DATSUN 210 1979 Service Manual

Rear
Axle
Rear

Suspension

TROUBLE
DIAGNOSES
AND

CORRECTIONS

When
rear
axle
and

suspension
is

suspected
of

being
noisy
it
is

advis

able
to
make

thorough
test
to
deter

mine
whether
the
noise

originates

in
the

tir
s

roads
rfac
exhaust
propeller
shaft

engine
transmission

universal

joint
wheel

bearings
or

suspension

Noise
which

originates
in

other

places
cannot
be
corrected

by

adjust

Condition

Noise
unusual
sound

Instability
in

driving

This

problem
is

also

related
to
the
front

suspension
For

trouble

diagnosis
also
refer
to

the
FA
section

Oil

leakage
Probable
cause

Loose
wheel

nuts

One
or
more

securing
bolts
loose

Lack

oflubricating
oil

or

grease

Faulty
shock
absorber

Incorrect

adjustment
of
rear
axle
shaft
end

play

Damaged
or
worn
wheel

bearing

Worn

spline
portion
of
rear
axle

shaft

Breakage
of
leaf

spring

ose

journal
connections
etc

Unbalance
of
wheel
and
tire

Damage
of
the
rubber

parts
such
as
link

bU
hing

shock
absorber
moun

ting
bush

ing

Faulty
universal

joints

Breakage
of
coil

spring

Loose
wheel
nuts

Damaged
rear
link
rubber

bushings

Worn
shock
absorber

Incorrect
wheel

alignment

Spring
wear

Damaged
oil
seal
on
rear
axle
shaft

Oil

leakage
from

the
differential
carrier

Damaged

grease
seal
of
rear
axle
shaft

RA
l0
ment

or
replacement
of

parts
in

the

rear
axle

and
rear

suspension

In
case
of
oil
leak
first

check
if

there
is

any
damage
or
restriction
in

breather

Corrective
action

Tighten

Tighten
to

specified
torque

Lubricate

as

required

Replace

Adjust

Replace

Replace
if

necessary

Replace

Tighten
to

torque

Balance

Replace
damaged

parts

Adjust
or

replace

Replace

Tighten
to

specified
torque

Replace

Replace

Adjust

Replace

Replace

Replace
parts
as

required

Replace

Rear
Axle
Rear

Suspension

SPECIAL

SERVICE
TOOLS

Tool
number
tool

name

KV40101000
Rear

axle
stand

ST36230000

Sliding
hammer

esPY

HT72480000
Rear
axle
shaft

bearing

puller

ST38210000
Wheel

bearing
collar

press

stand

KV
401
00300
Rear

axle
oil
seal
drift
Kent
Moore
No

Reference

page
or

Fig
No

J
25604
01

Fig
RA
1O

J

25840

Fig
RA
1O

Fig
RA
12

Fig
RA
13

J

25729

Page
RA
4
Tool
number
tool
name

ST37840000
Rear
axle

shaft

guide

KV40l016S0

CD
KV40
10
I

610

V
KV40101620

ID
KV4010l630

@
KV40101430

CID
KV4010144
Link
rubber

bushing
drift

Adapter

Link

bushing

guide

Link

bushing
guide

Base

Ring

GG943
1

0000
Flare
nut

torque
wrench

RA
ll
Kent
Moore

No

Reference

page
or

Fig
No

Page
RA
4

Fig
RA

24

Page
RA
3

Page
RA
5

DATSUN
2

0
Model
83
0
Series

SECTIONBR

BRAKE
SYSTEM

CONTENTS

ADJUSTMENT

BRAKE
PEDAL

FRONT
DISC
BRAKE

REAR

BRAKE

HAND

BRAKE

BLEEDING
HYDRAULIC
SYSTEM

SERVICE
BRAKE

BRAKE
PEDAL

MASTER
CYLINDER

BRAKE
FLUID
LEVEL

GAUGE

BRAKE
LINE

NP
VALVE

FRONT
DISC
BRAKE
BR
2

BR
2

BR
2

BR
2

BR
2

BR
2

BR
3

BR
3

BR
4

BR
5

BR
5

BR
6

BR
6
ROTOR

REAR

BRAKE

BRAKE
BOOSTER

HAND
BRAKE

SERVICE
DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

INSPECTION
AND
ADJUSTMENT

TIGHTENING
TORQUE

TROUBLE
DIAGNOSES
AND

CORRECTIONS

SPECIAL
SERVICE
TOOL
BR

9

BR

l0

BR
12

BR
14

BR
16

BR
16

BR
17

BR
18

8R
19

8R
22

BRAKE
PEDAL

a

a

Fr

play

h
Free

height

d

Depressed
height

Tightening
torque
Icg
m
ft
tb

@

@
Push
rod
or

operating
rod
lock

nut

1

6
to
2
2

12
to

16

Brake

lainp
switch
lock
nut

1
2
to

I
5
9
to
11

BR121A

Fig
BR
1

Adjusting
Broke
Pedal

I

Adjust

pedal
height
h
to
the

specifications
by
moving
brake

lamp

switch
and

operating
rod
if

equipped

with
brake
booster

Pedal

height
h

143
to
149
mm

5

63
to
5
87

inl

Then
secure
brake

lamp
switch
and

operating
rod

C
l
Tightening
tOlque

Blake

lamp
witch
lock
nut

1
2
to
1

5

kg
m

9
to
11
ft

lb

Operating
lad
lock
nut

1

6
to
2

2
kg
m

12

to
16
ft
b
Brake

System

ADJUSTMENT

2
With
brake

booster

Adjustment
is
not

necessary
under

normal
conditions
Check
pedal
free

play
If
it
exceeds
the
above

specifica

tion

adjust
push
rod

length
refer
to

brake
booster
for

adjustment
by
re

moving
master

cylinder
rerer
to
Mas

ter

Cylinder
for
removal

3
After

adjustment
is

completed

depress
brake

pedal
several
times
to

ensure
that
it

travels
over
its
entire

stroke

smoothly
without

squeaking

noise

twisting
or
interference

Pedal

depr
d

Might
d

more
than
70
mm
2
76

in

FRONT
DISC
BRAKE

Front
disc
brake
does
not

require

adjustment
under
normal
conditions

since

pad
to
rotor
clearance
is

auto

malically
adjusted
by
elasticity
of

piston
seal

REAR
BRAKE

Auto

edJuster
type

Adjustment
is
not

necessary
under

normal
conditions
since
brake
drum

t
shoe
clearance
is

automatically

compensated
for

by
operating
hand

brake

Wlien
brake
drum
to
shoe

clearance

is

correct

operating
noise

of

adjuster

is

not
heard
even
if
hand
brake
is

operated

HAND
BRAKE

I

Adjust
rear
brake
shoe

to
drum

clearance
before

adjusting
hand
brake

2
Turn

turnbuckle
so
that
when

hand
brake
control
lever
is

pulled

by
specified
force

lever
stroke
or

number
of
notches
is
as

follows

Pulling
fOil
20

kg
44
Ib

lever
stroke

93
to
106

mm

3
66
to
4

17
in

Numbel
of
notches
7
to
8

BR

2
f

BAQ05A

Fig
BR
2
Adjusting
Hand
Brake

Then

tighten
lock
nut

securely

3

After

returning
hand
brake
con

trol

lever
to
its

original
position

ensure
that

e
All
rear
brake

toggle
levers

return

to
their

original
positions

Rear
cables
are
not
slack

HAND
BRAKE
WARNING

LAMP
SWITCH

Bend
hand
brake

warning
lamp

switch

plate
down
so
that
brake

warn

ing
light
comes
on
when
ratchet
at

hand
brake
lever
is

moved
back
one

notch
and

goes
out
when
returned
to

its

original
position

BLEEDING

HYDRAULIC
SYSTEM

Hydraulic
brake

system
must
be

bled
whenever

any
line
has
been
dis

connected
or
air
has
in
some

way

entered

system

Spongy

pedal
action
is
an
indica

tion
that
air
has
entered
brake

system

Bleeding
hydraulic
system
deserves

much
attention
as
it
is
an
essential

element
in

regular
brake

servicing

Clean
all

dirt
around
master
cyl

inder
reservoir
remove
reservoir

cap

and

top
up
reservoir
with
recommend

edbrake
fluid

Note
Do
not
mix

two
different
brand

oils

2

Thoroughly
clean
mud
or
dust

from
bleeder
valve

so
that
outlet
hole

is
free
from

foreign
particles
Install
a

bleeder
hose
on
bleeder
valve

L

@
fl
JJ

l

f
m

ff
v
1

II
2

I

I
II

B

s1

r
Dip
other
end

of
hose
into
brake

fluid
bled
in

a
container

3

Pepress
brake

pedal
two
or
three

times
and
then

keep
pedal
fully
de

pressed

4

With
brake

pedal
fully
depressed

open
bleeder
valve

to
exhaust
air

Note

a
Carefully
monitor
brake
fluid
level

at
master

cylinder
during
bleeding

operation

BRAKE
PEDAL

REMOVAL

I

Remove

snap
pin
installed
at
the

end

of
clevis

pin
Draw
out

clevis

pin

and

separate
push
rod
or

operating
rod

from
brake

pedal

2
Remove
bolt
and
E

ring
securing

fulcrum

pin
and
draw
out
fulcrum

pin

Then
brake

pedal
can
be
taken
out

along
with
return
coil

spring
Brake

System

b
Do
not
reuse

brake
fluid
drained

during
bleeding
operation

c
Bleed
air
in
the

following

sequence

Master

cylinder
Rear

wheel

front
wheel

d

Be
careful
not
to

splash
brake
fluid

on

painted
areas

5

Close
bleeder
valve

quickly
as

brake

pedal
is

on
down
stroke

6
Allow
brake

pedal
to
return
slow

ly
with
bleeder
screw
closed

SERVI
CE

BRAKE

fJ

Brake

lamp
switch

Lock

nut

Fulcrum

pin

Brake

push
rod
or

operating
rod

Snap

pin

Bolt

E

ring

Tightening
torque
kg
m
ft
Ib

@
1

6
to
2
2

12
10
16

@
1
2
to

l
S
9
to

II

BROS8A

Fig
BR
3
Broke
Pedal

INSPEctioN

Check
brake

pedal
for

the

following

items

servicing
as

necessary

I
Check
brake

pedal
for
bend

2
Check
return

springs
for

fatigue

3
Check

clevis
for

deformation
and

crack
at
welded

part

BR
3
7

Repeat
bleeding
operations
until

no
air

bubbles
show
in

hose

Note

a

Brake
fluid

containing
air
is

white

and
contalns
air
bubbles

b
Brake
fluid

containing
no
air

rons

out
of
bleeder
valve
in
a
solid

stream
free
of
air

bubbles

8

Repeat
steps
above
on

remaining

brake
line
to

expel
air

INSTALLATION

Install
brake

pedal

following
the

reverse

procedure
of
removal

paying

attention
to
the

following
items

I

Apply
coating
of
recommended

multi

purpose
grease
to

sliding
portion

and
return
coil

spring

BA113A

Fit
BR

4
Lubricating
Point

2
Be

sure
to

install
E

ring
and
bolt

securely

3
Insert
CleviS

pin
through
brake

pedal

4

Adjust
brake

pedal
after

installa

tion
Refer
to
Blake
Pedal
for

adjust

ment

j
Tightening

torque

Push
rod

or
op8leting
rod

lock
nut

1
6
to

2
2

kltm

12
to
16
ft

Ibl

Brake

lamp
switch
lock
nut

1
2
to
1
5

kltin

9
to
11
ft
lb

Tightening
torque
kg
m
ft
Ib

@
8
0
to

9
0
581065

@
0
7
to
0

9
5
1

to
6
5
I

Brake

System

MAstER
CYLINDER

I

Reservoir

cap

2
Filter

3

Stopper

ring

4

Stopper
Crew

5

Stopper

6

Primary

piston

7

Primary

piston
return

spring

8

Secondary
piston

9

Secondary
piston
return

spring

10

Plug

11
Check

valve

12
Reservoir

BR009A

Fig
BR

5
Ma
ler

Cylinder
Made

by
Tokico

1
Re

rvoir

cap

2

Filter

3

Stopper

ring

4

Stopper
screw

5

Stopper

6

Primary
piston

7

Primary
pinon
return

spring

8

Secondary
piston

9

Secondary
piston
return

spring

10

Plug

11
Check
valve

12
Reservoir
Tightening
torque

kg
m
ft

Ib

@
2

5
to
3
5
18
10
25

@
0
15
00
3
l
l
o

2
2

BR
4

I
BA010A

Fill
BR
6
Master

Cylinder
Made

by
Nabco

REMOVAL

I

Disconnect

wiring
to
brake
fluid

level

gauge

2
Disconnect
front
and
rear
brake

tubes
from
master

cylinder

CAUTION

When

removing
brake
tubes

use

suitable
tube

wrench

Never
use

open
end
or

edjustllble

wrench

Note
When

disconnecting
brake

tubes

be
sure
to
use
a
container

to
receive

draining
brake
fluid

Use
of

raga
is
also

suggested
to

keep
adjacent
perts
and
area

clean

3
Remove

master

cylinder
securing

nut
Master

cylinder
can
then
be
taken

out

DISASSEMBLY

1
Remove
reservoir

caps
and

filtern

and

drain
out
brake
fluid

2

Pry
off

stopper
ring
using
a

screwdriver

3
Remove

stopper
screw
and
take

out

stopper

primary
piston
assembly

spring
and

secondary
piston
assembly

in

the
order

shown

Note

Discard

caps
if

they
are
reo

moved
from

piston
assemblies
and

use

new
ones

4

Unscrew

pluga
to

gain
access
to

check
valve
for

disassembling

Note

a

Never
detach
reservoir
tanks

If

they
are
removed
for

any
reason

discard
them
and
install
new

ones

b
Do

not
remove
or
disassemble

brake
fluid
level

gauge

INSPECTION

Thoroughly
clean
all

parts
in
a

suitable
solvent
and
check
them
for

wear
or

damage
Replace
any

part
that

is

faulty
Brake

System

CAUTION

Use
brake
fluid

to
clean
Never

use

mineral
oil

I
Check

cylinder
and

pistons
for

evidence
of
abnonnal

wear
or

damage

Replace
if
found

faulty

2
Check

piston
to
cylinder
clear

ance
If
it

exceeds
the

specified
value

replace
either

piston
or

cylinder

Piston
to

cylinder
clearance

less
than
0
15

mm
0

0059
in

3

Check

springs
for
weakness

fatigue
or

damage
Replace
if
neces

sary

4
When

master

cylinder
is
disas

sembled
be

sure
to
discard

caps
and

valves

Replace
any
other

parts
which

show
evidence
of

deformation
wear
or

other

damage

S

Replace
damaged
oil
reservoirs

and

caps

ASSEMBLY

Assemble
master

cylinder
following

the
reverse

procedure
of

disassembly

paying
particular
attention

to
the
fol

lowing
note

Note

a

Replace
gaskets
and

packing
with

new
ones

b

Apply
brake
fluid

or
rubber

grease

to

sliding
contact
surface
of

parts

to
facilitate

assembly
of
master

cylinder

c
The
brake
master

cylinder
is

avail

able
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
brake

master

cylinder

body
Be
sure

to
use

parts
of
the

same

make
as
the

fonner
ones

INSTALLATION

Install

master

cylinder

following

the
reverse

procedure
of
removal

After

installation
bleed
brake

system

BR
5
CAUTION

When

installing

Flare
Nut

6694310000
brake
tubes

use

Torque
Wrench

CiJ

Tightening
torque

Brake
master

cylinder

securing

nut

0
8
to
t
1

kg
m

5
8
to
8
0
ft
lb

Brake
tube
flare
nut

1
5
to
1
8

kg
m

11
to
13
ft
b

BRAKE
FLUID

LEVEL
GAUGE

Inspection

I

Disengage
hand

brake
control

lever

2
Raise

cap
and

make
sure
that

hand

brake

warning
lamp

goes
on

when

float
comes
into
contact
with

stopper

BRAKE
LINE

REMOVAL

I
Remove
flare

nuts
on
both
ends

and

remove
retainers
and

clips

CAUTION

When

removing
brake
tubes
and

hoses
use
suitable
tube
wrench

Never
use

open
end
or

adjustable

wrench

2
To
remove
brake
hose

first
re

move
flare

nut

securing
brake
tube
to

brake
hose
and

withdraw
lock

spring

End
of
hose
can
then
be

removed
from

bracket
Next
remuve

brake
hose
Do

not
twist

brake
hose

INSPECTION

Check

brake
lines
tubes
and

hoses

for
evidence

of
cracks
deterioration
or

other

damage
Replace
any
faulty

parts

If

leakage
oCcurs

at
end
around

joints
re

tighten
Of

if

necessary
re

place
faulty

parts

INSTALLATION

Pay
particular
attention
to
follow

ing
instructions
when

installing
brake

lines

I
Leave
a
sulfident

space
between

brake
lines
and

adjacent
parts
so
that

brake
lines
are

completely
free
from

vibration

during
driving

2
Be
careful
not
to

warp
or
twist

brake

lines

3
When

installing
brake
tube

keep

a
certain

distance
between
tube
and

adjacent

parts
as

follows

Tube
to

rotating
parts

30

mm
1
18
in

Tube
to

moving
parts

10
mm
10
39
in

Tube
to
other

palls

5

mm
10
20
in

4

Always
fasten
brake
tubes
with

mounting

clips
where

necessary

On
rear
axle

case
are
two

double

dips
which

should
be
used
to

secure

brake
tubes

in

manner
described
be

low

Bend
short

clip
straight
up
With

brake
tube

on

long
clip
bend

clip

up

and
around
tube

Finally

wrap
short

clip
around
tube
to

secure
the
in

slallation

f
J

i

2

BA141

Fig
BR
7

Fastening
Brake
Tube

Securely
with
Double

Clip

5

Do

not

tighten
brake
line
mount

ing
flare
nut

excessively

CAUTION

When

installing

Fla
e
Nut

6694310000
brake
tubes

use

Torque
Wrench
Brake

System

t
D
Tightening

torque

Brake
tube
flare
nut

1
5
to
1
8

kg
m

11
to
13
ft
lb

Brake
hose
connector

1
7
to
2
0

kg
m

112
to

14
ft
lb

J

way
connector
bolt

0
8
to

1
1

kltm

5
8
to
8
0
ft

Ib
NP

VALVE

Front
wheel

cylinder

Front
wheel

cylinder
Master

cylinder

front
jde

6

Upon
completion
of

installation

of

brake
lines

bleed
air
out
of

brake

lines
Rear
wheel

cylinder

BR114A
Master

cylinder

rear
side

Fig
BR
B
NP
Valve

FRONT

DISC
BRAKE

9
ilJ

I

Bias
s

pring

2
Yoke

3
Bleeder

4

Piston
seal

5
Piston
B
11
Piston
A

12

Cylinder
body

13
Pad

spring

14
Pad

15
Pin
6
Boot

7

Retaining
ring

8
Clip

9
Yoke

spring

10
Bias

ring

BR123A

Fig
BR
9
Di
c
Broke

PAD
REPLACEMENT
Note
Check
to
ensure
that

pad

springs
rebound

easily

3
Detach

pads
from

caliper
assem

bly
with

pliers
Removal

I
Jack

up
front
of
car
and

support

it
on

safety
stands
Remove
wheel

2
Remove

clips
and

pull
out

pins

extracting
coil

spring
and

pad
springs

by
hand
CAUTION

After

removing
pads
do
not

depress

brake

pedal
or

piston
will

jump
out

BR

INSTALLATION
INSTRUCTIONS

Typical
Glrllng
B
ake
Pad

SYIlem

Girling
disc
brakes
are

very
similar
to
ATE
disc
brakes

except
that
the

piston
seal
does

not

pul
the

piston
and
brake
pads

away
from
the
rotor
In
the

Girling
System
with

the

pistons
i

the

relaxeilposition
the

pad
just
touches
the

rotor

Ped
Removal

1
Raise
the
car

alid
removiHire
and
wheel

2

Girling
disc
brake

pads
ere
held
in

piece
either

by
a
retainer

plates
or
b
retainer

pins
Retainer

plates
are
boiled
to

the
caliper
housing
and

need

only
to

be
loosened

and

roteted
out
of
the

way
Some
models
use
anti
raWe

springs
which
must

be

replaced
whenever
new

pads
ere
installed
The
retainer

pins
are

held
in

place
by

hairpin
type
spring
clips
There
are
two

types
of
breke

pads
used
with
the
retainer

pins
One
is

cut

away
for
the

pin
end
the
other
is
drilled
These

padS
ere

definitely

not

interchengeable

3
Remove
the
reteiner

4

Lift

padS
up
and
out
of
the

celiper

Pad

Installation

1
Attach

a

piece
of
hose
to
the
bleeder
screw
and

place
the

hose
into
a
container

2

Open
bleeder
screw
one
turn
and
with
even

pressure
push
the

pistons
down

to
the

bottom
of
the

caliper
bores

3
Tighten
the
bleeder
screw
and
remove
the

piece
o
hose
This

procedure
makes

room
for
the

added
thickness
of
the

new

linings

4

Reposition
the

pad
retainer
and
the
anti
rattle

spring
i

used
and

tighten
the
bolts

or

replace
the

retaining
pins
and
screw
them
with
the

hairpin
Iips

5
Check
to
be
sure

you
have

a

high
hard

pedal
then
test
the
car

See
Instructions
On
Back
of
Ball
For
Correct

Usage
of
EMP

Gh11ng
dlac
brall

Ilmple
to
art
lc

Depending
III

ppU

aUon
atalnln

pilla
nd

clip

may
blt

placed
by
larga
QU

pin

Form
No
91

FOREIGN
DISC
PAD
INSTALLATION
INSTRUCTIONS

Typical
Ate
Teves

System

Removel

1

Drain
about
half

of
the

brake
fluid
out
of
the

master

cylinder
prior
to

replacing
the

disc
brake

pads
This
will
allow
sufficient

expansion
room

for
the
brake
fluid
in
the

lines
when
the

pistons
are
pushed
back

into
their
bores
to
make
room
for
the
added

Ihickness
of
the
new

pad
linings

2

Reise
the
car
and
lemove
tire
and
wheel

3
The
breke

pads
can

be
removed
without

lemovinll
the

caliper
from
the
car

4
The
brake

pad
reteining
pins
are

held
in

plaCe
bY
lock
rinlls
in
Ihe
inner

caliper

housing
The

pins
must
be
knocked
out
with

e
hammel
end

punch
from
theoulllide

5
Remove

spreader
spring
which
is

positioned
under
the

pins

6
A

special
tool
is
available
flom
the
car

manufacturer
forremoving
pads
from
caliper

or

pliers
can
be
used
to

pull
them
oul
be
careful
not
to

damage
the
rotor

7
Push
Ihe
brake

pistons
back
into

their
boros
If

you
encounter

difficulty
in

pushingil

he

pistofls
back
lhere

may
very
weIL
Wr9Jl
l

ern
in
lh

e
caliper
that
calls
for
more

attention
than

simplY
replecing
worn
out

pads
IUhe
pistons
are

eticking
or
If
the

seals
are

leaking
you
should
disassembl
the

caliper
and

repair
il

8

Lift
out
old

pads
from

Ihe

caliper

9
Remove
O

Ring
from
inside

caliper

Inslallatlon

II

1

Apply
silicone
lubricanl
to
Ihe

O

Rings
ana
to

grooveS
inside
each

caliper

2
Assemble
an
O

Ring
in

each

groove

3
Position
innor

pads
in

caliper

4
Position

oulpad
in

caliper

5

Replacespreadet
spring

8

ReplaceiPtnsaM
lighter

7
Install
wheel
and
lire

l

Final

Checl

A
Iter
Ihe
new

padS
have
been
installed
on

bolh
front

wheel
check
the

master

cylinder

fluid
level
Rlllhe

reservoiril

necessary
Depress
Ihe
brake

pedal
firmly
severaUlmes

to
sellhe
new

pads
on
he
rotor

i

See
Inst
ctionsOnBat
k
of
Box
For
rr

l8ge
of

EMP

l
iL
1
f

J

TypIcal
Ale

System

New
Brake
Division
Boston
MA
02135
Commerce
CA
90040
Fort
Worth
TX
76106