change wheel DATSUN 610 1969 Workshop Manual

Gearbox

GEARBOX
Removal

GEARBOX

Dismantling

GEARBOX
Inspection
and
Overhaul

GEARBOX

Assembling

THREE
SPEED
GEARBOX
GEARCHANGE
CONTROL
Removal
and

Adjusting

AUTOMATIC
TRANSMISSION

Gearchange
control

linkage

DESCRIPTION

Three

types
of
transmission
are
available
for
the
Datsun

models
covered

by
this
manual
Either
a
three

speed
gearbox

a
four

speed
gearbox
or
three

speed
automatic
transmission

can
be
fitted

The

three
and
four

speed
gearboxes
are

equipped
with

nchromesh
on
all
forward

gears
with
the
three

speed
gearbox

operated
by
a

steering
column

gearchange
system
and
the
four

speed
gearbox
by
a
floor
mounted

gear
lever

Two

types
of

synchromesh
are
used
in
the
four

speed

gearboxes
Either

Borg
Warner
or
Servo

types
may
be
fitted

The

gearboxes
differ

only
in
the

synchromesh
devices

whereby

the
baulk

rings
synchronize
the

coupling
sleeve
with
the
main

shaft

gear
on

the
Warner

gearbox
This
action
is

accomplished

by
a

synchrcrring
on
the
servo

gearbox

THREE
SPEED
GEARBOX
Removal

I
Jack

up
the
vehicle
and

support
it
on
stands

2
Disconnect
the
hand
brake
cable
at
the

equalizer
bracket

Slacken
the
two
exhaust

pipe
centre

clamps
and
turn
the

centre
section
of
the
exhaust
assembly
to
the
left
as
shown

in

Fig
F
2

3
Disconnect
the

propeller
shaft
from
the
rear
axle
drive

flange
by
removing
the
four

securing
bolts
Seal
off

the

gearbox
extension

housing
to

prevent
the
loss
of
oil
and

withdraw
the
shaft
to
the
rear

4
Disconnect
the

speedometer
drive
cable
from

the
adaptor

in
the

gearbox
extension

housing
Fig
F3

S
Disconnect
the
lower
shift
rods
from
the
shift
levers

Fig
F
4
and
remove
the
cross
shaft

assembly
from
the

gearbox
casing
Remove
the
clutch
slave

cylinder
from
the

clutch

housing
Fig
F
5

6

Support
the

engine
with

ajack
positioned
underneath
the

oil

sump
making
sure

that
the

jack
does
not
foul
the
drain

plug
A
block
of
wood
should
be

placed
between
the

sump

and

jack
to

avoid

damaging
the

sump

7
Remove
the
bolts

securing
the
rear

engine
mounting
to

the
crossmember
Position

ajack
under
the

gearbox
and

remove
the
bolts

attaching
the
crossmember
to
the

body

Lower
the

jack
under
the

engine
so
that
the

engine
is

tilted
to
the
rear
Remove
the
starter

motor
and
the
bolts

securing
the

clutch

housing
to
the

engine
Lower
the

jack

slowly
and
withdraw
the

gearbox
towards
the
rear
of
the

vehicle
THREE
SPEED
GEARBOX

Dismantling

Drain
the

gearbox
oil
Remove
the
dust
cover
release

the
retainer

spring
and
remove

the
withdrawal
lever

complete

with
release

bearing
from
the
clutch

housing
See
section

CLUTCH

Remove
the

gearbox
bottom
cover
the

speedometer
drive

pinion
assembly
and
the
rear
extension

housing
Take
out

the

cross
shaft

retaining
rings
and
unscrew
the
nuts

securing
the

operating
lever
lock

pins
Use
a
hammer
and

punch
to
drive

out
the

pins
and
withdraw
both
cross
shafts

Fig
F
6

Remove
the
fr
mt
cover

and
withdraw
the
counter
shaft

Lift
out

the
countersbaft

gear
cluster

together
with
the
needle

roller

bearings
and

spacers
Fig
F
7
Remove
the
reverse
idler

gear
shaft
lock
bolt
and
remove
the
shaft
and
the
idler

gear

Fig
F
B
Drive
out
the

pins
securing
the
selector
forks
to
the

selector
rods

Unscrew
the
interlock

plug
and
remove
the
detent
ball

and

spring
Fig
F
9
Remove
the
first
reverse

speed
and
second

third

speed
selector
rods
and
lift
out

the
selector
forks

Withdraw
the
main
shaft
assembly
and
the
drive
shaft

assembly
from
the

gearbox
See

Fig
F
1O
and
F
11

To
dismantle
the
mainshaft
release
the

circlip
from
the

front
of
the
mainshaft
as
shown
in

Fig
F
12
and
remove
the

second
and
third

speed
synchronizer
hub
and
second

speed

gearwheel
Fig
F
13
Remove
the

circlip
securing
the
speedo

meter
drive

gear
and
withdraw
the

gear
together
with
the
ball

and

spacer
Fig
F
14
Remove
the
mainshaft

bearing
using
a

press
Hold
the
rnainshaft
reverse

gear
and

tap
the
shaft
on
a

piece
of
wood
to
release
the
reverse

gear
assembly
together

with
the
first

speed
gearwheel

GEARBOX

Inspection
and
Overhaul

Oean
all

parts
thoroughly
and
examine
the

gearbox
case

and
extension
housing
for
cracks

If
the

joint
faces
are
burred
or

pitted
it

may
be

necessary

to

replace
the
units
if

repair
cannot
be
carried
out
satisfactorily

Remove
any
adhesive
which
remains
on

the
faces

The
rear
extension

housing
bush
should
be
renewed
if

worn

unevenly
Clean
the

bearings
and

dry
with
compressed
air

taking
care
that
the
bearings
do
not

spin
Turn
the
ball

bearings

to
make
sure

that
they
run

smoothly
and
without
play
Replace

the
needle

bearings
if
worn
or

damaged
in
any

way

It
is
advisable
to
renew

the
needle
roller

bearings
after

they

have
been
installed
for
a
considerable

period
as
it
is
difficult

51

THREE
SPEED
GEARBOX

GEARCHANGE
CONTROL
LINKAGE

Fig
F
35

As

previously
described
the
three

speed
gearbox
is

equipped
with
a

steering
column

gearchange
linkage
system

which

incorporates
a

collapsible
control
rod
when
combined

with
the

collapsible
type
of

steering
column

assembly

The
gearchange
linkage
can
be
removed
and

inspected
in

the

following
manner

Remove
the

steering
wheel

Fig
F
36
and
take
off
the

steering
column
shell
cover
Remove
the
turn

signal
and
lighting

switch

Fig
F
37
These
removal
details

can
also
be
found
in

the
section
STEERING
Remove
the
C
washer

I
in

Fig
F
38

and
the
washer
then
remove
the

upper

support
bracket

by

releasing
the

locating
bolt
and
screw
The
control
rod
insert
with

bush
and
return

spring
can
now
be
removed
Remove
the
snap

and

gear
lever

pivot
pin
and
withdraw
the

gearlever

Remove
the
cotter

pin
plain
washer

and

spring
washer
and

disconnect
the
shift
rods
from
the

gear
selector
levers

Fig
F
39

Unscrew
the
bolts
securing
the
lower

support
bracket
and
the

clamp
Remove
the

clamp
and

gear
change
lever
retainer

Remove
the
second
third

speed
selector
lever
the
lower

support
bracket
and
the
first
reverse
selector
lever
from
the

control
rod
Withdraw
the
control
rod
Disconnect
the

gear

change
rods

by
removing
the
cotter

pins
and
remove
the
cross

shaft
bracket
from
the
side
member
Withdraw
the
cross
shaft

assembly
Fig
F
40

Examine
the

components
for

signs
of
wear
and

damage

and
replace
if

necessary

Installation
is
a
reversal
of
the
removal

procedure
noting

the

following
points

Take
care
not
to
strike
or

apply
a
load
to

the
collapsible

type
of
control
rod
or

the
rod
may
be
damaged

The
rod
should
not

be
slack
in

the
axial
direction
when

installed
and
must
be
removed
if
slackness
is
detected
Coat

the

sliding
surfaces
with

grease
before

assembling
them
Acijusting

Set
the
gear
lever
to

the
neutral

position
and

temporarily

connect
the
trunnion
on
the
lower

support
bracket
to
each
rod

Fig
F41

Set
the
rod
on
the
lever
so
that
the
neutral

adjustment

grooves
on
the

upper
surface
of
the
lower
support
bracket
are

aligned
with
the

grooves
on
each
lever

When
the

adjustment
is

completed
operate
the

gear
lever

to
select
each
gear
and
make
sure
that
the
lever
can
be
moved

smoothly
and

positively

AUTOMATIC
TRANSMISSION

Gearchange
control
linkage

The
automatic
transmission

gear
change
control

linkage

can
be
removed
in
a

similar
manner
to
the
three

speed
gearbox

linkage
Carry
out
the

operations
previously
described
under

the
relevant

heading
as
far
as
the
removal
of
the
gear
lever
and

proceed
as
follows

Disconnect
the

upper
selector
rod
from
the
selector
lever

by
removing
the
cotter

pin
plain
washer
and
lock
washer
See

Fig
F
42
Remove
the

speed
range
position
plate
the

snap
ring

at
the
lower
end
of
the
control
rod
and
unscrew

and
remove

the
lower

support
bracket
Release
the

locking
screw
and
with

draw
the
selector
lever

assembly
Withdraw
the
control

rod

disconnect
the
selector
rods
and
remove
the
cross
shaft
bracket

and
cross
shaft

assembly
Clean
all

parts
and

repair
or
renew

any
part
which
is
worn
or

damaged
Installation
is
a
reversal
of

the
removal

procedure
noting
the

following
points

Coat
all

the
sliding
surfaces
with
chassis

grease
prior
to

assembling

Set
the
converter
side
lever
and
the

gear
lever
in
the
neutral

position
Install
the

upper
selector
rod
to

the
selector
lever
and

adjust
the

gear
position
plate
to

give
a
clearance
of
0
5
I
Omm

0
02
0
04
in
between
the
selector
lever

stop
pin
and
the

position
plate
The

adjustment
can

be
obtained

by
turning
the

selector
rod

adjusting
nuts

Finally
tighten
the
nuts
on

each

side
of

the
trunnion

S9

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

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

increase
the
thickness
of
the
drive

pinion
adjusting
shim

and
washer
to
move
the
drive

pinion
closer
to
the
crown
wheel
A
correct

contact

pattern
showing
the

impressioll
ithill

a

range
of
2

3
to
4

of
the

distance
bct
l
en

t
h

tip
lllU
till

root
of
the
teeth

under
no

load

Toe

contact

Fig
G
34

Rcdu
e

the
thickness

of
the
drive

pinion
adjusting
shim
and

washer
to
move
the
drive

pinion
away
from
the
crown
wheel
It
will
be
neCL

ssary
to
rc

check
the
backlash
bl

tW
Cl1
drivt

pinion
and
crown

wheel
if
the

adjusting
shim

1l1d
washer
arc

changed

Flank
contact

Fig
G

35

DIFFERENTIAL
Installation

This

pattern
should
be

adjusted
in

a
similar
manner

to
toe

contact

Face
contact

Fig
G
36
Installation
of
the
differential
carrier
is
J

reversal
of
the

removal

procedure
Reference
should
be

made
to
the
section

REAR
AXLE
AND
REAR
SUSPENSION
for
a
dl

saipIion
of

the

operations
required
to

replace
the
axle

shafts

This

pattern
should
be

adjusted
in

a
similar
manner
to

heel
contact

Correct
contact

Fig
G
37

Technical
Data

PROPELLER
SHAFT

Axial

play
of

spider
journal
0800

Axial

play
of

spider
journal
1400
and
1600
cc
0
Q2
mm

0
0008
in

0
08
mm
0
003
in

Max
run

out
of
shaft

Wear
limit
of

spider
diameter
0
6
mm
0
024
in

0
15
mm

0
006
in

Permissible

dynamic
unbalance

Two

joint
shaft

Three

joint
sh
lft
15
gr
em

0
208
in
oz
at
4000

rpm

35

gr
cm
0
5
in

oz
at
5800

rpm

FINAL
GEAR
RATIOS

1800cc
Saloon
6101

ISOOcc
Estate
Car

610

1800cc
Van
610

1600cl
SJloon
610

1400

and
1600cc

510
4
Door
Saloon
RHO

4
Door
Saloon
LHD

De

Lu
e
4
Door
Saloon
RHO

SSS
4
Door
Saloon
RHO

Door
Saloon
LHO
3700

3
889

4
375

3
900

4375

4111

3
889

3
900

3
700

DRIVE
PINION

InitiJI

turning
torque
without
oil
sea

Saloon
modds

Estate
CJr
models
7

10

kg
em

0
506
0
723Ib
ft

10
13

kg
em
0
723
0
940Ib
ft

Thickness
of

pinion
height

adjusting
washers
1400

and
1600
CC

Saloon

1400
and
1600cc
510

Thickncss
of

pinion
height

adjusting
washers
0800
cc
Saloon
0
4
mm
0
078
0
086
0
094
in

3
09
3
66mm

0
1
17

0
1441
in

in
increments
of
0
03
mm

0
00
I
in

Thickness
of

pinion
height

adjusting
washers
0800
n
Estate
car
0
050
0
070
0
100
0
200
0
500mm

0
0020
0
0028
0
0039
0
0079
0
0197
in

Thickness
of

pinion
height

adjusting
washers

1800
CL
Van
37
97111m
0
0933
0
I
69
in

in
increments
of
0
03
mm
0
00
I
in

73

factory
parts

Installation

is
a

reversal
of
the
removal

procedure

REAR
SUSPENSION

ARM
Removal
and
Installation

Saloon

I
J
ad

up
the
car
at

the
rear
and

support
it
on
stands

2
Remove
the
road
wheel
and
brake
drum
as
described
in

the

section
BRAKES

3
Disconnect

the
drive
shaft
from
the
axle
shaft

4
Disconnect

the
handbrake
cable
from
the

equalizer
bracket

and
the
wheel

cylinder
lever
Disconnect

the
brake
hose

from
the
brake
line

by
removing
the
lock

spring
and
then

withdrawing
through
the
connector

Plug
the
end
of
the

brake

line
to

avoid
loss

of
fluid
and

ingress
of
dirt

5
Remove
the
wheel

bearing
locknut

Fig
H
9
the
rear

axle

shaft

wheel

bearings
and
oil
seal
Remove
the
rear
brake

assembly
from
the

suspension
ann
See
section
BRAKES

6
Jack

up
the

suspension
arm
to

relieve
the
tension
on
the

shock
absorber
and
disconnect
the
shock
absorber
from

the
lower

mounting
Lower
the

jack
gradually
and
remove

the
coil

spring
seat
and

bump
rubber

7
Remove
the
bolts

securing
the

suspension
arm
to

the

suspension
member

Fig
H
IO
and
withdraw
the

suspension

arm

The
rubber
bushes
can

be
drawn
out

of
the

suspension
arm

if

necessary
using
the

special
tool
ST
38280000

Fig
H
Il

O1eck
the

suspension
arm
for
distortion
or

cracks
and

inspect
the
rubber
bushes
for

signs
of
wear
or

damage
Renew

any
part
which

is

unsatisfactory

Installation

is
a

reversal
of
the
removal

procedure
Tighten

all
the

suspension
arm

mounting
bolts
with
the

weight
of

the

vehicle

resting
on
the
rear
wheels
The
self

locking
nuts
must

be
renewed
at
each
overhaul

REAR

AXLE
SHAFTS
BEARINGS
AND
SEALS

Saloon
Removal
and

Dismantling

I
Raise
the
vehicle
at
the

rear
and

place
stands
under
the

body
member

2
Remove

the
road
wheel
and
brake
drum

3
Disconnect
the
drive
shaft
from
the
axle
shaft
and
remove

the
wheel

bearing
locknut
The

special
wrench
ST
38060001

can
be
used
to
hold
the

flange
as

shownin

Fig
H
12

4
Withdraw

the
axle

shaft

assembly
as
shown
in

Fig
H
13

using
the

special
tool
ST
07640000

and
sliding
hammer

ST
36230000
Remove

the
rear
axle
drive

flange

5
Use
a
suitable
drift
or

special
tool
ST
37750000
See

Fig

H
14
to
drive

out
the
inner

bearing
and
oil
seal

F
6
Remove

the

grease
retainer
and
withdraw
the
outer

bearing
with
a
conventional

puller
DO
NOT
re
use
this

outer

bearing

REAR
AXLE
SHAFTS
BEARINGS
AND
SEALS
Saloon

Assembly
and
Installation

Oleck
the
axle
shaft
for

straightness
make
sure
that
it
is

not
cracked
or

damaged
in

any
way
00
NOT
heat
the
shaft

if

attempting
to
re
straighten

Make
sure
that
the

lip
of
the
oil

seal
is
not

damaged
or

distorted
Check
the

bearing
for
excessive

wear
and

damage

Oean
the
wheel

bearings
the
oil
seal

and
the
inside
of
the

axle

housing

When

installing
the
wheel

bearings
the
sealed
side
of
the

outer

bearing
should
face

the
wheel
and
the
sealed

side
of

the

inner

bearing
should
face
the
differential
See

Fig
H
IS

Pressure
must
be

applied
to
the
inner
race
when

fitting

When

replacing
the

suspension
arm
check
that
the
distance

piece
is
0
05
mm
0
002
in
shorter
than
the

length
of
the

housing
dimension
LI
See

Fig
H
16
The
distance

piece
and

axle

housing
code

markings
must
coincide

The
wheel

bearing
grease
must
be

replaced

every
50
000

km
30
000
miles
Pack
the
wheel

bearings
with

grease
at
the

positions
shown
in

Fig
H
IS
and
coat
the

lip
of
the
oil
seal

Renew
the
locknut
and
oil
seal
at

each
overhaul

Wheel

bearing
adjustment

Tighten
the
locknut
to

the

specified
torque
reading
of

25
33

kgm
181
239
lb
ft
and
check
that
the
rear
axle
shaft

end

play
does
not
exceed
0
15
mm
0
006
in
with
a

turning

torque
of
less
than
7

kg
em
6
11b
in
for
the
1400
and
1600cc

models
510

series
or
4
5

kg
em
3
91b
in
for
the
1800cc

610
series

If
the
correct
end

play
or

turning

torque
cannot
be

obtained
it
will
be

necessary
to

change
the
distance

piece
See

above

DRIVE
SHAFTS
Removal
and

Dismantlill8

Disconnect
the
end

flanges
and
remove
the
shaft
See

Fig
H
17
The
drive
shaft
should

only
be
dismantled
to

lubricate
the

splines
This

operation
will

only
be

necessary
every

two

years
or
50
000
km
30
000
miles

Remove
the
universal

joint
spider
at
the
differential
side

Refer
to
the

propeller
shaft
section
Remove
the

snap
ring

securiilg
the
sleeve

yoke
plug
and
take
out

the

plug
Compress

the
drive
shaft
and

remove
the

snap
ring
and

stopper
Fig
H
17

Disconnect
the
boot
and

split
the
shaft
Make
sure
that
the

balls
and

spacers
are
retained

DRIVE
SHAFTS

Inspection
and

Assembly

The
drive
shaft
should
be

replaced
as
an

assembly
if

any

part
is
found
to

be
defective

Check
the
shaft
for

straightness
damage
or
wear
Old

79

SteerIng

DEsn
IPTION

S
i
EERlNG
MaintenaDce

STEERING
WHEEL
AND
STEERING
GEAR

Removal
and
Installation

STEERING
GEAR

Dismantling

STEERING
GEAR

Inspection
and
Adjustment

DESCRIPTION

A
worm
and

recirculating
ball

type
steering
system
is

fitted
to

the
vehicle
the

component
parts
of
the

steering
gear

are
shown
in

Fig
K
I

The

steering
linkage
consists
of
the
centre
tie
rod

pitman

ann
idler
arm
outer
tie
rods
and
the
knuckle
arms
as
shown

in

Fig
K
2

A

collapsible
steering
column
assembly
can
be
fitted
to
the

vehicle
to

protect
the
driver
from

injury
in
a
head
on

collision

Details
of
this

type
of

assembly
are

given
under
the

appropriate

heading

STEERING
Maintenance

O1eck
the
oil

level
in
the

steering
box
every
10
000
km

6
000
miles
and

top
up
with
recommended
lubricant
if

necessary

Grease
the

steering
linkage
every
50
000
km
30
OOO

miles
It
will
be

necessary
to

replace
the

plug
in
the
tie
rod
ball

joints
with
a

grease
nipple
for
this

operation
as

previously

described
in
the
section
FRONT
SUSPENSION

Use
a

grease
gun
to

completely
replace
the
old

grease
with

new

grease
making
SUfe
that
the

grease
is
not
forced
from
under

the
cover

clamp
if
a

high

pressure
gun
is
used

STEERING
WHEEL
AND
STEERING
GEAR
Removal

1
Take
out
the

retaining
bolts
and
remove
the
horn
ring

remove
the

steering
wheel
nut

Fig
K
3
and

pull
off

the

steering
wheel
The
special
tool
ST
27180000
should
be

used
if
available

2
Disconnect
the

battery
leads
remove

the
steering
column

shell
covers

and
the
turn

signal
and

lighting
switch
assembly

3
On
vehicles
fitted
with

steering
column

gear
change

assemblies
the

gear
lever
must
be
removed
from
the

control
rod

assembly
Unscrew
the
retaining
boltg
and

disconnect
the

gear
lever

4
Remove
the
bolts
from
the

steering
column

upper
clamp

Fig
K
4
and
the
bolts

holding
the
lower

plate
Fig
K
5

5
If
the
vehicle
is
fitted
with

steering
column
gear
change

remove
the

cotterpin
from
the
trunnion
and
detach
the

gearchange
rod
and
selector
rod
from
the

change
lever
and

selector
lever
STEERING
GEAR

Assembly
and

Adjustment

COLLAPSIBLE
STEERING

COLLAPSIBLE
STEERING
Removal
and

Inspection

COLLAPSIBLE
STEERING
Installation

STEERING
LINKAGE

6
Remove
the
bolts

securing
the

steering
gear
housing
to

the
car

body
Fig
K
6
and

pull
the
steering

gear
towards

the

engine
compartment

Remove
the
gearchange
control
from
the

steering
gear

assembly
as
described
in
the
section
GEARBOX

STEERING
WHEEL
AND
STEERING
GEAR
Installation

Installation
is
a
reversal
of
the
removal

procedure
When

the
installation
has
been
completed
make
sure
that
the

steering

wheel
can

be
turned

smoothly
and
is
correctly
aligned
The

free
travel
of
the

steering
wheel
should
be
between
2S
30mm

0
9B
1
18
in
Tighten
the

steering
wheel
locknut
to
a

torque

reading
of
4
0
5
0

kgm
29
36Ib
ft
and
the

steering
column

upper
clamp
and
plate
bolts
to
a

torque
reading
of
1
3
1
8

kgm

94
1
3
Ib
ft

Ensure
that
the

steering
box
is
topped
up
to
the
correct

level
with
recommended
lubricant

STEERING
GEAR

Dismantling

Remove
the

pitman
arm

retaining
nut

and
pull
out
the
arm

The

special
puller
ST
27140000
should
be

used
if
available

Remove
the
drain

plug
from
the

steering
gear
housing
and

drain
the
oil

Slacken
the

adjusting
screw
nut
and
turn
the
sector
shaft

adjusting
screw
a
few
turns
in
the
anti
clockwise
direction

Remove
the
sector

shaft
cover

retaining
bolts
and

pull
the

sector
shaft
cover
and
sector
shaft
from
the
gear
housing
Fig

K
7

Remove
the
bolts

securing
the
column

jacket
to
the

gear

housing
and

carefully
withdraw
the
main
column
jacket
assembly

from
the
gear
housing
Fig
K
B

NOTE
The
ball
must
not
be
allowed
to
run
to
either
end
of

the
worm
or
the
ends
of
the
ball

guides
will
be

damaged

Pull
the
column
assembly
from
the
column
jacket
Remove

the
sector
shaft
oil
seal
and
take
out
the
rear

bearing
outer

race

from
the
column

jacket
with
a
suitable

puller

Withdraw
the

bearing
inner
races
from

the
front
and
fear

worm

bearings

Remove
the
column
shaft

bearing

91

the

system

operates
smoothly

COLLAPSIBLE
STEERING

The

collapsible
steering
column
is

designed
so
that

compression
occurs
when
the
vehicle
is
involved
in
a

head
on

collision
See

Fig
K
13

Two
forces
can
be
considered
when
a
collision
of
this

type
takes

place
These

being
the

primary
force
in
which
the

forward
motion
of
the
car
is

suddenly
halted
and
the

secondary

force

as
the
driver
continues
in

a
forward
direction
onto
the

steering
wheel

and
column
The

collapsible
column
is

designed

so
that
it
does
not
move
to
the
rear
i
e
into
the

driving
com

partment
when

the

primary
force
or
forward

motion
of
the
car

is

suddenly
halted
When
the

secondary
force
takes

place
as

the
driver
is
thrown
forward

the
column

jacket
gradually

collapses
and

partially
absorbs
the
amount
of

impact

The

collapsible

type
of
column
is
no
more

susceptible
to

damage
than
an

ordinary
column
when
it

is
installed
in
the

vehicle
however
when
a

collapsible
column

is
removed
it
must

be

carefully
handled
A

sharp
blow
on
the
end
of
the
shaft
or

gear
change
levers

dropping
or

leaning
on

the

assembly
can

cause

the
column

jacket
to
bend

particularly
at
the
bellows

part
which
absorbs
the
shock

The

steering
movement
is
transmitted

by
the

lower
shaft

and

upper
tube
The
lower
shaft
exterior
and

upper
tube

interior
are

tightly
fitted

together
with
four

plastic

pins
com

pletely

eliminating

any
gap

When
a
collision
occurs
the

plastic
pins
shear

and
the
lower

shaft
enters

the

upper
tube
this
action
will
cause
the
shaft
end

to

spread
and
the
lower
shaft
cannot

then
be
withdrawn
unless

an

extremely
high
load
is

applied

The
shaft
is

prevented
from

moving
towards
the
drivers

compartment
when
the

primary
force

takes

place
i

e
when

the
forward
motion
of
the
vehicle
is

suddenly
halted

by
the

three

stoppers
on

the

jacket
tube
The

steering
lock
collar

mounted
to
the
shaft
contacts

the
stoppers
and

prevents
a
rear

ward
movement

A
part
of

the

jacket
tube
is

specially
formed
to
act
as
an

energy
absorbing

part
of
the

collapsible

steering
The

upper

and
lower

guide
tubes

joined
with

polyacetal
resin
are

inserted

into
the
mesh
tube
so
that

energy
generated
by
a

collision
can

be
absorbed
as

smoothly
as

possible
with
a

low
load

The

steering
column

clamp
shown
in

Fig
K
14
is
secured

to

the

jacket
tube
and

body
by
bolts
with
two
aluminium

slidings
blocks
set
to
the

body
by
plastic
pins
An

impact
from

the
drivers
side
causes

the

plastic
pins
to
shear

and
leave
the

sliding
block
in
the
column

clamp
side

allowing
the

clamp
to

move
with
the

jacket
as
it

collapses

COLLAPSffiLE
STEERING
Removal

and

Inspection

Steering
Wheel

I
Disconnect
the

battery
earth
cable

2
Disconnect
the
horn

wiring
and

remove
the
horn

pad
3
Remove
the

steering
wheel
nut

using
the

special
puller

ST

27180000

Eig
K
15
Remove
the
column
shell
covers

Fig
K
16
and
the
turn

signal
switch

assembly

Column
shaft

4
Remove
the
cotter

pin
and
detach
the
shift

rod
Automatic

Transmission
Remove
the
bolt

securing
the
worm
shaft

and

coupling
Fig
K
17

5
Take
out

the
bolts

securing
the
column
tube

flange
to
the

dash

panel
and
the
bolts

securing
the
column

clamp
With

draw
the

steering
column
shaft
towards
the
car
interior

A
careful
check
should

be
made
to
ensure

that
the

assembly

is
not

damaged
in

any
way

Pull
out
the
lower
shaft

tap
the
column

clamp
towards

the

steering
wheel
end
and
remove

the
screws

securing
the

upper
and
lower
tubes

Separate
the

upper
and
lower

tubes

Remove
the

snap
ring
from

the

upper
end
of
the
column

pull

the

upper
jacket
down
and

separate
it
from
the

upper
jacket

tube

Take
care
not
to

damage
the

bearing
Remove
the

plain

washer

and

spring
from
the

upper
shaft

Check
the

column

bearings
for

damage
and
lack
of
smooth

ness

Apply
multi

purpose
grease
to
the

bearing
if

necessary

Inspect
the

jacket
tubes
for

signs
of
deformation
renew
the

tubes
if

necessary
Check
the
dimension

A
in

Fig
K
1B
to

make
SUfe
that

the

jacket
has
not
been
crushed

Check
the

dimension
B

Fig
K
14

COLLAPSffiLE
STEERING

Assembly
and
Installation

Assembly
is
a
reversal
of

the

dismantling
procedure
noting

the

following

points

Lubricate
the
column

bearing
the

spring
and
dust
seal

sliding

parts
Ensure
that
the

upper
shaft

steering
lock
hole
and

the

steering
lock
are

correctly
positioned
Fig
K
19
When

assembling
the
lower
shaft
take
care
to

coincide
the
notch
on

the
universal

joint
with

the

punched
mark
on
the
shaft

Coat
the

upper
and
lower
shaft

serrations
with
multi

purpose

grease
Set
the

steering
in
the

straight
ahead

position
and
fit

the

column
shaft
to

the

steering
gear
See

Fig
K
20
Insert
the

column

through
the
dash
board

and
install
it
to
the

gear
so
that

the

punch
mark
at
the

top
of

the
shaft
is
forced

upwards
Slide

the

universal

joint
to

the

steering
gear
and

temporarily
install

the
column

clamp
6
Fit

the
lower
cover

flange
7
and

tighten

the
column

clamp
bolts

Check
the

steering
wheel

alignment
with
the
wheels
in
the

straight
ahead

position
If
the

steering
wheel

and

steering
lock

are

misaligned
by
more
than
35
mm

I
4
in
from
the
vertical

position
femove

the

steering
wheel
and
re
centre

it

STEERING

LINKAGE
Removal

Jack

up
the
front
of
the

vehicle
and

support
it
on

stands

2
Remove
the

cotterpins
and
castle
nuts

fastening
the
tie
rod

ball

joints
to
the
knuckle
arms

95

4
Remove
the
shell
covers

from
the

steering
column
slacken

the

screws
securing
the
meter

housing
and
withdraw
the

panel
from
the
facia

Fig
M
33

5
Pull

out
the
12

pole
round

shaped
connector
and
remove

the

speedometer
cable
union

nut
then
remove
the
instru

ment

panel
completely

WINDSCREEN
WIPERS

A
two

speed
wiper
motor
is
fitted

The
motor
has
an
auto

stop
mechanism
and
drives
the

wiper
arms

through
a
link

mechanism
located
behind
the
instrument
panel
If
the

wiper

system
does
not

operate
check
the
fuses
connectors
control

switch
and
motor
If
the

wiper
speed
does
not

change
the

switch
must

be
repaired
or

replaced
If

the

wiper
motor
becomes

unserviceable
it
can
be
removed
from
the
vehicle
in
the

fOllowing

manner

I
Remove
the
connector

plug
from

the
motor
See

Fig
M

34

2

Working
from
the

passenger
compartment
side
of
the
dash

panel
remove
the
nut

connecting
the

wiper
motor
worm

wheel
shaft
to
the

connecting
rod

3
Remove
the
three
bolts

securing
the

wiper
motor
to

the

cowl
and
lift
out
the
motor

Battery

Starter
motor

Type

Output

No
load

Terminal

voltage

Current

Revolution

Load

Terminal

voltage

Current

Torque

Brushes

Brush

length

Wear
limit

Spring
tension

Commutator

Standard
outer

diameter

Wear
limit

Depth
of

nuca

Repair
limit

Repair
accuracy

Qearance
between
armature

shaft
and

bushing

Repair
liinit

Repair
accuracy

Armature
shaft
ou
ter

diameter

Pinion
side

Rear
end

Wear
limit

Bend
limit
The

wiper
arms
can
be
removed
quite
easily
by
taking
off

the
attachment
bolt
as
shown
in

Fig
M

J
5
and
then

pullin

the

wiper
arm
from
the

pivot
shaft
When

installing
the

wiper

arm
make
sure
that
the
blade
is

positioned
approximately

27mm
1
06
in
away
from
the

bottom
of
the
windscreen
and

tighten
the

wiper
arm
attachment
bolt

WINDSCREEN
WASHERS

The
windscreen
washer
SWItch
and

wiper
switch
are
com

bined
in
a

single
unit
See

Fig
M
36
the
washers
can
be

operated
by
turning
the
switch
in
the

appropriate
direction
It

should
be
pointed
out
that
it
is
inadvisable
to

operate
the
washers

for
more
than
30
seconds
at
a
time
If
the
washers
are

operated

in
short

spells
of

approximately
10
seconds
duration
their

working
efficiency
will
remain

unimpaired
for
a
considerable

length
of
time

IGNITION
SWITCH
AND
STEERING
LOCK

The

steering
lock
is
built
in

to
the

goition
switch
When

the

key
is
turned
to
the
LOCK

position
and

then
removed

the
steering
system
is

automatically
locked

by
the

steering
lock

spindle
which

engages
in
a
notch
in
the
collar
on
the

steering

shaft

See

Fig
M
37
The
heads
of

the
screws
are
sheared
off

on
installation
so
that
the

steering
lock

system
cannot
be

tampered
with
If

the

steering
lock
is
to

be

replaced
it
will
be

necessary
to
remove
the
two

securing
screws
8
and
then
drill

out

the
self

shearing
screws
7
When

installing
a
new

steering

lock

tighten
the
new
self

shearing
screws
until
the
heads
shear

TechnICal
Data

12
volt

HITACHI
S114
87M

1
0KW

12
volts

Less
than
60

amperes

More

than
7000
r

p
m

6
3

volts

Less
than
420

amperes

More
than
0
9

mkg
6
5
lb

ft

16
mm

0
630
in

6
5mm
0
256
in

0
8

kg
1
8
lb

33mm
1
299
in

2mm

0
078
in

0
2mm
0
008
in

0
5
0
8mm
0
0197

0
0315
in

0
2mm
0
008

in

0
03
O
lmm
0
0012

0
0039
in

13mm
0
512
in

11
5
mm

0
453
in

O
lmm
0
0039

in

0
08

mm
0
0031

in
Oearance
between

pinion
and

stopper
0
3
1
5mm
0
0118

0
0591
in

ALTERNATOR

Type
HITACHI
LTl25
06

HITACHI
LTl33
05
USA

Canada

More
than
18

amps
at

14

volts
2500
r

p
m

More
than
25

amps
at

14

volts
5000
r

p
m
Output
current

LTl25
06

Output
current

LT
133
05

More
than
24

amps
at

14

volts
2500
r

p
m

More
than
33

amps
at
14

volts
5000
r

p
m

Brushes

Lengtb

Wear
limit

Spring
pressure
14
5mm
0
571
In

7mm
0
2756
in

0
25
0
35

kg
0
55
0
771b

Slip
ring

Outer
diameter

Reduction
limit

Repair
limit

Repair
accuracy
31
mm
1
220
in

I
mm

0
039

in

O
3mm
0
0118
in

0
05
mm

0
0197
in

VOLTAGE
REGULATOR

Type

Regulating

voltage
HITACHI
TL
lZ
37

14
3
15
3
volts
at
200C
680F

117