gearbox DATSUN 610 1969 Workshop Manual

EngIne

INTRODUCTION

ENGINE

Removal

ENGINE

DismantUng

ENGINE

Inspection
and
Overhaul

VALVES
VALVE
GUIDES
VALVE
SEAT
INSERTS

CAMSHAFT
AND
CAMSHAFT

BEARINGS

Checking

CYliNDER

BLOCK

PtSTONS

AND
CONNECTING
RODS

INTRODUCTION

The
1400
1600
cc

and
1800
cc

engines
are
four

cylinder

in
line
units
with
a

single
overhead
camshaft

and

fully
balanced

five

bearing
crankshaft

The
valves
are

operated
through
rockers

which
are

directly
activated

by
the

earn
mechanism

The
crankshaft
is
a

special
steel

forging
with
the
centre

main

bearing

equipped
with
thrust
washers

to
take

up
the
end

thrust

of
the
crankshaft
The

special
aluminium

pistons
are
of

the
strut

construction
to

control
thermal

expansion
and

have

two

compression
rings
and
one
combined
oil

ring

The

gudgeon
pins
have

special
hollow
steel
shafts

and
are

a

fully
floating
fit
in

the

pistons
and
a

press
fit

in
the

connecting

rods

The
aluminium

alloy
cylinder
head
contains

wedge
type

combustion
chambers

and
is
fitted
with
aluminium

bronze
valve

seats

for
the
intake
valves

and
heat
resistant
steel
valve
seats

for
the
exhaust

valves

The
cast

iron
camshaft
is
driven

by
a
double
row
roller

chain
from
the
crankshaft

pulley

The

engine
is

pressure
lubricated

by
a
rotor

type
oil

pump

which
draws
oil

through
an

oil
strainer
into
the

pump
housing

and
then
forces

it

through
a
full
flow

oil
filter

into
the
main
oil

gallery

ENGINE
Removal

Place

alignment
marks
on
the
bonnet

and

hinges
remove

the
bonnet
from
the
vehicle

2

Drain
the

cooling
system
and
engine
and
transmission

lubricant
Remove

the
radiator

grille

3
Discon
ect
the

battery
cables

and
lift
out
the

battery

4
Detach
the

upper
and
lower
radiator

hoses
remove

the

radiator

mounting
bolts
and
lift
the
radiator

away
from

the
vehicle

The

torque
converter

c

jng
pipes
must

be

disconnected
from
the
radiator
on
vehicles

fitted
with

automatic
transmission

S
Remove

the

COOling
fan
and

pulley
disconnect

the
fuel

pipe
from
the
fuel

pump
and

the
heater
hoses
from

the

engine
attachments

6
Disconnect

the
accelerator
control

linkage
and
the

choke
CRANKSHAFT
AND
MAIN
BEARINGS

CAMSHAFT
AND
SPROCKET

FLYWHEEL

ENGINE

Assembling

VALVE
CLEARANCES

Adjusting

ENGINE

LUBRICATION
SYSTEM

OIL
PUMP

OIL
FILTER

CHANGING
THE
ENGINE

OIL

cable
from
the

carburettor

7
Disconnect

the

wirings
from

the
starter
alternator

ignition
coil
oil

pressure
switch

and

temperature
sender

unit

8
Remove

the
clutch
slave

cylinder
Fig
A
2

and
its
return

spring

9
Disconnect

the

speedometer
cable
and
withdraw

the

plug

connector
from
the

reversing
light
switch

10
Disconnect

the
shift
rods
and
seJector

rods
and
remove

the
cross
shaft

assembly
as
described

in
the
section
Gear

box

II
Disconnect

the
front
exhaust

pipe
from
the

exhaust

manifold
disconnect
the
centre

pipe
from

the
rear

pipe

and
remove

the
front

pipe
pre
muffler
and
centre

pipe

assembly

12
Disconnect
the

propeUer
shaft

flange
from
the

companion

flange
from
the

gear
carrier

13
Jack

up
the

gearbox
slightly
and
remove
the
rear

engine

mounting
bracket
bolts
remove
the

mounting
cross

member
and
handbrake

cable

c1amp

14
Remove
the
bolts

securing
the
front

engine
mounting

brackets
to
the
crossmember

15

Attach

lifting
cable
or

chains
to
the
hooks
installed
at

the
front
and
rear
of
the

cylinder
head

Lower
the

jack

under

the

gearbox
and

carefully
lift
and
tilt
the

engine
and

gearbox
unit
Withdraw
the

engine
and

gearbox
from
the

compartment

making
sure
that
it
is

guided

past
the

accessories
installed
on
the

body

ENGINE

Dismantling

Remove
the

engine
as

previously
described
and

carefully

clean

the
exterior
surfaces

Cbeck
for

signs
of
fuel
oil
or

water
leaks

past
the

cylinder
head
and
block
Remove
the
air

cleaner
alternator

distributor
and
starter
motor

Plug
the

carburettor
air
horn

and
distributor
hole
to

prevent
the

ingress

of

foreign
matter

Remove
the

gearbox
from

the

engine
drain
the

engine
oil

and
coolant
Mount
the

engine
in
a
suitable

stand
the

special

engine
attachment
ST05260001
and

engine
ST0501SOO0
should

be
used
if
available

Fig
A
3

5

h
W

and

connecting
rod
assemblies
Use
a

piston
ring

compressor
to

install
the

pistons
through
the

top
of
the

cylbder
bore
Make

sure
that
the

pistons
and

rings
and
the
cylinder
bores
are

lubricated
with
clean

engine
oil
The

pistons
should
be

arranged

so
that
the
F

mark
faces
to

the
front
and
with
the

piston

ring

gaps
positioned
at
1800
to
each
other
Each
piston
must

be
refitted

into
its

original
bore

NOTE

Single
inlet
valve

springs
are
used
on

the
1400
cc

engine
double

valve
springs
are
used
on
the
1600cc

and
1800
cc

engines

Screw
the
valve
rocker

pivots
with
the
locknuts
into
the

pivot
bushing
Set
the
camshaft

locating
plate
and
install
the

camshaft
in
the
cylinder
head
with
the

groove
in
the

locating

plate
directed
to

the
front
of
the

engine
Install
the
camshaft

sprocket
and
tighten
it

together
with
the
fuel

pump
earn
to
a

torque
reading
of
12
16

kgm
86
116
IbJt
a
eck
that
the

camshaft
end
play
is
within

the
specified
limits
Install
the

rocker
arms

using
a
screwdriver
to

press
down
the
valve

springs

and
fit
the
valve
rocker

springs

Gean
the

joint
faces
of
the

cylinder
block
and
head

thoroughly
before

installing
the
cylinder
head
Turn
the
crank

shaft
until
the
No
1

piston
is

at
T
D
C
on
its

compression
stroke

and
make
sure
that
the
camshaft

sprocket
notch
and
the

oblong

groove
in
the
locating
plate
are

correctly
positioned
Care

should
be
taken
to
ensure
that
the
valves
are

clear
from
the

heads
of
the

pistons
The
crankshaft
and
camshaft
must
not
be

rotated

separately
or
the
valves
will
strike
the
heads
of
the

pistons
Temporarily
tighten
the
two

cylinder
head
bolts
1
and

2
in

Fig
A
37
to
a

torque
reading
of
2

kgm
14
5
lb
ft

Fit
the
crankshaft

sprocket
and
distributor
drive

gear
and

install
the
oil
thrower
Ensure
that
the

mating
marks
on
the

crankshaft

sprocket
face
towards
the
front
Install
the

timing

chain

making
sure
that
the
crankshaft
and
camshaft

keys
are

XJinting
upwards
The
marks
on
the

timing
chain
must
be

aligned
with
the
marks
on
the

right
hand
side
of
the
crankshaft

and
camshaft

sprockets
It
should
be
noted
that
three
location

holes
are

provided
in
the
camshaft

sprocket
See

Fig
A
38
The

camshaft

sprocket
being
set
to
the
No
2
location
hole

by
the

manufacturers
A
stretched
chain
will
however
affect
the

valve

timing
and
if
this
occurs
it
will
be

necessary
to
set
the
camshaft

to
the
No
3
location
hole
in
the
camshaft

sprocket
The
chain

can

be
checked

by
turning
the

engine
until
the

No
1
piston
is

at
T
D
C
on
its

compression
stroke
In
this

position
adjustment

will
be

required
if
the
location
notch
on

the
camshaft

sprocket

is
to
the
left
of
the

groove
on
the
camshaft

locating
plate
as

shown
in
the
illustration
The
correction
is
made

by
setting
the

camshaft
on

the
No
3
location
hole
in
the
camshaft

sprocket

the
No
3
notch
should
then
be
to
the

right
of
the

groove
and

the
valve

timing
will
have
to

be
set

using
the
No
3

timing
mark

Install
the
chain

guide
and
chain
tensioner
when
the
chain

is
located

correctly
There
should
be
no

protrusion
of
the
chain

tensioner

spindle
See

Fig
A
39
A
new
tensioner
must
be

fitted
if
the

spindle

protrudes

Press
a
new
oil
seal
into
the

timing
cover
and
fit
the
cover

into

position
using
a
new

gasket
Apply
sealing
compound
to

the
front
of
the

cylinder
block
and
to
the

gasket
and
to
the

top

of

the

timing
cover

Ensure
that
the
difference
in

height
between

the

top
of
the

timing
cover
and
the

upper
face
of
the

cylinder

block
does
not

exceed
0
15
mm
0
006
in
Two
sizes
of

timing

cover
bolts
are

used
the
size
M8
0
315
in
must

be
tightened

to

a

torque
reading
of
1
0
1
6

kgm
7
2
17
Ib
ft
and
the
size
M6
0
236
in
to
a

torque
reading
of
0
4
0
8

kgm

2
9
81b
ft

Install
the
crankshaft

pulley
and
water

pump
tighten
the

pulley
nut
to
a

torque
reading
of

12
16

kgm
86
8
115
7Ib
ft

then
set

the
No
1

piston
at
T
D
C
on
its

compression
stroke

Finally
tighten
the

cylinder
head
bolts
to
the

specified

torque
reading
in
accordance
with
the

tightening
sequence
shown

in

Fig
A
3
The
bolts
should
be

tightened
in
three

stages
as

follows

First

stage

Second
stage

Third

stage
4

kgm
28
9
lbJt

6

kgm
43
4
IbJ
t

6
5
85

kgm
47
0
61
5lb
ft

The

cylinder
head
bolts
should
be

retightened
if

necessary

after
the

engine
has
been
run
for
several
minutes

Install
the
oil

pump
and
distributor
drive

spindle
into
the

front
cover
as
described
under

Engine
Lubrication

System

r
rf

i

Install
the
fuel

pump
water
inlet
elbow
and
front

engine

slinger
Fit
the
oil
strainer
into
position
coat
the
oil

sump

gasket
with
sealing
compound
and
fit
the

gasket
and
oil
sump

to
the

cylinder
block

Tighten
the
oil

sump
bolts
in
a

diagonal

pattern
to

a

torque
reading
of
0
6
0
9

kgm
4
3
6
5
IbJt

Adjust
the
valve
clearances
to
the

specified
cold

engine

ftgures
following
the

procedures
described
under
the

appropriate

heading
Final

adjustments
will

be
carried
out
after
the

engine

has
been
assembled

completely
and
warmed

up
to

its
nonnal

temperature

Install
the
rear

engine
slinger
exhaust
manifold
and
inlet

manifold
Refit

the
distributor
and
carburettor
assemblies
as

described
in
their
relevant
sections

Install
the
fuel

pipes
and

vacuum
hose

making
sure
that

they
are

securely
cl

ped
Refit

the
thermostat

housing
thermostat
and
water
outlet

together

with
the

gasket
Bond
the
rocker
cover

gasket
to
the
rocker

cover

using
sealant
and
fit
the
rocker
cover
to
the

cylinder

head

Install
the
spark
plugs
and
connect
the

high
tension
leads

Fit
the
left
hand

engine
mounting
bracket
and
install
the
clutch

assembly
using
the

alignment
tool
ST20600000
to
fit
the
clutch

to
the

flywheel
as
described
in
the
section
ClUfCR

Lift

the
engine
away
from
the

mounting
stand
and
into

the

engine

compartment
Install
the
alternator
bracket
adjusting

bar
alternator
fan

pulley
fan
and
fan
belt
in
the
order

given

Check
the
tension
of
the
fan
belt

by
depressing
the
belt
at
a

point
midw

y
between
the

pulleys
The

tension
is
correct
if

the
belt
is
deflected

by
8
12
mm
0
3
0
4
in
under
thumb

pressure

Fit
the

right
hand
engine
mounting
bracket
the
oil
filter

oil

pressure
switch
oil
level

gauge
and
water

drain
plug
Take

care
not
to

overtighten
the
oil
nIter
or

leakage
will
occur

Fill
the

engine
and

gearbox
to
the
correct
levels
with

recommended
lubricant

and
refill
the

cooling
system
Adjust

the

ignition
timing
and
carburettor
as
described
in
the

appro

priate
sections

17

Clutch

DESCRIPTION

CLUTCH
Removal
and

Dismantling

CLUTCH
Inspection
and

Adjustment

CLUTCH
Installation

CLUTCH
PEDAL
Removal
and
Installation

DESCRIPTION

Either
a

diaphragm
spring
or

coil

spring
type
clutch

is

fitted
to

the
vehicle
The

component
parts
of
the

diaphragm

spring
clutch
are
shown
in

Fig
E
l
and
the

component
parts

of
the
coil

spring
clutch
are
shown
in

Fig
E
2

The
clutch
is
of
the

single
dry
plate
type
consisting
of

the
drive

plate
clutch
coveT
and

pressure
plate
and
release

bearing

The
driven

plate
comprises
a

flexible
disc
and

splined
hub

which
slides
on
the

clutch
shaft
Friction
linings
are

rivetted
to

both

sides
of
the
disc

The
clutch
cover

and

pressure
plate
are
combined

by
nine

spring
setting
bolts
The

diaphragm
is
dished
to

maintain
a

constant

pressure
on
the

pressure
plate
which
in
turn
holds

the
driven

plate
in
contact
with
the

flywheel
The
release

bearing

is
a
sealed

type
ball

bearing
mounted
on
a

bearing
sleeve
Both

bearing
and
sleeve
are
operated

by
the
withdrawalleveT
when

the
clutch

pedal
is

operated

The
clutch

pedal
actuates
a
master

cylinder
which
transmits

fluid

under

pressure
to
a
slave

cylinder
The
movement
of

the

slave

cylinder
piston
operates
the
clutch
withdrawal
lever
via

a

push
rod
See

Fig
E
14

CLUTCH
Removal
and

Dismantling

The

gearbox
must

be
removed
from
the
vehicle
before

the
clutch
can

be
withdrawn
The

procedures
for

removing
the

gearbox
can
be
found
in
the
section
GEARBOX

If
a

diaphragm
clutch
is
fitted
insert
a

spare
clutch
shaft

or
a

special
alignment
tool
ST20600000
into
the

splines
of

the
driven

plate
So
that
the
dutch
is

supported
Slacken
the

six
bolts

securing
the
clutch
cover
to
the

flywheel
by
a
single

turn
at
a
time
and
in
a
diagonal

pattern
until
the

spring

pressure

is
relieved
Remove
the
bolts

completely
and
lift

away
the

clutch

assembly

When

removing
the
coil

spring
type
clutch
it
will

be

necessary
to
insert
suitable
hooks

under
the
release
levers
to

restrain
the
tension
of
the
clutch

spring
before

removing
the

clutch
cover
lx
llts

Ensure
that
the
friction

linings
of
the
driven

plate
do
not

become
comtaminated
with
oil
or

grease
when
removing
the

plate
from
the

splined
shaft

Diaphragm
clutch

The
clutch
cover
and

pressure
plate
assembly
should
not

be
dismantled
and
must
be

replaced
if
wear
or

damage
has

occurred
Make
sure
that
the
friction
face
of

the

pressure
plate
CLUTCH
PEDAL
Adjusting

CLUTCH
MASTER
CYLINDER

CLUTCH
SLAVE
CYLINDER

CLUTCH
WITHDRAWAL
LEVER

Adjusting

CLUTCH
SYSTEM

Bleeding

is
perfectly
flat
and
smooth

Coil

spring
clutch

A

special
tool
No
ST200S0000
is
available
to
ensure

that

the
clutch
can
be
dismantled
and

accurately
reassembled
The

tool
shown
in

Fig
E
3
consists
of
a
Base

plate
I
Centre

spigot
2
Distance

pieces
3

Height
gauge
4
Operating
lever

5

Securing
bolts
6

A
chart
is
included
to
indicate
the
various

parts
to
be
used

for
each

type
of
clutch

To
dismantle
the
clutch
place
the
distance

pieces
on

the

base
plate
as
shown
and

arrange
the
clutch
cover
on
the
base

plate
so
that
the
cover
holes
coincide
with
the
threaded
holes

in
the
base

plate
Insert

the

securing
bolts
provided
in
the
kit

and

tighten
them
gradually
and

evenly
in
a

diagonal
pattern

until
the
cover
is

firmly
attached
to
the
base

plate
Mark
the

clutch
cover

the

pressure
plate
lugs
and
the
release
levers
with

a

centre

punch
so
that

they
can

be
reassembled
in
their
original

positions

Remove
the

restraining
hooks
from
the
release
levers
and

unscrew
the
three
nuts
from
the

eye
bolts
Slowly
release
the

pressure
on
the
clutch
coil

springs
by
unscrewing
the
bolts

securing
the
cover
to
the
base

plate
and
lift
off
the
cover

springs

and

pressure
plate

CLUTCH

Inspection
and
Adjustment

Use
a
solvent
to
clean
the
dismantled

parts
with
the

exception
of
the
disc

linings
and
the
release

bearing

Check
the
clutch
cover

diaphragm
spring
and

pressure

plate
assembly
for
wear
or

damage
and
renew
the

complete

assembly
if

necessary
The

pressure
plate
on
the
coil

spring

clutch
can
be

lapped
if
necessary
as
described
below
Ensure

that
the
disc
rivets
are
not
loosened
and

inspect
the

linings
for

contamination
Grease
or
oil
should
be
removed
and
the

linings

dressed

using
a
wire

brush

Check
the
disc
for

run
ut

using
a
dial

gauge
as
shown
in

Fig
E
4
Position
the
dial

gauge
at
a

point
approximately
9Smm

3
74
in
from
the
centre
of
the
disc
and
check
that
the
run

out
does
not

exceed
the
permissible
limit
of
0
5
mm

0
02in

A
slight
deflection
can
be
corrected

by
hand

pressure
with

the
disc
mounted
on
the

gearbox
shaft

The
disc
must
be
renewed
or
relined
if
the
height
of
the

linings
above
the
rivets
is
less

than
0
3mm
0
012
in

Replace

the
bearing
sleeve
if
it
shows

signs
of
wear
at

the
point
of

contact
with
the
withdrawal
lever

Replace
the
release

bearing

if

grease
is

leaking
from
it
or
if
it
is

noisy
when
turned

43

The
coil

spring
clutch

pressure
plate
can

be

lapped
with
a

surface

grinder
to
remove

dents
or

scratches

only
the
minimum

amount
of
metal
should
be
removed
to
restore
the
surface

Check
the

plate
for
distortion

by
placing
it

on
a
surface

plate
with

the
friction
face
towards
the
surface

plate
Press

the
pressure

plate
down
and
insert
a
feeler

gauge
of
1
0mm

0
0039
in

between
the

pressure
plate
and
surface

plate
If
it

is

possible
to
insert
the
feeler

gauge
then
the

pressure
plate
must

be

repaired
or

replaced
The

plate
can
be
skimmed
but
the

maximum
amount
of
metal
that
can
be
removed
is
1
0mm

0
0039in

CLUTCH
SPRING

Diaphragm
clutch

With
the

diaphragm
spring
assembled
to
the

pressure
plate

inspect
the

spring
height
and
load
in
the

following
manner

Place
distance

pieces
of
7
8
mm

0
307
in
on
the
base

plate
as

shown
in

Fig
E
3
and
bolt
down
the
clutch
cover

using
the

special
bolts

provided
with
the
kit
Meas
Jre
the

height
B
in

Fig
E
5

at
a
diameter
of
44mm
1

732
in
The
release

fingers

should
not

exceed
a

height
of
43
45
mm
1
693
1
772
in

from
the
base

plate
Replace
the

spring
if

the

height
is
in
excess

of
the

figures

quoted

Press
the
dutch
down
as

shown
in
Fig
E
6
to
a

depth
of

7
8mm
0
307
in
or
until
the
clutch
driven

plate

upper
surface

lines

up
with
the
clutch
cover

mounting
face
If

the
load

applied

is
less
than
350

kg
770
lbs
it
will
be

necessary
to
renew
the

diaphragm
spring
Do
not

press
the
clutch
disc
down

by
more

than
9mm
0
35
in
or
the

diaphragm
spring
may
be
broken

CLUTCH
SPRINGS
Coil

spring
clutch

The
clutch

springs
must
be

replaced
as
a

set
if

any
of
the

springs
are
found
to
be
defective
Specifications
for
the

springs

are

given
in
Technical
Data
at
the
end
of
this
section

Generally

a

spring
may
be
considered
faulty
if
when
assembled
the
load
is

reduced

by
more
than
15
or
if
the
free

length
has
altered

by

more
than
1
5mm
0
0590
in
or
if
the
deflection
B
to
A

in

Fig
E

7
exceeds
5mm

per
100mm
0
2
in

per
3
94
in

Release

Bearing

The
release

bearing
should
be
renewed
if

excessively
worn

or
if

roughness
can
be
felt
when
the

bearing
is
turned

by
hand

The

bearing
should
also
be
renewed
if
the

grease
has

leaked

away
or
if
the
clearance

between
the
clutch
cover
and
inner

diameter
of

the
sleeve
is
more
than
0
5
mm
0
0197
in

The

bearing
can
be

removed

using
a
conventional

puller

as
shown
in

Fig
E
8
Two

types
of
release

bearings
are

available

and
care
must
be
taken
when

fitting
onto

the
bearing
sleeve

The
release
bearing
should
be

pressed
into

place
on
the

diaphragm

spring
type
of
clutch
with
a
force
of
400

kg
880
lbs

applied

at
the
outer
race
as
shown

in

Fig
E
9
On
the
coil

spring
clutch

the
same

force
must

be

applied
at

the
inner
race
as
shown
in

Fig
E
IO
It
should
be

possible
to
turn
the

bearing
freely
and

smoothly
when
it
is

pressed
into

place
CLUTCH

Assembly

Coil

spring
type

Press
the

pin
into
the

eyebolt
and

through
the

lug
on

the

pressure
plate
Place
the
three
distance

pieces
on
the
surface

of
the
base
plate
of
the

special
tool
ST20050000
and

position

the

pressure
plate

pressure
springs
and
retainers

on
the

plate

Set
the

retracting
springs
on
the
cover

and
insert
the

release
levers

through
the

spring
Place

the
clutch
cover
over

the

pressure
plate
and

springs
making
sure
that
the

retracting

springs
do
not

become
dislodged
or
distorted

Compress
the

pressure
springs
by
screwing
the

special
set

bolts
into
the
holes
in

the
cover

Tighten
the
bolts

gradually

in
a

diagonal

pattern
to
avoid

distorting
the
cover
Place
the

release
levers
on

the

eye
bolts
and
screw
OR
the

securing
nuts

Place

retaining
hooks
under
the
release
levers
and
remove
the

clutch
assembly
from
the
base

plate
slackening
the
set
bolts
in

a

diagonal
pattern

COIL
SPRING
CLUTCH

Adjusting

Screw
the
centre

pillar
into
the
base

plate
and

place
the

high
finger
over
the

pillar
The
height
of
the
release
levers
must

be

adjusted
by
turning
the
eye
bolt
nuts
until
the

tops
of

the

release
levers
are

just
touching
the

tip
of
the
gauge
See
Fig
E

11
Remove
the
centre

pillar
when
the
release
levers
are

correctly
adjusted
and
screw
in
the

actuating
lever
Fig
E
12

Turn
the

actuating
mechanism
several
times
to
bed
down
the

parts
and
then
recheck
the

height
of
the
release
levers
Check

for
run
out
as
near
to
the

edge
as
possible
and

readjust
if
the

deviation
is
more

than
0
5
mrn
0
020
in

CLUTCH
InsWlation

Ensure
that
the
friction
faces
are

free
from

oil
and

grease

and
place
the
driven

plate
on
the

flywheel
The

longer
chamfered

splined
end
of
the

assembly
should
face

the

gearbox
Use
a

spare
drive
shaft
to

align
the
driven

plate
The
shaft
must

be

inserted

through
the
splined
hub
of
the
driven

plate
and
into

the

pilot
bearing
of
the

flywheel

Place
the
clutch
cover
into

position
on

the
flywheel
and

tighten
the
dutch
bolts

gradually
in
a

diagonal

pattern
to
a

torque
reading
of
1
5
2
2

kgm
11
16Ib
ft

Remove
the

dummy
shaft
and
the

restraining
hooks
from
the
release
levers

Refit
the
release

bearing
and
the
bell

housing

CLUTCH
PEDAL
Removal
and
Installation

Remove
the
clevis

pin
from
the
end
of
the
master

cylinder
pushrod
and
disconnect
the
pushrod
Remove
the

return

spring
Remove
the

pushrod
after

slackening
the

pushrod

adjuster
Coil

spring
clutch

only
Remove
the

pedal
lever

securing
bolt
slacken
the
handbrake
bracket
bolts
and
lift
out

the

pedal

Clean
all

parts
thoroughly
and
check
them
for
wear
or

damage
paying
particular
attention
to
the
rubber

parts
return

spring
and

pedal
lever
bush

Installation
of
the
clutch

pedal
is
a
reversal
of

the

removal

procedures

45

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

VP

F
rr

l
I

lip

J

I
I
ii

iI

a

l

Fig
F

1
View

through
the
four

speed
gearbox

It
j

j
4

C
J

f

e

V

tJ

J

I

P

Fig
F
2
The

propeUer
shaft

Fig
F
3
Disconnecting
the

speedometer
cable

Fig
F
4

Disconnecting
the
remote
control

linkage

Fig
F

5

Removing
the
clutch
slave

cylinder

52

to
ascertain
the
amount
of
wear
that
has
taken

place

Check
the
teeth
of
the

gearwheels
and
the
machined
surfaces

for

signs
of
wear

scoring
pitting
and
burrs
Ensure
that
the

synchronizer
hubs
slide

freely
on
the

splines
of

the
main
shaft

with
minimum
clearance
Check

the
mainshaft
for
run
out

using
V
blocks
and
a
dial

gauge
as
shown
in

Fig
F
15
Renew

the
mainshaft
if
the
run
out
exceeds
0
15mm
0
0059
in

Check
the

synchronizer
rings
for
wear
and
renew
them
if

necessary
Place
the

rings
in

position
on

their

respective
gear

wheel
cones
and
check
the

gap
between
the
end
of
the

ring
and

the
front
face
of

the
teeth
Fig
F
16
The
correct

gap
should

be
within
1
2
1
6mm
0
047
0
063
in
Renew
the
synchronizer

ring
if
the

gap
is
less
than
0
8mm
0
0315
in

Place
the
selector
rods
on
a
flat
surface
and
check
them
for

traightness
Renew

any
rod
which
is
bent
Renew
the

locking

pins
and
interlock
balls
if

they
are
worn
or

damaged
The

standard
clearance
between
the
selector
forks
and

operating

sleeve

groove
is
0
15
0
30mm
0
006
0
012
in

Make
sure
that
the
oil
seals
are

satisfactory
and
discard

the
O

rings

THREE
SPEED
GEARBOX

Assembly

Press
the
main
drive
gear

bearing
onto
the
main
drive
shaft

and
fit
the

spacer
Select
a

snap
ring
of
suitable
thickness
so

that
all

play
is
eliminated
between
the

bearing
and

snap
ring

Seven
sizes
of

snap
rings
are
available
and

vary
in
thickness
from

1
52mm
0
0598
in
to
1
89mm
0
0747in

The

synchromesh
unit
consists
of
a

coupling
sleeve
baulk

ring
spring
synchronizer
hub
and
insert
When

assembling
the

unit
make
sure
that
the
correct
insert

pressure
springs
are
fitted

to

the
relevant

speed
unit
The
first
reverse

gear
synchronizer

should
be
fitted
with
the
three
coil

spring
type
and
the
second

third

gear
synchronizer
with
the
two

expanding
springs

To
assemble
the
fiI3t

speed
synchronizer
insert
the

sliding

insert

snap
ring
onto

the
synchronizer
hub
as
shown
in

Fig
F
17

Fit
the

sliding
inserts

Fig
F
18
and

the
synchronizer
springs

on
the

synchronizer
hub
and
assemble
the

synchronizer
hub

complete
with
inserts
into
the

coupling
sleeve

Fig
F
19

Assemble
the
second
third

gear
synchronizer
hub
and

coupling
sleeve

making
sure

that
the
sleeve
slides

freely
on
the

hub

splines
Fit
the
three

shifting
inserts
and
install
a

spring
ring

on

each
side
of
the
hub
Fig
F
20

To
assemble
the
mainshaft
start
from
the
front
end
of
the

shaft
and
slide
the
second

speed
gearwheel
on
to
the
shaft
with

the

tapered
cone

facing
forwards
Install
the
baulk
ring
on
the

gearwheel
and

place
the
second
third
speed
synchronizer
assembly

on
the
front
end
of
the
shaft
and
retain
it
with
a

snap
ring
which

will

give
an
end

play
of
0
05
0
25
mm
0
002
0
009
in

Snap
rings
are
available
in
five
sizes
from
1
60
1
80
mm

0
063
0
071
in

Fit
the
first

speed
gear
and
baulk

ring
on
the
rear
of

the

shaft
so
that
the

tapered
cone
faces
to

the
rear

Assemble
the

first

speed
synchronizer
and
reverse

gear
on
the
shaft
Fit
the

spacer
and

press
the
mainshaft

bearing
complete
with
retainer

onto
the
shaft
Install
the

spacer
ball
and

speedometer
drive
pinion

Select
a

snap
ring
which
will
give
an
end
float
of
0
05
0
22mm

0
002
0
009
in
on
the
mainshaft
first

gear
Snap
rings
are

available
in

eight
thicknesses
from
1
30mrn
0
0512
in

to

1
70mm
0
0669
in

Secure
the
drive

gear
with
the
selected

snap
ring
and
check

the
end
float
of
the

gearwheels
as

shown
in

Fig
F
21
The
correct

end
float
should
be
as
follows

I
st

speed
gearwheel
0
2
o
3mm

0
008
0
012
in

0
2
0
3mm

0
008
0
012
in
2nd

speed
gearwheel

Fit
the
main
drive

gear
and
mainshaft

assembly
into
the

gearbox
casing
Fit
the
selector
rods
and
forks
as
follows

Turn
the

gearbox
casing
so
that
the
detent
ball
hole

is

uppermost
and
insert
the

spring
and
ball
in
the
bottom
of
the

hole
Hold
the
ball
witb
a

dummy
shaft

and
install
tbe
first

reverse
selector
fork
and
rod
pushing
the

dummy
shaft
out

of

position
Insert
the

interlocking
plunger
and
fit
the
second
third

speed
selector
fork
and
rod

Insert
the
steel
ball
and

spring
and

refit
the

interlocking
plug
after

coating
the
threads
of
the

plug

with

sealing
compound
See

Fig
F
22

Secure
the
selector
forks

to

the
rods

by
inserting
the

retaining
pins

Fit
the
reverse
idler

gear
and
shaft
and
secure

the
shaft

with
the
lock
bolt
and

plate
Insert
the
counter

gear
cluster
and

shaft

using
a
suitable
thrust
washer
to
obtain
an
end
float
of

0
04
0
12
mm
0
0016
0
0047
in
Thrust
washers
are
available

in
five
sizes
from
3
85
4
05
mm
0
1516
0
1594
in
thickness

in
increments
of

0
05
mm
0
002
in

Fit
the
cross
shafts

1
in

Fig
F
23
the
thrust
washers
2

and
the

operating
levers
3
Secure
the
cross
shafts
with
the

retaining
rings
5
and
lock
the

operating
levers
to
the
shafts
with

the

pins
4

Locate
the
rear
extension

housing
on
the

gearbox
case

and

tighten
the
bolts
to
a

torque
reading
of
2
8
4
4

kgm

20

32
Ib
ft
Insert
the

speedometer
drive

pinion
and
retain
it

with
the
set

bolt
and
lock
plate
Check
the
backlash
of
all
the

gears
using
a
dial

gauge
as
shown
in

Fig
F
24
The
backlash

should
be
between
0
05
0
20
mm
0
002
0
008
in
Fit
the

gearbox
front
cover
and

tighten
the
fixing
bolts
to
a

torque

reading
of
1
I
1
7

kgm
8
0
12
3
lb
ft

taking
care
not
to

damage
the
oil
seal
Fit
the
clutch
release
bearing
and
with

drawallever

Fig
F
25

Replace
the
bottom
cover
and
tighten

the
bolts
to
a

torque
reading
of
1
I
1
7

kgm
8
0
12
31b
ft

THREE
SPEED
GEARBOX
Installation

Installation
of
the

gearbox
is
a
reversal
of

the
removal

procedure
noting
the
following

points

Fit
the

gearbox
with
I
7

litre
0
45
US
gall
0
37

Imp

gall
of
MP
90

gear
oil

Adjust
the
clutch
slave

cylinder
push
rod
as
described
in

the
section
CLUTCH
to

provide
a
free

play
of
2
2
mm
0
087in

at
the
withdrawal
lever

55

inter

iillu@U

Fig
F
20

Filting
the

spring
rings

Fig
F
21

Olecking
the
end
float
of
lhe

gearwheels

Fig
F
22
The
interlock
mechanism

c

Fig
F
23

Installing
the
cross

shaft

1
crossshil
t

2
l
hnut
washers

3

OperatirJ8levm

4

Lock

pim

5

Retaining
rings

Fig
F

24

Ole
king
the

gear
backlash

hk

rmJ

t
0
o

y

9

Ll

7

1
l

i

A
I

f

0

Fig
F

25
Withdrawal
lever
and
reIe
e

bearing
Fig
F
26
View
of
the
four

speed

gearbox
with

bottom
cover
removed

II

56

FOUR
SPEED
GEARBOX
Removal
and
Installation

The
removal
and
installation

procedures
for
the
four

speed

gearbox
are
similar
to

those

previously
described
for
the

three

speed
gearbox
However
the
floor
mounted

gear
lever
must
be

removed
from
the
controllevef
bracket
in
addition
to

the

operations
already
detailed

FOUR
SPEED
GEARBOX

Dismantling

Drain
the
oil
from
the

gearbox
Remove
the
dust
coveT
and

release
the

spring
securing
the
clutch
withdrawal
lever
Remove

the
withdrawal
lever
and
release

bearing
from
the
clutch

housing

as
described
in
the
section
CLurCH
Remove
the
clevis

pin

securing
the

striking
rod
to
the
control
lever

Remove

the
speedometer
drive

pinion
assembly
and
with

draw
the
rear

extension

housing
Disengage
the

striking
rod
from

the
selector
rod

gates
Remove
the

gearbox
covers
See

Figs
F
26

and
F
27

Unscrew
the
three
detent
ball

plugs
and
remove
the

spriags

and
detent
balls
Drive
out
the

pins
securing
the
selector
forks

to
the
rods
and
withdraw
the
forks
and
rods
Lock
the
main

shaft

by
moving
the
first
second
and
third
fourth

coupling
sleeve

into

gear
at
the
same
time
and
release
the
ffiainshaft
nut

Remove
the
countershaft
and
the
gear
cluster

together

with
the
two
needle
roller

bearings
and

spacers
Remove
the

snap
ring
holding
the
revep
e

idler

gear
and
withdraw
the
reverse

idler

gears
and
shaft

Fig
F
28

Take
off

the
bolts

securing
the
mainshaft

bearing
retainer

to
the

gearbox
case

Fig
F
29
Withdraw
the
mainshaft

assembly
Fig
F
30
and
the
main
drive
shaft

The
mainshaft
can
be
dismantled
in
the

following
manner

Release
the
third
fourth

synchronizer
unit

snap
ring
and
with

draw
the
hub

complete
with

coupling
sleeve
Remove
the
third

speed
gearwheel
and
the
needle
roller

bearing
from
the
main

shaft
Take
off
the
mainshaft
nut
and

locking
plate
Remove
the

speedometer
drive

gear
with
the

retaining
ball
Withdraw
the

mainshaft
reverse

gear
and
the
hub
Press
off

the
mainshaft

bearing
complete
with
the

bearing
retainer

Remove
the
thrust
washer
and
the
first

speed
gear
together

with
the
needle
roller

bearing
taking
care
not
to
lose
the
small

baU
used
to

locate
the
thrust
washer
Slide
off

the
first

speed

gearwheel
bush
Withdraw
the
first
second

synchronizer
and

hub
Remove
the
second

speed
gearwheel
and
needle
roller

bearing

FOUR
SPEED

GEARBOX
Installation

Refer
to

the
instructions

given
for
the
three

speed
gearbox

and
to
Technical
Data
for
the

specifications
applicable
to
the

different

gearboxes

FOUR
SPEED
GEARBOX

Assembly

Assembly
of

the

gearbox
is
similar
to
the

procedures

previously
described
for
the
three

speed
gearbox
with
the

following
exceptions
When

assembling
the
main
drive

gear
bearing
on
the
shaft

insiall

the

spacer
and
select
a
new

snap
ring
to
eliminate
all
end

float

between
bearing
and

snap
ring
Snap
rings
are
available
in

five
thicknesses
from
1
52
1
77mm
0
06
0
07
in

The

assembly
procedures
for

the
Warner

type
synchronizers

are
similar
to
the
instructions

previously
described
for
the
three

speed
gearbox
Refer
to
THREE
SPEED
GEARBOX

Assembly

for
further
details

To
assemble
the
Servo
F4C63

type
synchronizers
proceed

as
follows

Place
the

gear
on
a

clean
flat
surface
and
install
the

synchronizer
ring
on
the
inner
side
of
theclutch
gear
Fit
the

thrust
block
into

place
as
shown
in
Fig
F
31
Place
the
anchor

block
and
brake
band
into

position
and
fit
the

circlip
into
the

groove
in
the

gear
to
secure
the

synchromesh
assembly

When

assembling
the
mainshaft
select
a

snap
ring
which

will

give
an
end
float
between
0
05
0
15
mm
0
002
0
006in

to
the
third

speed
gearwheel
Snap
rings
are

available
in
five

sizes
from
1
40
mm

0
0551
in
to
1
60
mm
0
0630
in
thick

ness

Tighten
the
locknut
at

the
rear

of
the
mainshaft
to
a

torque
reading
of
7
1

kgm
51
87Ib
ft

Assemble
the
reverse
idler

gear
as
shown
in
Fig
F
32
The

reverse
idler
driven

gear
3
should
be

placed
on
the
end
of
the

reverse
shaft
1
with
the

longest
spline
and
retained
with
a

suitable

snap
ring
2
Install
the
reverse
shaft
and

gear
assembly

into
the

gearbox
case
from
the
rear
with
the
thrust
washer
4

between
the

gear
and
the
case

Fit
the
thrust
washer
5
and

idler
gear
6
18
teeth
and
secure
with
a
suitable

snap
ring

2
The
end
float
of
the

gear
should
be
checked
and

adjusted

to

0
1
O
3mm
0
004
0
012
in

by
selecting
a
suitable

snap

ring
2
Five
thicknesses
of

snap
rings
are
available
from
I
lmm

0
043in
to
1
5mm
0
06in
See
Technical
Data
for
F4W63

and
F4C63

gearboxes
Adjust
the
counter

gear
end
float
to

0
05
0
15
mm
0
002
0
006in

by
selecting
a
thrust
washer

of

the

required
thickness
Thrust
washers
are
available
in

five

thicknesses
from
2
40
2
60
mm
0
094
0
102
in

When

assembling
the
selector
mechanisms

Fig
F
33
fit

the
first
second
selector
forks
I
and
the
third
fourth
selector

forks
2
onto
the

coupling
sleeves
and
insert
the
first
second

fork
rod
3

Fit
an

interlock
plunger
4
and
the
third
fourth

speed

selector
rod
5
Do
not

forget
the
interlock

pin
7
A
section

through
the
selector
and
interlock
mechanism
is

given
in

Fig

F
34
Install
an

interlock

plunger
6
and
assemble
the
reverse

selector
fork
8
and
fork
rod
9
Secure
the
selector
forks
to

the
rods
with
the

retaining
pins
10

Place
a
check
ball

and
spring
into
each
of
the
holes
and

screw

the

plug
down
to
a

torque
reading
of
1
7
2
1

Jegm

12
3
15
2
Ib
ft
after

coating
the
threads
with
sealing
com

pound

Install
the
rear
extension

housing
engaging
the

striking
rod

with
the
fork

rod

gates
and

tighten
the

housing
bolts
to

a

torque
reading
of
1
6
2
5

kgm
12
18Ib
ft
Fit
the
front

and
bottom
covers
and

tighten
the
bolts
to

a

torque
reading

of
1
1
1
8

kgm
8
13Ib
ft

57