technical data DATSUN 610 1969 User Guide

The
coil

spring
clutch

pressure
plate
can

be

lapped
with
a

surface

grinder
to
remove

dents
or

scratches

only
the
minimum

amount
of
metal
should
be
removed
to
restore
the
surface

Check
the

plate
for
distortion

by
placing
it

on
a
surface

plate
with

the
friction
face
towards
the
surface

plate
Press

the
pressure

plate
down
and
insert
a
feeler

gauge
of
1
0mm

0
0039
in

between
the

pressure
plate
and
surface

plate
If
it

is

possible
to
insert
the
feeler

gauge
then
the

pressure
plate
must

be

repaired
or

replaced
The

plate
can
be
skimmed
but
the

maximum
amount
of
metal
that
can
be
removed
is
1
0mm

0
0039in

CLUTCH
SPRING

Diaphragm
clutch

With
the

diaphragm
spring
assembled
to
the

pressure
plate

inspect
the

spring
height
and
load
in
the

following
manner

Place
distance

pieces
of
7
8
mm

0
307
in
on
the
base

plate
as

shown
in

Fig
E
3
and
bolt
down
the
clutch
cover

using
the

special
bolts

provided
with
the
kit
Meas
Jre
the

height
B
in

Fig
E
5

at
a
diameter
of
44mm
1

732
in
The
release

fingers

should
not

exceed
a

height
of
43
45
mm
1
693
1
772
in

from
the
base

plate
Replace
the

spring
if

the

height
is
in
excess

of
the

figures

quoted

Press
the
dutch
down
as

shown
in
Fig
E
6
to
a

depth
of

7
8mm
0
307
in
or
until
the
clutch
driven

plate

upper
surface

lines

up
with
the
clutch
cover

mounting
face
If

the
load

applied

is
less
than
350

kg
770
lbs
it
will
be

necessary
to
renew
the

diaphragm
spring
Do
not

press
the
clutch
disc
down

by
more

than
9mm
0
35
in
or
the

diaphragm
spring
may
be
broken

CLUTCH
SPRINGS
Coil

spring
clutch

The
clutch

springs
must
be

replaced
as
a

set
if

any
of
the

springs
are
found
to
be
defective
Specifications
for
the

springs

are

given
in
Technical
Data
at
the
end
of
this
section

Generally

a

spring
may
be
considered
faulty
if
when
assembled
the
load
is

reduced

by
more
than
15
or
if
the
free

length
has
altered

by

more
than
1
5mm
0
0590
in
or
if
the
deflection
B
to
A

in

Fig
E

7
exceeds
5mm

per
100mm
0
2
in

per
3
94
in

Release

Bearing

The
release

bearing
should
be
renewed
if

excessively
worn

or
if

roughness
can
be
felt
when
the

bearing
is
turned

by
hand

The

bearing
should
also
be
renewed
if
the

grease
has

leaked

away
or
if
the
clearance

between
the
clutch
cover
and
inner

diameter
of

the
sleeve
is
more
than
0
5
mm
0
0197
in

The

bearing
can
be

removed

using
a
conventional

puller

as
shown
in

Fig
E
8
Two

types
of
release

bearings
are

available

and
care
must
be
taken
when

fitting
onto

the
bearing
sleeve

The
release
bearing
should
be

pressed
into

place
on
the

diaphragm

spring
type
of
clutch
with
a
force
of
400

kg
880
lbs

applied

at
the
outer
race
as
shown

in

Fig
E
9
On
the
coil

spring
clutch

the
same

force
must

be

applied
at

the
inner
race
as
shown
in

Fig
E
IO
It
should
be

possible
to
turn
the

bearing
freely
and

smoothly
when
it
is

pressed
into

place
CLUTCH

Assembly

Coil

spring
type

Press
the

pin
into
the

eyebolt
and

through
the

lug
on

the

pressure
plate
Place
the
three
distance

pieces
on
the
surface

of
the
base
plate
of
the

special
tool
ST20050000
and

position

the

pressure
plate

pressure
springs
and
retainers

on
the

plate

Set
the

retracting
springs
on
the
cover

and
insert
the

release
levers

through
the

spring
Place

the
clutch
cover
over

the

pressure
plate
and

springs
making
sure
that
the

retracting

springs
do
not

become
dislodged
or
distorted

Compress
the

pressure
springs
by
screwing
the

special
set

bolts
into
the
holes
in

the
cover

Tighten
the
bolts

gradually

in
a

diagonal

pattern
to
avoid

distorting
the
cover
Place
the

release
levers
on

the

eye
bolts
and
screw
OR
the

securing
nuts

Place

retaining
hooks
under
the
release
levers
and
remove
the

clutch
assembly
from
the
base

plate
slackening
the
set
bolts
in

a

diagonal
pattern

COIL
SPRING
CLUTCH

Adjusting

Screw
the
centre

pillar
into
the
base

plate
and

place
the

high
finger
over
the

pillar
The
height
of
the
release
levers
must

be

adjusted
by
turning
the
eye
bolt
nuts
until
the

tops
of

the

release
levers
are

just
touching
the

tip
of
the
gauge
See
Fig
E

11
Remove
the
centre

pillar
when
the
release
levers
are

correctly
adjusted
and
screw
in
the

actuating
lever
Fig
E
12

Turn
the

actuating
mechanism
several
times
to
bed
down
the

parts
and
then
recheck
the

height
of
the
release
levers
Check

for
run
out
as
near
to
the

edge
as
possible
and

readjust
if
the

deviation
is
more

than
0
5
mrn
0
020
in

CLUTCH
InsWlation

Ensure
that
the
friction
faces
are

free
from

oil
and

grease

and
place
the
driven

plate
on
the

flywheel
The

longer
chamfered

splined
end
of
the

assembly
should
face

the

gearbox
Use
a

spare
drive
shaft
to

align
the
driven

plate
The
shaft
must

be

inserted

through
the
splined
hub
of
the
driven

plate
and
into

the

pilot
bearing
of
the

flywheel

Place
the
clutch
cover
into

position
on

the
flywheel
and

tighten
the
dutch
bolts

gradually
in
a

diagonal

pattern
to
a

torque
reading
of
1
5
2
2

kgm
11
16Ib
ft

Remove
the

dummy
shaft
and
the

restraining
hooks
from
the
release
levers

Refit
the
release

bearing
and
the
bell

housing

CLUTCH
PEDAL
Removal
and
Installation

Remove
the
clevis

pin
from
the
end
of
the
master

cylinder
pushrod
and
disconnect
the
pushrod
Remove
the

return

spring
Remove
the

pushrod
after

slackening
the

pushrod

adjuster
Coil

spring
clutch

only
Remove
the

pedal
lever

securing
bolt
slacken
the
handbrake
bracket
bolts
and
lift
out

the

pedal

Clean
all

parts
thoroughly
and
check
them
for
wear
or

damage
paying
particular
attention
to
the
rubber

parts
return

spring
and

pedal
lever
bush

Installation
of
the
clutch

pedal
is
a
reversal
of

the

removal

procedures

45

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

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

FOUR
SPEED
GEARBOX
Removal
and
Installation

The
removal
and
installation

procedures
for
the
four

speed

gearbox
are
similar
to

those

previously
described
for
the

three

speed
gearbox
However
the
floor
mounted

gear
lever
must
be

removed
from
the
controllevef
bracket
in
addition
to

the

operations
already
detailed

FOUR
SPEED
GEARBOX

Dismantling

Drain
the
oil
from
the

gearbox
Remove
the
dust
coveT
and

release
the

spring
securing
the
clutch
withdrawal
lever
Remove

the
withdrawal
lever
and
release

bearing
from
the
clutch

housing

as
described
in
the
section
CLurCH
Remove
the
clevis

pin

securing
the

striking
rod
to
the
control
lever

Remove

the
speedometer
drive

pinion
assembly
and
with

draw
the
rear

extension

housing
Disengage
the

striking
rod
from

the
selector
rod

gates
Remove
the

gearbox
covers
See

Figs
F
26

and
F
27

Unscrew
the
three
detent
ball

plugs
and
remove
the

spriags

and
detent
balls
Drive
out
the

pins
securing
the
selector
forks

to
the
rods
and
withdraw
the
forks
and
rods
Lock
the
main

shaft

by
moving
the
first
second
and
third
fourth

coupling
sleeve

into

gear
at
the
same
time
and
release
the
ffiainshaft
nut

Remove
the
countershaft
and
the
gear
cluster

together

with
the
two
needle
roller

bearings
and

spacers
Remove
the

snap
ring
holding
the
revep
e

idler

gear
and
withdraw
the
reverse

idler

gears
and
shaft

Fig
F
28

Take
off

the
bolts

securing
the
mainshaft

bearing
retainer

to
the

gearbox
case

Fig
F
29
Withdraw
the
mainshaft

assembly
Fig
F
30
and
the
main
drive
shaft

The
mainshaft
can
be
dismantled
in
the

following
manner

Release
the
third
fourth

synchronizer
unit

snap
ring
and
with

draw
the
hub

complete
with

coupling
sleeve
Remove
the
third

speed
gearwheel
and
the
needle
roller

bearing
from
the
main

shaft
Take
off
the
mainshaft
nut
and

locking
plate
Remove
the

speedometer
drive

gear
with
the

retaining
ball
Withdraw
the

mainshaft
reverse

gear
and
the
hub
Press
off

the
mainshaft

bearing
complete
with
the

bearing
retainer

Remove
the
thrust
washer
and
the
first

speed
gear
together

with
the
needle
roller

bearing
taking
care
not
to
lose
the
small

baU
used
to

locate
the
thrust
washer
Slide
off

the
first

speed

gearwheel
bush
Withdraw
the
first
second

synchronizer
and

hub
Remove
the
second

speed
gearwheel
and
needle
roller

bearing

FOUR
SPEED

GEARBOX
Installation

Refer
to

the
instructions

given
for
the
three

speed
gearbox

and
to
Technical
Data
for
the

specifications
applicable
to
the

different

gearboxes

FOUR
SPEED
GEARBOX

Assembly

Assembly
of

the

gearbox
is
similar
to
the

procedures

previously
described
for
the
three

speed
gearbox
with
the

following
exceptions
When

assembling
the
main
drive

gear
bearing
on
the
shaft

insiall

the

spacer
and
select
a
new

snap
ring
to
eliminate
all
end

float

between
bearing
and

snap
ring
Snap
rings
are
available
in

five
thicknesses
from
1
52
1
77mm
0
06
0
07
in

The

assembly
procedures
for

the
Warner

type
synchronizers

are
similar
to
the
instructions

previously
described
for
the
three

speed
gearbox
Refer
to
THREE
SPEED
GEARBOX

Assembly

for
further
details

To
assemble
the
Servo
F4C63

type
synchronizers
proceed

as
follows

Place
the

gear
on
a

clean
flat
surface
and
install
the

synchronizer
ring
on
the
inner
side
of
theclutch
gear
Fit
the

thrust
block
into

place
as
shown
in
Fig
F
31
Place
the
anchor

block
and
brake
band
into

position
and
fit
the

circlip
into
the

groove
in
the

gear
to
secure
the

synchromesh
assembly

When

assembling
the
mainshaft
select
a

snap
ring
which

will

give
an
end
float
between
0
05
0
15
mm
0
002
0
006in

to
the
third

speed
gearwheel
Snap
rings
are

available
in
five

sizes
from
1
40
mm

0
0551
in
to
1
60
mm
0
0630
in
thick

ness

Tighten
the
locknut
at

the
rear

of
the
mainshaft
to
a

torque
reading
of
7
1

kgm
51
87Ib
ft

Assemble
the
reverse
idler

gear
as
shown
in
Fig
F
32
The

reverse
idler
driven

gear
3
should
be

placed
on
the
end
of
the

reverse
shaft
1
with
the

longest
spline
and
retained
with
a

suitable

snap
ring
2
Install
the
reverse
shaft
and

gear
assembly

into
the

gearbox
case
from
the
rear
with
the
thrust
washer
4

between
the

gear
and
the
case

Fit
the
thrust
washer
5
and

idler
gear
6
18
teeth
and
secure
with
a
suitable

snap
ring

2
The
end
float
of
the

gear
should
be
checked
and

adjusted

to

0
1
O
3mm
0
004
0
012
in

by
selecting
a
suitable

snap

ring
2
Five
thicknesses
of

snap
rings
are
available
from
I
lmm

0
043in
to
1
5mm
0
06in
See
Technical
Data
for
F4W63

and
F4C63

gearboxes
Adjust
the
counter

gear
end
float
to

0
05
0
15
mm
0
002
0
006in

by
selecting
a
thrust
washer

of

the

required
thickness
Thrust
washers
are
available
in

five

thicknesses
from
2
40
2
60
mm
0
094
0
102
in

When

assembling
the
selector
mechanisms

Fig
F
33
fit

the
first
second
selector
forks
I
and
the
third
fourth
selector

forks
2
onto
the

coupling
sleeves
and
insert
the
first
second

fork
rod
3

Fit
an

interlock
plunger
4
and
the
third
fourth

speed

selector
rod
5
Do
not

forget
the
interlock

pin
7
A
section

through
the
selector
and
interlock
mechanism
is

given
in

Fig

F
34
Install
an

interlock

plunger
6
and
assemble
the
reverse

selector
fork
8
and
fork
rod
9
Secure
the
selector
forks
to

the
rods
with
the

retaining
pins
10

Place
a
check
ball

and
spring
into
each
of
the
holes
and

screw

the

plug
down
to
a

torque
reading
of
1
7
2
1

Jegm

12
3
15
2
Ib
ft
after

coating
the
threads
with
sealing
com

pound

Install
the
rear
extension

housing
engaging
the

striking
rod

with
the
fork

rod

gates
and

tighten
the

housing
bolts
to

a

torque
reading
of
1
6
2
5

kgm
12
18Ib
ft
Fit
the
front

and
bottom
covers
and

tighten
the
bolts
to

a

torque
reading

of
1
1
1
8

kgm
8
13Ib
ft

57

Gearbox
mode

Gearchange
type

Gear
ratios
I
st

gear

2nd
gear

3rd

gear

4th
gear

Reverse

Num
ber
of

teeth
on

mainshaft
Drive

gear

3rd

speed

2nd

speed

1st

speed

Reverse

Num
ber
of

teeth
on

counter

shaft
Driven

gear

3rd
speed

2nd

speed

1st

speed

Reverse

Reverse

idler

gear

Speedometer
Drive

gear

Driven
gear
Technical
Data

GENERAL
SPECIFICATIONS

R3W65
L
F4C63

F4W63L

Column

change
Floor

change

3
263
1
3382
1

1
645
I
2
013
1

1
000
1
1
312
1

1
000
1

3
355
I
3
364
1

19
22

27

25
30

31
36

34
39
3N71B

iFloor
change

Column
change

2
458
1

1458
1

1
000
1

2
098
1

30
31

29

24
21

15
15

16
14

16
18

5

19
or
17
16

CLEARANCES
AND
PLAYS

Model
R3W65L
F4W63L

Mainshaft

end
float
0
0
19mm
0
0
008
in
0
08
0
29mm
0
003
0
0
II
in

Max
mainshaft
end

float
0
20mm

0
008
in
0
30mm
0
012
in

Countershaft
end
float
0
04
0
12mm
0
002
0
005
in
0
05
0
15mm
0
002
0
006
in

Max
countcrshaft
end
float
0
20mm
0
008
in
0
20mm
0
008
in

Reverse
idler

gear
end
float
0
20
0
40mm
0
008
0
016
in
0
10
0
30
mm
0
004
0
012
In

Max
idler

gear
end
float
0
50mm
0
020
in
0
50mm
0
020
in

Gearwheel
end
float

I
st

speed
gearwheel
0
20
0
30mm
0
008
0
012
in
0
05
0
15mm
0
002
0
006
in

2nd

speed
gearwheel
0
20
0
30mm
0
008
0
012
in
0
05
0
15mm
0
002
0
006

in

3rd

speed
gearwheel
0
05
0
15mm
0
002
0
006
in

Gear
backlash
all

gears
0
05
0
20mm
0
002
0
008
in
0
05
0
20mm
0
002
0
008
in

Oearance
between
fork
and

coupling
sleeve
0
15
0
30mm
0
006
0
012
in
0
15
0
30mm
0
006
0
012
in

Mallshaft

run
out
0
15mm
0
006
in
0
25mm
OmO
in

Model
F4W63
and
F4663
R3W65

Gear
backlash
all

gears
0
05
0
14mm
0
002
0
0055
in
0
05
0
14mm
0
002
0
0055
in

Gearwheel
end
float

1
st

speed
gearwheel
0
05
0
15mm
0
002

0
0059
in
0
05
O
22mm
0
002
0
0087
in

2nd

speed
gearwheel
0
05
0
15mm
0
002
0
0059
in
0
10
0
22mm
0
0039
0
0087
in

3rd

speed
gearwheel
0
05
0
15mm
0
002
0
0059
in

Max
countershaft
end
float
0
05
0
15mm
0
002
0
0059
in
0
04
0
12mm
0
0016
0
0047
in

Reverse
idler

gear
end
float
0
05
0
15mm
0
002
0
0059
in
0
20
0
40mm
0
0079
0
0157
in

Oearance
between
baulk

ring
and

clu
tch

gear
I
2
1
6mm
0

047
0
0630
in
12
1
6mm
0
0472
0
0630
in

61

Propeller
Shaft
and

DIfferentIaJ

DESCRIPTION

PROPELLER
SHAFT

DIFFERENTIAL

Removal
and

Dismantling

DIFFERENTIAL

Assembly
and

Adj
Jstment

DIFFERENTIAL

Installation

DIFFERENTIAL
Estate
car
and
van

TOOTH
CONTACT

PATTERN

Checking

DESCRIPTION

The
tubular
steel

propeller
shafts
are
shown

in
Fig
G
1

The
shaft
is
connected
to
the
drive

pinion

flange
by
a

yoke

flange
at
the
rear
and
to

the
transmission

output
shaft

by
a

splined
yoke
sleeve

at
the
front
The
Datsum

I800ce
station

wagon
and
van
has
a
three

section
shaft

in
contrast
to
the
two

piece
shaft

used
on

the
other
models
covered

by
this
manual

The
differential

carrier
houses
a

hypoid
bevel

gear
assembly

Although
this
manual
contains

dismantling
and

adjustment

procedures
for

the
differential

assembly
it
must

be

pointed
out

that

only
workshops
with

specialized
tools
and

equipment
will

be
able
to

carry
out
the
work

involved

PROPELLER

SHAFT
Removal

1
Release

the
hand
brake

jack

up
the
vehicle
at
the
fear

and

support
it
on
stands

2

Loosen
the

clamps
and
turn
the

pre
silencer
to
the
left

saloon

only

3
Remove
the

adjuster
nut
from

the
handbrake
cable
rear

adjuster
and
disconnect
the
left
hand
cable
Saloon

only

Remove
the
bolts

securing
the
centre

bearing
bracket

1800
cc

stati
n

wagon

4
Disconnect

the
fear

flange
from
the
rear

axle

flange
With

draw

the

propeller
shaft
to
the
rear

away
from
the

gear

box
mainshaft
Take
care

that
the
shaft
is
not

dropped

during
removal
or

the
balance
of
the
shaft

may
be
altered

5

Plug
the

gearbox
rear

extension
to

prevent
the
loss
of
oil

PROPELLER
SHAFT

Dismantling
and

Inspection

Oean

all

components
and
mark
them
before

dismantling

so
that

they
can
be

reassembled
in
their

original
positions

Correct

reassembly
is
most

important
otherwise

the
balance

of
the
shaft

may
be
affected

Remove

the
four

snap
rings
from
the

journal
assembly
and

withdraw

the
needle

bearing

cap
by
tapping
the

yoke
with
a

wooden
mallet

The
wear
on

the

spider
journal
diameter
must
not
exceed

0
15mm
0
006
in
the

standard
size
of

a
new

journal
is
14
7mm

0
579

in
Check
the

spider
seal

rings
and

replace
them
if

necessary
The
radial

backlash
of
the
sleeve

yoke
splines
to

gearbox
splines
should
not

exceed
0
5mm

0
002
in
Renew

the
sleeve

yoke
if
the

figures
are
in
excess
of
the

specified
value

E
Mount
the
shaft
between
the
centres
of
a
suitable
fixture

and
use
a
dial

gauge
to

check
that
the
run
out
of

the
shaft

does

not

exceed
0
6mm
0
024
in
at
the
centre
of
the
tubular

portion

The
shaft
can

only
be

straightened
with
a

hydraulic

press
it
is

advisable
however
to
renew

the
shaft
if

the
run
out

is
excessive

Check
that
the

dynamic
balance
of

the
shaft

does
not

exceed
15

grm
cm
0
208
oz
in
at
4000
r

p
m

PROPELLER
SHAFT

Assembly
and
11Istallation
r

Assembly
and

installation
is
a

reversal
of

the
removal
and

dismantling
procedures
not
the

following
points

Grease
the
needle
rollers
with
wheel

bearing

grease
before

placing
them
into
the

bearing
race

Lubricate
all

splines
with

gear
oil

Adjust
the

journal
radial
end
float
to
within
0
02mm

0
0008
in

using
a
suitable

snap
ring
Snap
rings
are
available

in

eight
thicknesses
from

2
00mm
0
079
in
to

2
14mm

0
084
in
and
are
colour
coded
as
detailed
in
Technical
Data

at
the

end
of

this
section

DIFFERENTIAL
Removal

Saloons
with

independent
rear

suspension

Remove
the
hand

brake
rear

cable
remove

the

propeller

shaft

and
drive
shafts
as
described
in
their
relevant
sections

2

Support
the
differential

with

ajack
and
remove

the
nuts

securing
the
differential

mounting
crossmemb
er

Fig
G
3

3
Remove
the
bolts

holding
the
differential
to
the

suspension

member
Withdraw
the
differential

and
jack
to

the
rear

4

Support
the

suspension
member
with

a
stand
to

prevent

the

mountings
from

becoming
twisted
or

damaged

DIFFERENTIAL

Dismantling

Before

dismantling
place
the
carrier

assembly
in
a
suitable

mounting
stand
or

special
stand
ST

06270001
and

carry
out

preliminary
checks
as
follows

Check
the
tooth
contact

pattern
of
the
crownwheel
and

pinion
by
applying
lead

oxide
to
three
or
four

teeth
of

the

crownwheel
Turn
the
crownwheel
several
times
to
obtain
an

impression
of

the
tooth
contact

pattern
Check
the
backlash

between
the
teeth
of
the
crownwheel
and

pinion
using
a
dial

gauge
The
backlash
should
be
within
0
10
0
20mm
0
004

0
008
in

63

Check
the
run
out
at
the

ceac
of
the
crownwheel
if
the
back

lash
or

tooth
contact

pattern
is
incorrect
The
run
out
should

not
exceed
0
08mm
0
003
in
Measure
the

turning
torque

of

the
drive

pinion
which
should
be
within
7

IOkg
cm
6
9Ib
in

Shims
and

adjusting
washers
must
be

changed
if
the
tooth

contact

pattern
and
backlash
is
incorrect
the
necessary
details

for
these

operations
can

be
found
towacds
the
end
of
this

section
under
the

heading
TOOTH
CONTACT
PATTERN

To
dismantle
the
differential
remove

the

flange
clamp
bolt

and
extract

the
side

flange
as
shown
in

Fig
GA

using
the

special
stand
ST
33730000
and

sliding
hammec
ST
36230000

Remove
the

bearing

caps
with
a
suitable

puller
as
shown

in

Fig
G
5
Remove
the
left
hand

cap
first
followed

by
the

right
hand

cap
The

caps
should

be
marked

to
ensure
that

they

are

refitted
in
their

original
positions
Withdraw
the
differential

cage
from

the
carrier

Fig
G
6

Slacken
the
drive

pinion
and
hold
the

flange
with
a

suitable
wrench
as

shown
in
Fig
G
7
Withdraw

the
flange
with

a
standard

puller
Press
the
drive

pinion
out
of
the
differential

carrier

together
with
the
rear

bearing
inner
races
the

spacers

and
the
shims
Place
a

press
plate
between

the
drive

pinion
head

and
rear

bearing
and

press
out
the

pinion
shaft

The
inner
races

need
not
be
removed
if
the
tooth
contact

pattern
is
correct
and
the
crownwheel
drive

pinion
carrier

rear

bearing
and
shims
etc
are
to

be
re
used
The
front
and

rear
outer
races
of
the

pinion
bearings
can
be
removed
with
the

special
tool
ST
30610000
or
with
a

suitable
drift

To
dismantle
the
differential

cage
remove

the

right
hand

bearing
cone
as
shown
in

Fig
G
8
The

special
puller
ST
3306

0000
and

adaptor
ST
33052000
should
be
used
for

this

pur

pose

taking
care
not
to

damage
the

edge
of
the

bearing
innec

race
Flatten
the

lock

straps
slacken
the

crownwheel
bolts
in

a

diagonal
pattern
and
remove

the
crownwheeL

Remove
the
left
hand

bearing
cone
in
a
similar

manner
to

the

right
hand

bearing
cone
Make
sure
that
the

parts
do
not

become
mixed
and
can
be
assembled
in
their

original

positions

Punch
out
the
differential
shaft
lock

pin
from
the
crownwheel

side

using
a

suitable
drift
Great
care
must

be
taken
when

carrying
out
this

operation
as
the

pin
is
caulked
into
the
hole

in
the
differential

cage

Remove
the
shaft
the
differential

pinion

gears
and
the
side

gears
and
thrust
washers

Separate
the
left
and

right
hand

gears

and
washers
so
that

they
can
be
reassembled
in
their

original

positions

Replacing
oil

seals
with

the
differential
installed

The
oil
seals
can

be

replaced
if
necessary
with
the
differ

ential
fitted
to
the
vehicle

Front
oil

seal

Drain
the
oil
from
the
differential

unit
and
jack
up
the

vehicle
at
the
rear
Remove
the

propeller
shaft
from
the

differential

flange
Disconnect
the
handbrake
left
hand
rear

cable
Slacken
and
remove
the
drive

pinion
nuts
whilst

holding

the
drive
flange
with
a
suitable
wrench
or

special
tool
ST

31530000
Withdraw
the
drive

flange
with
a
conventional
two
l

arm

puller
as
shown
in

Fig
G
9
Use
the
oil
seal

puller
ST

33290000
to
withdraw
the
oil
seal
from
the
retainer

Replace

the
oil
seal

using
a
suitable
drift
or

special
tool
ST
33270000

Fill
the
oil
seal

lips
with

grease
when
installing
Fit
the
oil
seal

retainer
and
replace
the
various

parts
in
reverse

order
to

the

removal

procedure

Side
oil
seal

Detach
the
drive
shaft
from
the
side
flange
of
the
differ

ential
carrier
Extract
the
side

flange
with
the
slide
hammer

ST
36230000
and

adaptor
ST
33730000
as
shown
in

Fig
G
lO

Remove
and
replace
the
oil
seal
in
a
similar
manner
to

that

previously
described
for
the
front

oil
seal

taking
care
to

apply

grease
between
the
oil
seal

lips

DIFFERENTIAL

Inspection

Clean
the

parts
thoroughly
and

inspect
them
for

signs
of

wear
or

damage

Check
the
gear
teeth
for
scores
cracks
or

excessive
wear

Check
the
tooth
contact

pattern
of
the
crownwheel
and

pinion
for
correct

meshing
depth
The
crownwheel
and

pinion
are

supplied
as
a
set

and
should
either

part
be

damaged
it
will
be

necessary
to
renew
the

complete
set

2
Check
the

pinion
shaft
and

gear
mating
faces
for
scores
or

wear

Inspect
the
inner

faces
of
the
side

gears
and
their

seating
faces
on

the
differential

cage

3

Any
small
defects
on
the
faces
of
the
thrust
washers
can

be
corrected

using
emery
cloth
The
thrust
washers
must

be

replaced
however
if

the
backlash
between
the
side

gear

and

pinion
exceeds
0
2mm
0
008
in
and
the
clearance

between
the
side

gear
and
thrust
washer
exceeds
O
3mm

0
012
in
Three
sizes
of
washers
are
available
and
the

thicknesses
are
detailed
in
Technical
Data
at

the
end
of

this
section

4
Measure
the
run
out
of
the
crownwheel
at
the
rear
with
a

dial

gauge
Replace
the
crownwheel
and
drive
pinion
as
a

set
if

the
run
out
exceeds
the

permissible
value
of
O
08mm

0
003
in

5
Examine
the
differential
carrier

and

cage
for
cracks
or

distortion
Renew

any
part
found
to

be
defective

It
is

advisable
to
renew
all
oil
seals

DIFFERENTIAL

Assembly
and

Adjustment

Assembly
is
a
reversal
of
the
removal

procedure
noting

the
following
points

Arrange
the
shims
and
washers
etc
in
their
correct

order

and

thoroughly
clean
the
surfaces
to

which
the
shims
washers

bearings
and

bearing
retainecs
are
to
be
installed

Differential

cage

Fit
the
differential
side

gear
and
bevel

gear
in
the

cage

using
the
correct
thrust
washers
Insert
the

pinion
shaft
so
that

the
lock

pin
hole

corresponds
with
the
hole
in
the
differential

65

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