clock DATSUN 210 1979 User Guide

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

RANGE
REVERSE

Po

r
flow

With
the
selector

lever
in
R

range
the
front
clutch

is

applied
to

transmit

clockwise

engine
torque

through
the

connecting
shell
to
the

sull
gear
The
clockwise
otation

of
the

sun

gear
causes
the

planet
gears
to

rotate
counterclockwise
With
the
low

and

reverse
brake

holding
the

rear

planet
carrier
the
rear
internal

gear

splined
to
the

output
shaft
turm

counterclockwise
in

a
reduction
ratio

ofapproximately2
18
to
1

Fluid
flow

Manual
Valve
4
Automatic

Tninsmission

Front

gear
set

Rear

gear
ell

Output

Input
throush
front
clutch

Held

by
low
A
reverse
brake

AT329

lW
w

Y

Front
clutch

Rear
clutch

Low
and
reverse
brake

Brake
band
servo

On
way
clutch

5
Throttle
Back

up
Valve
Low
A
reverse
brake
ON

Downshift
Valve

1st

2nd
Shift
Valve
12

6

L
Pressure

Regulator
Valve

2nd
3rd
Shift
Valve

10

AT

8
AT085

ON

OFF

ON

OFF
Preuwe
release

o

ernmnin

F
AT
9
M
hanical

Operation
during
R

Range

13
2nd
3rd
Shift
Valve

L

1st
2nd
Shift
Valve

I
Throttle
Back

up
Valve

y
Low
Reve
Brake

Band
Servo
Release
Side

11
Front

Clut
h

I

DI
RANGE
LOW

GEAR

Po
r
flow

With
the
shift
selector
in
0
low

gear
engine
torque
is

traJWnitted

through
the

applied
rear

clu
tch
to
the

internal

gear
of
the
front

gear
set
The

c1o
kwise
rotation

o
f
the

front
inter

naI

gear
causes
the
front

planet
gears

to
rotate
clockwise

driving
the

com

pound
sun

gear
counterclockwise
The

front

planetary
carrier
is

splined
to
the

output
shaft
This
cau
the

planet

gears
to
drive
the
sun

gear
instead
of

walking
around
the
sun

gear
This

counterclockwise
rotation
of

the
sun

gear
causes
the
rear

planet
gears
to

rotate
clockwise
With
the
one

way

clutch

holding
the
rear

planet
carrier

the
rear

planetary
gears
turn
the
rear

internal

gear
and

output
shaft
clock

wise
in
a
reduction
ratio

of

approxi

mately
2
46
to
L

Fluid
flow

Manual
Valve

2

3
Automatic
Transmission

Fiont

gear
set
Rear
gear
set

Input
t1uOllsh

rear
clutch

Output
shaft

Held

by
on
way
clutch

Input
from
front

gear
set

Output
to
real

gear
set

AT330

1

J

ld

AT081

Front
clutch

Reu
clutch

Low
and
revcrx
brake

Brake
band
servo

Onto

way
clutch
OFF

ON

OFF

OFF

HOLDING

Fig
AT
12

MochanicaIOp

rationduri

DJ
Ra

Governor
Valve

Pressure
Modifier
Valve
15

2nd
3rd
Shift
Valve

lst
2nd
Shift
Valve

2nd
3rd

Timing
Valve

1st

2nd
Shift
Valve

j
Rear

Clutch

I

Second
Lock
Valve

Second
Lock

Valve

LOrifice

Check

Valve
2nd
3rd

Shift
Valve

AT12

D2

RA
NGE
2ND
GEAR

Power
flow

In

02
range
the

brake
band
is

applied
to

hold
the

connecting
shell

and
sun

gear
stationary
Engine

torque
through
the

applied
rear
clutch

is
delivered

to
t
he
int

D
1l

1
gear
of
the

front

gear
set
in
a

clockwise
rotation

Clockwise
rotation
of
the
internal

gear

causes
the

planet
gears
to
walk

around
the

stationary
sun

gear
in

a

clockwise
direction
This
causes
the

output
shaft
which
is

splined
to
the

front

planet
carrier

to
turn
ina
clock

wise

direction
with

a
reduction
ratio

of
about
I
46
to
I

Fluid
flow

As
car

speed
and

governor
pressure

increase
the

governor

pressure
acting

on
the
end
of
the
1

2
shift

valve

Manual
Valve
I
Automatic
Tra

l
mission

Front

Bear
set
Rear

gear
set

Input
throuah
rear
clutch

AT331

1f

j
cW
oo
w

I

ATD79

Front
Clutch

Rearc1utch

Low
and
reverse
brake

Broke
band

One
way
clutch
OFF

ON

OFF

ON

OFF

AT447

F
S
AT
14
MechanicalOperation
during

DJ
Range

overcomes
the
force
of
the
1
2

shift

valve

spring
and
line

pressure
This

allows
the

1
2
shift

valve
to
move
to
the

upshift
position
which
directs
line

pressure

through
the

2nd
lock
valve

and

on
to
the
brake
band

Governor
Valve

15
Pressure
Modifier
Valve

2nd
3rd

Timing
Valve

2nd
3rd
Shift
Valve

1st
2nd
Shift
Valve

econd
Lock
Valve
9

Band
Servo

I
Apply
Side
1st
2nd
Shift
Valve
8

l
Rear

CIutclt

I

Second

Lock
Valve
2

3
Second
Lock
Valve

L

Orifice
Check
Valve
2nd
3rd
Shift
Valve

AT
14

Automatic
Transmission

D3
RANGE
3RD

GEAR

Front

gear
set
Rei
r

gear
set

Input
through
flODt

and
rear
clutches
Power
flow

In

D3
range
engine

troque
is

transmitted

through
both
clutches

The

front
clutch
turns
the
internal

gear
of
the
forward

gear
set
clockwise

The

rear
clutch

turns
the

sun

gears
in
a

clockwise
direction
also

With
both
the

internal

gear
and
the
sun

gear
of
the

forward

gear
set

turning
in
the

same

direction
at
the
same

speed
the

planet

gears
are
locked
in

position
and
turn

as
a
unit
The

output
shaft

spIined
to

the
forward

planet
carrier

turns
at
a

ratio
of
L
Output

shaft

AT332

Front
clutch

ON

Ij
1f

Front
clutch

Rear
e1utd

Low
reverse

brake

Brake
band

On

way
clutch
ON

ON

OFF

OFF
Pressure
rdeaJe

OFF
A

T083

Fill
AT
I6
Mechanical

Operation
hiring
D

Ronge

Fluid
flow

Governor

pre
ure
increases
to
the

poinl
that
it

can
overcome
the
com

bined
forces

of

spring
and
throttle

pressure
and
move
the
2nd
3rd
shift
valve
When
the
2nd
3rd
shift
valve

opens

pressure
passes
through
the

valve
lands
to
the
2
3

timing
valve
and

on
to

apply
the
front
clutch
and
release
the
brake
band
The
car
is
now

in

D3
or
direct
drive
the
rear
clutch

was

already

applied

Manual
Valve
I
Governor
Valve
IS
Pressure
Modifier
Valve

2nd
3rd

Timin8
Valve

2nd
3rd
Shift
Valve

ht
2nd
Shift
Valve

1st
2nd
Shift
Valve
8
Second
Lock
Valve

9
Band
Servo

Apply
Side

2
i

I

I

Band
Servo
is
released

t

Second
Lock
Valve

L

Orifice
Check
Valve
2nd
3rd
Shift
Valve
10

r
Band
Servo
Rele

Side

I

L
2nd
3rd

Timing
Valve
I
I

I
Front
Clutch

I
J

Second
Lock
Valve
I
Rear
Clutch

I

3

AT

16

Note
If
difficulty
is
encountered
in

removing
retainer
direct

8

jet
of

air

toward
release

side

Ph

i

AT132

Fig
AT
40
Remov
I
Band
Servo

21

Pry
snap
rings
CD
from
both

ends
of

parking
brake
lever

@
and

remove
the

lever
Back
off
manual

shan
lock
nut

CID
and
remove
manual

plate
@
and

parking
rod

CID

Fig
AT

41
Rtmoving
Manual
Pl4tt

22
Remove

inhibitor
switch
and

manual
shaft

by
loosening
two
secur

ing
bolts

INSPECTION

Torque
converter

houslns

trensmlsslon
use
end

reer
extension

I

Check
for

damage
or

cracking
if

necessary
replace

2
Check
for
dents

or
score
marks

on

mating
surfaces

Repair
as
nee

essary

3
If

rear
extelUlion

bushing
is

worn

or
cracked

replace
it
an

mbly
of

bushing
and
rear
extension

housing
Automatic
Transmission

Geskots
end
Gorin

J

Always
use
new

gaskets
when
the

units

are
to
be
disassembled

2

Check
O

rings
for
burrs

or
crack

ing
If

necessary
replace
with
new

rings

011
distributor

I
Check
for

signs
of
wear
on

seal

ring
and

ring
groove

replacing
with

new
ones
if
found

worn

beyond
use

2
Check
that

clearance
between
seal

ring
and

ring
groove
is

correct
If
out

of

specification
replace
whichever
is

worn

beyond
limits

Clearence
1
n
58el

ring
end

ring
groove

0
04
to
0
16

mm

0
0016
to
0
0063
in

Clearance

Seal

ring

0
o
ii

J

0
1

FI

AT13

Fig
AT
42
Mea

uring
Seal

Ring

to

Ring
Groove
Clearance

ASSEMBLY

Assembly
is
in
reverse
order
of

disassembly
However
observe
the
fol

lowing
assembly
notes

After

installing

piston
of
low
and

reverse
Drake

assemble
thrust

spring

ring
return

spring
thrust
washer
and

one

way
clutch
inner

race

Tighten

hex
head
slotted
bolt

using
Hex

head
Extension
ST2SS7000J

ST2SS70000

Torque
Wrench

GG930JOOOO
and

Socket
Extension

ST2S490000

ST2SSI200J

AT
29
J
Tightening
torque

One

way
clutch
inner
race
to

transminion

case

1
3
to
1
8

kg
m

9
to
13

ft
b

ST25570001

h
ST25490000

GG9
30
10000

Fig
AT
43

1
lalli
ll
One

way

Clutch
Inner
Race

2
After
low

and
reverse
brake
has

been
assembled
measure
the

clearance

between

snap
ring
CD
and

retaining

plate
@
Select

proper
thickness
of

retaining
plate
to

give
correct

ring
to

plate
clearance

Low
and
revene
br
ke

de
r
nce

0
80
to
1
25
mm

0
031
to
0

049
in

Fig
A
T
44
Measuring
Ring
to

Plate
Clearance

Available

retaining
plete

Refer
to
Service
Oeta
and

Specifications

3

Install
one

way
clutch
so

that
the

arrow
mark
4
is
toward
front
of

vehicle
It
should
be

free
to
rotate

only
in
clockwise
direction

Steering
System

STEERING
COLUMN

AND
GEAR

Tightening
torque
of

bolts
and
nuts

kg
rn
ft4b

@
3
8

to
5
2

27
to

38

@
1
3
to
1

8
9
to
13

@
0
35
to
0
45
25
to
3
3

@
4

0
to
5

0
29
to
36

@
7
0

to
8
0
51
to
58

lEi
13
to
15

94
to
108
1

Steering
wheel

2
olumn

clamp

3

Steering
column

4

Jacket
tube

flange

S

RUbbercoupling

6

Steering
gear

ST860

Fig
ST

l

Steering
Column

and
Gear

STEERING
WHEEL
2

spoke
steering
wheel

I

Remove
bolts
from
back
side
of

steering
wheel

2
Lift

horn

pad
from

steering

wheel

and
disconnect
horn
wire
REMOVAL

I

Disconnect

battery
ground
cable

2
Remove
horn

pad

3

spoke
sport
steering
wheel

Pull
off

pad

ST766

Fig
ST
3

Removing
Horn
Pod

ST765

Fig
ST

2

Removing
Horn
Pod
3
Remove

steering
wheel
nut

4

Using

Steering
Wheel
Puller

ST2718000l
install

puller
anchor

51
2
bolts
into
threaded
holes

provided
in

steering
wheel
Turn
center
bolt
of
the

special
tool
clockwise
to
remove
steer

ing
wheel

CAUTION

a
00
not

strike
end

of

steering
col

umn
shaft
with
a
hammer

Striking

shaft
will

damage
bearing
or
col

lapsible
shaft

b
Be
careful
not
to

damage
cancel

pole

Fig
ST
4
Removing

Ste
ing
WhHl

INSTALLATION

Install

steering
wheel
in
the
reverse

order
of
removal
Observe
the
follow

ing
instructions

Apply

grease
to

sliding
portions

2
When

installing
steering
wheel
to

column
shaft

align
punch
mark

on

steering
wheel
with

punch
mark
on

the

top
end
of

column
shaft

til

Tightening
torqu

Steering
whee

nut

3
8
to
5

2

kg

27

to
38

ft
Ibl

Note
After

imtol1ing

steering
wheel

turn

it
clockwise
end
counterclock

wise

cheddng
for
catch
or

drag

Also
check
horn
for

operation

Steering
System

6
Reriiovebolt

Securing
worm
shaft

to
rubber

coupling

7
Remove
nut

and
lock

washer

se

curing
gear
arm
to
sector
shaft

Using

Steering
Gear
Arm

Puller

512902000
I

remove

steering
gear

arm

from
sector
shaft

Gear

housinif
I

0

Cearar
8
Remove

bolts

securing
steering

gear
housing
to

body
side
member

and
withdraw

steering
gear
housing

from

engine
compartment

n

ST289

Fig
ST

IB

Removing
Ste

i1l
Gear

Arm

Disassembly

f

Tightening
torque
of
bolts

and
nuts

kg
m
ft

Ib

@
2
0
to
3

0
14
to

22

@
2

0
to
3
0

14
to

22

@
7

0
to
8
0
51

to
58

@
2

0
to
3

0
14
to
22

ST864
1
Lock
nut

2
Filler

plug

3

Adjusting
shim

4

Adjusting
screw

5
Sector

shaft

bushing

6

Steering
gearhou
ing

7
Oil
seal

8
BaU

nut
9
Worm

shaft

10
Wonn

bearing

11
Wann

bearing
adjUsting

shim

12
Rear

cover

13
Oil
seal

14
Sector
shaft

Fig
ST

19

Steeri1l
Gear

SHi
Thoroughly
drail

steCring
gear
oil

by

removing
filler

plug
Place
steer

ing
gear
in

a
vise
with

Steering
Gear

Attachment
KV48100300
in

place

2

Loosen
lock
nut
and

remove
see

tor
shaft
cover

attaching
bolts
After

removing
sector
shaft
with
cover
re

move
cover
from
sector
shaft

by
turn

ing
screw
clockwise

1

Filler

plug

2
Lock

nut

3
Sector

shaft
cover

attaching

bolts

Fig
ST
20

Mounti1l

Steeri1l
Gear

in
a
Vue

3
Remove

rear
cover

securing
bolts

and
detach

rear
cover

4
Remove

bearing
adjusting

shim

s
and

steering
worm

assembly

ST
426

Fig
ST
21

Drawi1l
Steeri1l
Worm

A
em

b
y

Fig
ST
23
Mea

uring
Initial

Turning

Torque

6
After
correct
worm

bearing
pre

load
has
been

obtained
remove
rear

cover
and

apply
sealant
on

housing

and

cover
sides
of
shims

Reinstall
rear
cover
with
shims
at

tached
under
cover

fJ
Tightening

torque

2
0

to
3
0

kg
m

14
to
22
fHbl

Adjustment
of

sector
shaft

and

adjusting
screw

7

Insert

adjusting
screw
with

adjust

ing
shUn

into
T

shaped
groove
at
the

sector
aft

head
and

adjust
the

end

play
between

sector
shaft

and

adjust

ing
screw

End

play
betwean
sector

shaft
and

IKljusting
screw

0

01
to
0

03
mm

0
0004

to
0
0012
in

Available
sector
shaft

adjusting

screw
shims

No
Thickness
mm
in

2
1
575

to
1

600

0

0620
to
0

0630

1

550
to
1
575

0
0610

to
0

0620

1
525
to
1

550

0

0600
to
0

0610

1
500
to
1

525

0
0591
to
0

0600
3

4

Note
When

installing

adjUsting
shim

pay
attention
to

which
face
is

upper
and
which

is
lower
Steering
System

Adjusting
shilli

Upper
1

sector

l

cover
side

ST258

Fig
ST

24

Measuri
End
l
UJy

tween
Sector

Shaft
and

AeVusting
Screw

8

Rotate
wonn
shaft

by
hand
until

ball
nut
is
in
the
center
of
travel
then

install

sector
shaft

together
with
ad

justing
screw
in

gear
housing
ensuring

that
center

gear
of
sector
shaft

engages

with
the
center

gear
of
the
ball
nut

Note
Be

careful
not
to

damage
seal

ing
lips
of
oil
seal

during
thi5

operation

9

Install
sector
shaft
cover
to

gear

chousing
Be
sure
to

apply
sealant
to

each
face
of
sector
shaft
cover

packing

when

installing
cover

By
turning
adjusting
screw
counter

clockwise
attach
sector
shaft
cover
to

gear
housing
and
then

temporarily

secure
it

with
its

futing
bolts

10
Pull
sector
shaft
toward
cover

approxUnately
2

to
3
mm
0
08
to

0
12
in

by
turning

adjusting
screw

counterclockwise
and

tighten
sector

shaft
cover

fIXing
bolts

fJ

Tightening
torque

Sector
shaft
co
er
bolts

2
0

to
3
0

kg
m

14

to
22
ft
Ib

II

Push
sector

shaft

against
ball
nut

gear
by

gradually
turning

adjusting

screw
clockwise
until
sector
shaft

gear

lightly
meshes
with

ball
nut

gear
and

then

temporarily
secure

adjusting

screw
with
lock
nut

12

Install

gear
arm
to
sector

shaft

and
move
sector
shaft
several
times

from

the
side
of

gear
ann

and
make

sure

that
it

turns

smoothly

SHl
13

Adjust
backIashat
neutral

posic

tion
of

steering
gear
by

turning
adjust

iog
screw
in

or
out
so
that

movement

of

gear
arm

top
end
is

less
than

specified
value

Backlash
at

gear
arm

top
end

Less
than

0
1

mm
0
004
in

ST
427

Fig
ST
25

Measuri
Bocklash

14

Then

tighten
lock
nut
after

mov

ing
sector

shaft
several
tUnes

fJ

Tightening
torqu

Lock
nut

2
0
to

3
0

kg
m

14

to
22
ft

Ibl

ST
428

Fig
ST
26

Tighteni
Loek

Nut

15
Measure
initial

turning
torque
of

wonn
shaft

assembly

At
center

portion

4
0
to
9
0

kt
c
m

3
5

to
7
8
in
lbl

Maximum

turning
torque

Less
than

11
0

kg
c
m
9
5
in
Ib

If
found

out
of
above

turning

torque

readjust
adjusting
screw
uniil

correct

turning

torque
is
obtained

16

Pour
recommended

gear
oil
into

assembly

through
fdler
hole
and
install

filler

plug

Engine
Control

fuel
Exhaust

Systems

Non
California
models

except
FU

model

Automatic
transmission

equipped
models

@

REMOVAL

CALIFORNIA

MODELS

AND
FU

MODEL

I

Remove

catalytic
converter
shel

ter
and
rear
exhaust
tube
shelter

2

Temporarily
loosen
bolts

securing

exhaust

mounting
insulator
to

body

and

remove
bolts

securing
muffler

lower

clamp
imd
muffler
to
muffler

upper
clamp

Note
Take
care
Dot
to

drop
muffler

heat
insulator

3

Remove
rear
exhaust
tube
from

catalytic
converter
and
remove
it

from

car
as
follows

I
Remove
bolts

securing
exhaust

mounting
insulator
to

body
and

put

rear
exhaust

tube
on
rear
axle
case

as

shown
in

Fig
FE
9
1

Front
tube

assembly

2

Pre
muff1er

3

Exhaust
tube

clip

4
Momer

wembly

5
Muffler

clamp
ring
rubber

6
Rear

tube

7
Exhaust

mounting
insulator

8
Exha
st
tail

mounting
bracket

9
Exhaust

mounting

1
ttacket
8@

@

4

wp

8

@

Tightening
torque

kg
m
ft
lb

@
2
0
to
2

6

14
to
t9

@
0
8

to
1
2

5
8
to
8
7

@
3
2
to

4
3
23
to
31

FE629

Fig
FE
B
E
haust

System
Non

California
mode
e

cept
FU
modet

FE639

Fig
FE

9

Putting
Rear
E
halUt

Tube

2

Pull
rear
exhaust
tube

assembly

forward

to

place
as
shown
in

Fig

FE
IO
Then

pull
it

further
while

swaying
rear

exhaust
tube

assembly

clockwise

and
counterclockwise

FE

B
II

F

E640

Fig
FE
IO

Removing
Rear

E
xhault

Tube

Assembly

4

Remove
catalytic
converter
from

front

exhaust
tube

5

Temporarily
loosen
nuts

securing

f

root
exhaust
tube

to
exhaust
mani

fold

6
Remove
front
exhaust
tube
from

exhaust

mounting
bracket

7

Remove
bolt

securing
V
bolt

housing

clamp
to

gusset