light DATSUN 510 1968 Service Owner's Manual

CHAPTER
TWELVE

DIFFERENTIAL
REAR
AXLE

AND
REAR
SUSPENSION

The
dIfferential
rear
axle
and
rear

suspen

sIon
dIffer
for
the
various
models
ThIS

chapter

deals
WIth
each

separately

Due

to
the
need
for

SpecIal
tools
and

exper

Ience
to
dIsassemble
and

repaIr
these
unItS
the

followmg
procedures
generally
cover
removal

InspectIon
and

replacement
only
If
mechanIcal

dIfficultIes

eXIst
WIthIn
the
dIfferentIal
and
rear

axle

components
refer
servIce
and

repair
to
a

Datsun
dealer
or

competent
garage

DIFFERENTIAL

SEDAN

The
cast
Iron
dIfferentIal

assembly
used

in

the
sedan
is
shown
in

Figure
1
next

page

Proper
lubncatlOn
of
the

gear
housmg
IS
essen

tIal
Check
lubncant

every
3
000
mlles
and
re

plenISh
as

necessary
Drain
and
refill
lubncant

at
least

every
30

000
miles

Differential
Removal
Sedan

1
DISconnect
handbrake
rear
cable
dnve

shaft

and
axle
dove
shafts

by
removing
bolts
shown

by
arrows
of

Figure
2

2

Place
a

Jack
under
the
dIfferential
and

lift

slIghtly
Remove
nuts
on
both
ends

of
dtfferentIal

mountlng
member
See

Figure
3

3
Remove
four

fixIng
bolts
that
hold
dIfferentIal

to
the

suspensIon
member

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

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

BODY
ELECI
RlCAL
SYSTEM
207

CD

1

Ignition
SWItch

2

Ignrtlonl
starter
cylmder

5

light
swrtch

6
Knob

10
Nut

11
Screw
and
washer

12
Wiper
swrtch

13

Wiper
swrtch
Jut

16
Knob

18
Cigarette
lighter

19
Element

20
Knob

45
Hazard

wamlOg
switch

46
Hazard
and

parlung
swrtch

47

Wammg
SWItch
knob
CD

13

44
y
l
l

42
43

r
48
cr
23
41

f
Jj

it
d

F
1L

f7
IF
f
0

l
Q
U

lJ
37
1

2S
26
38
A
3S
36
G

21
Turn
signal
and
dimmer
switch

22
Turn
signal
switch
knob

23
Stop
light
switch

24
Door
switch

25
WarnIng
buzzer

26
Warning
buzzer

28
Fuse
block

29
Fuse
block
cover

30
Fuse
10
ampere

31
Fuse
20
ampere

32
Fuse
30
ampere

33
Machlnescrew

34
Lock
washer

35
Horn
hIgh
pitch

36
Horn
low
pitch

37
Machine
acrew

38
Lock
washer

39
Horn
relay

40
Lower
beem
relay

41
Inhibitor
switch

42
Screw

43
Flasher
unit

44
Screw

48
Bracket
o
i

138

INDEX

H
OIl

pump

Descnptlon
36

Handbrake

Exploded
view

29

Adjustment
202

Inspection
and

repaIr
28

Cable
removal

front
sedan
and

wagon
197

Installation

58

Cable
removal
rear

pick
up
201

Removal

28
40

Cable
removal
rear
sedan

and

wagon
197

Cross
rod

removal

wagon
201

Exploded
views

198
200

p

Inspection
and

repair
201

Installation

201

Penodlc

mamtenance

Headlights

MaIntenance

mtervals
chart

7

Bulb

replacement
210

Penodlc

checks
6

Descnptlon
210

Recommended
lubncants
8

Exploded
view

219

Routine

checks
6

HeatIng
system

Piston

nngs

Descnptlon
210

Exploded
view

pick
up
213
Inspection
50

Exploded
VIews
sedan
and

wagon
214
215
Removal

45

Hood

lock
control
RIng
gap
50

Exploded
View

pick
up
225
Pistons

Descnptlon
34

Exploded
VIew
sedan
and

wagon
226

Inspection
50

Reassembly
54

Igmtlon
coil

111

R

Igmtlon

system

Tlmmg
23
Radiator

Troubleshooting
13

Exploded
view
90

Instrument

meters
and

panels
Removal
and

replacement
90

Descnptlon
210
Rear
axle

pick
up

Exploded
View

pick
up
213
Axle

case

166

Exploded
view
sedan
and

wagon
Inspection
and

mstalIatlon
164

1970
1972

212

Removal

164

Exploded
view

sedan
and

wagon
Sectional

view

163

through
1969

211
Rear

axle

wagon

Intake
manifold

Disassembly
158

Descnptlon
36

Exploded
view

158

Removal

42

Inspection
and

reassembly
160

InstallatIOn

160

Removal

158

M
Rear
axle
and

suspenSion
sedan

Exploded
view

152
153

Mam

beanngs
52

Inspection
and

repaIr
154

MaIntenance

penodlc
6
8

InstalIatlon
154

Master

cylInder
Removal

151

Exploded
vIew

smgle
188
Rear

spnngs
pick
up
166

Exploded
view
tandem

189
Rear

spnngs
wagon
161

Inspection
and

repllIr
188
Rear
axle
shaft
sedan

155
156

Reassembly
and
InstalIatlon

190
Rear

suspension
arm
sedan

155

Removal
and

disassembly
188
Rear

suspenSion
pick
up

Modelldentdicatlon

1

Exploded
view

166

Inspection
and

repllIr
167

InstalIatlon

167

0
Rear

spnngs
166

Removal

165

011

filler

30

Spnngs
166

d

43

Torques
67