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 201 of 252

196
CHAPTER
FOURTEEN
WHEEL
CYLINDERS
pICK
UP
Figures
17
and
18
illustrate
the
front
and
rear
wheel
cylinders
used
on
the
pick
up
Mainte
nance
procedures
are
essentially
the
same
as
specIfied
for
the
sedan
wagon
BRAKE
SYSTEM
BLEEDING
Brakes
require
bleeding
whenever
air
enters
the
system
lowering
the
effectIve
braking
hy
draulic
pressure
This
can
happen
when
the
@
@
@
@
D
1
Wheel
cylmder
hOUSing
2
Piston
3
Piston
cup
4
Piston
head
5
Dust
cover
6
Connector
7
Connector
bolt
8
Paclang
9
Bleeder
screw
10
Bleeder
cap
master
cylinder
or
wheel
cylinders
are
serviced
or
If
the
fluid
m
the
reservoir
TWlS
dry
Air
can
also
enter
through
a
leaky
brake
line
or
hose
Find
the
leaky
line
or
hose
and
replace
it
before
bleeding
When
handling
brake
fluid
be
careful
not
to
get
any
on
the
brake
shoes
or
body
paint
Brake
shoes
will
be
permanently
damaged
requiring
replacement
Body
pamt
can
be
damaged
unless
you
Wipe
the
area
with
a
clean
cloth
immedi
ate
then
wash
it
with
a
soapy
solution
r
@
@
1
Wheel
cyhnder
hOUSing
2
Piston
3
Piston
cup
4
Dust
cover
5
Snap
ring
6
Connector
7
Packmg
8
Connector
bolt
9
Bleeder
screw
10
Bleeder
cap
@
Page 202 of 252

BRAKES
IV
197
I
Ensure
that
the
brake
flUid
reservOir
at
the
master
cylmder
IS
full
and
that
the
vent
m
the
cap
is
open
2
Connect
a
plastIc
or
rubber
tube
to
the
bleeder
valve
on
the
nght
rear
wheel
Suspend
the
other
end
of
the
tube
m
a
Jar
or
bottle
filled
With
a
few
Inches
of
clean
brake
flwd
During
the
remaInIng
steps
keep
thiS
end
submerged
at
all
times
and
never
let
the
level
in
the
brake
flUid
reservoir
drop
below
full
3
Open
the
bleeder
valve
on
the
nght
rear
wheel
about
one
turn
Have
an
asSistant
depress
the
brake
pedal
slowly
As
soon
as
the
pedal
is
all
the
way
down
close
the
bleeder
valve
and
let
the
pedal
up
Repeat
thiS
step
as
many
tImes
as
necessary
until
pure
flUid
WithOUt
au
bubbles
comes
from
the
tube
4
Bleed
the
remammg
wheels
m
the
followmg
order
left
rear
nght
front
and
left
front
Keep
checkmg
the
brake
flUid
reservoir
to
make
cer
tam
It
doesn
t
TWl
out
of
flUId
5
When
all
wheels
are
bled
fill
the
reservOIr
to
the
full
level
Never
reuse
the
brake
flwd
bled
from
the
system
or
any
that
has
been
lymg
around
Start
With
a
fresh
contaIner
HANDBRAKE
Figures
19
next
page
and
20
page
199
are
exploded
views
of
the
handbrake
system
used
on
the
sedan
and
statIon
wagon
respectively
F1gDre
21
page
200
shows
the
pick
up
handbrake
system
Front
Cable
Removal
Sedan
and
Wagon
I
Release
handbrake
completely
Disconnect
the
front
cable
by
removmg
the
cleVIS
pm
that
connects
to
the
handbrake
control
stem
2
Screw
out
the
adJusting
nut
from
the
rear
end
of
the
front
cable
Disconnect
the
cable
from
the
center
lever
4
Remove
the
hand
brake
cable
clamp
from
under
the
verucle
Pull
out
the
lock
plate
fixmg
the
front
cable
to
the
front
cable
retamer
Ex
tract
the
front
cable
5
Unfasten
the
front
cable
outer
casing
from
the
bracket
Remove
the
cable
Front
Cable
Removal
Pick
up
I
Loosen
handbrake
2
Remove
cleVIS
pm
and
separate
cable
from
outer
lever
See
Figure
22
p
3
Remove
cleVIS
pm
and
eparate
cable
from
front
lever
Removecable
4
Remove
center
cable
from
control
levers
by
removmg
cleViS
pms
Rear
Cable
Removal
Sedan
I
Remove
adJusting
nut
from
adJuster
DIScon
nect
left
hand
rear
cable
from
handbrake
ad
Juster
2
Pull
out
lock
plates
see
Figure
23
and
re
move
cleVIS
pms
that
connect
rear
cable
With
rear
wheel
cylJnder
levers
Remove
cable
Rear
Cable
Removal
Wagon
1
Remove
both
cleVIS
pins
at
the
ends
of
the
rear
cable
2
Remove
cable
Page 203 of 252

f
I
I
3
21
24
22
2
Control
slem
16
Retainer
spring
34
Fulcrum
pin
3
Bracket
17
Nylon
spacer
35
Return
spring
16
4
Control
gUide
18
Front
cable
assembly
36
Equalizer
16
5
Ratchet
nail
20
Bolt
With
spring
washer
37
lock
washer
6
Nail
spnng
21
Plain
washer
38
Hex
nut
15
7
Set
sprIng
22
Hex
bolt
39
Clevls
pin
tr
8
Set
sprlOg
plO
23
Spring
washer
40
Cotter
pin
9
lever
assembly
24
Plain
washer
41
Right
hand
rear
cable
10
Control
yoke
25
Warmng
sWItch
42
left
hand
rear
cable
16
7
11
CleVIS
pm
26
Warnlng
SWitch
43
Cable
clevis
18
12
Clevis
pin
28
Truman
pin
44
Cable
adjuster
13
CleVIS
pin
29
Adjusting
nut
45
Adjusting
nut
14
CleVIS
pin
30
Hex
nut
46
lock
plate
15
Washer
33
Center
lever
47
CleVIS
pin
48
Cotter
pin
46
47
I
36
4
U39
I
11
43
48
J
I
l
ft
l
I
46
a
z
@
9
Page 204 of 252

18
I
70
I
69
72
lt
n
30
2
Control
stem
3
Bracket
4
Control
gUide
5
Ratchet
nail
6
NaIl
sprtng
9
Level
assembly
10
Control
yoke
11
Clevis
pin
12
ClevIs
pin
13
CleviS
pIn
1
CleviS
pIn
15
Washer
16
Retainer
spring
17
Nylon
spacer
18
Front
cable
assembly
20
Bolt
With
spring
washer
67
n
67
64
68
2
600
56
63
H
54
52
P73
74
i1
51
8
52
e
75
@
53
52a
57
55
58
8
56
21
Plain
washer
22
Hex
bolt
23
SprIng
washer
24
Plain
washer
25
Warning
switch
26
Warning
switch
29
Adjusting
nut
30
Hex
nut
51
Bushing
52
O
nng
53
Plain
washer
54
PlalO
washer
55
Hex
nut
56
Cotter
pIn
57
Lock
washer
58
Hex
nut
65
66
4
62
59
Balance
lever
60
Cross
rod
61
Cross
rod
62
Clip
63
Screw
64
Nut
65
Spring
66
Grommet
67
CleVIS
pin
68
Cotter
pin
69
Center
lever
70
Pin
71
Pin
72
Trunlon
73
Cable
assembly
74
Cotter
pin
75
CleVIS
pin
@
67
68
Ie
Ie
Page 205 of 252

1
Control
bracket
2
Control
ever
3
Control
stem
4
Control
gUide
5
Control
yoke
6
Set
spring
7
Ffont
lever
8
Front
cable
9
Outer
lever
g
10
Center
cable
11
Inner
lever
12
Arm
spring
13
Center
link
rod
14
Equalizer
Imk
15
Equalizer
16
Rear
cable
17
Lock
plate
18
Cable
sprmg
@
a
lI
l
l
o
Page 206 of 252

BRAKES
ZOI
Cross
Rod
Removal
Wagon
I
Remove
the
pull
off
spnngs
at
each
end
of
the
cross
rods
2
RelI
ove
clevis
pms
and
cross
rods
Rear
Cable
Removal
Pick
op
1
Remove
cleVIS
pm
and
disconnect
equalizer
from
equal1zer
link
2
Remove
lock
plate
1
and
cable
spring
2
as
shown
ill
Figure
24
3
Remove
both
rear
brake
drums
DISConnect
rear
cable
from
toggle
lever
3
Separate
cable
connecting
flange
4
from
brake
dIsc
See
Figure
25
4
Remove
rear
cable
Handbrake
Inspection
and
Repair
1
Inspect
all
cables
and
parts
for
damage
ex
cessive
elongation
and
general
wear
Replace
as
reqUlred
I
2
Inspect
ratchet
pawl
and
teeth
on
control
stem
for
excessive
wear
Replace
as
reqUIred
3
Check
springs
for
weakness
Replace
as
reqUIred
Handbrake
Installation
I
Install
parts
of
the
handbrake
system
m
the
reverse
of
removal
Make
certam
all
connections
are
tight
2
Lubncate
all
slIdmg
parts
With
muItl
purpose
grease
Front
Brake
Adjustment
Sedan
and
Wagon
AdJustment
of
the
front
dIsc
brake
units
18
not
reqwred
as
it
18
made
automatIcally
Re
place
the
front
dISC
brake
pads
and
rebwld
the
pISton
assemblJes
If
the
brakes
are
defective
Front
Brake
Adjustment
Pick
up
I
Refer
to
Figure
26
Jack
up
vehicle
to
lIft
wheel
requiring
adJustment
2
Remove
rubber
boot
from
brake
disc
3
Lightly
tap
adJuster
housmg
and
move
It
for
ward
Turn
adJuster
wheel
with
a
screwdriver
and
spread
brake
shoes
Stop
turnmg
adJuster
wheel
when
a
considerable
drag
is
felt
on
brake
drum
NOTE
For
both
left
and
right
brakes
brake
shoes
spread
when
adJuster
wheelIS
turned
downward
4
Return
adJuster
wheel
12
ratchet
teeth
to
obtam
correct
clearance
between
brake
drum
and
shoes
5
Turn
brake
drum
to
make
sure
that
drum
turns
Without
draggmg
If
draggmg
exists
readJust
Page 207 of 252

202
h
l
CHAPTER
FOURTEEN
Rear
Brake
Adjustment
Sedan
and
Wagon
I
Jack
up
the
rear
wheel
2
Release
the
handbrake
completely
3
Figure
27
shows
the
adJustmg
screw
for
the
sedan
Figure
28
for
the
wagon
Depress
the
I
rake
pedal
several
tImes
and
turn
the
adJusting
screw
clockWise
untIl
the
drum
cannot
be
moved
I
by
hand
4
Return
adJusting
screw
counterclockwISe
untIl
the
shoes
are
Just
clear
of
the
drum
ThIS
should
be
about
three
notches
5
Rotate
the
drum
to
see
If
the
shoes
are
draggmg
It
so
readJust
untIl
the
drag
IS
gone
Rear
rake
Adjnstment
pick
np
I
Jack
up
rear
wheel
2
Release
handbrake
AdJust
the
wheel
usmg
the
same
procedure
given
for
the
front
wheel
See
Figure
29
Handbrake
Adjnstment
f
I
Release
handbrake
and
adJust
rear
brakes
as
preViously
descnbed
2
AdJust
the
front
and
rear
handbrake
cable
by
adJustIng
nuts
shown
m
Figure
30
The
stroke
of
the
handbrake
control
stem
should
be
3
346
to
3
740
m
85
to
95mm
sedan
only
3
Refer
to
Figure
31
AdJust
the
front
cable
by
turnmg
the
adJusting
nut
so
that
the
control
stem
stroke
IS
4
330
to
4724
m
110
to
120mm
wagon
only
Page 208 of 252

BRAKES
203
4
32
shows
the
adJusting
pomts
for
the
pick
up
With
rear
cable
stretched
adJust
equal
IZer
link
With
adJust
screw
A
so
that
L
dimensiOn
Is
1
161
m
295mm
Lock
adJust
screw
wlth
locknut
5
AdJust
front
cable
adJust
screw
8
so
that
control
stem
stroke
IS
3
15
to
394
m
80
to
100mm
Lock
adJust
screw
With
lock
nut
SERVICE
DATA
AND
SPECIFICATIONS
Table
1
prOVides
the
servIce
data
and
specm
catIons
for
the
sedan
wa
n
and
pick
up
Table
1
BRAKE
SERVICE
DATA
AND
SPECIRCATlONS
Brake
Pedal
m
Pedal
free
height
Full
stroke
of
pedal
ead
Master
Cylinder
Inner
diameter
MaXImum
clearance
between
cylinder
and
piston
Wheel
Cylinder
Inner
diameter
front
Inner
diameter
rear
MaXimum
clearance
between
cylinder
and
piston
Brake
Drum
and
Rotor
Drum
brake
Inner
diameter
front
DISC
brake
outer
diameter
front
Drum
brake
outer
diameter
rear
MaXimum
allowable
out
of
round
LImit
of
drum
reconditioning
Inner
diameter
MaXimum
rotor
runout
MInimum
rotor
thickness
A
Lining
DImenSion
Front
WIdth
x
thIckness
x
length
Front
dISC
pad
Width
x
thickness
x
length
Rear
Width
x
thickness
x
length
Total
friction
ar
a
drum
type
Total
friction
area
front
diSC
Sedan
Wagon
Pick
up
8
150
In
207mm
533m
135
5mm
5
709
In
145mm
f
o
75
In
1905mm
o
75
In
1905mm
00051
In
0
l
mm
o
006
In
0
15mm
i
20m
508mm
08125
m
20
64mm
o
8
2
In
20
64mm
o
8125
In
20
64mm
il
0007
In
0
18mm
0006
In
015mm
1000
In
254mm
9
130
In
232mm
900
In
228
imm
1000
In
254mm
o
002
m
0
05mm
o
008
In
0
20mm
9
039
In
229
6mm
1004
m
255mm
00024
In
006mm
0331
In
84mm
18x02x96m
45
x
4
5
x
244mm
1
563
x
0
354
x
3
386
In
39
7
x
9
x
86mm
1
575
x
0
18
x
8
642
m
40
x
4
5
x
219
5mm
54
4
sq
In
351
sq
cm
18x02x96m
45
C
4
5
x
244mm
682sq
m
440
sq
cm
1777
sq
In
1142
sq
cm
continued
Page 209 of 252

204
CHAPTER
FOURTEEN
Table
1
BRAKE
SERVICE
DATA
AND
SPECIFICATIONS
continued
Sedan
Wagon
Pick
up
Tightening
Torque
ft
lb
Ikg
m
Fulcrum
pm
25
3
to
28
9
253to289
3
5
to
4
0
3
5
to
4
0
Master
cylinder
mounting
bolts
15
2
to
18
1
152
to
18
1
2
Ito
2
5
2
1
to
2
5
Front
brake
wheel
cylinder
108
to
152
30
4
to
37
6
1
5
to
2
1
4
2
to
5
2
Rear
brake
wheel
cylinder
10
8
to
15
2
10
8
to
13
0
1
5
to
2
1
1
5
to
1
8
Rotor
fixing
bolts
28
2
to
38
3
39to53
Brake
hose
to
wheel
cylinder
123
to
14
5
123
to
14
5
1
7
to
2
0
1
7
to
2
0
Page 210 of 252

CHAPTER
FIFTEEN
BODY
ELECTRICAL
SYSTEM
Exploded
diagrams
of
the
various
systems
are
given
below
Inspection
of
the
constructIon
de
tails
as
given
m
the
exploded
diagrams
should
enable
the
mechanic
to
Identify
remove
repauj
replace
and
mstall
defectIve
parts
General
pro
cedures
are
given
at
the
end
of
the
chapter
WIRING
FJgUres
1
and
2
illustrate
the
winng
and
har
nesses
for
the
sedan
and
statIon
wagon
respect
2
VOLTAGE
REGULATOR
JOE
MARKER
l
AMJ
STARTER
MOTOR
IGHITION
COIL
t
ively
Figures
3
and
4
show
pick
up
winng
SWITCHES
FUSES
Figure
5
page
208
prOVides
details
of
switches
used
through
1969
Figure
6
page
207
covers
SWitches
used
smce
1970
FIgDI
eS
7
page
209
and
8
page
210
provide
further
SWitch
locatlon
and
fnnctIon
informatIon
Fuse
blocks
are
located
on
the
firewall
within
the
engine
compartment
ROOM
LAMP
COMBINATION
lAMP
LICENCE
lAMP
1
Engme
room
harness
2
Instrument
harness
3
Body
harness