pin

Nut
Manual

Transmission

2

Remove

striking
rod
and

stiking

guide
from
rear

end
of
rear

extension

j

1
Lock

pin

2

Striking
lever

3
Return

spring
plug

4

Con
trollevcr

5

Striking
rod

6

Striking
fod

guide

7
Control
Ie
o
eI

pin

8

Stopper
pin
bolt

INSPECTION

Wash
all

parts
in
a
suitable

cleaning

solvent
and

check
for
wear

damage
or

other

faulty
conditions

CAUTION

a
Be
careful
not

to

damage
any

parts

with

scraper

b
Do
not
clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE
AND

REAR
EXTENSION

I
Check

for
cracks
which

might

cause
oil
leak
or
other

faulty
condi

tions

2

Check

mating
surface
of
case
to

engine
or

adapter
plate
for
small
nicks

projection
or

sealant

Remove
all

nicks

projection
or

sealant
with
a

fine
stone

3
If
rear
ext

nsion

bushing
is
worn

or
cracked

replace
it

as
an

assembly
of

bushing
and
rear
extension

BEARING

Thoroughly
clean

bearing
and

dry

with

compressed
air

2

When
race
and
ball
surfaces

are

MT
9
Note
Do

not
remove
rear
extension

bushing
from
rear
extension

@

TM804

Fig
MT
33
Shifting
Mechanism

worn
or
rough
or
when
balls
are

out
of
round
or

rough
replace
bearing

TM372

Fig
MT
34
In

pecting
Ball

Bearing

3

Replace
needle

bearing
if

worn
or

damaged

GEARS
AND
SHAFTS

I

Check
all

gears
for
excessive

wear

chips
or

cracks

replace
as

required

2

Check
shaft
for

bending
crack

wear
or

worn

spline
if

necessary

replace

3
It
is

necessary
to

measure
end

play
before

disassembling
mainshaft

and
after

reassembling
rnainshaft

Tighten
mainshaft
lock
nut
to

speci

fied
limit
and
measure
end

play
to
in

sure
that
it
is

within

specified
limit

If
end

play
is
not
within

specified

limit
disassemble
and
check

parts
for

condition

Replace
any

part
which
is

worn
or

damaged

standard

gea
end

play

1st

gear

0
15
to
0
25

mm

0
0059
to
0
0098

inl

2nd

gear

0
30
to
0
40
mm

0
0118
to
0
0157
in

3rd

gear

0
15
to
0

30
mm

0
0059
to
0
0118

in

TMB05

Fig
MT

35

Me
uring
End

Phly

4

Check
for

stripped
or

damaged

speedometer
pinion
gear
If

necessary

replace

BAULK
RING

1

Replace
any
baulk

ring
which
is

deformed
or
cracked

2

Position
baulk

ring
in

place
on

gear
cone
and

measure
the
baulk

ring
to

gear
clearance
with
baulk

ring

pushed
toward

gear

If
the

clearance
is
smaller
than

the

specified
value

replace
baulk

ring

Standard
baulk

ring
to

cone

clearance

0
80
to
1
65

mm

0
0315
to
0
0650

inl

If
it
is

less
than
0
5
mm
0
020
in

a
worn
baulk

ring
may
be
the

cause

and
a

new

ring
should
be

fitted

TM806

Fig
MT

36
Baulh

Ring
10
Cone

Gap
Manual
Transmission

SHlFTING
INSERT

Replace
if
worn

excessively
worn

unevenly
deformed

or

damaged

OIL

SEAL

I

Discard
a

ring
or
oil

seal
which
is

once
removed

Replace
oil
seal

if

sealing
lip
is
deformed
Or
cracked

Also

discard
oil
seal
if

spring
is

out
of

position

2

Check
the
oil

seal

lip
contacting

with

shaft
if

necessary
replace
oil
seal

and

shaft
as
a
set

REAR
ENGINE
MOUNTING

INSULATOR

Replace
rear

engine
mounting
insu

lator

if
weakened
deteriorated
or

cracked

ASSEMBLY

To
assemble
reverse

the
order
of

disassembly
Observe
the

following
in

structions

FRONT
COVER
ASSEMBLY

I

Make
sure
that
seal

mating
sur

face
is

clean

Using
a

press
and
Oil
Seal
Drift

ST23800000
drive
new
seal
into

place

on
front
cover

Note
When

pressing
oil
seal
into

place
apply
coat
of

gear
oil
to

surface

adjoining
oil

seal

2
Lubricate
seal

lip
and
main

drive

shaft
with

gear
oil

when

installing

front

cover

Front

4

Main
drive

gear

2
Gear
oil

TM098A

Fig
MT
37
Fronl

Cover
Oil
Seal

MT10
TRANsMISSION
CASE

ASSEMBLY

1
Press
countershaft
needle

bearing

into
transmission
case
from
outside

Note

a
Needle

bearing
should
not
be
fe

used
after
removal

b
When

iDstalling
needle

bearing
be

sure
to

project
it
2
mm
0
08
in

fromtramission

so
front
surface

c
Make
sure

that
needle

bearing
turm

smoothly

d
After

installing
needle

bearing

apply
multi

purpose
grease
to
the

bearing
surface

Front

t

2
mm

0
08
in

TM

707

Fig
MT
38

Counterlhaft
Needk

Bearing

2
Install

withdrawal
lever

ball

pin

on

case
and

tighten
screw

iJ
Tightening
torque

Ball

pin

2
0

to
3
0

kg
m

14
to
22
ft
lb

REAR
EXTENSION

ASSEMBLY

I
Make

sure
that

seal

mating
sur

face
is
clean

Using
a

press
and
Oil
Seal
Drift

ST35300000

drive
new
seal
into

place

on
rear
extension

Note
When

pressing
oil

seal
into

place

apply
coat
of

gear
oil
to
rear

smace

adjoining
oil
seal

2

Coat
oil
seal

lip
and

bushing
with

gear
oil
for
initial

lubri
tion

Pack

cavity
between
seal

lips
with

recom

mended

multi

purpose
grease
when
in

sta1ling
See

Fig
MT

39