height DATSUN 510 1968 Service Repair Manual

4

CHAPTER
ONE

chassIs

number
Write
the
numbers
down
and

carry
them
ill

your
wallet

Service
Hints

Throughout
thIs

manual
keep
two
conven

bons

ill
mmd
Front
refers
to
the
front
of
the

vehicle
The
left
and

nght
sides
of
the

ve

hicle
refer
to
a

person
sittIng
ill
the

car

facing

forward
For

example
the

steenng
wheelIS

on

the
left
hand
Side
All
dimensIOns
and

capacities

are
expressed

ill
units
fanuhar

to
a
Umted

States

mechaniC
such
as
illches
and

pounds
Metric

measurements

are
also

given
Metnc

tools
are

reqUITed
to
work

on
the
Datsun
CD

DATSUN

IENGINE
CAPACITY

IMAX
HP
RPM

IWHEELBASE

IENGINE
NUMBER

FAR
NO

NlSSAN

MOTOR

co
LTD

YOKOHAMA
JAPAN
TYPEI
510

1595
cc

961P
6600

rpm

mm

L

1
00988

P61
l
O
1
l
M

Table
1
MAIN
SPECIFICATIONS

AND
DIMENSIONS

r
ITEM
Sedan

Wagon
Plm

up

EnglDe
Type
L16

L16
L16

Valve

Arrangement
Overhead

Cam
Overhead
Cam
Overhead
Cam

Bore
3
26n
ID
83mm

3
2677
ID
83mm
3
2677
ID
83mm

Stroke
2902
ID

73
7mm
2
902
ID

73
7mm
2
902
In

73
7mm

Displacement
97
3
cu
ID

l595cc
97
3
cu
In

l595cc
97
3
cu
ID
1595cc

CompressIOn
Ratio
851

851
851

MaXimum
SAE

Hompower
96

@
5

600

rpm
96

@
5
600

rpm
96

@
5
600

rpm

MaXimum
SAE

Torque
998ft
Ib
138

kg
m
998ft
Ib
138

kg
m

9911
ft
Ib
138

kg
m

Fuel
Octane
85

85
85

Lengtb
1622
ID

4
12Omm
163
2
ID
4
I45mm
168
9
ID
4
290mm

Width

61
4
ID

l
560mm
61
4
ID
1
560mm
62
8
In

Cl
595mm

Height
55
lID
1
400mm
565
ID

Cl
435mm
60
8
ID

Cl
545mm

Wheelbase

95
3
ID

2
42Omm

95
3
ID

2
420mm
99
6
In

2
530mm

Room

Space

Inner

Length
63
3
In
1
61Omm
673
ID

1
710mm
72
8
ID

1
850mm

Inner
Width

499
ID
1
27Omm

507
ID

1
29Omm
563
In

1
430mm

Inner

Height
44
4
In
1
130mm

44
61D
1
135mm
15
7
ID

399mm

Tread

Front

50
4
ID

28Omm
502
In
1
275mm
492
In
1
250mm

Rear
504
In

1
280mm
496
In

Cl
260mm
499
ID
1
267mm

Road

Clearance
741n

l88mm
64
ID
l63mm
787
ID
200mm

Weight

4

Speed
2
0611b
935

kg
2
138
Ib

970

kg
2
127
Ib
965

kg

Automatic

2
114Ib
959

kg
2
182
Ib
990

kg

Minimum

Turning
RadiUS
157ft
48m

157ft
48m
171
ft
52m

Seating

Capaaty
5

5
2

Battery

Volt

12

12
12

Capacity
400rSOAH

400r50AH
40
or
60
AH

Connection

Negative
ground
Negative
ground
Negative
ground

Fuel

Tank

Capaaty
11

9

gal
45
liter
11
9

gal
45
liter
108

gal

41J
r

011

Pan

Capacity
42

qts
40

liter
4
2

qb
40
liter

1
06

gal
40
Iller

011
Filter

Capaaty
74

ql
07
liter
74

ql
0
7
liter
1
48

Pint
0
7
liter

Transmission

Capaaty
1
8

ql
1
7
liter

18

ql
1
7
Iller
2
11

qt
20
Iller

Dlflerenbal

Capaaty
85

ql
80
liter
11

ql
1
0
liter
87

ql
0
83
lIter

Coolant

Capaaty
7
2

ql
6
8
liter
7
2

ql
6
8
lIter
7
2

qt
6
8
Iller

Clutch

Type

Dry
Single
diSC

Dry
slDgle
diSC

Dry
slDgle
diSC

Draphragm
spnng
Diaphragm

spnng
Diaphragm

spnng
l

60
SIX

Table
1
ENGINE
SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Cylinder
Arrangement

DIsplacement

Bore
and
Stroke

Valve

Arrangement

MaxImum
Brake

Horsepower

MaxImum
Gross

Torque

Firing
Order

Engme
dle

Smgle
POint

Dual
Pomt

CompressIon
RatIo

Engme
Idle
Mamfold
at
Idle

rpm

011
Pressure
hot

@
2
000

rpm

i
TIGHTENING

TORQUE
ft
Ib

kg
m

Cylinder
Head
Bolts

1st
turn

2nd
turn

Flywheel

Flxmg
Bolts

M
In

Beanng
Cap
Bolts

Camshaft
Gear

Bolt

I
011
Pan

1
1

fF
I

011

Pump

QII
Stramer

F

I
Crank

Pulley
Bolt

SPECIFICATIONS
In
mm

Valve
Mechamsm

Valve
Clearance
Hot

Valve
Clearance
Cold

Valve
Head
DIameter
Intake

Valve
Head
DIameter
Exhaust

Valve
Stem

DIameter
Intake

Valve
Stem
DIameter

Exhaust

Valve

Length
Intake

Valve

Length
Exhaust

Valve

LIft

Valve

Spring
Free

Length
Outer

Valve

Sprmg
Free
Length
Inner

Vaiv

Spnng
Loaded

Length
Outer

Valve

Spring
Loaded

Length
Inner

Valve

Sprmg
Assembllld

HeIght
Outer

Valve

Spnng
Assembled

Helght
Inner

Valve

Spnng
Effective
Turns
Outer

Valve

Sprmg
EffectIve
Turns

Inner

Valve
GUIde

Length
Intake

Valve
GUIde

Length
Exhaust

Valve

GUIde

HeIght
from
Head
Surface

Valve
GUIde
Inner
DIameter
Intake

Valve
GUIde
Inner
DIameter
Exhaust

Va
Ive
GUIde

Outer
Dlam
eter
Intake

Valve
GUIde
Outer

DIameter
Exhaust

Valve
GUIde
to

Stem
Clearance
Intake

Valve

GUIde
to
Stem
Clearance
Exhaust

Valve
eat

W
dth
Intake

Valve

SEtat
WIdth
Exhaust
4
m

Ilnil

97
3
cu
m
1595cc

3
2677
x
2
9016
In
83
x
73

7mm

Overhead
Camshaft

96

@
5
600

rpm

110
ft
Ib
13
8
kg
m

@
3
600

rpm

1
3
4
2
r

600

rpm

700

pm

85
1

i7
7
In

Hg
450mm

Hg

54
to
60
Ib
m
2

3
8
tQ
4
2

Iig
cm

325
4
5

39
8
5
5

68
No
75
9
9
50

to
1039

325

to
39
8
4
5

to
5
5

362
to
43
4
50
to
60

2
9
to
5
1
0
4
to
0
7

108
to
15
2
1
5
to
2
1

58t087
08to
12

1157
to
130
1
160
to
180

o
118
0
30

o

0C
98

0
25

1
50
38

0

1
30
33
0

031
80

031
80

456
1159

4
57
116
O

03937
100

2
05
52
0

1
77
44
96

1
21

@
1054
Ib
3
07

@
47
8

kg

o
96

@
56
Ib
24
5

@
25
5

kg

1
53

@
63
9

Ib
38
9

@
29

0
kg

1
38

@
27
1
Ib
35

@
123

kg

45
I

55

2
32
59
0

2
32
59
0

0409

to
0
417
104

to
106

0315

to
03154
80

to
8018

0315
to
03154
80
to
8
Oi8

04718
to
04723
11
985
to
11
996

04718
to

04723
11
985
to
11
996

00006
to
00018
0
015

to
0
045

00016
to
00028
0040

to
0070

o
055

to
0
071
1
4

to
1
8

0063
to
0079
1
6
to
20

ENGINE
61

SPECIFICATIONS
In
mm
continued

Valve
Seat
Interference

Fit
Intake

Valve
Seat
Interference
Flt
Exh

ust

Valve
GUide
Interference
fit

I

Camshaft
and

Timing
Chain

Ca
mshaft
End

Play

Camshaft
Lobe
LIft

Camshaft
Journal
Diameter

Camshaft
Bend

Camshaft

Bearing
Inner
Diameter

Camshaft
Journal
to

B

arlng
Clearance

Rocker
Arm
Lever
Ratio

Connecting
Rod

Center
Distance

Standard

Bearing
Thickness

Big
End

Play

Connectmg
Rod

Beanng
Clearance

Connecting
Rod
Bend

per
3
937
In
100mm

Crankshaft
and
Main

Beanng

Journal
Diameter

Journal

Taper
and
Out
ot
Round

Crankshaft
Free
End

Play

Crank
Pin
Diameter

Crank
Pin

Taper
and
Out
ot
Round

Main

Bearing
Thickness

Main

Beanng
Clearance

Crankshaft
Bend

Piston

Standard
Diameter

Ellipse
Difference

Ring
Groove

Top

Second

011

Piston
to
Bore
Clearance

Piston
Pm
Hole
Offset

Piston
Pin

Piston
Pin
Diameter

Piston
Pin

Length

Piston
Pin
to
Piston
Clearance

Interference
Fit
ot
Piston
Pin
to

Connecting
Rod

Bushing

Piston

Ring

Ring
Height

Top

Second

011

Side
Clearance

Top

Second

011

Ring
Gap

Top

Second

011
Table
1
ENGINE
SERVICE
DATA
AND
SPECIFicATIONS
continued

00031
to
0
0043
0
OB

to
0
11

00024
to
0
0039
006
to
0
10

00011
to
00019
0027
to
0049

00031
to
0
0150
0
08
to
0
38

o
261
6
63

18877
to

1
8883
47
949
to
47
962

o
0020
0
05

1
8898
to
1
8904
48

0
to
48
016

00015
to
0
0026
0038
to
0
076

15

5
507
to
5
509
139
87
to

139
93

o
0588
to
0
0593
1
493
to
1
506

00079
to
0
0118
0
20
to
030

o
0006
to
0
0022
0
014
to
0
056

o
0012
003

2
1631
to
2
1636
54
942
to
54
955

less
than
00012
003

o
002
to
0
0059
0
05

to
0
15

1
9670
to
1
9675
49961
to
49
975

less
than
0
0012
0
03

o
0717
to
0
0722
1

822
to
1
835

o
0008
to
0
0028
0
020
to
0
072

00019
005

3267

to
3
269
8299
to
83
04

0013

to
0014
032
to
035

008
20

o
08
2
0

o
16
4

0

00010
to
0
0018
0
025
to
0
045

00394
0
0020
1
O
0
05

o
8266
to
0
8268
20
995
to
21
0
0

2
8346

to
2
8445
72
00
to
72

251

o
0003

to
0
0004
0
OOS
to
0
OlD

00006
to
0
0013
0015
to
0
033

o
0787
2
0

o
0787
2
0

o
1575
40

00018
to
00031
0
045
to
0
078

00012

to
0
0025
0030
to
0
063

00010
to
00025
0025
to
0
063
i
J

I

n

T

00091
to
0
0150
023
to
038

00059
to
0
0118
0
15
to
0
30

00059

to
0
0118
0
15

to
0
30

104

CHAPTER

NINE

2
When

one
sIde
shows
low
resIstance

and
the

other
shows

high
resIstance
the

dIode
IS
satls

factory
If
both
sIdes
are
low

there
IS
a
short

CIrCUIt
If
both
sIdes
are

hIgh
there

IS
an

open

CIrcUIt
All
diodes
With

open
or
short
ClrC
ts

must
be

replaced

BRUSH

INSPECTION

1

VIsually
check
the
brushes

for

SIgnS
of
wear

or

damage
If

wear
IS

greater
than
the
wear
lIrmt

shown
in

Figure
47

replace
the
brush

2

ChecJ
the
movement
of
the

brush
for
smooth

ness
If

unsmooth
check

and
clean
the
brush

holder

3
To

check

spnng

pressure
place
a
SUItable

block

on
a

platform
scale
and

press
down

the

brush
holder

WIth
the
brush
and

spnng
on
the

block

untIl
the
brush
smks

In
the

holder
to

00394

m

lmm

heIght
from

the
holder
Sub

tract
the

block

weight
from

the

reading
to
derive

the

spnng
pressure
It
should

be
0
77
Ibs
035

kg
If
the

readmg
IS
under
0
44
Ibs
0
2

kg

replace
the

spring
Figure
48
shows
thIS

test

being

performed

ALTERNATOR
OUTPUT

INSPECTION

To
check
alternator

output
remove
the
alter

nator
from
the
vehIcle

and
connect

wumg
as

shown
m

Figure
49

Dq
ve
the
alternator
WIth

a

motor

Through
the
CIrcUItS
shown

m
the
Illustra

tIon

current
flows
from
the

battery
to
the
field

coll
of
the
alternator
RaISe
the

speed
of

the

alternator

slowly
to
the

pOInt
where
no
reverse

flow

eXISts
ThIs

pOInt
should
be
about

2

amps

I
at
1
000

rpm
Increase
the
load

reSIStance
untIl

the
load
current

IS
almost

stopped
and

tlI
rn
off

the
SWItch
RaIse
the
load

current

slowly
and

mcrease
the

speed
of
the

alternator
Observe

that
the

output
current
mcreases
as
the

speed

of
the
alternator

mcreases
If
the

output
is
wlthm

the
above

specmcatIon
at
the

proper

rp
ll
the

alternator

IS

satIsfactory

ALTERNATOR
ASSEMBLY

To
assemble
the
alternator

reverse
the

pro

cedures

given
for

dIsassembly
The
use
of
an

arbor

press
to

mstall
dIodes
and

bearmgs
is

essentIal

so
that

parts
are
not

damaged

VOLTAGE
REGULATOR

The

voltage
regulator
is

mounted
to
the

right

hand

engme
compartment
SIde

wall
and
has
a

removable
cover

Figure
SO
shows
the

regulator

With
the

cover
removed

AdjustIng
the

voltage

regulatpr

reqUIres
special
eqUIpment
not

or

dmanly
avallable
to
the

home
mechanlc
If

trouble
seems
to
be
in
the

regulator
refer
servIce

to
a
Datsun
dealer

or

competent
garage

128

CHAPTER
ELEVEN

1
Clutch
disc

assembly

2
Clutch
cover

3
Hex
bolt

4
Lock
washer

5
Withdrawal
lever

6
Withdrawal
lever

ball

pin

7
Lock
washer

8
Retainer

spnng

9
Clutch
sleeve

10
Release

bearing

11
Holder

spring

12
Dust
cover

13
Return

spring

14
Push
nut

15
Hex
nut
CD

9

11

8

6

7

1
Release

beanng
2

Beanng
sleeve
2

5
13

12

15

14

Clutch

Inspection
and

Repair

1

Thoroughly
clean
all
dISassembled

parts
ex

cept
for
the

dISc

assembly
and
release

bearmg

In
a
SUItable
solvent

2
Check

all

parts
carefully
for
wear
cracks

and
other
defects

3
Check
the
clutch
disc
for
oil
soaked

or

cracked

faCIngs

warpmg
loose
nvets

exceSSIve

wear
and
broken

spnngs

4
Check
the

pressure
plate
for

sconng
bum

marks
blue
tlnted
areas
and
cracks

If

any
of

the
above
condItIons
are
found

re

place
the
clutch
dISC
and
or
the

pressure
plate

Replace
dISC

assembly
1f

facmg
IS
worn
so
that

the

facmg
heIght
above
the

nvet
IS
less
than

00118m
03mm

Very
mmor
bum

marks
and

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
129

scratches
on
the

pressure
plate
may
be

removed

with

crocus
cloth

If
the
source
of
clutch
trouble
IS
still
not
evl

dent
take
the

pressure
plate
and
disc
to
a

compe

tent

garage
to
check
the

pressure
plate
finger

release

height
and
nmout
Never

attempt
to
ad

just
the

fingers
or
dismantle
the

pressure
plate

Without

proper
tools
and

experience

Check
the
release

bearing
by
holdmg
the
Inner

race
and

rotatmg
the
outer
race
With

hght
pres

sure

applied
If
the

bearing
is

rough
or

noisy

replace
it

CAUTION

Never
clean
the
release

bearing
In

solvent
It
IS

prelubriCflted
at

the

fac

tory
Simply

wipe
with
a
Unt

free
cloth

If
the
release

bearing
shows

any
signs
of
loss

of

lubncant
install
a
new

bearing
Replace
the

sleev
lu
SignS
of
wear
are
evident

Clutch

Reassembly

1
Be

sure

your
hands
are
clean
for
the
initIal

assembly

2

Inspect
the
clutch

facings
pressure
plate
and

flywheel
to
be
sure

they
are
free
from

grease
oil

and
other

foreIgn
material

3

TIghtly
fit
release

bearmg
onto
the

bearing

sleeve
When

beanng
IS
mstalled
turn

bearmg

With

a

finger
to
make
sure
It

operates
smoothly

4

Apply
multI

purpose
grease
to
the

bearmg

sleeve
InSIde

groove
See

Figure
5

CD
Ji

rot

Pac
thiS
r

r
r

1
1i

QI
ecess

5

Apply
multi

purpose
grease
to
the

WIth

drawallever
and

bearing
sleeve
contact

point
and
to
the
Withdrawal
lever
ball

pm
and
with

drawallever
contact

point

f

6
Clean
the
clutch

pllot
bushmg
and
fill
It

With
multi

purpose
grease

7
Mount
the
WithdraWal
lever
release

bearing

and

bearing
sleeve
to
the
clutch

housing
Install

dust
cover
on
clutch

housing
and
connect
return

spring
to
WithdraWal
lever

8
Place
the

pressure
plate
and
clutch
disc
in

positIon
on
the

flywheel
Make
certain
the

pres

sure

plate
is
In
the
same

positIon
relative
to

fly

wheel
as
when
removed
Use
a
clutch

alIgning

bar

Special
Tool
ST20630000

FIgDfe
6
to

alIgn
the
clutch
dISc

splIne
to
the

pllot
bearing

CD

NOTE

If
the

special
tool
is
not
avail

able

cut
an

input
shaft
from
a

Junk

transmission

9
Install
the

pressure
plate
mounting
bolts

Tighten
the
bolts

dIagonally
opposite
each
other

one
turn
at
a
time
to

prevent
warpmg
Torque

the
bolts
to
10
8
to
15
9
ft
lbs
1
5
to
2
2

kg
m
Remove

durmny
shaft

10
Install
the
clutch

housing
to
the

engme

Clutch
ntrol

Datsuns
have
a

hydraulic
clutch
control

system
It
consISts
of
a

pendant
clutch

pedal

130

CHAPTER

ELEVEN

master

cylInder

operatlng
cylinder
and
with

drawal
lever

Figure
7
shows
all

components

whlle

Figures
8
and
9
are

exploded
VIews
of
the

master

cylmder
and

operatIng
cylinder
for

models
smce
1970
Prior
models

are

similar
In

construction

MASTER

CYLINDER

Master

Cylinder
Removal

Sedans
and

Wagons

1
Remove
cleVIS

pin
mstalled
at
the

pushrod

2

Disconnect
clutch
hose

from
the
master

cylin

der
and
dram
flwd

3

Remove
bolts
to
free

master

cylinder

Master

Cylinder
Removal

Pick
up

1
DIsconnect

pushrod
from
clutch

pedal

2
DIsconnect
clutch
hose
from
master

cylInder

and
drain
fluid

3
Remove
bolts
to
free
master

cylInder

Master

Cylinder
Disassembly

1
Remove
filler

cap
and
drain
fluid

2
Pull
back
dust
cover
and

remove

snap
ring

3
Remove

stopper
pushrod
piston
assembly

cup
and
return

spnng

CD

i
Master

Cylinder
Inspection

1
Clean
all

parts
thoroughly
In
clean
brake

flwd

2
Check

cylInder
and

pISton
for

wear
or
dam

age
Replace
as

required

3
Check
the

clearance
between

cylInder
and

pIston
If
clearance
is

larger
than

0
005
in

0

13mm

replace
the

cylinder

4

Replace
the

pISton
cup
whenever
it
is
re

moved
from

the

cylInder
or
when
It
shows

SIgnS

of

wear
or

damage

5
Check
all
other

parts
for
wear
or

damage

and

replace
as

required

Master

Cylinder
Assembly

1
Soak

piston
cup
m
brake
fluid

2
Install

pIston
cup

3
Coat
the

cylinder
and

pIston
thoroughly
WIth

brake
flwd
and
assemble

4

Replace
other

parts
in
the

reverse
order
of

removal

Master

Cylinder
Installation

1
Bolt
the
master

cylInder
into

pOSItion

2

Adjust
clutch

pedal
heIght
by
adjusting
the

pushrod
length
Pedal

heIght
from
floorboard

132
CHAPTER

ELEVEN

CD

NAnCO
22
20
21

r

i

T

l
C

r
Jl

i

i

18
Clutch

operating
cylinder

19
Piston

cup

20
PIston

21
Dust
cover

22
Push
rod

23
Bleeder
screw

24
Bleeder
cap
22

I

should
be
8
150
m
207mm
for
the
sedan
and

wagon
Pedal

heIght
should
be
591
m

150mm

for
the

pick
up

3

Apply
multI

purpose
grease
to
all

PIvot

pOInts

4
Bleed
all
aIr
out
of
the

sy
tem
as

dIscussed

below

OPERATING
CYLINDER

Operating
CyHnder
Removal

1
Remove
retum

spring

2
Disconnect
clutch
line
from

operating
cyl

inder
18

Ii

TOKICO

21

I

LL

18
23
24

I
I

3
Disconnect

pushrod
from
wIthdrawal
lever

4
Release
two
bolts

holdmg
operating
cylInder

to
clutch

hOUSIng

5
Remove

operating
cymder
from
clutch
hous

mg

Operating
CyHnder
Disassembly

1
Remove
dust
cover

2
Remove

snap
ring
All
other

parts
can
now

be
removed
See

Figure
10

Operating
CyHnder
Inspection

Check
all

parts
especIally
the

pIston
cup
for

wear
and

damage
Replace
if
defects
are
found

134

CHAPTER

ELEVEN

CLUTCH
SERVICE
DATA

AND

SPECIF1CATIONS

Table
1

proVIdes
serVIce
data

and

specifica

tIons
for
the
clutch

system

TRANSMISSION

Description

Datsuns
are

eqUIpped
with
either

an
auto

matic
or
manual
transrmSSIOn

Due
to
the
com

pleXity
of
the
unIt
and

the
need
for

special
tools

and

knowledge
overhaul

of
the
automatic
trans

mISSIon
is
not

covered
In
thIS
manual
Auto

matIc
transmISSIOn

checks
and

adjustments
are

given
later
m
thIS

chapter
Reparr
and
mainte

nance

should
be
referred
to

a
Datsun
dealer

or

qualIfied
mechamc

The
manual
transmission
is

a
four
forward

Table
1
speed
unlt
controlled
With
a
floor

mounted
lever

It
consIsts
of
transrmSSIOn

case
rear
extensIOn

housing
and

gear
assembly
The
clutch

housmg

and
transmissIOn

case
are
a

sIngle
unIt
The

rear

extension

housmg
is

detachable

Figure
12
shows

the
4
forward

speed
transmission

Transmission

Removal

Removal
of
the

transmIssion
from
dIfferent

models

Varles

accordmg
to
the

dIfferent
struc

ture
Involved
The

following
procedures

gen

erally

apply
to
all

types

Important
dIfferences

are
noted

1
Prom

InsIde
the
vehicle

remove
the
floor

covenng
around
the

gear
shift

so
that
the
shIft

lever
can
be
removed

2
Jack

up
the
vehIcle
and

support
it
with
four

CLUTCH
SERVICE
DATA
AND
SPECIFICATIONS

Pressure

Spring

Free

length

Fitted

length
and
load

Out
of

rlght

angle

MInimum

sprmg
force

Clutch
Release
Lever

Release

bearlng
to

dlaphragm
clearance

Diaphragm
sprlng
to

flywheel
height

Release

lever
to

flywheel
height

Clutch
DISC

FaCing
size

Outer

dIameter
x
inSide
diameter

x
thlckness

Thickness

Free

Compressed

Number
of

tOrslO
1
springs

Minimum

depth
of
rivet
head

from

faCing
surface

Allowable

facmg
runout

Allowable

spline
free

play

Pressure

Plate

Allowable

refacmg
limit

Clutch
Pedal

Height
when
not

depressed

Free
stroke
of

pedal
head

Pressmg
strength
at
full

stroke

Clutch
Master

Cylinder

Diameter

MaXimum

clearance
between

cylinder
and

pIston

Tightening

Torque

Clutch

assembly

securing
bolt
2
059
In
52
3mm

1
149
In
197
4
4
Ib
29
2mm
44
2

kg

o
1968

per
3
937
In
5

per
100mm

15

00472
to
0
0551
In

1
2
to
1
4mm

1732
0
0394
m

44
O
1

Omm

1
988

0
0197
In

505
0
05mm

787
X

5
120
x
0
0140
In
200
x
130
x
3
5mm

o
3386
to
0
3543
m
8
6
to
9
Omm

03012
to
0
3130
m
765

to
7
95mm

6

00118
In
03mm

o
097
In
0
5mm

00157
m
04mm

o
0394

In
1
Omm

8
150
m
207mm

o
984
m
25mm

33
Ib
15

kg

0625
m

15
87mm

00051
m
0
13mm
J

i

r

174
to
188ft
Ib
24

to
2

6

kg
m

DIFFERENTIAL
REAR
AXLE
AND
REAR

SUSPENSION

163

@

j
@

@

@

1

Companron

flange

2
Front

bearmg

3

Spacer

4
Pmlon

heIght
adjust

shim

5
PmlOn

mate

gear

@
6
Pmlon

mate

gear
11

7
Side

gear
thrust
washer
12

8
Side

bearmg
13

9

Bearing

cap
14

10
Differential
case

15
011
seal

Adjusting
washer

Drive

pmlon

Rear

beanng

Drive

gear
16
Lock

pm

17

AdJustmg
shim

18
Thrust
block

19
SIde

gear

20
Pmlon
mate
shaft
@

1
Axle
case

2
Axle
shaft

3
Wheel

beanng

4
Plam
washer

5
Lock
washer

6
Lock
nut

7
011
seal

8
Beanngcage

9
Shim

10
Grease
seal

11
Brake
drum

12
Wheel
nut