ECU DATSUN PICK-UP 1977 Workshop Manual

Fig
AT

96

Measuring
clearanc
Automatic
Transmission

6

u

ST255801JOO

AT264

Fig
AT

99

Measuring
runout

5

Tighten
pump
securing
bolts
to

specified

torque
0
6
to
0
8

kg
m
4

to
6
ft
Ib
Clearance

between
seal

ring
and

ring

groove
See

Figure
AT

97

Standarddearance
Note
Be
sure
to

a1ign
converter

0
04
io
0
16
mm
housing
securing
bolt

holes

0
0016
to
0
0063
in

6

Again
check
the

runout

of
oil

pump
cover

I
learance

Seal

ring

q

I

n
l

1
AT

5

Fig
AT
97

Measuring
clearance

Assembly

I

Set

up

pump
housing
with
inner

and
outer

pump
gears
on
it

2

Using
Oil

Pump

Assembling

Gauge
ST25580000

instail

pump

coverta

pump
housing
as
shown

in

Figure
A

T

98

ST

5

000

J
I

I

JL

AT166

Fig
AT
98

Centering
oil

pump

3

Temporarily
lighten

pump
secur

ing
bolts

4

Set

the
runout
of
oil

pump
cover

within

0
D7
mm
0
0028
in

total

indicator

reading
See

Figure
AT
99
Note

When
former
Oil

Pump
As

sembling

Gauge
is
to
be

used
make

a
screw
hole
in
side
of
it

PLANETARY
CARRIER

The

planetary
carrier

cannot
be

divided

into
its
individual

components

If

any
part
of

component
is

faulty

replace
the
carrier

as
a
unit

Inspection

Check
clearance

between

pinion

washer
and

planetary
carrier
with

a

feeler

See

Figure
AT

100

Standard
clearance

0
20
to

0
70
mm

0
0079
to
0
0276
in

Clearance

I

Jr

I
1

11

r

AT167

Fig
AT
100

Measuring
pinion
washer

to

ca
ier

clearance

AT
44
Replace
if

over
0

80
mm
0

0315

in

CONTROL
VALVE

The

control
valve

assembly
consists

of

many
preci
ion

parts
and

requir
s

extreme

care
when
it
has
to

be
reo

moved
and
serviced
It

is

good
practice

to

place
parts
in

a

part
rack
so
that

they
can
be

reassembled
in

valve

body

in

their

proper
positions
Added
care

should
also
be

exercised
to

prevent

springs
and
other
small

parts
from

being
scattered
and
lo
t

Before

assembly

dip
all

parts
in

clean
automatic
transmission

fluid
and

check
to
be
certain

that

they
are
free

of

lint
and
other
minute

particles
If

clutch
or
band
is

burnt
or
if
oil

becomes
fouled
the
control

valve
as

sembly
should

be

di
ssembled
and

flushed

Disassembly

I
Remove
bolts

and
nuts
which

retain
oil

trainer
Bolts

may
be
re

moved

with
a
screwdriver
but
it

is

recommended
that

Hexagon
Wrench

HT610oo800
and

Spinner
Handle

HT62350000
be
used
See

Figure

AT
101

HT61000800

Fig
AT
101

Disassembling
valve

body

2

Remove

attaching
bolts
With

bolts

removed
lower
valve

body

separate

plate
and

upper
valve

body

are
free
for

removal
See

Figure

AT
102

Note
Do
not
allow

orifice
check

vah
e

and
valve

spring
in
lower
valve

body
to
be
scattered
and
lost
when

removing
separate
plate

Using
the

tester
check
the

two

black

yellow
BY
wires
from
the
in

hibitor
switch
in
the

ranges
N

and

I
and
the

tw
re
d

black

RBj
wir
s

in

the

range
R
for

continuity
Turn

range
select
lever
in
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
30

on
both

sides
from
each
lever
set
line
How

ever
if
its

continl
ity

range
is
obvious

ly
unequal
on

both
sides

adjustment
is

required

If

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

clicking
sound

MSlVe
the

switch

slightly
asj
Je
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
mm
0
059
in
diameter

pin
into

the
holes
If

the

alignment
is
correct

fasten

the
switch

body
with
the
bolts

pull
out
the

pin
tighten

up
the
screw

in

the
hole
and
fasten
the
selector

lever
as
before
Check
the

continuity

again
with
the
tester
If

the
malfunc

tion
still

remains

replace
the
inhibitor

switch
Chcck
whether
the

reverse

lamp

and
the
starter
motor

operate
normal

ly
in
these

ranges
If
Ihere
is

any

lrouble

first
check
the

linkage
If

no

fault
is
found
in

the

linkage
check
the

inhibitor
switch

Separate
the
manual
lever
from
Ihe

remote
control
selector

rod
and
turn

the

range
selcct

lever
to

N

Note

In
the

position
N

the
slot
of

the

manual
shaft

is
vertical

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission

and

engine
for
trou

ble

by
measuring
the
maximum
num

bers
of
revolutions
of

the

engine
while
Automatic

Transmission

vehicle
is
held
in
a

stalled

condition

The
carburctor
is
in

full
throttle

opera

tion
with

the
selector
lever
in

ranges

f
2

and
I

respectively
Com

pare
the

measured
results
with
the

slandard

values

Components
to

be
tested

and

test

items

I
Clutches
brake

and
band
in
trans

mission
for

slipping

2

Torque
converter

for

proper
fune

tioning

3

Engine
for
overall

properly

STALL
TEST

PROCEDURES

Before

Icsting
c
heck
the

engine
oil

and

torque
converter

oil
warm

up
the

engine
cooling
water
to
suitable
tem

perature
by
running
at

1
200

rpm
with

the
selector
lever
in

the

range
P
for

several
minutes
Warm

up
the

torque

converter
oil
to
suitable

temperature

6010
1000C
140
to

2l20F

I

Mount
the

engine
tachometer
at
a

location
that
allows

good
visibility

fro

the
dri
er
s
seat
and

put
a
mark

on

specified
revolutions
on
the
meter

2

Secure
the
front
and
rear
wheels

with
chocks
and

apply
the
hand
brake

Be
sure
to

depress
the
brake

pedal

fumly
with
the
left
foot
before
de

pressing
the
accelerator

pedal

3
Throw
the
selector
lever
into

the

range
1

4

Slowly
depress
the
accelerator

pedal
until
the

throttle
valvc
is

fully

opened

Quickly
read
and
record
the

engine
revolution
when

the

engine

begins
to
rotate

steadily
and
then

release
the
accelerator

pedal

5

Shift
the
selector
lever
to
N

and

operate
the

engine
at

approxi

mately
1
200

rpm
for
more
than
one

minute

to
cool
down
the

torque
con

ver
ter
oil

and
coolant

6

Make
similar
stall
tests
in

ranges

2
I
and
RIO

Note
The
stall
test

operation
as

speci

f
d
in
item
4

should
be

I
l3de

wiihin
five
seconds
If
it

takes
too

long
the
oil
deteriorates
an

the

clutches
brake

and
band
are
ad

versely
affected
Sufficient
cooling

time
should
be

given
between
each

AT
5O
test
for
the
four

ranges
0
2

I
and
R

JUDGEMENT

High
stall
revolution
more

than

standard
revolution

If
the

engine
revolution
in
stall

condition
is

higher
than
the
standard

values
it

indicates
that
one

or
more

clutches
in

the
transmission
are

slipping
and
therefore
no
further
test

is

required

For
the

following
abnormalities

the

respective
causes
are

presumed

High

rpm
in

all

ranges
low
Iine

pressure

High
rpm
in
D
2
and
I

and

normal

rpm
in
R
Rear
clutch

slipping

High
rpm
in
0

and

normal

rpm
in
I

clutch

slipping

High
rpm
in
R

only
Front

clutch
or
low
and
reverse

brake

slipping

To

determine
which
is

slipping

front
clutch
or
low

and
reverse
brake

a
road
test
is
nceded

If
whilc

coasting
after

starting

with
the
lever
in
1

range
engine

braking
does

not
work

properly
the

low
and

reverse
brake
is

slipping

Otherwise
the
front
clutch
is

slipping

Slipping
of
the
band
brake
is

diffi

cult
to
ascertain

However
if
it

occurs

with
the
lever
in
2

range

engine

revolution
increases

Jp
to
thesarne

level
as
in

I

strange
It

is

impossible

to
check

it
in
the
stall
test
2
and

One

way

2
Standard
stall
revolution

If
the

engine
revolution
in

stall

condition
is
within

the
standard

values
the
control
elements
are

nor

mally

operating
in
the

ranges
0

2
I

and
R

Also

tIle

engine
and
one

way

clutch
of
the

torque
converter
are

normal
in

performance
and

operation

The
one

way
clutch
of

the

torque

converter
however
sometimes

sticks

This
is
determined
in

the
road
test

3
Lower
stall
revolution
than
stand

ard
revolution

If
the

engine
revolution
in
stall

condition
is

lower
than
the
standard

PROPELLER
SHAFT
DIFFERENTIAL
CARRIER

REMOVAL

I
Jack

up
rear
of
vehicle
and

sup

port
it

by
placing
a

safety
stand
under

rear
axle
case
Drain

gear
oil

2
Remove

propeller
shaft
and
rear

axle
shafts
These
works
can
be
done

by
referring
to
Rear
Axle
and
Rear

Suspension

3
Loosen
off
bolts

securing
differ

ential
carrier
to
rear
axle
cas
and

take
out
differential
carrier

assembly

PRE
DISASSEMBLY

INSPECTION

Differential
carrier

should
be
in

spected
before

any

parts
are
removed

from
it

These

inspections
are

helpful
to

fmd
the

cause
of
a

problem
and

to

determine
the
corrections

needed

I

Mount
differential
carrier
on
Dif

ferential
Attachment
ST063
I
0000

ST063
10000

Fig
PD
7

Holding
differential
can
ier

2

Visually
inspect
parts
for
wear
or

damage

3

Rotate

gears
to
see
if
there
is

any

roughness
which
would
indicate
dam

aged
bearings
or

chipped
gears
Check

the

gear
teeth
for

scoring
or

signs
of

abnormal
wear

Measure

preload
of

drive

pinion
See

Figure
PD
19

4

Set

up
a
dial
indicator
and
check

the
backlash
at
several

points
around

ring
gear
Backlash
should
be
0
15

to

0
20
mOl
0
00S9
to
0
0079
in

S
Check
the

gear
tooth
contact

with
a
mixture
of
ferric
oxide
and

g
ar
oil
to
all

ring
gear
teeth

For
the
tooth
contact

pattern
see

paragraph
dealing
with
tooth
contact

pattern
adjustment
DISASSEMBLY

I
Put
match

tpark
on
side

bearing

caps
and
carrier
and

remove
side

bearing
caps
and
take
out

differential

case
assembly

P0203

Fig
PD

B
Removing
differenlwl

case
assem

bly

Note
Care

should
be

taken
not
to

confuse
the
left
and

right
hand

bearing

caps
and

bearing
outer
race

so
that

reassembly
will
be

easily

carried
out
with
the
same
parts
in

the

original
position

2
Remove

drive

pinion
nut

using

Drive
Pinion

Flange
Wrench

ST31530000
and

pull
off

companion

flange
using
a
standard

puller

Fig
PD
9

Removing
drive

pinion

nul

3

Extract
drive

pinion
assembly
to

the
rearwards

by
tapping
the
front
end

with
a
soft
hammer
Drive

pinion
can

be
taken
out

together
with
rear
bear

ing
nner
race

bearing
spacer
and

washer

4
Remove
oil
seal
and
take
out

front

bearing
inner
race

Note
Oil
seal
must
not
be
used

PD
7
5

Hold
rear

bearing
inner

race
with

Drive

Pinion
Rear

Bearing
Inner

Race

Puller
ST30031000
and
extract
from

drive

pinion
with
a

press

STJ0031000

PD205

Fig
PD
10

Removing
pinion
rear

bearing
inner
race

6
To

remove
outer
races
of
both

front
and
rear

bearing
apply
a

brass

drift
to

race
side
surface
and
with

draw

them

by
tapping
the

top
of
drift

with
a
hammer

Fig
PD
l1
Removing

pinion
front
and

rear

bearing
outer
races

Dissssembly
of
dHferentIeI

case

1
When

replacing
side

bearing
use

Differential
Side
Bearing
Puller
Set

ST3306S00
I

set
of
ST330S100
I

and

ST33061000

Fig
PD
12

Removing
ide

bearing

PROPElli

ER
SHAfT
DIFFERENTIAL
G

ARRIERf

Notes

a
PUller
should
be
handled
with

care

in

catchins
the

edge
of

bearing

inner

race

b
Be
careful

not
to

confuse
left
and

right
hand

parts

2
Remove

ring

gear
by
spreading

out
lock

strap
and

loosening
ring
gear

bolts
in

diagonally

3

Punch
off

pinion
mate

shaft
lock

pin
from

ring

gear
side

using
Solid

Punch
ICV31100300

KV31100300

PD022

Fig
PD

13

Removing
lock

pin

Note

Lock

pin
i
cauIked
at

pin
hole

mouth
on
differential
case

Do
not

punch
it
off

forCibly
without

checkins
how
it
is
uIked

4

Draw

out

pinion
shaft
and

re

move
thrust

block

pinion
mates
side

gears
and

thrust
washers

Note
Put
marks

on

gear
and
thrust

Wasliersotliat

they
can
be
reinstaD

ed
in

their

original
positions
from

which

they
were
removed

INSPECTION

Thoroughly
clean

all
disassembled

parts
and
examine

them
to
see
if

they

8re

worn

damaged
or
otherwise

faulty
and

how

they
are
affected

Repair
or

replace
ail

faulty

parts

whichever
is

necessaiy

I

Check

gear
teeth
for

scoring

cracking
and

chipping
and

make
sure

that

tooth
contact

pattern
indicates

correct

meshing
depth
If

any
fault
is

evident

replace
parts
as

required
Note
Drive

pinion
and

ring
gear
are

supplied
for

replacement
as
a
set

therefore

should
either

part
be

damaged
replace
as
a
set

2

Check

pinion
shaft
and

pinic
m

mate
for
scores

and

signs
of
wear
and

replace
as

required

Follow

the
same

procedure
for

side

gear
and
their
seats

on
differential

case

3

Inspect
all

bearing
races
and

rollers
for

scoring
chipping
or
evi

dence
of
excessive
wear

They
should

be
in

tiptop
condition
such
as
not

worn
and

with
mirror
like

surfaces

Replace
if
there
is
a
shadow

of
doubt

oil

their
efficiency
as
an
incorrect

bearing
operation
may
result
in
noises

and

gear
seizure

4

Inspect
thrust

washer
faces

Small

faults
can

be
corrected
with

sand

paper
If

pinion
mate

to
ide

gear

backlash
or

the
clearance

between

side

gear
and
thrust
washer
exceeds

limits
0

02

to
0
08
nun
0
0008
to

0
0031
in

replace
thrust
washers

S

Inspect
carrier

and
differential

case
for
cracks

or
distortion

If
either

condition
is

evident

replace

faulty

parts

6
As

a

general
rule

oil
seal
should

be

replaced
at
each

disassembly

ASSEMBLY

AND

ADjUSTMENT

Assembly
can
be

done
in

the

reo

verse

order
of

disassembly
The
foDow

ing
directions
for

adjustment
and

usage
of

special
tools
enable
to

obtain

a

perfect
differential

operation

PRECAUTIONS
IN

REASSEMBLY

I

Arrange
shims
w

shers
and
the

like
to
install
them

correctly

2

Thoroughly
clean

the
surfaces
on

which
shims

washers

bearings
and

bearing

caps
are
installed

3

Apply
gear
oil

when

installing

bearings

4

Pack

grease
cavity
between

lips

when

fitting
oil
seal

PD
8
ASSEMBLY
OF

DIFFERENTIAL
CASE

I

Assemble

pinion
mates
side

gears
thrust
block
and

thrust
washers

in
differential

case

2
Fit

pinion
shaft
to
differential

case
so

that
it

meets
lock

pin
holes

3

Adjust

pinion
mate

to
ide

gear

backlash
or
the
clearance

between
the

rear
face
of

side

gear
and
thrust

washer
to
0
02
to

0
08
mOl
0
0008

to
0

0031
in

by

selecting
side

gear

thrust
washer

Side

gear
thrust

WlISber

Thickness

nun

in

Over

0
7S

to
0
80

0
029S
to
0
03IS

Over

0
80
to
O
8S
Om

IS
to
0
033S

Over

0
8S
to
0
90
0

033S
to
0
03S4

Over

0
90
to
0
9S
0
03S4

to
0
0374

4

Lock

pinion
shaft
lock

pin
using
a

punch
after
it

is
secured
into

place

S

Apply
oil
to

gear
tooth

surfaces

and
thrust
surfaces
and
check
if

they

turn

properly

6
Place

ring

gear
on

differential

case

and
install

bolts
and
lock
washers

Torque
bolts
to

specification
and

bend

up
lock

strap

Tightening

torque

7
0
to
8
0

kg
m

S1to
Sifft
Ib

Notes

ao
Use

only
genuine
ring
gear
bolts

and
new
lock

strap

b

Tighten
bolts
in

criss
cross
fashion

lighdy
tapping
fOund
bolt

heac
Js

with
a
hammer

7

When

replacing
side

bearing

measure

bearing
width

using
a

stand

ard

gauge
20
00
nun
0
7874
in

thickness
and
a

weight
block
2
5

kg

S
S
Ib

prior
to
installation
See

Figure
PD

I4

Standard
bearing
width

20
00
nun
0
7874
in

P
ROPELLER
SHAFT
DIFFERENTIAL
CARRIER

c
Flank
oontact

Adjust
in

the
same
manner
as
in

b

cV

t

PD195

Fig
PD
25
Flank
contact

d
Face
contact

Adjust
in
the

same
manner
as
in

a

P0196
t

Fig
PD
26
Face

contact

e
Correct
tooth
contact

Fig
PD
27
Correct

contact

Note

Change
in
thickness
of

adjWll

ing
washer
is

accompanied
by

change
in
backlash
Oled
it
when

instaIIi
gear
INSTALLATION

Installing
can
be

done
in
the
reverse

order
of
removal

Tightening
torque

Gear
carrier
to
rear
axle
case

1
7

to
2
5

kg
m

12
to
18
ft
lb

Drain
and
filler

plug

6
0
to
10
0

kg
m

43
to
72
ft
lb

Gear
oil

capacity
1
0
liter

2
US

pt
I
Y

Imp
pt

REPLACEMENT
OF

FRONT
OIL
SEAL

Replacement
of
front
oil

seal
with

d
ifferential
carrier

assembly
installed

on
the
vehicle

When

replacing
front
oil
seal

do
as

follows

1
Drain

gear
oil

2
Raise

the
rear
end
of

vehicle

and

support
it
with

safety
stands

3
Detach

propeller
shaft
from
com

panion

flange
of
carrier

4

R
1
ove
drive

pinion
n
t

holding

companion
flange
with
Drive
Pinion

Flange
Wrench

ST31S30000
P0238

Fig
PD

29
Removing
companion

flange

6
Remove
oil
seal

7
Set

new
oil
seal
in

position
using

Oil
Seal

Fitting
Tool

KV38102SS0

Apply
grease
in
between
seal

lips

8
Fit

companion
flange
and
flat

w

sher
on
drive

pinion
and
secure

them
in

position
by
tightening
nut
to

the

given

torque
confirming
specified

preload
using
Drive
Pinion

Flange

WrencliST31530000

Tightening
torque

14
0

to
17
0

kg

101
to
123
ft
Ib

Pinion

bearing
preload

with
oil
seal

11
0
to
14
0

kg
cm

9
5
to
12
in
lb

At

companion
flange
bolt
hole

3
1
to
4

o
g

6
8
8
8Ib

Notes

a
Preioad
of
old

bearing
is
the
same

value
as
that
of

a
new
bearing

b
If
the
desired
nut

tightening
torque

P0237
can
ot
be
obtained
renew
nut
and

readjust

Fig
PD
28
R

moving
drive

pinion

nut

S
Extract

companion
flange

using
a

standard

puller

PD
13
8
Reinstall

propeller
shaft
and
fill

up
differential
carrier

with

gear
oil

The

design
of
the
front

suspension

adopts
the

independent
double

wishbone

type
suspension
used
the

torsion
bar

spring
Both
the

upper
and

lower
links

are
installed
on
the
bracket

which
is
welded
on
the
frame

A
1d
the

above
links

swing
to
allow
the
knuckle

spindle
to
move

freely
in
a
vertical

dimension

The

top
and
bottom

of
the
knuckle

spindle

support
are
connected
to
the

upper
link

through
rubber

bushing
and

to
the
lower
lick

through
screw

bushing

The
tension

rod
held

by
the
brack

ets
on
the
chassis
frame
and
lower
lick

wiih
rubber

bushings
bears
the
force

of
fore
and
aft
direction

The
front
end

of
the
torsion

bar

spring
is

installed
to
the

torque
arm

which

attaches
to
the
lower
link
The

opposite
end
is

installed
to
the

spring

anchor
that

secures
to
chassis
frame

firmly
The
both
ends
of

the
torsion

bar

spring
are
serrated

The

shock
absorber
is

double

action

telescopic

hydraulic
type

The

upper
stem
is
attached
to
the

bracket
of
the
chassis
frame
The

lower
insulated
bracket
is

bolted
to

the
lower
lick

The

bumper
rubber
secured
to
the

bracket
Of
the
frame
limits
the
verti

cal
motion
of
the

suspension
lick

The
knuckle

spindle
is

connecied
to

the
k

ufkle
spindle
arm

by
the

king

pin
The

king

pin
bushings
are
fitted

to

the

upper
and
lower
arm

portIOns
of

the
knuckle

spindle
and

seals
are

provided
at
the

portions
mentioned
to

keep
water
and

dirt
from
enteri

g

The
knuckle
arm
is

connected
to

the
lower
end
of
the
knuckle

spindle

to
transmit

ttLe
movement
of
the

steering
wheel
to
the
knuckle

spindle

The
wheel
hub
is

supported
by
two

taper
roller

bearings
on
the

knuckle

spindle
Tlie
brake
drum
and
wheel
are

secured
to
ihe
hub

by
the

hub
bolts
Front
Axle
Front

Suspension

FRONT
AXLE

REMOVAL
AND

INSTALLATION

Removal

I
Jack

up
and

support
vehicle
on

the
stands

at
the
frame
in

a
safe

manner

2
Remove

front
wheel

3
Re

ove
brake
hose

together
with

connector
from
wheel

cylinder

4
Remove

brake
drum

S

Remove
hub

cap
and
then

remove

cotter

pin
adjusting
cap
and

spindle

nut
from
knuckle

spindle

6
Remove
wheel
hub
outer
and

inner

wheel

bearings
bearing
washer

and

grease
seal
from
knuckle

spindle

7
Remove
brake
disc

assembly
from

the

flange
of
knuckle

spindle

8

Remove
knuckle
arm
from

knuckle

spindle

9
Remove

king
pin
lock
bolt

FA225

Fig
FA
R

mol1ing
king
pin
loch
nut

10
After

removing
air
breather
re

move

plug
from
the

top
of

king
pin

with
the

following
method
Drill
a

10
5
mm
0
413
in

diameter
hole
on

the

plug
thread
hole
with
a

tap

M
12
1
2S
screw
a
bolt
into
threaded

hole
and

pull
out
the

plug

II

Apply
drift
to
the

top
of

king

pin
and
drive
out

king
pin
along
with

lower

plug

12

Tap
spindle
with
a
soft
haJnmer

and

detach
it
from
knuckle

spindle

support
Take

care
not
io

drop
thrust

bearing

FA
3
FA226

Fig
FA
3
R

moving
knuckle

piridle

Installation

Install
front
axle
in
reverse
se

quence
to
removal

by

noting
the
fol

lowing
matters
Furthermore

when

installing
front
axle

lightly
coat

grease

to

sliding
parts

I
Insert

O

ring
on
the
lower
end
of

knuckle

spindle
support
Install
thrust

bearing
and

spindle
shim

together
with

knuckle

spindle
to
knuckle

spindle

support

In

this

operation
select

spindle

shims
to
obtain
the

specified
clearance

between
knuckle

spindle
and
knuckle

spindle
support
To

measure
the
Clear

ance
with

a
filler

gauge
jack
up
the

bottom
of

spindle
slightly

Standard
clearance

0
1

mOl
0
004
in
or
less

Note
Be

sure
to
iristsll
thrust

bearing

to
face
coverea
side

upward

2
Line

up
locking
bolt
hole
of

knuckle

spindle
support
with
the

notch
in

king
pin
and

secure
lock
bolt

Be
sure
to
check
killJckle

spindle
for

smooth
movement
Be

certain
to
move

knuckie

spindle
smoothly
and

reailjust

shim
if

necessary
In
addition
check

bushings
and

king
pin
as

required

3
Press
fit

plug
to
the

upper
of

knuckle

spindle
Then
install
lower

plug
to
the
lower
knuckle

spindle

Note
Make
sure
to

place
lower

plug

conectly

4

Secure
knuckle

arm
to
knuckle

spindle
and

torque
bolt
to
10
3

to

12
1

kg
m
75
to

88
ft

lb
Bend

lock

plate
to

engaged
flats
on
boll
head

Note

When
disassembled
discard

used
lock

plate

5

Pack

grea
to
the

upP
r

and

lower

bushings
on

knuckle

spindle

until

grease
c
omes
out

from

gr
ease

seal

6
Fill
wheel
hub
and

cap
with

grease

up
to
the

described
level
See

Figure
F
A
4

FA141

Fig
FA
4

Gre
ing
wheel
hub

7
Pack

roller
and
cone

assembly

and
the

cavity
of

grease
seal

lip
with

grease

8
Coat

grease
to

the
thread
of

knuckle

spindle

bearing
washer
and

bearing
lock
nul

9
Secure
wheel
hub

bearings
bear

ing
washer
and

spindle
nut
on
knuckle

spindle
and

adju
t

bearing

preload

referring
to

the

paragraph
Wheel

bearing
adjustment

Note
Be

sure
to
obtain

correct

pre

load

on
wheel

bearings
for
the

pu
rpose
of

ving
their

long
life

taking
care
to

keep
wheel

be8rlngs

grease
seal

bearing
washer
and

spin

dle
nut
clean
when

installing
them

WHEEL

BEARING

D

TM
NT

Wrong

adjustment
of
wheel
bear

ing
causes
abnonnal
wear
and
score

on
the

bearings
and
knuckle

spindle
Front
Axle
Front

Suspension

To
attain

proper
preload
on
wheel

bearings

proceed
the

following

opera

tions

I

Torque
spindle
nut

to
3

0
to
3
S

kg
m
22
to

25
ft
lb

using

torque

wrench

FA227

Fig
FA
5

Tightening
apindle
nut

2

Rotate
wheel

hub
a
few
turns

clockwise
and

counterclockwise
to

seat

bearings
Then

retighten
spindle

nut
to
the
same

tightening

torque
Be

certain

to
rotate
hub

smoothly

3

Back
off

spindle
nut
in

range

from
40
to
70

degrees
Locate

adjust

ing
cap
on

spindle
nut

so
as
to

align

the
castellation
on

the

cap
with

the

cotter

pin
hole
in

the

spindle

4

Check
the
hub
rotation

If
hub

rotates

properly
measure

bearing
rota

tion

starting
torque
If
measured

torque
is
deviated
from

the

specified

value
r

place
beari

gs
r
re

dju
st

The

starting

torque
can

be
mea

sured

by
a

spring
balance
as
shown
in

Figure
F

A
6

Spring
balance

indication
at
hub
bolt

New

bearing

2
1

kg
4

Ib
o

ess

Used

bearing

1
0

kg
2
2
lb
or

less

Notes

a

When

measuring
the

starting
force

pull
the

spring
balance
toward
tan

gential
direction

against
normal
line

connected
between
hub
boll
and

spindle
center

b

Axial

play
is

permissible
to
exist

in

0
1
mm
0
004
in
or
less

FA
4
fA22S

Fig
FA
6
Mea

uring
bearing
rotation

atarting
torque

S

Install

a
new
cotter

pin
Bend

the

ends
of
coller

pin
around
the

castel

lated

flange
of

adjusting
cap
Then

install
hub

cap

DISASSEMBLY
AND

ASSEMBLY

Knuckle

spindle

I
Drive

spindle
bushing
and

grease

seal
out
of
knuckle

spindle
with

KiTlg

Pin
Bush
Drift

ST3S380000
Discard

bushing
and

grease
seal
when

disas

sembled

2

After

cleaning
king
pin
bores

thoroughly
install

bushing
carefully

by
using
the
above

special

tpol
Posi

tion

bushing
in

accordance
With
the

instructions
fIlled
in

Figure
F
A

7
and

FA
8

34
mm

1
34
in
Upper
side
in

lower
boss

I

I

1

II

I
Pla
ce
this

position
in
line
with

grease
nipple
hole

Upper
side
in
upper
boss

FA229

Fig
FA
7

King
pin
bu

hing

SHOCK
ABSORBER

REMOVAL
AND

INSTAUATION

1
Raise
vehicle
on
a
hoist
or
stands

2
Remove

wheel

3
Hold
the

upper
stem
of
shock

absorber
and

remove
outs
washer

and

rubber
bushing

4

Remove
bolt
from
the
lower
end

of
shock
absorber

FA232

Fig
FA

13
Shock
absorber

S
Retain

lower
rubber

bushing
in

position
install
the

lower
end
of
shock

absorber
to
the
bracket
of
lower
link

and

torque
the
bolt

to
3

1

to
4

1

kg
m

23
to
30
ft
lb

Note
Insert
the
bolt
from
the
front

side
of
vehicle

6
Install
the

upper
end
of
shock

absorber
to

body
bracket
and

tighten

lock

n
Jt
to
the

specifjcations

Tightening
torque

1

6
to
2

2

kg
m
121016
ft
lb

INSPECTION

I

Check
shock
absorber
for
visible

defects
and
oil

leaks
Place
shock

absorber

vertically
in

a
vise
and
hand

stroke
shock
absorber

as
outlined
be

low

Extend
and

compress
shock
ab

sorber

as
faI

as

possible
travelling
as

long
as

possible

If
smooth

hydraulic
resistance
is

not

present
in

bqth
Iirection
replace

absorber

2

Replace
rubber

bushing
if
crack

or
deterioration
is
detected
Front
Axle
Front

Suspension

Specifications
for

shock
absorber

Model

Item

Piston
stroke

mm
in

Damping
force

kg
lb

0
3

m
sec
0

98
ft
sec

j

Rebound

Compression

STABILIZER

REMOVAL

AND

INSTAUATION

I

Raise
vehicle
on
a

hoist
or
stands

2

Remove
wheel

3
Loosen

secUring
nut
at
the
lower

link
side
of

stabilizer

4

Remove
bolt

securing
stabilizer

mounting
bracket

to
chassis
frame

Install
stabilizer
in

the
reverse
se

quence
to
removal

noting
the
follow

ing
instructions

S
Attach
stabilizer

mounting
brack

et
to
chassis
frame

tightening
bolt
to

1
6
to
2
2

kg
m
12

to
16
ft

lb

torque

6
Install
stabilizer
lower
link
side

to

connecting
rod
and

tighten
nut
to
the

specifications
as
shown

in

Figure

FA
14
Then

torque
lock

nut
toJ
6

to

2
2

kg
m
12
to

16
ft
lb

F

A233

Fig
FA
14
Stabilizer
detail

INSPECTION

Check

stabilizer
for
deformation

FA
S
All
models

110
4
3

76
168

38
84

and
rubber

bushings
for

crack
wear

and
deterioration

Replace
if
ne

cessary

TENSION
POD

REMOVAL
AND

INSTALLATION

I

Raise
vehicle
on

a
hoist

or
stands

2
Remove

wheel

3

Remove
nuts

CD
from

both
ends

of
tension

rod

4

Remove
bracket
bolt

@
from
the

front
end
of
tension
rod
and
remove

tension
rod

with
bracket

CD

@

f
A234

Fig
FA
15
Ten
ion
rod

Install
tension

rod
in

reverse
00

qunce
to
removal

noting
the

following

instructions

UPPER
AND
LOWER

LINKS

REMOVAL
AND

INSTALLATION

Removal

I
Raise

vehicle
on
a
hoist
or

stands

2
Remove
wheel
and

brake
drum

as

an

assembly

3
Remove
wheel
hub
Refer
to
see

tion
Front
Axle

4

Loosen
bolts

retaining
brake
disc

to
knuckle

spindle
and

remove
brake

disc

5
Remove

knuckle
arm
torsion
bar

spimgJ
stabilizer
shock

absorber
and

tension

rod
in

t
ili
order

referring
the

related
sections

6
Remove

upper
fulcrum
bolt
se

curing
knuckle

spindle
support
to

upper
link

assembly
and
disassemble

them

7
Remove

upper
link

bushings
from

knuckle

spindle
support

8

Remove
screw
bushings
from

both
ends
of
lower
link
fulcrum

pin

9
Loosen
nut
at
lower

portion
of

knuckle

spindle
support
from
inside

and

pull
out
cotter

pin
retaining
ful

crum

pin

10
Pull

out
fulcrum

pin
with

drift

and
remove
knuckle

spindle

support

with
knuckle

spindle
from
lower
link

Then
detach
dust

cover

FA237

Fig
FA

19

Removing
fulcrum
pin

II

Remove
bolts

retaining
upper

link

spindle
and
remove

upper
link

spindle
with
camber

adjusting
shims

from

body
bracket
FrClnt

Axle
Front

Suspension

FA238

Fig
FA

20

Removing
upper
link

spindle

12
Remove
nut

retaining
lower
link

spindle
and
remove

lower
link

spindle

Remove
lower
link

with

torque
arm

from

mounting
bracket

13

Using
Transverse
Unk

Bushing

Replacer
ST36070000
to

lower
link

bushing
tap
it

with
a

hammer
and

drive

out
lower

link

bushing
from

bracket

F

A239

Fig
FA

21

Removing
lower
link

bushing

InstallatIon

Install

upper
and

lower
links
in

the

reverse

sequence
to
removal

noting

the

following
instructions

I

When
the

collar

inside
of

lower

link

mounting
bracket
and

bushing

outside

are
rusted

remove
rust
with

emery

paper

2

Fit
lower
link

bushing
into
lower

link

mounting
bracket

using
Trans

verse
Link

Bushing
Replacer

ST36070000
When

tapping
the
frift

with
a
hammer
be
careful

to
hit
the

drift

squarely

3

Secure
lower
link
to
lower
link

bushing
with
lower
link

spindle
and

torque
nut
to
74

to
8
0

kg
m
54

to

S8
ft
Ib

1

4
1n
4
Install

upper
link

spindle
to

upper

link

mounting
bracket
with

used

camber

adjusting
shims
and
bolts

Torque
bolt
to
7

0
to
9
0

kg
m
SI

to
6S
ft

lb

S

Install
dust
seat
to

the
lower
end

of

j
nuckle

spindle
support

6
Coat

grease
on
the
thread
of

fulcrum

pin
and
line

up
the

notch
of

fulcrum

pin
with

knuckle

spindle

sup

port
for

inserting
cotter

pin
Fit

fulcrum

pin
to

spindle
support
with
a

soft
hammer
Secure
cotter

pin
and

torque
lock
nut
to
0
8

to
1
1

kg
m

S
8

to
8
0
ft
lb

7

Coat

grease
to
the
tIuead

portion

of

screw

bushing
inside

liberally
Posi

tion

knuckle

spindle
support
at
the

center
of
lower
link
and
secure
screw

bushings
temporarily
by
hand
Mter

ascertaining
the
dimensions
become

correct
as
shown
in

Figure
F
A

22

torque
screw

bushings
to
20
to
30

kg
m

I4S
to
217
ft
lb

3

9
05
to

11
05

36
5
9
05
to
11
05

0
3563
to
0
4350

1
431
0
3563
to

0
4350

FA240

Fig
FA
22
In

tailing
IICrew
bu

hing

8

Replace
filler

plug
with

grease

nipple
and

pack
grease
until

grease

comes
out
from
dust
cover
Reinstall

filler

plug

9

Upon
installation
make
sure
that

fulcrum

pin

operates
smoothly
with

the

following
torque

Operating
torque

Less
than
0
5

kg
m
3
6
ft
lb

10
Install

upper
link

bushing
to

knuckle

spindle
support

I
I
Install
knuckle

spindle
support

to

upper
link
insert
fulcrum
bolt
and

torque
nut
to
3
9

to
S
3

kg
m
28
to

38
ft
lb

Note
When

installing
fulcrum

pin

insert
it

from
rearward

of
vehicle

12

Install

tension
rod
shock
ab

sorber

I
stabilizer
torsion

bar

spring

and

knuckle
arm

referring
to
the

related

paragraphs

13

Install
brake
disc

to
knuckle

spindle
and

torque
securing
bolt
to
4
2

to
5

0

kg
m
30

to
36
ft
Ib

14

Install
wheel
and
brake

drum
as

an

assembly
and

torque
knuckle

spin

dle

nut
to
8
0

to
9
0

kg
m
58
to
65

ft
Ib

DISASSEMBLY

AND

ASSEMBLY

Upper
link

I

Detach

upper
link

spindle
from

upper
links
and

remove

clamp
dust

cover
and
dust
seal
Secure

upper
link

in
a
vise
and

loosen
screw

bushing

Assemble
link

spindle
in
reverse

sequence
to

disassembling
noting
the

following
instructions

2

Torque
screw

bushing
on

upper

link
to
3S
to

55

kg
m
253
to

398

ft
Ib

Install
new
dust
seal
and
dust

cover
and
secure
them
with

clamp

3

Coat

grease
to

screw

bushing
in

side
and
the
thread

portion
of

upper

link

spindle

liberally
Screw
front
and

rear
links
to

upper
link

spindle
in
the

same

length
so
as
to
obtain

the

speci

fied

figures
as
shown
in

Figure
FA

23

Unit
mm
in

I

44

6
1
156
FA2

Upper
link

and

upper
link

spindle
Fig
FA
23
Front
Axle
Front

Suspension

4

Make
sure
to

operate
upper
link

spindle
smoothly
after

installation

5

Replace
filler

plug
with

grease

nipple
and

pack
grease
until

grease

comes
out
from

dust
cover

Reinstall
f1ller

plug

Lower
link

When

installing
torque
arm
on

lower
link

tighten
it

to
the

following

specifications

Serration
boss

1
8

to
2

6

kg
m

13
to

19
ft

Ib

Arm

head

2
7

to
3
7

kg
m

20
to

27
ft
tb

INSPECTION

Upper
link

spindle
fulcrum

pin

and
screw

bushing

Apply
screw

bushing
to

upper
link

spindle
or
fulcrum

pin
and
measure

axial
end

play
between

them

When
the
end

play
exceeds
0
35

mm
0

0138
in

replace

upper
link

spindle
or
fulcrum

pin
together
with

screw

bushings

Condition

Vehicle

empty
no

payload

Vehicle
loaded

Notes

a
Vehicle

empty
no

payload
consists

of
the

following
conditions

I
Full

tank
of

gasoline
radiator

f1lled
and

engine
oil
level
full

2

Spare
tire
wheel

jack
and

jack

handle
in

design
position

b
Vehicle
loaded
consists
of
the
fol

lowing
conditions

For
all
models
2

persons
and
SIlO

leg
I
103lb

payload

FA
Check
the
screw
of

upper
link

spindle
fulcrum

pin
and
screw
bush

ing
and

repair
or

replace
if

necessary

Note

Discard
dust
cover
and

dust
seal

when
disassembled

ADJUSTMENT

VEHICLE
POSTURE

Vehicle

posture
may
be
incorrect

due

to
weakened

spring
or

other

faulty

condition
The

following
procedures

are

necessary
when

adjustment
is

Ie

quired

That
is

the
vehicle

posture
can
be

adjusted
by

obtaining
only
the

speci

fied
H

dimension

changing
the

length
of
anchor
bolt

I

Raise
front
of
vehicle

on
stands

2

Adjust
H

dimension
with

turn

ing
nut

adjusting
anchor
bolt
H

dimension

changes
approximately
3
5

mm
0

J38
in

vertically
when

adjust

nut
is
turned

one

complete
turn

3
To

make
the
best

vehicle

posture

H
dimension
must
be
in
the
follow

ing
range

H

dimension
mOl

in

All
models

79
to

84
3

11
to
3
31

54
5
2

15

o
i

Fig
FA

24
FA242

Dimension

for
standard

vehicle

postl4re