DATSUN 510 1968 Service Repair Manual

136
CHAPTER
ELEVEN

5
DIsconnect
and
remove
starter
motor
from

flywheel
housmg
as
descnbe4
In

Chapter
NIne

6

Dls
onnect
handbrake
WIre
at

equalIzer

pIVOt
See

Figure
15
sedan
and

wagon

I

j

7
Loosen
the
two

exhaust
center

p1pe
clamps

and

turn
the

premuffier
complete
With
center

pIpe
to
the
left
as
shown
m

FJgure
16
sedan
and

wagon

f

W

y
I

0
Y
h

0

ilo

8
DIsconnect
front
exhaust
tube
from
exhaust

man1fold

pICk
up

9
Rem

ye
four
bolts
from

companion
flange

of

gear
carner
and
detach

dnve
shaft
See

Figure

17
Seal
the
end
of
rear
extensIon

housmg
to

prevent
011

leakage

1
0
Dlsconn

i
gpeedometer
drive
cable
from

rear
extensIOn
as
shown
In

Figure
18

11
On
models
s

quipped
disconnect
neutral

gear
sWitch
third

gear
sWitch
and
reverse

gear

sWItch
as
shown
in

Figure
19
next

page

f
t

iT
l
t

t

W
12
Refer
to

Figure
20
whIch

IS
an

exploded

View
of

the

gear
shIft
lever
and
control

system

DependIng
on
the
model
dISconnect
the
shift

lever
as
shown

13
Remove
cross
shaft

assembly
from
trans

rmsslOn
case
See

Figure
21

14
Remove
clutch

operating
cylinder
from

clutch

housmg

15
Place
a

Jack
beneath
the

engme
011

pan
and

SuppOFt
the

engme
Do
not

apply
Jack
pressure

M

I

CL
SMISSION
AND
DRIVESIIAF1
137

i@

v

l
ll
r

1
Neutral

gear
swrtch

2
TransmISSIon
swllch

thud

geu

3

Reverse
gear
SWitch

@1
Control
arm
14
Return
spnng

2
StnkBr

bushmg
15
Re
erse
check
ball

3
O

nng

cep
16
Check

spnng

4
O

nng
17
Retalmng
pm

5
Control
O

nng
18
Slnlung
rod

6

First
and
second
fork
rod
19
Slnlung
pm

7
First
and
second
shill
fork
20
O

nng

8
Thud

and
fourth
lork
rod
22
Control
arm

pm

9
Third

and
fourth
shill
fork
23
Control
washer

10
Reverse
fork
rod
24
Control
arm

bushmg

11
Reverse
shill
fork
25
Control

spnng

12
Rolled

pm
26
Thrust
wesher

13
Reverse
fork

pm
27
Retammg

pm

9

0

11

f
Ir

foUr

1
i

1
k

jl

n

1

1
l

28
Control
lever
35
Lower
washer

29
Control
lever
knob
36
Self

lockmg
nut

31
Washer
37
Rubber
boot

32
Controlle
er
rubber
41
Tnmsmlsslon
hole

cover

33
Washer
42
Tappmg
screw

34

Upper
washer

29

c

28

37

16
t

f

f

1

I
13

1

12
5

T

2V

T
19

25
26

20
31

e
32

@
35

@
36

138
CHAFfER
ELEVEN

to
dram

plug
Use
a

block
of
wood
between
the

011

pan
and
the

Jack

16
Remove
two
bolts

attaching
the
transmIS

sion
to
the
rear

engine
mount
Place
a

Jack
under

the
transmISSIon
and

support
the

transmissIOn

Remove
four
bolts

holdmg
the
rear

engme
cross

member
to
the

body
sedan
and

wagon

17
Place
a

Jack
under
the
transmISSIon
and

sup

port
the
transmISSIon
Remove
rear

engine

mount
from
transmlssiod
and
cross
member
as

shown
In

Figure
22

pIck
up

18
Lower
the

supporting
jacks
to
mclme
the

engine
downward
and
there
IS
sufficient
room

to
remove
the
transmission

19
Pull
the
transmission
towards
the
rear
until

the
dnve
shaft

splme
IS
clear
of
the
clutch

pres

sure

plate
Be
careful
not
to

damage
the

splines

or
the

pressure
plate

6

40

t

I
j

fI
1
2

fr

l

3332

3

1
TransmiSSion
case

2
TransmiSSion
case

3

Thread
taper
plug
t

4
TransmiSSion
Iront
cover

5
Front
cover
011
seal

6
Front

cover
gasket

7

fixmg
bolt

8

Flxmg
bolt

9

Spnng
washer

10
Rear
extension

11
Reer

extenSIon
011
seal

12
Breather

assembly

13
Extension
bushmg

14
Extension

gasket

15
Hex
bolt

16
Hex
bolt
17

Spllng
washer

18
Dowel

pm

19

Beallng
retainer

20
Hex
bolt

21

Spnng
washer

22
Bottom
cover

23
Bottom
cover

gasket

24
Bottom
cover
hex
bolt

25

Spnng
washer

26
Drem

plug
essembly

27
Dram

plug
assembly

29
SwItch

30
Hex
bolt
l
r

I

J

J
I
n

S
T

r
re
l

1
Rear
extension
mountmg
bolts

2
Rear

engme
mounting
bolts

20
Remove
the
transmISsion

by
lowenng
the

transmISsion

Jack

Transmission

Disassembly

Figures
23
and
24
are

exploded
views
of
the

transrmSSlon
case
and

gear
assembly

@

46

47
6

i

4826J

1
41

44

5

31

Spring
washer

32
Hex
bolt

33

Spnng
washer

34
Check
ball

35
Check
ball

spnng

36

Plunier

37

Plug

r

38

P1
g

39
Washer

o
12

10

13

11

40
MaIO
dllve

beanng
retamer

41
Pinion

42
PInion
sleeve

43
Sleeve
011

seal

44
O

lIng

45
Retamer

46
Lock

plate

47

Spnng
washer

48
Hex
bolt

50
Neutral
SWitch

51
Dust
co
er

52
Hex
bolt

53

Sprmg
washer

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
139

@
1
Re
erse

gear

2
Re
erse
shaft

3
Reverse

gear

4

Snep
nng

5
Thrust
washer

6
Reverse

gear
needle

beanng

7
Counter

gear

8
Counter
shaft

9
Counter

spacer

10
Needle
bearing
assembly

11
Thrust
washer

12
Thrust
washer
J

f

I

I

I

I

I

I

I

I

I

I

J

I

I

i

I
f

4
rm

9
13
MaIO
dnve

gear

14
MaIO
dn
e

beanng

15
MaIO
drl
e

spacer

16
MelO
drl
e

snap
ring

17
MaIO
shaft

18
steel
ball

19
Thrust
washer

20
MaIO
shaft
needle
bearing

21
Meln
shaft

bushlOg

22
MaIO
shaft
flm

gear

23
Baulk

nng

24
Sh

ftlOg
Insert

25

Spread
sprlOg

9

1
Remove
the
drain

plug
and
dram
the
trans

rmSSlon

gear
011
Into

a
SUItable
container

2
Remove
the
dust
cover
and
release
the

re

tainer

spring
securing
the

Withdrawal
lever
Re

move
the
lever
and
release

bearing
from
the

clutch

housmg

3
Remove
the

pIn
securing
the

strikmg
rod
to

the
control
lever
and
remove
the
control
lever

4
Remove
five
front
cover

securing
bolts
and

the
front

cover

i

j

5
Remove
14
hex
bolts

and
washers
from
bot

tom
cover
Remove
bottcifu
cover
from
trans
I

I

I

I

I

I

i

i

J
34

34
26
Synchronize
hub

27
CoupllOg
slee
e

28
MaIO
shaft
needle

beanng

29
Second

gear
assembly

30
MaIO
shaft
needle

beanng

31
Third

speed
gear

32
Baulk

nng

33

ShlftlOg
IOsert

34

Spread
spring

35

Synchro
hub

36
Slee
e

coupllOg

37

Snep

nng

38
MaIO
shaft

pilot
beanng

39
Main
shaft

bearing

40
MaIO
shaft

snap
ring

41
Re
erse
maIO

gear
and
hub
set

42
Rwerse
hub
maIO
shaft

43

Speedometer

gear

44
Steel
ball

45
MaIO
sheft
loc
l
washer

46
MaIO
shaft

nut

28
iy

25

25

21

rmssion
case

Figure
25
shows
the
tranSmISSIon

With
the
bottom
cover
removed

6
Remove

speedometer
dnve

pmion
assembly

7
Remove
hex
bolts

holdmg
rear
extension

housmg
to
transmISSIon
case
Remove
rear
ex

tenSIon

housing
as
shown
m

Figure
26

8

fDlsengage
stnkmg
rod
from
fork
rod

gates

9
Unscrew
three
check
ball

plugs
and
remove

sprmgs
and
balls

10
Drive
out

retatnmg
pms
used
to
secure
forks

to
fork
rods
and
remove
rods
and
forks

11
Move
the
1st
2nd

and
3rd
4th

coupling

140

CHAPTER

ELEVEN

@

sleeve
into

gear
at

the
same
tune
This
will
lock

the
mam
shaft

Release
the
main

shaft
nut

12

Withdraw
the

counter
shaft
and
remove
the

counter

gear
with

the
two
needle
roller

bearings

and

spacers

13

Refer
to

Figure
27

Release
reverse
idler

gear
snap
ring
Remove
reverse

idler

gears
and

shaft

@
14
Remove

four
bolts

holding
maIn
shaft
bear

Ing
retainer
to
transmissIOn

case
as
shown
in

Figure
28

@

15

Withdraw
the
main
shaft

assembly
from

transmIssion
case
See

Figure
29

16
Release
the

snap
ring

securing
the
3rd
4th

synchronizer
and
hub

Remove
the
hub

com

plete
With

couplIng
sleeve

17

Remove
the

300

speed
gear
and

needle
roller

bearings
from

maIn

shaft

18

Unscrew
the
main
shaft

nut
and

remove
the

nut

and

locking
plate

19
Remove
the

speedometer
drive

gear
and

steel
ball

20
WIthdraw
the

main
shaft

reverse

gear
and

hub

21
Press
off
the
main
shaft

bearmg

complete

With
the

bearing
retainer

CLUTCH
TRANSMISSION
AND
DRlVESHAFI
141

22
Remove
the
thrust
washer
and
mam
shaft

1st

speed
gear
complete
With
needle
roller
bear

mg
Be
careful
not
to
lose
the
small
steel
ball

which
locates
the
thrust
washer
Remove
main

shaft
1st

gear
bushmg

23
Remove
the
mam
shaft
2nd

speed
gear
and

needle
roller

bearmg

24
To
dISassemble

synchronizer
assembly
re

move

sprmgs
from
both
ends

Figure
30
shows

the

synchronIZer
dIsassembled

@

d

@

n

9
cr

1

Coupling
slee
e

3

Synchro
hub

2

Shlftmg
msert
4

Spread
spnng

25
DIsassemble
the
mam
dnve

gear
by
remov

mg
the

snap
nng
Use

snap
nng
phers

26
Remove
mam
dnve

gear
bearmg
With
bear

Ing
puller
and
arbor

press

Transmission

Inspection
and

Repair

1

Thoroughly
clean
all
dtsassembled

parts
With

solvent
Check
all

parts
carefully
for
wear
dam

age
or
other
defects

2
Check
the

mountIng
faces

carefully
for

pittIng

or
burrs
that
could
cause
011
leaks
Make
certatn

to
clean
off
all
old

gaskets
and

gasket
adhesive

3

RepaIr
or

replace
dowel

pm
if
bent
or
dam

aged

4

Inspect
rear
extensIon

bushing
for

SIgnS
of

mtenor
wear

Replace
as

reqUIred

5

Inspect
ball

bearmgs
for

SIgnS
of

damage
to

inner
or
outer
race
Rotate
the
ball

bearmg
and

feel
for

SIgnS
of
fnctIon
or

draggmg
If
ball
bear

mgs
are
defectIve
In

any
way
replace
them

6

Replace
needle

bearIngs
1f
wom
or

damaged

7
Check
the
mam
shaft
and

gears
for
wear
damage
or
cracks

Replace
defectIve

parts
as

required
Check
the
maIn
shaft
for

straIghtness

WIth
a

measurmg
gauge
as
shown
m

Figure
31

MaxImum

runpulls
0
0059
m
0
15mm

@

8
Measure
the
backlasH
of
each

gear
See

Fig

nre
32
Standard
backlash
is
0
0020
to
0
0039

In
0
05
to
0
10mm
Gear
wear
hrmt
IS
0
0079

In
0
20mm
If
the

gears
are
worn

beyond
limtt

both
the
dnve
and
dnven

gears
should
be
re

placed
as
a
set

@

9
Check
the
end

play
of
all

gears
WIth
a
feeler

gauge
End

play
should
be
between
0
0020
to

0
0059

m
005
to
0
15mm
If
end

play
IS
not

correct
Sh1nIS
of
vanous
thicknesses
are
avail

able
to
correct
the
condItIon

10
Check
balk

nngs
for
wear

plttmg
and

burrs

Replace
1f
defective

11
Place
balk

rmg
in

pOSItion
on
cone
of
each

gear
Push
the
balk

rmg
onto
the

gear
and
check

gap
between
balk

nng
end
face
and
clutch
tooth

142

CHAPTER

ELEVEN

face
See

Figure
33
When
the

gap
IS
less
than

o
031
m
0
8mm

replace
the
balk

ring

@
1
2

to
1
6

mm

0047
to
0

063
In

12
Check
the

sh1fnng
msert
for

damage
or

wear

Replace
as

required

13
Check
the

OIl
seal
for
deformatIon
wear

or
cracks

Replace
1f
defectIve

14
Check

the
rear

engme
mount
Insulators
Re

place
1f
worn
or

defectIve

Transmission

Reassembly
and

Adjustment

Reassemble
the
transmISSIon
In
the

reverse

sequence
used
ill

dIsassembly
The

followmg

Items
should
be
observed

dunng

reassembly

1
Be
certaIn
that
the
1st

2nd
and
3rd
4th

syn

chronizer
hubs
are

facmg
ill
the
correct
dIrec

tIon

2
Use
a
brass
dnft

to
fit
the
1
st

gear
needle

bearlOg
collar

to
the
shaft

as
shown
In

Figure
34

il

@
3
Use

a
hollow
dnft
and

press
arbor

to
fit

the

main
shaft

ball

bearmg
to
the
shaft

as
shown

10

Figure
35

4
To
hold

synchronIZer
hub
end

play
to
a
mm

imum

snap
rmgs
of

vanous
thIcknesses

are

available

5
To
lock
the
malO
shaft

m
the
transrmSSlOn

case
double
mesh
the

gears
and
msert
the
as

sembly
10
the

case
Install
the
lockwasher
and

lock
nut

on
the

mam
shaft

Torque
the
lock

nut

to
57
8
to

79
5
ft
lb
8
0
to
11
0

kg
m

Fumly

bend
the

lock
washer
around
the
lock

nut
as

shown

In

Figure
36

1
lock
washer
2
Lock

nut

6
Assorted

thIckness

snap
nngs
and
thrust

washers

are
avallable
to
malOtam

proper
end

play
after

assembly
ThIS

applIes
to
the
main

CLUTCH
TRANSMISSION
AND
DRlVESHAFI
143

dnve

gear
counter

gear
and
reverse
Idler

gear

7
Reassemble
the
shIft
fork
and

operatIng
lever

correctly
Refer
to

Figure
37
Be
certam
there
IS

no

gap
between
fork
rod
and
shUt
fork

8
Install
each
fork
rod

together
with
check
ball

plug
check
ball
check
ball

spnng
and
mterlock

plunger
PosItIon
so
that
fork
rod
check
ball

groove
comcldes
wIth
the
ball
When
mstalled

correctly
the

upper
surface
of

plug
IS
flush
With

upper
surface
of

adapter
Install

a
sUItable
lock

Ing
agent
on
the
threads
of
the

plugs
durmg

assembly
Figure
38
shows
the
check
ball

layout

@
9
Install

operatIng
lever
In
correct

pOSItIon

See

Figure
39
Assemble
thrust

washer

snap

nng
and

operatlDg
lever
m
case
Install
lock

pm

Torque
the
lock

PIDS
to
0
2
to
0
3
In
lb

0
3
to

04

kg
cm

@

Washer

Cross
shall

lock

pm

Transmission
Installation

Install
the
tranSmISSIon
m
the
reverse
order

used

durmg
removal
Make
certam
that
all
bolts

Wires
and

parts
are
remstalled

TRANSMISSION
SERVICE
DATA

AND
SPECIFICATIONS

Table
2

proVIdes
the
servlce
data
and

specm

catIons
for
the
sedan

wagon
an
d

pIck
up

u

1

Operating
lever

assembly

2
Reverse
check

3
Reverse
shift
fork
shift
rod
4
3rd
4th
shift
fork
shift
rod

5
3rd
4th
shIft
fork
shift
rod

6

Operating
lever

assembly

144

CHAPTER

ELEVEN

TAANSMISSlON
SERVICE
DATA
AND
SPECIRCATIONS
Table
2

r

General

SpecificatIOns

Gear
Ratlo

1st

2nd

3rd

4th

Reverse

011

capacity

Detail

SpeCIfications

Gear
backlash

Replacement
standard

Gear
end

play

Balk

ring
cone

clearance

Replacement
standard
5
tl
viV

t
O

5
0

If

3657

2558

1419

1000

3638

3
6

pints

Tightening
Torque
ft
Ib

kg
m

Engine
transmission
installation
bolt

Front
cover

transmission
installation
bolt

Rear
extensIon
transmIssion
installation
bolt

Main
shaft

tlghtel
lng
bolt

Companion
flange
tightening
nut

Rear

engine
mount
installation
bolt

Filler

plug

Drain

plug

Back

up
lamp
sWItch

Bottom
cover
bolt

Speedometer

pinion
bolt

Interlock

plug

Operating
lever

Reverse
check

Control
lever
installatIOn
bolt
00020
to
0
0039
In

005
to
0
10mm

o
0079
In

0
20mm

o

0020
to
0
0059
In
0
05
to
0
15mm

00472
to
0
0630
In

1
2
to
1
6mm

00315
In

08mm

174
to
20
2
24
to
2
8

5
8
to
7
2
0
8
to
1
0

10
1
to
130
1
4
to
1
8

57
8t079
5
80to
11
0

72
3
to
101
2
100

to
140

239

to
27
5
3
3

to
38

18
1
to
25
3
25

to
3
5

14
5

to
21

7
20

to
3
0

14

5
to
21
7
2
0
to
3
0

5
8

to
7
2
0
8

to
1
0

2
2
to

2
9
03
to

0
4

123
to
15
2
1
7
to
2
1

22

to
2
9
0
3

to
0
4

14

5
to
21
7
20
to
3
0

13
7
to

15
9
1
9
to
2
2

DRIVE
SHAFf

Descripti

ll

TIie
dnve
shaft

on
the
sedan
and

wagon
is

a

smgle
plece
tubular

steel
unit
The

pick
up
uses

a
two

pIece
umt

Joined
by
a

Journal
assembly

unIversal

Joint
UnIversal

Jomts
connect
the

drive
shaft
ends
to
the
transmissIOn
and
d1f

ferentIal
The

Jomts
consist
of
the

Journal
as

sembly
yoke
sleeve
and

yoke
flange
Figure
40

is
an

explOded
VIew
of
the
dnve
shaft

used
on

the

sedan
and

agon
Figure
41

page
146

shows
the

dnve
shaft
used
on
the

pIck
up

The

pIck
up
has
a

grease
mpple
on
the

dnve

shaft
to
lubncate
the
dnve
shaft

spline
The

sedan
and

wagon
are
not

so

equipped
The
uni

versal

Jomts
shouldebe
removed
and

lubncated

every
24
000

rmles

Removal

1
Release
the
handbrake

j
2
Jack

up
the
rear
of
the
vehIcle
and

support

on
stands

3
Loosen
the
end

clamps
on
the
exhaust

pipe

and
turn
the
exhaust

pIpe
and

premuffier
to
the

left
so
that
dnve
shaft
can
be

removed
sedan

4
Remove
handbrake
rear
cable

adjustIng
nut

from
the

adjuster
DIsconnect
left
hand
cable

from
the

adjuster
sedan

5
DIsconnect

rear

flange

yoke
from
the
com

panIon
flange

by
removmg
the
nuts
and
bolts

See

Figure
42

CAUTION

Be

careful
not
to
let
end

of
dnve

shaft

drop
to

ground
Lower

It

gently

6
Pull
the
dnve

shaft

backwards

away
from
the

transmISSIon
Remove
the
dnve
shaft

as
soon

as
It
IS
clear
of
the
transmISSIon
Make

cert
n
to

support
both
ends
of
the

shaft

duriftgi
mb

sedan
and

wagon
v

4
1tr
l

t

t

CLUTCH

TRANSMISSION
AND

DRIVESIIAFT

145

r

@

l

S

St

P

t
ii

t

1

1

1

0

8
12

3

5

8
12
13

i

f

p
1
2

5

7

Remove

mounting
bolts
from
both
transmis

sion
and

dllIerential

gear
case
Remove

bearing

mounting
bracket
Lower

drive
shaft
to

ground

pick
up

J
iw

sembly

The
drive

shaft
is
a

balanced
unIt
and
must

be

marked
as
to

parts
location
before
dIS

assembly
Mark
the
relative

positions
of
the

drive

shaft
sleeve

yoke
flange
yoke
and
other

parts
so

they
can
be
reassembled
m
their

origmal

positions