DATSUN 510 1968 Service Repair Manual

186

CHAPTER

TIURTEEN

STEERING
SERVICE
DATA

AND
SPECIFICATIONS

r
SpeaficatJons
Sedan

Wagon
P1c11

up

Type
Reclrculatmg
Ball

Reclrculatmg
Ball

Gear
Ratio
1501
1981

Steenng
Wheel
Diameter
159m
405mm
157m
400mm

Wonn

Beanng
Shim
Thickness
0059
m

1
5mm
0059
m

1
5mm

011

CapacJ
y
o
7
pts
0
33

hter
o
7

pts
0
33
hter

Imtlal

Steering
Wheel

Turnmg
Torque
3552mlb

3
5
5
2
In

Ib

4
6

kg
an

4
6

kg
an

End
Clearance
of
Sector

Shaft

AdJustmg
Screw
o
0004

0
0012
m

00004
00012
m

0
01

0
03mm

0
01
0
03mm

Tiglrtenlng
Torque

Flange
Bolts

13
18

ft
Ib
13

18
ft
Ib

1
8
2
5

kg
m

1
8
2
5

kg
m

Gear
Ann
100
ft
Ib

14
kg
m
100
ft
lb
14

kg
m

Gear

Housmg
72
ft
Ib
10

kg
m
27
ft
Ib
3
7

kg
m

dJustmg
Screw
Nut
13
18
ft
Ib
13
18
ft
Ib

y
1
8
2
5

kg
m
1
8
2
5

kg
m

dler
Ann
Bolts
32
44
ft
rb
43

50
ft
Ib

4
6

kg
m
6

7

kg
m

Idler
Arm

Nut
39
55
ft
Ib

43
50
ft

lb

5
8

kg
m

6
7

kg
m
St

I

j

i

I

i
1
l
I

I

CHAPTER
FOURTEEN

BRAKES

The
sedan
and
station

wagon
are

equipped

With
disc
brakes
on
the
front
wheels
drum

brakes

on
the

rear
wheeis
and
a
tandem
master

cyhnder
The

pIck

up
has
drum
brakes
on
all

four
wheels
and

a

single
master

cylmder
All

vehicles
have

a
mechanIcal
handbrake
that

works

on
the

rear
wheels

only

BRAKE

PEDAL

Figures
1
and
2
show
the

mounting
location

and
the

components
of
the
brake

pedal
for

sedans
and

wagons
The

pick
up
is
smlliar

Brake

Pedal
Removal

1
Remove

pedal
return

spring

2
Remove
cleViS

pm
on
the

push
rod
CD

3
Disconnect
brake

pedal
from
the
master

cyhnder

4
Remove
the
fulcrum

pm
Remove
the
brake

pedal

Brake
Pedal

Inspection
nnd

Repair

Check
all

parts
for
wear

damage
and
defor

matIon

Replace
defective

parts
as

reqwred

J

188

CHAPTER
FOURTEEN

Brake
Pedal
Installation

1

Apply
pedal
grease
to
the

pedal
shaft
sleeves

and

push
rod
cleVIS

pm

2
Installation
is
the

reverse
of

removal

3

Torque
the
fulcrum

pm
to

25
3
to

28
9
ft
lb

3
5
to

4
0

kg
m

MASTER
CYLINDER

FIgure
3
is

an

exploded
view
of
the
tandem

master

cyhnder
used
on
the
sedan
and

wagon

starting
m
1969
Earher
models
are
sinnlar

Figure
4
IS
an

exploded
View
of
the
master

cyhn

der
used
on
the

pIck
up

Master

Cylinder
Removal

1
Remove
reservOIr

cap
and
drain
brake
f1wd

2
DISconnect
brake

pedal
return

spring

3
Disconnect
brake
tube
from
master

cyhnder

4
Remove
two
bolts

holdmg
master

cyhnder
to

front
dash

assembly

5
Remove
master

cylinder

Master

Cylinder
Disassembly

1
Remove

dust
cover
and

piston
stopper
screw

2
Remove

snap
nng
and

stopper
ring
then

pllShrod
3
Remove
the

piston
and
related

parts
from

cyhnderbody

4
Remove

valve

cap
gasket
check
valve
and

check
valve

spring

NOTE
DISassemble
master

cylmder

carefully
Don
t

damage
the

slldmg

surfaces

of
pISton
and

pISton

cup
Do

not
remove

flUId
reservOlT

unless
ab

solutely
necessary
Remove

pISton
cup

only
If

pISton
must
be

replaced

r

Master

Cylinder
Inspection
nnd

Repair

1
Clean

all

parts
thoroughly
with
clean
brake

fiwd

2
Check

cyhnder
and

piston
for
abnormal
side

wear
and

damage
Replace
as

reqUIred

3
Check
all

spnngs
for
weakness
and

damage

Reparr
as

reqUIred

4
As
a
matter
of
sound

practIce
replace
all

cups
and
valves
whenever
the
master

cyhnder
is

dISassembled

DefinItely
replace
them
1f

they
are

deformed
due
to

swellmg
wear
and

age

5

Inspect
all
other

parts
Replace

any
that

are

defective

CD
1
Valve

cap

2
Valve
cap

gasket

3
Check
valve

4
Check
valve

spnng

5
011

reservoIr

cap

6
Reservoir

7
ReservOir
band

8

Paclang

9

Stopper
bolt

10

PIston
return

spnng
11

Sprmg
seat

12

Spnng

13
Valve

14
PIston

15

Pnmary
pIston
cup

16

Secondary
piston

cup

17

Stopper
nng

18

Snap
nng

19
Rubber
boot

20
Push
rod

10
29
27
28

24
25

18
19
20
22
8

1
Master
cyllOder
assembly

2
Piston
assembly

3
Piston
cup

4
Cylinder
spring

5
Piston
assembly

6
PIston
cup

7
Inlet
valvaassembly

8
Intetvalv8Spnng

9
Push
rod
assembly

10
Push
rod
11
Push
rod
head
assembly

12
Nut

13
Stopper

14
Snap
rlOg

15
Dust
cover

16
PackIng

17
Stopper
screw

18
Valve
seat

19
Valve
spnng

20
Valve
assembly
21
Valve
retatner

22
Gasket

23
Valve
cap

24
Bleeder
screw

25
Bleeder
screw
cap

26
ReservoIr

27
Reservoir

28
Band
assem
bly

29
Reservolf
cap
set

190

CHAPTER
FOURTEEN

Master

Cylinder
Assembly
and
Installation

I
Assemble
the
master

cyhnder
m
the

reverse

order
of

dIsassembly

2
Pnor
to

assembly
soak

piston
cap
m
brake

flwd

Install

piston
so
that
It
seats

firmly
on
the

piston

cup

3
Coat
the

cyhnder
bore

and

pISton
assemblies

With
clean

brake
flwd
before

assembly

4
When

assembly
IS

complete
mount
master

cylmder
on
dash

wall
and
hook

connecting
rod

to
brake

pedal
Replace
return

sprmg
Fill
the

reservOir
With

clean
brake
flUid

5
If

aIr
has

seeped
mto
the
brake
Imes
bleed

the

brakes
as
descnbed
later
m
thIS

chapter

FRONT
DISC
BRAKES

SEDAN
AND

WAGON

Brake

Pad

Replacement

Pad
wear
should
be
checked

every
4
000

nuIes
Clearance
between

the

pad
and
the
rotor

IS

adjusted

automatIcally
and
therefore
IS
not
a

wear
mdlcator

Pad
thiCknesS
IS
checked

by
re

movmg
the
antI

rattle

clJp
When
the

pad
hning

becomes

worn
to

0
04

Imm
replace
all

pads
on
the

front
wheels

I
Remove

the
hub

cap
loosen
the
hub
nuts

jack

up
the
vehicle

support
with

stands
and

remove
the
front
wheels

2
Remove

the
antI
rattle

clJp
from

the

caliper

plate
as
shown
m

Figure
S

jty

3
Loosen
the
bleed
screw
Pull
the

calJper
plate

outward
4
Push
the

pISton
m

approximately
0
157
in

4mm

as
shown

m

Figure
6

5
The
outer

plate
should

be
loose

enough
to
be

removed
See

Figure
7

6

Dra
y
the

calJper
plate
rlfward

and
remove

the
inner

pad

7

Wipe
exposed
surface
of

piston
thoroughly

8
Push
the

piston
mto
the

cyhnder
bore
untJI

the

new

pads
can
be
mstalled
onto
the

calJper

plate

9
After

instl
llatIon
test
the
brakes
at
slow

speed
to
make
certam

they
are
fitted

properly

and
that

no
au
entered
the

hydraul1c
hnes
Bleed

the
brake

system
If

required

Front
Disc
Brake
Removal

I
Jack

up
the
vehicle

place
It
on
stands
and

remove
the
wheels

P

BRAKES
191

2
Disconnect
the
front
brake
hose
from
the

brake
tube
See

Figure
8
and

plug
the
brake

hne
to
avoid
flwd

loss

3
Screw
out
the
bolts

fixing
the

calJper
to
the

knuckle

flange
and
remove
the

calJper
assembly

as
shown
m

Figure
9

4
Remove
the

spmdle
nut
and
the
dISC
hub

Separate
the
rotor
from
the
hub

assembly
See

Figure
10

Front
Disc
Brake

Disassembly

Figure
11
next

page
IS
an

exploded
diagram

of
the
front
disc
brake

assembly
Refer
to

figure

and
follow
the

followmg
procedures

I
Remove
the
antI
rattle

clip
from
the

calJper

plate
and
remove
the
brake

pads
4

2
Remove
the
tension

spnngs
and

pull
the

cyhnder
out
of
the

caliper

plate
3
Remove
the

piston
by
applymg
air
or

hy

draulJc

pressure
to
the
flwd
mlet
hole
Remove

the
rubber
seal
from
the

groove
on
the

cyhnder

Remove
the
retamer
and

Wiper
seal
The

pISton

can
now
be
removed

Front
Disc
Brake

Inspection
and

Repair

I
Check
the

cyhnder
assembly
for

leakage
and

damage
Replace
If
defects
or

damage
are

apparent

2
Check
the
disc
brake

pads
for
wear
and

cracks

Replace
all

pads
If
It
IS

necessary
to

replace
any

fi

3
Check
the

caliper
for

damage
Replace
as

reqUIred

4
Check
the
rotor
for
scratches

sconng
and

general
conditIon
The
rotor
can
be
resurfaced
If

defects
are
found
Standard
rotor
thiCknesS
IS

o
0394
m

IOmm
The
hm1t
of

reconditIOning

thickness
IS
0
331
m
8
4mm

Replace
rotors
If

recondltIomng
limits
have
been
reached

5
Check
the
rotor
for
TWlout

usmg
a
dial

gauge
as
shown
m

Figure
12
Rnnout

ot
the

rotor
should
be
less
than
0
0024

m
0

06DlIll

1
Right
hand
calIper

2
Left
hand
caliper

3
Mounting
bracket

s
6
Caliper
plate
assembly

7
Hold
dO
m
pIn
set

8
PiVot
pIn

2
stlUn
6
L
6
9
H

O
L
9
10
C
tlmder
and
pIston
assemblY

11
PIston
seal
set

12
Bleeder
screw

13
lleeder
sere
ll
caP

1
lotslORSpnng
set

1S
16
Mtl
rattle
clip

17
Mt
Squeal
s1l
m

18
19
Bral
e
pad

20
caliper
tlxlng
bolt

21
LocI
washer

22
23
laff
e
plate

24
MachIne
screw

2S
lOtI
washer
22
all

23
LIl
@

2S
24

7
6
a

9
LH

s
I
a
z

BRAKES
193

Front
Disc
Brake
Piston
Seal

Replacement

If
oil

leakage
is
detected
around
the

piston

seal
It
should
be

replaced
as
follows

I
Rinse
the

cyhnder
bore
With
brake
flwd
In

sert
new
seal
into
the

groove
taking
care
not
to

damage
It
Attach
the

wiper
seal
Lubricate

cylinder
bore

lightly
With
brake
fluid

2
Clean
the

piston
Inspect
the

pISton
for
scor

ing
or
other

damage
before

inserting
It
Make

sure
that
the
relieved

portion
of
the

pISton
faces

the

pivot
pin
Prevent

tilting
of
the

piston
when

It
IS
mserted
mto
the

cyhnder
Refer
to

Figure
13

@

4

Front
Disc
Brake

Assembly
and
Installation

I
Clean
the

mounting
surface
and
disc
surface

Attach
the
disc
to
the
hub

2
Install
the
hub
to
the
knuckle

spindle

3
Insert
the

piston
into
the

cylinder
untIl
its

face
is
almost
flush
With
the
face
of
the

wiper

seal
retamer

4
Install
the

cyhnder
mto
the

caliper
plate
and

secure
with
the
torsion

spnngs

5

Assemble
the
hold
down

pm
spring
washer

and

nut
to
the

support
bracket

6

Insert
cotter

pin
into
the
nut

7
Assemble

mounting
bracket
and

calJper
plate

with

pivot
pm
washer

spring
and
nut

Tighten

nut

completely
and
insert
cotter

pin

8

Pry
up
the
hold
down
bracket
with
a
screw

dnver
Hook
it

to
the

upper
end
of
the

mounting

bracket
Turn
the

cal1per
plate
to
make
sure
it

slides

smoothly

9
Install
the

caliper
assembly
to
the

knuckle

flange
10
Attach
shun
to
inner

pad

I
I
Insert
the
inner
dIsc

pad
Pull

the

caliper

plate
outward
and
insert
the
outer
disc

pad

12
Attach
the
anti
rattle

plate

13

Replace
wheel
and
remove
stands

REAR
BRAKE
SEDAN
AND

WAGON

Figure
14
IS
an

exploded
view
of
the
rear

brake

assembly
used
m
the
sedan
and

wagon

Rear
Brake
Removal
and

Disassembly

1
Jack

up
the
rear
of
the
vehicle
and

support
It

on
stands
Remove
the
wheels

2
Release
the

parkIng
brake
DISConnect
the

cross
rod
from
the
lever
of
the
ie
wheel

cylinder

3
Remove
the
brake
drum

4
Remove
the
return

springs
and
take
out
the

brake
shoe
assemblies

5
Disconnect
the
brake
tube
from
the
wheel

cylinder

6
Remove
the
wheel

cylinder
by
removing
dust

cover

plates
and

adJusting
shIms

7
DISassemble
the
wheel

cylinder
by
removing

the
dust
cover
and

snap
nng

8
Remove
the

adJuster
assembly

Rear
Brake

Inspection
d

Repair

Sedan
and

Wagon

I

Inspect
the
brake

druf
1s
for

scoring
signs
of

excessive
heat
and
out
of
round

Repair
or
re

place
the
drums
as

reqUIred
The

following

specificatIons
apply

Drum
Out
of
Round

Inner
Olameter

MaXImum
Diameter
after

IlI1ndmg
Less
than
0
0020
In
0
05mm

8
999
m
228
6mm
1

9040
In
229
6mm

2

Inspect
brake

limngs
for
wear

signs
of
oil
or

grease
and
cracks
If

any
of
these
conditions
are

found

replace
the

linmgs
Have

a
brake

special

ISt
arc
the

limngs
to
match
the
diameter
of
the

drums
after

replacement
If
the
thickness
of
the

limng
is
under
0
0591
m
1
5mm

replace
it

3
Check
the

adjusting
cams
for
smooth

opera

tion

Replace
as

reqUIred

4
Check
the

spnngs
If

they
appear
weak
or

uneven
m
tension

replace
them

v

194

CHAPTER

FOURTEEN

3

Right
hand
rear
brake
disc

4
Left
hand
rear

brake
disc

5
Fore
rear

brake
shoe

6
Aft
rear

brake
shoe

7
Brake

IImng

8
Rear
brake

adjuster

9

Adjuster
wedge

11
Lock
washer

12
Hex
nut

13
Wheel

cylinder

assembly

14
Piston

cup

15
Piston

16
Dust
cover

6
@

5
Check
the
wheel

cylinder
for

wear

rust
and

damage
If

defectIve

replace

6
Check
die
clearance

between
th

cyhnder
and

the

piston
If
the
clearance
18

greater
than

Q
0059
m
0
15mm

replace
the

cylinder
The

cyluiders
can
be
honed
With

a
wheel

cyhnder

hone
If
the
maXImum
dimensIOn
has

not
been

reached

7

Replace
the

piston

cups
whenever
the

cyhn

derds
disassembled

even

though
the

cups
appear

to

be
m

good
condition

Rear
Brake

Assembly

1

Assembly
IS
the
reverse
of

disassembly

2
Be
careful

not
to

get
dirt
or
brake
fluid

on
the

brake

hnnlgs

3

AdJust
shoe
clearance

then
bleed
the

hy

draulIc

system
17
Dust
cover

ring

18
21
Lock

plates

22
Dust
cover

23

Lever

assembly

24

Bleeder
screw

25
Bleeder

cap

26
Return

spring

27
Return

spring
adjuster

slide

29
Anti
rattle

spring

30
Anti
rattle

pin

31
Anti

rattle

spring
set

32
Anti

rattle
retainer

spring

23

22

24

e

17

a
25

FRONT
BRAKE

pICK
UP

Figure
15
shows
the
front
brake

system
for

the

pick
up
Generally
speaking
follow
the
same

procedures
given
for
removal

disassembly
re

pair
and

assembly
of
the
sedan

wagon
rear

brake
The

followmg
specifications
apply
to
the

pick
up
front
brakes

Inner

Drum
Diameter

Drum

Out
of
Round

MaXimum
DIameter
after

gnndlng
10
00
In

254mm

Less
than
0
0008
In
0
02mm

10
04
In
255mm

REAR
BRAKE

pICK
UP

Figure
16
shows
the

rear
brake

system
for
the

pick

up
Generally
follow
the

same

procedures

given
for

removal

disassembly

repaIr
and

assembly
as

given
for
the
sedan

wagon
rear

brake
Pertment

specificatIons
are
the
same
as

for
the
front
brakes

BRAKES
195

@
@

r
@

I

1
Brake
disc
9

Adjuster
wheel

2
Front
brake
shoe
10

Adjuster
scre

assembly
leadmg
11

Adjuster

lead

3
Front
brake
shoe
12
Shim

assembly
trallmg
13
Lock

spring

4
Return

spring
14

Spring
plate

5

Trailing
shoe
return

spring
15
Lock

plate

6
Wheel
cylinder
assembly
16
Shim

7

Adjuster
assembly
17
Rubber
boot

8

Adjuster
housmg

@

j

@@

1
Brake
disc
7

Adjuster
assembly
13
Lock

spring
19

Spring
seat

2
Rear
brake
shoe
8

Adjuster
housmg
14

Sprmg
plate
20
Ant
rattle
spring

assemblies
9
Adjuster
wheel
15
Lock

plate
21
Retamer

3

Upper
return
spring
10
Adjuster
screw
16
Shim
22
Extension
link

i
l

4
Lower
return

spring
11

Adjuster
head
17
Rubber
boot
23
Toggle
lever

5
After
shoe
return

sprmg
12
Shim
18

Anti
rattle

pm
24
Return
spring

6
Wheel
cylinder
assembly