DATSUN B110 1973 Service Repair Manual

CLUTCH

CLUTCH

CONTENTS

DESCRIPTION

REMOVAL

DISASSEMBL
Y

INSPECTION
AND

ADJUSTMENT

Clutch

assembly
Cll

CL

2

CL
2

CL
2

CL
2

DESCRIPTION

The

clutch
is
a

single
dty
disc

diaphragm
spring

type

clutch
The

major

components
are
clutch

cover

pressure

plate

diaphragm
spring
and

wire

rings
The

clutch

disc
is

provided
with

riveted

pia
tes
on

both
surfaces

and
coil

springs
arranged
in
a

link
The
coil

springs
absorb

shock

while

engaging
the
clutch

softening
and

smoothing
clutch

30

1181

I
4J

I

m

I

I

5

O

N
l
l

9

p

1L
oz
l
t
O

Ii
N
lt

o

O

Vf

I

1

I

t
I

0

tN

00

f
M

g

1

co
0

00

U
N

N

y
Disc

assembly

Release

bearing
and

sleeve

REASSEMBL
Y
CL

3

CL

4

CL
4

CL
4

CL
5
Release

mechanism

REINSTALLATION

engagement

Release

bearing
sleeve
and

withdrawal
lever
are
used

to

control

clutch

engagement
and

disengagement

Each

part
of
the

clutch

assembly
is
secured
with
rivets

Therefore
when
a

trouble
is
uncorrectable

replace
the

clutch

assembly
wHh
J
new

assembly

93

53

3
682
JOOD4

33

Unit

mm
in

Fig
CL
l

Construction

of
clutch

ell

CHASSIS

REMOVAL

The
clutch

assembly
is

dismounted

primarily
in
the

same
manner
as
the

engine
assembly
Thus
when
dis

mounting
the

clutch

assembly
refer
to
the
Section

TM

Transmission
Removal
and
other

relative
sections

W

II

11
I
Clutch

assembly

I
2

I
Clutch
disc

assembly

Fig
CIr2
Clutch

assembly
and
disc

assembly

DISASSEMBLY

When

separating
the
clutch

assembly
from
the

flywheel
loosen

and
remove
the
installation
bolts

diago

nally
and

gradually

Note
When

separating
the
clutch

assembly
from

the

flywheel
support
the
clutch

cover

sufficiently
and

loosen
the
installation
bolts

gradually
and

carefully

because
the

diaphragm
spring
tension
is

always

applied

2

Removing
release
mechanism

I
Remove

the
dust
cover
from
the
clutch

housing

2
Remove

the
return

spring
from

the

bearing
sleeve

and

separate
the
withdrawal
lever
from

the

bearing
sleeve

3
Remove

the
release

bearing
and

bearing
sleeve

from

the

front
cover
and
remove
the
withdrawal

lever
from
the

withdrawal

lever
ball

pin
1

I
Withdrawal

lever
3

Release

bearing

2
Return

spring

Fig
CL
3

Disassembling
release
mechanism

3
Withdraw
the

release

bearing
from
the

bearing
sleeve

by
the
use
of
a

bearing
puller

I
t

I
Release

bearing

I
2

I
Bearing
sleeve

Fig
CIr4

Withdrawing
rekas

b04ring

INSPECTION
AND

ADJUSTMENT

Thoroughly
clean
all

disassembled

parts
except
for

disc

assembly
and
release

bearing
and
check
them

for

wear

crack
and
other

defective
conditions

Clutch

assembly

I

Check
the
clutch
cover

diaphragm

spring
pressure

plate
etc
for
excessive

wear
crack
and

damage
When

noise

occurs
on
the
clutch

assembly
replace

CL
2

CLUTCH

2

Measuring
and

adjusting
height
of

diaphragm
spring

I
Line

up
distance

piece
special
tool

ST20059001

on

clutch

assembly
base

plate
special
tool
ST20101O
0

ST20059001

I

ST20101000

Fig
CL
5

Base

plate
and
distance

piece

2

Place
the
clutch

assembly
on
the
distance

piece
and

set
the

clutch

assembly
on

the
base

plate
stationarily

Under
this
condition
the

distance

piece
is

placed
beneath

the

pressure
plate

3
Measure
the

diaphragm
spring
height
from
the

upper

surface
of
the
base

plate
with
vernier

caliper
depth
gauge

Height
of

diaphragm
spring
end
29
0

to
31
mm

1
142
to
1
220

in
at
diameter
62
mm
2
441
in

29
0
to
31

It
142
to
1

2201

6212
44
t

r
1

G
L
ir

I
LJIlW

I

y
y
x
l
i
0

BASE
PLATE

Unit

mm
in

Fig
CL
6

Measuring
height
of
dio

phTagm
spTing
4

Adjust
height
of

the

diaphragm
spring
by
the
use
of

diaphragm
spring
adjusting
wrench

special
tool

ST20
1
05000

if

required

Fig
CL
7

Adjusting
dio

phTagm
spring
height

Disc

assembly

If

the

facing
is

soiled
with

grease
or
oil
clean
off

with

gasoline
tetracWoride
and
dress
the

facing
with
a

wire
brush

Replace
the

facing
if

required

2

Check
the
disc
for
deflection
and

repair
or

replace
if

the

deflection
at
the
outer
circumference
of
the

facing

exceeds
the
following
value

Upper
limit
of
the
deflection

0
5

mm
0

0197
in

at

85
mm
3
3460
in

radius

Unit
mm
in

Fig
CL
8

Checking
disc

fOT
deflection

CL
3

CHASSIS

Replace
the

disc

assembly
if
the

facing
is
worn

to

such
an
extent
that
the

facing
height
above
rivet
is
less

than
0
3
mm
0
0118
in
the

facing
is
worn

unevenly
or

rivets
are
loose

Depth

9au@e
II

i
I

I
il

S
I
I

F

d
I
id

Above
0

3
10
0118

Unit
mm
in

Fig
CL
9

Checking
clutch

facing
for
wear

Release

bearing
and
sleeve

When
withdrawal
lever
and

bearing
sleeve
contact

pomt
is
worn
in

step
replace
the
sleeve

2
When

grease
leaks
from
the
release

bearing
or
noise

occurs
on
the
release

bearing

replace
the
release

bearing

Fig
CL
J
0

Fittitlg
release
bearir

g

REASSEMBLY

Release

mechanism

Tightly
fit
the

release

bearing
to

the

placc
on
the
bearing
sleeve
as

shown
in

Figure
CL
10

When
the

hearing

is
installed

completely
turn

the

bearing
with
a

finger
and

make

sure
that
the

bearing
operates
smoothly

2

Apply
multi

purpose

grease
to
the

following
places

Bearing
sleeve

inside

groove

l

Pack
this
recess

I

1

II

J

Fig
CL
11

Lubricated

position
m
the

bearing
sleeve

Withdrawal
lever
and

bearing
sleeve
contact

point

Withdrawal
lever

ball

pin
and
withdrawal
lever

contact
surface

I
I

1
Withdrawal
ball

pin

I
2
Withdrawal

lever

Fig
CL
12
Position
on
the
withdrawal

lever
to

which

grease
is

applied

3

When

grease
is

applied
to
the

necessary
places
install

the
withdrawal
lever

release

bearing
and

bearing
sleeve

un
the

clukh

housing
connect
them
with

return

spring

and

install
the
dust

cover
on
the
clutch

housing

CL

4

CLUTCH

J

I

I
Withdrawal

lever

2
Return

spring

I
31
Release

bearing
ST20610000

iwn

rm
hj

sf

W

Fig
CL
13

Installing
release
mechanism

REINSTALLATION

L
Clean
the

clutch

pilot
bushing
and

fill
it
with

multi

purpose
grease

2
Install
the
disc

assembly
and

clutch

assembly
on
the

flywheel
by
the
use

of
a

special
tool
clutch

aligning
bar

ST206
I
0000
12
I
Flywheel

Clutch

assembly

131
Clutch
disc

assembly

Fig
CL
14

Installing
disc
and
clutch

assembly

CLUTCH
CONTROL

CONTENTS

DESCRIPTION

CL
5
Removal
CL
9

CLUTCH
PEDAL

Hydraulic
clutch

CL
6
Disassembly
CL
9

Removal

CL
6
Inspection
CL

9

Inspection
CL
6
Reassembly
CL
9

Reinstallation

CL
6
Reinstallation

CL
10

Adjustment
CL
6
OPERATING
CYLINDER

Hydraulic
clutch

CL
10

CLUTCH
PEDAL
CLUTCH
CONTROL
Removal

CL
10

CABLE
Mechanical
clutch
CL
7
Disassembly
CL
10

Removal
CL
7
Inspection
CL
10

Inspection
CL
7
Reassembly
CL
10

Reinstallation

CL
7
Reinstallation
CL
10

Adjustment
CL

7
ADJUSTING
WITHDRAWAL
LEVER
CL

10

CLUTCH
MASTER
CYLINDER
BLEEDING
CLUTCH
SYSTEM

Hydraulic
clutch
CL
9
Hydraulic
clutch
CL
11

DESCRIPTION

The
B
I
IO

series
vehicles
with

left
hand

steering
wheel

and

right
hand

steering
wheel

respectively
adopt
hydraulic

type
and
mechanical

type
clutch
control

systems
The

hydraulic
type
clutch
control

system
consists
of

pendent
clutch

pedal
master

cylinder
operating
cylinder

and
withdrawal
lever
The

withdrawal
lever
is
of
an

inner

CL

5

CHASSIS

fulcrum

type

The
mechanical

type
clutch
control

system
consists

of

pendent
clutch

pedal
clutch

control
cable
and
with

drawallever
The

withdrawal
lever
is
of
an

outer
fulcrum

type
which

provides
a

great
lever
ratio
and
thus
force

required
in

depressing
clutch

pedal
is
reduced

CLUTCH

PEDAL

Hydraulic
clutch

Removal

Remove
the
return

spring

2

Loosen
the
lock
nut
of
the
master

cylinder
push
rod

and

disconnect
the

push
rod
end

3

Remove
the
lock

nut
and
washer

of
the

pedal
shaft

and

remove
the

pedal
lever

Inspection

Thoroughly
clean
all
disassembled

parts
indicated

below
and

carefully
check
them

for
wear

damage
and

other
abnormal
conditions

Repair
or

replace
them

with

new
ones
if

required

f

fS

C5

J

dJ

YII

10

1

@
c
i
@

j

1

4

K

Clutch

pedal
free
trrlel

30
mm
1
181

nl

00

@

P

IO
Pedal
head
rubber

2

Return

spring

3

Pedal
lever
bush

4
Fulcrum

pedal
pin
etc

Reinstallation

Reinstall
the

clutch

pedal
in
reverse

sequence
of

removal

Adjustment

I

Adjust
pedal
pad
height
to
143
5
mm
5
65
in

without

stopper
The

adjustment
is

made

by
selecting
and

applying
shim
s

having
adequate
thickness

Be

sure
to
use
shims

having
same
thickness
for

both

upper
and
lower

2

Next

adjust
the

pedal
stopper
properly
so
that
the

pedal
pad
height
is

141
5
mm
5
57
in
and
secure
the

position
with
lock

nut

Note
Make
sure
that
chassis

grease
has
been

applied
to

the

leG
marked

portions
two

places
Grease
if

required

Adjusting
shim

Part
number

Thickness
mm
in

30611
27260

30612
27260

30613
27260
1

6
0
0630

0

8
0
0315

0
5
0
0197

I

2

3
Adjusting
shim

Pedal
lever

Pedal

stopper

Unit
mm

inl

Fig
CL
J5

Pedal

height
adjustment

CL
6

CLUTCH

CLUTCH

PEDAL
AND
CLUTCH

CONTROL
CABLE

Mechanical
clutch

Removal

Loosen

the
control
cable

adjusting
nut
and
discon

nect
the

control
cable
from

the
withdrawal
lever

III
Adjusting
nut
2

I
Lock
nut

Fig
CL
16
Clutch

cunITol
cable

11
I
Withdrawal
lever

I
2

I
Clutch
control
cable

Fig
CL
17

Disconnecting
clutch
control
cable

2

Unhook
the

clutch

pedal
return

spring

3
Remove

the
clutch
brake

Pedal
installation
bolts
and

remove
the

clutch

pedal
and

control
cable
1

I
Return

spring

31
au
tch

pedal

2
Fulcrum

pedal
pin

Fig
CL
I8

Removing

pedal
installation
bolt

Inspection

Thoroughly
clean
all

disassembled

parts
indicated

below
and

carefully
check

them
for

wear

damage
and

other
abnormal
conditions

Repair
or
replace
as

required

Control
cable

2

Pedal
head
rubber

3

Pedal
lever
bush

4
Fulcrum

pedal
pin

5

Others

Reinstallation

Reinstall

the
clutch

pedal
and
clutch
control

cable
in

reverse

sequence
of
removal

Alljustment

Adjust
the

pedal
stopper
so

that

pedal
height
is
in

range
from
136
5
to
146
5

mm
5
4

to
5

8
in
and
secure

the

position
with

lock
nut

completely

2

Next

adjust
the
control
cable

adjust
nut
so

that

clutch

pedal

play
is
in

range
from
II

to
15

mm
0
433

to

0
591
in
at

the
center
of
the

clutch

pedal
pad
and
make

sure
that

play
at
P

point
of

the
withdrawal

lever
is
in

range
from
3

0
to
4
0

mm

0
1181
to
0
1575
in

Secure

the

alignment
with

lock
nut

completely

CL
7

CHASSIS

i

I

I

I

II
I

I

J
u
IlllrP

Zll
I
ff
Pedal
play
11

to
15

I
0
433
to

0
591

I

W

p
da
stfO
l
e

1
P

point
end

play

l
e

A
1

C
3
0
to
A
O

Chassis

grease
20

0
1181
to
0
1575

I

Y
136
5
to
lA6
5

I
5
A

to
5

81

0
Note
Connect
the
control
cable

correctly
so
that
mark

cap
is
faced

upward
as
shown
in
the
following

figure
Make
sure
that
chassis

grease
has
been

I

2

3
Lock
nu

t

Adjusting
nut

Pedal

stopper
applied
to
the
CG
marked

positions
three

places
Apply

grease
if

required

@

300R

t2

8J

Unit
mm
in

Fig
CL
19

Pedal

height
adjustment

3
When
the

clutch

pedal
is

heavy
remove

grease
filler

cap
from
front

portion
of
the

adjust
nut
and

grease
Be

sure
to

use

grease
containing
molybdenum
disulfide

Fig
CL
20

Greasing
to
the

nipple
of
clutch

control
cable

CL
8

CLUTCH

CLUTCH

MASTER
CYLINDER

Hydraulic
clutch

3

V

t

2

3

4

5

6

7

8

9

10

tt

12

13
Snap
ring

Dust
cover

Push
rod

Clutch

piston

Piston

spring

Inlet
valve

spring

Inlet
valve

Spring
retainer

Shim

Inlet
valve
release

pin

Body

Oil
reservoir

Oil
reservoir

cap
6

D
ll

Q

6

i

0

l

Y
r@

cb

Fig
CL
21
Clutch
master

cylinder

Removal

Disconnect
the

push
rod

from
the
clevis

2

Disconnect
the
clutch
line
from
the
master

cylinder

and
drain
fluid

3
Remove

the

securing
bolts
and
remove
the

master

cylinder
assembly
from
the

vehicle

Disassembly

Remove
the
filler

cap
and

drain
fluid

2

Pull
back
the
dust
cover
and

remove
the

snap

ring

The

stopper
push
rod

piston
assembly
primary
cup
and

return

spring
assembly
can
be

removed

Inspection

Thoroughly
clean

all

parts
with
brake

fluid
before

inspection

CL
9
1
Check

the

cylinder
and

piston
for
uneven
wear

or

damage
Replace
if

required

2

When
clearance
between
the

cylinder
and

piston
is

more
than
0
15
mm
0
0059

in

replace
the

cylinder

3

Replace
the

piston
cup

primarily
whenever
the

master

cylinder
is

disassembled
It
must
also
be

replaced

when
wear
or

deforma
tion

due
to

fatigue
or

damage
is

found

4
Check

the
dust

cover
oil
reservoir
filler

cap
and

clutch
line

for

damage
or
deformation
If

abnormal

condition
is

found

replace
with

new
one

Reassembly

Reassemble
the

master

cylinder
assembly
in
reverse

sequence
of

disassembly

noting
the

following
matters

The

piston
cup
should
be

soaked
in
brake

fluid

before

reassembly
Install
the

piston
cup
carefully
so
that

it
is

correctly
faced

CHASSIS

2

Apply
brake

fluid

sufficiently
to
the

cylinder
and

piston
and

assemble
them

Reinstallation

Reinstall
the
master

cylinder
assembly
in
reverse

sequence
of

removal
and

adjust
as
follows

I

Adjust
the

pedal
height
by
changing
the

push
rod

length

2
B

eed
air

out
of
the

hydraulic
system

OPERATING

CYLINDER

Hydraulic
clutch

Removal

Remove

the
return

spring

2

Disconnect
the
clutch
line

from
the

operating
cyl

inder

3

Disconnect
the

push
rod

from
the

withdrawal
lever

4

Release
two
bolts
used

to
mount

the

operating

cylinder
to
the
clutch

housing

Disassembly

1
Remove
the

dust

cover

2
Remove
the

snap
ring
and
all
other

parts
can
be

disassembled

@

Fig
CL
22

Operating

cylinder
disassembled

CL
10
Inspection

Check
all

parts
especially
the

piston

cup
and

replace

if
worn
or

damaged

Reassembly

Reassemble

the

operating
cylinder
in

reverse

sequence

of

disassembly

noting
the

following
matters

Soak
the

piston
cup
in
fluid
before

reassembly

Install
the

piston

cup
carefully
so
that
it
is
faced

correctly

2

Apply
brake

fluid

sufficiently
to
the

cylinder
and

piston
and

assemble
them

Reinstallation

Reinstal
the

operating
cylinder
in

reverse

sequence
of

removal

1

Bleed
air
out
of

the

hydraulic
system

2

Adjust
the

push
rod
so
that
the

withdrawal
lever
end

play
is
0
to
2
0

mm
0

0394

to
0
0787
in

in

accordance

with
the

following
instructions

AD
USTING
WITHDRAWAL
LEVER

Correct

adjustment
of

the
clutch
withdrawal
lever
is

essential

Insufficient
free
travel
between
the
release

bearing
and
the

diaphragm

spring
fingers
causes
the
clutch

to

slip
while
excessive

free
travel
affects
full

disengage

ment
of
the
clutch

The
clearance
between
the
release

bearing
and
the

diaphragm
spring

fingers
can
be

adjusted
at

the
with

drawallever
end

as
follows

Hydraulic
clutch

Loosen

the
lock

nut
tighten
the

adjusting
nut
and

eliminate

clearance
between
the

top
of

the
withdrawal

lever
and
release

bearing

2
Return
the

adjusting
nut
from

that

position
I
4

turns
and

set
the

adjusting
nut
stationarily
with
the
lock

nut