torque 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

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

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

Check
the
run
out
at
the

ceac
of
the
crownwheel
if
the
back

lash
or

tooth
contact

pattern
is
incorrect
The
run
out
should

not
exceed
0
08mm
0
003
in
Measure
the

turning
torque

of

the
drive

pinion
which
should
be
within
7

IOkg
cm
6
9Ib
in

Shims
and

adjusting
washers
must
be

changed
if
the
tooth

contact

pattern
and
backlash
is
incorrect
the
necessary
details

for
these

operations
can

be
found
towacds
the
end
of
this

section
under
the

heading
TOOTH
CONTACT
PATTERN

To
dismantle
the
differential
remove

the

flange
clamp
bolt

and
extract

the
side

flange
as
shown
in

Fig
GA

using
the

special
stand
ST
33730000
and

sliding
hammec
ST
36230000

Remove
the

bearing

caps
with
a
suitable

puller
as
shown

in

Fig
G
5
Remove
the
left
hand

cap
first
followed

by
the

right
hand

cap
The

caps
should

be
marked

to
ensure
that

they

are

refitted
in
their

original
positions
Withdraw
the
differential

cage
from

the
carrier

Fig
G
6

Slacken
the
drive

pinion
and
hold
the

flange
with
a

suitable
wrench
as

shown
in
Fig
G
7
Withdraw

the
flange
with

a
standard

puller
Press
the
drive

pinion
out
of
the
differential

carrier

together
with
the
rear

bearing
inner
races
the

spacers

and
the
shims
Place
a

press
plate
between

the
drive

pinion
head

and
rear

bearing
and

press
out
the

pinion
shaft

The
inner
races

need
not
be
removed
if
the
tooth
contact

pattern
is
correct
and
the
crownwheel
drive

pinion
carrier

rear

bearing
and
shims
etc
are
to

be
re
used
The
front
and

rear
outer
races
of
the

pinion
bearings
can
be
removed
with
the

special
tool
ST
30610000
or
with
a

suitable
drift

To
dismantle
the
differential

cage
remove

the

right
hand

bearing
cone
as
shown
in

Fig
G
8
The

special
puller
ST
3306

0000
and

adaptor
ST
33052000
should
be
used
for

this

pur

pose

taking
care
not
to

damage
the

edge
of
the

bearing
innec

race
Flatten
the

lock

straps
slacken
the

crownwheel
bolts
in

a

diagonal
pattern
and
remove

the
crownwheeL

Remove
the
left
hand

bearing
cone
in
a
similar

manner
to

the

right
hand

bearing
cone
Make
sure
that
the

parts
do
not

become
mixed
and
can
be
assembled
in
their

original

positions

Punch
out
the
differential
shaft
lock

pin
from
the
crownwheel

side

using
a

suitable
drift
Great
care
must

be
taken
when

carrying
out
this

operation
as
the

pin
is
caulked
into
the
hole

in
the
differential

cage

Remove
the
shaft
the
differential

pinion

gears
and
the
side

gears
and
thrust
washers

Separate
the
left
and

right
hand

gears

and
washers
so
that

they
can
be
reassembled
in
their

original

positions

Replacing
oil

seals
with

the
differential
installed

The
oil
seals
can

be

replaced
if
necessary
with
the
differ

ential
fitted
to
the
vehicle

Front
oil

seal

Drain
the
oil
from
the
differential

unit
and
jack
up
the

vehicle
at
the
rear
Remove
the

propeller
shaft
from
the

differential

flange
Disconnect
the
handbrake
left
hand
rear

cable
Slacken
and
remove
the
drive

pinion
nuts
whilst

holding

the
drive
flange
with
a
suitable
wrench
or

special
tool
ST

31530000
Withdraw
the
drive

flange
with
a
conventional
two
l

arm

puller
as
shown
in

Fig
G
9
Use
the
oil
seal

puller
ST

33290000
to
withdraw
the
oil
seal
from
the
retainer

Replace

the
oil
seal

using
a
suitable
drift
or

special
tool
ST
33270000

Fill
the
oil
seal

lips
with

grease
when
installing
Fit
the
oil
seal

retainer
and
replace
the
various

parts
in
reverse

order
to

the

removal

procedure

Side
oil
seal

Detach
the
drive
shaft
from
the
side
flange
of
the
differ

ential
carrier
Extract
the
side

flange
with
the
slide
hammer

ST
36230000
and

adaptor
ST
33730000
as
shown
in

Fig
G
lO

Remove
and
replace
the
oil
seal
in
a
similar
manner
to

that

previously
described
for
the
front

oil
seal

taking
care
to

apply

grease
between
the
oil
seal

lips

DIFFERENTIAL

Inspection

Clean
the

parts
thoroughly
and

inspect
them
for

signs
of

wear
or

damage

Check
the
gear
teeth
for
scores
cracks
or

excessive
wear

Check
the
tooth
contact

pattern
of
the
crownwheel
and

pinion
for
correct

meshing
depth
The
crownwheel
and

pinion
are

supplied
as
a
set

and
should
either

part
be

damaged
it
will
be

necessary
to
renew
the

complete
set

2
Check
the

pinion
shaft
and

gear
mating
faces
for
scores
or

wear

Inspect
the
inner

faces
of
the
side

gears
and
their

seating
faces
on

the
differential

cage

3

Any
small
defects
on
the
faces
of
the
thrust
washers
can

be
corrected

using
emery
cloth
The
thrust
washers
must

be

replaced
however
if

the
backlash
between
the
side

gear

and

pinion
exceeds
0
2mm
0
008
in
and
the
clearance

between
the
side

gear
and
thrust
washer
exceeds
O
3mm

0
012
in
Three
sizes
of
washers
are
available
and
the

thicknesses
are
detailed
in
Technical
Data
at

the
end
of

this
section

4
Measure
the
run
out
of
the
crownwheel
at
the
rear
with
a

dial

gauge
Replace
the
crownwheel
and
drive
pinion
as
a

set
if

the
run
out
exceeds
the

permissible
value
of
O
08mm

0
003
in

5
Examine
the
differential
carrier

and

cage
for
cracks
or

distortion
Renew

any
part
found
to

be
defective

It
is

advisable
to
renew
all
oil
seals

DIFFERENTIAL

Assembly
and

Adjustment

Assembly
is
a
reversal
of
the
removal

procedure
noting

the
following
points

Arrange
the
shims
and
washers
etc
in
their
correct

order

and

thoroughly
clean
the
surfaces
to

which
the
shims
washers

bearings
and

bearing
retainecs
are
to
be
installed

Differential

cage

Fit
the
differential
side

gear
and
bevel

gear
in
the

cage

using
the
correct
thrust
washers
Insert
the

pinion
shaft
so
that

the
lock

pin
hole

corresponds
with
the
hole
in
the
differential

65

inter
M
j

@
jJ

2

t

1
5c

t
J
i
3

jp

7
i
r
4

Ilc
d

I

l

@

l
lb
r

s
ril

1

iF
C

Q
Fig
G
12
Section

through
the
drive

pinion

1
Pinion

height
adjusting
kUsher
4
Fte
Ioad

for
pinion
bearing

2
Pinion

height
ad
usting
shims
without
oil
mlI
and
drive
7
to

3

Tightening
torque
of
nut
dril
e
10

kgt1L
5a

6
to
72
3
lb

jl

pinion
17
to

20kg1n
22
9
to

ffnion
bearing
adjusting
w

uher

44

6Ib
ft
J
6
Pillion
bt
flrillgadjusti

lg
s
Jtu
er

fl

i
Ji
l
I
I

J

lJ

i

V
r
IHei
t

giluge

I
lST31210c
0

l

B
I

0
QJ

DUrnmYPinlOn

Drive

pinion
collar

lST3121QOCX
f
1
L

r

IST315000001

Dummvspacer

ST318500001
I
Fig
G
ll

Measuring
the
clearance
between
the

differential
side

gear
and
thrust
washer

Fig
G
t3
Drive

pinion
markings

Fig
G
14

Adjusting
the

pinion
height

1

Fig
G
t
5

Adjustment
diagram
for
the
dif

feren
tiaI
side
covers
Fig
G

16lnstalling
the
differential
side
covers

fig
G

Checking
the
backlash
of
crownwheel

and

pinion
Fig
G
tS

Fining
the

differential

mounting

member

bb

cage
Mcasure
the
clearance
between
the

rear
face
of
thc
side

gear
and
the
differential
cage
as

shown
in

Fig
G
ll

and
if

necessary
use
a

tluust
washer

which
will

given
a

clearance
of

0
1
0
2mm
0
004
0
008
in
Fit
the

pinion
shaft
lock

pin

and
secure
it

by
caulking
with
a

punch
Lubricate
the

gear
teeth

and
check
the

gear
for
freedom
of
rotation

Install
the
crown
wheel
in
the

differential

cage
and
insert

the
bolts
with
new
lock

straps
Tap
the
head
of
each
bolt

lightly

and

tighten
the
bolts
in
a

diagonal

pattern
to
a

torque
reading

of
7
0
8
0

kgm
51
58Ib
ft
Measure
the
width
of

the
side

bearings
before

installing
them
Place
a

weight
of
2
5

kg
5
5
1b

on
the

bearings
and
check
the
nominal
width
which
should
be

20mm
0
787
in
Press
the

side

bearings
into
the
differential

cage

Adjustment
of
drive

pinion

preload

This

adjustment
is
carried
out
without

fitting
the
oil
seal

Press
the
front
and
rear

bearing
outer
races

into
the

gear
carrier

and
fit

the

pinion
height
adjusting
washer

Fig
G
12
the

shims

and
the
rear

bearing
inner
race
onto

a

dummy
shaft

special
tool
ST
31
120000
The
old
washers
and

shims
can

be

re
used
if
the
tooth
contact

pattern
was
found
to
be

correct

on
the

pre
dismantling
check
Fit
the
drive

pinion
bearing
spacer

the
washer
ans

special
collar
5T
312140000
or
5T
31500000

and

the
drive

flange
on
to

the

dummy
shaft

Tighten
the
drive

pinion
nut
to
a

torque
reading
of
17

20

kgm
123
145
Ib

ft

Measure

the
drive

pinion
bearing
pre
load
and
select
washers
and

spacers
to

give
a

pre
load

of
7
1
0

kg
cm
6

9Ib
in
with
new

bearings
or
3

6
kg
cm
2

6
5
Ib
in
with
used

bearings

Adjusting

spacers
are
available
in

lengths
of
56
2
57
2
mm

2
2126
2

2520
in
and

adjusting
washers
in
thicknesses
of

59
2
31
mm
0
1020
0
0909
in

Adjustment
of

pinion
height

The

pinion
height
or
distance

of
the
face
of
the

pinion
to

the
axis
of
the

crownwheel
is

adjusted
by
the
thickness
of
the

adjusting
washer
behind
the
drive

pinion
gcar

The
drive

pinion
has
a

tolerance
mark
etched
on
its
face

this
tokrance
is

accompanied
by
a

or

sign
to
show
the

deviation
from
the
nominal
dimension
Thc

plus
sign
indicates

that

the
nominal
distance
must
be
increased
and

the
minus

sign
that
it
mllst
be
decreased
The
tolerances
are
shown
in

Fig

G
I3

The

pinion
height
can

be

adjusted
using
the

original

adjusting
washer
and
shims
between
the
rear

bearing
cone

and

the

drive

pinion
Install
the

setting
gauge
5T
31210000
on
the

carrier
with
the

dummy
pinion
installed
Sce

Fig
G
14

Measure
the
clearance
between
the
head
of
the

dummy

shaft

and
the
tip
of
the

setting
g
wge
using
a
feeler

gauge
as

shown
in

Fig
G
15
The
clearance
is

also
shown
at
the

point

T
in
Fig
G
14
The

required
thickness
of
the

adj
lsting

washer
can

be
obtained

using
the
following
formula

S
W

T
H
x

0
01
0
20

Where
W

thickness
of
inserted
shims
and
washers

T
Measured
thickness

H
Figure
engraved
on

pinion
head
o

S

Required
thickn
ss
of
washers
and
shims

A

typical
example
is
given
below

w

20
1
20

T

H

S
340
0
24
2
x
0
01

0
20
3
40
mm

0
24
mm

3
46
mm

An
adjusting
washer
rrlust
be
selected
which
is
nearest
in

thickness
to
the
value
of
3
46mm
Adjusting
washers
are
available

in
thicknesses
of
3
09mm
0
01217
in
to
3
66m
0
1441
in

for
the
l800cc
models
and
in
thicknesses
of
O

2
and
2
4mm

0
787
0
866
and
0
945
in

for
the
1400
and
1600
cc
models

Fit
the
selected

adjusting
washer
and
shims
to
the
drive

pinion
and

press
on
the
rear

bearing
inner

race
Install
the
drive

pinion
into
the
differential
carrier

together
with
the

bearing

spacer
and
washer

the
front

bearing
inner
race
and
the
front

bearing
pilot
spacer

Fit
the
drive
flange
and
washer
on
the
drive

pinion
and

secure
them
with
the

pinion
nut

Tighten
the
nut
to
a
torque

reading
of
17
20

kgm
123
145Ib
ft

SIDE
BEARING
SHIMS
Selecting

The
side

bearing
pre
load
must

be
adjusted
with
selected

shims

if
the

differential
carrier
the

cage
the
side
bearings
or

the
bearing
covers
have
been
renewed

The

required
thickness
of

the
shims
can
be
obtained

using

the

following
formula
and

referring
to

Fig
G
l
5

T1
left
side
bearing
A
C
GI
D
E
H
x
0
01

0
76

T2

right
side
bearing
B
D
G2
F
H
x
0
01
0
76

Where

A
B

C
D

E
F
The

figure
on
the
differential
carrier

The

figure
on
the
differential

cage

The
differences
in
width
of
the
left
or

right
hand

bearings
against
the
nominal
width
of
20
0mm

0
7874
in

given
in
units
of
1
100
mm

Gl

G2

H
The

figure
on

the
side
cover

The
figure
on
the
crownwheel

The
A
B
C
D
G
and
H

figures
indicate
the
dimensional

variations
in
units
of
1
100
mm
fr
Jm
the
standard
measurement

An

example
of
the
calculations
to
decide
the
thickness
of
shim

required
is

given
below

Where

A
I
B
2
C
2
D
1
GI
3
G2
1
E
O
Olmm
F

O
02mm
H

Left
side

bearing

Tl
A

C
G
1
D
H
x

0
01
0
76
E

I
3
1
2
x

0
01
0
76
0
01
0
8mm

Right
side

bearing

T2
B
D
G2
H
x
0
01
0
76
F

2

I
I
2

x
0
01
0
76
0
02
0
8mm

67

The

standard
width
of
the
side

bearings
is
20
0mm

0
7874

this
width
must
be

measured
before

attempting
to

calculate
the
thickness

of
the

adjusting
shims
Use
a

dial

gauge

and
surface

plate
to
ohtain

the
measurement
Place
a

weight
of

approximately
2

5

kg
5
5
lb
on
the

bearing
to

obtain

steady

readings

Install
the
differential

cage

assembly
in

the
carrier

Fit
the

sckcted

shims
and
O

rings
into
both

differential
side

bearing

covers

and
install
the
covers

in
the

carrier

using
the

special
tool

ST
33720000

Fig
G
16
l
Make
sure

that
the
side

bearing

outer

races
are
not

damaged

by
the

roller
Measure
the
backlash

between
the

teeth
of

the
crown
wheel

and
drive

pinion
with
a

dial

gauge
as
shown
in

Fig
G
I
Sct
the
dial

gauge
to
0
10

f
O

mm

0
004
0
008
in

I
If
the

backlash
is

less
than
the

specifIed

value
move
he
left
side

adjusting
shim
to
the

right
side
and
vice

versa

if
the
backlash

exceeds
the
specified
figure

Check

that
the
run
out
at
the
rear

of
the

crownwheel
does

not

excecd
O
OSmm
0
002

in
for

the
1800ce
model
or

O
08mm
0

003
in

for
the
1400
Check
the

drive

pinion

turning

torque
Thc

turning
torque
should
be

higher

by
I
3

kg

em

compared
with
the

turning
torque
obtained
before

fitting

the
differential

cage
in
the
carrier
The

higher
value
can

be

provided
if

necessary
by

dmnging
the

jde
cover

shims
Note

howcver

that
any
decrease
or
increase
in

the
thickncss
of
shims

wjJl

alter
tht
budlush

between
the
teeth
of
the
crownwhee1

and

pinion

Check

the
tooth
contact

pat
tern

of
the
crown
wheel
and

pinion
as

described
under
the

appropriate
heading

DIFFERENTIAL

Installation

Secure
the
differential

carrier
on
the
rear

suspension
mem

ber

using
the
four

bolts
and
washers
Fit
the
differential

mounting
member
to
thc

mounting
holes

by
pushing
it
forwards

with
a

suitable
lever

Fig
G
18

Tighten
the

nuts
to
a

torque

reading
of
8

5

kgm
61
5

Ib
ft

Tighten
the
bolts

attaching
the

gear
carrier
to
the

suspension
member
to
a

torque
reading
of

6
7

kg
36
5Ilb
ft
t

The

rcmainder
of
the
installation

operations
are
a
reversal

of

thc
removal

procedure
Fill
the
differential
with

the
correct

quantity
of
recommended
oil

DIFFERENTIAL
CARRIER

Removal
and

Dismantling

Estate
car
alld
Vanl

To

remove
the
differential

carrier
disconnect
and
remove

rhe

propeller
shaft
as

previously
described

and
remove

the
two

rear
axle

shafts
as

described
in

the
section
REAR
AXLL
With

draw

the
nuts

securing
the
differential

and
remove

the
carrier

from
the
rear
axle

Mount

the
unit
on
the

special
attachment
as
shown
in

Fig
G
19
and

carry
out
a

preliminary
check
before

dismantling

Oleck
the
tooth
contact
of
the

crownwheel

and

pinion
by

applying
lead
oxide

to
three
or
four

teeth
of
the

crownwheel

Turn
the
crown

wheel
several
times

to
obtain
an

impression
of

the

tooth
contact

pattern
Check
the
backlash

between
the
teeth

of
the
crownwheel
and

pinion
with
a

dial

gauge
Hold
the
drive

pinion
with
one

hand
and
move

the
crown
wheel

backwards
and
forwards
to

check

that
the
backlash
is
Io

ithin
thL

speL
ified
limits

Shims
and

adjusting
washers
must
bL
altered
if

the
tooth
con

tact

pattern
and
backlash

is

incorre
L
the
neL

cssary
details
for

these

operations
can
be
found
towards
the

end
of

this
section

under
the

appropriate
he
Jdjn

s
Fil1JJly
mark
the

bearing
caps

with
a
hammer

and

punch
to
ensure
correct

t1ignment
on
re

assembly

Remove
the

bearing

caps
nd
withdraw

the
differ

ntial

cage
make

a
note
of

the
left
and

right
hand

positions
so
h
Jt

the

bearing
caps
and
outer
race
can

be
re

assembled
in

their

original
positions

Withdraw

the
side

beJrings
with
the
s

cjal

puller
as

shown

in

Fig
G
20

taking
care
not
to

catch
the

edge
of
the

bearing

inner
races

Place
the

assembly
in
a
vice
and
detach

the
crownwheel

by
slackening
the

retaining
bolts
in
a

diagonal

patter
Fig
G
lf

Drive

out
th

pinion
shaft
lock

pin
from

left
to

right
using
a

suitable

punch
or

special
tool
ST
23520000

Fig
C
22

With

draw
the

pinion
shaft
and
take
out

the

pinions
side

gears
and

thrust
washers

Store
the

gears
and
thrust
washers
so
that

they

can

be
assembled
in
their

original

positions

Check
the
initial

turning
torque
of
the

drive

pinion
with

the

preload
gauge
ST
3190000

and
measure

the

height
of

the

drive

pinion
with
the

special
gauge
ST
31941000

Compare
the

figures
obtained
with
those

givcn
in

Technical
Data
at

the
end

of
this
section

Hold
the
drive

pinion
with

the

speciaJ
wrench
ST
3
J
530000

as
shown
in

Fig
C

23
and
unscrew
the

drivc

pinion
nut

then

pull
out
the
drive

pjnion
flange

Tap
the
drive

pinion
assembly
to
the
rear
with
a

plastic

mallet
and
withdraw
it

together
with

the
rear

bearing
inner
race

bearing
spacer
and
adjusting
washer

Remove

and
discard
the
oil
seal
and

withdraw
thc
front

bearing
inner
race
Drive
out
the
outer
races

of
the
front
and

rear

bearings
with
a
suitable

drift

Fig
G
25

The
drive

pinion
rear

bearing
inncr
race
can
be
removed

with
the

special
tool
ST
300310000
as

shown
in

Fig
G
24

DIFFE
l
ENTlAL

Inspection

Clean
all

components
thoroughly
and

examine
for

signs

of
wear
or

damage

Check
the
teeth
of
the

crownwhcel

and

pinion
for

scoring

and

hipping
Ii
should
be

noted
that
the
crownwhecl

and

pinion
are

supplied
as
a

matched
set
and
if
either

part
is

damaged

the

complete
set
must
be

replaced

Examine
the

inner
faces
of
the
side

gears
and
seats
on
the

differential
case

Inspect
the

bearing
races
and

rollers
and

replace

them
if

necessary

Small
defects

on
the
faces
of

the
thrust

washers
can
be

corrected

using
emery
cloth
however
if

the
clearance
between

side

gear
and

thrust
washer

exceeds
0
1
O
2mm
0
0039

0
0079

in
it
ill
be

necessary
to

replace
the
washer

Various

sizes
of
washers
are
available

and
the
thicknesses
arc
detailed

under
the

heading
DIFFERENTIA
L

GEAR
CAGE

Assembling

69