height DATSUN 610 1969 User Guide

J

Ie

T

I

Baseplate

@

2
Czn
e

piUfU

i

y
3
Distance

preces

4

height
iPuge
P

5

Actuilting
mechanl

sQ
6
Set

bolt

I

e
r

ft
I

Fig
E
3
autch

assembly
tool

Fig
E
4

Checking
the
driven

plate
for
run
out

81

I

1
1111
11
I
r

A

I

1

1111111111
if

jI

4
J
J
J

FiB
E
5

Checking
the

height
of
the

diaphragm

spring
Fig
E

6
Olecking
the

load
of

the
d

t
b

spring

I

I

I

A

j

I
1
1

I

l
i
y
8

Fig
E
7
Inspecting
the
clutch

spnngs
for

distortion
Fig
E
8

Removing
the
releaSe
bearing

p

l
0
I
0

W
Illmi
i
hm
17
9

FiB
E
9

Installing
the

lea
bearing

diaphragm

spring
FiB
E
I
0

Installing
the
lease

bearing
coil

spring

46

CLUTCH
PEDAL

Adjusting

400
and
1600
cc
models

Adjust
the

pedal
height
to
209
mm
8
22
in

with
the

pedal

stop
slackened
off

by
altering
the

length
of
the
master

cylinder

push
rod
See

Fig
E
13

Tighten
the

pedal
stop
and
obtain

a

pedal
height
of
207
ffim

8
15
in
for
Left
Hand
drive
models

or
182
mID
7
I7
in
for

Right
Hand
drive
models
Secure
the

stop

by
tightening
the
locknut
and
make
sure

that
the

points

illustrated
are

correctly
greased

CLlTfCH
PEDAL

Adjusting

1800cc
models

Adjust
the

pedal
height
to

175
mm
6
89
in

by
adjusting

the

pedal

stop
See

Fig
E
13
then

retighten
the
locknut
A

to
a

torque
reading
of
0
79
1
07

kgm
6
8Ib
ft
Turn
the

master

cylinder
push
rod
to
obtain
a

play
between
1
Smm

0
04

0
2
in
at

the
clevis

pin
then

tighten
the
locknut
B

to

a

torque
reading
of
0
79
1
07

kgm
6
8
Ib
ft
Ensure
when

adjusting
the

play
that
the

port
on
the

master

cylinder
is
not

blocked

too
small
a

play
at
the
clevis

pin
may
block
the

port

Bend
the
clevis

pin
over

completely

CLlTfCH
MASTER
CYLINDER
Removal

and

Dismantling

Disconnect
the

push
rod
from
the
clevis

Fig
E
14

Detach
the
fluid
line
from
the
master

cylinder
and

pump

the
fluid
into
a
suitable
container

3
Withdraw
the

retaining
bolts
and
remove
the
master

cylinder
assembly
from

the
vehicle

To

dismantle
the
master

cylinder
remove

the
filler

cap
and
drain

away
the
fluid

Pull
back
the
dust
cover

and
remove

the

snap
ring
the

stopper

push
rod

piston
assembly
and
return

spring

Oean
the

components
in
brake
fluid

and
check
them
for
wear

or

damage

Renew
the

cylinder
and

piston
if
uneven
wear
has
taken

place

the
clearance

between
the

cylinder
and

piston
must
not
exceed

0
13
mm
0
005
in

Renew
the
dust
cover
oil
reservoir
filler

cap
and
fluid
line
if

necessary

Reassembly
of
the
master

cylinder
is
a
reversal
of

the
dismantling

procedure
take
care
to

soak
the

components
in
brake
fluid
and

assemble
them
while
still
wet

When
the
master

cylinder
is
installed
in
the
vehicle
make
sure

that
the

pedal
height
is

adjusted
as

previously
described
and

bleed
the
hydraulic
system

by
following
the

procedures
given

under
the

heading
CLlTfCH
SYSTEM

Bleeding

CLlTfCH
SLAVE
CYLINDER
Removal
and

Dismantling

Remove
the
return

spring

2
Disconnect
the
fluid
line
from
the
slave

cylinder

D
3
Disconnect
the
push
rod
from
the
clutch
withdrawal
lever

4
Take
out

the
mounting
bolts
and
withdraw
the
slave

cylinder
from
the
clutch
housing

To
dismantle
the
slave
cylinder
remove
the
dust
cover

and

snap
ring
and
withdraw
the

remaining
parts
from

the
cylinder

Oean
all

components
carefully
and
check
them
for

signs

of

damage
or
wear
renew

any

part
found
to

be
defective
and

fit
a
new

piston
seal

CLUTCH
SLAVE
CYLINDER

Assembly
and
Installation

Reassembly
is
a
reversal
of

the
dismantling
procedure

Ensure
that
the

parts
are

dipped
in

brake
flu
d
before

assembling

and
that
the

piston
seal
is

correctly
installed

When
the
slave

cylinder
is
installed
in
the
vehicle
bleed

the
hydraulic
system
by
following
the

procedures
given
under

the

heading
CLlTfCH
SYSTEM

Bleeding

The

push
rod
must
be

adjusted
so
that
the
withdrawal

lever

has
an
end

play
of
2
0
2
3
mm
0
078
0
091
in
details

of
this

operation
are

given
below

CLlTfCH
WITHDRAWAL
LEVER

Adjusting

The
correct

adjustment
of
the
clutch
withdrawal
lever
is

most
essential
as
insufficient

clearance
between
the
clutch

release

bearing
and
the

diaphragm
will
cause
the
clutch
to

slip

On
the
other
hand
an
excessive
clearance
will

prevent
the
clutch

from

disengaging
correctly

The
clearance
between

the
release

bearing
and

diaphragm

or
release
levers
can
be

adjusted
in
the

following
manner

Slacken
the
locknut

Fig
E
IS
and
screw

the

push
rod

fully
home
with
the

adjusting
nut
Return
the

adjusting
nut

I
3
4
turns

to
adjust
the

play
at
the
end
of
the
clutch
withdrawal

lever
to

2
0
2
3
mm
0
078
0
091
in
This
will

give
a
clear

ance
of

approximately
1
3
mm

0
051
in

between
the
release

bearing
and
the

diaphragm
spring
or
release
levers

NOTE
When

adjusting
clutch

pedal
free
travel
at

the
withdrawal

lever
it
is
essential
to
check
that
the
clutch
driven

plate

has
not
worn

by
more
than
2mm
0
08
in
otherwise

the
clutch
will

slip
even
if

it
is

correctly
adjusted
See

Technical
Data
for
the
relevant
clutch
driven

plate

thickness

CLUTCH
SYSTEM

Bleeding

The
clutch

system
must
be
bled
after
it
has
been
dismantled

or
if

any
part
of
the
circuit
has
been

opened
This

operation

should
also
be
carried
out
if
the
fluid
level
in

the
reservoir
has

been
allowed
to
fall
and

pennit
air
to
enter
the

system

The

presence
of
air
in
the

system
may
be
noticed

by

incorrect
disengagement
of
the
clutch
but
in
any
case
if
air
is

suspected
the
clutch
must

be
bled
in

the
following
manner

Remove
the
dust

cap
from
the
slave

cylinder
bleed
screw

Connect
a

length
of
tube
to
the
bleed
screw
and
immerse
the

47

inter
1D7
J

3

T
T

aj

W

n
J

I

1

T

f
T
7

e

Fig
E
II

Adjustillll
the

height
of
the
release

levers
Fig
E
12
Actuating
the
clutch
to
settle
the

mechanism

Tightening
torque
3
5
to
4
0

kltm

125
to
29

h
lb

Rs

@

A
l

I
l

1
3
fP

I

01
I

8J

I

Jt
I

Lock
A

2

Lock
ul
Bn

Adjwt
by
adjust
of
master

cyl

@
Lubricatic
l

Clutch
dal
full

trek
140
4

mm
5
51
0
16

Clutch

pedal
free
stroke
25
mm
0
98
Pedal

height
175
mm
6
89
nl

Pc

dalfullstrokc
b

135mm
5
JI
n

@
Multi

purpo
greasc

510
series
610
series

Fig
E
l3

Adjusting
the
clutch

pedal

I

48

other
end
of
the

tube
into
a
clean
container

partly
filled
with

brake
fluid

Top

up
the
master

cylinder
reservoir
with
recommended

fluid
and

open
the
bleed
screw

approximately
three

quarters

of
a
turn

Depress
the
clutch

pedal
slowly
and
hold
it

completely

down
re

tighten
the
bleed
screw
and
allow
the

pedal
to
return

slowly

Repeat
the

operation
until
the
fluid

emerging
from
the

tube
is
free
from
air
bubbles
It
should
be
noted
that
assistance
will
be

required
when

carrying
out

bleeding
operations
as
not

only
must
the
fluid

entering
the

glass
container
be
watched
but
also
the
clutch

pedal
has
to
be

operated
and
the
reservoir

topped
up
frequently

throughout
the

procedure

When
the
fluid
is
completely
free
from
air
bubbles
the

bleed
screw
should
be

retightened
on
a
down
stroke
of
the

pedal

Finally
remove
the
bleed
tube
and

replace
the
dust

cap

TechnIcal
Data

Outch

type

Pressure

spring

Free

length

Fitted

length
and
load

Side
distortion

Permissible
deterioration

of

spring
force

Outch
release
levers

Oearance
between
release

bearing
and

diaphragm
spring

release
levers

Height
between
diaphragm
spring
and

flywheel

Height
between
release
levers
and
flywheel

Outch
driven

plate

Outer
diameter

Inner
diameter

Thickness
of

facingS

Total
friction
area

TIrickness
of

clutch
plate

Free

Compressed

No
of
torsion

springs

Permissible
minimum
depth
of
rivet
heads
from

facing
surface

Permissible
run
out
of
clutch

facing

P
rmissible
free

play
of

splines

Outch

pedal
1400
and
1600cc
models

Pedal

height
in
the
rest

position

P
da1
free
stroke

P

da1
effort

Master

cylinder

Diameter

Maximum
clearance
between

piston
and

cylinder

Pressure

plate

Permissible
refacing
limit

Outch

pedal
180Occ
models

P
da1

height

Play
at
clevis

pin

Full
stroke

P
da1
effort

50
Diaphragm
spring
or
coil

spring

52
3mm
2
059
in

29
2mm
44

2kg

1
149
in

197
t

4
4
lb

5mm

per
IOOmm

0
2in

per
3
94
in

15

1
2
I

4mm
0
047
0
055
in

44
t

Imm
1
732
t

0
039
in

50
5
t
0
05mm
1
988
t

0
0197
in

200mm
7
87
in

130mm
5
12in

3
5mm
0
140in

362

sq
cm
56
11
sq
in

8
6
9
0mm
0
3386
o
3543in

7
65
7
95mm
0
3012
o
3130in

6

O
3mm
0
0118

in

0
5mm
0
0197
in

0
4mm
0
0157
in

182mm
7
17in
R
H
D

207mm
8
15in
L
H
D

25mm
0
984in

15kg
33
lb

15
87mm
0
625in

O
13mm
0
005lin

Imm
0
0394in

175mm
6
89in

1
5mm
0
04
0
20in

135mm
5
3lin

10

5kg
23Ib

inter
E
lill
j

lll
jIl

1

3

I

i

1r
I
An
t

1
ll

1
11
5
85

1
Sleeve

voke
arsembh

Bearillg
race
assembh

Jvumal
asst

mb
r

4

Snap

ring

5

Prope
ier
shaft
tube
assl

mblv

6
flan

oke
2

O

L

l
OIlU

39
I

JII

I

I

i
i

3

1
378

@
Fig
G
I
Section

through
the

propeller
shaft
Unit

mm
in

@
@

j

c

@

I
I

i

@

@

@

J

q

cJi
y

j

rID

@

62
Fig
G
2
Section

through
the
differential
carrier

1

Supply
rrwlti

purpose
gTet1M
to

oil
seal

lip
when
ass

mb1ing

Pinion

bearing
adjusting
lWSher

Adjust
pinion
ber
uing

X
eload

by

selecting
2
and
3

Pinio

bearing

adjusting
spacer

4
PInion

height
adiustinx
MUS1m

5
Lock

strap

6

Ring
gear
bolts
T
7

0
to

8
0

kgm

50
6
ro
578

bIt

TIghten
by
tapping
bolt
head
with

Jj41b3
hamTMr

7
Lock

pin

8
Rear
cover

9

Ring
gmr

10

Diff
mounting
member

1
J
Bolt

diff
to

diff
mounting
member

T
6
0
to
8

0kKm
43
4
0
7
8

b
ft

12

ShIlf

pinion
m1te

13
Thnl

lWlJIJer

14
Pinion
mate

15
17vust
washer

Adjust
the
backla
h
in

pinion
mate

and
ide

gear
or
the
clearance

betwun
the

differential
ctlSI

and
the

rear

fact
ofridt
gror
to
0
1
to
0
2

mm

0
0039
0
0

0079
bv
16

16
Side
ar

17

BoltsideflilngeT
1
9to

6kgm

13
710
18

8Ib
f

18
Oil
tal

Supply
chassi

grea
e
to
oil

seal

lip
Vtlhen

autmbling

19
Side

flange

20
Side

retainer

21
Bolt
side
retainer
T
0
9
to
1
2

kgm

6
5
to
8
71b

22

ring

23

Side
bearing

24

Diff
Gear
case

25
Pinion
rear

bearing

26
Dril
e

pinion
27
Pinion

front
bearing

28

Spacer
front
pilot
beaTing

29
Front

pilot
bearing

30
Oil
seal

3J

CompanionfliInge

32
Dri

pinion
nut
T
17

to
20

Jwn

122
9
0144

6Ib
fI

inter
M
j

@
jJ

2

t

1
5c

t
J
i
3

jp

7
i
r
4

Ilc
d

I

l

@

l
lb
r

s
ril

1

iF
C

Q
Fig
G
12
Section

through
the
drive

pinion

1
Pinion

height
adjusting
kUsher
4
Fte
Ioad

for
pinion
bearing

2
Pinion

height
ad
usting
shims
without
oil
mlI
and
drive
7
to

3

Tightening
torque
of
nut
dril
e
10

kgt1L
5a

6
to
72
3
lb

jl

pinion
17
to

20kg1n
22
9
to

ffnion
bearing
adjusting
w

uher

44

6Ib
ft
J
6
Pillion
bt
flrillgadjusti

lg
s
Jtu
er

fl

i
Ji
l
I
I

J

lJ

i

V
r
IHei
t

giluge

I
lST31210c
0

l

B
I

0
QJ

DUrnmYPinlOn

Drive

pinion
collar

lST3121QOCX
f
1
L

r

IST315000001

Dummvspacer

ST318500001
I
Fig
G
ll

Measuring
the
clearance
between
the

differential
side

gear
and
thrust
washer

Fig
G
t3
Drive

pinion
markings

Fig
G
14

Adjusting
the

pinion
height

1

Fig
G
t
5

Adjustment
diagram
for
the
dif

feren
tiaI
side
covers
Fig
G

16lnstalling
the
differential
side
covers

fig
G

Checking
the
backlash
of
crownwheel

and

pinion
Fig
G
tS

Fining
the

differential

mounting

member

bb

cage
Mcasure
the
clearance
between
the

rear
face
of
thc
side

gear
and
the
differential
cage
as

shown
in

Fig
G
ll

and
if

necessary
use
a

tluust
washer

which
will

given
a

clearance
of

0
1
0
2mm
0
004
0
008
in
Fit
the

pinion
shaft
lock

pin

and
secure
it

by
caulking
with
a

punch
Lubricate
the

gear
teeth

and
check
the

gear
for
freedom
of
rotation

Install
the
crown
wheel
in
the

differential

cage
and
insert

the
bolts
with
new
lock

straps
Tap
the
head
of
each
bolt

lightly

and

tighten
the
bolts
in
a

diagonal

pattern
to
a

torque
reading

of
7
0
8
0

kgm
51
58Ib
ft
Measure
the
width
of

the
side

bearings
before

installing
them
Place
a

weight
of
2
5

kg
5
5
1b

on
the

bearings
and
check
the
nominal
width
which
should
be

20mm
0
787
in
Press
the

side

bearings
into
the
differential

cage

Adjustment
of
drive

pinion

preload

This

adjustment
is
carried
out
without

fitting
the
oil
seal

Press
the
front
and
rear

bearing
outer
races

into
the

gear
carrier

and
fit

the

pinion
height
adjusting
washer

Fig
G
12
the

shims

and
the
rear

bearing
inner
race
onto

a

dummy
shaft

special
tool
ST
31
120000
The
old
washers
and

shims
can

be

re
used
if
the
tooth
contact

pattern
was
found
to
be

correct

on
the

pre
dismantling
check
Fit
the
drive

pinion
bearing
spacer

the
washer
ans

special
collar
5T
312140000
or
5T
31500000

and

the
drive

flange
on
to

the

dummy
shaft

Tighten
the
drive

pinion
nut
to
a

torque
reading
of
17

20

kgm
123
145
Ib

ft

Measure

the
drive

pinion
bearing
pre
load
and
select
washers
and

spacers
to

give
a

pre
load

of
7
1
0

kg
cm
6

9Ib
in
with
new

bearings
or
3

6
kg
cm
2

6
5
Ib
in
with
used

bearings

Adjusting

spacers
are
available
in

lengths
of
56
2
57
2
mm

2
2126
2

2520
in
and

adjusting
washers
in
thicknesses
of

59
2
31
mm
0
1020
0
0909
in

Adjustment
of

pinion
height

The

pinion
height
or
distance

of
the
face
of
the

pinion
to

the
axis
of
the

crownwheel
is

adjusted
by
the
thickness
of
the

adjusting
washer
behind
the
drive

pinion
gcar

The
drive

pinion
has
a

tolerance
mark
etched
on
its
face

this
tokrance
is

accompanied
by
a

or

sign
to
show
the

deviation
from
the
nominal
dimension
Thc

plus
sign
indicates

that

the
nominal
distance
must
be
increased
and

the
minus

sign
that
it
mllst
be
decreased
The
tolerances
are
shown
in

Fig

G
I3

The

pinion
height
can

be

adjusted
using
the

original

adjusting
washer
and
shims
between
the
rear

bearing
cone

and

the

drive

pinion
Install
the

setting
gauge
5T
31210000
on
the

carrier
with
the

dummy
pinion
installed
Sce

Fig
G
14

Measure
the
clearance
between
the
head
of
the

dummy

shaft

and
the
tip
of
the

setting
g
wge
using
a
feeler

gauge
as

shown
in

Fig
G
15
The
clearance
is

also
shown
at
the

point

T
in
Fig
G
14
The

required
thickness
of
the

adj
lsting

washer
can

be
obtained

using
the
following
formula

S
W

T
H
x

0
01
0
20

Where
W

thickness
of
inserted
shims
and
washers

T
Measured
thickness

H
Figure
engraved
on

pinion
head
o

S

Required
thickn
ss
of
washers
and
shims

A

typical
example
is
given
below

w

20
1
20

T

H

S
340
0
24
2
x
0
01

0
20
3
40
mm

0
24
mm

3
46
mm

An
adjusting
washer
rrlust
be
selected
which
is
nearest
in

thickness
to
the
value
of
3
46mm
Adjusting
washers
are
available

in
thicknesses
of
3
09mm
0
01217
in
to
3
66m
0
1441
in

for
the
l800cc
models
and
in
thicknesses
of
O

2
and
2
4mm

0
787
0
866
and
0
945
in

for
the
1400
and
1600
cc
models

Fit
the
selected

adjusting
washer
and
shims
to
the
drive

pinion
and

press
on
the
rear

bearing
inner

race
Install
the
drive

pinion
into
the
differential
carrier

together
with
the

bearing

spacer
and
washer

the
front

bearing
inner
race
and
the
front

bearing
pilot
spacer

Fit
the
drive
flange
and
washer
on
the
drive

pinion
and

secure
them
with
the

pinion
nut

Tighten
the
nut
to
a
torque

reading
of
17
20

kgm
123
145Ib
ft

SIDE
BEARING
SHIMS
Selecting

The
side

bearing
pre
load
must

be
adjusted
with
selected

shims

if
the

differential
carrier
the

cage
the
side
bearings
or

the
bearing
covers
have
been
renewed

The

required
thickness
of

the
shims
can
be
obtained

using

the

following
formula
and

referring
to

Fig
G
l
5

T1
left
side
bearing
A
C
GI
D
E
H
x
0
01

0
76

T2

right
side
bearing
B
D
G2
F
H
x
0
01
0
76

Where

A
B

C
D

E
F
The

figure
on
the
differential
carrier

The

figure
on
the
differential

cage

The
differences
in
width
of
the
left
or

right
hand

bearings
against
the
nominal
width
of
20
0mm

0
7874
in

given
in
units
of
1
100
mm

Gl

G2

H
The

figure
on

the
side
cover

The
figure
on
the
crownwheel

The
A
B
C
D
G
and
H

figures
indicate
the
dimensional

variations
in
units
of
1
100
mm
fr
Jm
the
standard
measurement

An

example
of
the
calculations
to
decide
the
thickness
of
shim

required
is

given
below

Where

A
I
B
2
C
2
D
1
GI
3
G2
1
E
O
Olmm
F

O
02mm
H

Left
side

bearing

Tl
A

C
G
1
D
H
x

0
01
0
76
E

I
3
1
2
x

0
01
0
76
0
01
0
8mm

Right
side

bearing

T2
B
D
G2
H
x
0
01
0
76
F

2

I
I
2

x
0
01
0
76
0
02
0
8mm

67

inter
lJIi

@
pl

J

J
Y

e

c

J
r
c

A

Ir

f
1

r
i

ST06J60000

0

i
J

estate
car
r

I

f
o
t
t
iJ
J

I

l

G

L

i

f1

v
f
P

r

5T0631110UO

I
sr
s

s

r

u
h

van

Fig
G
20

Removing
the
side

bearing

Fig
G
19

Mounting
the

differential
carriers

V

1

tj
l
fl4j
P

ff

P

tffST23510000
f

S

I
l
1

rig
G
22

Punching
out

the

pinion
shaft
lock

pin
j
Fig
C

21

Removing
the

crownwheel
bolts

Fig
C
23

Removing
the
drive

pinion
nut

t

1

Fig
G
24

Removing
the

pinion
rear

bearing
inner

race
rig
G
25

Checking
the

crownwheel
for

run
out

I

u
l

o

F
Ice
idth
Ol
1
lction

Ibvr
ti

3
3S6
L

i

1

Fig
G

26
Drive

pinion

markings
Estate
cars
Fig
G

27

Standard

pinion
height
dimension

68

The

standard
width
of
the
side

bearings
is
20
0mm

0
7874

this
width
must
be

measured
before

attempting
to

calculate
the
thickness

of
the

adjusting
shims
Use
a

dial

gauge

and
surface

plate
to
ohtain

the
measurement
Place
a

weight
of

approximately
2

5

kg
5
5
lb
on
the

bearing
to

obtain

steady

readings

Install
the
differential

cage

assembly
in

the
carrier

Fit
the

sckcted

shims
and
O

rings
into
both

differential
side

bearing

covers

and
install
the
covers

in
the

carrier

using
the

special
tool

ST
33720000

Fig
G
16
l
Make
sure

that
the
side

bearing

outer

races
are
not

damaged

by
the

roller
Measure
the
backlash

between
the

teeth
of

the
crown
wheel

and
drive

pinion
with
a

dial

gauge
as
shown
in

Fig
G
I
Sct
the
dial

gauge
to
0
10

f
O

mm

0
004
0
008
in

I
If
the

backlash
is

less
than
the

specifIed

value
move
he
left
side

adjusting
shim
to
the

right
side
and
vice

versa

if
the
backlash

exceeds
the
specified
figure

Check

that
the
run
out
at
the
rear

of
the

crownwheel
does

not

excecd
O
OSmm
0
002

in
for

the
1800ce
model
or

O
08mm
0

003
in

for
the
1400
Check
the

drive

pinion

turning

torque
Thc

turning
torque
should
be

higher

by
I
3

kg

em

compared
with
the

turning
torque
obtained
before

fitting

the
differential

cage
in
the
carrier
The

higher
value
can

be

provided
if

necessary
by

dmnging
the

jde
cover

shims
Note

howcver

that
any
decrease
or
increase
in

the
thickncss
of
shims

wjJl

alter
tht
budlush

between
the
teeth
of
the
crownwhee1

and

pinion

Check

the
tooth
contact

pat
tern

of
the
crown
wheel
and

pinion
as

described
under
the

appropriate
heading

DIFFERENTIAL

Installation

Secure
the
differential

carrier
on
the
rear

suspension
mem

ber

using
the
four

bolts
and
washers
Fit
the
differential

mounting
member
to
thc

mounting
holes

by
pushing
it
forwards

with
a

suitable
lever

Fig
G
18

Tighten
the

nuts
to
a

torque

reading
of
8

5

kgm
61
5

Ib
ft

Tighten
the
bolts

attaching
the

gear
carrier
to
the

suspension
member
to
a

torque
reading
of

6
7

kg
36
5Ilb
ft
t

The

rcmainder
of
the
installation

operations
are
a
reversal

of

thc
removal

procedure
Fill
the
differential
with

the
correct

quantity
of
recommended
oil

DIFFERENTIAL
CARRIER

Removal
and

Dismantling

Estate
car
alld
Vanl

To

remove
the
differential

carrier
disconnect
and
remove

rhe

propeller
shaft
as

previously
described

and
remove

the
two

rear
axle

shafts
as

described
in

the
section
REAR
AXLL
With

draw

the
nuts

securing
the
differential

and
remove

the
carrier

from
the
rear
axle

Mount

the
unit
on
the

special
attachment
as
shown
in

Fig
G
19
and

carry
out
a

preliminary
check
before

dismantling

Oleck
the
tooth
contact
of
the

crownwheel

and

pinion
by

applying
lead
oxide

to
three
or
four

teeth
of
the

crownwheel

Turn
the
crown

wheel
several
times

to
obtain
an

impression
of

the

tooth
contact

pattern
Check
the
backlash

between
the
teeth

of
the
crownwheel
and

pinion
with
a

dial

gauge
Hold
the
drive

pinion
with
one

hand
and
move

the
crown
wheel

backwards
and
forwards
to

check

that
the
backlash
is
Io

ithin
thL

speL
ified
limits

Shims
and

adjusting
washers
must
bL
altered
if

the
tooth
con

tact

pattern
and
backlash

is

incorre
L
the
neL

cssary
details
for

these

operations
can
be
found
towards
the

end
of

this
section

under
the

appropriate
he
Jdjn

s
Fil1JJly
mark
the

bearing
caps

with
a
hammer

and

punch
to
ensure
correct

t1ignment
on
re

assembly

Remove
the

bearing

caps
nd
withdraw

the
differ

ntial

cage
make

a
note
of

the
left
and

right
hand

positions
so
h
Jt

the

bearing
caps
and
outer
race
can

be
re

assembled
in

their

original
positions

Withdraw

the
side

beJrings
with
the
s

cjal

puller
as

shown

in

Fig
G
20

taking
care
not
to

catch
the

edge
of
the

bearing

inner
races

Place
the

assembly
in
a
vice
and
detach

the
crownwheel

by
slackening
the

retaining
bolts
in
a

diagonal

patter
Fig
G
lf

Drive

out
th

pinion
shaft
lock

pin
from

left
to

right
using
a

suitable

punch
or

special
tool
ST
23520000

Fig
C
22

With

draw
the

pinion
shaft
and
take
out

the

pinions
side

gears
and

thrust
washers

Store
the

gears
and
thrust
washers
so
that

they

can

be
assembled
in
their

original

positions

Check
the
initial

turning
torque
of
the

drive

pinion
with

the

preload
gauge
ST
3190000

and
measure

the

height
of

the

drive

pinion
with
the

special
gauge
ST
31941000

Compare
the

figures
obtained
with
those

givcn
in

Technical
Data
at

the
end

of
this
section

Hold
the
drive

pinion
with

the

speciaJ
wrench
ST
3
J
530000

as
shown
in

Fig
C

23
and
unscrew
the

drivc

pinion
nut

then

pull
out
the
drive

pjnion
flange

Tap
the
drive

pinion
assembly
to
the
rear
with
a

plastic

mallet
and
withdraw
it

together
with

the
rear

bearing
inner
race

bearing
spacer
and
adjusting
washer

Remove

and
discard
the
oil
seal
and

withdraw
thc
front

bearing
inner
race
Drive
out
the
outer
races

of
the
front
and

rear

bearings
with
a
suitable

drift

Fig
G
25

The
drive

pinion
rear

bearing
inncr
race
can
be
removed

with
the

special
tool
ST
300310000
as

shown
in

Fig
G
24

DIFFE
l
ENTlAL

Inspection

Clean
all

components
thoroughly
and

examine
for

signs

of
wear
or

damage

Check
the
teeth
of
the

crownwhcel

and

pinion
for

scoring

and

hipping
Ii
should
be

noted
that
the
crownwhecl

and

pinion
are

supplied
as
a

matched
set
and
if
either

part
is

damaged

the

complete
set
must
be

replaced

Examine
the

inner
faces
of
the
side

gears
and
seats
on
the

differential
case

Inspect
the

bearing
races
and

rollers
and

replace

them
if

necessary

Small
defects

on
the
faces
of

the
thrust

washers
can
be

corrected

using
emery
cloth
however
if

the
clearance
between

side

gear
and

thrust
washer

exceeds
0
1
O
2mm
0
0039

0
0079

in
it
ill
be

necessary
to

replace
the
washer

Various

sizes
of
washers
are
available

and
the
thicknesses
arc
detailed

under
the

heading
DIFFERENTIA
L

GEAR
CAGE

Assembling

69

Check
the
run
out
of
the
crownwheel
as

shown
in

Fig
G
15

Position
the

dial
gauge
to

the
rear

of
the
crownwheel
and
check

that
the
run
out
does
not

ceed
0

0
mm
0

0020
10
I
It
the

run
out

limit
is
exceeded

replace
the
crownwheel
and

pinion

as
a
t

Inspect
the
differenti
l
L
arrier
nd
case
for

cracks
or

distortion
and

replace
them
if

necessary

DIFFERENTIAL

GEAR
CAGE

Assembli
g

V
Install
the
differential

side

geaI
5
pinions
and

original
thrust

washers
into
the

cage
and
check
the
clearance

between
side

gears

and
thrust
washers
The

clearance
must
be

adjusted
to

within

0

05
0
20
mm
0
002
0
008

in
for

the
1400
and
1600
cc

models

and
to

within
0
10
0
20
mIT

0
004
0
008
in
for

the

1800
cc
models
Correction
can

be
made
if

necessary
by
replacing

the

thrust
washers
which
are
available
in
the

following
sizes
t

SIDE

GEAR
THRUST
WASHERS

f
1400
and
1600

cc
Estate
car
0
78
0
83
0

88
1
03
1
23
mm

0
0030
0
0327
0
0346

0
0406
0

0484
in

l800cc

Estate
car
0
785
0
835
0
885

1
035

I
185
mm

0
0309
0
0329
0
0348
0
0408

0
0467
in

1800
cc

Van
0

75
0
80
mm
0
80
0

85
mm

0
85

0
90
mm
0
90
0
95
mm

0
0295
0
0315

in
0
0315

0
0335
in
0
0335
in
0
0354
in

0
0354
0

0374
in

Drive
in

the
differential

pinion
lock

pin
from
the

right
hand

side
of
the
case
and

peen
the
rim
of
the
hole

to

prevent
the

pin

from

working
loose

Fit
the
crownwheel

to
the
differential

cage
and

install
the

bolts
and
new
lock

plates
Tap
the
head
of

each
bolt

lightly

and

tighten
the
bolts
in
a

diagonal
pattern
to
the

specified

torque
readings

Press
in
the
side

bearing
inner
race
with
a
suitable
drift

The

crown
wheel

adjusting
shims
must
be

placed
behind
the

bearings
to
obtain

the
correct

pre
load
Press
the

drive

pinion

rear

bearing
outer
race

and
front

bearing
outer
race
into
the

carrier

The
shim
at
the

rear
of
the
outer
race

must
be
increased

or
decreased
to

adjust
the

pinion
height
as
described

below

Adjusting
the
drive

pinion

The

pinion
height
or
distance
from

the
face

of
the

pinion

to
the
axis
of

the
crownwheel
is

adjusted
by
altering
the
thick

ness
of
the

adjusting
shim

between
the

drive

pinion
gear
and

the
rear

bearing
cone
The
drive

pinion
ha

a
tolerance
mark

etched

on
its
face
as

shown
in

Fig
G
26
This
tolerance
is

accompanied
by
a
or

sign
to
show

the
deviation
from
the

nominal
dimension
of

86mm
0
386
in
see

Fig
C

n
The

plus

sign
indicates
that
the

nominal
dimension
must
be
increased

by
the

figure
on

the

pinion
and
the
minus

sign
that
it
must
b

decreased

To
determine
the
thickness
of

the
drive

pinion
shim

press

the
front

and
rear

bearing
outer
races
into
the

carrier
fit
the

70
rear
be

ring
and

dummy
shafr
and

place
the

Ippropriatt
ettil1g

gauge
on

the
carrier
See

Fig
C
2S
l

The

fOllowing
setting

gaUges
and

dUlllmy

shaft
houlJ
bt
llsed
for
th
various

modds

I
OO
and

1600
Estate
c

r

Setting
g
3uge
ST
1941000

Dummy
shaftST
31942000

ISOOce
Estate
car

Setting
gauge
ST
31141000

Dummy
shaftST
1941000

1800cc
V

n

Setting
gauge
5T
3
I
Y41

000

Dummy
sh
ftST

31941000

Measure
the
clearance
N

Fig
C
l8
berween
the

tip
of

the

setting

gauge
and
the
face
of

the

dummy
shaft

with
a
feeler

gauge
Determine
the
thickness
of
shim

required
using
the

following
formula

T
N
H
D

S
x
0
01
0
28
station

wagon

T
N
H
D
S
x
0
01
2
18
Van

Whe
rc

T
The

required
thickness
of

adjusting
shim
mrn

N
The
measured
clearance
mm

H
The

plus
or

minus

figure
on
the

pinion
head

D
The

figure
on

the

dummy
shaft

S
The

figure
on
the

setting
gauge

As
an

example
for

the
Estate
car

N
0
30mm
H

1
D
I
S
O

T
0
30
2
1
0
x
0
01
0
28
0
59
mm

Shims
are

available
in
thicknesses
of
0
050

0
070
0
10

0
20
and
0
50
mID
0
0019
0
0027

0
0039
0
0078
and

0
0196
in
for
the
Estate

cars
and
in
thicknesses
of
2
37
2
97mm

0
0933
0
1169
in
for
the
1800cc
Van

Take
off

the
drive

pinion
and
the
rear

bearing
outer
race

and

adjust
the

position
of

the
drive

pinion
by
installing
shims

of

selected
thicknesses
Fit
the
drive

pinion
and

bearing

spacer

in

the

pinion
housing
and

tighten
the
drive

pinion
nut
to
a

torque
reading
of
14
17

kgm
101
130
Ib
fl
for

the
Estate

cars
or

13
20

kgm
94
145Ib
ft
for
the
1800
cc
Van

Adjusting
the
drive

pinion
preload

The
drive

pinion
preload
on
Estate
car
models
is

adjusted

by
meam
of
the

adjusting
spacer
and
the
shims
between
the

spacer
and
the
front

bearing
inner
race

On
the
1800
cc

van
a

collapsible

pacer
is
u
sed

to

adjust

the

preload

Estate
car

O1eck
the

preload

by
attaching
a

preload
gauge
to

the

pinion

flange
and

adjust
by
selecting
spacers
and
shims
from
the

sizes

given
in
Technical

Data
The
initial

turning

torque
without

the
oil
seal
and
with

the
drive

pinion
nut

tightened
to
a

torque

reading
of
14

17

kgm
101
130
Ib
ft
should
be
10
13

kg
m

138
9
180
5
in
oz
for
new

bearings
If
used

bearings
are

fiued

the
initial

torque
must
be
reduced

by
20
to
40
Cneck

the

pinion
height
as

previously
described
and
re

adjust
if

necessary

Remove
the

pinion
nut
and

nange
Press
the
new
oil
seal

into
the
carrier

ensuring
that
the

lips
of
the

seal
are

thoroughly