DATSUN 510 1968 Service Repair Manual

196
CHAPTER
FOURTEEN

WHEEL

CYLINDERS

pICK
UP

Figures
17
and

18
illustrate
the
front
and
rear

wheel

cylinders
used
on
the

pick
up
Mainte

nance

procedures
are

essentially
the
same
as

specIfied
for
the
sedan

wagon

BRAKE
SYSTEM

BLEEDING

Brakes

require
bleeding
whenever
air
enters

the

system
lowering
the
effectIve

braking
hy

draulic

pressure
This
can

happen
when
the

@

@

@

@

D

1
Wheel

cylmder
hOUSing

2
Piston

3
Piston

cup

4
Piston
head

5
Dust
cover
6
Connector

7

Connector
bolt

8

Paclang

9
Bleeder

screw

10
Bleeder

cap
master

cylinder
or
wheel

cylinders
are
serviced

or
If
the
fluid
m
the
reservoir

TWlS

dry
Air
can

also
enter

through
a

leaky
brake
line
or

hose

Find
the

leaky
line
or
hose

and

replace
it
before

bleeding

When

handling
brake
fluid
be
careful
not
to

get
any
on
the
brake
shoes
or

body
paint
Brake

shoes
will
be

permanently
damaged

requiring

replacement
Body

pamt
can
be

damaged
unless

you
Wipe
the
area
with
a
clean
cloth
immedi

ate
then
wash
it
with
a

soapy
solution

r

@

@

1
Wheel

cyhnder
hOUSing

2
Piston

3
Piston

cup

4
Dust
cover

5

Snap

ring

6
Connector

7

Packmg

8
Connector

bolt

9
Bleeder
screw

10
Bleeder

cap

@

BRAKES
IV

197

I
Ensure
that
the
brake

flUid
reservOir

at
the

master

cylmder
IS
full

and
that
the
vent

m
the

cap
is

open

2
Connect

a

plastIc
or

rubber
tube
to
the

bleeder
valve

on
the

nght
rear
wheel

Suspend

the
other
end
of
the

tube
m
a

Jar
or
bottle
filled

With
a
few
Inches
of
clean

brake
flwd

During
the

remaInIng

steps
keep
thiS

end

submerged
at
all

times
and
never
let
the
level

in
the

brake
flUid

reservoir

drop
below
full

3

Open
the

bleeder
valve
on
the

nght
rear

wheel
about

one
turn
Have
an
asSistant

depress

the
brake

pedal

slowly
As
soon
as
the

pedal
is

all
the

way
down

close
the
bleeder
valve
and
let

the

pedal

up
Repeat
thiS

step
as

many
tImes
as

necessary
until

pure
flUid
WithOUt
au
bubbles

comes
from
the

tube

4
Bleed
the

remammg
wheels
m
the

followmg

order
left
rear

nght
front
and
left
front

Keep

checkmg
the

brake
flUid
reservoir
to
make

cer

tam
It
doesn
t
TWl

out
of
flUId

5
When
all
wheels

are
bled
fill
the
reservOIr
to

the
full
level

Never
reuse
the
brake
flwd

bled

from
the

system
or

any
that

has
been

lymg

around
Start

With
a
fresh
contaIner

HANDBRAKE

Figures
19
next

page
and
20

page
199

are

exploded
views
of
the
handbrake

system
used
on

the

sedan
and
statIon

wagon
respectively
F1gDre

21

page
200

shows
the

pick
up
handbrake

system

Front

Cable
Removal
Sedan
and

Wagon

I
Release

handbrake

completely
Disconnect

the
front

cable

by
removmg
the
cleVIS

pm
that

connects
to
the
handbrake
control
stem

2
Screw
out
the

adJusting
nut

from
the

rear

end
of
the
front
cable
Disconnect
the
cable
from

the
center
lever

4
Remove
the

hand
brake

cable

clamp
from

under
the
verucle

Pull
out
the
lock

plate
fixmg

the
front

cable
to
the
front
cable
retamer
Ex

tract

the
front
cable

5

Unfasten
the
front
cable
outer

casing
from

the
bracket
Remove
the
cable

Front
Cable
Removal

Pick
up

I

Loosen
handbrake
2
Remove
cleVIS

pm
and

separate
cable

from

outer
lever
See

Figure
22

p

3
Remove
cleVIS

pm
and

eparate
cable
from

front
lever
Removecable

4
Remove
center
cable
from

control

levers

by

removmg
cleViS

pms

Rear
Cable
Removal
Sedan

I
Remove

adJusting
nut
from

adJuster
DIScon

nect
left
hand
rear
cable

from
handbrake
ad

Juster

2
Pull
out
lock

plates
see

Figure
23
and
re

move
cleVIS

pms
that

connect
rear
cable
With

rear
wheel

cylJnder
levers
Remove
cable

Rear
Cable

Removal

Wagon

1
Remove
both

cleVIS

pins
at
the
ends
of
the

rear
cable

2
Remove
cable

f
I
I

3
21
24
22
2
Control
slem
16
Retainer
spring
34
Fulcrum
pin

3
Bracket
17
Nylon
spacer
35
Return
spring

16
4
Control
gUide
18
Front
cable
assembly
36
Equalizer

16
5
Ratchet
nail
20
Bolt
With
spring
washer
37
lock
washer

6
Nail
spnng
21
Plain
washer
38
Hex
nut

15
7
Set
sprIng
22
Hex
bolt
39
Clevls
pin

tr
8
Set
sprlOg
plO
23
Spring
washer
40
Cotter
pin

9
lever
assembly
24
Plain
washer
41
Right
hand
rear
cable

10
Control
yoke
25
Warmng
sWItch
42
left
hand
rear
cable

16
7
11
CleVIS
pm
26
Warnlng
SWitch
43
Cable
clevis

18
12
Clevis
pin
28
Truman
pin
44
Cable
adjuster

13
CleVIS
pin
29
Adjusting
nut
45
Adjusting
nut

14
CleVIS
pin
30
Hex
nut
46
lock
plate

15
Washer
33
Center
lever
47
CleVIS
pin

48
Cotter
pin

46
47

I
36

4
U39
I
11

43
48
J
I
l

ft
l
I
46
a
z

@

9

18
I
70
I
69

72
lt
n
30
2
Control
stem

3
Bracket

4
Control
gUide

5
Ratchet
nail

6
NaIl
sprtng

9
Level
assembly

10
Control
yoke

11
Clevis
pin

12
ClevIs
pin

13
CleviS
pIn

1
CleviS
pIn

15
Washer

16
Retainer
spring

17
Nylon
spacer

18
Front
cable
assembly

20
Bolt
With
spring
washer

67
n
67

64

68
2

600
56

63
H
54
52

P73
74
i1
51
8
52

e
75
@

53
52a

57
55

58
8
56
21
Plain
washer

22
Hex
bolt

23
SprIng
washer

24
Plain
washer

25
Warning
switch

26
Warning
switch

29
Adjusting
nut

30
Hex
nut

51
Bushing

52
O
nng

53
Plain
washer

54
PlalO
washer

55
Hex
nut

56
Cotter
pIn

57
Lock
washer

58
Hex
nut
65

66
4
62
59
Balance
lever

60
Cross
rod

61
Cross
rod

62
Clip

63
Screw

64
Nut

65
Spring

66
Grommet

67
CleVIS
pin

68
Cotter
pin

69
Center
lever

70
Pin

71
Pin

72
Trunlon

73
Cable
assembly

74
Cotter
pin

75
CleVIS
pin
@

67

68
Ie
Ie

1
Control
bracket

2
Control
ever

3
Control
stem

4
Control
gUide

5
Control
yoke

6
Set
spring

7
Ffont
lever

8
Front
cable

9
Outer
lever
g

10
Center
cable

11
Inner
lever

12
Arm
spring

13
Center
link
rod

14
Equalizer
Imk

15
Equalizer

16
Rear
cable

17
Lock
plate

18
Cable
sprmg
@
a
lI
l
l
o

BRAKES

ZOI

Cross
Rod

Removal

Wagon

I
Remove
the

pull
off

spnngs
at
each
end
of

the

cross
rods

2

RelI
ove
clevis

pms
and

cross
rods

Rear
Cable

Removal

Pick
op

1
Remove

cleVIS

pm
and

disconnect

equalizer

from

equal1zer
link

2
Remove
lock

plate
1
and
cable

spring
2

as
shown

ill

Figure
24

3
Remove
both

rear
brake
drums
DISConnect

rear
cable
from

toggle
lever
3

Separate
cable

connecting
flange
4
from
brake
dIsc
See

Figure
25

4
Remove
rear
cable

Handbrake

Inspection
and

Repair

1

Inspect
all

cables
and

parts
for

damage
ex

cessive

elongation
and

general
wear

Replace
as

reqUlred
I

2

Inspect
ratchet

pawl
and
teeth
on

control

stem
for
excessive

wear

Replace
as

reqUIred

3
Check

springs
for

weakness

Replace
as

reqUIred

Handbrake

Installation

I

Install

parts
of
the
handbrake

system
m
the

reverse
of

removal
Make
certam
all

connections

are

tight

2
Lubncate
all

slIdmg
parts
With

muItl

purpose

grease

Front
Brake

Adjustment
Sedan
and

Wagon

AdJustment
of
the

front
dIsc
brake
units
18

not

reqwred
as
it

18
made

automatIcally
Re

place
the
front
dISC
brake

pads
and
rebwld
the

pISton
assemblJes
If
the

brakes
are

defective

Front
Brake

Adjustment
Pick

up

I
Refer
to

Figure
26
Jack

up
vehicle
to
lIft

wheel

requiring

adJustment

2

Remove
rubber
boot

from

brake
disc

3

Lightly
tap
adJuster

housmg
and
move
It
for

ward
Turn

adJuster
wheel

with
a
screwdriver

and

spread
brake
shoes

Stop
turnmg
adJuster

wheel
when

a

considerable

drag
is

felt
on
brake

drum

NOTE
For

both

left
and

right
brakes

brake
shoes

spread
when

adJuster

wheelIS

turned
downward

4
Return

adJuster
wheel
12
ratchet
teeth
to

obtam
correct
clearance

between
brake
drum

and

shoes

5

Turn

brake
drum
to
make

sure
that
drum

turns
Without

draggmg
If

draggmg
exists

readJust

202
h

l
CHAPTER

FOURTEEN

Rear

Brake

Adjustment
Sedan

and

Wagon

I
Jack

up
the
rear
wheel

2
Release
the

handbrake

completely

3

Figure
27
shows

the

adJustmg
screw
for
the

sedan

Figure
28
for
the

wagon
Depress
the

I
rake

pedal
several
tImes
and
turn
the

adJusting

screw

clockWise
untIl
the
drum

cannot
be
moved

I

by
hand

4
Return

adJusting
screw
counterclockwISe

untIl
the

shoes
are

Just
clear
of
the

drum
ThIS

should
be

about
three
notches

5
Rotate

the
drum
to
see
If
the
shoes

are

draggmg
It
so

readJust
untIl
the

drag
IS

gone

Rear
rake

Adjnstment

pick
np

I
Jack

up
rear
wheel

2
Release
handbrake

AdJust
the
wheel

usmg

the

same

procedure
given
for
the
front

wheel

See

Figure
29
Handbrake

Adjnstment
f

I
Release

handbrake
and

adJust
rear
brakes
as

preViously
descnbed

2

AdJust
the
front

and
rear
handbrake
cable

by

adJustIng
nuts

shown
m

Figure
30
The
stroke

of
the
handbrake

control
stem
should
be
3
346

to
3
740
m

85
to
95mm
sedan

only

3
Refer
to

Figure
31

AdJust
the
front
cable

by

turnmg
the

adJusting
nut
so
that
the

control

stem
stroke

IS
4
330
to
4724
m
110
to

120mm

wagon

only

BRAKES

203

4

32
shows
the

adJusting
pomts
for
the

pick
up
With

rear
cable
stretched

adJust

equal

IZer
link

With

adJust
screw
A

so
that

L

dimensiOn

Is
1
161
m
295mm

Lock

adJust

screw
wlth

locknut

5

AdJust
front
cable

adJust
screw

8
so
that

control

stem
stroke
IS
3

15
to

394
m
80
to

100mm

Lock

adJust
screw
With

lock
nut

SERVICE
DATA
AND
SPECIFICATIONS

Table
1

prOVides
the

servIce
data
and

specm

catIons
for
the
sedan
wa

n
and

pick

up

Table
1
BRAKE
SERVICE
DATA

AND
SPECIRCATlONS

Brake

Pedal

m

Pedal

free

height

Full
stroke
of

pedal
ead

Master

Cylinder

Inner
diameter

MaXImum
clearance
between

cylinder
and

piston

Wheel

Cylinder

Inner
diameter
front

Inner
diameter

rear

MaXimum
clearance
between

cylinder
and

piston

Brake
Drum
and
Rotor

Drum
brake

Inner
diameter
front

DISC
brake
outer
diameter

front

Drum
brake
outer
diameter
rear

MaXimum
allowable

out
of
round

LImit
of
drum

reconditioning

Inner

diameter

MaXimum
rotor

runout

MInimum
rotor
thickness

A

Lining
DImenSion

Front
WIdth
x
thIckness

x

length

Front
dISC

pad

Width
x
thickness

x

length

Rear
Width
x
thickness
x

length

Total
friction
ar
a
drum

type

Total
friction

area
front
diSC
Sedan
Wagon
Pick

up

8

150
In

207mm
533m
135
5mm

5
709
In

145mm

f

o
75
In
1905mm
o
75
In

1905mm

00051
In

0
l
mm

o
006
In
0
15mm

i

20m
508mm

08125
m
20
64mm

o
8
2
In

20
64mm
o
8125
In

20
64mm

il

0007
In

0
18mm

0006
In
015mm

1000
In
254mm

9
130
In
232mm

900
In
228

imm
1000
In
254mm

o
002
m

0
05mm
o
008
In
0
20mm

9
039
In
229
6mm
1004
m
255mm

00024
In

006mm

0331
In
84mm

18x02x96m

45
x

4
5
x
244mm

1
563
x
0
354
x
3
386
In

39
7
x
9
x

86mm

1
575
x
0
18
x
8
642
m

40
x
4

5
x
219

5mm

54
4

sq
In

351

sq
cm
18x02x96m

45

C
4
5
x
244mm

682sq
m

440

sq
cm

1777

sq
In

1142

sq
cm

continued

204
CHAPTER
FOURTEEN

Table
1
BRAKE
SERVICE
DATA
AND
SPECIFICATIONS
continued

Sedan
Wagon
Pick

up

Tightening
Torque
ft
lb

Ikg
m

Fulcrum

pm
25
3
to
28
9
253to289

3
5
to
4
0
3
5
to
4
0

Master

cylinder

mounting
bolts
15
2
to
18
1
152
to
18

1

2
Ito
2
5
2
1
to
2
5

Front
brake
wheel
cylinder
108
to
152
30

4
to
37

6

1
5
to
2
1
4
2
to
5
2

Rear
brake
wheel

cylinder
10
8

to
15
2
10
8
to
13
0

1
5
to
2
1
1
5
to
1
8

Rotor

fixing
bolts
28
2
to
38
3

39to53

Brake

hose
to
wheel

cylinder
123
to
14
5
123

to
14
5

1
7
to
2
0
1
7
to
2
0

CHAPTER
FIFTEEN

BODY

ELECTRICAL
SYSTEM

Exploded
diagrams
of

the
various

systems
are

given
below

Inspection
of
the
constructIon
de

tails

as

given
m
the

exploded
diagrams
should

enable
the

mechanic
to

Identify
remove

repauj

replace
and
mstall
defectIve

parts
General

pro

cedures

are

given
at
the
end
of
the

chapter

WIRING

FJgUres
1
and
2

illustrate
the

winng
and
har

nesses
for
the
sedan
and
statIon

wagon
respect

2

VOLTAGE
REGULATOR

JOE
MARKER
l
AMJ

STARTER
MOTOR

IGHITION
COIL
t

ively

Figures
3
and
4
show

pick

up
winng

SWITCHES

FUSES

Figure
5

page
208

prOVides
details
of

switches
used

through
1969

Figure
6

page

207
covers
SWitches
used

smce
1970

FIgDI
eS
7

page
209
and
8

page
210

provide
further

SWitch
locatlon
and
fnnctIon

informatIon
Fuse

blocks

are
located

on
the

firewall

within
the

engine

compartment

ROOM
LAMP

COMBINATION
lAMP

LICENCE

lAMP

1

Engme
room
harness

2
Instrument

harness

3

Body
harness