lock DATSUN PICK-UP 1977 Repair Manual

W
t
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l
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t

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tl
onitotifl

circuit

Ratt
e
cump
LOCK
preyen
tn

circuit
f

l
o1
unl
l
EE44

f
o
o

Fig
ER
2
ER207

Removing
front
engine

mounting
bolts

20
Place
a

jack
under
transmission

and

jack
it

up

21
Loosen

two
rear

engine
mount

ing
bolts

CD

22
Loosen
two

exhaust
tube

hanger

bolts

V
California
models

only

23
Remove
four
bolts

CID
securing

engine
mounting
rear

support
to
side

member
and
detach
rear

support

j
r

O

1

ER271

Fig
ER
3
Removing
rear

engine

mounting
support

24
Remove

steering
idler
arm
secur

ing
bolts
and

push
down

cross
rod

iC

EA278

Fig
ER

4
Removing
idler
arm

25
Pull

engine
towards
front
as
far

as

possible
and

carefully
raise
if
and

transmission
with
a
hoist
and
cable

Note
In

this

r
an

care
should

always
be
taken
not
to
allow
the

unit
to
hit

against
any

adjacent

parts
Engine
Removal
Installation

INSTALLATION
E
R367

Fig
ER
5
Lifting
engine

Install

engine
with
transmission
in

reverse
order
of

removal

observing
the

following

I
When

installing
first
secure

rear

2

Front

1
Bracket
R
H

2

Insulator
R
H

3
Bracket
LH

4

Heat
shield

plate

5
Insulator

L
H

6
Rear

support

7
Rear
insulator

8
Exhaust
tube

hanger

California
models

only
engine
mounting

support
to

body

2
Refer
to

applicable
section
when

installing
and

adjusting
any
parts

@

E

A279

Fig
ER

6
Structual
view

of
engine
mounting

ENGINE
MOUNTING

INSULATORS

Three
insulators
are
used
to

mount

the

engine
and
transmission

two
are

located
at

the
left
and

right
of
the

cylinder
block
and
one
at
the
transmis

sion

rear
extension

housing
Replace
any
insulator
that
shows

signs
of

separation
or
deterioration

Be
sure
to

keep
insulator
free
from

oil

or

grease

ER
3

Engine
Removal
Installation

FRONT

INSULATOR

Removal
and
installation
7
To

install
reverse
order
of

re

moval

1

Disconnect

battery
ground
cable

2
Remove

hood

3

Suspend
engine
with
wire
or

chain

4
Loosen
front

engine
mounting

insulator

upper
nuts

both
sides

5

Carefully
raise

engine
a
little
with

a
hoist
and
cable

6
Remove
front

mounting
insula

tors
at
front

supports
after

removing

front

mounting
bolts
REAR
INSULATOR

Ramoval
and
Installation

1

Place
a

jack
under
transmission

TIGHTENING

TORQUE

Fixing
bolts
and
nuts

Front

mounting
bracket
to

cylinder
block

Front

mounting
in

lator
to
brac
t

Front

mounting
insulator
to
front

support

Rear

mounting
insulator
to

transmission

Rear

mounting
insulator
to

rear

support

Rear

support
to
frame

Clutch

operating
cylinder
to
transmission

Exhaust
front

tube
to
exhaust
manifold

Center

bearing
bracket
to

crossrnember

Propeller
shaft
to

companion

flange
kg
m
ft
lb

kg
m
ft
Ib

kg
m
ft
lb

kg
m
ft
lb

kg
m
ft
Ib

kg
m
ft
lb

kg
m
ft
Io

kg
m
ft
lb

kg
m
ft
lb

kg
m
ft
lb

ER
4
and

jack
it

up
slightly

2

Loosen
two

rear

engine
mounting

bolts

3

Loosen
two

exhaust
tube

hanger

bolts
California

models

only

4

Remove
rear

mounting
insulator

at
transmission
rear
extension

after

removing
insulator

securing
bolts

5

To
install

reverse
order

of
Ie

moval

2
6
to
3
6
19
to
26

2

6
to
3

6

19
t
o

76

1
4

to
1
8
10
to
13

3

2
to
3
7
23
to

27

1
6
to
2
2

12
to
16

3

2
to
4
3
23
to
31

2
5

to
3

5

18
to
25

1

9
to
2
5
14
to
18

1
6

to
2
2

12
to
16

2
4
to

3
3

17
to

24

Stroke
30
mm

Jt
i
I
1
18
in

Sj

1

i
J
o

Fig
CL
15
Non

adj
table

operating

cylinder

CLUTCH
PEDAL

Removal
and

installation

Removal
See

Figure
CL
16

1

Pry
off
cotter

pin
and
take
out

clevis

pin
disconnect

push
rod
from

pedal
assembly

2
Unhook

return

spring
Loosen
off

fulcrum

pin
and
remove

pedal
as

sembly

CfJ

W5
6

3

ch

fD

ij

ll

i
A
1
aevis

pin

2
Cotter

pin

3
Return

spring

4
Pedal
boss

S
Pedal

assembly

6
Bush

7

Nut

8
Push
rod

9
Fulcrum

pin

Fig
CL

16

Exploded
view

of
clutch

pedal

Note
Before

removing
clutch

pedal

note
toe
board

clearance
at

pedal

pad

Installation

To

install

reverse
the

order
of

removal

Apply
multi

purpose
grease

to

the
friction
surfaces
of

the
disas

sembled

parts
as

shown
in

Figure

CL
17

Tightening

torque

Pedal

installation
bolt

Fulcrum
pin

1

9
to
2
4

kg
m

14
to
17
ft
Ib

Lock

nuts
A
and
B

0
8
to
1
2

kg
m

5
8
to
8
7
ft
lb
CLtJTCH

Note
Refer
to

Figure
Clot8
for
the

correct
direction
of
return

spring

1

Pedal

assembly

2
Push
rod

3
Return

spring

eL116

Fig
CL

1B

Hooking
return

pring

Inspection
and

adjustment

Clean
all
the

following
parts
in

cleaning
solvent
and
check
for
wear

damage
or

any
other
abnormal
condi

tion

Replace
the

parts
which
are

faulty

1
Return

spring

2
Bush

3
Pedal
boss

etc

CL
6
1

Lock
nut

A

2
Lock

nut
8

Pedal

beiBht
a

53
mm

6
02
in

Pedal
full

stroke
b
117
10
23
4
6
104

84
in

@
Multi

purpose
grease

CL102

Fig
CL

17
Adju
ting
pedal
height

1

Adjust
the

pedal
height
to
153

mm
6
02
in

by

adjusting
pedal
stop

per
and

tighten
lock
nut
A

to
the

specified

torque
0
8
to
1
2

kg
m
5
8

to
8
7
ft
lb

2

Turn
in

or
out

push
rod

adjusting

screw
until
a

play
of
I
to
3
mm
0

039

to
0

118
in
at
clevis

pin
is

obtained

Then

tighten
lock
nut
B

to
the

specified

torque
0
8
to

1
2

kg
m
5

8

to
8
7ft
Ib

Note
Exercise

care
in

adjusting
the

play
not
to
block

the

port
or

master

cylinder
A
blocked

port

may
result
if
too
small

play
at

clevis

pin
exists

3
After

adjusting
check

the

pedal

full
stroke

is
in
117

to
123
mm
4

61

to
4
84

in

Note

Depress
and
release
clutch

pedal
over
its
entire
stroke
to

en

sure
that
the
clutch

linkage
op

erates

smoothly
without

squeak

noise
interference
and

binding

CLUTCH

CYLINDER

MASTER

Removal
and

installation

Removal

I

Remove
clcvis

pin
at

push
rod

2

Disconnect

clutch

tube
from

master

cylinder
and
drain
clutch
fluid

3

Remove
bolts

securing
master

Disassembly
and

assembly
CLUTCH

cylinder
to
the
vehicle

and
dismount

master

cylinder

Note
Remove
dust

cover
from
master

cylinder
body
on
the

side
of
driv

er

s
seat

Installation

To
install

reverse
the
order
of

removal

Closely
observe
the

following

instructions

1

Adjust
pedal

height
by

changing

pedal

stopper
length

Disassembly

1

Remove
dust

cover
and

remove

stopper
ring
from

body

2

Remove

push
rod

and

piston
as

sembly

3

Take
off

piston

cups

4

Remove

spiing
seat
from

piston

and
take
off

supply
valve
if

necessary

See

Figure
CL

19

Note
Discard

piston
cup
supply

valve
and

spring

seat
after
removal
Assembly

To

assemble
reverse
the
order
of

disassembly

Closely
observe
the
fol

lowing
instructions

I

Dip
piston
cup
in
brake
fluid

before

installing
Make

sure
that
it
is

correctly
faced
in

position

2

Apply
a

coating
of

brake
fluid
to

cylinder
and

piston
when

assembling

3
Press

piston
into

spring
seat
when

assembling

CL
7
2

Bleed
air

out
of

hydraulic

system

Tightening
torque

Master

cylinder
to

dash

panel

0
8

to
1
2

kg
m

5
8
to
8
7
ft

lb

Clutch
tube

connector
Flare
nut

1
5

to
1
8

kg
m

II
to
13
ft

lb

3

Using
Flare

Nut

Torque
Wrench

GG94310000

tighten
each

connector

to
the

specified

torque

1
Reservoir

cap

2
Reservoir

3
Reservoir
band

4

Cylinder
body

5

Supply
valve

stopper

6
Return

spring

7

Spring
seat

8
Valve
spring

9

Supply
valve
rod

10

Supply
valve

11

Primary
cup

12
Piston

13

Push
rod

14

Secondary

cup

15

Stopper

16

Stopper

ring

17
DU5t
cover

18
Lock
nut

CL265

Fig
CL
19

Exploded
view

of
maater
cylinder

Note

The
clutch
master

cylinder
is

available
in
both
NABCO
make
and

TOKICO
make
There
is
no
inter

changeability
of

repair
kits
or
com

ponent
parts
between

NABCO
and

TOKlCO
makes

When

replacing
the

repair
kit

or

component
parts
ascertain
the

brand
of

the
clutch
IIIBSter

cylinder

body
Be
sure
to
use

parts
of
the

same
make
as
the
former

ones

CLUTCH

SERVICE

DATA
AND

SPECIFICATIONS

Clutch
cover

Clu
tch

cover

type

Diaphragm
spring
to

flywheel
distance

Unevenness
of

diaphragm
spring
toe

height

Full
load

Out
of
flatness
of

pressure
plate

Allowable

refacing
limit
of

pressure
plate

Clutch
disc

Facing
size

Outer
dia
x
inside
dia
x
thickness

Thickness
of
disc

assembly

Free

Compressed

Number
of
torsion

springs

Allowable
minimum

depth
of

rivet

head
from
surface

Allowable

facing
run
out

Allowable
free

play
of

spline

at
the
outer

edge
of
disc

Clutch

pedal

Pedal

height

Play
at

clevis

pin

Full

stroke

Clutch
master

cylinder

Dia
of
master

cylinder

Allowable
maximum
clearance

between

cylinder
and

piston

Clutch

operating
cylinder

Dia
of

operating
cylinder

Tightening
torque

Clutch

assembly
to

flywheel
securing
bolt

Pedal

installation
bolt
Fulcrum

pin

Pedal

stopper
lock
nut

Push

rod
lock

nut

Master

cylinder
to
dash

panel
securing
bolt

Clutch

tube
connector
Flare
nut

Clutch

hose
connector

Operating
cylinder
to

clutch

housing
securing

bolt

Bleeder
screw
mm
in

mm
in

kg

Qb

mm
in

mm
in
Diaphragm
C225S

33

to
35
1
23

to
1
38

less
than
0
5

0
020

400

882

0
1

0
004

1

0
0
040

mm
in
225
x

150
x
3
5
8

86
x

5
91
x
0

138

mm
in

mm
in
8
3
to

8
9
0
327
to
0

350

7

6
to
8
0
0
299

to
0
315

6

0
3
0
012

0
5

0
020

0
4
0
016
mm
in

mm
in

mm
in

mm
in

153
6
02

mm
in
I

to
3

0
039

to
0
118

mm
in
117

to
123
4

61
to
4
84

mm
in

15

87
5
8

mm
in

0
15

0
0059

mm
in

19

05

Yo

kg
m
ft
lb
1

5
to
2

2
lito

16

kg
m
ft

Ib

1
9
to
2
4

14
to
17

kg
m
ft
b
0

8
to
1
2
5

8
to
8
7

kg
m

ft
lb

0
8
to

1
2
5
8
to
8
7

kg
m
ft
Ib
0
8
to
1
2
5
8
to
8

7

kg
m
ft
lb

1
5
to

1
8
11
to

13

kg
m
ft
lb

1
7
to
2
0
12
to
14

kg
m
ft
lb

2
5
to
3
5
18
to
25

kg
m
ft
Ib

0
7
to
0
9
5
1

to
6
5

CL
9

Manual
Transmission

o

cCl

4
@

@

fl

t

o

@

Fig
MT
3

MT
3
TM857
1
Main

drive
gear

2
Baulk

ring

3
d
4th

3

Synchronizer
hub
r

4

Shifting
insert

spnng

5
Shifting
insert

6
Coupling
sleeve

7
3rd
main

gear

8
Mainshaft

9
2nd
main

gear

10
1st
main

gear

11
ht

gear
spacer

12
Reverse
main

gear

13
Counter
drive

gear

14
Countershaft

15
Reverse
counter

gear

16
Reverse
idler
shaft

17
Reverse
idler

gear

Fig
MT
2
n
ear

component
F4W71B
transmlsBIO

g

@

f1f@

n
1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27
Striking
lever

Lock

pin

O

ring

Striking
guide

Oil
sea1

Striking
rod

E
ring

Stopper
guide
pm

Return

spring
plunger

Return

spring

Reverse
check

spnng

Return

spring
plug

Check
ball

plug

Check

spring

Check
baD

Interlock
ball

Retaining
pin

k

1st
2nd
shift
or

ht

2nd
fork
rod

3rd
4th
fork
rod

Reverse

fork
rod

3rd
4th
shift
fork

Reverse
shift
fork

Con
trollever

Control
lever
b

shmg

Control
lever

p
n

Control
lever

bushmg

TM045A

I

ponents
shift
contro
com

F4W71

B
transmuswn

REMOVAL

In

dismounting
transmission
from

the
vehicle

proceed
as
follows

I
Disconnect
battery
ground
cable

from
terminal

2

Place
transmission
control
lever
in

neutIal

position

3
Remove
E

ring
and
control
lever

pin
from
transmission

striking
rod

guide
and
remove
control
lever
See

Figure
MT
4

TM335

Fig
MT

4
Remouing
controllelJ
r

4
Jack

up
the
vehicle
and

support

its

weight
on

safety
stands
Use
a

hydraulic
hoist
or

open
pit
if
avail

able

Confirm
that

safety
is
insured

5
Disconnect
exhaust
front
tube

6
Disconnect
wires
from
reverse

lamp
switch
See
Figure
MT
5

7
Disconnect

speedometer
cable

from
rear
extension

housing
See

Figure
MT
5

8
Remove
clutch

operating
cylinder

from
transmission
case
See

Figure

MT5

O

m

J

@

1

Speedometer
cable

2
Reverse

lamp
switch

3
Outch

operating
cylinder

TM774

Fig
MT
5
Bottom
view
of
car
Manual
Transmission

9
Remove
bracket

holding
center

bearing
on
3rd
crossmember

by

loosening
off

attaching
bolts
See

Figure
MT
6

PD219

Fig
MT

6
Removing
center
balring

holding
brucket

10
Uetach

propeller
shaft
from

companion
flange
of

gear
carrier

by

removing
four
bolts

See

Figure
MT
7

Not

a
Remove

propeller
shaft

carefully
so

as
not
to

damage

spline
sleeve

yoke

and
rear
oil
seal

b

Plug

up
the

opening
in
the

rear
of

rear
exteDSion

housing
to

prevent

oil
from

flowing
out

P0220

Fig
MT
7

Remouing
four
bolt

6ecuring
prop
ller

shtJft
to

companion
ltJnge

11

Support
engine
by
locating
a

jacft
under
oil

pan
with
a
wooden

block
used
between
oil

pan
and

jack

12

Support
transmission
with
a

transmissionjack

13
Remove
exhaust

pipe
btacket

by
unscrewing
attaching
bolts
2

California
models

only
See

Figure

MT
8

14
Remove
rear

engine
mounting

insulator

securing
bolts
I
and
rear

mounting
member

securing
bolts
3

See

Figure
MT
8

MT
4
E
A277

Fig
MT
8

Removing
engine
mounting

rear

support

15

Remove
starter
motor

16
Remove
bolt

securing
transmis

sion

to

engine

After

removing
these
bolts

support

the

engine
and
transmission
with

jacks

and
then
slide
tra
ion
rearward

away
from

engine
and
remove
from

the
vehicle

Note
Take
care
in

dismounting
trona

mission
not
to
strike

any
adjacent

parts
and
main
drive
shaft

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

I
Prior
to

disassembling
transmis

sion

thoroughly
wipe
off
dirt
and

grease
from
it

2

Drain
oil

thoroughly

3
Remove
dust
cover
from
trans

mission
case

Remove
release

bearing
and
with

drawallever

4

Remove
reverse

lamp
switch

5
Move

gear
to
Neutral

6
Remove
speedometer
pinion
and

pinion
sleeve

by

taking
off
lock

plate

7
Remove
E

ring
and

stopper
guide

pin
from
rear
end
of

re
ll
extension

See

Figure
MT

9

TM337

Fig
MT
9

Removing
triking
rod

E

ring
and

topper
pin

8

Remove
return

spring

plug
return

spring
reverse
check

spring
and

plung

er
from
rear
extension

See

Figure

MT
10

TM338

Fig
MT

10
Removing
return
spring

plull

9
Remove
rear
extension

securing

bolts
and
turn
the

striking
rod
toward

left

Drive
out
rear
extension
backward

by

lightly
tapping
around
it
with
a
soft

hammer
See

Figure
MT
11

TM339

Fig
MT

11

Removing
rear
extension

10
Remove

front
cover

securing

bolts
and
remove
front
cover

Detach
countershaft
front

bearing

shim

II
Remove
main

drive

bearing
snap

ring
with

Expander
See

Figure
MT
12

j

12

Separate
transmission
case
from

adapter
plate
with
a
soft
hammer
See

Figure
MT
13
Manual
Transmission

qJiiiiiI

TM341

Fig
MT
13

Removing
trammission

case

13
Set

up
Setting
Plate

Adapter

ST238
1000
I

on

adapter
plate

With
countershaft
side

up
place
the

above

assembly
in
a
vise

See

Figure

MT

14

TM342

Fig
MT
14

Attaching
l
or

mbly

to

special
tool

DISASSEMBLY
OF
GEAR

ASSEMBLY

Fork
rod

Drive
out

retaining
pins
from

each
fork
rod
with
Fork

Rod
Pin

Punch
ST23540000
See

Figure

MT
15

S

ST23540000

TM343

Fig
MT
15
Drive
out

retaining
pim

2
Remove
three
3
check
ball

piugs

and
drive
out
fork
rods
from

adapter

pia
te

by
lightly
tapping
on
the
front

end

Be
careful

not
to
lose
three
3

check

balls
and
four
4

interlock
balls

See

Figure
MT
16

Note
Each

gear
and
shaft
can
be

detached
from

adapter
plate
with

out

removing
each
fork
rod

MT
5
Fork
rod

ht
2nd

Interlock

ball

TM344

Fig
MT
16

Layout
o
ch
ck
boll

and
interlock
ball

Gear

assembly

I

With

gears
doubly
engaged
draw

out

countershaft
front

bearing
using
a

suitable

gear
puller
See

Figure

MT
17

2
Remove
counter
drive

gear

snap

ring

3
Draw
out

counter
drive

gear
com

plete
with
main

drive

gear
assembly
by

means
of
a

gear
puller

When

drawing
out
main
drive

gear

assembly
be

careful
not
to

drop

pilot

needle

bearing
onto
floor
from
the

front
end

of
mainshaft
See

Figure

MT
18

TM398

Fig
MT
17

Removing
countershaft

front
b

aring

TM345

Fig
MT
18

Removing
count
r
drive

gear
and
main
drive

gear

REAR

EXTENSION

DISASSEMBLY

Remove
lock

pin
from

striking

lever
and
remove

striking
rod
Manual
Transmission

Note
00

not
diSlssemble

rear
exten

sion
bush
from

rear
extension

ADAPTER
PLATE

DISASSEMBLY

I

Remove
six

6

bearing
retainer

attaching
screws
with
an

impact

wrench
and
remove

bearing
retainer

from

adapter
plate

2

Remove
reverse
idler
shaft

3
Remove
mainshaft

bearing
from

the
rear
extension
side

INSPECTION

Wash
all

parts
in
a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

a
Be
careful

not
to

damage
any

parts

with

scraper

b

00
not

clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE

AND

REAR

EXTENSION
HOUSING

I
Clean
with

solvent

thoroughly

and
check
for

cracks
which

might

cause
oil
leak

or
other

faulty
con

ditions

2

Check

mating
surface
of
the

case

to

engine
or

adapter
plate
for
small

nicks

projection
or
sealant
e
1
Control
lever

2

Striking
rod

guide

3

Striking
rod

4

Striking
lever

5

Return

spring
plug

6

Stopper

pin

TM353

Fig
MT

27

Exploded
view
of
shifting
mechani6m

Remove
all

nicks

projection
or

sealant
with

a
frne

stone

3

If
rear

extension
bush
is

worn
or

cracked

replace
it
as
an

assembly
of

bush
and
rear
extension

housing

BEARING

I

Thoroughly
clean

bearing
and

dry

with
a

compressed
air

2
When
race
and
ball
surfaces
are

worn
or

rough
or
when
balls
are
out

of

round
or

rough

replacebearihg

with
a
new
one
See

Figure
MT
28

I

TM372

Fig
MT
28

l
pecting
ball

bearing

3

Replace
needle

bearing
if

worn
or

damaged

GEARS
AND

SHAFTS

I

Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

MT
8
2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure
backiasii
in

gears

Standard

0
05
to0
10mm

0
0020
to
0
0039
in

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4
Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0
0126
to
0
0154
in

2nd

gear

0
12
to

0
19
mm

0
0047

to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to
0

0146
in

TM374

Fig
MT

29

Measuring
end

play