check oil DATSUN 210 1979 Manual Online

Place
the
vehicle
in
a

pit
and

by

sampling
the
lealeed
oil
deiermine
if
it

is
the

torque
converter
oil
The

torque

converter
oil
has

a
color
like
red
wine

so
it
is

easily

distinguished
from

engine

oil
or

gear
oil

Wipe
off
the

lealeing
oil
and

dust

and
detect
the

spot
of
ill

lell8e

nonflammable

organic
solvent
such
as

carbon
tetrachloride
for

wiping

Raise
the
oil

tcmperature
by

op

erating
the

engine
and
shift
the
lever

to
D

to
increase
the
oil

pressure

The
sp

Q
of
o
1

1I8
u

J1en
be

found
more

easily

Note
As

oil

leakage
from
the
breath

er
does
not
talee

place

except
when

running
at

high
peed
it

iSimpos

sible
to
ate
this

lealcage
with

vehicle

stationary

CHECKING
ENGINE
IDLING

REVOLunON

The

engine

idling
revolution
should

be

properly
adjusted

If
the

engine
revolution
is

too
low

the
e

gine
does
not

operate
smoothly

and
if
too

high
a

strong
shocle
or

creep
develops
when

changing
over

from
ON
to

Dn
or
R

CHECKING
AND

ADJUSTING

KICK

WN

SWITCH

AND

DOWNSH
FT

SOLENOID

When
the
Ieickdown

operation
is

not
made

properly
or
the

speed

chang

ingpoint
is
too

high
check
the
kick

down
switch
downshift
solenoid

and

wiring
between
them
When
the

igni

tion

Ieey
is

po
iti
ned
at
the
1st

stage

and
the
accelerator

pedal
is

depressed

deeply
the
switch

contact
hould

be

closed
and
the
solenoid
should
clicle
If

it
does

not
click
it

indicates
a
defect

Then
check
each

part
with
the

testing

inatrumen15
Auto
lT1atic

Transmissiqn

Fi
J
A
T
84
Down

ltift

Sole
id

Note
Watch
for
oil

leekage
from

tnnsmission
case

INSPECTION
AND

ADJUSTMENT
OF

MANUAL

LINKAGE

The

adjustmcnt
of
manual

linkage

i

equany
important
as

Inspection
of

Oil
Level
for
the
automatic
transmis

sion
Therefore

great
care

should
be

cxercised
oecause

incorrect

adjustment

will
result
in
the

breakdown
of
the

transmission

Inspection

pun
the
selector
lever
toward

you

and
turn
it
as
far
as
p
to

range

where
clicks
will
be
ell

by
the
hand

This
is
the

detent
of
manual
valve
in

the
valve

body
and
indicates
the

corrett

position
of
the
lever

Inspect
whether
the

pointer
of

selector
dial

corresponds
to
this

point

and
also
whether
the
lever
comes
in

alignment
with
the

stepping
of

posi

iion

plate
when
itis
released

CHECKING
AND
ADJUSTING

INHIBITOR

SWITCH

The
inhibitor
switch

lights
the

re

verse

lamp
in
the

range
R

of
the

transmission

operation
and
also
rotates

the

starter
motor
in

the

ranges
N

and
P

AT
40
i

j

tI

IlV

@

@

AT

I

Inhibitor
switch

2
Manual
shaft

3
Washer

4

Nut

5
Manual

plate

Fi
J
AT
85
Comtruction

of
Inhibitor

Switch
6
Nut

1

Washer

8

Inhibitor
wilch

9

Ran
q
Iect
lever

Check
w

ethcr
he
leverse

lal
1p

and

the
starter
motor

operate
nonnal

Iy
in
these

ranges
If
there
is

any

trouble
first
check
the

inkage
If
no

defect
is

fo
nd
in

the

Ii
leage
check

tlie

inhibitor
Swi
ch

Separate
the
manual

lever
from
the

remote
control
selector
rod
and
turn

the

range
select
lever
to
N

Note
In
the

position
N

the
slot
of

the

manual
shaft
is
vertical

Using
the
tester
check
the
two

black

yellow
BY
wire

from
the
in

hibitor
switch
in

the

ranges
N
and

p
and
the
two
red
blacle
RB
wires

in

the

lange
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

continuity
range
is

obvioUs

ly
u
nequal
on

both
sides

adjustment
is

required

If

any
malfunction
is

found
un

screw
the

fastening
nut
o
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

Iy
to
the

position
N

by
means
of

the

selector

leVer

When
the
slot
of
the

shaft
becomes
vertical
the
detent

worles
to

position
the
shaft

correctly

with
a

clicking
sound

Move
the
switch

slightly
aside

so

that
the

scie
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

pin
with
the
lesler
If

Ihe
malfunc

tion
still
remains

replace
the
inhibitor

switch

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission
and

engine
for
trou

ble

by
measuring
the
maximum
num

bers
of
revoiutions
o
the

cngine
while

vehicle
is
held
in

a
stalled

condition

The
carburetor
is
in

fullthrollle

opera

tion
with
the
selector
lever
in

ranges

1
2
and
I

respectively
Com

pale
the
measured

results
with
the

standard

values

Components
to
be
tested
and

test
itelJUl

I

Clutches
brake
and
band
in
trans

mission
for

slipping

2

Torque
converter
for

proper
func

tioning

3

Engine
for
overall

properly

STAU

TEST
PROCEDURES

Before

testing
check
the

engine
oil

and

torque
converter

oil
warm

up
the

engine

cooling
w

ter
to

suitable
tem

perature
by

running
at
1
200

rpm
with

the

selector
lever
in
the

range
P

for

sevcral
minutes

Warm

up
the

torque

converter
oil

to
suitable

temperature

60
to
lOOoC

140
to
2120F

I

Mount
the

engine

tachometer
at
a

location
that

allows

good
visibility

from

the
driver

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
SIIre

to

depress
the
brake

pedal

firmly
with
the
left
foot
before
de

pressing
the

accelerator

pedal

3
Throw
the

selector
lever
into
the

range
11

4

Slowly

depress
the

accelerator

pedal
until
the

throttle
valvc
is

fully
Automatic

Transmission

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

verter
oil
and
coolant

6
Make
similar
staU
tests
in

ranges

2
I
and
R

CAUTION

The

dill
test

operstion
81

specified
in

i18m
4

should
be

I118de
within

fiv

lIeonds

If
it
tBkes
too

long
the

oil

If

and
the
cluti
hn
blllke

and
b
nd

elll

ly
I
Suf

ficient

cooling
time
should

be

given

r

eech
test
for
the
four

IlInges

0
Z
1
end
R

JUDGEMENT

High
stall
revolution

more
than

staitdard
revolution

If
the

engine
levolulion
in

stall

condi
ion
is

higher
than
the
standard

values
it
indicates

that
onc
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
line

pr
ssure

High
rpm
in
0

2
and
I

and

normal

rpm
in
6R

Rear
clutch

slipping

High
rpm
in
D

and
2
and

normal

rpm
in

One

way

clutch

slipping

High
Ipm
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

needed

If
while

coasting
after

starting

with
the
levcr
in
I

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

cuJt
to
ascertain

However
jf
it

occurs

with

the
lever
in
1

range
engine

AT
41
revolution
increases

up
to
the
same

level

as
in
1st

range
It

is

impossible

to

check
it
in
the

stall
test

2
Standard
stall
rnoluiion

If
the

engine
revoluiion
in

stall

ondition
is
within

he
standard

values
the
control
elements
are

nOf

mally

operating
in

the

ranges
D

2n
I

and
R

Also
the

engine
and
one

way

clutch
of
the

torque
converter
are

norinal
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
lIand

ard

revolution

If

the

engine
revolution
in

stall

condition
is

lower
than
the

standard

values
it

indicates
that
the

engine
is
in

abnormal

condition
or
the

torque
con

verter
s
one

way
clutch
is

slipping

4
O
hers

I
If

the

accelerating
performance

is

poor
until
vehicle

speed
of

approxi

mately
SO

kmfh
30
MPH
is
attained

and
then
normal

beyond
that

speed
it

can
be

judged
that
the

torque
con

verte
c

s
one

way
clutch
is

slipping

2

If
the

torque
converter

sane

way
dutch
sticks

vehicle

speed
can

not

exceed

approximately
80

kmfh

SO
MPH
in
the

road
tesl

In
such

a

case
the

torque
converter

oil
tem

perature
rises

abnormally
and
so

special
care
is

required

3
If
the

transmission
does
not

op

erate

properly
at
all
vehicle

speeds
it

indicates

poor
engine
performance

ROAD

TEST

An

accurate

knowledge
of
the
au
to

matic

transmission
is

required
for
an

exact

diagnosis

II
is

recommended
that
a

diagnosis

guide
chart
with
the
standard

vehicle

speeds
for
each

stage
of

the

up
and

down

shiftings
be

prepared
Measured

vehicle

speeds
are
to

be
filled
in

the

adjoining
column
after
each

testing

Also
it

is
advisable
to

mount

a

stopper
for

positioning
the
throttle

opening

CHECKING
SPEED

CHANGING
CONDITION

The

driver
s

feeling
during
gear

changes
should
also
be
checked

atten

lively

J
A

sharp
shock
or

unsrnoothness
is

felt

duting
a

gear
change

Tlus
indicates
that

the
throttle

pres

sure
is
too

high
or

some
valve
con

nected
to
the

throttle
is

faulty

2
A

gear
change
is
made
with

a

long

and

dragging
feeling

This
indicates
that
the

throttle

pres

sure
is
too
low
or

some
valve
con

nected
to
the

throttle
is

faulty
Automatic
Transmission

CHECKING
ITEMS
DURING

SPEED
CHANGE

I
In
D

range
gear
changes
DJ

D

D3
are
effected
In
R

range
the

speed
does
not
increase

2

The
kickdown

operates
properly

3

By
moving
the
lever
from
D
to

I

gearchangesD3
2
1
1

are
effected
In
the

ranges
j
and

I

the

engine
braking
works

prop

erly

4
In
I
the

speed
does

not
in

crease

S
Should
be

quickly
fixed
at
2

SHI

SCHEDULE

Non
Cellfornla
models
Sedan
end
Hetchbeck

1
2

1
l
2

I

I
2

L
3

1

1

1
0

E

I
Kickdown

range

I

T

7
87f

1

500
2
000

2
500

Output
shaft

speed
rpm

km
h
9

1P
29
30
4
0
50
6

0
70
80

MPH

6
1
0
io

30
40
5

0

California
models
All
models
and
Non
Callfornie
models

Wegon
0

E

c

E

3
00

11

81f

5

400

u

a
15
75

0

u

If

z
5
0
0

19
69

0

500

I

c

I

100

3
94

E

I
1

000

I
Kickdown

range
1

2

1
2
1

2

2
3

2
0

0

7
87

E

c

E

300

11
81

5

400

15
75

a

500

0

19
0

0

i

z

km
h

9

MPH

6
3

1

1

1

1

11
12

1

1

1
range

6
In
P

vehicle
can
be

parked

properly

If

any
malfunction
occurs
in
second

gear

during
the

road
test
thai
is

if

vehicle
shakes

drags
or

slings
while

shifting
up
from
D

directly
to

D3
or
in

shifting

up
from
D

to

D
the

braKe
band
should
be
ad

justed
If
these
troubles
remain

after

the
brake
band
is

adjusted
check
the

servo

piston
seal
for
oil

leakage

2

32
3

3
0
00

4
000
3
50
0

9
0

60
100

AT434

2

321
3

500
1

000
1
500
2
600

2
50
0
3
600
3
500
4
000

Output
shaft

speed
rpm

10

20
30

40
50
6
0
70
80
90

100

1

0
io

3

0
4

0
50
60

AT435

Fig
A
T
86

Shift
Schedule

AT
43

LlNE
PRESSURE

TEST

When

any
slipping
occurs
in

clutch

or
brake

or
the

feeling

during
a

speed

change
is
not
correct
the
line

pressure

must
be
checked

Measuring
line

pressure
is

done

by
a

pressure
gatqle
attached
to

pressure

measuring
holea
after

removing
blind

pluga
locate
d
at

transmission
case

The
line

pressure
measurement
is

begun
at

idling
and
taken

step
by

step

by

enlarging
the
throttle

opening
Automatic

Transmission

For

line

pressure
data
when
shift

ing
gem
refer
to
Road
Test

1
A

sharp
shock
in

up
shifting
or

too

high
changing
speeds
are
caused

mostly
by
too

high
throttle

pressure

2

Slipping
or

incaPability
of

opera

tion
is

mostly
due
to
oil

pressure

leakage
within
the

gear
trains

or

spool

valve

LINE
PRESSURE

GOVERNOR
FEED

PRESSURE

Non
Cellfornill
models

Seden
and
Halchbeck

At

idling

Range
At
stall

test

R
Une

pressure
kg
em

psi

Range

3

0
to
5
5
43
to
7S

3

0
to
4

0
43

to
57

6

0
to
12
0
S5to
171
o

2
R

D

3
0
to
4
0
43

to
57
2
snSOSSOOI

CD

AT454

1
Line

pressure

2

Governorpressure

3
Servo
release

prenure

Fig
AT
87

Mecuuring
Line
Pre

Line

pressure

kg
cm2

psi

14
0

to
16
0
199
to

22S

94
to
11
0

134
to
156

10
0

to
12
0

142
to
171

94
to

11
0

134
to
156

At

idling
California
models
All
models

end
Non
Callfornill
modela
Wa
on

At
stall

test

R
Line

pressure
kg
cm

psi
Range
Range

R

o
4
2
to
5
6

60
to
SO

3
2

to
3
S
46
to
54
D

2

6
0
to
II
7
S5

to
166
2

3
2

to
3
S

46

to
54

AT44
Une

pressure
kg
cm2

psi

143
to

16
2

203
to
230

9
9
to
11
1
141

to
15S

10
2

to
II

7
145
to
166

9
9
to
11
1

14110
15S

JUDGEMENT
IN
MEASURING

LINE

PRESSURE

Low

idling
line

pressure
in
the

ranges
D
2

R
and
P

This
can
be
attributed
to
trouble
in

the

pressure
supply
system
or
too
low

output
of

power
caused

by

I
A

worn
oil

pump

2
An
oil

pressure
leak
in
the

oil

pump
valve

body
or
case

3
A

sticking
regulator
valve

2
Low

idling
line

pressure
i

n
cer

tain

ranges
only

This
is

presumably
caused

by
an
oil

leak
in
the
devices
or
circuits
con

nected
to
the
relevant

ranges

I
When
there
is

an
oil

leaJi
in

the

rear
clutch
and

governor
the

line

pressure
in
on
2
and
I

are
low

but
the

pressure
i

nonnal
in

R

2
When
an
oil
leak
occurs
in

the

low
and
reverse
brake
circuit
the
line

pressure
in

oR
and
P
are
low

b
t

the

pressure
is

normal
in

0
2

and

I

3

High
idling
line

pressure

Thi
is

presumably
caused

by
an

increased

aC

1ulT
t
rott
e

pr
ssure

owing
to
a

leak
in

the
vacuum
tube
or

diaphragin
or
by
an
increased
line
Automatic
Transmission

pressure
due
to
a

sticking
regulator

valve

Vacuum

leakage
is
checked

by

directly
measuring
the

negative

pres

sure
after

removing
the
vacuum

pipe

A

puncture
of
the
vacuum
dia

phragm
can
be

easily
ascertained

because
the

torque
converter
oil
is

absorbed
into
the

engine
and

the

exhaust

pipe
emits
white
smoke

4
Item
to
be
checked
when
the

Ii

e

pressure
is

increasing

In
this

c
1eck
the
line

pressure

should
be
measured
with
vacuums
of

300

mmHg
Il

SI

inHg
and
0

mmHg

0

inHg
in

accordance
with
the
staIl

test

procedure

i
If
the
line

pressure
does
not
in

crease

despite
the
vacuum
decrease

check
whether
the
vacuum
rod
is

i

corporated

2

If
the
line

pressure
does
not
meet

tile
standard
iUs

caused
mostly
by
a

sticking
pressure
regulating
valve

pres

sure

regulating
valve

plug
or

amplifier

TROUBLE
SHOOTING

CHART

INSPECTING
ITEMS

I

Inspection
with
automatic
trans

mission
on
vehicle

AT
45
A

Oil
level

B

Range
select

linkage

C
Inhibitor
switch
and

wiring

D

Vacuum

diaphragm
and

piping

E
Downshift

solenoid
kickdown

switch
and

wiring

F

Engine
idling

rpm

G

Oil

pressure
throttle

H

Engine
stall

rpm

I

Rear
lubrication

J
Control
valve
manual

K
Governor
valve

L

Band
servo

M
Transmission
air
check

N
Oil

quality

o

Ignition
switch
and
starter
motor

P

Engine
adjustment
and
brake
in

spection

2

Inspection
after

inspecting
auto

matic
transmission
on
vehicle

m
Rear

clutch

n

Front
clutch

q
Band
brake

r
Low
and
reverse
brake

s
Oil

pump

t

Leakage
of
oil

passage

u
One

way
clutch
of

troque
converter

v

One

way
clutch
of
transmission

w
Front

clutch
check
ball

x

Parking
linkage

y
Planetary
gear

Automatic
Transmission

TROUBLE
SHOOTING
GUIDE
FOR
3N71B

AUTOMATIC
TRANSMISSION

Ordel
Test
item

Checking
Oil
level

gauge

j
Downshift
solenoid

3
Manual

linkage

4

Inhibitor
switch

5

Engine
idling
rpm

6
Vacuum

pressure
of
vacuum

pipe

7

Operation
in
each

range

g

Creep
of

vehicle

Stall
test
1
Oil

pressure
before
t
sting

2
Stall
test

3

Oil

pressure
after

teSling

Road
test
L

Slow
acceleration

Ist
2nd

2nd
3rd

2

Quick
acceleration

Ist
2nd

2nd
3rd

3
Kick
down

operation

3rd
2nd
or
2nd
1st
Procedure

Check

gauge
for
oil
level
and

leakage
before
and
after
each

test

Check
for
sound
of

operating
solenoid
when

depressing

accelerator

pedal
fully
with

ignition
key
ON

Check

by
shifting
into

P
R
N
0
2
and

ranges
with
selector
lever

Check
whether
starter

operates
in
N
and
p

ranges
only

and
whether
reverse
lamp
operates
in
R

range
only

Check
whether

idling
rpm
meet
slandard

Check
whether
vacuum

pressure
is
more
than
450

mmHg

17

72

inHg
in

idling
and
whether
it

decreases
with

increasing
rpm

Check
whether
transmission

engages
positively
by

shifting

N

0
N

2
N
to
I

and
N
R

range

while

idling
with

brake

applied

Check
whether
there
is

any
creep
in

0
2

and

R

ranges

Measure
line

pressures
in
D
2
I
and
R

range
while

idling

Measure

engine
rpm
and
line

pressure
in
0
2
t

and

R

ranges
during
full
throttle

operation

Note

Temperature
of

torque
con
erter
oil
used
in

test

should
be
from
6

to
lOO

C
140
to
2120F

i
e
suf

ficiently
1

up
but
not

o
heeted

CAUTION

To
cool
oil
between
IIch
mil

test
for
OH
ZH
1
H

Ind

RH

nnges
idle

engine
i
e

rpm
It
Ibout

1
200

rpm
for

more
thin
1
minutll
in

P

nnge
MeeRlr
ment
time

mUlt

not
be
more
then
5

seconds

Same
as
item
1

Check
vehicle

speeds
and

engine
rpm
in

shifting
up
1

st

2nd

range
and
2nd
3rd

range
while

running
with
lever
in

D

range
and

engine
vacuum

pressure
of
about

200

mmHg

7
87

inHg

Same
as
item

1
above

except
with

engine
vacuum

pressure
of

o

mrnHg
0

inHg
i
e
in

position
just
before
kickdown

Check
whether

the
kickdown

operates
and
measure
the
time

delays
while

running
at
30
40

50
60
70
km
h

19
25
31

37
43

MPH
in

OJ
range

AT
49

Oldel

Others
Automatic
Transmission

Test
item

4
Shift
down

Or
O
O

5
Shift
down

Or
I

1

6
Shift
down

0
2

7
Shift

up

1
1

8
Shift

up
or
down
when
start

ing
in

2

ranae

9

Parking

Abnormal
shock
oil

leakage
Procedure

Check
vehicle

speeds
and

engine

rpm
in

shifting
down
from

3rd
2nd
1st

sequentiaUy
while

coasting
with

accelerater

pedal
released
in
0

range
and

engine
vacuum

pressure
of
about
450

mmHg
17
72

inHg

Check
for
shifti

ng
do
n

I
I
nd

engine
blaking
and

further
for

shifting
down
I
I
and

engine
braking
tel

shifting
the
leyer
into

I

range
with
the
accelerator

pedal

released
and
the

engine
vacuum

pressure
of
0

mmHg
0

inHg

while

driving
at
about
50
km
h
30

MPH
in
0

range

Check
for

quick
shifting
down

OJ
2
and

engine
braking

after

shifting
the
lever
into
2

range
while

driving
at
about

50

km
h
30
MPH
in

0

range

Further
chec
for

locking
of
the
transmission
i

2nd

gear

ratio

regardless
of
vehicle

sPeed

Check
for
failure
of
the
transmission

to
shift

up
during

acceleration
when

starting
in

range

Check
the
transmission
for
not

shifting
up
or
down

during

acceleration

or
deceleration
when

starting
in

2

range

Confirm
that
yehicle
will
notmoye
on

grade
when

shifting

to
pn

range

Enter
into
record
conditions
observed

durq
these
lests

such
as

gear
noise

abnormal
clutch
noise

and
acceleration

performance

AT

50

Rropeller
Shaft
Differential

Carrier

PROPELLER
SHAFT

INSPECTION

GENERAL
INSPECTION

I

Check

propeller
shaft
tube
sur

Cace
for
dents

or
cracks
If

damaged

replace
with
an

assembly

2
Check

journal
for

axial

play
If

there
is

play
replace
propeller
shaft

mbly

Note

JournaI
cannot
be
disassem

bled

PROPELLER
SHAFT

VIBRATION

To
check
and

correct
an
unbal

anced

propeller
shaCt

proceed
as
Col

lows

L
Remove

undercoating
and
other

foreign
material

which
could

upset

shaft
balance
and

check
shaft
vibra

tion

by
road
test

2
If
shaft
vibration
is
noted

during

road

test
disconnect

propeller
shaft

et

differential
carrier

companion
flange

rotate

companion

flange
180

degrees

and

reinstall

propeller
shaft
ff

3

Again
check

shaft
vibration
If

vibration
still

persists
replace

propel

ler
shaft

assembly

REMOVAL
AND

INSTALLATION

REMOVAL

I

Raise
car
on
hoist
Put
match

malks
both

on

propeller
shaft
and

companion

flange
so
that
shaft

can
be

reinstalled
in
its

original
position

2
Remove
bolts

connecting
pro

peller
shaft
to

companion

flange

PD459

Fig
PD
2

Removing

Propeller
Shaft

PD
2
Tightening
torque
kg
m
ft
b

@
2
410
3
3
1710

24

PD468

Fig
PD
l

PropellerSha
t

3

Draw
out

propeller
shall
sleeve

yoke
from
transmission

by

moving

shaft
realWard

passing
it
under
rear

axle

Plug
up
rear
end
of

rear
extension

housing
to

prevent
oil

leakage

Note
Remove

propeller
aheCt

care

Cully
so
as
not

to

demege
spline

sleeve

yoke
and
rear
oil
seal

INSTALLAnON

To

inS
aJI
reverse
the

foregoing

removal

prOCedure

CAUTION

Align

propeller
shift
with

com

penion

fllnge
of

differentiel
Clrrier

ulling
reference
marks

prl
1Cribed
in

Remova

procedure
and

tightsn

them
with
bolts

Failure
to
do

so

could
resuh
in

driving
vibration

fJ
Tightening
tOlquo

Propellol
sheft

to

companion

f1enge
bolts

2
4

to
3
3

kg
m

117
to
24
ft
b

Propeller
Shaft
Differential
Carrier

DIFFERENTIAL
CARRIER

fQ

@

1

11
Thrust
washer

12

Ring
gear

13
Differential
case

14
Lock
strap

15
Drive

pinion

16
Pinion
height
adjusting
washer

17
Pinion
rear

bearing

18

Collapsible
spacer

19
Side

bearing
cap

20
Gear
carrier
1

Companion
flange

2
Oil
seal

3
Pinion
front

bearing

4
Sidebearing

5
Side

bearing
adjusting
shim

6
Thrust
walher

1
Side

gear

8

Lock

pin

9
Pinion
mate
shaft

10
Pinion
mate
Tightening
torque
kg
rn

ft
lb

@
14
to
30

101
to

211

@
6
0101
0
43
to
51

@
5
0
to
5
0
36
to
43

@
1

6
to
2
4

12
to
11

PD446

Fig
PD

3
Differential
Carrier

2

Visuany
inspect
parts
for
wear

of

damage

3

Rotate

gears
to
see
that
there
is

any

roughness
which

would
indicate

damaged

bearings
or

chipped
gears

Check
the

gear
teeth
for

scoring
or

signs
of
abnonnal

wear
Measure

pre

load
of
drive

pinion

4

Set

up
a
dial
indicator
and
check

the
backlash
at
several

points
around

ring

gear
Backlash
should
be

specified

value

Ring
gear
to
drive

pinion
backlash

0
10

to
0
15

mm

0

0039
to
0

0059
inl
spected
before

any

parts
are
removed

from
it

These

inspections
are

helpful
in

fmding
the
cause
of
a

problem
and
in

detennining
the

corrections
needed

Mount
carrier
on
Differential

Carrier
Attachment
ST06320000
REMOVAL

I

Jack

up
rear
of

car
and

sup

port
it

by

placing
a

safety
stand
under

rear
axle

case
Drain

gear
oil

2
Remove

propener
shaft
and
rear

axle
shafts

These
works
can
be
done

by

referring
to
Rear

Axle
and
Rear

Suspensionu

3
Loosen
off
bolts

securing
differ

ell
tial
carrier

to
rear
axle
ca
se
and

take
out
differential

gear
carrier

as

sembly

PRE

DISASSEMBI
Y

INSPE
CTION

Differential
carrier
should
be
in
5

Check
the

gear
tooth
contact

with
a
mixture

of
recommended

Fig
PD
4

Holding
Differential
Carrier

PD

3

I

powder
and
oil

applied
sp
hingly
to

all

ring
gear
teeth

For
the
tooth

contact

pattern
see

paragraph
dealing
with
tooth
contact

pattern
adjustl1ll
nt

DISASSEMBLY

FINAL
DRIVE
ASSEMBLY

I
Put

match
marks

on
side

bearing

caps
and

carrier
and
remove
side

bearing
caps
and

take
out
differential

case

assembly

using
Slide
Hammer

HTI2400000

PD266

Fig
PD

5

Removing

Diffe
ntial

Ca
e

A
embly

Note
Care
should
be
taken

not
to

confWle
the

left
end

right
hand

bearing
caps
and

bearing
outer

races

so
that

reassembly
will
be

easily

carried
out
with
the
same

parts
in

the

original
position

2

Rel
love
drive

pinion
nut

using

Drive
Pinion

Flange
Wrench

ST31530000
and

pull
off

companion

flange
using
a
standard

puller

Fig
PD

6
Removing
Drive
Pinion

Nut

3
Extract
drive

pinion
assembly
to

the
rearwards

by

tapping
the

front
end
Propeller
Shaft
Differential
Carrier

of

drive

pinion
with
a
soft
baminet

Drive

pinion
can
be
taken
out

together

with
rear

bearing
inner

race

collapsi

ble

spacer
and
washer

4

Remove
oil
seal
and
take
out

front

bearing
inner

race

Note

Oil
seal

must
not
be
reused

5

Hold
rear

bearing
inner

race
with

Drive

Pinion
Rear

Bearing
Inner
Race

Puller
ST30031000
and
extract
from

drive

pinion
with

a

press

STJ0031000

r

1

i
9

PD205

Fig
PD
7

Removing
Pinion

Rear

Bearing
I
nfUr
Race

6

To
remove
outer
races

of
both

front

and
rear

bearings
apply
a
brass

drift
to

race
side
surface
and

with

draw

them

by
tapping
the

top
of

drift

with

a
hammer

PD268

Fig
PD

B
Removing
Pinion
Front

and
Rear

Bearing
Outer
Race

DIFFERENTIAL
CASE

I

When

replacing
side

Wle
Differenliai

Side

Puller
ST3305
1001

and

ST33052000
bearing

Bearing

Adapter

PD
4
Fig
PD
9
Removing
Side

Bearing

Note

a

Puller
should
be
bandlOd
with
care

in

catching
the

edge
of

bearing

inner
race

b
Be
careful
not
to
confuse
left
and

right
band

parts

2

Rel
love
ring
gear
by
sp
readJ
lg

out
lock

straps
and

loosening

ring
gear

bolts
in

diagonally

3

Punch
off

pinion
mate
shaft
lock

pin
from

ring
gear
side

using
Solid

Punch
KV3810Ig00

KV3810I800

PD319

Fig
PD
I0
Removing
Lock
Pin

Note
Lock

pin
is
slaked
et

pin
hole

mouth
on
differential

case
Do
not

punch
it
off

forcibly
without

checking
how
it
is

staked

4

Draw
out

pinion
mate
shaft
and

remove

pinion
ID3
tes
side

gears
and

thrust
washers

Note

Put
mams
on

gear
end
thrust

waaher
so
that

they
can
be
re

installed
in
their

origiital
positions

from
which

they
were
removed

INSPECTION

Thoroughly
clean
all
disassembled

parts
and

examine
them
to
see

that