steering DATSUN 510 1969 Service Repair Manual
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1969, Model line: 510, Model: DATSUN 510 1969Pages: 171, PDF Size: 10.63 MB
Page 4 of 171
inteN
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Index
ENGINE
COOLING
SYSTE
l
IGNITION
SYSTE
I
FUEL
SYSTBl
CLUTCH
GEARUOX
PROPELLER
SHAFT
Id
DIFFERENTIAL
REAR
AXLE
nd
REAR
SUSPENSION
FRONT
SUSPENSION
STEERING
BRAKING
SYSTEM
ELECTRICAL
EQUIP
JENT
WIRING
JAGRA
IS
TROUBLE
SHOOTING
TIGHTENING
TORQUES
SERIES
C
30
MODEL
SUPPLEMENT
AUTOSERVlCE
DATA
CHART
PART
NA
ES
nd
ALTERNATIVES
CONVERSION
TABLES
S
15
2S
33
43
51
62
7S
83
91
9S
lOB
liB
I2S
129
51
End
of
manuir
IntroductIon
OUf
intention
in
writing
this
Manual
is
to
provide
the
reader
with
all
the
data
and
in
formation
required
to
maintain
and
repair
the
vehicle
However
it
must
be
realised
that
special
equipment
and
skills
arc
required
in
some
caseS
to
carry
out
the
work
detailed
in
the
text
and
we
do
not
recommend
that
such
work
be
attempted
unless
the
reader
possesses
the
necessary
skill
and
equipment
It
would
be
better
to
have
an
AUTHQRISED
DEALER
to
carry
out
the
work
using
the
special
tools
and
equipment
available
to
his
trained
staff
He
will
also
be
in
possession
of
the
genuine
spare
parts
which
may
be
needed
for
replacement
The
information
in
the
Manual
has
been
checked
against
that
provided
by
the
vehicle
manufacturer
and
any
peculiarities
have
been
mentioned
if
they
depart
rom
usual
work
shop
practice
A
fault
finding
and
trouble
shooting
chart
has
been
inserted
at
the
end
of
the
Manual
to
enable
the
reader
to
pin
point
faults
and
so
save
time
As
it
is
impossible
to
include
every
malfunction
only
the
more
usual
ones
have
been
included
A
composite
conversion
table
has
also
been
included
at
the
end
of
the
manual
and
we
would
recommend
that
wherever
possible
for
greater
accuracy
the
metric
system
units
are
used
Brevity
and
simplicity
have
been
our
aim
in
compiling
this
Manual
relying
on
the
number
ous
illustrations
and
clear
text
to
inform
and
instruct
the
reader
At
the
request
of
the
many
users
of
our
Manuals
we
have
slanted
the
book
towards
repair
and
overhaul
rather
than
maintenance
Although
every
care
has
been
taken
to
ensure
that
the
information
and
data
are
correct
WE
CANNOT
ACCEPT
ANY
LIABILITY
FOR
INACCURACIES
OR
OMISSIONS
OR
FOR
DAMAGE
OR
MALFUNCTIONS
ARISING
FROM
THE
USE
OF
THIS
BOOK
NO
MATTER
HOW
CAUSED
I
3
Page 52 of 171
Gearbox
GEARBOX
Removal
GEARBOX
Dismantling
GEARBOX
Inspection
and
Overhaul
GEARBOX
Assembling
THREE
SPEED
GEARBOX
GEARCHANGE
CONTROL
Removal
and
Adjusting
AUTOMATIC
TRANSMISSION
Gearchange
control
linkage
DESCRIPTION
Three
types
of
transmission
are
available
for
the
Datsun
models
covered
by
this
manual
Either
a
three
speed
gearbox
a
four
speed
gearbox
or
three
speed
automatic
transmission
can
be
fitted
The
three
and
four
speed
gearboxes
are
equipped
with
nchromesh
on
all
forward
gears
with
the
three
speed
gearbox
operated
by
a
steering
column
gearchange
system
and
the
four
speed
gearbox
by
a
floor
mounted
gear
lever
Two
types
of
synchromesh
are
used
in
the
four
speed
gearboxes
Either
Borg
Warner
or
Servo
types
may
be
fitted
The
gearboxes
differ
only
in
the
synchromesh
devices
whereby
the
baulk
rings
synchronize
the
coupling
sleeve
with
the
main
shaft
gear
on
the
Warner
gearbox
This
action
is
accomplished
by
a
synchrcrring
on
the
servo
gearbox
THREE
SPEED
GEARBOX
Removal
I
Jack
up
the
vehicle
and
support
it
on
stands
2
Disconnect
the
hand
brake
cable
at
the
equalizer
bracket
Slacken
the
two
exhaust
pipe
centre
clamps
and
turn
the
centre
section
of
the
exhaust
assembly
to
the
left
as
shown
in
Fig
F
2
3
Disconnect
the
propeller
shaft
from
the
rear
axle
drive
flange
by
removing
the
four
securing
bolts
Seal
off
the
gearbox
extension
housing
to
prevent
the
loss
of
oil
and
withdraw
the
shaft
to
the
rear
4
Disconnect
the
speedometer
drive
cable
from
the
adaptor
in
the
gearbox
extension
housing
Fig
F3
S
Disconnect
the
lower
shift
rods
from
the
shift
levers
Fig
F
4
and
remove
the
cross
shaft
assembly
from
the
gearbox
casing
Remove
the
clutch
slave
cylinder
from
the
clutch
housing
Fig
F
5
6
Support
the
engine
with
ajack
positioned
underneath
the
oil
sump
making
sure
that
the
jack
does
not
foul
the
drain
plug
A
block
of
wood
should
be
placed
between
the
sump
and
jack
to
avoid
damaging
the
sump
7
Remove
the
bolts
securing
the
rear
engine
mounting
to
the
crossmember
Position
ajack
under
the
gearbox
and
remove
the
bolts
attaching
the
crossmember
to
the
body
Lower
the
jack
under
the
engine
so
that
the
engine
is
tilted
to
the
rear
Remove
the
starter
motor
and
the
bolts
securing
the
clutch
housing
to
the
engine
Lower
the
jack
slowly
and
withdraw
the
gearbox
towards
the
rear
of
the
vehicle
THREE
SPEED
GEARBOX
Dismantling
Drain
the
gearbox
oil
Remove
the
dust
cover
release
the
retainer
spring
and
remove
the
withdrawal
lever
complete
with
release
bearing
from
the
clutch
housing
See
section
CLUTCH
Remove
the
gearbox
bottom
cover
the
speedometer
drive
pinion
assembly
and
the
rear
extension
housing
Take
out
the
cross
shaft
retaining
rings
and
unscrew
the
nuts
securing
the
operating
lever
lock
pins
Use
a
hammer
and
punch
to
drive
out
the
pins
and
withdraw
both
cross
shafts
Fig
F
6
Remove
the
fr
mt
cover
and
withdraw
the
counter
shaft
Lift
out
the
countersbaft
gear
cluster
together
with
the
needle
roller
bearings
and
spacers
Fig
F
7
Remove
the
reverse
idler
gear
shaft
lock
bolt
and
remove
the
shaft
and
the
idler
gear
Fig
F
B
Drive
out
the
pins
securing
the
selector
forks
to
the
selector
rods
Unscrew
the
interlock
plug
and
remove
the
detent
ball
and
spring
Fig
F
9
Remove
the
first
reverse
speed
and
second
third
speed
selector
rods
and
lift
out
the
selector
forks
Withdraw
the
main
shaft
assembly
and
the
drive
shaft
assembly
from
the
gearbox
See
Fig
F
1O
and
F
11
To
dismantle
the
mainshaft
release
the
circlip
from
the
front
of
the
mainshaft
as
shown
in
Fig
F
12
and
remove
the
second
and
third
speed
synchronizer
hub
and
second
speed
gearwheel
Fig
F
13
Remove
the
circlip
securing
the
speedo
meter
drive
gear
and
withdraw
the
gear
together
with
the
ball
and
spacer
Fig
F
14
Remove
the
mainshaft
bearing
using
a
press
Hold
the
rnainshaft
reverse
gear
and
tap
the
shaft
on
a
piece
of
wood
to
release
the
reverse
gear
assembly
together
with
the
first
speed
gearwheel
GEARBOX
Inspection
and
Overhaul
Oean
all
parts
thoroughly
and
examine
the
gearbox
case
and
extension
housing
for
cracks
If
the
joint
faces
are
burred
or
pitted
it
may
be
necessary
to
replace
the
units
if
repair
cannot
be
carried
out
satisfactorily
Remove
any
adhesive
which
remains
on
the
faces
The
rear
extension
housing
bush
should
be
renewed
if
worn
unevenly
Clean
the
bearings
and
dry
with
compressed
air
taking
care
that
the
bearings
do
not
spin
Turn
the
ball
bearings
to
make
sure
that
they
run
smoothly
and
without
play
Replace
the
needle
bearings
if
worn
or
damaged
in
any
way
It
is
advisable
to
renew
the
needle
roller
bearings
after
they
have
been
installed
for
a
considerable
period
as
it
is
difficult
51
Page 59 of 171
inter
lli
r@
ig
F
28
Re
oving
the
reverse
idler
gear
q
F
8
F
27
View
of
the
four
speed
gearbox
with
front
cover
removed
F
8
F
29
Removing
the
mainshaft
bearing
retainer
Fig
F
30
Withdrawing
the
mainshaft
assembly
CD
1ib
1
@
II
c
I
@
d
I
Q
n
j2
JJ
I
0
6
r
7
1
L
l
Hv
9
1l
ij07
u
1
1
v
1
ISland
2nd
selector
fork
5
Fork
rod
2
3rd
and
4th
selector
fork
6
Inter
ock
phmgtr
3
Fork
rod
7
Intulock
pin
4
Interlock
plunger
8
Revene
selLetor
fork
9
Fori
rod
10
Retaining
pin
Fig
F
33
Assembly
of
the
selector
forks
1
17uu
t
block
2
md
bruke
3
Synchro
rint
4
Anchor
block
5
Circlip
6
Band
b
ke
r
1
R
nt
shaft
SntJpring
3
R
idler
driving
geor
UT
4
Thrust
washer
5
1
hnat
washer
6
Idlergeor
18T
Fig
F
32
Reverse
idler
gear
F
8
F
31
Syncbromesh
assembly
3rd
4th
Rod
Fig
F
36
Removing
the
steering
wheel
Fig
F
34
Section
tIuough
the
gearbox
showing
the
inlerlock
mechanism
58
Page 60 of 171
THREE
SPEED
GEARBOX
GEARCHANGE
CONTROL
LINKAGE
Fig
F
35
As
previously
described
the
three
speed
gearbox
is
equipped
with
a
steering
column
gearchange
linkage
system
which
incorporates
a
collapsible
control
rod
when
combined
with
the
collapsible
type
of
steering
column
assembly
The
gearchange
linkage
can
be
removed
and
inspected
in
the
following
manner
Remove
the
steering
wheel
Fig
F
36
and
take
off
the
steering
column
shell
cover
Remove
the
turn
signal
and
lighting
switch
Fig
F
37
These
removal
details
can
also
be
found
in
the
section
STEERING
Remove
the
C
washer
I
in
Fig
F
38
and
the
washer
then
remove
the
upper
support
bracket
by
releasing
the
locating
bolt
and
screw
The
control
rod
insert
with
bush
and
return
spring
can
now
be
removed
Remove
the
snap
and
gear
lever
pivot
pin
and
withdraw
the
gearlever
Remove
the
cotter
pin
plain
washer
and
spring
washer
and
disconnect
the
shift
rods
from
the
gear
selector
levers
Fig
F
39
Unscrew
the
bolts
securing
the
lower
support
bracket
and
the
clamp
Remove
the
clamp
and
gear
change
lever
retainer
Remove
the
second
third
speed
selector
lever
the
lower
support
bracket
and
the
first
reverse
selector
lever
from
the
control
rod
Withdraw
the
control
rod
Disconnect
the
gear
change
rods
by
removing
the
cotter
pins
and
remove
the
cross
shaft
bracket
from
the
side
member
Withdraw
the
cross
shaft
assembly
Fig
F
40
Examine
the
components
for
signs
of
wear
and
damage
and
replace
if
necessary
Installation
is
a
reversal
of
the
removal
procedure
noting
the
following
points
Take
care
not
to
strike
or
apply
a
load
to
the
collapsible
type
of
control
rod
or
the
rod
may
be
damaged
The
rod
should
not
be
slack
in
the
axial
direction
when
installed
and
must
be
removed
if
slackness
is
detected
Coat
the
sliding
surfaces
with
grease
before
assembling
them
Acijusting
Set
the
gear
lever
to
the
neutral
position
and
temporarily
connect
the
trunnion
on
the
lower
support
bracket
to
each
rod
Fig
F41
Set
the
rod
on
the
lever
so
that
the
neutral
adjustment
grooves
on
the
upper
surface
of
the
lower
support
bracket
are
aligned
with
the
grooves
on
each
lever
When
the
adjustment
is
completed
operate
the
gear
lever
to
select
each
gear
and
make
sure
that
the
lever
can
be
moved
smoothly
and
positively
AUTOMATIC
TRANSMISSION
Gearchange
control
linkage
The
automatic
transmission
gear
change
control
linkage
can
be
removed
in
a
similar
manner
to
the
three
speed
gearbox
linkage
Carry
out
the
operations
previously
described
under
the
relevant
heading
as
far
as
the
removal
of
the
gear
lever
and
proceed
as
follows
Disconnect
the
upper
selector
rod
from
the
selector
lever
by
removing
the
cotter
pin
plain
washer
and
lock
washer
See
Fig
F
42
Remove
the
speed
range
position
plate
the
snap
ring
at
the
lower
end
of
the
control
rod
and
unscrew
and
remove
the
lower
support
bracket
Release
the
locking
screw
and
with
draw
the
selector
lever
assembly
Withdraw
the
control
rod
disconnect
the
selector
rods
and
remove
the
cross
shaft
bracket
and
cross
shaft
assembly
Clean
all
parts
and
repair
or
renew
any
part
which
is
worn
or
damaged
Installation
is
a
reversal
of
the
removal
procedure
noting
the
following
points
Coat
all
the
sliding
surfaces
with
chassis
grease
prior
to
assembling
Set
the
converter
side
lever
and
the
gear
lever
in
the
neutral
position
Install
the
upper
selector
rod
to
the
selector
lever
and
adjust
the
gear
position
plate
to
give
a
clearance
of
0
5
I
Omm
0
02
0
04
in
between
the
selector
lever
stop
pin
and
the
position
plate
The
adjustment
can
be
obtained
by
turning
the
selector
rod
adjusting
nuts
Finally
tighten
the
nuts
on
each
side
of
the
trunnion
S9
Page 61 of 171
6
T
1
0
4
k
m
7
2
10
1
h
b
Lowe
bra
ket
T
1
2
kl1
m
So
ft
lb
Change
J
P
dl
s
1
T
2
0
kg
m
S
d
Trunnion
i14
5ft
lb
k
R
b
hifirod
I
i
f
S
3
d
h
h
1m
1
L
7fOC
v
Rev
Rev
lst
lhift
le
er
Fig
F
35
Three
speed
gearchange
linkage
column
mounted
inter
IUI
j@
l
ce
Steering
gear
Fig
F
37
Removing
the
indicator
and
lighting
switch
60
k
Upper
bracket
id
m
mb
r
Control
rod
eros
shalt
e
r
i
2nd
Steerin
Reve
e
lu
Reverle
Neutral
od
3
Neutral
H
C
dl
n
3
Note
Fig
F
38
Removing
the
upper
support
bracket
lO
br
Gr
fOf
trllllett
il
ll
1
Ch
lwer
i
Fig
F
41
Neutral
setting
adjustment
T
0
35
0
5
kg
m
2
S
3
6
ft
lb
1
2
T
Tightening
torque
@
Chauis
grease
Apply
grease
to
the
points
shown
by
@
when
recnsembling
Fig
F
39
Removing
the
lower
bracket
Fig
F
42
View
of
the
selector
lever
Page 84 of 171
Front
SuspensIon
DESCRIPTION
WHEEL
HUBS
WHEEL
BEARINGS
Adjusting
FRONT
AXLE
AND
SUSPENSION
ASSEMBLY
DESCRIPTION
The
front
suspension
is
of
the
strut
type
with
the
coil
spring
and
hydraulic
damper
units
mounted
on
the
suspension
member
and
transverse
link
assembly
See
FigJ
1
Vertical
movement
of
the
suspension
is
controlled
by
the
strut
assembly
the
tension
rod
absorbs
the
forward
and
backward
movement
of
the
transverse
links
whilst
side
move
ment
of
the
body
is
controlled
by
the
stabilizer
rod
which
is
attached
to
the
body
and
transverse
links
WHEEL
HUBS
Removal
1
Jack
up
the
vehicle
remove
the
road
wheel
and
disconnect
the
brake
hose
at
the
strut
outer
casing
bracket
as
described
under
the
previous
heading
Plug
the
opened
end
of
the
hose
to
prevent
loss
of
fluid
2
Remove
the
brake
calliper
assembly
or
the
brake
drum
as
described
in
the
section
BRAKES
3
Remove
the
grease
cap
from
the
hub
by
tapping
lightly
at
the
joint
using
a
screwdriver
and
hammer
4
Withdraw
the
cotter
pin
from
the
wheel
bearing
locknut
and
remove
the
nut
Remove
the
wheel
hub
together
with
the
wheel
bearing
and
washer
Fig
J
2
On
cars
fitted
with
disc
brakes
the
hub
is
removed
complete
with
brake
disc
5
The
wheel
bearing
outer
race
can
be
removed
from
the
hub
using
a
drift
as
shown
in
Fig
I
3
WHEEL
HUBS
Inspection
and
Overhaul
Gean
the
hub
and
bearings
by
washing
in
petrol
Examine
the
grease
seal
and
make
sure
that
it
is
not
worn
or
cracked
renew
the
seal
if
necessary
Ensure
that
the
races
are
not
pitted
or
scored
rotate
them
and
check
for
signs
of
wear
and
play
A
sectional
view
of
the
wheel
bearing
assembly
is
given
in
Fig
14
to
provide
an
indication
of
the
points
to
be
checked
WHEEL
HUB
AND
BEARING
Installation
The
wheel
bearing
outer
race
can
be
refitted
with
a
suitable
drift
or
special
tool
ST
35310000
Fill
the
wheel
hub
and
the
hub
cap
to
the
positions
shown
in
Fig
J
5
with
multi
purpose
grease
Fill
the
spaces
between
the
bearing
rollers
and
the
lip
of
the
grease
seal
with
the
same
type
of
grease
Lightly
smear
the
spindle
shaft
and
threads
the
bearing
washer
and
bearing
lock
SPRING
AND
STRUT
ASSEMBLY
TRANSVERSE
LINK
AND
LOWER
BALL
JOINT
FRONT
WHEEL
ALIGNMENT
ADJUSTING
THE
STEERING
ANGLE
nut
with
grease
and
assemble
the
parts
onto
the
wheel
spindle
Make
sure
that
dirt
and
foreign
matter
does
not
adhere
to
the
greased
surfaces
Adjust
the
wheel
bearings
as
described
under
the
following
heading
WHEEL
BEARINGS
Adjusting
The
wheel
bearings
can
be
adjusted
with
the
road
wheel
the
hub
cap
and
the
bearing
locknut
cotterpin
removed
as
previously
described
Tighten
the
wheel
bearing
locknut
to
a
torque
reading
of
3
0
3
5
kgm
21
7
25
3lb
ft
Turn
the
hub
several
times
in
each
direction
to
settle
the
bearing
and
then
retighten
the
bearing
locknut
to
the
specified
torque
reading
Slacken
the
bearing
locknut
to
an
angle
between
40
to
700
a
ay
from
the
previously
tightened
position
and
align
the
cotter
pin
hole
with
the
hole
in
the
spindle
Turn
the
wheel
hub
a
few
times
in
each
direction
and
then
measure
the
torque
required
to
cause
the
hub
to
turlI
A
spring
balance
should
be
used
as
shown
m
Rig
J
p
make
sure
that
the
brake
pads
are
not
binding
on
the
disc
type
of
brake
unit
and
check
that
the
force
required
to
turn
the
hub
is
within
the
following
fIgures
Wheel
bearing
rotation
starting
torque
1800ce
With
new
bearing
7
0
kg
cm
97
in
oz
1400
1600cc
With
new
bearing
8
0
kg
cm
111
2
in
oz
With
used
bearing
4
0
kg
cm
56
0
in
oz
Starting
torque
at
the
hub
bolt
lWth
new
bearing
ith
used
bearings
1
57
kg
3
46
lb
0
7
kg
1
541b
Adjust
the
locknut
slightly
if
the
fIgures
do
not
conform
and
replace
the
cotterpin
Refit
the
hub
cap
and
the
road
wheel
FRONT
AXLE
AND
SUSPENSION
ASSEMBLY
Removal
Jack
up
the
front
of
the
vehicle
and
place
stands
under
the
ront
side
members
Remove
the
road
wheels
and
the
splash
board
3
Disconnect
the
front
brake
hoses
and
remove
the
brake
hose
locking
springs
Withdraw
the
plates
and
remove
the
hoses
from
the
strut
assembly
Plug
the
ends
of
the
hoses
to
prevent
the
ingress
of
dirt
and
loss
of
fluid
4
Remove
the
cotter
pin
from
the
tie
rod
ball
joint
remove
83
Page 87 of 171
inteN
GD
j
@fPJ
2
FiB
J
14
Removing
the
gIand
packing
V
l
i
I
I
DJ
U
i
i
r
FiB
J
15
Greasing
points
0
if
Fig
J
17
Removing
the
link
bush
FiB
J
16
Removing
the
transverse
link
0
1
mm
O
039
n
AI
FiB
J
19
Section
through
the
lower
ball
joint
FiB
J
18
Section
through
the
transverse
link
bush
1
r1
J
I
r
11
e
0
f
F
8
J
20
Adjusting
the
toe
in
setting
FiB
J
21
Adjusting
the
steering
angle
86
Page 89 of 171
Removal
from
the
vehicle
can
be
carried
out
in
the
following
manner
Jack
up
the
front
of
the
vehicle
and
support
it
on
stands
2
Remove
the
stabilizer
bar
and
tension
rod
from
the
transverse
link
as
previously
described
Remove
the
knuckle
arm
fixing
bolts
and
separate
the
ball
joint
from
the
strut
asse
m
bly
3
Remove
the
transverse
link
mounting
bolt
Fig
J
16
and
detach
the
transverse
link
from
the
suspension
member
Remove
the
cotter
pin
from
the
knuckle
arm
castle
nut
and
remove
the
knuckle
arm
from
the
ban
joint
Unfasten
the
ball
joint
securing
nut
and
withdraw
the
ball
joint
from
the
transverse
link
r
The
bushing
can
be
withdrawn
from
the
transverse
link
using
a
press
and
the
special
tools
shown
in
Fig
J
17
TRANSVERSE
LINK
AND
LOWER
BALL
JOINT
Inspection
The
transverse
link
bushing
is
shown
in
Fig
J
18
If
the
rubber
and
inner
tube
joints
are
melted
or
cracked
the
complete
transverse
link
assembly
must
be
replaced
The
ban
joint
cannot
be
dismantled
and
should
be
replaced
if
the
dust
cover
is
split
or
if
the
axial
play
of
the
joint
exceeds
1
0
mm
0
039
in
Oleck
the
axial
play
with
a
spring
balance
The
force
required
at
the
cotterpin
hole
pOsition
is
between
6
6
1
I
3
kg
15
25
lb
Lubricate
the
ball
joint
with
multi
purpose
grease
every
50
000
km
30
000
miles
or
two
year
whichever
comes
first
A
grease
nipple
must
be
installed
in
place
of
the
plug
See
Fig
J
19
and
the
old
grease
completely
replaced
If
a
high
pressure
grease
gun
j
used
make
sure
that
the
grease
is
injected
slowly
and
is
not
forced
out
through
the
joint
clamp
Remove
the
grease
nipple
and
replace
the
plug
TRANSVERSE
LINK
AND
BALL
JOINT
Installation
Installation
is
a
reversal
of
the
removal
procedure
noting
the
following
points
Remove
all
rust
from
the
transverse
link
bushing
interior
with
a
piece
of
emery
cloth
The
bushing
and
transverse
link
bore
should
be
wetted
with
soapy
water
so
that
the
bushing
can
be
more
easily
inserted
Fit
the
bushing
into
the
transverse
link
using
the
special
tool
ST
36700000
Adjust
the
bushing
inner
tubes
so
that
the
distances
from
the
transverse
link
collar
ends
are
equal
at
both
sides
88
Install
the
lower
ball
joint
on
the
transverse
link
and
tighten
the
installation
bolt
to
a
torque
reading
of
1
9
5kgm
14
18Ib
ft
Oean
the
knuckle
arm
and
the
ball
joint
stud
install
the
knuckle
arm
on
the
ball
joint
and
tighten
the
castle
nut
to
a
torque
reading
of
5
5
74
kgm
4o
53Ib
ft
fit
the
cotterpin
and
bend
it
over
Apply
sealing
agent
over
the
ball
joint
castle
nut
to
prevent
the
formation
of
rust
Locate
the
knuckle
arm
beneath
the
strut
assembly
and
tighten
the
mounting
bolts
to
a
torque
reading
of
4
9
63kgm
35
46Ib
ft
Make
sure
that
the
shorter
of
the
bolts
is
fitted
at
the
front
Install
the
transverse
link
on
the
suspension
crossrnember
and
temporarily
tighten
the
mounting
bolts
Make
sure
that
the
nut
faces
the
front
of
the
car
and
not
the
bolt
head
Fit
the
tension
rod
and
stabilizer
bar
Lower
the
vehicle
and
remove
the
jack
Tighten
the
trans
verse
link
mounting
bolts
to
a
torque
reading
of
9
0
10
0
kgm
65
72
Ib
ft
with
the
vehicle
unladen
FRONT
WHEEL
ALIGNMENT
The
castor
and
camber
angles
are
preset
and
cannot
be
adjusted
If
the
angles
do
not
conform
with
the
fIgures
in
Techni
al
Data
then
a
check
must
be
made
for
damage
to
the
uspenSlon
system
Wheel
alignment
is
carried
out
with
the
tyres
mflated
to
the
correct
pressures
and
with
the
vehicle
on
a
level
surface
The
toe
in
should
be
checked
and
adjusted
if
necessary
by
slackening
the
locknuts
FigJ
20
and
turning
the
track
rods
by
an
equal
amount
until
the
correct
toe
in
is
achieved
The
standard
length
between
the
ball
joints
is
309
5
mm
12
19
in
for
the
1400
and
1600
cc
models
and
105
5
mm
4
14
in
for
the
1800
cc
models
ADJ
USTING
THE
STEERING
ANGLE
The
steering
angle
at
the
full
lock
positions
must
be
checked
with
the
front
wheels
placed
on
a
turntable
Adjust
ment
can
be
made
changing
the
length
of
the
stopper
bolt
shown
arrowed
in
FigJ
21
The
clearance
between
the
tyre
and
tension
rod
should
be
30
mm
1
181
in
or
more
and
can
be
increased
if
necessary
by
extending
the
length
of
the
stopper
bolt
The
bolt
length
should
not
exceed
27
5
mm
1
083
in
when
the
adjustment
is
completed
Steering
angle
figures
are
given
in
Technical
Data
at
the
end
of
this
section
Page 90 of 171
TechnICal
Data
FRONT
WHEEL
ALIGNMENT
1400
and
1600
cc
models
Sedan
Toe
in
mm
in
Camber
Castor
R
H
Drive
3
to
6
0
118
to
0
236
35
1035
LH
Drive
3
to
6
0
118
to
0
236
25
1035
Hard
suspension
3
to
6
0
118
to
0
236
25
1025
R
H
Drive
3
to
6
0
118
to
0
236
30
1020
L
R
Drive
exc
4
to
7
0
158
to
0
276
35
1040
U
S
A
and
Canada
U
S
A
and
Canada
2
to
5
0
079
to
0
197
10
1005
Hard
suspension
3
to
6
0
118
to
0
236
20
1005
Steering
angle
In
Out
380
31040
Wagon
1800cc
Models
610
Body
Wheel
alignment
Vehicle
unladen
Applied
model
Camber
Castor
Kingpin
inclination
Toe
in
Side
slip
Standard
1005
to
2035
50
to
2020
6015
to
7045
7
to
10
o
to
3
R
H
drive
Suspension
0
276
to
0
394
0
to
0
118
Sedan
Hard
2
1000
to
2030
55
to
2025
6020
to
7050
6
to
9
o
to
3
Hardtop
0
236
to
0
354
0
to
0
118
Standard
1005
to
2035
40
to
2010
6015
to
7045
7
to
10
o
to
3
L
H
Drive
Suspension
0
276
to
0
394
0
to
0
118
Sedan
Hardtop
Hard
2
1000
to
2030
45
to
2015
6020
to
7050
6
to
9
o
to
3
Suspension
0
236
to
0
354
0
to
0
118
Standard
1000
to
2030
40
to
2010
6020
to
7050
6
to
9
o
to
3
Suspension
0
236
to
0
354
0
to
0
118
LH
Drive
Sedan
Hardtop
Hard
2
55
to
1025
45
to
2015
6025
to
7055
5
to
8
I
to
2
Suspension
0
197
to
0
315
0
004
to
0
079
Standard
1000
to
2030
45
to
2015
6020
to
7050
6
to
9
o
to
3
R
H
Drive
Suspension
0
236
to
0
354
0
to
0
118
R
H
Drive
Station
Wagon
Hard
2
1005
to
2035
45
to
2015
6015
to
7045
7
to
10
o
to
3
Suspension
0
276
to
0
394
0
to
0
118
Standard
1010
to
2040
55
to
2025
6010
to
7040
8
to
11
I
t04
L
H
Drive
Suspension
0
315
to
0
433
0
004
to
0
158
Station
Wagon
Hard
2
1005
to
2035
45
to
2015
6015
to
7045
7
to
10
o
t04
Suspension
0
276
to
0
394
0
to
0
158
Standard
1005
to
2035
50
to
2020
6015
to
7045
8
to
11
I
t04
R
H
drive
Suspension
0
315
to
0
433
0
004
to
0
158
Van
Standard
1015
to
2045
100
to
2015
6005
to
7035
10
to
I3
2
to
5
L
H
drive
Suspension
0
394
to
0
512XO
079
to
0
197
Van
I
for
U
S
A
Canada
2
Optional
parts
89
Page 92 of 171
SteerIng
DEsn
IPTION
S
i
EERlNG
MaintenaDce
STEERING
WHEEL
AND
STEERING
GEAR
Removal
and
Installation
STEERING
GEAR
Dismantling
STEERING
GEAR
Inspection
and
Adjustment
DESCRIPTION
A
worm
and
recirculating
ball
type
steering
system
is
fitted
to
the
vehicle
the
component
parts
of
the
steering
gear
are
shown
in
Fig
K
I
The
steering
linkage
consists
of
the
centre
tie
rod
pitman
ann
idler
arm
outer
tie
rods
and
the
knuckle
arms
as
shown
in
Fig
K
2
A
collapsible
steering
column
assembly
can
be
fitted
to
the
vehicle
to
protect
the
driver
from
injury
in
a
head
on
collision
Details
of
this
type
of
assembly
are
given
under
the
appropriate
heading
STEERING
Maintenance
O1eck
the
oil
level
in
the
steering
box
every
10
000
km
6
000
miles
and
top
up
with
recommended
lubricant
if
necessary
Grease
the
steering
linkage
every
50
000
km
30
OOO
miles
It
will
be
necessary
to
replace
the
plug
in
the
tie
rod
ball
joints
with
a
grease
nipple
for
this
operation
as
previously
described
in
the
section
FRONT
SUSPENSION
Use
a
grease
gun
to
completely
replace
the
old
grease
with
new
grease
making
SUfe
that
the
grease
is
not
forced
from
under
the
cover
clamp
if
a
high
pressure
gun
is
used
STEERING
WHEEL
AND
STEERING
GEAR
Removal
1
Take
out
the
retaining
bolts
and
remove
the
horn
ring
remove
the
steering
wheel
nut
Fig
K
3
and
pull
off
the
steering
wheel
The
special
tool
ST
27180000
should
be
used
if
available
2
Disconnect
the
battery
leads
remove
the
steering
column
shell
covers
and
the
turn
signal
and
lighting
switch
assembly
3
On
vehicles
fitted
with
steering
column
gear
change
assemblies
the
gear
lever
must
be
removed
from
the
control
rod
assembly
Unscrew
the
retaining
boltg
and
disconnect
the
gear
lever
4
Remove
the
bolts
from
the
steering
column
upper
clamp
Fig
K
4
and
the
bolts
holding
the
lower
plate
Fig
K
5
5
If
the
vehicle
is
fitted
with
steering
column
gear
change
remove
the
cotterpin
from
the
trunnion
and
detach
the
gearchange
rod
and
selector
rod
from
the
change
lever
and
selector
lever
STEERING
GEAR
Assembly
and
Adjustment
COLLAPSIBLE
STEERING
COLLAPSIBLE
STEERING
Removal
and
Inspection
COLLAPSIBLE
STEERING
Installation
STEERING
LINKAGE
6
Remove
the
bolts
securing
the
steering
gear
housing
to
the
car
body
Fig
K
6
and
pull
the
steering
gear
towards
the
engine
compartment
Remove
the
gearchange
control
from
the
steering
gear
assembly
as
described
in
the
section
GEARBOX
STEERING
WHEEL
AND
STEERING
GEAR
Installation
Installation
is
a
reversal
of
the
removal
procedure
When
the
installation
has
been
completed
make
sure
that
the
steering
wheel
can
be
turned
smoothly
and
is
correctly
aligned
The
free
travel
of
the
steering
wheel
should
be
between
2S
30mm
0
9B
1
18
in
Tighten
the
steering
wheel
locknut
to
a
torque
reading
of
4
0
5
0
kgm
29
36Ib
ft
and
the
steering
column
upper
clamp
and
plate
bolts
to
a
torque
reading
of
1
3
1
8
kgm
94
1
3
Ib
ft
Ensure
that
the
steering
box
is
topped
up
to
the
correct
level
with
recommended
lubricant
STEERING
GEAR
Dismantling
Remove
the
pitman
arm
retaining
nut
and
pull
out
the
arm
The
special
puller
ST
27140000
should
be
used
if
available
Remove
the
drain
plug
from
the
steering
gear
housing
and
drain
the
oil
Slacken
the
adjusting
screw
nut
and
turn
the
sector
shaft
adjusting
screw
a
few
turns
in
the
anti
clockwise
direction
Remove
the
sector
shaft
cover
retaining
bolts
and
pull
the
sector
shaft
cover
and
sector
shaft
from
the
gear
housing
Fig
K
7
Remove
the
bolts
securing
the
column
jacket
to
the
gear
housing
and
carefully
withdraw
the
main
column
jacket
assembly
from
the
gear
housing
Fig
K
B
NOTE
The
ball
must
not
be
allowed
to
run
to
either
end
of
the
worm
or
the
ends
of
the
ball
guides
will
be
damaged
Pull
the
column
assembly
from
the
column
jacket
Remove
the
sector
shaft
oil
seal
and
take
out
the
rear
bearing
outer
race
from
the
column
jacket
with
a
suitable
puller
Withdraw
the
bearing
inner
races
from
the
front
and
fear
worm
bearings
Remove
the
column
shaft
bearing
91