service DATSUN 210 1979 Workshop Manual

12

Disconnect

speedometer
cable

from
rear
extension

housing

13

Remove
transmission
control

linkage

I

For
cars

equipped
with
manual

transmission

remove

gear
shift
control

lever

Fig
ER
6

Removing
Gear
Shift

Control
Lever

2

For
cars

equipped
with
auto

matic
transmission
disconnect
selector

range
lever

e

a

EA163

Fig
ER

7
Di8connecting
Selector

Range
Lever

14

Disconnect
exhaust
front
tube

from

exhaust
manifold
and
exhaust

mounting
bracket
rom
transmission

I

liJ
Tightening
torque
I

ER370

Front
tube

to
exheust

manifold

1
9
to
2

5kg
m

14

to
18

ft
Ibl

Fig
ER
S

Disconnecting
E
chaust

Front
Tube
Engine
Remov
1
Installation

15

Hang
front
tube
end

with
a

suitable
thread
or
a
wire
to

prevent

tube
from

falling

J
6
Remove

propeller
shaft

Refer
to

Propeller
Shaft
Section

PO

for
removal

Plug
the

opening

end

of
rear
extension

housing
to

pre

vent
oil

leakage

P0315

liJ
Tightening
torque

Propeller
shaft
to

companion

flange

2
4
to
3
3

kg
m

17
to
24
ft
bl

Fig
ER
9

Removing

Propeller
Shaft

Note

Pul
me
tch
mark
on
both
shaft

and

companion
flange
so
that
shoft

can
be
reinstalled
in

original
posi

tion

17

Support
transmission
with

jack

18

Remove
bolts

securing
rear

engine
mounting
member
to
the

body

19
Attach

Engine
slinger

10006H7202
as
shown
in

Fig
ER
IO
Note

Use

slinger
only
wheo

engine
is

removed
from

or
installed
on
car

Be

sure
to
remove
it
efter
Ulle

This

slinger
is
listed
in

Parts
Cet

log

as
a
service

optiop

20

Connect

suitable
wire

or
chain

to

Engine

Slingers
and
raise

engine
a

little
to
take

weight
off
front
mount

ing
insulators

WARNING

For

sofety
in

subsequent

steps
ten

sion

of
wire
or
chain
should

be

slackened

against
engine

21
Remove

bolts

securing
front

engine

mounting
brackets
to
froni

engine
mounting
insulators

22
Reise

engine
and

transmission

and
remove
from

car
as

a

single
unit

See

Fig
ER
IO

CAUTION

a
Before

raising
engine
10gether
with

transmission
make
sure
that

all

hoses
and
wires
connected

thereto

are
disconnected
or
removed

b
When

raising
engine
be

especially

careful
not
to
knock
it

against

adjacent
parts

ER
4
EA225

Fig
ER
IO

Removing
Engine

Engine
Removal
Installation

SERVICE
DATA
AND
SPECIFICATIONS

TIGHTENING

TORQUE

Front

engine
mounting
bracket
to

engine

Front
insulator
to

engine
mounting

bracket

Front
insulator
to

suspension
member

Rear
insulator
to
rear

engine
mounting

member

Rear

engine
mounting
member
to

body

Rear
insulator
to
trailsmission

Clutch

operating

cylinder
to
clutch

housing

Front

tube
to
exhaust
manifold

Propeller
shaft
to

companion
flange

Emaust

mounting
bracket
to
tranSmission
kg
rn
ft
lb

kg
rn
ft
Ib

gem
ft
Ib

g
m
ft
lb

g
m

ft
Ib

g
m
ft
Ib

kg
m
ft
Ib

g
m
ft
lb

kg
m
ft
lb

g
m
ft
Ib

ER
6
1

6
to
2
1

12
to
IS

1
6
to

p
12
0
I

3
2
to
4
3
23
to
31

0
9

to
1
2

6
5
to
8
7

3
2
to

4
3
23
to
31

0
9
to

q
6
5
to
8
7

3
1

to
4
1
22

to
30

1
9

to
2
5

14
to
18

2
4

to
3
3

17
to
24

0
8
to
1
2
5
8

to
8

7

DATSUN
210
Model
8310
Series

SECTIONCL

CLUTCH

CONTENTS

ADJUSTMENT

CLUTCH
PEDAL
HEIGHT

CLUTCH
PEDAL
FREE

TRAVEL

BLEEDING
CLUTCH
SYSTEM

CLUTCH
CONTROL

CLUTCH
PEDAL

CLUTCH
MASTER
CYLINDER

OPERATING
CYLINDER

CLUTCH
LINE

CLUTCH
UNIT

CLUTCH
DISC
AND

COVER
CL
2

CL
2

CL
2

CL
2

CL
3

CL
3

CL
4

CL
5

CL
6

CL
7

CL
7
RELEASE

BEARING

PILOT
BUSHING

SERVICE
DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

INSPEctiON
AND
ADJUSTMENT

TIGHTENING
TORQUE

TROUBLE
DIAGNOSES
AND

I

ECTIONS

SPECIAL

SERVICE
TOOLS
CL
8

CL
9

CL
10

CL
10

CL10

CL
11

CL
12

CL
14

CLUTCH
PEDAL

HEIGHT

I

Adjust
clutch

pedal
height
H
to

the

specified
range
with

pedal
stopper

adjusting
nut
Then

tighten
lock
nut

CD

2

Adjust
clutch

pedal
free

play
A

to
the

specified
range
at

pedal

pad

with
clutch
master

cylinder
push
rod

Then

tighten
lock
nut

@

Note

a

Pedal
free

play

appeared
due
to

clearance

among
pedal
hole

push

rod
and

piston
should
be

measured

on

top
face
of

pedal
pad

b

Depress
and
release
clutch

pedal

over
its
entire
stroke
to
ensure
that

the
clutch

linkage

operates
smooth

ly
without

squeak
noise

inter

ference
and

binding

I

I

Lock
nut

2

Lock
nut

Cl325

Fig
CL
I

AdjlUting
Clutch

Pedal

Height

Pedal

height
H

143

to
149

mm
5

63
to
5
87
in

Pedal
free

play
An

1

to
5
mm

0
04

to
0

20
in
Clutch

ADJUSTMENT

tfl
Tightening
torque

Lock
nut

CD

0
8

to
1
2

kg
m

5
8
to
8
7

ft
Ib

Lock
nut

@

0
8
to
1

Icll
m

5
8
to
8
7
ft

lbl

CLUTCH
PEDAL

FREE
TRAVEL

Adjust
clutch

pedal
free
travel

whenever
clutch
does
not

disengage

properly
or
whenever
new

clutch

parts
are

i
lslalled

I
Loosen
lock

nut
and

push
nut

djust
length
of

push
rod

by
turning

p
lsh
rod
with

open
end
wrench

until

release

bearing
lightly
touches
clutch

dia

phragm

spring

2

Then
turn

push
rod
back

approxi

mately
I

4
turns
so
that
withdrawal

lever

play
B

clearance
between

withdrawal
lever

push
nut
and
with

drawal
lever

is
within
the

specified

range

V

@

1
B

I

Lock

nut

2
Push
nut

3

Withdrawallcver

CL327

Fig
CL

2

AdjlUting
Clutch

Pedal

Free

Trauel

3

Tighten
lock
nut

against
push

nut

being
careful
not
to
disturb
the

adjustment

4

Depress
and
release
clutch

pedal

several
times

then
recheck

with

drawal

lever

play
B

Readjust
if

necessary

5

Finally
measure

pedal
free
travel

C
at
center
of

pedal
pad

CL
2
Withdrawalle

er
play
nBn

clearance
between
withdrawal

I
er

push
nut
and
withdrawal

le
erl

1
0

to
2
0

mm

0

039
to

0
079
in

Clutch

pedal
free

tr
el
en

at
center
of

pedal
pad

16to33
mm

0
63
to
1
30
in

BLEEDING
CLUTCH

SYSTEM

The

hydraulic
clutch

system
must

be
bled
whenever

clutch
line
has
been

disconnected
or
air
has
entered
it

When

pedal
action
has
a

spongy

feeling
it
is
an
indication
that
air
has

entered
the

system

Bleeding
clutch

system
is

an
essen

tial

part
of

regular
clutch
service

I
Remove

cap
of
reservoir
and

top

up
with
recommended
brake
fluid

2

Thoroughly
clean
mud
and
dust

from
bleeder
screw
of

operating
cyl

inder

so
that
outlet
hole

is
free
from

any

foreign
material
Install
bleeder

hose

vinyl
hose
on
bleeder
screw

Place
the
other
end
of
it
in

a

container

filled
with
brake
fluid

3
Have

a
co
worker

depress
clutch

pedal
two
or

three
times

With
clutch

pedal
depressed
fully
loosen
bleeder

screw

to
bleed
air
out
of
clutch

sys

tem

4
Close
bleeder

screw
quickly
as

clutch

pedal
is
on
down
stroke

5
Allow
clutch

pedal
to
return

slowly
with
bleeder

screw
closed

6

Repeat
steps
3

through
5
until
no

air

bubble
shows
in

the

vinyl
hose

tfl

Tightening
torque

Bleeder
screw

0
7

to
0
9

kg
m

5
1

to
6
5
ft

lbl

7

Depress
and
release

clutch

pedal

several
times
then

check
for

external

hydraulic
leaks
at

connections

Clutch

SERVICE
DATA
AND

SPECIFICATIONS

ENERALSPECIFICATIONS

Clutch
control

system

Type
of
clutch
control

Clutch
master

cylinder

Diameter

Clutch

operating
cylinder

Type

Diameter

Clutch
disc

Type

Facing
size

Outer
dia

x
Inner
dia

x
Thickness

Thicmess
of
disc

assembly

Free

Installed

Number
of
torsion

springs

Clutch
cover

Type

FuU
load
Hydraulic

mill
in
15
88

mm
in
Adjustable

1746

180CBL

mrn
in
180
x
125
x
3
5

7
09
x
4

92
x
0
138

mm
in

mm
in
8
5
to
9
2
0
335
to
0
362

7

6
to
8
0
0
299
to
0
315

6

kg

Ob
CI80S

335
to
385
739
to
849

INSPECTION
AND
ADJUSTMENT

Clutch

pedal

Pedal

height
H

Pedal
free

play
A

Withdiawallever

play
B

Pedalfree
travel
C

Clutch
master

cylinder

Maximum
clearance
between

cylinder
bore
and

piston

Clutch

operating
cylinder

Maximum
clearance
belween

cylinder
bore
and

piston

Clutch
disc

Wear
liinit
of

facing

Depth
of
rivet

head
below

facing
surface

Runoullimit

Distance
of

runout

checking
point

from
the
hub

center

Maximum
backlash

of

spline

at
outer

edge
of

disc
mm
in

mm
in

mm
in

mm
in
143
to
149
5

63
to

5
87

1

to
5

0
04
to
0

20

1

0
to
2

0
0
039
to
0
079

16
to
33
0
63
to
1
30

mm
in

Less
than
0
15
0
0059

mm
in

Less
than
0
15
0
0059

mm
in

mm
in
0

3
0
012

0
5
0
020

mm
in
85

3
35

mm
in

0
4
0
016

CLIO

Condition

Clutch

slips

Clutch

drags
Clutch

TROUBLE

DIAGNOSES
AND

CORRECTIONS

Probable

cause
and

testing
Corrective
action

Slipping
of
clutch

may
be
noticeable

when

any
of
the

following
symptoms
is

encountered

during
operation

I
Car
will
not

respond
to

erigine
speed
during
acceleration

2
Insufficient

car

speed

3
Lack
of

power

during
uphill

driving

Some
of
the

above
conditions

may
also
be
attributable
to

engine
problem
First
determine

whether

engine
or
clutch
is

causing
the

problem

If

slipping
clutch
is

left
unheeded
wear

and
or

overheating
will
occur
on
clutch

facing
to
such

an
extent
that
it
is

no

longer
serviceable

TO

TEST
FOR
SLIPPING
CLurCH

proceed
as
follows

During
upgrade
havelling
run

engine
at

about
40
to
50

km
h
25
to
31
MPH

with

gear
shift

lever
in

3rd
speed
position
shift
into

highest

gear
and
t
the
same
time

rev

up
engine
If
clutch

is

slipping
car
willnot

readily
respond
to

depression
of
accelerator

pedal

Clutch

facing
warn

excessively

Oil
or

grease
on
clutch

facing

Warped
clutch

cover
or

pressure
plate
Replace

Replace

Repair
or

replace

Dragging
clu

tch
is

particularly
noticeable

when

shifting

gears
especially
into

low

gear

TO
TEST
FOR

DRAGGING
CLurCH

proceed
as
follows

I
Start

engine

Disengage
clutch
Shift
into

reverse

gear
and
then
into
Neutral

Gradually

increase

engine

speed
and

again
shift
into
reverse

gear
If
clutch
is

dragging
gear
grating

is
heard
when

shifting

gears
from
Neutral
into

Reverse

2

Stop
engine
and
shift

gears
Conduct
this
test
at
each

gear
position

3
In

step
2

gears
are
shifted

smoothly

except
1st

speed
position
at

idling

a
If

dragging
is

encountered

at
the
end
of

shifting
check
condition
of

synchro

mechanism
in

transmission

b
If

dragging
is
encountered
at
the

beginning
of

shifting
proceed
to

step
4

below

4

Push

change
lever
toward
Reverse
ide

depress
pedal
to
check
for
free

travel
of

pedal

a
If

pedal
can
be

depressed
further
check
clutch
for

condition

b
If

pedal
cannot
be

depressed
further

proceed
to

step
5

below

5
Check

clutch
control

pedal
height
pedal
free

play
free

travel
withdrawal
lever

play
etc

If

any
abnormal

condition
does
not
exist
and
if

pedal
cannot
be

depressed
further
check

clutch
for

condition

Clutch
disc

runout
or

warped

Wear
or
rust

on
hub

splines
in

clutch

disc

Diaphragm
spring
toe

height
out
of

adjustment
or
toe

tip
worn

Worn

or

improperly
installed

parts
Replace

Clean
and
lubricate

with

grease
or

replace

Adjust
or
replace

Repair
or

replace

CL12

Clutch

SPECIAL
SERVICE
TOOLS

Tool
number
tool

name

ST206100ll0
Clutch

aligning
bar

KV30100100
Clutch

aligning
bar

STI0050100
Distance

piece

ST20050010
Base

plate

0
@
IKent
Moore

No

Reference

page
or

Fig
No

Unit

application

125673

Fig
CL

1O

Fig
CL
15

F4W60L

Fig

qIO

Fig
CL
15

FS5W60L

Fig
CL
13

Fig
CL
13
Tool
number
tool
name

ST2005005
I

Set
bolts

YVYYVYVV

ST20050240

Diaphragm
spring
adjusting

wrench

KVIOl02800
Pilot

bushing

puller

GG94310000
Flare
nut

torque
wrench

Applicable
to
all
B310
series
model

C114
Kent
Moore
No

Reference

page
or

FiR
No

Unit

application

Fig
CL

I3

Fig
CL
14

J25657

Fig
CL
21

Page
CL
3

Page
CL
5

Page
CUi

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

SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Transmission

model

F4W60L
FS5W60L

Item

No

of

speeds
4
5

Synchromesh
type
Warner

Shift

type

t
3

I
I
R
2
4

2
4
R
r

I
I

1

3
5

1st
3
513

3
513

2nd
2
170
2
170

3rd

1
378
1
378

Gear
ratio

4th
1

000
1
000

5th

0

846

Rev
3

764
3

464

Final

gear
ratio
3
700
3

700

155

13
6
15
13
4PR

16
5

Speedometer

Tire

155SRI3
16
5

gear
ratio

175
70SR13
16
5

Oil

capacity
liter

US

pt
Imp
pt
1
3
2
U

2
Y

I
1
2

2
i
i
i

MT31

Manual
Transmission

SPECIAL
SERVICE
TOOLS

Tool
number
tool
name

KV32
I

00300

Adapter
setting
plate

ST23540000
Fork
rod

pin
punch

ST22730000

Bearing
puller

STJ0031000

Bearing
puller

STJ5300000
Oil
seal
drift
I
Kent
Moore
No

Reference

page
or

Fig
No

Unit

application
Tool
number

tool
name

J

25693
ST23800000

Fig
MT
12

Fig
MT
40

Fig
MT
77

Fig
MT
104

J
25689

Fig
MT
13

Fig
MT

78

J
2568
1

Fig
MT
24

Fig
MT
27

Fig
MT
28

Fig
MT
92

J
25733
1

Fig
MT
22

Fig
MT
90

Page
MT
IO

Page
MT
24
Transmission

drift

ST22350000

Mainshaft

bearing
drift
I
Kent
Moore
No

I
Reference

page
or

Fig
No

Unit

application

J

25691

Page
MT
IO

Fig
MT
46

Page
MT
24

Fig
MT
I
II

J

25678

Fig
MT
44

Fig
MT
55

Fig
MT

I08

Fig
MT
I
25

Fig
MT
48

Fig
MT
50

F4W60L

KV32
100100

Counter

gear

height
gauge
J

26070

Fig
MT
49

F4W60L

J

26071

Fig
MT
52

Fig
MT
115

Applicable
to
all
B310
series

models
F4W60L
and
FS5W60L

MT35
KV32
100200

Countershaft

bearing

press
stand

KV32
100400
Mainshaft

puller

Fe
rnuffiUQ

cP