clutch DATSUN 610 1969 User Guide

CLUTCH
PEDAL

Adjusting

400
and
1600
cc
models

Adjust
the

pedal
height
to
209
mm
8
22
in

with
the

pedal

stop
slackened
off

by
altering
the

length
of
the
master

cylinder

push
rod
See

Fig
E
13

Tighten
the

pedal
stop
and
obtain

a

pedal
height
of
207
ffim

8
15
in
for
Left
Hand
drive
models

or
182
mID
7
I7
in
for

Right
Hand
drive
models
Secure
the

stop

by
tightening
the
locknut
and
make
sure

that
the

points

illustrated
are

correctly
greased

CLlTfCH
PEDAL

Adjusting

1800cc
models

Adjust
the

pedal
height
to

175
mm
6
89
in

by
adjusting

the

pedal

stop
See

Fig
E
13
then

retighten
the
locknut
A

to
a

torque
reading
of
0
79
1
07

kgm
6
8Ib
ft
Turn
the

master

cylinder
push
rod
to
obtain
a

play
between
1
Smm

0
04

0
2
in
at

the
clevis

pin
then

tighten
the
locknut
B

to

a

torque
reading
of
0
79
1
07

kgm
6
8
Ib
ft
Ensure
when

adjusting
the

play
that
the

port
on
the

master

cylinder
is
not

blocked

too
small
a

play
at
the
clevis

pin
may
block
the

port

Bend
the
clevis

pin
over

completely

CLlTfCH
MASTER
CYLINDER
Removal

and

Dismantling

Disconnect
the

push
rod
from
the
clevis

Fig
E
14

Detach
the
fluid
line
from
the
master

cylinder
and

pump

the
fluid
into
a
suitable
container

3
Withdraw
the

retaining
bolts
and
remove
the
master

cylinder
assembly
from

the
vehicle

To

dismantle
the
master

cylinder
remove

the
filler

cap
and
drain

away
the
fluid

Pull
back
the
dust
cover

and
remove

the

snap
ring
the

stopper

push
rod

piston
assembly
and
return

spring

Oean
the

components
in
brake
fluid

and
check
them
for
wear

or

damage

Renew
the

cylinder
and

piston
if
uneven
wear
has
taken

place

the
clearance

between
the

cylinder
and

piston
must
not
exceed

0
13
mm
0
005
in

Renew
the
dust
cover
oil
reservoir
filler

cap
and
fluid
line
if

necessary

Reassembly
of
the
master

cylinder
is
a
reversal
of

the
dismantling

procedure
take
care
to

soak
the

components
in
brake
fluid
and

assemble
them
while
still
wet

When
the
master

cylinder
is
installed
in
the
vehicle
make
sure

that
the

pedal
height
is

adjusted
as

previously
described
and

bleed
the
hydraulic
system

by
following
the

procedures
given

under
the

heading
CLlTfCH
SYSTEM

Bleeding

CLlTfCH
SLAVE
CYLINDER
Removal
and

Dismantling

Remove
the
return

spring

2
Disconnect
the
fluid
line
from
the
slave

cylinder

D
3
Disconnect
the
push
rod
from
the
clutch
withdrawal
lever

4
Take
out

the
mounting
bolts
and
withdraw
the
slave

cylinder
from
the
clutch
housing

To
dismantle
the
slave
cylinder
remove
the
dust
cover

and

snap
ring
and
withdraw
the

remaining
parts
from

the
cylinder

Oean
all

components
carefully
and
check
them
for

signs

of

damage
or
wear
renew

any

part
found
to

be
defective
and

fit
a
new

piston
seal

CLUTCH
SLAVE
CYLINDER

Assembly
and
Installation

Reassembly
is
a
reversal
of

the
dismantling
procedure

Ensure
that
the

parts
are

dipped
in

brake
flu
d
before

assembling

and
that
the

piston
seal
is

correctly
installed

When
the
slave

cylinder
is
installed
in
the
vehicle
bleed

the
hydraulic
system
by
following
the

procedures
given
under

the

heading
CLlTfCH
SYSTEM

Bleeding

The

push
rod
must
be

adjusted
so
that
the
withdrawal

lever

has
an
end

play
of
2
0
2
3
mm
0
078
0
091
in
details

of
this

operation
are

given
below

CLlTfCH
WITHDRAWAL
LEVER

Adjusting

The
correct

adjustment
of
the
clutch
withdrawal
lever
is

most
essential
as
insufficient

clearance
between
the
clutch

release

bearing
and
the

diaphragm
will
cause
the
clutch
to

slip

On
the
other
hand
an
excessive
clearance
will

prevent
the
clutch

from

disengaging
correctly

The
clearance
between

the
release

bearing
and

diaphragm

or
release
levers
can
be

adjusted
in
the

following
manner

Slacken
the
locknut

Fig
E
IS
and
screw

the

push
rod

fully
home
with
the

adjusting
nut
Return
the

adjusting
nut

I
3
4
turns

to
adjust
the

play
at
the
end
of
the
clutch
withdrawal

lever
to

2
0
2
3
mm
0
078
0
091
in
This
will

give
a
clear

ance
of

approximately
1
3
mm

0
051
in

between
the
release

bearing
and
the

diaphragm
spring
or
release
levers

NOTE
When

adjusting
clutch

pedal
free
travel
at

the
withdrawal

lever
it
is
essential
to
check
that
the
clutch
driven

plate

has
not
worn

by
more
than
2mm
0
08
in
otherwise

the
clutch
will

slip
even
if

it
is

correctly
adjusted
See

Technical
Data
for
the
relevant
clutch
driven

plate

thickness

CLUTCH
SYSTEM

Bleeding

The
clutch

system
must
be
bled
after
it
has
been
dismantled

or
if

any
part
of
the
circuit
has
been

opened
This

operation

should
also
be
carried
out
if
the
fluid
level
in

the
reservoir
has

been
allowed
to
fall
and

pennit
air
to
enter
the

system

The

presence
of
air
in
the

system
may
be
noticed

by

incorrect
disengagement
of
the
clutch
but
in
any
case
if
air
is

suspected
the
clutch
must

be
bled
in

the
following
manner

Remove
the
dust

cap
from
the
slave

cylinder
bleed
screw

Connect
a

length
of
tube
to
the
bleed
screw
and
immerse
the

47

inter
1D7
J

3

T
T

aj

W

n
J

I

1

T

f
T
7

e

Fig
E
II

Adjustillll
the

height
of
the
release

levers
Fig
E
12
Actuating
the
clutch
to
settle
the

mechanism

Tightening
torque
3
5
to
4
0

kltm

125
to
29

h
lb

Rs

@

A
l

I
l

1
3
fP

I

01
I

8J

I

Jt
I

Lock
A

2

Lock
ul
Bn

Adjwt
by
adjust
of
master

cyl

@
Lubricatic
l

Clutch
dal
full

trek
140
4

mm
5
51
0
16

Clutch

pedal
free
stroke
25
mm
0
98
Pedal

height
175
mm
6
89
nl

Pc

dalfullstrokc
b

135mm
5
JI
n

@
Multi

purpo
greasc

510
series
610
series

Fig
E
l3

Adjusting
the
clutch

pedal

I

48

inter
lliJ
j

flDlJ
l

Jl

iO

n
cxB
L

of

lii
t
hl
9

q
6
15

1

r

8t

r

L
L
I
i

1
2
9

@
7
5I1

9
QlIf12
12J
J
7
ll
I

I

o

Q

1

Cylinder

2

Return

spring

3
Piston

4

Secondary
cup

5
Piston

cup

6

Supply
valve
seat

7

Supply
valve
stem

8

Supply
lIOlve

spring
9

Spring
seat

10
Va
ve

stem

stop

11

Stopper
gasket

12
Gasket

ring

13
Push
rod

14
Push
rod
ht
lld

15
Wdd
nut

16
Lock
nut
17
Piston

stopper

18

Stopper
ring

19
Boots

20
Oil
reservoir

21
Rese1l
Oir
band

22

Reservoir

cop

23

Cap

24

Pipe
seat
J

J

5

9

a

ID

1

Cylinder

2
Return

spring

C1

3
Piston

4

Spring
seat

5
Push
rod

6
Nut

7

Stopper
ring

8

Stopper

9
Dust
cover

10
on
reservoir

1
J
Reservoir
balld

12
Reservoir

cap

Fig
E

14
Section

through
the
clutch
master

cylinder

Adjusting
nut

Fig
E
l
S

Adjusting
the
clutch
withdrawal
lever

49

other
end
of
the

tube
into
a
clean
container

partly
filled
with

brake
fluid

Top

up
the
master

cylinder
reservoir
with
recommended

fluid
and

open
the
bleed
screw

approximately
three

quarters

of
a
turn

Depress
the
clutch

pedal
slowly
and
hold
it

completely

down
re

tighten
the
bleed
screw
and
allow
the

pedal
to
return

slowly

Repeat
the

operation
until
the
fluid

emerging
from
the

tube
is
free
from
air
bubbles
It
should
be
noted
that
assistance
will
be

required
when

carrying
out

bleeding
operations
as
not

only
must
the
fluid

entering
the

glass
container
be
watched
but
also
the
clutch

pedal
has
to
be

operated
and
the
reservoir

topped
up
frequently

throughout
the

procedure

When
the
fluid
is
completely
free
from
air
bubbles
the

bleed
screw
should
be

retightened
on
a
down
stroke
of
the

pedal

Finally
remove
the
bleed
tube
and

replace
the
dust

cap

TechnIcal
Data

Outch

type

Pressure

spring

Free

length

Fitted

length
and
load

Side
distortion

Permissible
deterioration

of

spring
force

Outch
release
levers

Oearance
between
release

bearing
and

diaphragm
spring

release
levers

Height
between
diaphragm
spring
and

flywheel

Height
between
release
levers
and
flywheel

Outch
driven

plate

Outer
diameter

Inner
diameter

Thickness
of

facingS

Total
friction
area

TIrickness
of

clutch
plate

Free

Compressed

No
of
torsion

springs

Permissible
minimum
depth
of
rivet
heads
from

facing
surface

Permissible
run
out
of
clutch

facing

P
rmissible
free

play
of

splines

Outch

pedal
1400
and
1600cc
models

Pedal

height
in
the
rest

position

P
da1
free
stroke

P

da1
effort

Master

cylinder

Diameter

Maximum
clearance
between

piston
and

cylinder

Pressure

plate

Permissible
refacing
limit

Outch

pedal
180Occ
models

P
da1

height

Play
at
clevis

pin

Full
stroke

P
da1
effort

50
Diaphragm
spring
or
coil

spring

52
3mm
2
059
in

29
2mm
44

2kg

1
149
in

197
t

4
4
lb

5mm

per
IOOmm

0
2in

per
3
94
in

15

1
2
I

4mm
0
047
0
055
in

44
t

Imm
1
732
t

0
039
in

50
5
t
0
05mm
1
988
t

0
0197
in

200mm
7
87
in

130mm
5
12in

3
5mm
0
140in

362

sq
cm
56
11
sq
in

8
6
9
0mm
0
3386
o
3543in

7
65
7
95mm
0
3012
o
3130in

6

O
3mm
0
0118

in

0
5mm
0
0197
in

0
4mm
0
0157
in

182mm
7
17in
R
H
D

207mm
8
15in
L
H
D

25mm
0
984in

15kg
33
lb

15
87mm
0
625in

O
13mm
0
005lin

Imm
0
0394in

175mm
6
89in

1
5mm
0
04
0
20in

135mm
5
3lin

10

5kg
23Ib

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

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

interQ
8
j

@W
2

m
tV

r
ReJld

cop
level

th
elk

FIg
M
I

llIecking
the

specific
gra
ity
of
the

battery
electrolyte
I
Thermal
u
e

Hydrometer

f
j
0
l

Q

I
iJ

Qy@

I
@
@

@
ti

II
@
@

Fig
M
3
Brush
cover
removed

j
i

Fill
M
2
Starter
motor

components

1

L
u
uJIner

pin

2
Drive
mil
Nack

t

3
Dult
COPD

4
E
mmtle
r

5
Aut
mzl

6
Solmoid
mlch

7
Arm
zturr

8
Thnut

9
IJriv
mil

blllck
t
bush

10
17uust

WdSMr

11

Stop
washer

12
CiTc
ip
13
PirUon

srap
collar

14
Pinion

IS
IWfni1l6
clutch

16
Field

coil

17
Yok

18
Politive
brwh

19

N
J1iP
bnuh

20
Bnuh

rprinK

21
Brullr
holder

22

Bearing
bwh

23
Rmr
COJIU

24

Through
botrr
@

FIg
M
5
Yoke

assembly
removed

Fill
M
4
Solenoid
switch
1

108
Fig
M
6
Annatore

assembly
and

engagemenr

lever

removed

ElectrIcal

EquIpment

DESCRIPTION

BATTERY
Maintenance

STARTER
MOTOR

Removal
and

Dismantling

STARTER
MOTOR

Testing

STARTER
MOTOR

Assembly
and
Installation

ALTERNATOR
Removal

Dismantling
and

Inspection

DESCRIPTION

A
12
volt

negative
earth
electrical

system
is
used
in
which

the

battery
is

charged
by
an
alternator
In
the
alternator
a

magnetic
field
is

produced
by
the
rotor

which
consists
of
the

alternator
shaft
field
coil

p
le

pieces
and

slip
rings

Output
current
is

generated
in
the
armature
coils
located

in
the
stator
Six
silicon
diodes
are

incorporated
in
the
alternator

caSing
to

rectify
the

alternating
current

supply
A
voltage

regulator
and

pilot
lamp
relay
are
built
in
the

regulator
box

which

nonnally
does
not

give
trouble
or

require
attention

The
starter
motor
is
a

brush

type
series
wound
motor

in

which

positive
meshing
of
the

pinion
and

ring

gear
teeth
are

secured

by
means
of
an

overrunning
clutch

BATTERY
Maintenance

The

battery
should
be
maintained
in
a
clean
and

dry

condition
at
all
times
or
a
current

leakage
may
occur

between

the
terminals
If

frequent
topping

up
is

required
it
is
an

indication
of

overcharging
or
deterioration
of
the

battery

When

refitting
the
cables
clean
them

thoroughly
and
coat

their

terminals
and
the
terminal

posts
with

petroleum
jelly

Check
the
level
of
the

electrolyte
in
the

battery
at

frequent

intervals
and

top
up
if

necessary
to

the
level
mark
on

the

battery
case
with
distilled
water
A

hydrometer
test
should
be

carried
out

to
determine
the
state

of

charge
of

the

battery
by

measuring
the

specific
gravity
of
the

electrolyte
It
should
be

pointed
out

that
the
addition
of

sulphuric
acid
will
not

normally

be

necessary
and
should

only
be
carried
out

by
an

expert
when

required

The

specific
gravity
of
the

electrolyte
should
be
ascertained

with
the

battery

fully
charged
at
an

electrolyte
temperature
of

200C
680F

The

specific
gravity
of
the

electrolyte
decreases
or
increases

by
0
0007
when
its

temperature
rises
or
falls

by
10C
1
80F

respectively

The

temperature
referred

to
is
that
of
the

electrolyte
and

not
the
ambient

temperature
to
correct
a

reading
for
an
air

temperature
it
will
be

necessary
to

add
0
0035
to
the

reading

for

every
50C
above
200C

Conversely
0
0035
must

be
deducted

for

every
SOC
below
200C
Test
each
cell

separately
and
draw

the

liquid
into
the

hydrometer
several
times
if
a
built
in

thermometer
type
is
used

The
correct

specific
gravity
readings
should
be
as
follows
ALTERNATOR

Assembly
and
Installation

HEAD
LAMPS

Replacing

HORN

INSTRUMENT
PANEL
Removal

WINDSCREEN
WIPERS

WINDSCREEN
WASHERS

IGNITION
SWITCH
AND
STEERING
LOCK

Cold
climates

Temperature
climates

Tropical
climates
Permissible

value

Over
1
22

Over
1
20

Over
1
18
Fully
charged
at
200C

680F

1
28

1

26

1
23

The

battery
should
be

recharged
if
a
low

specific
gravity

reading
is
indicated

Always
disconnect
both
terminals
of
the

battery
when

charging
and
clean
the
terminal

posts
with
a

soda

solution
Remove
the
vent

plugs
and

keep
the
electrolyte

temperature
below
450C
l130F
during
charging

Check
the

specific
gravity
after

charging
and
if
it
is
above

1
260
at

200C
680C
add
distilled
water

STARTER
MOTOR
Removal
and
Dismantling

As
previously
stated
the
starter
motor

is
brush

type
series

wound
motor
in
which
the

positive
meshing
of
the

pinion
and

ring
gear
teeth
are
secured

by
an

overrunning
clutch
The
over

running
clutch

employs
a
shift
lever
to
slide
the

pinion
into

mesh
with
the
flywheel
ring

gear
teeth
when
the
starter
is

operated

When
the
engine
starts
the

pL
lion
is

permitted
to
overrun

the
clutch
and
armature

but
is
held
in
mesh
until
the
shift
lever

is
released
An

exploded
view
of
the
starter

is
shown
in

Fig
M
2

To
remove
the
starter

motor

proceed
as
follows

Disconnect
the

battery
earth
cable

2
Disconnect
the
black
and

yellow
wire
from
the
solenoid

terminal
and
the
black
cable
from
the

battery
terminal

3
Remove
the
two
bolts

securing
the
starter
motor
to
the

clutch

housing
Pull
the
starter
motor

assembly
forwards

and
withdraw

it
from
the
v
hicle

To
dismantle
the
starter

motor
ftrst
remove
the
brush

cover
and
lift
out

the
brushes
as
shown
in

Fig
M
3

Loosen
the
nut

securing
the

connecting
plate
to

the

solenoid
M
terminal
Remove
the
solenoid

retaining
screws

take
out

the
cotter

pin
and
withdraw

the
shift
lever

pin
Remove

the
solenoid

assembly
as
shown
in

Fig
M
4

Remove
the
two

through
bolts

and
rear
cover

assembly

then
remove

the
yoke
assembly
by
lightly
tapping
it
with
a

wooden
mallet

Fig
M
S
Withdraw
the
armature
and
shift

lever

Fig
M
6
Remove
the
pinion

stopper
from
the

armature
shaft

by
removing
the

stopper
washer
pushing
the

109