DATSUN 510 1968 Service Repair Manual

126
CHAPTER

TEN

@

r

Removal

Pick

up

1
Remove

mountlng
clIps
and

U
bolt
See

FIgure
16

2
Disconnect
front
tube
and

exhaust
manuold

flange
connectIon

3
Remove
exhaust

system
from
vehicle

Inspection

1
Check
for

damage
at
tube

flanges
Replace
u

defectIve
2
Check
for
dIstortIon

damage
or
detenora

tIon
of
tubes
and
mufHers

Replace
or

reparr
as

required

3
Check
for

damage
to

hanger
straps
mounting

clIps
U
bolts
and
rubber
Insulators
Remove

and

replace
as

requrred

Installation

Install
the
umts

m
the

reverse
of
removal

After
InstallatIon

nm
the

engme
and
check
for

exhaust

gas
leaks

CHAPTER
ELEVEN

CLUTCH
TRANSMISSION
AND
DRIVESHAFf

CLUTCH

i
es

ription

Datsun
uses
a

single
dry
dtsc
clutch
with

dIaphragm
spring
The

major
components
are

clutch
cover

pressure
plate
dIaphragm

spring

and
WIre

nngs
The
clutch
dISC
has
riveted

plates

on
both
surfaces
and
coll

spnngs
arranged
in
a

link
The
coll

springs
absorb

shock
to
soften
and

smooth
clutch

engagement
Figure
1
next

page

is
an

exploded

diagram
of

the
clutch

assembly

Clutch
Removal

The
transmIssion
must
be

separated
from
the

engme
to
remove
tlte
clutch

assembly
This
can

be
done

by
removmg
the
transmISSIon
and

engme

from
the
vehicle
as
a
umt
or

by
remoVIng
the

transmiSSIon

separately
Removal
of
the

engine

and
transmissIOn
IS
descnbed
In

Chapter
Six

Removal
of
the
transmISSIon

only
IS
descnbed

later
in
tills

chapter

Outcb

Disassembly

1

Separate
clutch

assembly
from

flywheel

Loosen
and

remove
bolts

dIagonally
and

gradu

ally
as
shown
m

Figure
2

2
Remove
dust
cover
from
clutch

housmg

3
Remove
return

spnng
from

beanng
sleeve

Separate
the
Withdrawal
lever
from

bearing

sleeve
w

1

4
Remove
release

bearmg
and

bearing
sleeve

from
front
cover
Remove
wIthdrawal
lever

ball

pm
Figure
3

CD

1
Withdrawal
lever

ball

pin

2
Withdrawal
lever

3
Return

spnng

4
Release

beanng
4

128

CHAPTER
ELEVEN

1
Clutch
disc

assembly

2
Clutch
cover

3
Hex
bolt

4
Lock
washer

5
Withdrawal
lever

6
Withdrawal
lever

ball

pin

7
Lock
washer

8
Retainer

spnng

9
Clutch
sleeve

10
Release

bearing

11
Holder

spring

12
Dust
cover

13
Return

spring

14
Push
nut

15
Hex
nut
CD

9

11

8

6

7

1
Release

beanng
2

Beanng
sleeve
2

5
13

12

15

14

Clutch

Inspection
and

Repair

1

Thoroughly
clean
all
dISassembled

parts
ex

cept
for
the

dISc

assembly
and
release

bearmg

In
a
SUItable
solvent

2
Check

all

parts
carefully
for
wear
cracks

and
other
defects

3
Check
the
clutch
disc
for
oil
soaked

or

cracked

faCIngs

warpmg
loose
nvets

exceSSIve

wear
and
broken

spnngs

4
Check
the

pressure
plate
for

sconng
bum

marks
blue
tlnted
areas
and
cracks

If

any
of

the
above
condItIons
are
found

re

place
the
clutch
dISC
and
or
the

pressure
plate

Replace
dISC

assembly
1f

facmg
IS
worn
so
that

the

facmg
heIght
above
the

nvet
IS
less
than

00118m
03mm

Very
mmor
bum

marks
and

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
129

scratches
on
the

pressure
plate
may
be

removed

with

crocus
cloth

If
the
source
of
clutch
trouble
IS
still
not
evl

dent
take
the

pressure
plate
and
disc
to
a

compe

tent

garage
to
check
the

pressure
plate
finger

release

height
and
nmout
Never

attempt
to
ad

just
the

fingers
or
dismantle
the

pressure
plate

Without

proper
tools
and

experience

Check
the
release

bearing
by
holdmg
the
Inner

race
and

rotatmg
the
outer
race
With

hght
pres

sure

applied
If
the

bearing
is

rough
or

noisy

replace
it

CAUTION

Never
clean
the
release

bearing
In

solvent
It
IS

prelubriCflted
at

the

fac

tory
Simply

wipe
with
a
Unt

free
cloth

If
the
release

bearing
shows

any
signs
of
loss

of

lubncant
install
a
new

bearing
Replace
the

sleev
lu
SignS
of
wear
are
evident

Clutch

Reassembly

1
Be

sure

your
hands
are
clean
for
the
initIal

assembly

2

Inspect
the
clutch

facings
pressure
plate
and

flywheel
to
be
sure

they
are
free
from

grease
oil

and
other

foreIgn
material

3

TIghtly
fit
release

bearmg
onto
the

bearing

sleeve
When

beanng
IS
mstalled
turn

bearmg

With

a

finger
to
make
sure
It

operates
smoothly

4

Apply
multI

purpose
grease
to
the

bearmg

sleeve
InSIde

groove
See

Figure
5

CD
Ji

rot

Pac
thiS
r

r
r

1
1i

QI
ecess

5

Apply
multi

purpose
grease
to
the

WIth

drawallever
and

bearing
sleeve
contact

point
and
to
the
Withdrawal
lever
ball

pm
and
with

drawallever
contact

point

f

6
Clean
the
clutch

pllot
bushmg
and
fill
It

With
multi

purpose
grease

7
Mount
the
WithdraWal
lever
release

bearing

and

bearing
sleeve
to
the
clutch

housing
Install

dust
cover
on
clutch

housing
and
connect
return

spring
to
WithdraWal
lever

8
Place
the

pressure
plate
and
clutch
disc
in

positIon
on
the

flywheel
Make
certain
the

pres

sure

plate
is
In
the
same

positIon
relative
to

fly

wheel
as
when
removed
Use
a
clutch

alIgning

bar

Special
Tool
ST20630000

FIgDfe
6
to

alIgn
the
clutch
dISc

splIne
to
the

pllot
bearing

CD

NOTE

If
the

special
tool
is
not
avail

able

cut
an

input
shaft
from
a

Junk

transmission

9
Install
the

pressure
plate
mounting
bolts

Tighten
the
bolts

dIagonally
opposite
each
other

one
turn
at
a
time
to

prevent
warpmg
Torque

the
bolts
to
10
8
to
15
9
ft
lbs
1
5
to
2
2

kg
m
Remove

durmny
shaft

10
Install
the
clutch

housing
to
the

engme

Clutch
ntrol

Datsuns
have
a

hydraulic
clutch
control

system
It
consISts
of
a

pendant
clutch

pedal

130

CHAPTER

ELEVEN

master

cylInder

operatlng
cylinder
and
with

drawal
lever

Figure
7
shows
all

components

whlle

Figures
8
and
9
are

exploded
VIews
of
the

master

cylmder
and

operatIng
cylinder
for

models
smce
1970
Prior
models

are

similar
In

construction

MASTER

CYLINDER

Master

Cylinder
Removal

Sedans
and

Wagons

1
Remove
cleVIS

pin
mstalled
at
the

pushrod

2

Disconnect
clutch
hose

from
the
master

cylin

der
and
dram
flwd

3

Remove
bolts
to
free

master

cylinder

Master

Cylinder
Removal

Pick
up

1
DIsconnect

pushrod
from
clutch

pedal

2
DIsconnect
clutch
hose
from
master

cylInder

and
drain
fluid

3
Remove
bolts
to
free
master

cylInder

Master

Cylinder
Disassembly

1
Remove
filler

cap
and
drain
fluid

2
Pull
back
dust
cover
and

remove

snap
ring

3
Remove

stopper
pushrod
piston
assembly

cup
and
return

spnng

CD

i
Master

Cylinder
Inspection

1
Clean
all

parts
thoroughly
In
clean
brake

flwd

2
Check

cylInder
and

pISton
for

wear
or
dam

age
Replace
as

required

3
Check
the

clearance
between

cylInder
and

pIston
If
clearance
is

larger
than

0
005
in

0

13mm

replace
the

cylinder

4

Replace
the

pISton
cup
whenever
it
is
re

moved
from

the

cylInder
or
when
It
shows

SIgnS

of

wear
or

damage

5
Check
all
other

parts
for
wear
or

damage

and

replace
as

required

Master

Cylinder
Assembly

1
Soak

piston
cup
m
brake
fluid

2
Install

pIston
cup

3
Coat
the

cylinder
and

pIston
thoroughly
WIth

brake
flwd
and
assemble

4

Replace
other

parts
in
the

reverse
order
of

removal

Master

Cylinder
Installation

1
Bolt
the
master

cylInder
into

pOSItion

2

Adjust
clutch

pedal
heIght
by
adjusting
the

pushrod
length
Pedal

heIght
from
floorboard

e
j

11
i
Il
Il

15
2
Tl

CTOKICO
2
Piston
assembly

3
Piston
cup

4
Valve
assembly
CI

5
Val
e
spring
I

6
Spnng
seat

7
Return
spring

8
Spnng
seat

9
Push
rod
assembly

10
Push
rod
head

11
Nut

12
Stopper

13
Stopper
ring

14
Dust
cover

15
0
reservoir

2
rl
16
Reservoir
bend
assembly

17
ReservOir
cap

NABCO

1
k
IN

132
CHAPTER

ELEVEN

CD

NAnCO
22
20
21

r

i

T

l
C

r
Jl

i

i

18
Clutch

operating
cylinder

19
Piston

cup

20
PIston

21
Dust
cover

22
Push
rod

23
Bleeder
screw

24
Bleeder
cap
22

I

should
be
8
150
m
207mm
for
the
sedan
and

wagon
Pedal

heIght
should
be
591
m

150mm

for
the

pick
up

3

Apply
multI

purpose
grease
to
all

PIvot

pOInts

4
Bleed
all
aIr
out
of
the

sy
tem
as

dIscussed

below

OPERATING
CYLINDER

Operating
CyHnder
Removal

1
Remove
retum

spring

2
Disconnect
clutch
line
from

operating
cyl

inder
18

Ii

TOKICO

21

I

LL

18
23
24

I
I

3
Disconnect

pushrod
from
wIthdrawal
lever

4
Release
two
bolts

holdmg
operating
cylInder

to
clutch

hOUSIng

5
Remove

operating
cymder
from
clutch
hous

mg

Operating
CyHnder
Disassembly

1
Remove
dust
cover

2
Remove

snap
ring
All
other

parts
can
now

be
removed
See

Figure
10

Operating
CyHnder
Inspection

Check
all

parts
especIally
the

pIston
cup
for

wear
and

damage
Replace
if
defects
are
found

CLUTCH
TRANSMISSION
AND
DRlVESIIAFI
133

C
8

Q@J

@

C

Operating
Cylinder
Reassembly

1
Soak

pISton
cup
m
brake
flUid
and
Install
It

In
the
same

pOSitIOn
as
before
removal

2

Apply
brake
flUid

to
the

cylInder
and

pIston

before

mstalImg
piston

3

Replace
all

parts
m
the
reverse
order
of

removal

Operating
Cylinder
Installation

1
RemstallatIon
IS
the
reverse
of
removal

2
Bleed
aIr
from
the

hydraulIc
system

3

Adjust
the

pushrod
so
that
withdrawal
lever

end

play
IS
0
0787
to
0
1181
In
2

0
to
3
Omm

Procedures
for

the

adjustment
are

given
below

WITHDRAWAL
LEVER
AD
JUSTMENT

Correct

adjustment
of
the
clutch
withdrawal

lever
IS
essentIal
InsufficIent
free
travel
between

the
release

bearmg
and

dIaphragm
fingers
can

cause
the
clutch
to

slIp
ExceSSIve
free
travel
can

prevent
full

dISengagement
of
the
clutch
Refer

to

Figure
11

1
Loosen
lock
nut

2
SCrew
In
the

pushrod
fully
with
the

adjustmg

nut

3
Unscrew

adJustmg
nut
1
turns

TIghten

lock
nut

J

4
Check
the
end

play
of
the
wIthdrawal
lever

End

play
should
be
0
0787
to
0
0906
in
2
0
to

2
3mm
The
correct
end

play
will

give
a
clear

ance
of
0
0512
m

1
3mm
between
the
release

bearmg
and

diaphragm
fingers
@

1
Lock
nut

2

AdJustmg
nut

3
Wrthdrawal
ever

4
Release
beer

ng

5

Diaphragm
spnng
20
to
30

0
079
to
0
11

B

Unit
mm
m

5
If
the
above

adjustment
does
not
result
in

satIsfactory
clutch

operatIon
the
clutch
dISC
is

probably
worn

excessIvely
and
will

reqUire
re

placement
as

preVIously
dIScussed

BLEEDING
CLUTCH
SYSTEM

AIr
In
the
clutch

hydraulIc
system
makes
shIft

Ing
gears
extremely
difficult
1f
not

impOSSIble

To
bleed
the

system
proceed
as
follows

1
Remove
the
bleed
screw
dust

cap
from
the

operating
cylInder

2
Attach
a
bleeder
hose
to
the

bleed
screw

Immerse
the
other
end
of
the
hose
m
a
container

f

hydraulIc
brake
fluid

3
Check
to
see
that
clutch
master

cylInder

reservoir
IS
full
of
brake
flUid

ReplenISh
if

necessary

4

Open
the
bleeder
screw

three
quarters
of
a

tlIrn
and
have
an
assistant

pump
the
clutch

pedal
slowly
Pump
the
clutch
until
the

flUid

entenng
the

contatner
is
clean
and
free
from

bubbles

5

TIghten
bleed
screw

Replace
dust

cap
Refill

the
flUid

reservoir

134

CHAPTER

ELEVEN

CLUTCH
SERVICE
DATA

AND

SPECIF1CATIONS

Table
1

proVIdes
serVIce
data

and

specifica

tIons
for
the
clutch

system

TRANSMISSION

Description

Datsuns
are

eqUIpped
with
either

an
auto

matic
or
manual
transrmSSIOn

Due
to
the
com

pleXity
of
the
unIt
and

the
need
for

special
tools

and

knowledge
overhaul

of
the
automatic
trans

mISSIon
is
not

covered
In
thIS
manual
Auto

matIc
transmISSIOn

checks
and

adjustments
are

given
later
m
thIS

chapter
Reparr
and
mainte

nance

should
be
referred
to

a
Datsun
dealer

or

qualIfied
mechamc

The
manual
transmission
is

a
four
forward

Table
1
speed
unlt
controlled
With
a
floor

mounted
lever

It
consIsts
of
transrmSSIOn

case
rear
extensIOn

housing
and

gear
assembly
The
clutch

housmg

and
transmissIOn

case
are
a

sIngle
unIt
The

rear

extension

housmg
is

detachable

Figure
12
shows

the
4
forward

speed
transmission

Transmission

Removal

Removal
of
the

transmIssion
from
dIfferent

models

Varles

accordmg
to
the

dIfferent
struc

ture
Involved
The

following
procedures

gen

erally

apply
to
all

types

Important
dIfferences

are
noted

1
Prom

InsIde
the
vehicle

remove
the
floor

covenng
around
the

gear
shift

so
that
the
shIft

lever
can
be
removed

2
Jack

up
the
vehIcle
and

support
it
with
four

CLUTCH
SERVICE
DATA
AND
SPECIFICATIONS

Pressure

Spring

Free

length

Fitted

length
and
load

Out
of

rlght

angle

MInimum

sprmg
force

Clutch
Release
Lever

Release

bearlng
to

dlaphragm
clearance

Diaphragm
sprlng
to

flywheel
height

Release

lever
to

flywheel
height

Clutch
DISC

FaCing
size

Outer

dIameter
x
inSide
diameter

x
thlckness

Thickness

Free

Compressed

Number
of

tOrslO
1
springs

Minimum

depth
of
rivet
head

from

faCing
surface

Allowable

facmg
runout

Allowable

spline
free

play

Pressure

Plate

Allowable

refacmg
limit

Clutch
Pedal

Height
when
not

depressed

Free
stroke
of

pedal
head

Pressmg
strength
at
full

stroke

Clutch
Master

Cylinder

Diameter

MaXimum

clearance
between

cylinder
and

pIston

Tightening

Torque

Clutch

assembly

securing
bolt
2
059
In
52
3mm

1
149
In
197
4
4
Ib
29
2mm
44
2

kg

o
1968

per
3
937
In
5

per
100mm

15

00472
to
0
0551
In

1
2
to
1
4mm

1732
0
0394
m

44
O
1

Omm

1
988

0
0197
In

505
0
05mm

787
X

5
120
x
0
0140
In
200
x
130
x
3
5mm

o
3386
to
0
3543
m
8
6
to
9
Omm

03012
to
0
3130
m
765

to
7
95mm

6

00118
In
03mm

o
097
In
0
5mm

00157
m
04mm

o
0394

In
1
Omm

8
150
m
207mm

o
984
m
25mm

33
Ib
15

kg

0625
m

15
87mm

00051
m
0
13mm
J

i

r

174
to
188ft
Ib
24

to
2

6

kg
m

CLUTCH
TRANSMISSION
AND
DRIVESIIAFI
135

stands
If

possible
the
use
of
an

open
pit
or

hydraulIc
hOISt
IS
recommended

3

Figure
13
shows
the
underside
of
the

sedan

and
statIon

wagon
Figure
14
IS
the

pick
up

4
DIsconnect

negatIve
battery
cable
from

termInal

r

j

7T
@

r

1
Cross
shall

2
Back
up

lamp
sWitch

cable
3

Speedometer
dn
e
cable

4
Exhaust
manifold

5

Propeller
shall