engine DATSUN 510 1968 Service Manual PDF

CHAPTER
ELEVEN

CLUTCH
TRANSMISSION
AND
DRIVESHAFf

CLUTCH

i
es

ription

Datsun
uses
a

single
dry
dtsc
clutch
with

dIaphragm
spring
The

major
components
are

clutch
cover

pressure
plate
dIaphragm

spring

and
WIre

nngs
The
clutch
dISC
has
riveted

plates

on
both
surfaces
and
coll

spnngs
arranged
in
a

link
The
coll

springs
absorb

shock
to
soften
and

smooth
clutch

engagement
Figure
1
next

page

is
an

exploded

diagram
of

the
clutch

assembly

Clutch
Removal

The
transmIssion
must
be

separated
from
the

engme
to
remove
tlte
clutch

assembly
This
can

be
done

by
removmg
the
transmISSIon
and

engme

from
the
vehicle
as
a
umt
or

by
remoVIng
the

transmiSSIon

separately
Removal
of
the

engine

and
transmissIOn
IS
descnbed
In

Chapter
Six

Removal
of
the
transmISSIon

only
IS
descnbed

later
in
tills

chapter

Outcb

Disassembly

1

Separate
clutch

assembly
from

flywheel

Loosen
and

remove
bolts

dIagonally
and

gradu

ally
as
shown
m

Figure
2

2
Remove
dust
cover
from
clutch

housmg

3
Remove
return

spnng
from

beanng
sleeve

Separate
the
Withdrawal
lever
from

bearing

sleeve
w

1

4
Remove
release

bearmg
and

bearing
sleeve

from
front
cover
Remove
wIthdrawal
lever

ball

pm
Figure
3

CD

1
Withdrawal
lever

ball

pin

2
Withdrawal
lever

3
Return

spnng

4
Release

beanng
4

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

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

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

BODY

ELECTRICAL

SYSTEM

217

bulb

socket
must

be

pulled
out
from
the
back

of

the
unit

and
then
the
bulb
can
be

replaced
Care

fully

mspect
the
unit
that

reqUIres
bulb

replace
ment
and
follow
the

appropriate

procedure

Make

certain

you

replace
the
bulb

with
one

rated
at
the
same

voltage
amperage
and
watt

age
Examples
of

units
that

might

require
bulb

replacement
are
the
front

park
and

directional

lamps
rear

combination

lamp
side

marker

lamps
interior
room

lamps
license

plate
lamps

and

engine

compartment
lamps

Fuse

Replacement

Whenever

a
fallure
occurs

m

any

part
of

the

electrical

system
always
check
the

fuse
box
to

see
1f

a
fuse
has
blown
The
fuse

box
is
located

on
the

firewall
within
the

engine

compartment

If
a
fuse
has
blown
It
will
be
eVident

by
bIacken

mg
of
the
fuse
or

by
a
break
of
the

metal
element

Within
the
fuse

The

wiring
diagrams
below

mdIcate

the
cir

cuits

that
are
connected

to
each
fuse

Before

replacing
a
fuse

always
detenIlIDe
what
caused

it
to
blow
and
correct
the

trouble

Never

replace

a
fuse
With
one
of

a

higher

amperage
ratIng
than

originally
used
Never

use
tmfOll
or
other
ma

tenal
to

Jump
across
fuse

tenIlIDals

Failure
to

follow
these

basic
rules

could
result
in

fire
or

damage
to

major
components

WIRING

DIAGRAMS

The

following
figures

provide
wiring
diagrams

for
the
sedan

wagon
and

pick
up
Figure
20

page
220

applies
to
the
sedan
and
station

wagon
with

manual
transmission

Figure
21

page
221
covers
the
sedan
and

station

wagon

With
automatic
transmission

Figure
22

page

222
is
for
the

pick
up
I

r

t

i

f
If

t
I

DAnUN
SE

1
5
10
AN

l
@
0

i1
rtr
JM
OIi
l
jj

I

I

if

J

I

f

lJ

I
I

f
I

I

tflr

f1

h
f

I

v

L

7

I

l1It
l

I

fIr

t

I

r

II
to

E

m

PAIIt
I
lANI

X
I
I

PICK
UP

1968
1972

t

t

I

0

l

1

j
f

r
t
g

I

I

0

r

r

This

completely
new
edition

is

Clymer
s

first

covering
late
model
Dat

ouns
The

popular

pick
up
truck
a

best
seller
in
its
own
is
also
included

Material
has
been

pai
stakingly
prepared
by
a

top
technical
writer

and

tlien

carefully
edited

Major
sections
include
Periodic
Maintenance

Trouble

hooting
Tune

up
Lubrication

Engine
Fuel

System
Cooling

Ele

rical

System
Emissio
ontrols

Clytch
Transmission
and
Drive

shaft
Differential
Rear

Axle

Steering
rakes

1

Body

Wbiie
a

f
re

airs
on
advan
lMI

eauipment
such
as

sophisticated

1
II

emissi

ontruls
are

beyond
e
mechanics
the

simple
tests

I

f
l

1
1

and
t
ubl

shooting
measures
ndtided
can

help
diagnose

problems

Wher
r

lrs
are

practical

cr
mplete
informatfon
is

given
Equally

im
t
nt

ho
gh
thi
autho

frequently
includes

cautioning
gotes

1
f
I

where

proCeduljes
are

confusing
and

occasionally
suggests
that
here
s

b
I

t
1

t

I
a

10

1requ
ring
uea
er
attentloru

Ii
l

I

As
in

ail
C

ymer
books

the

goal
has

j

I
I
1

be
n

to

kelp
owners
understand

th
ir

far
owpr
repair
costs
and

generaUi
i
lnprove
automotive
sat

isfadion

O
Jr
200
other
utomotive

and
motcwc

y
c1e
itles
deal
with

re

pairl
performance
tuning
and

nostalgia
Ask
for
them
at

leading

J

book
stores
and

auto

supply
outlets

I

CLY

PUBLI

ATll
LO
MGELES

1

6
r

I

l

t