steering DATSUN PICK-UP 1977 Owner's Manual

I

J

L6

3

4

5
1

Apply
recommended

grease
to

screw

bushing
interior

plain
bushing

interior
dust
seal
inside
and

bushing

sliding
surface
of
idler
ann

Screw

bushing
tightening

torque

12

kg
m

87
ft
lb

2

Before

installing
idler
arm
assem

bly

replace
f
iller

plug
with

grease

nipple
and

apply
recommended

grease

to
idler

ann

through
this

grease
nipple

until

grease
is
forced

out
at
the

lower

end
of

the
dust

seal

lip
Remove

grease

I

8
I

II

I

I

FIODt

Inspection
and

repair

Ball

joint

1
When
ball
stud
is

worn
or
axial

play
is
too

excessive

replace
cross
rod

socket
or
side

rod
with
a
new
one

2
When

dust
cover
is

broken
or

defonned

be
sure
to

replace
with
a

new
one

Axial
end

play
0
1
to
0
5

mm

0
004
to
0
020
in

Initial

swing
torque

S
to
15

kg
cm
70
to
209
in
oz
STEERING
SYSTEM

nipple
and
reinstall

filler

plug

3
In

installing
idler
arm

assembly

make

sure
that
the

standard

dimension

A
is

adjusted
correctly

Standard
dimension

A

137
8
to

139
8

mm

S

42S
to
S
504

in

See

Figure
ST

14

Furthermore
be

sure
to

install

washers

correctly
See

Figure
ST
IS

Spring
washer

Frame

Plain
washer

Weld
nut

Self

locking
nut

ST212

Fig
ST
15
Locations

of
washers

Initial

swing
torque
5

to
15

kg
cm

70
to
209
in
oz

ST213

ST
7
sary
To
renew

grease
remove

grease

nipple
cap
and

apply
recom

mended

grease
to
ball

joint

through

grease
nipple
until

grease
is
forced

out
at
the

grease
vent
hole

Idler
arm

3B8embly

Remove
old

grease
and
dirt
and

check
idler

ann

assembly
for
wear

deformation
and

damage

CrOBS
rod
side
rod

and

gear
arm

Check
them
for

bending
damage

and
crack
and

replace
as

necessary

Inspecting
steering
system
on

the
vehicle

which
comes
into

collision

Steering
system
is

very
important

for

driving
a
vehicle
When
the

vehicle

comes
into

collision

especially
the

front
of
the

vehicle
is

damaged
special

inspection
should

be
done

for
the

following
matters

If

any
component
parts
of

steering

system
is

found

to
be

damaged
re

place
them

with
new
ones

1

Steering

angles
correctness

Inspect
side

rods
and

cross
rod
for

bend
and
sector
shaft

for
distortion

2

Level
of

steering
wheel
bar
with

the
front

wheels
in

a

straight
ahead

position

If
its
deflection
is

more
than
about

90

degrees
the

bend
or
distortion
of

sector
shaft

and
column
shaft
can
be

seen

3
Noise

during

operation
of

steering

wheel

Inspect
column
shaft

and

jacket

tube
for
bend

4
Smooth

operation
of

steering

wheel

Inspect
sector

gear
for

breakage

ball

nut
screw
for
dint
and
column

shaft

for
bend

S
Gear
arm

breakage

6
Gear

housing
breakage

In
addition

inspect
gear
housing

f

IXing
bolts
for
looseness

7
Distortion
of
sector
shaft
serra

tion

8
Sector

gear
breakage

STEERING
SYSTEM

9
Column

shaft

breakage
on

the

welded
section

In

addition

inspect
column
shaft

for

scratch
10
Deformation
of

body
construc

tion

and
frame

Inspect
the
installation

portion
of
steering

system
on
the

body
construe

tion
and

frame
for
deformation

or

any

other

faulty
conditions

SERVICE
DATA
AND

SPECIFICATIONS

SPECIFICA
nONS

Gear

type

Gear
ratio

SERVICE
DATA

Standard
thickness
of

worm

bearing

adjusting
shims

mOl

in

Initial

turning

torque
of

steering
column

New

worm

bearing
kg
em
in
lb

Used

worm

bearing
kg
em
in
lb

End
clearance

of
sector
shaft

adjusting
screw
rom
in

Backlash

at
the

gear
arm

top
end
rom
in

Oil

capacity
t

U
S

pt
Impel

pt

Bail

joint
axial
end

play
rom

in

Standard
cross

rod

length
rom

in

Toe
in

rom
in

Steering
arigle

Inner

wheel

Outer
wheel

Tightening

torque

Steering
column

jacket
to

gear

housing

Sector
shaft

cover

Sector
shaft
lock
nut

Gear

housing

Gear
arm

Steering
wheel

Bail
studs
of
cross
rod

Ball
studs
of
side
roo

Knuckle

arm
side

Gear
or

idler
arm

side

ST
8
Recirculating
ball

type

19
8
I

1
5

0
OS9

4

0
to
6
0
3
5
to
S

2

2
4

to
4
4

2
1

to
3

8

om
to
0

03
0
0004
to

0
0012

o
to
0
1

0
to
0
004

0
33
J

X

0
1
to
0
5

0
004
to
0
020

516

20
31

I

to
S

0
04
to
0

20

35030

to
36030

30030

to
31030

Unit

kg
m
ft
lb

1
5

to
2
S

II

to
18

I

S
to
2
S

I
I

to
18

3

0
to
4

0

22
to
29

4

6
to
5
3
33

to
38

13
to
IS
94

to
108

7
to
7
S

SI
to
S4

S
S

to
10
0
40
to

72

S

S
to
10

0

S
5

to
10
0
40
to

72

40
to

72

STEERING
SYSTEM

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Steering
wheel
moves

heavily

Steering
wheel
turns

but

sluggishly

Vehicle

pulls
to
one

side
Probable
cause

Wheel

alignment
out
of

specifications
or
air

pressure
in
tires

too
low

Steering

linkage
out
of

adjustment

Steering
column
out
of

alignment

Wheels
out
of

alignment
or
air

pressure
in

tires

too
low

Damaged
steering
linkage

Wheels
out

of

proper
alignment

Wheel

bearing
out
of

adjustment

Damaged

steering
linkage

ST
9
Corrective
action

Align
or

inflate
tires

to
correct

pressure

Adjust
and

see
relative

topic
under
Front

Suspension

Repair

Repair
or
inflate
tires

to
correct
air

pressure

Replace
and
see
relative

topic
under
Front

Suspension

Align

Adjust

Replace
and

see
relative

topic
under
Front

Suspension

STEERING

SYSTEM

SPECIAL
SERVICE
TOOLS

No
Tool
number

tool

name
Description

Unit
mOl
in
For

use

on
Reference

page
or

Figure
No

ST27I80001

Steering
wheel

puller
This
tool

is
used
to

drive
out

steering
wheel

All

Fig
ST4

models

Caution
Do

not
hammer

on

steering
column
shaft

o
v

J

SE
116

2

ST29020001

Pitman
arm

puller
This
tool

is
used
to
remove

steering
pitman
arm
from

steering

sector

shaft
Fig
ST
6

SE401

3
ST3I

27S000
This
tool
is

used
to
measure

the
worm

bearing
preload

All

Page
ST
5

Preload

gauge
models

GG91030000

Torque

D

wrench

I

2
HT62940000

IJ

Socket

t

Y
ID

adaptor

114
3

8
Go

3

HT62900000
318
1
2

Socket

adaptor

4

HT72520000
This
tool
is

used
to

remove
ball

joint

All

Page
ST
6

Ball

joint
models

remover
620

B210

710

610

SE399

ST
10

CAB
BODY
Body
Frame

Ist

mounting
2nd

mounting

1
Bolt

2

Plain

washer

3
Rubber
washer

4

Upper
rubber

5
Bottom

rubber

6
Plain
w

er

7

Upper
washer

8

Lower
washer

1st

mounting

REMOVAL

AND

INSTALLATION

Remove

battery
from

engine

compartment

2

Disconnect
oil
cooler
hoses
from

radiator
automatic
transmission

model

only

3

Disconnect
air
conditioner

tubes

from

condenser
if
so

equipped

4

Drain
water
from

cooling
system

completely
and
remove
radiator

and

condenser
if
so

equipped

5

Remove

engine
hood
from
hood

hinges
after

scribing
hood
for
rein

stallation

6
Remove

bumper
stay
from
frame

and
remove
front

bumper

7
Remove

radiator

grille

8
With
the

aid
of

Steering
Wheel

Puller

ST27
180001
remove

steering

wheel
from

steering
shaft

9

Remove

steering

gear
arm
from

steering
sector
shaft

using
suitable

puller

10

Remove
screws

securing

steering

shaft
dust

seat
and
insulator
in

posi

tion
2nd

mounting

3rd

mounting

II

Remove

steering
gear

housing

from
frame
and

pull
it
out
into

engine

compartment

12

Disconnect

speedometer
cable
at

transmission

1
3

Disconnect

carbon
canister

hoses

between

canister
to

vacuum

gallery
and
canister

to
intake

manifold

at
canister

14

Disconnect
air

pump
to
air

pump
air

cleaner
hose
at
air
cleaner

15

Disconnect
air
conditioner

hoses

from

compressor
if
so

equipped

16

Disconnect
air
cleaner

duct
from

body

17

Disconnect

Master
Vac
vacuum

hose
at
intake

manifold

18
Remove

snap
ring
and
control

lever

pin
from
transmission

striking

guide
and

remove
control
lever

19
Disconnect
fuel

hoses
at
fuel

strainer

20
Disconnect
fuel

return
hose

and

evaporation
hose
at
connectors

21
Disconnect
brake
and
clutch

tubes

from
each

master

cylinder

22
Remove

all

clips
securing
fuel

tubes
brake

tubes
and
clutch
tube
at

cab

body

BF
4
BF472A

Unit
mm
in

Fig
BF
4
Cab

body
mountings

23
Loosen
hand
brake
control
cable

at
brake
control
lever

Then
discon

nect
cable
from
dash

panel

Note

Place
blocks

against
front
and

rear
wheels
to

prevent
vehicle
from

rolling
off

accidentally

24
Free

accelerator
wire
from

car

buretor

25
Disconnect

heater
hoses
at

engine
side

26
Disconnect
wire
harnesses
from

related

engine
electrical

parts

27
Disconnect

engine
and

chassis

harnesses
at
their
connection

on

right

sidemember
near

rear

engine
mounting

member

28
Remove
six

bolts

securing
body

to
frame

29
With
the
use
of
suitable

ropes

and
an
overhead
hoist
lift
cab

body

straight
up

slowly
and

place
it
on
a

level
surface

Note
In

lifting
up
cab

body
use

care

not
to

dash
it

against

engine
or
rear

body
Cab

body

weighs
approxi

mately
220

kg
485
Ib

BF646A
Body
Frame

INSTRUMENT
PANEL

1

Bracket
welded
to
dash

panel

2
Nut

3
Instrument

panel
assembly

Fig
BF
41
Instrument

panel
assembly

INSTRUMENT

PANEL

REMOVAL
AND

INSTALLATION
2

Disconnect
heater
control
cables

from
heater

assembly

3
Disconnect

speedometer
cable
on

the
back

of

speedometer

4

Disconnect
antenna
and

speaker
Disconnect

battery
cables

8F
17
wiring
harnesses
at
connectors

5

Disconnect
relative

wiring
har

nesses
from

instrument

panel
at
con

nectors

6

Remove

steering
column
shell

Removal
of

steering
wheel
at
this

stage

facilitates
further

removal
of
instru

ment

panel

7

Remove
two
side

ventilator

knobs

Remove

package
tray
attaching

bolt

and
detach

package
tray

2

I

Package
tray

2
Side

ventilator
knob

Fig
BF
42

Package

tray

8

Support
instrument

panel
assem

bly
and

remove
five

attaching
bolts

from

it

9

Withdraw
instrument

panel
as

sembly
while

lifting
it

slightly

10

To

install
reverse

the
order

of

removal

KNOB
ILLUMINATION

LAMP

The
illumination

lamp
is

located
on

the
illumination
control
rheostat

This

lamp
illuminates
the
knob
of

the

wiper
switch
and

lighting
switch

with

fiberscopes

The

fiberscopes
between
the
knobs

and

cap
of
the
illumination

lamp
carry

the

light
through
their
tubes
with
the

inner

reflective
walJ

CID

1
Bulb
socket

2

Screw

3

Lamp
body

8E705B

Fig
BE
17
Knob
illumination

lamp

BULB
REPLACEMENT

I
Reach

up
from
under
the
instru

ment

panel
and

pull
out
socket
with

bulb
from

lamp
body

2

Pick

up
bulb
and

install
a

new

one

3

Installation
is
in
the

reverse
se

quence
of

removal

LAMP
BODY
REPLACEMENT

1
Remove
illumination

control

rheostat
Refer
to
section

of
illumina

ti

on
control
rheostat
for
removal

2
Disconnect
lead
wires
for

illumination

lamp
at
connector

3
Remove
screw

retaining
lamp

body
to
instrument

panel

Lamp
body

can
then
be

taken
out

easily

4

Installation
is
in
the
reverse
se

quence
of
removal

TURN
SIGNAL
AND

DIMMER
SWITCH

REMOVAL
AND

INSTALLATION

I

Remove

steering
wheel

Refer
to
the
related
section

Steering
Body
Electrical

System

2
Unhook

wiring
assembly
from

clip
that
retains

wiring
assembly
to

lower
instrument

panel

3
Disconnect

multiple
connector

and
lead
wire

from
instrument
harness

wiring

4
Remove

shell
covers

Upper
and

Lower

5
Loosen
two
screws

attaching

switch

assembly
to

steering
column

jacket
and

remove
switch

assembly

6
Position
switch

assembly
to
steer

ing
column

jacket
Make
sure
that
a

location
tab
or
screw
fits
in

with

hole
of

steering
column

jacket
7

Tighten
two

attaching
screws

8

Install
shell
covers

9

Connect

multiple
connector
and

lead
wire

to
instrument

harness

wiring

10

Clip
wiring
assembly
at
lower

instrument

panel

II

Install

steering
wheel

INSPECTION

Test

continuity
through
lighting

switch

by
using
test

lamp
or
ohm

meter

3

terminal

4
terminal

7
terminal

Dimmer

R

STOP
LAMP
SWITCH

REMOVAL
AND

INSTALLATION

Stop
lamp
switch
is
mounted
at
the

bottom
of

pedal
and

steering
post

bracket

I
Disconnect
battery
ground
cable

2
Disconnect
lead
wires

at
coonee

tors

3
Loosen
lock
nut
unscrew
switch

assembly
and
remove
switch

assembly

4
Install
switch

assembly
as
de

scribed
under
Brake
Pedal
in

Section

BR

INSPECTION

When

plunger
is

pressed
into
switch

assembly
when
brake

pedal
is
reo

8El0
I
Ll

vt
r

I

ER
4JN
l
L

PlOSITlON

RI

j
LASH
n
I

I

12
STOP

9
91

I
JFRe

I
I

II

L
I
III
11

I

I
II
161

I
61616

BE706B

Fig
BE
IS
Turn

signal
and
dimmer
switch

leased

stop
lamp
switch
contacts
are

open
On
the

contrary
contacts
are

closed
with

plunger
projected

DOOR
SWITCH

Door
switch
is
installed
on
both

L
H
and
R
H
front
door

pillars

REMOVAL
AND

INSTALLATION

I
Disconnect

battery

ground
cable

2
To

pull
switch

assembly
out

of

lower

pillar
withdraw
switch
and

wiring
assembly

3

Disconnect
lead
wire

at
cannee

tor

4

Installation
is
in

the
reverse
se

quence
of
removal

INSPECTION

through
door

lamp
or
ohm
Test

continuity

switch

by
using
test

meter

When

plunger
is

pressed
into
switch

assembly
door

switch
contacts
are

open
Contacts
are
closed
when

plunger
is

projected

HAZARD
SWITCH

REMOVAL
AND

INSTALLATION

1
Disconnect

multiple
connector

and
lead
wire
from
instrwnent
harness

wiring

3
terminal
7
terminal

To
flasher
unit

1

terminal

4

terminal

5

terminal

6
terminal
I
TERMINAL
SWITCH

POSITION

OFF
ON

I

lli
ill

I
2

I
5

1
Hazard
flasher
unit

I
4
2
Turn

signal
flasher
unit
BE707B

I
5
Fig
BE
20
Flasher
unit

I
8

I
7

I

REPLACEMENT
Body
Electrical

System

2
Remove

shell

covers

Upper

3
Remove

two
screws

attaching

switch

to
lower
shell
cover
and
remove

switch

4
Install

hazard
switch
in
the
re

verse

sequence
of

removal

INSPECTION

Test

continuity
through
hazard

switch

by
using
test

lamp
or
ohm

meter

ON

BE308

Fig
BE
19
Hazard
switch

BE
11
FLASHER
UNIT

There
are
two
flasher
units
One
is

for
turn

signal
and
the
other
for

hazard

They
are
located

at
both
sides
of

instrument

panel
near

steering
column

They
can
be

distinguished
from
each

other

by
their

shape

The

large
one
is
for

turn

signal
the

smaller
for
hazard
See

Figure
BE

20

I
Disconnect

battery
ground
cable

2
Disconnect
connector
fitted
to

bottom
of
unit

3
Remove
screw

retaining
flasher

unit

4
Installation
is
in
the

reverse
se

quence
of
removal

Service

Equipment

Applied
Ser
77
620NA

Newly

No
Tool
Number
Tool

Name
vehicle
Class
Remarks

added

or

unit
KVOO
102000

ST31970000
Collar
All
X
2

610

ST30611000
Drive

pinion
outer
race
drift
bar
All
X
2

610

ST30613000
Drive
pinion
outer
race
drift

adapter
All
X
2

610

ST3062
1000
Drive

pinion
outer
race
drift

adapter
All
X
2

610

KV311
00300
Solid

punch
All
X
2

610
710
S30

ST3127S000
Preload

gauge
All
X
2
B21O
610
710
S30

KV381025S0
Oil
seal

fitting
tool
All
X
2
610

4

Front
axle

ST35380000
Kingpin
bushing
drift
All
X
2

HT56802000

Kingpin
bushing
reamer
All
X
2

ST36070000
Transverse
link

bushing
replacer
All
X
2

ST35390000
Kingpin

grease
seal
drift
All
X
2

5

Rear
axle

ST38020000

Bearing
lock
nut
wrench
All
X
2

KV40101000
Rear

axle
stand
All
X
2
B210

610
710
S30

ST36230000

Sliding
hammer
All
X
5

B210
610
710
S30

HT72480000
Rear

axle
shaft

bearing
puller
All
X
2

B210
610
710
S30

6

Steering

ST2902000
I
Pitman

arm

puller
All
X
2

B210
610
710
S30

ST27
180001

Steering
wheel

puller
All
X
2
FIO
B210
610
710

S30

HT72520000
Ball

joint
remover
All

X
2
FIO
B210
610
710

S30

ST3127S000
Preload

gauge
All
X
FlO
B210
610
710

S30

7

Brake

GG943
10000
Brake

pipe
torque
wrench
All
X
2

B210
610
710
S30

ST08060000
Master
Vac
oil
seal
retainer
drift
All
X
3

B210
610
710
S30

ST08080000
Master
Vac
wrench
All
X
3
B210
610
710
S30

SE
5