lock DATSUN 510 1968 Service Workshop Manual

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

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

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

glfferentlal
case

4
D
r
a
nd
pinion
2
FIxing
bolt

5
Bev
ntlal
case
7
Rear
eover
77
Stud

6
Lock
gear
Breather
79
Hex
nut

nut
75
Ta

7
Thrust
washer
76
Dr
red
plug
80
R
I
15

ea
r
cover

Plnlon
mate
n
plug
assembly
81
Spring
packing

82
H
washer

lD
Thrust
washer
72
ex
bolt

Pinion
sh
ft

11
Look
pm

12
FIxing
bolt
69

13
Bolt
10

14
Rear
eking
strap
53
52

m
J

17
Justlng
washer
70

18
Adjusting
shim

19
dJust
lng
shim
t

20
25ro
plnlon
bearing
i

26
40
A
rI
g
spacer
66

41
Front
J
S
Ing
washer
65

42
earlng
s

Bearing
ret
pacer

43
011
seal
alner

44
O
ring

45
Front

46
S
pilot
bearing

47
HPrlng
washer

48
ex
bolt

Compa

50
W
on
flange

51
asher

Nut
I

52
Bearl

53
0
I
g
retainer

I
seal

R
0

56
lde
bearing

65
S
Adjusting
shim

66
HPrlng
washer

6
ex
bolt

Side
flange

69
Dust
shield

a
ring

70
Plain
wash

71
S
er

pring
washer
48
8
a

71

152
CHAPTER
TWELVE

3
Shall

yoke
stopper

0
4
Rear

snap
nng

J
5
Dn
eshall

stopper

6

Snap
nng

7
Rubber
boot

8
Boot
band

9
Boot
band

10
Slee
e

plug

11
O

nng

12

Snap

nng

13
Yoke

flange

3
4
6

14
Whee

beanng
spIder

15

Spider

12
5
16

Beanng
race

assembly

j

50

CANADA
47

AtO

C
J

ty

9
1
Y

4

i
l

A

I

ii

1
o

l
J
Il

h

o

20
J

I

1
Brake
tube
connector

2
Handbrake
rear
cable

adjuster
3
Return

spnng

4

Propeller
shall
to

dlfferenballixlng
bolts
20
26

Snap
nng

27
Dn
er

bolt

28
Onveshall
nut

29
Lock
washer

30
Rear
axle
shall

assembly

31
Hub
bolt

32
Hub
bolt

33
Grease
catcher

34
Screw

35
Lock
washer

36
Screw
and
Ioc
l
washer

37

Right
rear
axle

beanng

38
40

Beanng
distance

piece

41
Grease
seal

42

Beanng

spacer

43
Lock

nut

44
lock

washer

45

Rear
axle
flange

46
Cover

plate

47
Brake
drum

48
Wheel

50
Wheel
oover

43
44
45

46

51

5
Jack

up
suspenSIon
arm
and
remove
shock

absorber
from
lower

mountlng
bracket

See

Figure
10
Take
care
not
to
lose
rubber

bushmgs

6

Support
the
center
of
the

suspensIon
member

and
dIfferential
With
a
transmISsion

Jack
Re

p

52
Rear
suspension
member
95
Nut
103
Washer

53
Mounting
spacer
96
Rubber
seat
104
Washer
e

54
Mounting
spacer
97
Bumper
assembly
105
Damper
to
weight
stud

55
Mounting
bolt
98
Fixmg
nut
106
Nut

56
Nut
99
Plain
washer
107
Dust
cover

57
Insulator
100
Damper
assembly
lOS
Spacer
ring

58
Stopper
101
Damper
weight
109
Hex
bolt
E

59
Stopper
102
FIxing
bolt
110
Spring
washer

60
Washer

61
Self
locking
nut

62
Bolt

63
Self
locking
nut
101

64
Washer

65
Mounting
member
with

Insulator
109
1
l

66
Insulator
110

67
Stopper
w

68
Stopper
E

69
Mountmg
bolt

70
Mounting
plate
@
8IAH

loa
9
181lH

71
Nut
a

72
Plain
washer

73
Plain
washer

75
Left
hand
suspension
a
12
I

ann
t

76
Brake
hose
bracket

77
Arm
bushing
assembly
Ik
I
f
I
f

78
Shock
bracket
M
@

79
Shock
bracket

80
Ann
pin

81
Self
locking
nut

82
Plain
washer
e

85
Rear
spring
v
IDO

86
Shock
kit
M
4r

87
Shock
rubber
bushing

88
Shock
rubber
bushing
105
l1

89
Washer
t
81
r
D9
55

90
Washer

91
Nut
I
Sf
l
I
81

I
92
Nut

93
Shock
rubber
bushing
e
81
101

94
Washer
t

L

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

DIFFERENTIAL
REAR

AXLE
AND
REAR
SUSPENSION
157

DIFFERENTIAL

WAGON

The
dIfferentIal
carner
is
made
of
alumInum

alloy
and
uses
a

hypoid
bevel

gear
Proper
lubri

catIon
IS
essentIal
Check
and

replemsh
the
lub

rIcant

every
3
000
mIles
Dram
and
refill

every

30
000
mlles

Figure
20

IS
an

exploded
dIagram

of
the
differential
used
in
the

wagon

Difterential
Removal

Wagon

1
Jack

up
the
rear
wheels
and

support
vehicle

with
stands

l

2
DIsconnect
drIve

pmlon
companion
flange

to

yoke
connectIon

3
Remove
rear
wheel
axles
as
descnbed
later

m

thIS

chapter

4
Remove
dtfferentIal
from
vehIcle

Difterential

Inspection
Wagon

The

followmg
Inspection
can
be
done
Without

dISassembly
of
the
differentIal
Perform
the
fol
lOWIng
mspectIon
and
If
abnormalitIes
or
dam

age
eXISts
refer
further
service
and

repair
to

YOI
f
dealer

1
Check
the
tooth
contact

pattern
with

lead

oXIde

at
two
or
three

pomts
after

remoVIng
rear

cover
Refer

to

FIgure
5
for
correct
contact

pat

tern
If
the

pattern
IS
not

correct

dIsassembly

and

adjustment
of
the
dtfferentIalIS

reqUIred

2
Measure
backlash
between
dnve

gear
and

pInIOn
WIth
a
dIal
mdlcator
Backlash
should
be

00059
to
00079
in

0
15
to
0
20mm

3
Rotate
the

gears
and
lIsten
for

SIgnS
of
bear

Ing
nOIse
DefectIve

beanngs
should
be

replaced

by
a
dealer

4

Inspect
gear
teeth
for

signs
of

damage
or

cracks
r

Difterential
Installation

Wagon

Install
the
dIfferentIal

by
reversing
the

pro

cedures
used
for
removal

2
Olfferenllal
case

16
Pmlon

10Ckmg
pm
28
42

AdjusllRg
washer

t
3

Beanng
stud
17
Dlflerenbal
Side

beanng
43
47

Adjusting
shim

4
Plem
washer
18
22

Adjusting
shim
53
Oil
seal

5

Locking
nut
23
Rear

plRlOn
gear
54

Range
assembly

6

Lockmg
nut
24
Front

plRlOn
beanng
55
Nut

7
PIRlOn

gear
set
25
27

Spacer
56
Wesher

Iff
8

Hex
bolt

9
Bolt

locking
strap
7

10
Case

@
11
Side

gear

12
PmlOn
mete

is

Thrust
washer
13

14
Thrust
washer

10

15
PIRlOn
shaft

23

43
47

2S
27
7

J

I
18

22

17

l
24

S3

S6
S4

55