DATSUN 510 1968 Service Repair Manual
Manufacturer: DATSUN, Model Year: 1968, Model line: 510, Model: DATSUN 510 1968Pages: 252, PDF Size: 12.2 MB
Page 131 of 252

126
CHAPTER
TEN
@
r
Removal
Pick
up
1
Remove
mountlng
clIps
and
U
bolt
See
FIgure
16
2
Disconnect
front
tube
and
exhaust
manuold
flange
connectIon
3
Remove
exhaust
system
from
vehicle
Inspection
1
Check
for
damage
at
tube
flanges
Replace
u
defectIve
2
Check
for
dIstortIon
damage
or
detenora
tIon
of
tubes
and
mufHers
Replace
or
reparr
as
required
3
Check
for
damage
to
hanger
straps
mounting
clIps
U
bolts
and
rubber
Insulators
Remove
and
replace
as
requrred
Installation
Install
the
umts
m
the
reverse
of
removal
After
InstallatIon
nm
the
engme
and
check
for
exhaust
gas
leaks
Page 132 of 252

CHAPTER
ELEVEN
CLUTCH
TRANSMISSION
AND
DRIVESHAFf
CLUTCH
i
es
ription
Datsun
uses
a
single
dry
dtsc
clutch
with
dIaphragm
spring
The
major
components
are
clutch
cover
pressure
plate
dIaphragm
spring
and
WIre
nngs
The
clutch
dISC
has
riveted
plates
on
both
surfaces
and
coll
spnngs
arranged
in
a
link
The
coll
springs
absorb
shock
to
soften
and
smooth
clutch
engagement
Figure
1
next
page
is
an
exploded
diagram
of
the
clutch
assembly
Clutch
Removal
The
transmIssion
must
be
separated
from
the
engme
to
remove
tlte
clutch
assembly
This
can
be
done
by
removmg
the
transmISSIon
and
engme
from
the
vehicle
as
a
umt
or
by
remoVIng
the
transmiSSIon
separately
Removal
of
the
engine
and
transmissIOn
IS
descnbed
In
Chapter
Six
Removal
of
the
transmISSIon
only
IS
descnbed
later
in
tills
chapter
Outcb
Disassembly
1
Separate
clutch
assembly
from
flywheel
Loosen
and
remove
bolts
dIagonally
and
gradu
ally
as
shown
m
Figure
2
2
Remove
dust
cover
from
clutch
housmg
3
Remove
return
spnng
from
beanng
sleeve
Separate
the
Withdrawal
lever
from
bearing
sleeve
w
1
4
Remove
release
bearmg
and
bearing
sleeve
from
front
cover
Remove
wIthdrawal
lever
ball
pm
Figure
3
CD
1
Withdrawal
lever
ball
pin
2
Withdrawal
lever
3
Return
spnng
4
Release
beanng
4
Page 133 of 252

128
CHAPTER
ELEVEN
1
Clutch
disc
assembly
2
Clutch
cover
3
Hex
bolt
4
Lock
washer
5
Withdrawal
lever
6
Withdrawal
lever
ball
pin
7
Lock
washer
8
Retainer
spnng
9
Clutch
sleeve
10
Release
bearing
11
Holder
spring
12
Dust
cover
13
Return
spring
14
Push
nut
15
Hex
nut
CD
9
11
8
6
7
1
Release
beanng
2
Beanng
sleeve
2
5
13
12
15
14
Clutch
Inspection
and
Repair
1
Thoroughly
clean
all
dISassembled
parts
ex
cept
for
the
dISc
assembly
and
release
bearmg
In
a
SUItable
solvent
2
Check
all
parts
carefully
for
wear
cracks
and
other
defects
3
Check
the
clutch
disc
for
oil
soaked
or
cracked
faCIngs
warpmg
loose
nvets
exceSSIve
wear
and
broken
spnngs
4
Check
the
pressure
plate
for
sconng
bum
marks
blue
tlnted
areas
and
cracks
If
any
of
the
above
condItIons
are
found
re
place
the
clutch
dISC
and
or
the
pressure
plate
Replace
dISC
assembly
1f
facmg
IS
worn
so
that
the
facmg
heIght
above
the
nvet
IS
less
than
00118m
03mm
Very
mmor
bum
marks
and
Page 134 of 252

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
129
scratches
on
the
pressure
plate
may
be
removed
with
crocus
cloth
If
the
source
of
clutch
trouble
IS
still
not
evl
dent
take
the
pressure
plate
and
disc
to
a
compe
tent
garage
to
check
the
pressure
plate
finger
release
height
and
nmout
Never
attempt
to
ad
just
the
fingers
or
dismantle
the
pressure
plate
Without
proper
tools
and
experience
Check
the
release
bearing
by
holdmg
the
Inner
race
and
rotatmg
the
outer
race
With
hght
pres
sure
applied
If
the
bearing
is
rough
or
noisy
replace
it
CAUTION
Never
clean
the
release
bearing
In
solvent
It
IS
prelubriCflted
at
the
fac
tory
Simply
wipe
with
a
Unt
free
cloth
If
the
release
bearing
shows
any
signs
of
loss
of
lubncant
install
a
new
bearing
Replace
the
sleev
lu
SignS
of
wear
are
evident
Clutch
Reassembly
1
Be
sure
your
hands
are
clean
for
the
initIal
assembly
2
Inspect
the
clutch
facings
pressure
plate
and
flywheel
to
be
sure
they
are
free
from
grease
oil
and
other
foreIgn
material
3
TIghtly
fit
release
bearmg
onto
the
bearing
sleeve
When
beanng
IS
mstalled
turn
bearmg
With
a
finger
to
make
sure
It
operates
smoothly
4
Apply
multI
purpose
grease
to
the
bearmg
sleeve
InSIde
groove
See
Figure
5
CD
Ji
rot
Pac
thiS
r
r
r
1
1i
QI
ecess
5
Apply
multi
purpose
grease
to
the
WIth
drawallever
and
bearing
sleeve
contact
point
and
to
the
Withdrawal
lever
ball
pm
and
with
drawallever
contact
point
f
6
Clean
the
clutch
pllot
bushmg
and
fill
It
With
multi
purpose
grease
7
Mount
the
WithdraWal
lever
release
bearing
and
bearing
sleeve
to
the
clutch
housing
Install
dust
cover
on
clutch
housing
and
connect
return
spring
to
WithdraWal
lever
8
Place
the
pressure
plate
and
clutch
disc
in
positIon
on
the
flywheel
Make
certain
the
pres
sure
plate
is
In
the
same
positIon
relative
to
fly
wheel
as
when
removed
Use
a
clutch
alIgning
bar
Special
Tool
ST20630000
FIgDfe
6
to
alIgn
the
clutch
dISc
splIne
to
the
pllot
bearing
CD
NOTE
If
the
special
tool
is
not
avail
able
cut
an
input
shaft
from
a
Junk
transmission
9
Install
the
pressure
plate
mounting
bolts
Tighten
the
bolts
dIagonally
opposite
each
other
one
turn
at
a
time
to
prevent
warpmg
Torque
the
bolts
to
10
8
to
15
9
ft
lbs
1
5
to
2
2
kg
m
Remove
durmny
shaft
10
Install
the
clutch
housing
to
the
engme
Clutch
ntrol
Datsuns
have
a
hydraulic
clutch
control
system
It
consISts
of
a
pendant
clutch
pedal
Page 135 of 252

130
CHAPTER
ELEVEN
master
cylInder
operatlng
cylinder
and
with
drawal
lever
Figure
7
shows
all
components
whlle
Figures
8
and
9
are
exploded
VIews
of
the
master
cylmder
and
operatIng
cylinder
for
models
smce
1970
Prior
models
are
similar
In
construction
MASTER
CYLINDER
Master
Cylinder
Removal
Sedans
and
Wagons
1
Remove
cleVIS
pin
mstalled
at
the
pushrod
2
Disconnect
clutch
hose
from
the
master
cylin
der
and
dram
flwd
3
Remove
bolts
to
free
master
cylinder
Master
Cylinder
Removal
Pick
up
1
DIsconnect
pushrod
from
clutch
pedal
2
DIsconnect
clutch
hose
from
master
cylInder
and
drain
fluid
3
Remove
bolts
to
free
master
cylInder
Master
Cylinder
Disassembly
1
Remove
filler
cap
and
drain
fluid
2
Pull
back
dust
cover
and
remove
snap
ring
3
Remove
stopper
pushrod
piston
assembly
cup
and
return
spnng
CD
i
Master
Cylinder
Inspection
1
Clean
all
parts
thoroughly
In
clean
brake
flwd
2
Check
cylInder
and
pISton
for
wear
or
dam
age
Replace
as
required
3
Check
the
clearance
between
cylInder
and
pIston
If
clearance
is
larger
than
0
005
in
0
13mm
replace
the
cylinder
4
Replace
the
pISton
cup
whenever
it
is
re
moved
from
the
cylInder
or
when
It
shows
SIgnS
of
wear
or
damage
5
Check
all
other
parts
for
wear
or
damage
and
replace
as
required
Master
Cylinder
Assembly
1
Soak
piston
cup
m
brake
fluid
2
Install
pIston
cup
3
Coat
the
cylinder
and
pIston
thoroughly
WIth
brake
flwd
and
assemble
4
Replace
other
parts
in
the
reverse
order
of
removal
Master
Cylinder
Installation
1
Bolt
the
master
cylInder
into
pOSItion
2
Adjust
clutch
pedal
heIght
by
adjusting
the
pushrod
length
Pedal
heIght
from
floorboard
Page 136 of 252

e
j
11
i
Il
Il
15
2
Tl
CTOKICO
2
Piston
assembly
3
Piston
cup
4
Valve
assembly
CI
5
Val
e
spring
I
6
Spnng
seat
7
Return
spring
8
Spnng
seat
9
Push
rod
assembly
10
Push
rod
head
11
Nut
12
Stopper
13
Stopper
ring
14
Dust
cover
15
0
reservoir
2
rl
16
Reservoir
bend
assembly
17
ReservOir
cap
NABCO
1
k
IN
Page 137 of 252

132
CHAPTER
ELEVEN
CD
NAnCO
22
20
21
r
i
T
l
C
r
Jl
i
i
18
Clutch
operating
cylinder
19
Piston
cup
20
PIston
21
Dust
cover
22
Push
rod
23
Bleeder
screw
24
Bleeder
cap
22
I
should
be
8
150
m
207mm
for
the
sedan
and
wagon
Pedal
heIght
should
be
591
m
150mm
for
the
pick
up
3
Apply
multI
purpose
grease
to
all
PIvot
pOInts
4
Bleed
all
aIr
out
of
the
sy
tem
as
dIscussed
below
OPERATING
CYLINDER
Operating
CyHnder
Removal
1
Remove
retum
spring
2
Disconnect
clutch
line
from
operating
cyl
inder
18
Ii
TOKICO
21
I
LL
18
23
24
I
I
3
Disconnect
pushrod
from
wIthdrawal
lever
4
Release
two
bolts
holdmg
operating
cylInder
to
clutch
hOUSIng
5
Remove
operating
cymder
from
clutch
hous
mg
Operating
CyHnder
Disassembly
1
Remove
dust
cover
2
Remove
snap
ring
All
other
parts
can
now
be
removed
See
Figure
10
Operating
CyHnder
Inspection
Check
all
parts
especIally
the
pIston
cup
for
wear
and
damage
Replace
if
defects
are
found
Page 138 of 252

CLUTCH
TRANSMISSION
AND
DRlVESIIAFI
133
C
8
Q@J
@
C
Operating
Cylinder
Reassembly
1
Soak
pISton
cup
m
brake
flUid
and
Install
It
In
the
same
pOSitIOn
as
before
removal
2
Apply
brake
flUid
to
the
cylInder
and
pIston
before
mstalImg
piston
3
Replace
all
parts
m
the
reverse
order
of
removal
Operating
Cylinder
Installation
1
RemstallatIon
IS
the
reverse
of
removal
2
Bleed
aIr
from
the
hydraulIc
system
3
Adjust
the
pushrod
so
that
withdrawal
lever
end
play
IS
0
0787
to
0
1181
In
2
0
to
3
Omm
Procedures
for
the
adjustment
are
given
below
WITHDRAWAL
LEVER
AD
JUSTMENT
Correct
adjustment
of
the
clutch
withdrawal
lever
IS
essentIal
InsufficIent
free
travel
between
the
release
bearmg
and
dIaphragm
fingers
can
cause
the
clutch
to
slIp
ExceSSIve
free
travel
can
prevent
full
dISengagement
of
the
clutch
Refer
to
Figure
11
1
Loosen
lock
nut
2
SCrew
In
the
pushrod
fully
with
the
adjustmg
nut
3
Unscrew
adJustmg
nut
1
turns
TIghten
lock
nut
J
4
Check
the
end
play
of
the
wIthdrawal
lever
End
play
should
be
0
0787
to
0
0906
in
2
0
to
2
3mm
The
correct
end
play
will
give
a
clear
ance
of
0
0512
m
1
3mm
between
the
release
bearmg
and
diaphragm
fingers
@
1
Lock
nut
2
AdJustmg
nut
3
Wrthdrawal
ever
4
Release
beer
ng
5
Diaphragm
spnng
20
to
30
0
079
to
0
11
B
Unit
mm
m
5
If
the
above
adjustment
does
not
result
in
satIsfactory
clutch
operatIon
the
clutch
dISC
is
probably
worn
excessIvely
and
will
reqUire
re
placement
as
preVIously
dIScussed
BLEEDING
CLUTCH
SYSTEM
AIr
In
the
clutch
hydraulIc
system
makes
shIft
Ing
gears
extremely
difficult
1f
not
impOSSIble
To
bleed
the
system
proceed
as
follows
1
Remove
the
bleed
screw
dust
cap
from
the
operating
cylInder
2
Attach
a
bleeder
hose
to
the
bleed
screw
Immerse
the
other
end
of
the
hose
m
a
container
f
hydraulIc
brake
fluid
3
Check
to
see
that
clutch
master
cylInder
reservoir
IS
full
of
brake
flUid
ReplenISh
if
necessary
4
Open
the
bleeder
screw
three
quarters
of
a
tlIrn
and
have
an
assistant
pump
the
clutch
pedal
slowly
Pump
the
clutch
until
the
flUid
entenng
the
contatner
is
clean
and
free
from
bubbles
5
TIghten
bleed
screw
Replace
dust
cap
Refill
the
flUid
reservoir
Page 139 of 252

134
CHAPTER
ELEVEN
CLUTCH
SERVICE
DATA
AND
SPECIF1CATIONS
Table
1
proVIdes
serVIce
data
and
specifica
tIons
for
the
clutch
system
TRANSMISSION
Description
Datsuns
are
eqUIpped
with
either
an
auto
matic
or
manual
transrmSSIOn
Due
to
the
com
pleXity
of
the
unIt
and
the
need
for
special
tools
and
knowledge
overhaul
of
the
automatic
trans
mISSIon
is
not
covered
In
thIS
manual
Auto
matIc
transmISSIOn
checks
and
adjustments
are
given
later
m
thIS
chapter
Reparr
and
mainte
nance
should
be
referred
to
a
Datsun
dealer
or
qualIfied
mechamc
The
manual
transmission
is
a
four
forward
Table
1
speed
unlt
controlled
With
a
floor
mounted
lever
It
consIsts
of
transrmSSIOn
case
rear
extensIOn
housing
and
gear
assembly
The
clutch
housmg
and
transmissIOn
case
are
a
sIngle
unIt
The
rear
extension
housmg
is
detachable
Figure
12
shows
the
4
forward
speed
transmission
Transmission
Removal
Removal
of
the
transmIssion
from
dIfferent
models
Varles
accordmg
to
the
dIfferent
struc
ture
Involved
The
following
procedures
gen
erally
apply
to
all
types
Important
dIfferences
are
noted
1
Prom
InsIde
the
vehicle
remove
the
floor
covenng
around
the
gear
shift
so
that
the
shIft
lever
can
be
removed
2
Jack
up
the
vehIcle
and
support
it
with
four
CLUTCH
SERVICE
DATA
AND
SPECIFICATIONS
Pressure
Spring
Free
length
Fitted
length
and
load
Out
of
rlght
angle
MInimum
sprmg
force
Clutch
Release
Lever
Release
bearlng
to
dlaphragm
clearance
Diaphragm
sprlng
to
flywheel
height
Release
lever
to
flywheel
height
Clutch
DISC
FaCing
size
Outer
dIameter
x
inSide
diameter
x
thlckness
Thickness
Free
Compressed
Number
of
tOrslO
1
springs
Minimum
depth
of
rivet
head
from
faCing
surface
Allowable
facmg
runout
Allowable
spline
free
play
Pressure
Plate
Allowable
refacmg
limit
Clutch
Pedal
Height
when
not
depressed
Free
stroke
of
pedal
head
Pressmg
strength
at
full
stroke
Clutch
Master
Cylinder
Diameter
MaXimum
clearance
between
cylinder
and
pIston
Tightening
Torque
Clutch
assembly
securing
bolt
2
059
In
52
3mm
1
149
In
197
4
4
Ib
29
2mm
44
2
kg
o
1968
per
3
937
In
5
per
100mm
15
00472
to
0
0551
In
1
2
to
1
4mm
1732
0
0394
m
44
O
1
Omm
1
988
0
0197
In
505
0
05mm
787
X
5
120
x
0
0140
In
200
x
130
x
3
5mm
o
3386
to
0
3543
m
8
6
to
9
Omm
03012
to
0
3130
m
765
to
7
95mm
6
00118
In
03mm
o
097
In
0
5mm
00157
m
04mm
o
0394
In
1
Omm
8
150
m
207mm
o
984
m
25mm
33
Ib
15
kg
0625
m
15
87mm
00051
m
0
13mm
J
i
r
174
to
188ft
Ib
24
to
2
6
kg
m
Page 140 of 252

CLUTCH
TRANSMISSION
AND
DRIVESIIAFI
135
stands
If
possible
the
use
of
an
open
pit
or
hydraulIc
hOISt
IS
recommended
3
Figure
13
shows
the
underside
of
the
sedan
and
statIon
wagon
Figure
14
IS
the
pick
up
4
DIsconnect
negatIve
battery
cable
from
termInal
r
j
7T
@
r
1
Cross
shall
2
Back
up
lamp
sWitch
cable
3
Speedometer
dn
e
cable
4
Exhaust
manifold
5
Propeller
shall