wheel torque DATSUN 610 1969 Workshop Manual
[x] Cancel search | Manufacturer: DATSUN, Model Year: 1969, Model line: 610, Model: DATSUN 610 1969Pages: 171, PDF Size: 10.63 MB
Page 6 of 171

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
Page 16 of 171

reading
Slacken
one
of
the
cap
bolts
and
check
the
clearance
between
the
cap
and
cylinder
block
with
a
feeler
gauge
See
Fig
A
29
The
bearing
crush
nip
should
be
between
0
0
03mm
0
0
0012
in
if
this
is
not
the
case
then
the
bearing
must
be
replaced
beck
the
connecting
rod
bearings
in
a
similar
manner
after
tightening
the
caps
to
the
specified
torque
readings
The
bearing
clearance
should
be
between
0
15
0
045
mm
0
0006
0
0018
in
CAMSIIAFf
AND
SPROCKET
Inspect
the
camshaftjoumals
for
signs
of
wear
or
damage
and
check
the
camshaft
for
run
out
using
a
dial
gauge
in
a
similar
manner
to
that
previously
described
for
the
crankshaft
The
bending
limit
of
0
02
mm
0
0007
in
must
not
be
exceeded
Install
the
camshaft
sprocket
mount
the
assembly
in
V
blocks
as
shown
in
Fig
A
30
and
check
that
the
run
out
of
the
sprocket
does
not
exceed
0
1
mOl
0
04331
in
O1eck
the
timing
chain
and
sprocket
to
ensure
that
the
chain
is
not
stretched
or
damaged
or
the
teeth
of
the
sprocket
damaged
or
distorted
A
timing
chain
which
has
become
stretched
will
affect
the
valve
timing
and
be
noisy
in
operation
Check
the
chain
tensioner
and
chain
guides
for
wear
and
damage
replacing
the
parts
if
necessary
Replace
the
sprocket
if
the
run
out
is
exceeded
or
if
the
teeth
of
the
sprocket
are
worn
or
damaged
in
any
way
The
camshaft
end
play
should
be
within
0
08
0
38
mm
0
0031
O
oI50
in
If
the
clearance
limit
of
0
1
mm
0
0039
in
is
exceeded
it
will
be
necessary
to
replace
the
cam
shaft
locating
plate
See
Fig
A
3l
FLYWHEEL
Inspecting
Ensure
that
the
clutch
disc
contact
face
of
the
flywheel
is
not
worn
or
damaged
The
run
out
of
the
flywheel
contact
face
should
not
exceed
0
2
mOl
0
008
in
when
measured
with
a
dial
gauge
The
flywheel
ring
gear
can
be
replaced
if
the
teeth
are
damaged
or
worn
This
operation
will
entail
splitting
the
ring
gear
to
remove
it
A
hacksaw
should
be
used
to
cut
between
the
teeth
followed
by
splitting
with
a
cold
chisel
When
replacing
the
ring
gear
it
must
be
heated
to
a
temperature
of
approximately
1800
2000
F
before
fitting
and
then
allowed
to
cool
slowly
ENGINE
Assembling
Before
starting
to
assemble
the
engine
make
sure
that
all
components
are
perfectly
clean
It
is
always
advisable
to
pay
particular
attention
to
the
following
points
when
assembling
an
engine
Keep
the
work
bench
and
tools
clean
and
make
sure
that
the
tools
are
to
hand
Ensure
that
all
engine
oil
ways
are
clear
of
foreign
matter
fit
new
gaskets
and
oil
seals
throughout
All
sliding
parts
such
as
bearing
shells
must
be
smeared
with
engine
oil
before
installing
B
Ensure
that
the
specified
tightening
torque
readings
are
strictly
followed
A
mbling
the
cylinder
Head
To
install
the
valves
and
valve
springs
place
the
valve
spring
seats
into
position
and
fit
the
valve
guides
and
oil
lip
seals
Assemble
in
the
following
order
valve
springs
spring
retainers
valve
collets
and
valve
rocker
guides
Use
the
special
compressor
ST
12070000
as
shown
in
Fig
A
32
to
compress
the
valve
springs
Piston
and
connecting
rods
The
piston
piston
pins
and
connectiJ1
rods
must
be
assembled
in
accordance
with
the
cylinder
numbers
The
gudgeon
pin
is
press
fitted
to
the
connecting
rod
and
requires
a
fitting
force
from
0
5
to
1
5
tons
This
operation
will
require
the
use
of
the
special
tool
ST
1303000
as
shown
in
Fig
A
33
Apply
engine
oil
to
the
gudgeon
pin
and
connecting
rod
before
fitting
It
should
be
noted
that
the
oil
jet
of
the
connecting
rod
big
end
must
face
towards
the
right
hand
side
of
the
cylinder
block
See
Fig
A
34
Fit
the
piston
rings
the
oil
control
ring
in
the
bottom
groove
followed
by
the
centre
and
top
compression
rings
which
must
be
installed
with
the
marks
facing
upwards
Install
the
connecting
rod
bearings
and
caps
making
sure
that
the
markings
coincide
Ensure
that
the
backs
of
the
bearing
shells
are
perfectly
clean
otherwise
they
will
be
damaged
when
tightened
Assembling
the
engine
Fit
the
baffle
plate
and
cylinder
block
net
Install
the
crankcase
halves
of
the
main
bearing
shells
the
flanged
shell
is
fitted
to
the
centre
bearing
Smear
the
bearing
surfaces
with
engine
oil
and
carefully
lower
the
crankshaft
into
position
Install
the
main
bearing
caps
with
their
shells
making
sure
that
the
arrow
on
the
caps
faces
to
the
front
of
the
engine
Rotate
the
crankshaft
to
settle
the
caps
and
tighten
the
bearing
cap
bolts
gradually
in
two
or
three
separate
stages
Work
out
wards
from
the
centre
bearing
and
finally
tighten
to
the
specified
torque
reading
of
4
5
5
5
kgm
32
40
Ib
ft
in
the
sequence
shown
in
Fig
A
35
Ensure
that
the
crankshaft
rotates
freely
after
finally
tightening
the
cap
bolts
Check
the
crankshaft
end
float
which
should
be
between
0
05
0
18
mm
0
002
0
0071
in
see
Fig
A
36
Smear
the
side
oil
seals
with
sealant
and
fit
them
into
the
rear
main
bearing
cap
Install
the
rear
oil
seal
using
a
suitable
drift
and
grease
the
lip
of
the
seal
Place
the
flywheel
in
position
and
install
the
lock
washers
and
retaining
baits
Tighten
the
bolts
evenly
to
a
torque
reading
of
14
16
kgm
101
106Ib
ft
Rotate
the
engine
by
a
quarter
turn
and
install
the
piston
15
Page 18 of 171

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
Page 46 of 171

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
Page 56 of 171

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
Page 58 of 171

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
Page 66 of 171

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
Page 67 of 171

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
Page 68 of 171

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
Page 70 of 171

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