transmission DATSUN PICK-UP 1977 Service Manual

m
W

D
to
l
l
0
c
l
l
s
Q
3
For
Automatic

Transmission
LB

B

For
Manual
Transmission

m
For
Automatic
Transmission

COLOR
CODE

B
Black

BI
Brown

G
Green

L
Blue

Lg
Light
green

R
Red

W
White

Y
Yellow

BW
Black
with
white
stripe

LgR
Light
green
with
red
stripe
BY
RB
RB

B
WB
RB

YB
2
RB
I
B

1

BW
r
BY

LB

For
Automatic

Transmission
to

o
c
m
r0

O
O
Dl

For
Manual

Transmission
@
CJ
lti
3

RB
fB

BY
YB
RB@RB
YB
BY

1
To
kickdown
solenoid

fOT
Automatic
Transmission

2
To
reverse
switch

for
Manual
Tranmission

3
To
inhibitor
switch

for
Automatic
Transmission

4
To
oil
pressure
switch

5
To
starter
motor

6
To
engine
room
harness

for
Manual
Transmission

7
To
engine
room
harness

for
Automatic
Transmission

Water
in
the

system
will

ice
the

orifice
when
the

high
pressure
re

frigerant
is

changed
to
low

pressure

refrigerant
by

expansion
valve
etc

and
will
obstruct
the

refrigerant

flow

The

following
items

are

general

instructions
to
be

closely
observed
in

servicing
the

system

I
When
a

system
line
is

discon

nected

plug
the

opening
immediately

This
is

especially
necessary
to

prevent

moisture

condensation
from

forming

in
the
line
and
to

keep
out
dirt
and

dust
It
is
also

necessary
to

keep
the

line
at
and
above

surrounding
air

temperatures
at
all

times
When

con

necting
system
lines
do

not

attempt

to
remove
the

plug
from
the

opening

until

ready
for
immediate
use

2

Always
keep
the

working
place

clean
and

dry
and
free
from
dirt
and

dust

Wipe
water
off
with
a
clean

cloth

3
Have
all

necessary
tools
in

pre

paration
beforehand

and
have

tools

clean
and

dry

4
The

compressor
oil
will

easily

absorb
moisture
when

exposed
to
air

Immediateiy
close
the

opening
of
the

container
after
use
It
is
also

necessary

to
observe
the

following
notes

Notes

a
The
oil
should
not
be
transfused

from
a
container
into

another
as

the
failure

will

possibly
cause
mois

ture
to
mix

with
the
oil

b
The

used
oil
should
not
be

returned

into
a
container

c

The
oil

should
not

be
used
if
its

state
of

preservation
is

not
clear

enough

5
When

connecting
or

disconnect

ing
pipes
from
the

refrigeration
sys

tem
use
two

wrenches
One
wrench
is

used
for

holding
the

fixing
nut

in

place

while
the

other
for

turning
the

mating

flare

nut
Failure
to
do

so

may
result

in
a

twisted
tube
or

may
damage

connection

6
Also
use
care
not
to

give
scratches

to
the

seating
surface
at
connections

A

small
scratch
on

the

seating
surface
Air

Conditioning

may
be
the
cause
of

gas
leakage

Before

connecting
pipes
be
sure
to

give
coating
of

compressor
oil
to
the

sea

ting
surfaces

SAFETY

PRECAUTIONS

I

Since
direct

contact
of
the

liquid

refrigerant
with

your
skin
will
cause

frostbite

always
be
careful

when

handling
the

refrigerant
Wear

gloves

or

wrap
a

piece
of
cloth
around
service

valve

to

protect
your
fingers
against

frostbite

by

refrigerant
If

any
of
the

refrigerant
should

get
into

your
eyes

when

charging
the

refrigerant
splash

your
eyes
with

cool
water
to
raise

the

temperature
gradually
Apply
a

protec

tive

film
to

the

eye
to

avoid
infection

Do
not
rub

your
eyes
Consult
an

eye

specialist
Always
wear

goggles
or

glasses
to

protect
your
eyes
when

working
around
the

system
Should

refrigerant
strikes

your
body
splash

on
cool
water
and

apply
a

protective

film

2
The

refrigerant
service
container

has
a

safe

strength
However
if
han

dled

incorrectiy
it
wili

explode

Therefore

always
follow
the
instruc

tions
on
the

label
In

particular
never

stpre
it
in

a
hot

location
above

S20C

l250F
or

drop
it
from

a

high

height

3
The

refrigerant
gas
is

odorless
and

colorless
and

breathing
may
become

difficult

due
to
the

lack
of

oxygen

Since
the

refrigerant
gas
is

heavier
than

air
and

will

lay
close
to
the
floor
be

especially
careful
when

handling
it

in

small

confined

spaces

4

The

refrigerant
itself
is
nonflam

mable
However
a

toxic

gas

phosgene

gas
is

produced
when
it

contacts
fire

and

special
care
is
therefore

required

when

checking
for

leaks
in

the

system

with

a
halide
torch

5

Do
not
steam

clean
on
the

sys

tern

especially
condenser
since
exces

sively
high
pressure
will
build

up
in

the

system
resulting
in

explosion
of
the

system

The

above

precautions
are
essential

in

handling
of

Refrigerant
l
2
and

their
strict
observation

requires
suffi

AC
9
dent

training
Therefore
it
is

of
first

importance
that

any
other

personnel

than
a
well
trained
serviceman
should

not
be

allowed
to
handle
the

refrig

erant

EVACUATING

AND

CHARGING
SYSTEM

During

servicing
use
caution
to

keep
air

from

getting
into

refrigerant

When
air

enters
the

system
all

refriger

ant

must
be
evacuated
from

system

prior
to

charging
new
refrigerant
Air

in

refrigerant
has
the

following
delete

rious

effects

I

Since
the
condensation

tempera

ture

of
the
air
is

extremely
low
the
air

will

not
be

condensed
when

refrigerant

gas
is
condensed

in
the
condenser
and

the

air
will

thus
remain
in

gaseous

form

Consequently
the
effective

thermal

transmission
area

of
condenser

for

refrigerant
gas
will
be
red
uced
and

refrigerant
gas
to
be
condensed
will
be

red
ueed
The

pressure
rise
will
become

proportional
to

the
volume
of
the
air

in

system

2

When
air
and

refrigerant
are

mixed
in

system
a
chemical
reaction

will
be

produced
and

hydrochloric

acid
which
will

adversely
affect
the

aluminum

copper
iron
and
other

materials
in

system
may
be

generated

HANDLING
MANIFOLD

GAUGE

The

pressure
at
the

high
and
low

sides
of

system
should
be

measured

when

evacuating
and

charging
refrig

erant
and
when

diagnosing
trouble
in

the

system
The
manifold

gauge
is
used

for
these

purposes
A

manifold

gauge

has
two

pressure
gauges
a

low

pressure

gauge
and
a

high
pressure
gauge
These

gauges
are

connected
to

the

high
and

low

side
service

valves
of

system

through
flexible

charging
hoses

The

construction

of
manifold

gauge
is

shown
in

Figure
AC
13

When
valve
stem
is

fully
screwed

the
valve
is
front
seated
and
valve

path

and
the
center

path
are
blocked
When

valve
stem
is

backed
off
the

paths
are

opened

INSPECTION

Evaporator

Check

evaporator
for

leakage
or

damage
If

damaged
replace

Expansion
valve

Check

expansion
valve
for

leakage

or

clogging
If

clogged
clean
filter
in

expansion
valve
If

damaged

replace

RECEIVER
DRYER

AND

PIPING

REMOVAL
AND

INSTAUATION

Receiver
dryer

I
Disconnect

battery
ground
cable

2

Discharge
system
Refer
to

Dis

charging
System
under
General
Service

section

3

Disconnect

compressor
lead
wire

at

connector

4

Disconnect

cooling
pipes
at

joints

Acno

Fig
AC
39

Diaconnecting
coo

ing

pipes

Notes

a

Plug
all

piping

joints
immediately

after

pipe
disconnection
to

prevent

entry
of
dust
or
moisture
laden
air

into

receiver

dryer
or
air
aJOdi

tioning
system

b
Use

two
wrenches
when
dIsconnect

ing
cooling
pipes

5

Remove
four
screws

securing

receiver

dryer
bracket

to
vehicle

body

and
detach

compressor
relay
and

pres

sure
switch
as
an

assembly

6
To

install
receiver

dryer
and

piping
reverse
the
order
of
removal
Air

Conditioning

Notes

a

Apply
a
coat
of
fresh

compressor

oil
to

sealing
surfaces
when
con

necting
cooling

pipes

b
Use
two
wrenches
when

connecting

cooling
pipes

c

Evacuate

cooling
system
then
re

charge
with

refrigerant

Refer
to

Evacuating
and

Checking

System
under
General
Service

sec

tion

d
Check

refrigerant

leakage
if
neces

sary
repair

Refer
to

Evacuating
and

Charging

System
under

General
Service
See

tion

Condenser

Disconnect

battery

ground
cable

2

Discharge

system
Refer

to
Dis

charging
System
under
General

Service

section

3
Drain

engine
coolant

4

Remove
radiator

grille

5

Remove

radiator

shroud
and

radiator

On
automatic
transmission

models

disconnect
both

torque
converter
oil

hoses

Note

While

cooling
water
is
hot

take

precautions

against
scalding

6
Disconnect
two

pipes
from

con

denser
remove
two

screws

securing

condenser

Condenser

can
now
be

removed

AC485

Fig
AC

40

Removing
conden
er

Notes

a
Use

two
wrenches
when
disconnect

ing
pipe

joints

b

Plug
openings
immediately
after

disconnecting
pipes

7

To
install

reverse
the
order
of

removal

AC

29
Tightening
torque

Flare
nut
for

copper
tube

from

compressor

2
5
to
4
0

kg
m

i8
to
29
ft
Ib

Flare
nut

for

copper
tube

to
receiver

dryer

2
5

to
3
5

kg
m

i8
to
25
ft
lb

Notes

a
When

disconnecting
and

connecting

cooler

pipes
be
sure
to

use
two

wrenches

b

Apply
a
coat
of
fresh

compressor

oil
to

sealing
surfaces
when

con

necting
cooler

pipes

c

To

prevent

possibility
of

explosion

due
to

high

pressure
within

cooling

system
do

not
clean
condenser

with
steam

Always
use
cold
water

or

cold

compressed
air

d
Evacuate

cooling
system
then
re

charge
with

refrigerant

Refer
to

Evacuating
and

Charging

System
under
General

Service
sec

tion

e
Check

refrigerant
leakage
if
neces

sary
repair
Refer
to

Checking
for

Leaks
under
General
Service

sec

tion

INSPECTION

RecelYer

dryer

Check
for

refrigerant
leakage
or

damage

Check
for

proper
connection
of

two

lead
wires

running
to

pressure

switch

If

any
component

part
is
found

damaged
replace
receiver

dryer
and

pressure
switch
as

an

assembly

Condenser

I

Check

inlet
and
outlet

pipe
joints

and

sealing
surfaces
for

damage
Re

place
parts
if

damaged
or

leaky

2

Clogged
condenser
fins
or

air

pas

sages
may
reduce

cooling
efficiency
of

condenser
Clean
these

areas
with

dry

compressed
air

Piping

Check

piping
for

leakage
If

leakage

occurs
at
connections

retighten

connecting
nuts

Replace
if

leakage

persists

GENERAL

DESCRI
PTION

Special
Tools

play
very
important

role
in

the
maintenance

of
vehicles

These
are

essential
to
the
safe

accu

rate
and

speedy
servicing

The

working
times
listed
in
the
col

umn
under
FLAT
RATE

TIME
in

FLAT
RATE
SCHEDULE
are
com

puted
based
on

the
use
of

Special

Tools

The
identification
code
of
mainte

nance
tools
is

made

up
of
2

alpha

betical
letters
and

8

digital
figures

The

heading
two
letters

roughly

classify
tools
or

equipment
as
fol

lows

STOOOOOOOO

KVOOOOOOOO
Special
Tool

Special
Tool

Recently
established

Engine
Overhauling

Machine

General

Gauge

Hand
Tool
EMOOOOOOOO

GGOOOOOOOO

HTOOOOOOOO

HOW
TO
READ

SPECIAL
TOOL
LIST

APPLIED
VEHICLE
OR
UNIT

In
this

column
word
All
is

given

for
tools

applicable
to
all
vehicle
mod

els
and
unit

types
treated
in

this
manu

al
for
tools

applicable
only
to

particu

lar
models
or
units

those
vehicle

models
or
unit

types
are
indicated

NEWLY
ADDED

X

put
in
this
column
shows

newly
added
tools
Service

Equipment

SERVICE
EQUIPMENT

CLASS

Indicated
in
this
column
are

classi

fication

ftg1ll
es
in

accordance
with

Classification
of

Speciai
Tool
REMARKS

As

regards

special
tools
which
are

also

applicable
to
models
other
than

those
dealt
ith
U

this
m
inual
this

coluITUl
names
those
other
models

CLASSIFICATION
OF
SPECIAL

TOOL

I

Inspection
and
minor

repairs

11
General

disassembly
and

assembly

Ill

Special
disassembly
and

assembly

A

Important

a
Exclusive
with

no
alternative

b

Parts
will
be

damaged
if

repaired

without

special
tool

c

Gauges

B

General

To
facilitate

servicing

I

Inspection
and
minor

repairs

a

Inspection
and
maintenance

b
Unit

replacement

c
Minor

unit

disassembly

SPECIAL
TOOL
SET

See

attached
tool
list

The
set
is

available
for
new

and

other
dealers
who

must

go
through

initial

preparation

SET
77
620NA

KV00102000

This
set
is

designed
for
the

chassis

and

body
of
the

620
models
without

regard
to
their
destination

SE
2
Classification

Important
General

2

3
4

5

6

11

General

disassembly
and

assembly

General

disassembly
such
as

engine

transmission
and

differential

111

Special
disassembly
and

assembly

a

Disassembly
of

exclusive

parts

such
as
automatic
transmission

and

electrical
accessories

b

Special
work
such

as

boring
and

welding

c

Work

very
rarely
required

SET
3N71B
KV0010l000

This
set
is

designed
for
use

on
the

3N71B
automatic

transmission
It
con

sists

of
the
same
service
tools
as
those

previously
available

separately

Service

Equipment

CHAssis
AND
BODY
TOOL

Applied
Ser
17
620NA

No
Tool
Number
Tool
Name

vehic
1e
Newly

Class
Remarks

added

or
unit
KYOO
1
02000

Clutch

5Tl
66
1000
I

Pilot

bushing
puller
All
X
3
610
710
530

KV30100200
Clutch

aligning
bar
All
X
2

610
710
530

5T200500
10
Base

plate
All
X
5

B210
610
710
530

5T20050100
Distance

piece
All
X
5

B210
610
710
530

5T20050051
5et
bolt
All
X
5

B210
610
710
530

5TZ0050240

Diaphragm
adjusting
wrench
All
X
5

B210
610
710
530

GG943
10000
Flare
nut

torque
wrench
All
X
2
FIO
B210
610
710

530

2
Manual

transmission

5TZ2360002
DriftC
All
X
2

B21O
530

5T23540000
Fork
rod

pin
punch
All
X
2
FIO
B210
610
710

530

5T23800000
Transmission

adapter
All
X
2
FIO
B210
610
710

530

5T23810001

5etting
plate
adapter
All
X
5
530

5T22520000
Wrench
All
X
2

B2iO
530

5T23860000
Counter

gear
drift
All
X
2
530

KV311
00400
Transmission

press
stand
All
X
5
530

5T30031000

Bearing
puller
All
X

2
FIO
B210
610
710

530

KV32101330

Bearing
puller
FSSW71B
X
X
2
B21O
530

3
Differential

ST063
I
0000
Diff

attachment
All
X
5

610

ST31530000
Drive

pinion
flange
wrench
All
X
2

B210
610
710
S30

ST3306S001
Diff
side

bearing
puller
All
X
2
610
S30

ST33051001
Puller

ST3306
I
000

Adapter

ST3090S000
Orive

pinion
rear

bearing
inner

race

All
X
2
610
S30

replacer

ST30031000
Puller

ST3090
1000
Base

ST33230000
Diff
side

bearing
drift
All
X
2
610

ST3194S000
Drive

pinion
setting
gauge
ass

y
All
X

2
610

ST3l941000

Height
gauge

5T3l942000

Dummy
shaft

SE
4

Service

Equipment

AUTOMATIC
TRANSMISSION
TOOL

Applied
Set
3N71B

Newly

Tool
Number
Tool

Name
vehicle

Class
Remarks

added

or
unit

KVOOlO1OOO

ST07870000
Transmission

case
stand
All
X
3

ST2505S001
Oil

pressure
gauge
set

All
X
I

ST25
I

60000

Torque
driver
All
X
3

ST2532000l

Snap
ring
remover
All
X
3

ST25420001
Clutch

spring
compressor
All

X
3

ST25490000
Socket
extension

All
X
3

ST2557000l
Hex

head
extension

All
X
3

8210
610
710
S30

ST25580000
Oil

pump

assembling
gauge
All
X
3

ST25850000

Sliding
hammers

All
X
3

GG930
I

0000

Torque
wrench

All
X

3

HT6
I
000800

Hexagon
wrench

All
X
3

HT62350000

Spinner
handle
All
X

6

HT69860000

Snap
ring
remover
All
X
3

SE
6