seat adjustment DATSUN PICK-UP 1977 Service Manual

EE322

Fig
ET
15
Checking
diltribu
tor

point

gap

AIR
GAP

California
models

For

inspection
procedures
and

reference
data
refer

to
the

topic
Air

Gap
in

Section
EE

page
EE
29

DISTRIBUTOR

Check

centrifugal
advance
unit
for

loose
connection
or

improper
opera

tion
If
it
is
not

operating
properly

the

problem
may
be

due
to
a

sticky

spring
or
excessively
worn

parts
This

operation
needs
a
distributor
tester

For

inspection
procedures
and

ref

erence
data
refer
to

relative

topic

under
Distributor
in

Section
EE

If
vacuum
advance
mechanism
does

not

properly
operate
check
for
the

following
items
and

correct
the

prob

lem

as

required

1
Check
vacuum
inlet
for

signs
of

leakage
at
connection
If

necessary

retighten
or

replace

2

Check
vacuum
diaphragm
for
air

leak

If

necessary
replace
diaphragm

3

Inspect
breaker

plate
for
smooth

movement

If

plate
does
not
move
smoothly

this
condition
could
be
due

to

sticky

steel
balls
If

necessary
replace
break

er
plate
assembly

IGNITION
WIRING

Use

an
ohmmeter
to
check
resist

ance
of

secondary
cables
Disconnect

cables
from

spark

plugs
and
install
a

proper
adapter
between
cable
and

spark
plug
Remove

distributor
cap

and
secondary
cables
as
an

assembly

Do
not
remove
cables
from

cap

Check
resistance
of
one
cable
at
a

time

Connect
ohmmeter
between

spark

plug
adapter
and

corresponding
elec

trade
inside
cap
If
resistance
is
more

than
30
000
ohms
remove
cable
from
Engine
Tune

up

cap
and
check
cable
resistance

only
If

resistance
is
still
more
than

30
000

ohms

replace
cable

assembly

EF125

Checking
high
tension

cable

CHECKING

DISTRIBUTOR
CAP

ROTOR
AND

CONDENSER

Note
This

operation
is

to
be

per

formed
while

checking
distributor

points
Inspect
distributor

cap
for

cracks
and

flashover

External
surfaces
of
all

parts
of

secondary
system
must
be
cleaned
to

reduce

possibility
of

voltage
loss
All

wires
should
be
removed
from
distrib

utor

cap
and
coil
so
that
terminals

can

be

inspected
and
cleaned
Burned
or

corroded
terminals
indicate
that
wires

are
not

fully
seated
which

causes

arcing
between
end
of
wire
and
ter

minal
When

replacing
wires
in

ter

minai
be

sure
they
are

fully
seated

before

pushing
rubber

nipple
down

over
tower
Check
distributor
rotor
for

damage
and
distributor
cap
for

cracks

CONDENSER

I
Clean

outlet
of
condenser
lead

wire

and
check
for

loose
setscrew

Retighten
if

necessary

2
Check

condenser
with
a
con

denser
tester

Condenser

capacity

0
20
to
0
24

IF

Micro
Farad

Condenser
insulation
resistance

5Mn

Mega
ohms

ADJUSTING

CARBURETOR
IDLE

RPM
AND
MIXTURE

RATIO

Cautions

a
On
automatic
transmission

equip

T
11
ped
models
check
should
be

per

fonned
in

the
D

position

Be
sure

to

engage
parking
brake
and

to
lock
both
front
and
rear

wheels

with
wheel
chocks

b

Keep
your
foot
down
on
the
brake

pedal
while

depressing
the
accelera

tor

pedal
Otherwise
vehicle

surges

forward

dangerously

Notes

a
Do
not

attempt
to
screw
the
idle

adjusting
sc
ew
down

completely

Doing
so
could
cause

damage
to

tip

which
in

turn
will
tend
to
cause

malfunctions

b

If
idle
limiter

cap
obstructs

proper

adjustment
remove
it

To
install
idle
limiter

cap
refer
to

Idle
Limiter

Cap

c

After
idle

adjustment
has

been

made
shift
the
lever
to
the
N
or

P

position
for
automatic
trans

mission

d
When

measuring
CO

percentage
in

sert

probe
into

tail

pipe
more
than

40
em
15
7
in

CO
idle

adjustment
with

CD
meter

Idle
mixture

adjustment
requires

the
use
of
a

CO
meter

especially
for

California
models
When

preparing
to

adjust
idle
mixture
it
is

essential
to

have
the
meter

thoroughly
warmed

up

and
calibrated

I
Check
carburetor

pipes
for

proper

connection

2

Warm

up
engine
until
water
tem

perature
indicator

points
to
the
middle

of

gauge
The

procedure
to
warm

up

engine
is
not

specifically
recom

mended
Either

driving
vehicle
or

oper

ating
engine
at

no
load
will
be

good

3
Make

sure
that
water
tempera

ture
indicator

points
to

the
middle

Further

keep
engine
running
at
about

2

000

rpm
for
about
5
minutes
with

out

applying
load
to

engine
in

order
to

stabilize

engine
condition
Engine

hood
should
be

open

4
Run

engine
for

about
10
minutes

at
idling
speed
During
this
10

minutes

proceeq
as
described
i

steps

5

to
9
below

5
Remove
air
hose
between
3

way

connector
5

way
connector
for
Cali

fornia
models
and
air

check
valve
as

shown
in

Figure
ET
17

Plug
the

dis

Replace
bulb
if

bulb
is
burned

ou
t

If

bulb
is
not
burned
trace

wireis

back

to

ignition
switch

Repair
or

replace
if

necessary

2

Be
sure
that

floor

temperature
is

cool

below
800C

1760F
before

carrying
out
the

following
procedure

1
Remove
rear
seat

2

Ignition
switch
is
turned
to

the

Temperature

sensing
switch
Temperature

warning
lamp

Contact
close
Off

Contact

open
On

Note

Avoid

heating
floor

tempera

ture

sensing
switch
directly

If

lamp
does

not

glow
check
floor

temperature
sensing
switch
connector

for

continuity
with
a
circuit

tester

If

continuity
should
exist

after

heated

surrounding
areas
of
floor
tern

rv
wnTP
sen
cinq
S
Vitch

reolace
tem

perature
sensing
switch

If

continuity
does
not
exist

trace

the

wiring
back
to

relay
or
check
the

following
step
3

Repair
or

replace

wire

s
if

necessary

Note
The
floor

temperature
sensing

switch

may
be
heated

through
the

floor

by
a

proper
heater

3
Turn

ignition
switch
to
the
IG

position
anf
disconnect
floor

temper

ature

sensing
connector
The

lamp

should
remain

on
If
not

check
floor

4
0
3

UJ

GJO
Engine
Tune

up

IGU

position

3
Ensure

that
floor
tem

perature

warning

lamp
goes
out

4

Heat

surrounding
areas
of
floor

temperature
sensing
switch
with
a

proper
heater

to
ensure
that
floor

temperature
warning

lamp
glows
when

floor
is

heated
to

lh

specifications
as

shown

in
the
table
below

Floor

temperature

Below

1050C

22IOF

Above
1050C

2210F

temperature
relay
for

continuity
with

a

circuit
tester

Referring
to
the

following
floor

temperature
relay
if

relay
is
normal

trace

wire
s
back
to

ignition
switch

Repair

faulty
wiring

Floor

temperature

rela

To

check
floor

temperature
relay

remove
it

and

proceed
as

follows

1
Check
for

continuity

between@

and

@
Continuity
should

exist

Check
for

continuity
between

D

and@
Continuity
should
exist

Check
for

continuity
between

D

and@
Continuity
should
not
exist

2

Apply
a
12
volt
doC

across@and

@
to

ensure
that

continuity
exists

between

D
and@and
that

continuity

does
not
between

D
and

@
If
test

r
I

141

ET
24
results
do
not

satisfy
the
above
reo

place
the
floor

temperature
relay

When
floor

temperature

warnln8
lamp
118hts

Check
floor

temperature
warning

lamp

I

Open
or

short
circuit
in

wiring

harness

2

Check
fuel

system
with

regard
to

the

following
items
Refer
to

Inspec

tion

of
Fuel

System

I
Floa

t
level

2

Choke

3

Normal

fuel

supply
system
Prima

ry
and

secondary

4

Accelerator

pump

5

Power
valve

6

B
C
D
D

7

Fuel
strainer

8
Air

cleaner

3
Check

ignition
system
with

regard

to

the

following
items
Refer

to

Inspection
of

Ignition
System

I

IgnItion
AMI

2

Distributor

3

Ignition
coil

4

High
tension

code

5

Spark

plug

4

Check

idle
CO

adjustment
Refer

to

Inspection
of
Idle

CO

Adjust

roeoC

Note
Even

if
there
is

nothing
wrong

with

engine

warning
lamp
may

come
on
if
vehicle
is

being
driven

on
a

steep
slope
continuously
in

lower

gears
at

high
engine

speeds

To
floor

temperature

warning
lamp

2
From
S

position

3
From
GOt

position

4

From

ignition
switch

5
To
floor

temperature

sensing
switch

EC343

Fig
ET
50

Checking
floor

temperature

relay

Engine
Tune

up

Condition

Probable

cause

Low
or
no

current

Ign
tion

system
out
of

order
Burned
distributor

point

Improper
point

gap

Faulty
condenser

Leak
at
rotor

cap
and

rotor

Faulty

spark

plug

Improper
ignition
timing

Faulty
ignition
coil

Disconnection

of

high
tension

cable

Loose
connection
or
disconnection
in

primary
circuit

Fuel

system
out
of

order
Lack
offuel

Dirty
fuel
strainer

Dirty
or

clogged
fuel

pipe

Fuel

pump
will
not
work

properly

Carburetor

choke
will
not
work

properly

Improper

adjustment
of
float
level

Improper
idling

Dirty
or

clogged
carburetor

Clogged
breather

pip
of
fuel
tank

Malfunctioning
an
ti

dieseling
solenoid
valve

Incorrect
sparle

plug
tightening
or

faulty

gasket

Improper
grade
engine
oil
or
low

viscosity

Incorrect
valve
clearance

Compression
leak
from
valve

seat

Sticky
valve

stem

Weak
or

damaged
valve

springs

Compression
leak
at

cylinder
head

gasket

Sticking
or

damaged
piston
ring

Worn

piston

ring
or

cylinder

Trouble
ooting

procedure

Pour

the

engine
oil
from

plug
hole
and
then

measure

cylinder

compression

Compression
increases

Compression
does

not

change
Low

comp
ion

ET
28
Corrective
action

Check
for
loose

terminal
or
disconnection

in

primary
circuit

Check
for

burned

points

Repair
or

replace

Adjust

Replace

Clean

or

replace

aean

adjust
plug
gap
or

replace

Adjust

Replace

Replace

Repair
or

replace

Supply

Replace

Clean

Repair
or

replace

Check
and

adjust

Correct

Adjust

Disassemble

and
clean

Repair
and
clean

Check
for

loose
terminal
or
wire
harness

Tighten
to
normal

torque
or

replace
gasket

Replace
with

proper
grade
oil

Adjust

Remove

cyljnder
head

and

lap
valves

Correct
or

replace
valve

and
valve

guide

Replace
valve

springs

Replace

gasket

Replace
piston
rings

Overhaul

engine

Malfunctiong

cylinder
or
piston
ring

Compression
leaks
from
valve

cylinder
head

or
head

gasket

Except
transistor

ignition
system

rpm
two
or
three

iimes
under
no

load

and
make

sure
that

specified
CO

per

centage
is
obtained

12

Connect
air

hose
to
air

check

valve

If

engine
speed
increases

readjust
it

to

the

specified
speed
with
throttle

adjustingsqew

CO
idle
edJustment
without

CO
meter

If
CO

meter
is
not

available
the

following
procedures
may
be
used

L
Check

carburetor

pipes
for

proper

connection

2
Warm

up
engine
until
water

tem

perature
indicator

points
to
the

middle

of

gauge
The

procedure
to
warm

up

engine
is
not

specifically
recom

mended
Either

driving
vehicle
or

oper

ating
engine
at

no
load
will

be

good

3
Make

sure
that

water

temperature

indicator

points
to
the
middle

Further

keep
engine
running
at
about
2

000

rpm
for
about
5

minutes
without

applying
load
to

engine
in
order

to

stabilize

engine
condition

Engine

hood
should
be

open

4
Run

engine
for

about
10
minutes

at

idling

speed

During
this

10

minutes

proceed
as

described
in

steps

5
to

9
below

5

Remove
air

hose
between
3

way

connector
5

way
connector

for
Cali

fornia
models
and
air

check
valve

shown
in

Figure
EF

35

Plug
the
dis

connected
hose

19
prevent
dust
from

entering

6
Race

engine
1
500
to
2
000

rpm

two
or

three
times
under

no
load
then

run

engine
for

one
minute

at

idling

speed

7

Adjust
throttle

adjusting
screw
so

that

engine
speeds
are

as
indicated

below

Engine
speed

Manual
transmission

815

rpm

Automatic
transmission

in
D

position

670

rpm

8
Check

ignition
timing
if
neces

sary

adjust
it

to
the
value

required
by

specifications
This

operation
need

not

be
carried
out
at
1

600
km
1

000

miles
service

9
At
about

10
minutes
after

engine
Engine
Fuel

is

run
at

idling

speed
adjust
idle

adjusting
screw
until
maximum

rpm
is

obtained

10

Repeat
procedures
as
described

in

steps
6
7
and

9
above

until

engine

speed
at
best
idle
mixture
is
815

rpm

for

manual
transmission

models
and

670

rpm
for
automatic
transmission

models

in
D

position
Adjustment

in

step
9
can
be
carried
out

right
after

step
7

11
Turn
the

idle

adjusting
screw

clockwise
until

engine
speed
drops
off

below

specified

rpm

Engine
speed

drops
off

Manual
transmission

60
to
70

rpm

Automatic
transmission

in
D

position

15
to
25

rpm

12

Connect
air
hose

to
air

check

valve

If

engine
speed
increases

readjust
it

to
the

specified

speed
with

throttle

adjusting
screw

Idle
limiter

cep

Do
not

remove
this
idle

limiter

cap

unless

necessary
If
this
unit
is
re

moved
it
must

be

readjusted
at
lime

of

installation
To

adjust
proceed
as

follows

I

After

adjusting
throttle

or
idle

speed

adjusting
screw
check

to
be
sure

that
the
amount

of
CO
contained
in

exhaust

gases
meets

the
established

standard

2

Install
idle
limiter

cap
in

position

making
sure
that
the

adjusting
screw

can
rotate
another
1
8

turn
in

the

CO

RICH
direction

Carbo
to

per

CO

rich

450
lIS
rotation

t
CO
lean

J

SQ

dl
lim

ET031
1
e
Iter

cap

Fig
EF

36

Setting
idle
limiter

cap

FUEL

LEVEL

1

Turn

down
float

chamber
to
al

low
float
to

come
into

contact
with

needle

valve
and
measure

Hu
shown

EF
22
in

Figu
re
EF

37

When
H

is

approximalely
7

mill
0
283

in

lOp
float

position
is

correct

The

top
float

position
can

be
ad

justed
by

bending
float

seat

Upon
completion
of
the

adjust

ment

check
fuel
level
wi
th

attached

level

gauge

p

j

i

I

it

I
Float
seat

2

Float

3

Float
chamber

4
Needle
valve
t
I
IIf

ET032

Fig
EF
37

Adjusting
float
level

2

Adjust
bottom
float

position
so

that
clearance
h
between

float
seat

and
needle

valve
stemis
I

3
to
L
7

mm

0
051
to
0
067
in
when

Iloat
is

fully

rals
n

Jloa
t

goppe

q
re

3

After

adjustments
in

steps
I
and

2

above
have
been
made

make
sure

that

when
fuel
is

delivered
to
the
float

chamber

the
fuel
level
is
maintained

within
the

range
of23
mm

0
91
in

as

shown
in

FigureEF
38

H
23

mm
0
91
in

EF260

Fig
EF
38

Checking
ruellevel

FAST
IDLE

I
With

carburetor

assembly
reo

moved
from

engine
measure
throttle

valve

clearance
A

with
a

wire

gauge

placing
the

upper
side

of
fast

idling

screw
on
the
first

step
on
fast

idling

cam

Engine
Fuel

toms
and

causes
of
carburetor
troubles

and

remedies
for
them

are
listed
to

facilitate

quick
repairs

There
are
various
causes
of

engine

malfunctions
It
sometimes

happens

that
a
carburetor
which
has
no
fault
TROUBLE

DIAGNOSES
AND

CORRECTIONS

In
the

following
table
the

syml

Condition

Probable
cause

Overflow
Dirt
accumulated
on

needle
valve

Fuel

pump
pressure
too

high

Needle
valve

improperly
seated

Excessive
fuel

consumption
Fuel
overflow

Slow

jet
too

large
on
each
main

jet

Main
air
bleed

clogged

Choke
valve
does
not

open

fully

Outlet
valve
seat
of
accelerator

pump

improper

Linked

opening
of

secondary
throttle
valve

opens
too

early

Power

shortage
Main

jets
clogged

Every
throttle
valve
does
not

open
fully

Idling

adjustment
incorrect

FIICI
tr

clogged

Vacuum

jet

clogged

Air

c1eane

clogged

Diaphragm
damaged

Power
valve

operating
improperly

Altitude

compensator
setting
incorrect
Cali

fornia

models

Improper
idling
Slow

jet
clogged

Every
throttle

valve
does
not
close

Secondary
throttle
valve

operating
im

properly

Throttle
valve

shafts
worn

Packing
between

manifold
carburetor

fauJiy

Manifold
carburetor

tightening
improper

Fuel
overflow

B

C
D
D

adjustment
incorrect

Vacuum
control
solenoid

damaged

Stuck
anti
stall
dash

pot

EF

36
appears
to
have

some

problems
when

actually
the

electric

system
is
at
fault

Therefore
whenever

the

engine
is

mal

functioning
the
electrical

system

should
be
checked
rust
before

adjust

ing
carburetor

Corrective
action

Clean
needle
valve

Repair
pump

Re

place

See
condition
overflow

Replace

Clean

Adjust

Lap

Adjust

Clean

Adjust

AdjusL

pa
ir

Clean

Clean

Replace

Adjust

Correct
H
L
lever

position

Clean

Adjust

Overhaul
and

clean

Replace

Replace
packing

Correct

tightening

See
l
ondition
ov

rl1ow

Adjust

Replace

Replace

Automatic
Transmission

TROUBLE

DIAGNOSIS
AND
ADJUSTMENT

INSPECTION
AND
ADJUSTMENT

BEFORE

TRQUBLE
DIAGNOSIS

TESTING

INSTRUMENT
FOR

INSPECTION

CHECKING
OIL

LEVEL

INSPECTION
AND
REPAIR
OF

OIL
EAKAGE

CHECKING

ENGINE
IDLING

REVOLUTION

CHECKING
AND
ADJUSTING

KICKDOWN

SWITCH
AND

DqWNSHIFT
SOLENOID

N
J
J
CII
Q

t
L
8li
p

JYSTMs
T
OF

MANUAL
LINKAGE

CHECKING
AND

ADJUSTING

INHIBITOR

SWITCH

STALL
TEST

STALL
TEST

PROCEDURES

JUDGEMENT

Since
most
automatic

transmission

troubles

can
be

repaired

by
simple

adjustment
do
not
disassemble
im

mediately

Firstly

inspect
and

adjust
the
auto

matic
transmission

in

place
utilizing

the
Trouble

Shooting
Chart

If
the
trouble
can

not
be
solved

by

this

procedure
remove
and
disas

semble

the
automatic
transmission

It

is

advisable
to
check

overhaul
and

repair
each

part
in
the

order
listed
in

the
Trouble

Shooting
Chart

I
In
the
Trouble

Shooting
Chart

the

diagnosis
items

are

arranged
ac

cording
to

difficulty
from

easy
to

difficult
therefore

please
follow
these

items
The
transmission
should
not

be

removed
unless

necessary

2
Tests
and

adjustments
should
be

made
on
the
basis
of
standard
values

and

the
data

should
be
recorded

INSPECTION

AND

ADJUSTMENT

BEFORE

TROUBLE
DIAGNOSIS

TESTING
INSTRUMENT
FOR

INSPECTION

I

Engine
tachometer

2
Vacuum

gauge
ROAD
TEST

VEHICLE
SPEED

AT
GEAR

SHIFT

CHECKING
SPEED
CHANGING

CONDITION

CHECKING
ITEMS
DURING
SPEED

CHANGE

SHIFT
SCHEDULE

LINE

PRESSURE
TEST

LINE

PRESSURE

governor
feed

pressure

JUDGEMENT
IN

MEASURING
LINE

PRESSURE

At
49

TR6
uBLE
SHOOTINC
CHART

INSPECTING
ITEMS

TROUBLE

SHOOTING
CHART
FOR

3N71B

AUTOMATIC
TRANSMISSION

TROUBLE

SHOOTING
GUIDE
FOR

3N71B

AUTOMATIC
TRANSMISSION
CONTENTS

AT
4B

AT
48

AT
4B

AT

49

AT
49

AT
49

AT
49

AT
50

AT

50

AT
50

3
Oil

pressure
gauge

It
is
convenient

to
install
these

instruments
in
a

way
that
allows
meas

urements
to
be
made
from
the
driver
s

seat

CHECKING
OIL
LEVEL

In

checking
the
automatic
transmis

sion

the
o
illevel
and
the
condition
of

oil
around
the
oil
level

gauge
should
be

examined
This
is

an

easy
and
effective

trouble

shooting

procedure
since

some

changes
in
oil
condition

are
often

linked
with

developed
troubles

For
instance

Lack
of
oil
causes

faulty
operation

by
making
the
clutches
and

brakes

slip
resulting
in

severe
wear

This
is
because
the
oil

pump
sucks

air

causing
oil

foaming
thus

rapidly

deteriorating
the
oil

quality
and

pro

ducing
sludge
and

varnish

Excessive
oil
is

also
bad
because
of

oil

foaming
caused

by
the

gears

stirring

up
the
oil

During
high
speed

driving

excessive

oil
in

the

transmission
often

blows
out

from
the
breather

Measuring
011
level

To
check
the
fluid
level
start
the

engine
and
run
it
until
normal

operat

T
AO
AT
51

AT
51

AT

52

AT
52

AT
52

AT

52

AT

53

AT
3

AT

53

AT

53

AT

54

AT
57

ing
temperatures
o

temperature
SO

to
800C

122
to
l760F

Approxi

mately
ten

minute
of

operation
will

raise
the

temperature
to
this

range

and

engine

idling
conditions

are
stabi

lized
Then

apply
the
brakes
and

move
the

transmission
shift
lever

through
all
drive

positions
and

place
it

in

park
P

position
In

this

inspec

tion
the
car
must
be

placed
on
a
level

surface

The
amount
of
the
oil
varies

with

the

temperature
As
a
rule
the
oil
level

must
be
measured
after
its

temper

ture
becomes

sufficiently
high

1

Fill
the
oil
to

the
line
H
The

difference
of

capacities
between
both

H
and
L
is

approximately
0
4

liter
Ji
V
S

p
Y

Imp
pl
and

therefore
do

not
to
fill

beyond
the

line

H

2
When

topping
up
and

changing

oil
care
should
be
taken
to

prevent

mixing
the
oil
with
dust
and
water

InspectIng
011

condition

The
condition
of

oil

sticking
to
the

level

gauge
indicates
whether
to
over

haul
and

repair
the
transmission

or

look
for
the

faulty

part

If
the
oil
has
deteriorated
to
a

varnish
ike

quality
it

causes
the

con

trol
valve
to
stick
Blackened
oil
indi

cates
a
burned
clutch
brake
band
etc

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

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

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