light DATSUN B110 1973 Service Repair Manual

AUTOMATIC

TRANSMISSION

Manual

linkage

The
hand
lever
motion

The
hand

lever
is
located

in
the
driver

s
com

part

men

mechanically
transmitted
from

the
remote
control

linkage
is
further

transmitted
to
the
inner
manual

lever

in

the
transmission

case
from
the

range

selector
lever
in

the

right
center

poc

tion

of
the

transmission
case

through

the
manual

shaft
The
inner

manual

lever
is

thereby
turned

A

pin
installed
on

the
bottom
of

the
inner
manual
lever
slides
the

manu

al

valve

spool
of
the

control
valve
and

thus
the

spool
is

appropriately
posi

lioned

opposing
to

each
select

position

The

parking
rod

pin
is

held
in
the

groove
on
the

top
of
the
inner

manual

plate
The

parking
rod

pin
operates
the

rod
at
p

range
and

operates
the

mechanical

lock

system

Moreover
the
above
described

manual
shaft
is

equipped
with
an

inhibitor
switch
A

rotor
inside
the

inhibitor
switch
rotates
in

response
to

each

range
When
the

range
is
selected

at
p
or
N
the

rotor
closes
the

starter

magnet
circuit
so
that
the

engine
can

be
started
When
the

range

is
selected

at
R
the

rotor
closes
the

back

up
lamp
circuit
and
the

back

up

lamp
lights

Vacuum

diaphragm

The
vacuum

diaphragm
is
installed

un
the
left

center

portion
of
the

transmission
case
The

internal
con

struction
of
the
vacuum

diaphragm
is

as
follows
A
rubber

diaphragm
forms

a

partition
in
the
center
The

engine

intake
manifold

negative
pressure
led

through
vacuum
tube
and

spring
force

are

applied
to
the
front
surface
of
the

rubber

diaphragm
and

atmospheric

pressure
is

applied
to
the
back
surface

A
difference
between
pressure

applied

to

the
front
and
back
surfaces
be

comes
a

vacuum
reaction
and
thus

the
throttle
valve
of
the

control
valve

inside
the
transmission
case
is

op

erated

When
accelerator

pedal
is

fully
de

pressed
and
the
carburetor
is

fully

upened
but
the

engine
speed
is
not
1

Housing

2
Cover

3

Outer
gear
AT071

4
Inner

gear

5
Crescent

Fig
AT
3
Oil

pump

1

Manual

plate

2

Inhibitor

switch
A
TOB7

3

Parking
rod

4
Manual

shaft

Fig
AT
4

Manuallinhage

To
intake
manifold

A

TOBB

Fig
A
T
5

Vacuum
diaphragm

iV

Down
shift
solenoid
i

KiCk
down

switch

A

TOB9

Fig
A
T
6

Downshift
solenoid

AT
5
sufficiently
increased
the
manifold

negative
pressure
lowers

becomes

similar
to
the

atmospheric
pressure

and
the

vacuum
reaction

increases

since

the
flow

velocity
of
mixture

inside
the
intake
manifold
is

slow

Contrarily
when
the

engine
speed

increases
and

the
flow

velocity
of

the

mixture

increases
or
when

the
carbure

tor
is
closed

the
manifold

negative

pressure
increases
becomes
similar
to

vacuum
and
the

vacuum
reaction

reduces

Thus
a

signal
to

generate
hydraulic

pressure
completely
suited
to

the

engine

loading
at
the

control
valve
is

transmitted
from

the
vacuum
dia

phragm
and

most
suitable

speed

change
timing
and
line

pressure
are

obtained
so

that
the
most

proper

torque
capacity
is

obtained

against
the

transmitting

torque

Downshift

solenoid

The
downshift

solenoid
is

of
a

magnetic
type
installed

on
the
left
rear

portion
of
the

transmiSsion
case

When

a

driver

requires
accelerating
power

and

depresses
the
accelerator

pedal

down
to

the

stopper
a

kick
down

switch

located
in
the

middle
of
the

accelerator
link
is

depressed
by
a

push

rod
the
kick
down
switch
closes
cur

rent
flows
to

the
solenoid
the
sole

noid

push
rod
is

depressed
the

down

shift
valve
of

the
control
valve
inside

the
transmission

case
is

depressed
and

the

speed
is

changed
forcedly
from

3rd
to
2nd
within
a

certain
vehi

cle

speed
limit

Note
As
the
kick
own

switch
closes

when
the
accelerator

pedal
is

depressed
from
7
8
to
IS
16
of

the
whole
stroke
the

accelera

tor

pedal
should
be

correctly

adjusted
and
fixed
so
as
to

afford

complete
stroke

The

arrangement
of
the
switch

differs

according
the
models
of

vehicle

Governor
valve

The

primary
and

secondary
gover

nor
valves
are
installed

separately
on

the

back
of
the
oil
distributor
on

the

I
transmission

output
shaft

They

op

erate
in
the
same

speed
as
that
of
the

output
shaft
In
other
wotds

they

operate
at

a

speed
in

proportion
to
the

vehicle

speed
To
those
valves
the

line

pressure
is

applied
as
the

input

ftom
the
control
valve

through
the

transmission
case
rear

flange
and
oil

distributor
The

governor
pressure
in

proportion
to
the

output
shaft

speed

vehicle

speed
is
led

to
the

shift

valve

of
the
control
valve

through

inverse

rou
te
as
the

output
and
thus

the

speed
change
and
the
line

pressure

are

controlled

Operation
of

secondary

governor
valve

The

secondary
valve
is
a
control

valve
which
receives

line

pressure
I

and

controls
the

governor
pressure

When
the
manual

valve
is

selected

D
2

or
1

range
line

pres

sure
is

applied
to
the

ring
shape
area
of

f
this

valve
from
circuit

I
and

this

valve
is

depressed
toward
the

center

side
Movement
of
this
valve
to
a

certain

position
closes
the
circuit

from

I
to

15

simultaneously
while
mak

ing
a

space
from
the

15
to
the
center

drain

port
and

pressure
in
the

circuit

IS
is

lowered

When

the
vehicle
is

stopped
and
the

centrifugal
force
of
this
valve
is
zero

the
valve
is

balanced
In
this
a

gover

nor

pressure
which
is
balanced
with

the

spring
force
occurs
on
the

15

When
the

vehicle
is

started
and
the

centrifugal
force
increases
this

valve

slightly
moves
to
the
outside
and

when

the

space
from

I
to
15

increases

space
from
the

15
to
the

drain

port
reduces

simultaneously
As

the
result

governor
pressure
of
the

15
increases

and
the

governor

pres

sure
is

balanced
with
the
sum
of

centrifugal
force
and
the

spring
force

The

governor

pressure
thus

changt
s
in

response
to
the

vehicle

speed

change

centrifugal
force

Operation
of

primary

governor

valve

The
valve
is

an
ON
OFF

valve

which
closes
the

governor

pressure

15

regulated
by
the

secondary

gover
CHASSIS

nor
valve
when
the
vehicle

speed

reaches
the

minimum

speed
and

when

the
vehicle

speed
exceeds
a
certain

level

open
the

governor
and
forwards

the

governor
pressure
15
to
the

control

valve

When
the

vehicle
is

stopped
the

governor

pressure
is

zero
However

when
the

vehicle
is

running
slowly

this
valve

is

depressed
to

the
center

side

and
the

groove
to

the

IS
is

closed
since
the

governor
pressure

applied
to
the

ring

shape
area
is

higher

than
the

centrifugal
force
of
this

valve

When
the

governor
speed
exceeds
cer

tain

revolution
the

governor

pressure

in
the
circuit
15
also

increases
How

ever
as
the

centrifugal
force
increases

and
exceeds

the

governor
pressure
this

valve

moves
toward
the
outside
and

the

governor
pressure
is
transmitted

to

the
circuit
15

Two
different

valves
are

employed

in
the

governor
so
that
it
will
inde

pendently
control

the

speed
at

high

speed
and
at

low

speed
That

is
within

the

low

speed

range
the

governor

pressure
is
not

generated
owing
to
the

primary
valve

whereas
at

the

high

speed
range
above
the

break

point
a

governor

pressure
regula
ted

by
the

sec0Hdary
valve
is

introduced

The
break

point
is
the

point
at

which
the

function
of
one

of
the

govp
rnors
is

transferred
to
the
other

whee

the

speed

changes
from

the

w

speed

range
to

the

high
speed

range

To
con
trol
valve

Governor

pressure

tiS

y
ID

t

4

From
control
valve

Line

pressure
I

J

I

Primary
governor

2
Secondar

governor

3
Governor
valve

body
AT090

4

Oil
distributor

5

Output
shaft

Fig
AT
7
Cross

sectional
view

of

governor

AT
6
AT091

Fig
A
T
B

Output
shaft
with
oil

distributor
and

governor

I
Oil

distributor

2

Governor
valve

body
AT092

3

Primary

governor

valve

4

Secondary

governor

valve

Fig
A

T

9

Exploded
uiew

of

gouernor

Control

valve

assembly
AUTOMATIC
TRANSMISSION

Oil

from

pump

ru
nn

i

I
I
I
Throttle
valve

I

I

1
m
nn

I
Auxiliary
valve

I
Regulator
valve

j

Manual
valve

I

Uoe

pressure

Speed
change
L

I
Governor

valve

I
I
valve

J
1
1

Clutch
and
brake

Flow

chart
of

control
valve

system

The
control
valve

assembly
receives

oil

from
the

pump
and
the

individual

signals
from
the
vacuum

diaphragm

and
transmits
the
individual

line

pres

sures
to
the
transmission
friction

ele

ment

torque
converter
circuit
and

lubricating
system
circuit

as
the
out

puts
To
be

more

specifically
the
oil

from
the
oil

pump
is

regulated
by
the

regulator
valve
and
line

pressures
build

up
The
line

pressures
are
fed
out
from

the
control
valve

assembly
as

they
are

through
various
direction

changeover

valves

including
ON
OFF
valve
and

regulator
valves

newly
reformed
to
a

throttle

system
oil

pressure
and

op

crates
other
valves

or

finally
the
line

pressure
are
transmitted
to

the
re

quired
clutch
or
brake
servo

piston

unit
in

response
to
the

individual

running
conditions
after

receiving
sig

nals
from
the

previously
described

vacuum
diaphragm
downshift
sole

noid

governor
valve

and
or

manual

linkage

The
control
valve

assembly
consists

of
the

following
valves

Pressure

regulator
valve

2
Manual
valve

3
1st

2nd
shift
valve
4

2nd
3rd
shift

valve

S

Pressure

modifier
valve

6

Yacuum
throttle
valve

7

Throttle
back

up
valve

8
Solenoid

downshift
valve

9
Second

lock
valve

0

2nd
3rd

timing
valve

Pressure

regulator
valve

PRV

The

pressure
regulator
valve

re

ceives

valve

spring
force
force
from

plug
created

by
the
throttle

pressure

16
and
line

pressure
7
and
force

of

the

throttle

pressure
18

With
the

mutual

operations
of
those
forces
the

PRY

regulates
the
line

pressure
7
to

the

most
suitable

pressures
at
the

individual

driving
conditions

The
oil
from
the
oil

pump
is

ap

plied
to
the

ring
shaped
area

through

orifice
20
As

the
result
the
PRY
is

depressed
downward
and

moves
from

port
7

up
to
such
extent
that
the

space
to
the

subsequent
drain

port

marked
with
x
in

Figure
AT
10

opens
slightly
Thus
the
line

pressure

7
is
balanced
with
the

spring
force

AT
7
and
the
PRY
is

thereby
balanced
In

this
the

space
from
the

port
7

to
the

subsequent
converter
oil

pressure
14

circuit

has
also
been

opened
As

the

result
the

converter
is
filled
with
the

pressurized
oil
in
the
circuit
14
and

the

oil
is

further
u
d

for
the

Iubrica

tion
of
the
rear
unit
Moreover

a

part

of
the
oil
is

branched
and

used
for
the

lubrication
of
front
unit

for
the
front

and
rear
clutches

When
the

accelerator

pedal
is
de

pressed
the
throttle

pressure
16
in

creases
as

described
in
the

preceding

paragraph
oil

pressure
is

applied
to

the

plug
through
orifice
21
and
the

pressure
is

added
to
the

spring
force

As
the

result
the
PRY
is

contrarily

depressed
upward
space
to
the
drain

port
is

reduced
and
the
line

pressure

7
increases

Afl

II

Jwi
06

A

J
L
I

7

I

tf

Iij

BL

i
il
J

jti
r

x

r
1
J

I

l

I

X

6

C

l
o

ii
J

f

A

T09S

Fig
AT
10
Pressure

regulator
value

tr
r

Low
in

the

range
I
is

led
to

the
low

and
reverse
clutch
from
the

line

pressure
5

through
the
line

pressure
12
and
at
the
same
time

the
same
is
led
to
the
left
end

spring

unit

Consequently
although
the

go

vernor

pressure
increases
the
valve
is

still

depressed
toward
the

right
and

the
SFV
is

fixed
in
the
Low

posi

tion
When

kicked
down

at
the

2nd

speed
the
SDV

operates
and
the

line

pressure
13
depresse
the
FSV
to

ward
the

right

Although
the

governor

pressure
15
is

considerably
high
the

valve
is

depressed
completely
toward

the

right
and
the

FSV
is

returned
to

the
Low

position
This

operation
is

called
Kick
down

shift

2nd
3rd
shift
valve
SSV

The
SSV
is

a
transfer
vaIve
which

shifts

speed
from
2nd
to
3rd

When
the
vehicle
is

stopped
the

SSV
is

depressed
toward
the

right
by
the

spring
and
is
in

the
2nd

position
It

is

provided
however
that
the
FSV

decides
the

shifting
either

to
Low

or

2nd

When
the

vehicle
is

running
the

governor

pressure
15
is

applied
to

the

right
end
surface
and
the
SSV
is

depressed
toward
the

left

Contrarily

the

spring
force
line

pressure
3
and

throttle

pressure
19

depress
the

SSV

toward
the

right

When
the

vehicle

speed
exceeds
a

certain
level
the

governor

pressure

exceeds
the
sum
of
the

spring
force

line

pressure
and
throttle

pressure
the

valve
is

depressed
toward
the
left
and

the
line

pressure
3
is
closed
Conse

quently
the
forces

are
rapidly
un

balanced
the
force
to

depress
the
SSV

toward
the

right
reduces
and
thus
the

SSV
is

depressed
to
the
Ie
ft
end

for
a

moment

With
the
SSV

depressed
to

ward
the

left
end
the
line

pressure
3

is

connected
with
the
line

pressure

10
the

band
servo
is
released
the

front
clutch
is

engaged
and

speed
is

shifted

to
3rd

When

the
accelerator

pedal
is

de

pressed
both
the
line

pressure
3

and

the
throttle

pressure
19

are

high
and
AUTOMATIC
TRANSMISSION

therefore
the

SSV
is

retained
in

2nd
unless
ihe

governor
pressure

IS
exceeds

the
line

pressure
3
and

the

throttle

pressure
19

In

the
3rd

position
force
to

depress
the

SSV
toward
the

right
is

remained

only
on
the
throttle

pressure

16
and

the
throttle

pressure
16
is

slightly
lower
than
that

toward
the

right
which
is

applied
while

shifting

from
2nd
to
3rd

Consequently
the
SSV
is
returned

to
the

2nd

position
at
a

slightly
low

speed
side

Shifting
from
3rd
to

2nd

occurs
at

a
speed

slightly
lower

than
that
for

2nd
to
3rd

shifting

When
kicked
down
at
the
3rd

line

pressure
13
is
led
from
the
SDV

and
the
SSV
is

depressed
toward
the

right
Although
the

governor
pressure

is

considerably
high
the
valve
is

de

pressed
completely
toward
the

right

and
thus
the
SSV
is
returned
to

2nd

position
This

operation
is

called
Kick
down
shift

When
the
shift
lever
is
shifted

to

2
or
I

range
at
the

3rd

speed

the
line

pressure
3
is

drained
at

the

MNV

Consequently
the
front
clutch

operating
and
band
servo

releasing
oils

are
drained
As

the

res
lIt
the
trans

mission
is
shifted

to
the
2nd
or

low

speed
although
the

SSV
is
in

the
3rd

position

When
the

speed
is
shifted
to
the

3rd
a

one

way
orifice
24
on
the

top
of
the

SSV
relieves
oil

transmitting

velocity
from
the
line

pressure
3

to

the
line

pressure
10
and
reduces
a

shock

generated
from
the

shifting

Contrarily
when
shifted
from
3rd

to
2
or

range
and
the

speed
is

shifted
to
the
2nd

spring
of
the
orifice
24
is

depressed
the
throttle

becomes
ineffective
the

line

pressure

10
is

drained

quickly
and
thus

delay
in
the

speed
shifting
is

elimi

nated

Throttle

of
the

line

pressure
6

relieves
the
oil

transmitting
velocity

from
the

line

pressure
6
to
the

line

pressure
10
when

the
lever
is

shifted

to
the

R

range
and
relieves
drain

velocity
from
the
line

pressure
10
to

the
line

pressure
6

when

shifting

from
3rd
to

2nd
at

the
D

range
Thus
the
throttle
of
the
line

pressure
6
reduces

a
shock

generated

from
the

shifting

A

plug
in
the
SSV
left

end

readjust

the
throttle

pressure
16
which
varie

depending
on
the

engine
throttle
con

dition
to
a

throttle

pressure
19

suited
to
the

speed
change
control

Moreover
the

plug
is

a
valve
which

applies
line

pressure
13
in

lieu
of
the

throttle

pressure
to
the

SSV
and
the

FSV
when
kick

down
is

performed

When
the
throttle

pressure
16
is

applied
to
the
left
side
of
this

plug

and
the

plug
is

depressed
toward
the

right
a
slight

space
is
made
from
the

throttle

pressure
16
to

19
A
throt

tIe

pressure
19
which
is
lower

by
the

pressure
loss

equivalent
to
this

space
is

generated
the

pressure
loss
is
added
to

the

spring
force
and
thus

the

plug
is

depressed
back
from
the

right
to
the

left

When
this

pressure
19
increases

excessively
the

plug
is
further
de

pressed
toward
the
left

space
from

the

throttle

pressure
19
to
the
drain

circuit

13
increases
and
the
throttle

pressure
19
lowers
Thus
the

plug
is

balanced
and
the

throttle

pressure

19
is
reduced
in
a

certain
value
b

3
Orifice

t

checking
valve

24

15

2
2

i
I

1
c

V
Y
ii
pr

W
jt1

iff
I
W
q

I
nHH

J

L19
H
10

15

AT
9
A

T098

Fig
AT

13
2nd
3rd

shiflvalue

Fig
A
T
49

Torque
converter

aligning
cut

3
When

connecting
torque
con

verter

to
transmission

measure
dis

tance
A

to
be

certain
that

they
are

correctly
assembled
See

Figure

AT
50

Distance
A

More
than
16
5
IllIll

0
650
in

A

AT117

Fig
A
T
50

Installing
torque
converter
CHASSIS

4
Bolt
converter
to
drive

plate

Tightening
torque

0
8

to
1
0

kg
Ill
5
8
to
7
2
ft
Ib

Note

Align
chalk

marks

painted
a

cross

both

parts
during
disas

sembling
processes

5

After
converter
is
installed

rotate

crankshaft

several
turns
and
check
to

be
sure
that

transmission
rotates

freely

without

binding

6
Pour

recommended
automatic

transmission
fluid

up
to

correct
level

through
oil

charge

pipe

7

Connect
manual

lever
to

shift

rod

Operation
should
be
carried

out

with
manual
and

selector
levers
in

N

8
Connect

inhibitor
switch
wires

Notes

a
Refer
to

covering
topic

under

Checking
and

adjusting

inhibitor
switch
on

page

AT
51

b

Inspect
and

adjust
switch
as

above
whenever
it
has

to
be

removed
for

service

9
Check
inhibitor
switch
for

op

eration

AT
34
Starter
should

be

brought
into

op

eration

only
when
selector
lever
is
in

P
and
N

positions
it

should
not

be

started
when
lever
is
in
D

2

1
and
R

positions

Back

up
lamp
should
also

light

when
selector
lever
is

placed
in
R

position

10
Check
level
of
oil
in

transmis

sion
For
detailed

procedure
see

page

AT
49

II
Move

selector
lever

through
all

positions
to
be
sure
that
transmission

operates
correctly

With
hand
brake

applied
rotate

engine
at

idling
Without

disturbing

the

above

setting
move

selector
lever

through
N

to
D

to
2
to
I

and
to
R
A

slight
shock
should
be

felt

by
hand

gripping
selector
each

time
transmission
is

shifted

Note
See

page
AT

50
for

checking

enigne

idling

12

Check
to
be

sure
that
line

pres

sure
is
correct

To

do
this
refer
to

relative

topic
under

Testing
line

pres

sure
on

page
AT
53

13

Perform

stall
test

as

per
the

instructions
on

page
AT

51

Assembly

I

Prior
10

assemlbing
dip
all

parts

in

clean
automatic

transmission
fluid

Reverse

disassembly
procedure
to

assemble
brake

2
Use
extreme
care
to

avoid

dam

aging
rubber

ring
when

installing
seal

lace

3
Blow

under

pressure
air
from

apply
side
of

piston
to
lislen
for
defi

nite

piston

operation
as

shown
in

Figure
AT

93

4

With

appIy
side
of

piston
plugged

with

thumb
blow
air
under

pressure

into

cylinder
from
release

side
as

shown
in

Figure
AT
94
If
retainer

is

raised
a
little
it
is

an
indication
that

attaching
bolts

are
loosened

calling

for

retightening

Governor

Disassembly

l

Separate

governor
from

oil
dis

tributor

by

unscrewing

attaching
bolts

2
To

disassemble

secondary
gover

nor

remove

spring
seat

spring
and

secondary
governor
valve
from
valve

body
in

this

written
order
as
shown
in

Figure
AT
95

3

If

primary

governor
is

to
be
dis

assembled
for

any
purpose
remove

spring
seat

primary
governor
valve

spring
and

spring
eal
CHASSIS

I
Anchor
end

pin

2
Band

strut

3

Return

spring

4

Piston
stem

5
Band

servo

piston

6
Release

7

Apply

8

Servo

piston

relainer

9

Transmission
case

10

Band
brake

AT074

Fig
A
T
92
Sectional
view

of
servo

piston

Fig
A
T
93

Testing
piston

Apply
side

Fig
A
T
94

Testing
pi8ton

Rele
side

Inspection

I

Check
valve
for

defective
condi

tion

Replace
spring
if

found

weaken

ed
too

badly
beyond
use
Defective

piston
should

also
be

replaced
with

a

new
one

2
Examine
if

primary

governor

slides

freely
without

binding

3

To
determine

if

secondary
gover

nor
is
in

good
condition
blow

air

under

light
pressure
into
hole
at

A

to

listen
for
noise

like
a

model

plane

AT
44
r
To
control

valve

Governor

pressure

15

1

4

From
control

valve

Line

pressure
I

I

Primary

governor

2

Secondary
governor

3

Governor
valve

body
A
TogO

4
Oil

distributor

5

Output
shaft

Fig
A
T
95

Testing
secondary

governor

Assembly

Reverse

disassembly
procedure
to

assemble

governor

Note
Do
nol

confuse

primary
gover

nor

wilh

secondary
governor

After

instaDation
check
to
be

sure
that

spring
is
nol

de

flecled

Oil

pump

Disassembly

I

Free

pump
cover
from

pump

housing
by

removing
attaching
bolts

2
Take
out
inner
and

outer

gears

from

pump

houisng

Inspection

1

Inspect
gears
for
wear
or

damage

to

gear
leeth

Replace
rubber

ring
if

found

damaged
excessively

beyond

use

2

Using
a

straight
edge
and
feelers

measure

pump
and

gear
clearances
as

follows

Clearance
between
inner

or
outer

gear
and

pump
cover
See

Figure

AT
96

Standard
clearance

0
02

to
0
04
mm

0

0008
to
0
0016
in

Replace
if

going
over
0

08
mm

0
0031
in

c

Inspection
and

adJu
Stmenf
trouble
first
check

the

linhge
f
no

1
i

jI
fect

is
found
in
the
lin1

age
check

of

manu
a
l

liiiJ
i

the
inhibitor
switch

Th

d
1F

aI
S
t
th
I
I
f
e

a

JU
i

J
u

epara
e
e

range
se
eet

ever
rom

Iy

important
ii
s3

ns
etion
of
oil
the
lower
shift

rod
and
turn
the

range

1

level
for
the
automatiC

tran
smission
select
lever
to
N

Therefore

great
care
should

be
exer

Note

In
the

position
N

the
slot
of

cised
because
defective

adjustment
will

the
manual
shaft
is

vertical

result
in

the
breakdown
of
the

trans

By
the
use
of
the
tester
check

the

two
bIack

yellow
BY
wires

from
the

inhibitor
switch
in
the

ranges
N

and

P

and
the

two
red
bIack

RB
wires

in
the

range
R
for

continuity
Turn

range
select
lever
to
both

directions

from
each
lever
set

position
and
check

each

continuity

range
It
is

normal
if

the

electricity
is
on
while
the

lever
is

within

an

angle
of

about
3
0

on

both

sides
from
each

lever
set
line
How

ever
if
its

continuity
range
is
obvi

ously
unequal
on
both

sides
the

adjustment
is

required

f

any
malfunction
is

found
un

screw
the

fastening
nut
of
the

range

selector
lever

and
two

fastening
bolts

of

the
switch

body
and
then
remove

the
machine
screw

under
the
switch

body
Adjust
the
manual
shaft
correct

ly
to
the

position
N

by
means
of

the
selector
lever

When
the
slot
of

the
shaft

becomes
vertical
the
detent

works
to

position
the
shaft

correctly

with

a
click
sound

Move
the

switch

slightly
aside
so

that
the
screw
hole
will
be

aligned

with
the

pin
hole
of
the
internal
rotor

combined
with
the

manual
shaft
and

check
their

alignment
by
inserting
a

1
5

0101
0
0591
in
diameter

pin
into

the
holes
If

the

alignment
is

made

correct
1
5ten
the
switch

body
with

the

bolts

pull
out
the

pin
and

tighten

up
the
screw

again
into
the
hole
and

fasten
the
selector
lever
as
before

Check
over

again
the

continuity
with

the

tester
If
the
malfunction
still

remains

replace
the
inhibitor
switch
mission

Inspection

Pull
the
selector
lever

toward

you

and
turn
it

so
far
as
p

to
1

range

where
clicks
will
be
felt

by
hand
This

is

the
detent
of
manual
valve
in
the

body
and
indicates
the
correct

posi

tion

of
the

lever

Inspect
whether
the

pointer
of

selector
dial

corresponds
to
this

point

and
also
whether
the
lever

comes
in

alignment
with
the

stepping
of

posi

tion

plate
when
it
is

released

Adjustment

This

procedure
can

be
accom

plished
by
referring
to
Removal
and

nstallation

Checking
and

adjusting

inhibitor
switch

The
inhibitor
switch
serves

to
light

the

reverse

lamp
in
the

range
R
of

the
transmission

operation
and
also
to

rotate
the

starter
motor
in
the

ranges

N
and
P

j

r@
I

If

r
f
B

@
I

Jt
@
@

c
v@

i

r
fji

AT109

1
Inhibitor

switch

2
Manual

shaft

3
Washer

4

Nut

5

Manual

plate

Fig
AT
II
0
Con
truction

of
inhibitor

witch
6
Washer

7

Nut

8
Inhibitor
switch

9

Range
select
lever

Check
whether
the

reverse
lamp

and
the
starter
motor

operate
normal

ly
in

these

ranges
If
there
is

any
t

ki

A

mm
ATIC
TRANSMISSION

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission

and

engine
for

trou

ble

by
measuring
the
maximwn

num

bers
of
revolutions
of
the

engine
while

vehicle
is
held
in
a
stalled
condition

and
the
carburetor
is
in
full

throttle

operation
with

the
selector
lever
in

AT
51
rang
s
D
2

and
I

respectively

and

by
com

pairing
the
measured

re

sults

with
the

standard
values

Standard
stall
revolution

1
750
to
2
000

rpm

Components
to
be
tested
and
test
items

1

Clutches
brake

and
band

in

trans

mission

for

slipping

2

Torque
converter

for
function

3

Engine
for
overall

property

Stall
test

procedures

Before

testing
check
the

enigne
oil

and

torque
converter
oil

warm

up
the

engine

cooling
water
to
the

suitable

temperature
by

warming
up

ope
ration

at

1
200

rpm
with
the

selector
lever
in

the

range
P

for
several
minutes

and

warm

up
the

torque
converter
oil

to

the

suitable

temperature
60
to
IOOoC

140
to
2120F

1
Mount
the

engine
tachometer
at
a

location
that
allows

good
visibility

from

the
driver

s
seat
and

put
a
mark

on

specified
revolutions

on
the
meter

2
Secure
the

front
and
rear
wheels

completely
with
chocks
and

apply
the

hand
brake
Be

sure
to

depress
the

brake

pedal
firmly
with
the
left
foot

before

depressing
down
the
accelerator

pedal

3
Throw
the

selector
lever
into
the

range
D

4

Slowly
depress
the

accelerator

pedal
down
till
the

throttle
valve
is

fully
opened
Quickly
read
and
record

the

engine
revolution
when
the

engine

begins
to
rotate

steadily
and

then

release
the
accelerator

pedal

5
Turn
the

selector
lever
into
N

and

operate
the

enigne
at

approxi

mately
1

200

rpm
for
more
than
one

minute

to
cool
down
the

torque
con

verter
oil
and
coolant

6
Make
similar
stall
tests
in
the

ranges
2
I

and
R

Note

The
stall
test

operation
as

spec

ified
in

the
item
4
should
be

made
within
five
seconds
If
it

takes
too

long
the
oil
deterio

rates
and
the

clutches
brake

CHASSIS

Mureover
excessive
sleeve

yoke
spline
ta
transmission

main

spline
lash
and

wear
of
both

front
and

rear
universal

joints
will

cause
vibrations

affecting
riding
comfort

REMOVAL

Disconnect

the

flange
yoke
and
the

pinion
flange
by

removing
bolts

at
the
rear
end
of
the

propeller
shaft

In

this
case
draw
out
the
sleeve

yoke
from
the
end

of

transmission

holding
the

disconnected
rear
end

of
the

propeller
shaft

Fig
PD
2

Removing
pmpeller
shaft

Before

disassembling
put
match

mark
on
all

com

ponents
of
shaft
so
that

they
are
reassembled
in
the

former

position
and
that
the

propeller
shaft
balance

may

not
be

deviated

DISASSEMBLY

Primarily
do

not
disassemble
the

propeller
shaft
since

it
has

been
balanced
as
an

assembly

When

disassembly
is

unavoidable
for

necessary
repair

the

following
instructions

apply

1

Remove

snap
rings
from
the

yoke
and
raise
the

propeller
shaft

2
Remove

snap
rings
used
to

secure
the

journal

bearings
in
the

yoke
flange
with
a

pair
of

pliers

If

the

snap
rings
cannot
be

snapped
out
of
the

groove

tap
the
end

of
the

bearing
with
a

wooden
mallet

slightly

This
will
relieve
the

pressure
from
the

snap
ring

3

Slightly
remove
the

journal
bearing
end

until
the

opposite
bearing
is

pushed
out
of
the

yoke
flange
Turn
over
and

secure
the

assembly
in
a
vise
Drive
the

first

spider
bearing
back
out

of
its

lug
by
tapping
the

projected

end

of
the

spider

4
Use
a
brass

drift
with
a

flat
face

5
Wash
and
clean
the

bearing
and

shaft
with

cleaning

solvent

1

W

SNAP
RING

V
I
1Iiff

BEARING

ASSEMBLY

JOURNA

V

Fig
PD
3

Exploded
view

of
universal

joint

INSPECTION

Check
all

parts
and

repair
or

replace
if
defective
When

replacing
the

journal
unit
be
sure
to

replace
as

an

assembly

Replace
if
the

journal
pin
exterior
is

damaged
or

scarred

2

Replace
if
the

yoke
hole
is
worn
or

damaged

3

Replace
if
the

snap
ring
is

damaged
or
deformed

4

Replace
if
the

bearing
needle
roller
is

damaged
or

worn

5

Replace
both
sleeve

yoke
and
main
shaft
if
the
sleeve

yoke
and
main
shaft

spline
are

damaged
or
worn

6

Replace
if
the

propeller
shaft
tube
surface
is
cracked

or
Indented

ASSEMBLY

The

propeller
shaft
is

reassembled
in

reverse

sequence

of

disassembly

Install
the

spider
on
the

yoke
flange

PD
2

PROPELLER
SHAFT
DIFFERENTIAL
CARRIER

The

gear
carrier
is
made
of

light
and

strong
aluminum

alloy
metal
and

hypoid
bevel

gear
is
used

Adjust
drive

pinion
bearing
preload
with
non
adjusting

type
spacer
and

pinion
height
and
side

bearing
adjust

ment
with

spacer

shim
s

Millimeter
standardization
stilI
remains

for
all
the

screw
threads
of

this
unit

Therefore

adjustment
figures

stamped
on

screws

adjusting
shims
washers

differential

case

drive

pinion
and
carrier
are
in
millimeters
in

accordance
with
the

millimeter
standardization
of

parts

The

proper
lubrication
to
the

gear
housing
is

necessary

otherwise
it

would
shorten
the

durability
of
the

gear
and

cause
other
troubles

The
lubricant
should
be

checked

each
5

000
km
3

000
miles
and

replenished
each
50
000

km
30
000
miles

The
lubricant
should
be
drained
and
ref11led
at
the

end

of
the

first
1
000

km
600
miles

to
eliminate

any
loose

material
from
the

sump
which
results
from

breaking

Differential
lubricant
should
be

changed
at
least

every

50
000

km
30
000
miles

ConsIderations
should
be

given
to
the

following

matters

I
Nominated

hypoid
gear
oil

must
be
used

2
It
is

prohibited
to
use

any
gear
oil
of

different

viscosity

The

same
brand
must

always
be

selected

3
The
standard
oil

capacity
is

about
0
75

liter
0
198

US

gal

REMOVAL

Fig
PD
5

Removing
differential

gear
carrier
To
remove
the

gear
carrier

assembly
disconnect
the

drive

pinion

companion
flange
te

flange

yoke
connection

and

remove
two
rear
axle
shafts
Refer
to

REAR
AXLE

for
the

work

DISASSEMBLY

I

Install
the

gear
carrier

assembly
on
the
Gear
Carrier

Attachment
ST06320000

ST06320000

Fig
PD
6

Holding
differential
camer

2

Inspect
the

following
before

disassembling

I

Inspect
the
tooth
contact

pattern
with
a

lead
oxide

2
Measure

backlash
between
drive

gear
and

pinion

gear
using
a
dial

indicator

3

Put
match
mark
on
one

side
of
the
side

bearing

cap

by
the

use
of
a

punch

SIDCBEMING
c

e

Fig
PD

7

Putting
mark

PD

5

PROPELLER
SHAFT
DIFFERENTIAL

CARRIER

Reassemble
the

differential
carrier
in
reverse
order

of

disassembly
The

following
instructions

for

adjustment

and

usage
of

special
tuols
are

essential
to

obtain

perfect

differential

operation

Assembling
differential

gear
case

1
Assemble
the

pinion
mate
side

gear
and
thrust

washer
in
the

differential
case

2

Adjust
clearance
between
the

side

gear
and
thrust

washer
within
0

10
to

0
20
mm
0

004
to
0

008
in

by

selecting
side

gear
thrust
washer

Fig
PD
17

Measuring
clearance

Side

gear
thrust
washers

Thickness
mm
in

0
76
to
0
81
0

0299
to
0
0139

0
81
to
0
86
0

0319
to
0

0339

0
86
to
0
91
0

0339
to
0
0358

3
Fit
the

pinion
lock

pin
from
the

right
side
of
the
case

opposite
side

of
drive

gear
and

peen
the
hole
rim
over
to

prevent
the
lock

pin
vibrating
loose

4

Bolt
the
drive

gear
to
differential

case

Only
genuine
drive

gear
bolts

and
new
lock
bolt

straps

should
be
used
Tighten
the
bolts

by
tapping
lightly
the

head
of
the

bolt

by
a
0
1

kg

l
4lb

hammer

The
drive

gear
bolts
should
be

tightened
in

a

diagonal

line
The

tightening

torque
should
be

6
to
7

kg
m

43
4

to
50
6
ft

lb

Fig
PD
18

Tapping
bolt

head

5
Press
the
side

bearing
inner
race
on
the
differential

case

using
a
Side

Bearing
Drift
ST33220000

cf

ST33220000

F

ig
p
19

Pressing
side

bearing
inner
race

Note
It
is

important
to
fit
the
drive

gear
adjusting
shims

behind
the

bearings
to
obtain

proper
preload
and

mounting
of

gear
teeth

The

procedure
for

adjustment
is

d
ibed
in

fourthcoming

page
in
detail
and
therefore

no

instruction
is

given
here

PD
9