wheel torque DATSUN PICK-UP 1977 Service Manual

6
Make

sure
that

crankshaft
has

proper
end

play

Crankshaft
end

play

0
05
to
0
18

mm

0

0020
to
0
0071
in

Fig
EM
89

Checking
crankshaft

end

play

7

Install
side
oil
seals
into

rear
main

bearing

cap
Prior
to

installing
apply

sealant
to
seals

Fig
EM
90

Driving
side
oil
seal

8
Install
rear
oil
seal

using
Crank

shaft
Rear

Oil
Seal
Drift

STI5310000

r

STl5310000

r

EM163

Fig
EM
91

Installing
rear
oi
seal
Engine
Mechanical

Note
When

installing
oil
seal

give

coating
of

engine
oil
to

mating

shaft
to

prevent
scratches
and

fold

ed

lip
Also

give

coating
of
oil
to

periphery
of
oil

seal

9

Install
rear
end

plate

10
Install

flywheel
securely
and

tighten
bolts
to

specified

torque

Tightening

torque

14

to
16

kg
m

101
to
116
ft
lb

I
I

Insert

pistons
in

corresponding

cylinder

using
Piston

Ring
Compressor

EM03470000

EM03410000

I

EM544

Fig
EM
92

Installing
pi8ton
rod

a
Sembly

Notes

a

Apply
engine
oil

to

sliding
parts

b

Arrange
80

that
notch
mark
on

piston
head
faces
to
front
of
en

gine

c
Install

piston
rings
at
1800
to

each

other

avoiding
their
fit
in
the

thrust
and

piston
pin
directions

6
Top
ring

I
iilring

Piston

pin
ireClioJ

EM165

Fig
EM

93
PUtan

ring
direction

12
Install

connecting
rod

caps

Tightening
torque

4
5
to
5
5

kg
m
33
to
40
ft
lb

EM
23
Fig
EM

94

Installing
connecting
rod

cap

Note
Install

connecting
rods

and
con

necting
rod

caps
80
that
their

as

signed
numbers
are

positioned
on

the

same
side
and
in
the
SlIme

direction
with

respect
to

cylinders

13
Make
sure
that

connecting
rod

big
end
has

proper
end

play

Fig
EM

95

Checking
big
end

play

Big
end

play

0
2
to
0
3
mm

0
008
to
0
Ql2
in

14

Install

cylinder
head

assembly

Fig
EM
96

Tightening
sequence

01

cylinder
head
bolts

J
Thoroughly
clean

cylinder
block

and

head
surface

Do

not

apply
sealant
to

any
other

part
of

cylinder
block
and
head

sur

face

30
Install
heatshieid

plate
on
mani

fold
assembly

31
Install
air

gallery
pipe
on
ex

haust
manifold

32
Install
manifold

gasket
and

manifold

assembly
on

cylinder
head

Tightening
torque

1
2to
1

6kg
m

8
7
to
11
6
ft
lb

33

Install
blow

by
gas

pipe
on

cyl

inder

block
and
tighten
with
rear

engine
slinger

34
Install
thermostat
housing

gas

ket
thermostat

housing
and

thermo

stat

35
Install
thermal
vacuum
valve
on

thermostat

housing
Before

installing

apply
a

liquid
packing
slightly
to
the

threads

36

Install
FJ

C
D
bracket
on

cylin

der

head

37

Install
E
G
R

passage
and

E
G
R
valve
on
intake
manifold

38
Connect
E

G
R
tube
to
E

G
R

tube
and

exhaust
manifold

39
Install
check
valve

on
air

gallery

pipe

40
Install
air
cleaner
bracket
on

intake
manifold

41
Install
air
control
valve
on
air

cleaner
bracket
California
models

42
Install
vacuum
and
fuel
tubes

combined
on

cylinder
head

43
Install
distributor

assembly

44
Install

heatshield
plate

joint

seat

and
carburetor

Carbure10r
tightening

torque

0
5

to
1

0

kg
m
3

6
to
7
2

ft
lb

Note
When

instalUng
joint
seat
be

sure
to

put
the
duct
into

primary

hole
in

intake
manifold

S

J

Heatshield

plate
4
Joint

seat

2

Primary
hole
5

Secondary
hole

3
Duct

EM534

Fig
EM
I06

Installing
carburetor

joint
seat
Engine
Mechanical

45
Install
dash

pot
bracket
and

dash

pot
to
intake

manifold

46
Connect
all
air

vacuum
and
fuel

hoses

and
then

secure
with

clamps

I
Cylinder
block
to

P
C
V
valve

hose

2
A
B

valve
to
E

G
R

passage
vac

uum
hose

3
A
B

valve
to
E
G

R

passage
air

hose

4
Vacuum
tube
to
carburetor
vac

uum
hoses

5
Fuel
ube

to
carburetor
fuel

hose

6
Fuel
tube
to
fuel

pump
fuelhose

7
Distributor
to
vacuum
switch
or

spark
delay
valve
vacuum
hose

8
Air
control
valve
vacuum
hose

9
Check
valve

to
air

control
valve

hose

10
Thermal
vacuum
valve
to

E
G
R
valve
vacuum
hose

I
I
Thermal
vacuum
valve
to

vacuum
tube
hose

47
Install
carburetor
air

cleaner
on

carburetor
and
then
connect
air

and

vacuum
hoses

as
follows

I

Air
cleaner
to

exhaust
manifold

hot

air
duct

2

Air
c1eaner
to
air

pump
hose

3

Air
cleaner
to
rocker

cover
hose

4

Air
cleaner

to
air
control
valve

hose

5

6

48
Install

spark
plugs
in

place

49
Connect
all
distributor

high
ten

sion

cables
to

spark
plugs

50
Install
air

pump
drive
belt
cool

er

compressor
and
idler

pulley

51

Install
left

engine
mounting

bracket

52
Install
clutch

assembly
on

flywheel
with
Clutch

Aligning
Bar

KV30100200
Air

cleaner
to
A
B

valve

hose

Other
vacuum
hoses

Tightening
torque

1
2
to
2
2

kg
m

8

7
to
15
9

ft
lb

EM
26
I

I

KV30100200

EM440

Fig
EM
I07
In

talling
clutch
embly

53

Using
an
overhead
hoist
and

lifting
cable
hoist

engine
away
from

engine
stand
and

then
down
onto

engine
carrier

54
Install

right
engine
mounting

bracket
oil
filter
oil

pressure
switch

oil

level

gauge
and
water

drain

plug

When

installing
oil

filter
fasten
it
to

cylinder
block

by
hand

Note
Do
not

overtighten

flit
or
oil

leakage
may
occur

55
Install
alternator
bracket

adjust

ing
bar
alternator

cooling
fan

and

belt

56

Adjust
the
deflection
of
drive

belts
when

thumb

pressure
is

applied

midway
between

pulleys
A

pressed

force
is
above
10

kg
22
0
lb

Deflection

of
drive
belts

8
to
12
mm

0
315

to
0
472
in

EM613

Fig
EM
lOB
Fan
belt
tension

57
Fill

engine
oil

up
to

specified

level

Engine
Mechanical

g
Piston

ring

Ring
height

Top
and

second

Side
clearance

Top

Second

Ring
gap

Top

Second

Oil
mm
in

mrn
in

mm
in

h
Cylinder
block

Cylinder
bore
inner
diameter
mm
in

Wear
limit
of
dittoed
inner

diameter

Cylinder
bore

taper
and
out
of
round

Difference
in

cylind
bore

Surface
flatness
mm
in

mm
in

mm
in

mm
in

i

Cylinder
head

Surface
flatness

mm
in

TIGHTENING
TORQUE

Cylinder
head

bolts

kg
m
fl
lb

Connecting
rod

big
end

nuts
kg
m
ft
Ib

Flywheel
fixing
bolts

kg
m
ft
Ib

Main

bearing
cap
bolts

kg
m
ft
lb

Camshaft
bracket
bolts

kg
m
ft
lb

Camshaft

sprocket
bolt

kg
m
ft
lb

Oil

pan
bolts

kg
m

ft
1b

Oil

pump
bolts

kg
m
ft
lb

Oil
strainer

bolts
kg
m

ft
lb

Oil

pan
drain

plug
kg
m
ft
lb

Rocker

pivot
lock
nuts

kg
m

ft
Ib

Camshaft

locating
plate
bolts

kg
m
ft
lb

Carburetor
nuts

kg
m

ft
lb

Manifold
bolts

kg
m
ft
lb

Fuel

pump
nuts

kg
m

ft
lb

Crank

pulley
bolt

kg
m
ft
lb

Water

pump
bolts

kg
m
ft
Ib

Front
cover
bolts

kg
m
ft

lb

EM

30
1
977
to
1
990
0

0778
to

0
0783

0
040
to
0
073
0
0016
to

0
0029

0

030
to
0

070
0
0012
to
0

0028

0
25
to

0
40
0
0098
to
0

0157

0

30
to
0

50
0
0118
to

0
0197

0
30
to
0

90
0

0118
to
0
0354

85
000
to
85
050

3
3465

to
3
3484

0
2

0
0079

om
5
0

0006

0
05
0
0020

less
than
0

05
0

0020

less
than
0
05

0
0020

6
5
to
8
5

47
to
61

4
5
to
5
5

33
to
40

14

to
16

101
to
116

4
5
to

5
5
33
to
40

1

8
to
2

0

13
to
15

12
to

16
87
to
116

0
6

to
0
9
4
3
to
6
5

I
J
to
1
5

8
0
to

10
8

0
8
to
1
1
5
8
to
8
0

2
0

to
3
0

14
to
22

5
0
to

6
0

36
to
43

0
6

to
0
9

4
3
to
6
5

0
5
to
1

0
3
6

to
7
2

1
2
to
1
6
8
7

to
11

6

1
2
to
1
8
8
7
to
13

0

12
to

16
87
to
116

0
4
to

0
5
2
9

to
3
6

8
mm
0
315
in

dia

6
mm
0

236
in
dia
1

0
to
1
3
7
2
to

9
4

0
4
to
0
6
2

9
to
4
3

The

pump
shaft
is

supported
by
a

double
row

of
ball

bearings

press
fit
in

an
aluminum
die
cast

pump
body
The

bearings
are

permanently
lubricated

and
sealed

to

prevent
loss
of
lubricant

and

entry
of

dirt

The

pump
is

provided
with
an

impeller
which
turns
on
a
steel

shaft

The

steel
shaft
rotates

together
with

the

torque

coupling
wheeL
The
volute

chamber
is
built
in
the

engine
front

cover

assembly

The
inlet
of
the

pump
is

connected

to

the
radiator
s
lower
tank

by
a
hose

i

o

CQ047

Fig
CO
2
Water

pump
and

engine

front
cover

REMOVAL
AND

INSTALLATION

Removal

in
to
a
clean

con

assembly

I

CQ048

Fig
CO
3
Removing
water

pump

Installation

1
Be

sure
to
clean
the

gasket
sur

faces
in
contact
with

pump
and
front

cover

Always
use
new

gaskets
when

installing

pump
assembly
Be
sure
to

tighten
bolts
Cooling
System

Tightening

torque

0
4
to
0
5

kg
m

3
0
to
3
6
ft
lb

2

Fill

cooling
system
and
check
for

leaks
at

pump

3

Install
fan
blade
and

tighten
at

taching
bolts

securely
Install
belt
and

adjust
for

specified
tension

4

Operate
the

engine
at
fast

idling

and
recheck
for
leaks

5
Install
fan
shrouds

Note
Ensure
that
clearance
between

shroud
and
Can
is

even
at

any

place

DISASSEMBLY

Water

pump
is

made
of
aluminum

and
its

bearing
outer
race
is
of
a

press

fit

type
For
this

reason
water

pump

should
not
be
disassembled

INSPECTION
AND

ADJUSTMENT

Inspection

Inspect
pump
assembly
for
the

fol

lowing
conditions
and

replace
if
nee

essary

1

Badly
rusted
or
corroded

body
as

sembly
and

vane

2

Excessive
end

play
or

roughness
of

bearings
in

operation

3
Reduced

cooling
efficiency
due
to

deteriorated
silicone
oil

4
Oil

leakage
in

torque
coupling
Adjustment

Fan

belt
should
be

properly
ad

justed
at
all
times
A

tight
belt
causes

wear
of

alternator
and
water

pump

bearings
A
loose
belt

brings
about

improper
cooling
fan
water

pump

and
alternator

operation

Check
the
belt
slack
between
alter

nator
and
fan

pulley
by
force
of
10

kg

22
lb

Slackness
of
fan
belt

8
to
12

mm

0
31
to
0
47
in

If

adjustment
is

necessary
loosen

bolt

retaining
alternator

adjusting
bar

to
alternator
Move

alternator
toward

or

away
from

engine
until
the
correct

tension
is
obtained

TORQUE
COUPLING

Except
air

conditioner

equipped

models

The

torque
coupling
keeps
the
fan

speed
at
2
500

rpm
rated
or
below

to

conserve
horsepower
at

high
engine

speed
It
also

helps
reduce
fan
noise
to

a
minimum

during
high
speed
opera

tion

This
unit
is
filled
with
a

special

silicone
oil
used
as
a

fluid

coupling

which
controls
the

fan

speed
Silicone

oil

can
not
be

replenished

1

Torque
coupling
wheel

2

Torque
coupling
cover

3

Torque
coupling
bearing

4
Pulley

5
Water

pump

C0060

Fig
CO
4
Sectional
view
of

torque
coupling
and
water

pump

00
3

REMOVAL

AND

INSPECTION

Removal
and

inspection
can
be

done

as
follows

Removal

Catalytic
converter

1

Apply
parking
brake

2

Place
wheel
lock
under
each
tire

3

Jack

up
the
vehicle

4
Remove
lower
shelter
of

catalytic

converter

5
Dismount

catalytic
converter

EC453

Fig
EC
69
Removing

catalytic

conuerter

Inspection

Preliminary
inspection

Visually
check
condition
of
all

component
parts
including

ho
s

tubes
and
wires

replace
if

necessary

Refer
to

Inspection
of
A
I
S
on

page
EC
17

Catalytic
converter

Whether

catalytic
converter
is
nor

mal
or
not
can
be
checked
by
ob

serving
variation
in

CO

percentage

The

checking

procedure
is

as
follows

Apply
parking
brake
Shift

gears

into
Neutral
for
manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Visually
check

catalytic
converter

for

damage
or
cracks
Emission
Control

System

2
Remove
air
hose
between

5

way

connector
and
air
check
valve

Plug
the

disconnected
hose
to

prevent
dust

from

entering
Refer
to

page
ET
12

3

Check
carburetor

pipes
for

proper

connection

4

Warm

up
engine
sufficiently

5

Race

engine
1

500
to
2
000

rpm

two
or
three
times

under
no
load
then

run

engine
for
o
e
minute
at

idling

speed

6

Adjust
throttle

adjusting
screw

until

engine
attains
to

specified
speed

Refer
to

page
ET
10

7
Check

ignition
timing
If
neces

sary
adjust
it
to

specifkations
Refer

to

page
ET
10

B

Adjust
idle

adjusting
screw
until

specified
CO

percentage
is

obtained

Refer
to

page
ET
12

9

Repeat
the

adju
stment

process
as

described
in

steps
5
to
8
above

until

specified
CO

percentage
is
obtained

Note

Adjustment
in

step
9
should
be

made
ten

minutes
after

engine
has

wanned

up

10
Race

engine

1
500
to
2
000

rpm
two
or
three
times

under
no
load

and
make
sure
that

specified
CO

per

centage
is
obtained

11
Remove

cap
and
connect
air

hose
to

air
check
valve

If

idling

speed
increases

readjust
it

to

specified
speed
with
throttle
ad

justing
screw

12
WaRn

up
engine
for

about
four

minutes
at
2
000

rpm
under
no
load

13
Measure
CO

percentage
at

idling

speed
After

step
12
has
been
coin

pleted
wait

for
one
minute
before

making
CO

percentage
measurement

14
If
CO

percentage
measured
in

step
13
is
less
than
0
3

the

catalytic

converter

is
normal

15
If
CO

percentage
measured
in

step
13
is
over
0
3

recheck
A
I
S

and

replace
air
check
valve
Then

perform
inspection
steps
12
and
13

EC
27
16
If
CO

percentage
is

still
over

0
3
in

step
15

catalytic
conyerter
is

malfunctioning
Replace
catalytic
con

verter

INSTALLATION

To
install

reverse
the
removal

pro

cedure

Bolt

lightening

torque

specifications

Tightening

torque

Catalytic
converter

2
6
to
3
4

kg
m

19
to
25
ft
Ib

FLOOR

TEMPERATURE

WARNING
SYSTEM

DESCRIPTION

The
floor

temperature
warning

system
consists
of
a
floor

temperature

sensing
switch
installed

on
the
vehi

cle
s
floor
floor

temperature
relay
and

a

warning

lamp
on
the
instrument

panel
and
wires
that
connect
these

parts

When
the
floor

tempera
ture
rises
to

an
abnormal
level
the

warning
lamp

will

light
to
call
the
attention
of
the

driver
The

wiring
diagram
of
this

system
and
location
of
the

floor

temperature
sensing
switch
are
ilIus

trated
in

Figures
EC
70
and
EC
71

OPERATION

When
the

ignition
switch
turned

fully
clockwise
to
the
START

posi

tion

battery
current
flows

through

series

and
shunt

coils
of
the

solenoid

magnetizing
the

solenoid

The

plunger
is

pulled
into
the
solenoid

so
that

it

operates
the
shift
lever

to

move
the

drive

pinion
into

the

flywheel
ring
gear
Then
the

solenoid

switch

contacts
close
after
the

drive

pinion
is

partially
engaged
with
the

ring
gear

Closing
of
the

solenoid
switch

contacts
c
uses
the

motor
to
crank
the

engine
and
also
cut
out
the
series

coil
of

the
solenoid
the

magnetic

pull

of
the
shunt

coil

being
sufficient

to

hold
the

pinion
in

mesh
after
the

shifting
has
been

performed

After
the

engine
starts

running
the

driver

releases
the

ignition
key
and
it

automatically
returns
to
the

ON

posi

tion

The
torsion

spring
then

actuates
the

shift
lever

to

pull
the

pinion
which

allows
the

solenoid
swi

tch
contacts
to

open

Consequently
the

starting
mo

tor

stops
Engine
Electrical

System

I

I

Ring
gear

2

Shift
lever

guide

3
Armature

4

Battery

5
Field
coil

6

Stationary
contact

7
Monble

contactor

More

positive

meshing
and

demeshing
of

the

pinion
and
the

ring

gear
teeth
are

secured

by
means

of
the

overrunning
clutch
The

overruIUling

clutch

employs
a
shift

lever
to
slide

the

pinion

along
the

armature
shaft

EE
6
F

l
cp

o

r

1

I
I

W

m

EE274

8
Shunt
coil

9

Plunger

10

Ignition
switch

11

Series
coil

12
Torsion

spring

13

Shift
lever

14

Pinion

Fig
EE

7
Starting
motor
circuit

into
or

out
of

mesh
with
the

ring

gear

teeth
The

overrunning
clutch
is

de

signed
to
transmit

driving

torque
from

the
motor
armature

to
the

ring
gear

but

prevent
the

armature
from
over

running
after
the

engine
has
started

Installation

I

Apply
a

light
coat
of
lithium
base

grease
containing
molybdenum
disul

phide
on
transmission
main
drive

gear

splines

Slide
clutch
disc
on
main

drive

gear

several
times
Remove

clutch
disc
and

wipe
off
excess
lubricant

pushed
off

by
disc
hub

2
Install
clutch
disc
and
clutch

cover
assembly
on

flywheel
Support

two
assemblies
with
Clutch

Aligning

Bar
KV30100200
See

Figure
CL
3

Note
Be
sure
to

keep
disc

facings

flywheel
and

pressure
plate
clean

and

dry

7
00

R

rr

CL109

Fig
CL
3

l
talling
clutch
cover

assem

bly

3
Install
six

bolts
to

tighten
clutch

cover

assembly
to

flywheel
squarely

Each
bolt
should
be

tightened
one

turn
at
a
time

to
the

specified
torque

15
to
2
2

kg
m
II

to
16
ft
Ib

Note
Three
dowels
are

used
to
locate

clutch
cover
on

flywheel
properly

4
Remove

Clutch

Aligning
Bar

KV30100200
after

tightening
the

bolts

securely

5
Install
transmission

Note
Make
certain
that
withdrawal

lever

engages
lever
ball

pin

6
Connect

push
rod
of
clutch

op

erating
cylinder
to
withdrawal
lever

DISASSEMBLY
AND

ASSEMBLY

Disassembly

I

Clutch
cover

assembly
can

not
be
CLUTCH

disassembled
since

diaphragm
spring
is

securely
reveted
to
clutch
cover
and

clutch

cover
assembly
is
balanced

If

necessary
replace
clutch
cover

assembly
as
a

complete
unit

2

Remove
clutch
release
mechanism

as
follows
See

Figure
CL4

1
Remove
dust
cover
from
clutch

houisng

2
Remove

withdrawal
lever
from

clutch

housing

3
Remove

retainer

spring
from

withdrawal
lever

4

Remove
release

bearing
bearing

sleeve
and

holder

spring
from
clu
tch

housing
as
an

assembly

1

lo

1

Release

bearing

2
Release

bearing

sleeve

3
Holder

spring

4
Dust

cover

5
Withdrawal

lever

6
Retainer

spring
CL119

Fig
CL
4

Exploded
view

of
clutch

releaae
mechaniam

3
Take

out
clutch
release

bearing

from

bearing
sleeve

using
a

universal

puller
See

Figure
CL
5

C
L014

Fig
CL
5
D

embling

rele
e

b

aring

4

Remove

pilot
bushing
in
crank

shaft

by
Pilot

Bushing
Puller

ST16610001
if

necessary
See

Figure

CL
6

CL3
CLOSS

Fig
CL
6

Removing
pilot
bu

hing

Asse

bly

Release

mechaniam

1
When

assembling
release

bearing

on
sleeve

use
a

press
and
seat

bearing

squarely
on

sleeve
See

Figure
CL
7

l
J

I

CL215
I

1

J

1

Fig
CL
7
1

tailing

rele
e

bearing

2
Before

or
during

assembling
lu

bricate
the

following
points
with

a

light
coat
of
multi

purpose

grease

I

Inner

groove
of
release

bearing

sleeve
See

Figure
CL
8

Lf

I

n

JQt
CL216

Fig
CL

B
Lu

bricating
ee

of

bearing
slee

2
Contact
surfaces
of

withdrawal

lever
lever
ball

pin
and

bearing
sleeve

3
Contact
surfaces
of

transmission

front
cover
See

Figure
CL

9

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

Adjustment
of
front
end

play

Sele
t
front
dutch
thrust
washer

by

calculating
the

following
formula

T

F
C
D

0
2
mm

where

T

F
Required
thickness
of
front

clutch
thrust
washer
mm
in

C
Measured
distance
C
mm
in

D
Measured
distance
D
mm
in

Available
front
clutch
thrust

washer

Thickness
mm
in

1
5
0
059

I
7
0
067

1
9
0
075

2
1
0
083

2
3
0
091

2
5
0
098

27
0
106

Specified
front
end

play

0
5
to
0

8
mm

0
020
to
0

031
in

Notes

a
Correct
thickness
of

bearing
race

and
thrust
washer
is
always
the
one

which
is
nearest
the
calculated
one

b
Installed
thickness
of
oil

pump
gas

ket
is
0
4

mm
0
016
in

10
Check
to
be
sure
that
brake

servo

piston
moves
freely
For
detailed

ptocedure
refer
to

page
AT
42
for

Servo
Piston
Use
care
to

prevent

piston
from

coming
out
of

place
dUI

ing
testing
since
servo
retainer
is
not

tightened
at
this

point
of

assembly

II
Make
sure
that
brake
band
strut

is

correctly
installcd

Torque
piston

stem
to
1
2
to
1
5

kg
m
9
to
11

f1
lb
Back
off
two
full
lurns
and

secure
with
lock
nut
Lock
nut

tight

ening
torque
is
1
5
to
4

0

kg
m

II
to

9

f1
lb
Automatic
Transmission

12
After
inhibitor
switch
is
in

stalled
check
to
be
sure
that
it

op

erates

properly
in

each
range
For

detailed

procedure
refer
to

page
AT

49
for
Checl
ing
and

Adjusting
Inhibi

tor
Switch

13
Check
the

length
L
between

case
end
to
rod
end
ofvacuum
throllle

valve
fully

pushed
in
Then
select

adequate
diaphragm
rod
of
corre

sponding
measured
length
See
Figure

AT
77

Available

diaphragm
rod

Distanl
e

measured
L
ITIm
in

Under25
55

l
OO59

25
65

to
26
05
1

0098
to
1
0256

26
15
to
26
55
1

0295
to
1

0453

26

65
to
27
05
1
0492
to
1

0650

Over
27
15
1
0689

COMPONENT
PARTS

The
transmission
cons
sts
of

many

small

parts
that
are

quite
alike
in

construction
yet
machined
to

very

close
tolerances
When
disassembling

parts
be
sure
to

place
them
in

order
in

part
rack
so

they
can

be
restored
in

the

unit
in
their

proper
positions
It
is

also

very
important
to

perform
func

tianal
test
whenever
it
is

designated

FRONT
CLUTCH

Disassembly

Front

clutch
drum

I

Pinon

lcz

t

AT146

1

Snap
ring

2

Retaining
plate

3
Drive

plate

4

Driven

plate

Fit
AT
78
S
Dished

plate

6

Snap

ring

7

Spring
retainer

8
Coil

spring

Sectional
view

of

front
clu
tch

AT
40
i

i
n
H

I
I

ni
c
A
i

iif

L

1

AT145

Fig
AT
77

Measuring
the
distance

L

Diaphragm
rod

length
mm
in

29
00
142
u

29

5
1161

30
0
1
81

30
5
1201

31
0
I
O

I

Pry
off

snap
ring
D
with

a

suitable
screwdriver
or

a

pair
of

pliers

Remove
a

retaining
plate
@
drive

plate
CID
driven

plate
@
and
dished

plate
@
in

the
order
listed
as
shown

in

Figure
AT
78

I

2

Compress
clutch

springs
using

Clutch

Spring
Compressor

ST25420001
or

51
25420000
Re

move

snap
ring
@
from

spring
re

tainer

using
Snap
Ring
Remover

ST2532000
I

See

Figure
AT
79

AT147

Fig
AT
79

Removing
snap
ring

Note
When
Clutch

Spring
Compres

sor
ST25420000
is
to
be
used
cut

the

toe

tips
of
three

legs
by
a

grinding
wheel
See

Figure
AT
80

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