ECU DATSUN 510 1968 Service Owner's Manual

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

DIFFERENTIAL
REAR

AXLE
AND
REAR

SUSPENSION
155

i

I

I

I

REAR
SUSPENSION
ARM

SEDAN

Rear

Suspension
Arm
Removal
Sedan

1
Jack

up
the
rear
of
the
vehIcle
and

support
It

on
stands

2
Remove
wheel
and
brake
drum

3
DIsconnect
dnve
shaft
from
axle
shaft

4
Remove
handbrake
cable
from
lever
attached

to
wheel

cylInder

5

Plug
brake
tube
to

prevent
loss
of
brake
flwd

6
Remove
wheel

beanng
lock
nut
rear
axle

shaft
wheel

beanngs
and
OIl
seal
Remove
rear

brake

assembly
from

suspensIOn
arm

7
Place

Jack
under

suspenSIon
arm
remove

shock
absorber
from
lower
bracket
lower

Jack

gradually
remove
coll

spnng
spnng
seat
and

bumper
assembly

8
Remove
two
bolts

secunng
suspensIOn
arm
to

suspensIOn
member
and
remove

suspensIOn
arm

See

Figure
14
9
Remove
rubber

bushmg
from

suspensIon
arm

usmg
a

bushmg
remover
as
shown
In

Figure
15

@

Rear

SllSpension
Arm

Inspection

Repair
and

Installation
Sedan

1
Examme

suspensIOn
arms
for

damage
dents

and
cracks

Replace
tf
defectIve

2
Check
rubber

bushmgs
carefully
for
wear

damage
and

general
condItIon

3
Install

suspensIOn
arm
m
reverse
of
removal

When

Installmg
suspensIOn
arm
to

suspensIOn

member
re

tIghten
the
bolts
after
the
vehIcle

IS

removed
from
stands

Change
self

lockmg
nuts

every
tIme

they
are
removed

dunng
semcmg

REAR
AXLE
SHAFf
WHEEL

BEARINGS
AND
SEALS
REMOVAL

AND
DISASSEMBLY

SEDAN

1
Jack

up
the
rear
of
the
vehIcle
and

support
It

on
stands

2
Remove
wheel
and
brake
drum

3
DIsconnect
dnve
shaft
from
axle
shaft

4
Remove
wheel

bearmg
lock

nut

usmg
axle

shaft

flange
wrench
to
hold
the

companIOn

flange
See

Figure
16

5
Use

a
slIde
hammer
to
Withdraw
the
axle
shaft

assembly
Refer
to

Figure
17

6
Remove
011
seal
and

Inner

bearmg
usmg
rear

axle
shaft

bearmg
dnft
as
shown
In

Figure
18

162

CHAPTER
TWELVE

14
Coat
the
front
bracket

pm
and

bushmg
and

shackle

pm
and

bushing
With
a

soap
solution

pnor
to

assembly

15
The
front

pm
secunng
nut
and
shock
ab

sorber
lower
end

securmg
nut
should
be

re

tightened
after

the
vehicle

is

sittmg
on
the

ground

16

Make
certaJn
the
shackle

bushmg
flange
is

clamped
evenly
on
both
Sides

SHOCK
ABSORBER

REMOVAL
INSPECTION
AND

INSTALLATION

WAGON

1
Jack

up
the

center
of
the
rear
axle
and

sup

port
th
e
axle

housmg
With
stands

2
Reinove
the

lower
end
of
the
rear
shock

absorber
from

spring
seat

3
Loosen
the
four
bolts

secunng
the

upper

bracket
to

body
Remove
shock
absorber
and

upper
bracket

4
Check
shock
absorber
for
leaks
and

cracks

Check
the
shaft
for

straighmess

Replace
1f

defective

5

Inspect
rubber

bushmgs
for

damage
cracks

and

general
condition

Replace
1f
defective

6
Install
the
shock
absorber

by
reversing
the

procedure
used

durmg
removal

DIFFERENTIAL

pICK
UP

The
dlfferenl1al

carner
IS
made

up
of
alum

mum

alloy
and
uses
a

hyp01d
bevel

gear

Proper

lubncatIon
IS
essenl1al
Check
and

replemsh
the

lubncant

every
3
000

mlles
Drain
and
refill

every
30
000
inlles

Figure
30
IS
a
cross
sectional

View
of
the

pick

up
dIfferential
Difterential
Removal

Pick

up

1
Jack

up
the
rear
wheels
and

support
vehicle

With
stands

2
DIsconnect
dnve

pmlOn
companlOn
flange

to

yoke
connectIon

3
Remove

rear
axles

as
descnbed
later
m
thIS

chapter

4
Remove
dlfferenl1al

gear
assembly

Difterential

Inspection
Pick

up

The

followmg

mspection
can
be
done
Without

disassembly
of

the
d1fferenl1al
If
abnormahties

or

damage
eXiSts
refer
further
serVice
and

reparr

to

your
dealer

1
Check
the

tooth
contact

pattern
WIth
lead

OXide
at
two
or
three

pomts
after

remoVlDg
rear

cover
Refer
to

FIgure
5
for

correct
contact

pattern
If
the

pattern
IS

faulty
disassembly
and

adJustment
of
the
dIfIerentialIs

required

2
Measure
backlash
between
dnve

gear
and

pmlOn
With
a
dial
mdlcator
Backlash
should

be

00051
to
0
0071

m
013

to
0
18mm

3
Rotate
the

gears
and
lISten
for

SignS
of
bear

mg
noise

4

Inspect
gear
teeth
for

SIgnS
of

damage
or

cracks

Difterential
Installation

Pick

up

Install
the
differential

by
reversmg
the

pro

cedures
used

dunng
removal

REAR
AXLE
AND

SUSPENSION

pICK
UP

The

rear
axle

IS
of
the

semi

floatIng
type
The

rear
wheels

use

tapered
roller

beanngs
Figure

31

IS
a
cross
sectional
view
of
the
rear
axle

REAR
SUSPENSION

TORQUE
TIGHTENING

SPECIFICATIONS
WAGON

Shock

absorber

upper
bracket
to

body
bolts

Shock
absorber
to

upper
bracket

lock
nuts

Shock
absorber

to
lower
bracket
lock
nuts

Rear

spnng
U
bolt
nuts

Shackle
nuts

Front

pm
nuts

Front
bracket

flxmg
nuts

Brake
dISC
to
rear

housmg
bolts

DifferentIal
carner

to
axle

housmg
bolt

Dnve
shaft

flange
nuts
11
to
18
ft
Ib
1

5
to
2
5

kg
m

12

to
16

ft
db
17
to
2
2

kg
m

25
to
33
ft
Ib
35
to
45

kg
m

43

to
47
ft
Ib
60
to
6
5

kg
m

32
to
36
ft
Ib
45
to
50

kg
m

32
to

36
ft
Ib
45
to
5
0

kg
m

13
to
17
ft
Ib
18
to
23

kg
m

20
to

28
ft
Ib
28

to
3
9

kg
m

14
to
16
ft
Ib
20
to
2
2

kg
m

20
to
28
ft
Ib
28

to
3
9

kg
m

164

CHAPTER

TWELVE

Rear
Axle
Removal

Pick

up

1
Jack

up
the
vehicle
and

support
It
With

stands

2
Remove
wheels

and
brake
drum

3
Remove
brake
shoe

and
chsconnect
hand

brake
WIre
See

Figure
32

4
Remove
four
nuts

holding
brake
end
to
axle

Disconnect

brake
hne
Refer
to

Figure
33

@

5
WIthdraw

axle
shaft
Be
careful
not
to
dam

age
01l
seal
ill
axle
case
SIde

6
Secure

axle
m

holdmg
fixture

or
secure

WIth

vise

7
Unbend
lockwasher
With
screwdnver

as

shown
m

FIgure
34

Do
not
reuse
lockwasher

replace
With

new
one

8
Remove
lock

nut
With
a
wrench
or

special

tool
shown

m

Figure
35

9
WIthdraw
axle

beanng
brake
disc
and
bear

mg
cage
by
usmg
a

puller
or

SpecIal
tool
shown

m

Figure
36
@

10

Remove
011
seal
as

required
Do
not

reuse

011
seal

agaJn
replace
It
With

a
new
one

t

11
To
remove

bearmg

cup
from

cage
remove

seal

apply
a
brass
bar
and

tap
It

evenly
With
a

hammer

Rear
Axle

Inspection
nnd

Installation

Pick
up

1
Check

the
axle
for
bends
and
cracks

Replace

1f

damaged

DIFFERENTIAL
REAR

AXLE
AND
REAR
SUSPENSION

165

2
Check

wheel

bearmgs
for

damage
or
noise

Replace
them
If
defective

3
Be

sure
to
use
new
011

seals
and
lockwashers

4
FIt

beanng

cup
and

grease
seal

to

cage
Tap

WIth

a
brass

hammer
while

fittIng
FIll

grease

seal

IIp
With

wheel

beanng
grease
after

fittmg

5
Install
brake

diSC
and

beanng
cage
on

axle

Fit

bearmg
cone
With

brass
bar

6

Tighten
lock
nut

Place
faced
Side
of
nut

to
washer
SIde

so
that

washer
IS
not

damaged

Torque
lock

nut
to
10S
to
145
ft
lb
15

to

20

kg
m

7
Match
washer

IIp
With

groove
m

nut

tIghten

nut
and
bend

washer

carefully
to

prevent

hp

damage

S
Use

a
brass
bar
to
fit
011

seal
to

tube
end

When

fitted

apply
grease
to

the

hp
Be
careful

not
to
deform
seal
or

damage

hp

9

Completely
fill

bearmg
With

grease

10
Install
shaft

AdJust
aXial

clearance
With

shIms
See

Figure
37
Clearance
should

be
0
012

to
0
035
m
0
3
to
09mm

Standard
shIm

thickness
IS
0
059
m
1

5mm

@

11
Install
other

shaft

AdJust
aXlal
clearance

With

shIm
Clearance
should
be
0
OOOS

to
0

0059

m
002
to
0
15mm

12

Install
bolts
and

torque
to

26
to
34
ft

lb

3
6
to
4
7

kg
m

REAR

SUSPENSION

PICK
UP

The
rear

suspension
IS
a

banJO

type
ngId

suspensIOn
With

parallel
semI
elhpnc

leaf
spnngs
Front
and

rear
ends
of
the

springs
are

secured
on
the
frame
with

rubber

bushmgs

Shock
absorbers

are
mstalled

on
the
cross
mem

ber
from
the

spnng
lower

pad
Figure
38
next

page
IS
an

exploded

dIagram
of
the
rear
sus

pensIOn

Rear

Suspension
Assembly
Removal

Pick
up

1
Jack

up
rear
of
vehicle
and

support
It
With

stands
Remove
wheels

2
Refer
to

Figure
39

DIsconnect

handbrake

Wire
and

equalIZer
unit

Separate

bracketJt
r

3
Remove
brake

tube
2
shock

absorller
3

and
dnve
shaft
4

r

r

0

it

1
Bracket
4

Propeller
shaft

2
Brake
tube
5

Spnng

pm

3
Shock
absorber
6
Shackle

assembly

4

Support
axle
case
With
a

Jack
at
the
center

Remove

spnng
pm
5
aJId
shackle

assembly

6
The

sprmg
seat
need
not
be
removed
from

shock

absorber

5
Lower

Jack
slowly
and
remove

susp
nslOn

assembly
as
shown
m

Figure
40

DIFFERENTIAL
REAR

AXLE
AND
REAR
SUSPENSION

167

REAR
SUSPENSION

pICK
UP

Rear

Suspension

Inspection
nnd

Repair
Pick

up

1
Check

spnngs
for
cracks
breaks
and

general

conditIon

Replace
as

reqwred
If

a

spnng
on

one

Side
IS

replaced
also

replace
the
other
one

2
Check

U
bolts
for
bends

stripped
threads

and

general
conditIon

Replace
as

reqUIred

3
Check

rubber

bumpers
and

bushings
for

cracks

wear
and

general
condll1on

Replace
if

defecl1ve

4
Check

shock

absorbers
for
leaks
or

other

damage
Replace
as

required

Rear

Suspension
Installation

Pick

up

1

Replace
the

rear

suspension
components
m

the
reverse

order
of
removal
2
When

msta11mg
rubber

bushmgs
coat
them

hghtly
With

a

soap
solution

3

Torque

parts
as
follows

Shackle
Pin

Spnng
Pm

U
Bolt

Secunng
Nut

Shock
Absorber

Upper
Nut

Shock
Absorber

Lower
Nut

Dnve
Shalt

Secunng

Bolt
83

to
94

It
Ib
11
5
to
13

kg
m

83
to
94
It
Ib
115
to

13

kg
m

61
to
72
ItAb
85
to

10

kg
m

26

to
31
It
Ib
36
t04
3

kg
m

10
to
12
ft
Ib
1
4

to
1
6

kg
m

18

to
22
ft
Ib
25
to
30

kg
m

NOTE

Retighten
bolts
and
nuts

that

hold

bushmgs
after
vehicle
has
been

removed

from

Jack
and
stands

BRAKES
193

Front
Disc
Brake
Piston
Seal

Replacement

If
oil

leakage
is
detected
around
the

piston

seal
It
should
be

replaced
as
follows

I
Rinse
the

cyhnder
bore
With
brake
flwd
In

sert
new
seal
into
the

groove
taking
care
not
to

damage
It
Attach
the

wiper
seal
Lubricate

cylinder
bore

lightly
With
brake
fluid

2
Clean
the

piston
Inspect
the

pISton
for
scor

ing
or
other

damage
before

inserting
It
Make

sure
that
the
relieved

portion
of
the

pISton
faces

the

pivot
pin
Prevent

tilting
of
the

piston
when

It
IS
mserted
mto
the

cyhnder
Refer
to

Figure
13

@

4

Front
Disc
Brake

Assembly
and
Installation

I
Clean
the

mounting
surface
and
disc
surface

Attach
the
disc
to
the
hub

2
Install
the
hub
to
the
knuckle

spindle

3
Insert
the

piston
into
the

cylinder
untIl
its

face
is
almost
flush
With
the
face
of
the

wiper

seal
retamer

4
Install
the

cyhnder
mto
the

caliper
plate
and

secure
with
the
torsion

spnngs

5

Assemble
the
hold
down

pm
spring
washer

and

nut
to
the

support
bracket

6

Insert
cotter

pin
into
the
nut

7
Assemble

mounting
bracket
and

calJper
plate

with

pivot
pm
washer

spring
and
nut

Tighten

nut

completely
and
insert
cotter

pin

8

Pry
up
the
hold
down
bracket
with
a
screw

dnver
Hook
it

to
the

upper
end
of
the

mounting

bracket
Turn
the

cal1per
plate
to
make
sure
it

slides

smoothly

9
Install
the

caliper
assembly
to
the

knuckle

flange
10
Attach
shun
to
inner

pad

I
I
Insert
the
inner
dIsc

pad
Pull

the

caliper

plate
outward
and
insert
the
outer
disc

pad

12
Attach
the
anti
rattle

plate

13

Replace
wheel
and
remove
stands

REAR
BRAKE
SEDAN
AND

WAGON

Figure
14
IS
an

exploded
view
of
the
rear

brake

assembly
used
m
the
sedan
and

wagon

Rear
Brake
Removal
and

Disassembly

1
Jack

up
the
rear
of
the
vehicle
and

support
It

on
stands
Remove
the
wheels

2
Release
the

parkIng
brake
DISConnect
the

cross
rod
from
the
lever
of
the
ie
wheel

cylinder

3
Remove
the
brake
drum

4
Remove
the
return

springs
and
take
out
the

brake
shoe
assemblies

5
Disconnect
the
brake
tube
from
the
wheel

cylinder

6
Remove
the
wheel

cylinder
by
removing
dust

cover

plates
and

adJusting
shIms

7
DISassemble
the
wheel

cylinder
by
removing

the
dust
cover
and

snap
nng

8
Remove
the

adJuster
assembly

Rear
Brake

Inspection
d

Repair

Sedan
and

Wagon

I

Inspect
the
brake

druf
1s
for

scoring
signs
of

excessive
heat
and
out
of
round

Repair
or
re

place
the
drums
as

reqUIred
The

following

specificatIons
apply

Drum
Out
of
Round

Inner
Olameter

MaXImum
Diameter
after

IlI1ndmg
Less
than
0
0020
In
0
05mm

8
999
m
228
6mm
1

9040
In
229
6mm

2

Inspect
brake

limngs
for
wear

signs
of
oil
or

grease
and
cracks
If

any
of
these
conditions
are

found

replace
the

linmgs
Have

a
brake

special

ISt
arc
the

limngs
to
match
the
diameter
of
the

drums
after

replacement
If
the
thickness
of
the

limng
is
under
0
0591
m
1
5mm

replace
it

3
Check
the

adjusting
cams
for
smooth

opera

tion

Replace
as

reqUIred

4
Check
the

spnngs
If

they
appear
weak
or

uneven
m
tension

replace
them