DATSUN 510 1968 Service Repair Manual

156

CHAPTER
TWELVE

r

IV

rli

@
18

1

P
l

hr
r
J

oJ

1

it

o

1f

f

7
Remove

grease
catcher
and
Withdraw
outer

beanng
usmg
a

beanng
puller
Smce
the
Inner

race
has
to
be

pulled
agamst
dunng
removal

always
replace
It
WIth

a
new
one

dunng

assembly
REAR

AXLE
SHAFf
WHEEL

BEARINGS
AND
SEALS
INSPECTION

AND
INSTALLATION

SEDAN

1

Inspect
all

parts
for

signs
of

damage
and

wear

2
Check
the
axle
shaft
for

straIghtl1ess
cracks

and
dIStortIon

Do
not

attempt
to

straIghten
a

bent
shaft

by
heatlng
ThIS
would
weaken
the

t

shaft

and
could
lead
to
more
senous
trouble

3
Check
the
011
seal

IIp
for

damage
As
a
mat

ter
of

good
practIce
dIScard
and

replace
oil
seals

whenever

they
are
removed

4
Check

bearmgs
for

SIgnS
of

leakage
and
ease

of
movement

Replace
if
defective

5
Before

assembly
clean
all

parts
thoroughly

WIth
solvent

6
Install
wheel

beanngs
so
that
the
sealed
SIde

of
the
outer

bearmg
faces
the
wheel
and
the

sealed
SIde
of
the

Inner

bearmg
faces
the

dIf

ferentIal

Apply

pressure
to

the
Inner
race

only

dunng
assembly

7
Refer
to

Figure
19

Apply
wheel

bearmg

grease
durmg

assembly
as
mdlcated

@
Pack
With
wheel

beanng
grease

MP2
or
MP3
at
e

ery
overhaul

1
Grease
seal

2
Inner
wheel

beanng

3
Distance

piece

8

Torque
wheel

bearing
nuLto
181
to
239

ft
lb
25
to
33

kg
m
Check
rear
axle
shaft

end

play
and

wming
torque
End

play
should

be

less
than

0
to
0
006
in

0
to
0
15mm
Turn

Ing
torque
should
be

less
than
65
in

oz
4
5

kg
cm
H
the
end

play
or

turnmg
torque
are

not
WIthm

specification
dIsassemble
md

replace

the
dIStance

pIece
with
one
of
the
correct

length

DIFFERENTIAL
REAR

AXLE
AND
REAR
SUSPENSION
157

DIFFERENTIAL

WAGON

The
dIfferentIal
carner
is
made
of
alumInum

alloy
and
uses
a

hypoid
bevel

gear
Proper
lubri

catIon
IS
essentIal
Check
and

replemsh
the
lub

rIcant

every
3
000
mIles
Dram
and
refill

every

30
000
mlles

Figure
20

IS
an

exploded
dIagram

of
the
differential
used
in
the

wagon

Difterential
Removal

Wagon

1
Jack

up
the
rear
wheels
and

support
vehicle

with
stands

l

2
DIsconnect
drIve

pmlon
companion
flange

to

yoke
connectIon

3
Remove
rear
wheel
axles
as
descnbed
later

m

thIS

chapter

4
Remove
dtfferentIal
from
vehIcle

Difterential

Inspection
Wagon

The

followmg
Inspection
can
be
done
Without

dISassembly
of
the
differentIal
Perform
the
fol
lOWIng
mspectIon
and
If
abnormalitIes
or
dam

age
eXISts
refer
further
service
and

repair
to

YOI
f
dealer

1
Check
the
tooth
contact

pattern
with

lead

oXIde

at
two
or
three

pomts
after

remoVIng
rear

cover
Refer

to

FIgure
5
for
correct
contact

pat

tern
If
the

pattern
IS
not

correct

dIsassembly

and

adjustment
of
the
dtfferentIalIS

reqUIred

2
Measure
backlash
between
dnve

gear
and

pInIOn
WIth
a
dIal
mdlcator
Backlash
should
be

00059
to
00079
in

0
15
to
0
20mm

3
Rotate
the

gears
and
lIsten
for

SIgnS
of
bear

Ing
nOIse
DefectIve

beanngs
should
be

replaced

by
a
dealer

4

Inspect
gear
teeth
for

signs
of

damage
or

cracks
r

Difterential
Installation

Wagon

Install
the
dIfferentIal

by
reversing
the

pro

cedures
used
for
removal

2
Olfferenllal
case

16
Pmlon

10Ckmg
pm
28
42

AdjusllRg
washer

t
3

Beanng
stud
17
Dlflerenbal
Side

beanng
43
47

Adjusting
shim

4
Plem
washer
18
22

Adjusting
shim
53
Oil
seal

5

Locking
nut
23
Rear

plRlOn
gear
54

Range
assembly

6

Lockmg
nut
24
Front

plRlOn
beanng
55
Nut

7
PIRlOn

gear
set
25
27

Spacer
56
Wesher

Iff
8

Hex
bolt

9
Bolt

locking
strap
7

10
Case

@
11
Side

gear

12
PmlOn
mete

is

Thrust
washer
13

14
Thrust
washer

10

15
PIRlOn
shaft

23

43
47

2S
27
7

J

I
18

22

17

l
24

S3

S6
S4

55

158

CHAPTER
TWELVE

REAR
AXLE
AND

SUSPENSION

WAGON

The

rear
axle
is

a
semI

f1oatlng
type
The
rear

wheel

bearmgs
are

presealed
and
do
not

require

penodlc

servIcmg
However
whenever
new

bearmgs
are
Installed

they
should
be

packed

v
lth
wheel

beanng
grease
durmg
InstallatIon

Figure
21
IS
an

exploded
view
of
the

rear
axle

whlle

Figure
22
IS
an

exploded
VIew
of
the
rear

suspensIon

Rear
Axle
Removal

Wagon

1
Remove
hub

caps
and
loosen
wheel
nuts

2
Jack

up
rear
of

vehIcle
and

support
it
on

stands

3
Remove
wheel
nuts
and
wheels
Remove

brake
drums
If
drums

are
not
free

or
are
dIffi

cult
to

remove
slacken
off
brake
shoe

adjuster

a
few
notches

4
DISconnect
brake

hose
from
brake
tube

Plug

up
the
hose
to

prevent
f1Uld
loss

@

4

16

6
5
DIsconnect
handbrake

rear
cable
from
bal

ance

lever

assembly

6
Remove
four
bolts

holdmg
dnve
shaft
to
the

dnve

pmlon
compamon
flange

7
Release
both
lower
shock

absorber
self

lockmg
nuts
and

slIde
the

mountlng
eyes
off
the

PIvot
of
the
rear

spnng
seat

8

Support
rear
axle
wIth
a
transrmsslOn

Jack

9
Loosen
the
U
bolt
lock
nuts
Remove
the
nuts

from
both

rear

spnng
shackles
and
remove
the

shackles
from
the
rear

spring
eyes

10
Remove

the
U
bolt
lock
nuts
Lower
the

jack

and
WIthdraw
the
rear
axle

assembly
See

Figure
23

Rear
Axle

Disassembly
and

Inspection
Wagon

1
DIsconnect
brake
lIne
ends
from

wheel

cylIn

ders
and
remove
the
line

complete
with

the
three

way
connector

2
Remove

cross
rod

clamp
and
balance
lever

arm
from
the

rear
axle

case
Remove
both
cross

1
Rear
shaft

assembly
11
Bea

ring

2
Rear
shaft
assembly
12
Bea

ring
colla
r

3
Wheel
hub
bolt
13
Axle
case
rear

shim

4
Rear
axle

assembly
14
Hex
bolt
With
washer

5
Stud
15
Brake
drum

6
011
seal
16
Rear
wheel

7
Axle
case
breather
48
Grease
catcher

9
Drain

plug
assembly
49
Seat

assembly

10
Rear
axle

spacer
53
Wheel
nut

DIFFERENTIAL
REAR
AXLE
AND
REAR

SUSPENSION
159

@

8
69

71

72

70

26
29

32

19
5
T1

31

30

21
4

23
58

20

57

37

45

6463

19
Center
bolt
33

Clip
45

Bushmg
62

Bushing

20
Hex
nut
34
Hex
nut
46
Washer
63
Nut

pin

21
Rebound

clip
35
Spring
washer
47
Self

locking
nut

64
Lock
washer

22
Rebound

clip
36

Locatmg
plate
50
Rear

spring
seat
65
Shackle

23
DIstance

piece
37
Seat

pad
54
Inner

clip
66
Shock
absorber
bracket

26
Front

pm
assembly
38
Lower
seat
assembly
55
Outer

clip
67
Bolt

27

Upper
bushing
39
Shock
kit
56
Center
bolt
68
Lock
washer

28
Lower

bushing
40
Rubber

bushing
57
Nut
69

Stopper
assembly

29
Shackle

assembly
41
Washer
58
Distance

piece
70
Nut

30
Hex
nut
42
Washer
59
Bracket

spring
71
Plam
washer

31

Spnng
washer
43
Hex
nut
60
Bolt
72

Spring
washer

32

Bumper
44
Lock
nut
61
Lock
washer

rod
ends
from
the
wheel

cylInder
lever

assembly

WIthdraw
the
handbrake

lInkage
assembly

3
Unscrew
the
011
dram

plug
and
draIn
011
into

sUItable
contamer

4
Remove
four
nuts

holdmg
brake
back

plate

to
the
axle
case
Draw
out
axle
shaft

assembly

WIth
the
brake
back

plate
and

grease
catcher

Use
a
slIde
hammer
as
shown
In

Figure
24

5
Press
off
the

beanng
collar
or
cut
it
loose

WIth

a
cold
chIsel
as
shown
m

Figure
25
The

removed

collar
should
not
be
reused

6
Use
a

beanng
puller
to
remove
the

bearmg

See

Figure
26
Take

out
brake
back

plate

160

CHAPTER

TWELVE

@

@

@
I

F

7
Remove
ten
nuts

holdmg
the
drlIerentIal

assembly
to
the
axle
case
and
withdraw
the

differential

aSsembly

Rear
Axle

Inspection
Assembly
nnd

Installation

Wagon

1
Check
the
axle
shafts
for

straighmess
cracks

damage
wear
and
chstortion

Replace
1f
de

fectIve

Do
not

attempt
to
heat
axle

to

straJghten

I
it
as
thiS
wlll
weaken
the
axle
and
could
lead
to

more
senous
trouble

2

Clean
all

parts
thoroughly
With
solvent

3
Check
011
seal

hp
for

damage
Replace
as

requrred

4
Check
the

beanngs
for

damage
and

replace

1f
defective

5
Assemble
the
rear
axle

urnt
in
the
reverse
of

disassembly

6
Use

a
new

gasket
between
axle

cases
and

drlIerentIal

7
The

gear
carner

fixmg
nuts
must

be

torqued

m
a

diagonal

pattern
to

prevent
011
leaks

Tighten

to
145
to
159ft
lb
20
to
22

kg
m

8
Install
the

grease
catcher

beanng
spacer

bearmg
and
new

bearing
collar
on
the
axle

shaft
The

beanng
collar
must
be
fitted

using
an

arbor

press
and
4
to
5
tons
of
force
Make
cectam

to

pack
the
wheel

beanng
With

grease
and
msert

the
wheel

beanng
With
the
seal
Side
toward
the

wheel

9
If
the
011
seal
has
been

replaced
take

care

not
to

damage
it
when

mstallmg
the

axle
shaft

assembly
As

a
matter
of

good

practice
replace

the
011

seal
whenever
the
axle
is
disassembled

10
Refer

to

Figure
27
and

grease
the
mdicated

areas

Torque
all
bolts
as

speCified

11

Adjust
the
aXial
end

play
between
the
wheel

beanng
and
the

recess
in
the
axle
tube
with

adjusting
shims
The
end

play
should
be
00118

to
00197
m
03
to
O
5mm
Check
end

play

with

a
dial

gauge
as
shown
in

Figure
28

DIFFERENTIAL
REAR

AXLE
AND
REAR

SUSPENSION

161

T
8

0
to
9

0

kg
m
57
8
to
65
11b

ft

@

T
2
8

to
3
9

kg
m

20
2
to
28
2
Ib

ft

Apply
grease
on
the

surface
of
the
collar

when

replacing
oil
seal

Brake
tube

T
1

7
to
2
0

kg
m

23
3

to
14
5
Ib

ft

Tread

1260

Use
the
shims
to

adjust
the

gap
C

between

the
wheel

bearing
and
the

recess
in
the
axle
tube
end
The

gap
should
be
beteewn
0
to
0
1
mm

0

to
0
0039

in

12

Fill
the
differentIal

housmg
With

specmed

lubncabng
011

REAR
SUSPENSION

WAGON

The
rear

suspensiOn
consists
of
semi
elhpnc

leaf

spnngs
hydraulJc
shock
absorbers
and
rub

ber

bumpers
Iso
clamp
deVices

are
used
for

attaching
the
axle

housmg
to
the

spnng
The

leaf

spnngs
shock

absorbers
and
rear
axle
hous

mg
are
mounted
on
rubber

bushmgs
at
each
end

See

Figure
22
REAR
SPRING

REMOVAL

INSPECTION
REPAIR

AND

INSTALLATION

WAGON

1
Jack

up
the
center
of

the
rear
axle
until
the

wheels
are
off
the

ground

Support
th
e
rear
end

With
stands

2
Remove

spare
tIre

3

Disconnect
shock
absorber
bottom

end
from

spnng
lower
seat

4

Loosen
rear

spring
U

bolt
nuts
Remove

bolts

bumper
assembhes

spring
seat
location

plates
and
seat

pads

5
Remove

four

fiXing
bolts

holdmg
the
front

bracket

See

Figure
29

l

6
Lower
the
rear

spnng
and
the
bracket
from

the

body

7
Remove
rear
shackle

upper
and

lower
nut

8

Separate
front
bracket
from

spnng
by
remov

mg
front

pms

9
Exanune
the

spring
leaves
for
fractIires

cracks
or
other

damage
Replace
as

reqwred

10
Check
front

pm
shackle

U
bolts
and

spnng

seat
for
wear
cracks

and
other

damage
Replace

1f
defects
are
found

11

Inspect
all
rubber

parts
for
wear

damage

and

general
condil1on

Replace
as

reqUired

12
Install
the

rear

spnngs
in
the
reverse
of

removal

13

See
that

bumper
is

properly
installed
The

elongated
flange
of

the
rubber

bumper
should

face
the
rear

162

CHAPTER
TWELVE

14
Coat
the
front
bracket

pm
and

bushmg
and

shackle

pm
and

bushing
With
a

soap
solution

pnor
to

assembly

15
The
front

pm
secunng
nut
and
shock
ab

sorber
lower
end

securmg
nut
should
be

re

tightened
after

the
vehicle

is

sittmg
on
the

ground

16

Make
certaJn
the
shackle

bushmg
flange
is

clamped
evenly
on
both
Sides

SHOCK
ABSORBER

REMOVAL
INSPECTION
AND

INSTALLATION

WAGON

1
Jack

up
the

center
of
the
rear
axle
and

sup

port
th
e
axle

housmg
With
stands

2
Reinove
the

lower
end
of
the
rear
shock

absorber
from

spring
seat

3
Loosen
the
four
bolts

secunng
the

upper

bracket
to

body
Remove
shock
absorber
and

upper
bracket

4
Check
shock
absorber
for
leaks
and

cracks

Check
the
shaft
for

straighmess

Replace
1f

defective

5

Inspect
rubber

bushmgs
for

damage
cracks

and

general
condition

Replace
1f
defective

6
Install
the
shock
absorber

by
reversing
the

procedure
used

durmg
removal

DIFFERENTIAL

pICK
UP

The
dlfferenl1al

carner
IS
made

up
of
alum

mum

alloy
and
uses
a

hyp01d
bevel

gear

Proper

lubncatIon
IS
essenl1al
Check
and

replemsh
the

lubncant

every
3
000

mlles
Drain
and
refill

every
30
000
inlles

Figure
30
IS
a
cross
sectional

View
of
the

pick

up
dIfferential
Difterential
Removal

Pick

up

1
Jack

up
the
rear
wheels
and

support
vehicle

With
stands

2
DIsconnect
dnve

pmlOn
companlOn
flange

to

yoke
connectIon

3
Remove

rear
axles

as
descnbed
later
m
thIS

chapter

4
Remove
dlfferenl1al

gear
assembly

Difterential

Inspection
Pick

up

The

followmg

mspection
can
be
done
Without

disassembly
of

the
d1fferenl1al
If
abnormahties

or

damage
eXiSts
refer
further
serVice
and

reparr

to

your
dealer

1
Check
the

tooth
contact

pattern
WIth
lead

OXide
at
two
or
three

pomts
after

remoVlDg
rear

cover
Refer
to

FIgure
5
for

correct
contact

pattern
If
the

pattern
IS

faulty
disassembly
and

adJustment
of
the
dIfIerentialIs

required

2
Measure
backlash
between
dnve

gear
and

pmlOn
With
a
dial
mdlcator
Backlash
should

be

00051
to
0
0071

m
013

to
0
18mm

3
Rotate
the

gears
and
lISten
for

SignS
of
bear

mg
noise

4

Inspect
gear
teeth
for

SIgnS
of

damage
or

cracks

Difterential
Installation

Pick

up

Install
the
differential

by
reversmg
the

pro

cedures
used

dunng
removal

REAR
AXLE
AND

SUSPENSION

pICK
UP

The

rear
axle

IS
of
the

semi

floatIng
type
The

rear
wheels

use

tapered
roller

beanngs
Figure

31

IS
a
cross
sectional
view
of
the
rear
axle

REAR
SUSPENSION

TORQUE
TIGHTENING

SPECIFICATIONS
WAGON

Shock

absorber

upper
bracket
to

body
bolts

Shock
absorber
to

upper
bracket

lock
nuts

Shock
absorber

to
lower
bracket
lock
nuts

Rear

spnng
U
bolt
nuts

Shackle
nuts

Front

pm
nuts

Front
bracket

flxmg
nuts

Brake
dISC
to
rear

housmg
bolts

DifferentIal
carner

to
axle

housmg
bolt

Dnve
shaft

flange
nuts
11
to
18
ft
Ib
1

5
to
2
5

kg
m

12

to
16

ft
db
17
to
2
2

kg
m

25
to
33
ft
Ib
35
to
45

kg
m

43

to
47
ft
Ib
60
to
6
5

kg
m

32
to
36
ft
Ib
45
to
50

kg
m

32
to

36
ft
Ib
45
to
5
0

kg
m

13
to
17
ft
Ib
18
to
23

kg
m

20
to

28
ft
Ib
28

to
3
9

kg
m

14
to
16
ft
Ib
20
to
2
2

kg
m

20
to
28
ft
Ib
28

to
3
9

kg
m

DIFFERENTIAL
REAR
AXLE
AND
REAR

SUSPENSION

163

@

j
@

@

@

1

Companron

flange

2
Front

bearmg

3

Spacer

4
Pmlon

heIght
adjust

shim

5
PmlOn

mate

gear

@
6
Pmlon

mate

gear
11

7
Side

gear
thrust
washer
12

8
Side

bearmg
13

9

Bearing

cap
14

10
Differential
case

15
011
seal

Adjusting
washer

Drive

pmlon

Rear

beanng

Drive

gear
16
Lock

pm

17

AdJustmg
shim

18
Thrust
block

19
SIde

gear

20
Pmlon
mate
shaft
@

1
Axle
case

2
Axle
shaft

3
Wheel

beanng

4
Plam
washer

5
Lock
washer

6
Lock
nut

7
011
seal

8
Beanngcage

9
Shim

10
Grease
seal

11
Brake
drum

12
Wheel
nut

164

CHAPTER

TWELVE

Rear
Axle
Removal

Pick

up

1
Jack

up
the
vehicle
and

support
It
With

stands

2
Remove
wheels

and
brake
drum

3
Remove
brake
shoe

and
chsconnect
hand

brake
WIre
See

Figure
32

4
Remove
four
nuts

holding
brake
end
to
axle

Disconnect

brake
hne
Refer
to

Figure
33

@

5
WIthdraw

axle
shaft
Be
careful
not
to
dam

age
01l
seal
ill
axle
case
SIde

6
Secure

axle
m

holdmg
fixture

or
secure

WIth

vise

7
Unbend
lockwasher
With
screwdnver

as

shown
m

FIgure
34

Do
not
reuse
lockwasher

replace
With

new
one

8
Remove
lock

nut
With
a
wrench
or

special

tool
shown

m

Figure
35

9
WIthdraw
axle

beanng
brake
disc
and
bear

mg
cage
by
usmg
a

puller
or

SpecIal
tool
shown

m

Figure
36
@

10

Remove
011
seal
as

required
Do
not

reuse

011
seal

agaJn
replace
It
With

a
new
one

t

11
To
remove

bearmg

cup
from

cage
remove

seal

apply
a
brass
bar
and

tap
It

evenly
With
a

hammer

Rear
Axle

Inspection
nnd

Installation

Pick
up

1
Check

the
axle
for
bends
and
cracks

Replace

1f

damaged

DIFFERENTIAL
REAR

AXLE
AND
REAR
SUSPENSION

165

2
Check

wheel

bearmgs
for

damage
or
noise

Replace
them
If
defective

3
Be

sure
to
use
new
011

seals
and
lockwashers

4
FIt

beanng

cup
and

grease
seal

to

cage
Tap

WIth

a
brass

hammer
while

fittIng
FIll

grease

seal

IIp
With

wheel

beanng
grease
after

fittmg

5
Install
brake

diSC
and

beanng
cage
on

axle

Fit

bearmg
cone
With

brass
bar

6

Tighten
lock
nut

Place
faced
Side
of
nut

to
washer
SIde

so
that

washer
IS
not

damaged

Torque
lock

nut
to
10S
to
145
ft
lb
15

to

20

kg
m

7
Match
washer

IIp
With

groove
m

nut

tIghten

nut
and
bend

washer

carefully
to

prevent

hp

damage

S
Use

a
brass
bar
to
fit
011

seal
to

tube
end

When

fitted

apply
grease
to

the

hp
Be
careful

not
to
deform
seal
or

damage

hp

9

Completely
fill

bearmg
With

grease

10
Install
shaft

AdJust
aXial

clearance
With

shIms
See

Figure
37
Clearance
should

be
0
012

to
0
035
m
0
3
to
09mm

Standard
shIm

thickness
IS
0
059
m
1

5mm

@

11
Install
other

shaft

AdJust
aXlal
clearance

With

shIm
Clearance
should
be
0
OOOS

to
0

0059

m
002
to
0
15mm

12

Install
bolts
and

torque
to

26
to
34
ft

lb

3
6
to
4
7

kg
m

REAR

SUSPENSION

PICK
UP

The
rear

suspension
IS
a

banJO

type
ngId

suspensIOn
With

parallel
semI
elhpnc

leaf
spnngs
Front
and

rear
ends
of
the

springs
are

secured
on
the
frame
with

rubber

bushmgs

Shock
absorbers

are
mstalled

on
the
cross
mem

ber
from
the

spnng
lower

pad
Figure
38
next

page
IS
an

exploded

dIagram
of
the
rear
sus

pensIOn

Rear

Suspension
Assembly
Removal

Pick
up

1
Jack

up
rear
of
vehicle
and

support
It
With

stands
Remove
wheels

2
Refer
to

Figure
39

DIsconnect

handbrake

Wire
and

equalIZer
unit

Separate

bracketJt
r

3
Remove
brake

tube
2
shock

absorller
3

and
dnve
shaft
4

r

r

0

it

1
Bracket
4

Propeller
shaft

2
Brake
tube
5

Spnng

pm

3
Shock
absorber
6
Shackle

assembly

4

Support
axle
case
With
a

Jack
at
the
center

Remove

spnng
pm
5
aJId
shackle

assembly

6
The

sprmg
seat
need
not
be
removed
from

shock

absorber

5
Lower

Jack
slowly
and
remove

susp
nslOn

assembly
as
shown
m

Figure
40