suspension DATSUN 510 1968 Service Repair Manual

CON1EN1S

CHAPTER
ONE

GENERAL
INFORMATION

Introduction

Model
Identification

CHAPTER
TWO

PERIODIC

MAINTENANCE

RoutIne
checks

Pen
odic
checks

CHAPTER
THREE

TROUBLESHOOTING

EqUIpment

Starter

ChargIng
system

EngIne

Igmtlon

system

Fuel

system

Exhaust

emIssIon
control

CHAPTER

FOUR

ENGINE
AND
IGNITION
TUNE
UP

EqUIpment

Battery

Spark
plugs

DIstrIbutor

Igmtlon

timIng

CHAPTER
FIVE

ENGINE
LUBRICATION
SYSTEM

Descnptlon

Lubncation

cIrcuIt
SpecIficatiOns
and
dImensIons

EngIne
lubncation
and

maIntenance

Recommended
lubncants

Clutch

TransmIssiOn

Brakes

Steenng
and

suspension

TIre
wear

analysIs

Wheel

balancIng

Idle

speed
and
Idle

mIXture

Dwell

angle
setting

CompressIon
test

Valve
clearance

adjustment

AddlllOnal
checks

Oil

pump
I

6

t
1

4

V

9
t

1

20

27

CHAPTER

TWELVE

DIFFERENTIAL
REAR
AXLE
AND
REAR
SUSPENSION
149

DIfferentIal

Rear
axle
and

suspension

Codspnng

Shock
absorber

Rear

suspensIOn
arm

Rear
axle

shaft
Wheel

beanngs

Seals

Rear

spnng

Axle
case

SpecificatIons

CHAPTER
THIRTEEN

FRONT

AXLE
FRONT
SUSPENSION
AND
STEERING
168

Wheel
hub
and

bearmg

StabilIzer

TenSion
rod

Spnng
and
strut

assembly

Transverse
lInk

Lower
ball

Jomt
Front

suspension
adjustment

Wheel

alignment

Posture

adJustment

Steenng
system

SpeCificatIons

CHAPTER
FOURTEEN

BRAKES
187

Brake

pedal

Master

cylInder

Front
diSC
brakes

Rear
brakes

Front
drum
brakes
Wheel

cylInders

Brake

system
bleedIng

Handbrake

Service
data
and

speCificatIons

CHAPTER
FIFTEEN

BODY
ELECTRICAL
SYSTEM

Wmng

SWitches
and
fuses

Instrument

meters
and

panels

Heater
205

Wmdshleld

wipers

Wmdslueld
washers

Headlamps

WIrIng
diagrams

CHAPTER

SIXTEEN

BODY

223

Front

body
trIm

Bumpers

Hood
lock
control

Doors
Door
locks
and

regulators

Trunk
lId
and

rear

bumper

Seats

Tad

gate

INDEX

235

I

GENERAL
INFORMATION
5

Table
1
MAIN

SPECIFICATIONS
AND
DIMENSIONS
continued

Suspension
Rear
Sedan
Wagon
Pick

up

Manual
Automatic
Manual
Automatic
Manual

HypoJd
Hypoid
Hypold

ReCIrculating
ball
ReCIrculating
ball
ReCirculating
ball

DIsc
DIsc
Drum

Drum
Drum
Drum

Mechanical
rear
wheels
Mechanical
rear
wheels
Mechanical
rear
wheels

Independent
strut

type
Independent
strut

type
Independent
torsion
bar

with
tension
rods
and
with
tension
rods
and

stabilizer
stabilIZer

Independent
semi

trailing
Semi

elliptiC
leaf

spring
Semi

elliptic
leaf

spnng

arms
wrtII
coli

springs
and

shock
absorbers

5
6O
13
4PR
5
6O
13
4PR
600
14
6PRLT
ITEM

Transmission

Type

Final
Gear

Type

Steering
Gear

Type

Brake

Front

Rear

Parking
Brake

Suspension
Front

Tires

6
2
Q
1
C
S

PA
l
PlLlU

EN
4
1
AJ
E

Dt7
A

1
1
1

2
A
ru
r
f
f
A

I
III

r
c

o
I
pP
D

LA
I
tV
r
IL

c

W

L
L
l
G

ftiv
TJ

dE
IJ
S
prlc
I

u

F
l
e

p
f
vi
Ii

ftl
1
3

l

1t
J
p7
5

PrlV

B4dc
u
11
1

S
t
f
PT

f
L
UJ
ff
zr
F

T
ff

lfo

1oo

4

t

M

0

IY
AJ
to
BTOL

@
OD

2

lP

S

PAtl
pI
c

5
IN
G

ex
Sf

0103
I
D
0
3
O

j

oo

0
0
0
to

l
c

o

0
0

2
JP
t
UE

SEIT
A

C
1

J

16

CHAPTER

TIlREE

sary
Also
check
all

parts
for

mlSaltgnment
and

uneven
wear

TRANSMISSION

1

Difficult
to
mesh

gears

Make
certam
the

clutch

pressure
plate
and
re

lease

beanng
are
m

good
condItion
The
trouble

can
be

caused

by
worn

gears
shaft
and
or
bear

mgs
DISassemble
and

repaIr
as

requIred
Also

can
be
caused

by
msufficlent

operatmg
stroke

due

to
worn
or
loose

sltdmg
parts
or
a
defective

synchronIZer
DIsassemble

carefully

InSpect
and

replace
as

requIred

2
Gears

slip
out

of
mesh

Generally
thIS
trouble
occurs
when

the
mterlock

plunger
check
ball
and

or

spnng
IS
weakened

or
worn
The
trouble
can

also
be
caused

by
worn

fork
rod
ball

groove

damaged

bearings
or
dam

aged

gears
DIsassemble

carefully
mspect
and

replace
as

required

3
NOIse

If
nOISes
are
heard

wIth
the

engme
idlmg
and
the

clutch

disengaged
the
nOIse
IS

probably

conung

from
the

transmISSIOn
Several
Items

can
cause

nOISes

either

smgly
or
m
combmatIon

Check
the

qualIty
and

quantity
of
lubrIcant

in
the
trans

mISSIon

Replace
or

replenISh
as

necessary
Worn

bearIngs
wIll

usually
produce
a

lugh
humming
at

hIgh
speed
and

a

cycltc
knockIng
sound
at
low

speed
Worn

or

damaged
splInes
and

bushmgs

will
also
cause

nOIse

BRAKES

1
Brake

pedal

goes
to

floor

There

are
numerous
causes
for
thIS

includIng

excessIvely
worn

Itnmgs
aIr
in
the

hydraultc

sys

tem

leaky
brake
lmes

leaky
wheel

cylmders
or

leaky
or
worn

master

cylmder
Check
for
leaks

and
thIn
brake

linmgs
Bleed
and

adjust
the

brakes
If

thIS
doesn
t
cure
the
trouble

rebwld

wheel

cylmders
a
nd
or
master

cylmder

2

Spongy

pedal

Normally
caused

by
aIr
m
the

system
blee
d
and

adjust
the
brakes

3

Brakes

pull

Check

brake

adjustment
Also
check
for
contam
inated

brake

Itmngs
from
leaks

leaky
wheel

cyltnders
loose

caltpers
frozen

or
seIZed

pIstons

and
restrIcted
brake
lmes

or
hoses
In
addItion

check
front
end

alignment
and

suspensIOn
dam

age
such
as
broken
front

or
rear

sprmgs
shocks

etc
Check
condItIon

of
tIres

4
Brakes

squeal
or
chatter

Check
brake

lmmg
thickness

and
brake
drum

roundness
Ensure

that
the
shoes
have
cham

ferred
ends

and
are
not
loose

Inspect
the
condI

tion
of

the
rotors
on
the
front
wheel
dISC

brakes

to
make

certain

they
are
not
scored

or

damaged

Clean

away
all
dIrt
on
shoes

pads
rotors

or

drums

5

Draggmg
brakes

Check

brake

adjustment
includmg
handbrake

Check
for
broken
or

weak
shoe
return

springs

swollen
rubber

parts
due
to

unproper
brake
flUId

or
other
contammatIon

Clean
or

replace
de

fectIve

parts

6
Hard

pedal

Check
brake

linmgs
for

contammation
Also

check
for

restrIcted
brake
lines

and
hoses

7

High
speed
fade

Check

for
dIstorted
or
out
of
round
drums

and

contamInated
brake

lmmgs
Make

certam
the

recommended
brake
flUId
IS

used
Dram
entIre

system
and
refill
If
In
doubt

8

Pulsatmg
pedal

Check
for
dIStorted
or
out
of
round
drums

or

rotors
Check
for

excessIVe
brake

dISC
run
out

STEERING
AND

SUSPENSION

NOTE
Unusual

steermg
pullmg
or

wandermg
IS

usually
caused

by
bent

or
otherwise

mIsaligned

suspenszon

parts
Because

of
the

speCialized
equIp

ment

reqUired
to
evaluate
and

correct

these

faults
It
IS
recommended

t
tat

servIce
to

the

steermg
and

suspension

system
be

referred
to

your
Datsun

dealer

oca

quallfied
specrallst
m

thiS

field

1
VibratIOn

felt
m

steermg
wheel

VIbratIon
can
be
caused

by
several

thmgs
includ

ing
lll1proper
aIr

pressure
m
tIres

uneven
wear

TROUBLESHOOTING
17

of
tIre
loose
wheels

unproper
adjustment
or

wear
of
front
wheel

bearIngs
faulty
wheel

align

ment
or
wear
of
transverse
lInk
and
tension
rod

bushings
Inspect
all

parts
carefully
for
wear
or

damage

Replace
or

replUI
parts
as

required

2
Shock

transmltled

through
steering
wheel

This
is

usually
most
noticeable
when

traveling

over
bad
roads
at

relatively
high
speeds
Causes

Include

damage
to
the
idler
ann
insuffiCient

tIghtening
of

steenng
gear
box
wear
of
the
steer

Ing
linkage
and
wear
of
the

suspension
ball

joint

Inspect
all

parts
for
wear
or

damage
Refer
to

Chapter
ThIrteen
for
service
or

repair
you
can

perform
and
for

procedures
which
should
be

referred
to

your
deal
r

3

Shlmmymg

This
is

usually
most
noticeable
when
a

specIfic

speed
IS
attained
and
will

normally
repeat
at
that

speed
Causes
are

generally
unbalanced
wheels

unproper
adjustment
of

steenng
gear
insuffi

cient
backlash
malfunction
of
the
shock
ab

sorbers
or
loose
bolts
for
the
strut

mountIng

Reparr
or

replace
defective

parts
as

required

Refer
to

Chapter
Thirteen

4

Wandermg
of
car
m
one
dlrectlOnl

This

problem
can
be
caused

by
improper
air

pressure
loose
wheel

nuts
difference
in
tire
tread

wear
from
left

to

right
side
Incorrect

adjustment

of
wheel

bearings
defectIve
wheel

beanngs

collapsing
or

twistIng
of
front

spnng
or
Incorrect

wheel

alignment
Also

binding
of
the
brake

shoes
worn

bushings
in
the
transverse
link
or
the

tension
rod
and
deformation
of
s

enng

lInkage

and

suspension
link
can
cause
wander

Carefully

iuspect
all

parts
for
looseness
and
wear
and
re

place
or

repaIr
as

required
In
some
c
ases
a
de

fective
rear

suspension
may
also
cause
the

vehicle
to
wander

5

InstabIlity

Instability
can

be
caused

by
unproper
tIre

pres

sures
worn

bushings
in
the
transverse
link
and

tension
rod
mcorrect
wheel

alignment
worn

steenng
linkage
Incorrect

adjustment
of
steer

ing
gear
and
unbalanced
wheels

Inspect
all

parts
carefully
for
wear
and

damage
Adjust

repair
or

replace
as

required
6

Heavy
feelmg
m

steering

This
can
be
caused

by
improper
tIre

pressures

insuffiCient
or
contamInated
lubncant
in

gear

box

damage
or
insuffiCient

grease
In

suspeuslon

ball

Joint
damaged
or

badly
adjusted
wheel

bearIngs
worn
or

damaged
steermg
gear
dam

age
of

upper
strut

bearing
and
mterference
of

steenng
column
With
turn

signal
SWitch

Inspect

all

parts
carefully
for
wear
and

damage
Adjust

repair
or

replace
as

required

7
ExceSSIve

play
m

steermg
wheel

This
is

usually
caused

by
Incorrect

adjustment
of

the

steenng
gear
worn

bushings
in
the

steering

linkage
or
Idler
arm
mcorrect

adjustment
of
the

front
wheel

bearings
worn

bushIngs
in
the
trans

verse
lInk
and
tension
rod

Carefully
inspect
all

parts
for
wear
or

damage
Adjust
repair
or
re

place
as

reqUIred

TIRE
WEAR
ANALYSIS

Abnormal
tIre
wear
should

always
be
ana

lyzed
to
deternune
the

cause
The
most
common

are
Incorrect
tIre

pressure
improper
dnving

overloading
and

Incorrect
wheel

ahgDment

Figures
2A

through
2F

identify
wear

patterns

and
mdicate

likely
causes

Of

I

1

l

D

1

Undennflatlon
Worn
more
on
Sides
than
In

center

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

DIFFERENTIAL
REAR
AXLE
AND
REAR
SUSPENSION
151

4
Lower
the

Jack
and

r
move
dIfferentIal
from

rear
of
vehIcle
See

Figure
4
After
removal

sup

port
suspensIon
member
wIth

a
stand
to

prevent

distortlon
and

damage
to
the
Insulators

Differential

Inspection
Sedan

The

followmg
mspectIon
can
be
done
WIthout

disassembly
of
the
dIfferential
If
abnormalitIes

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

removmg
rear

cover
Refer
to

Figure
5
which
shows
the

cor

rect
contact

pattern
If
the
contact

pattern
IS
m

correct

dIsassembly
and

adjustment
of
dIffer

entlalls

reqUIred

CD
TOE

HEEL
DRIVE

SIDE
HEEL
COAST

SIDE

2
Use
a
dIal
mdtcator
to
measure
backlash
be

tween
the
dnve

gear
and

pmIOn
Backlash

should
be

0
0039
to
0
0079
m
0
10
to

o
20mm
Check

all

gear
teeth
for

damage
and

cracks

3
Check
runout
at
the
rear
of
the
dnve

gear

If
the
tooth
contact

pattern
or
backlash

IS
ab
normal
Runout
should
be
less
than
00031

m

0
08mm
See

Figure
6

4
Rotate
the

gears
and
lIsten
for

SignS
of
de

fective

bearmgs
If
noises
are
eVIdent
the
dIf

ferential
must
be
dIsassembled
and

repaired

CD

Diflerentiallnstallation

Sedan

1
Mount
the
dIfferentIal

assembly
to
the
rear

suspensIOn
member

2
FIt
the
dIfferentIal

mountlng
member
to
the

fittmg
hole

by
pushIng
It
forward
with

a
bar

Torque
the

nuts
to
61
ft
lb

8
5

kg
m

3
Install
axle
dnve
shafts
dnve

shaft
and

handbrake

rear
cable

REAR

AXLE
AND
SUSPENSION

SEDAN

Figure
7
and

Figure
8

page
153
are
ex

ploded
dIagrams
of
the
sedan
rear
axle
and

suspensIOn
The

fully
independent
rear

suspen

SIon
IS
a
semI

traIlIng
arm

deSIgn
With
a
sus

penSIOn
member

suspensIOn
arms
coIl

spnngs

and

hydraulIc
shock
absorbers
The
wheel

bearings
are
lIfetime
lubncated

Rear
Axle

and

Suspension
Removal
Sedan

1
Jack

up
the

rear
of
the
veh1cle
and

support

It
on
stands

2
Remove
wheels

3
Refer
to

Figure
9
and
dtsconnect
handbrake

lInkage
and
rerum

sprmg
Remove
tall

pIpe
and

muffler

4
DISconnect
brake
hose
from
brake
tube
Re

move
four
bolts

holdmg
dnve
shaft
to
dIf

ferential

Lower
dnve

shaft

gently
to

ground

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

154
CHAPTER

tWELVE

move
two
nuts

attachmg
dtfferenual

suspension

member
to
the

body

7

Gently
lower
the

suspension
assembly
from

the

body
by
10wermg
the

jack
Support
the

suspension
so
It

does
not

fall
off
of
the

Jack

See

Figure
11
WIthdraw

Jack
and

suspension

from
vehicle

Rear
Axle
and

Suspension
Inspedion

And

Repair
Sedan

WIth
the
rear

suspension
removed
from
the

vehicle

InSpect
all

parts
for
wear
and

damage

Pay

special
attention

to
the

bushings
in
the

suspensIon
arms
and
robber

bumpers
Check

conditIon

of
the

spring
robber

msulators
in
the

suspensIOn
member
and
drive
unit

mounting

member

Replace
as

required

Rear
Axle

and

Suspension
InstaDation
Sedan

1
Instalation

procedures
are
the

opposite
of

removal

2
Be
sure
that
the

suspension
member
and
dnve

unit

mountmg
member
are
med

up
correctly

3

Tighten
fixing
nuts
and
bolts

as
follows

Suspension
Member

Mounting
Nuts
72
It

Ib
10

kg
m

Dlfferenbal

Mounting
Nuls
62
It
Ib
85

kg
m

Shock
Absorber
Lower
End
Nuts
17
It
Ib
23

kg
m

COIL
SPRING

SEDAN

Coil

Spring
Removal
Sedan

1
Jack

up
rear
of

vehicle
and

support
it
on

stands
2
Remove
wheels

3
Disconnect
handbrake

mkage
and
retl1rn

spring

4
Remove
dnve
shaft

flange
nuts

Figure
12

5
Remove
nuts
from
lower

part
of

bumper

assembly

6
Place
a

Jack
under

suspension
arm
and

re

move
shock
absorber
from

lower

mounting

Lower

Jack
and
remove
coll

spring
spnng
seat

and

bumper
assembly

Coil

Spring
Inspection
and

Repair
Sedan

1
Check
condItIon
of
coll

sprmg
for
wear
and

damage
Replace
if
defective

2
Check

all
robber

parts
for

wear

damage
and

general
condItion

3
Installation
of
the
coll

spnng
assembly
is
the

reverse
of
removal
Make
certam
the
coil

spring

is
installed
With
Its
flat
face
at
the

top

SHOCK
ABSORBER

REMOVAL
REPLACEMENT

INSTALLATION

SEDAN

1

Open
the
trunk
and

remove
the
mer

2
Remove
double
nuts
that
fasten

upper
end

of
rear
shock
absorber
to
the

body
Figure
13

3

DIsconnect
lower
end
of
shock
absorber
from

suspensIon
arm

4
Check

general
conditIon
of
shock
absorber

Check
for
011
leaks
cracks
and

straIghtness
of

shaft

Replaceif
defectIve

5

Inspect
robber

bushmgs
for

damage
wear

and

general
condition

Replace
as

required

6
InstallatIon
IS
the
reverse
of
removal