Fork DATSUN 210 1979 User Guide

J

xplanation
of
convet
ted

torque

Mainshaft
nut
should
be

tightened

to

10
to
11

kg
m
72
to
80
ft
Ib

torque
with
the

aid
of

Wrench

ST22520000

When

doing
w
the

amount
of

torque
to
be
read
on

wrench
needle
should
be
modified

according
to
the
following
formula

L

C

kg
m
10

x

L
O
I
to

11
L

x

L

O
I

or

C
ft
Ib
n

x

L
O
33
to

L

80
x

L
0
33

Where

C
Value
read

on
the

torque
wrench

kg
m

ft
Ib

L

Effective

length
of

torque
wrench

m
ft

ST22520000

Torque
wrench

r

Lm
ft

0
1
m

0
3
ft

TM587

Fig
MT
124

Setting
Wrench

Example

When
a

0
4
m

Iong
torque
wrench

is

used

the
C
in

Fig
MT

123

will

be

8
0
to

8
8

kg
m
58
to
64

ft
Ib

12

Measure

gear
end

play

Make

sure
that

they
are

held
within

the

specified
values

For

details
refer
to

Page
MT
23
for

Inspection

13

Fit

1
0
IDm
0
039
in
thick

snap
ring
10

the
front

side
of
main

shaft
end

bearing

14

Install

mainshaft
end

bearing

using
Bearing
Drift
ST22350000
Fit

thick

snap
ring
to
the
rear

side
of

bearing
to
eliminate
end

play
Manual
Transmission

Available

Sllap
ring

No

Thickness
IDm

in

1
1
0
0

039

2

1
2
0
047

on

LST22350000

TM250A

Fig
MT
125
In

talling
Main

haft

End

Bearing

Shift
forks
and

fork
rods

1
Insert
1st

reverse
fork
rod
into

its

shift
fork
and

adapter
plate

2
With
1st
reverse
fork
rod
set
at

Neutral
insert

interlock

plunger
into

adapter
plate

3

Insert
2nd
3rd
fork
rod
into

adapter

plate
2nd
3rd
and
4th

5th
shift
forks

4
With
2nd
3rd
fork
rod
set
at

Neutral
insert
interlock

plunger
into

adapter

plate

5
Insert

4th
5th

fork
rod
into

adapter
plate
and
its

s
Uft
fork
6

Secureshift
forks
and
fork

rOd
s

with
new

retaining
pins

Note

a
Be
sure

to
install

interlock

plunger

when

installing
any
adjacent
fork

rods
to

adapter
plate

Properly
align
the

groove
in
assem

bleMork
rod
with

inle
rlQck
plung

er

See

Fig
MT
SO

b
Be
su

to

align
4th
5th
shift
fork

with

the

groove
in

their

coupling

sleeve

befo
instalting

c
Also

align
2nd

3rd
shift
fork
with

their

coupling
sleeve

properly
be

fore

instalting

7

Install
check
balls
and

check
ball

springs
Applying
locking
sealer
to

check
ball

plug
and

install
in

place

Align
center

notch
in

each
fork
rod

with
check
ball

Note

a

Check
ball

plug
for
1st

reverse

fork

rod
is

longer
than
those
for

2nd
3rd
fork
rod
and
4th
5th

fork

rod

b
To

insure
that

interlock

plunger
i

installed

properly
slide

2nd
3rd

fork
rnd

andoperate
the

other
fork

rod

Make
sure

thaI

gear

except
20d

or
3rd

gear
doe

not
mesh

8

Apply
gear
oil
to

all

sliding
sur

faces
and

check

to
see
that
shift

rods

operate
correctly
and

gears
engage

smoothly

L

1
u

Revene

TM251A

Fig
MT
126
In

talling
Shift
Forks

and
Fork

Roth

MT
28

TRANSMISSION
ASSEMBLY

Transmission
case

assembly

r

I
Remove

adapter
plate
with

gear

assembly
from

Adapter
Setting
Plate

KV32100300

2

Clean

mating
surfaces
of

adapter

plate
and
transmission
case

Apply
sealant
to

mating
surfaces
of

adapter
plate
and
transmission

case

3
Install
counter

gear
tluust
washer

selected

previously

Note

a

Apply
grease
to

sliding
surface
of

thrust
washer

b
When

installing
thrust
washer
note

the

front
and
r
ar
directions

Front
Oil

groove
side
Rear
Thrust
side

TM727

Fig
MT
127
Counter
Gear
Thru
t

Wa
her

4
Place
wooden

plate
of
more
than

20
mm
0

79
in
thick
under
transmis

sion
case
to

make
it

level

Slide
transmission
case
onto

adapter
plate
by
lightly
tapping
with
a

soft
hammer
until
case
bears

against

adapter
plate
and
be

sure
to
line

up

dowel

pin

Carefully
install
main
drive

bearing

and
counter

gear
front

needle

bearing

Make

certain
that
mainshaft

rotates

freely

Wooden

block

TM252A

Fig
MT
128
Installing
Transmis
ion

Ca
e
Manual
rransmission

5

Fit
main
drive

bearing
snap
ring

to

groove
in
main
drive

bearing
with

snap
ring
pliers

Note

Make
sure

sno

p
ring
fits
in

groove

Fig
MT

129

Fitting
Main
Drive

flearing
Snap
Ring

ReBr
extension

assembly

I

Clean

I
lating
surfaces
of

adapter

plate
and

rcar
extension

Apply
sealant
to

mating
surfaces
of

adapter
plate
a
itd

rear
extension

2

Assemble
rear
extension

assembly

as
follows

q
Set
fork
rod
at

5th

position

2
P

sition

striking
rod

at
Neutral

position
turn

striking
guide
clockwise

and
then

set

striking
lever
and
shift

arm
as
shown
in

Fig
MT

130

3
In

this
state

align
shift
arm

pin

with

groove
in

fork
rod

and
assemble

rear
extension

assembly
on

adapter

plate

MT280A
Shift
ann

J

1
Fork
rod

J

At
5th

Installing
Rear
Extension

Assembly
Fig
MT
130

MT29
Note

a

Use
care
when

installing
rear
ex

tension

assembly
Do
not
allow

shift

ann
to

come
out
of
the
strik

ing
leVer

b
Install
shift
ann
onto
4th
5th

fork
rod
and
then
fit

striking
lever

pin
into
oth
r

fork
rods

3
Install

through
bolts
with

wash

ers

GJ

Tightening
torque

Rear
extension
installation

bolt

1
6
to
2
2

kg
m

12
to
16
ft
lb

4

Apply
grease
to

plunger
install
it

in
rear
extension

5

InstaU
return

spring

Apply
locking
sealer
to
return

spring
plug
and
mstall
it
in

place

GJ
Tightening
torque

Return

spring
plug

0
5
to
1
0

kg
m

3
6
to
7
2
ft
lbl

Front
coyer

assembly

I

Select
fron
cover

adjusting
shim

as
follows

I

Using
verruer

caliper
depth
gauge

measure
depth
A

from
front
end

of

transmission
case
to

main
drive

bearing

outer
race
with

front
cover

adjusting

shim
in

place

2

Select
a

shim
of
thickness
A

measured

Manual

Transmission

TROUBLE
DIAGNOSES
AND

CORRECTIONS

Condition

Difficult
to
intermesh

gears

Causes
for
difficult

gear

shifting
are
classi

fie

t
o

ro
lb
c
QncerlJing

coJltr
1

syste

and
transmission
When

gear
shift
lever
is

heavy
and

it
is
difficult

to
shift

gears
clutch

disengagement

may
also
be
unsmooth
First

make
sure

that
clutch

operates
correctly

and

inspect

transmjssion

Gear

slips
out
of

mesh

In

most
cases
this

troubk
occurs
when

check
baD
and
or

spring
is

waIn
or
weaken

ed

or
when
control

system
is

faulty
In

this

case
the
troubk

cannot
be
correct

by

replacing
gears
and
therefore

trouble
shoot

ing
must
be
carried
out

carefuDy
It
should

also
be

noted
that

gear

slips
out
of
mesh
due

to
vibration

generated

by
weakened
front

and
rear

enigne
mounts

Noise

When
noise
occurs
with

engine
idling
and

ceases
when

clutch
is

disengaged
or
when

noise
occurs
while

shifting
gears
it
is

an

indication
that
the
noise
is
from
trans

mission

Transmission

may
rallk

during
engine

idling

Check
air
fuel
mixture
and

ignition

timing

After
above

procedure
readjust
engine

idling
Probable

cause

Worn

gears
shaft
and

or

bearing

Insufficient

operating
stroke
due
to

worn

or
loose

sliding

part

Worn
or

damaged
syncluonizer

Worn

check
baD
and
or

weakened
or

broken

spring

Worn

fork
rod

baU

groove

Worn

or

damaged
bearing

Worn
or

damaged
gear

Insufficient
or

improper
lubricant

Oil

leaking
due
to

damaged
oil
seal
or

sealant

clogged
breather

etc

Worn

bearing
High
humming
occurs
at
a

high

speed

Damaged
bearing
Cyclic
knocking
sound

occurs
also
at
a
low

speed

Worn

spline

Worn

bushing

MT34
Corrective
action

Replace

Repair
ClI

replace

Replace

Replace

Replace

Replace

Replace

Add
oil
or

replace
with

designated
oil

Clean
or

replace

Replace

Replace

Replace

Replace
as
a
rear
ex

tension

assembly

Manual
Transmission

SPECIAL
SERVICE
TOOLS

Tool
number
tool
name

KV32
I

00300

Adapter
setting
plate

ST23540000
Fork
rod

pin
punch

ST22730000

Bearing
puller

STJ0031000

Bearing
puller

STJ5300000
Oil
seal
drift
I
Kent
Moore
No

Reference

page
or

Fig
No

Unit

application
Tool
number

tool
name

J

25693
ST23800000

Fig
MT
12

Fig
MT
40

Fig
MT
77

Fig
MT
104

J
25689

Fig
MT
13

Fig
MT

78

J
2568
1

Fig
MT
24

Fig
MT
27

Fig
MT
28

Fig
MT
92

J
25733
1

Fig
MT
22

Fig
MT
90

Page
MT
IO

Page
MT
24
Transmission

drift

ST22350000

Mainshaft

bearing
drift
I
Kent
Moore
No

I
Reference

page
or

Fig
No

Unit

application

J

25691

Page
MT
IO

Fig
MT
46

Page
MT
24

Fig
MT
I
II

J

25678

Fig
MT
44

Fig
MT
55

Fig
MT

I08

Fig
MT
I
25

Fig
MT
48

Fig
MT
50

F4W60L

KV32
100100

Counter

gear

height
gauge
J

26070

Fig
MT
49

F4W60L

J

26071

Fig
MT
52

Fig
MT
115

Applicable
to
all
B310
series

models
F4W60L
and
FS5W60L

MT35
KV32
100200

Countershaft

bearing

press
stand

KV32
100400
Mainshaft

puller

Fe
rnuffiUQ

cP