engine DATSUN PICK-UP 1977 Service Manual

Automatic
Transmission

TROUBLE
SHOOTING
GUIDE
FOR
3N71B
AUTOMATIC

TRANSMISSION

Order
Test
item

Checking
Oil
level

gauge

2
Downshift
solenoid

3

Manuallinkage

L

4
Inhibitor
switch

5

Engine
idling
rpm

6
Vacuum

pressure
of

vacuum

pipe

7

Operation
in
each

range

8

Creep
of
vehicle

Stall
test
I

Oil

pressure
before

tesling
1

2
Stall
test

3
Oil

pressure
after

testing

Road
test
Slow
acceleration

I

st
2nd

2nd
3rd

2

Quick
acceleration

lst
2nd

2nd
3rd

3

Kick
down

operation

3rd
2nd

or

2nd
1st
Procedure

Check

gauge
for
oil
level
and

leakage
before
and

after
each

test

Check
for
sound
of

operating
solenoid
when

depressing

accelerator

pedal
fully
with

ignition
key
ON

Check

by

shifting
into

P
lR
IN
D
2
and
I

ranges
with
selector
lever

Check

whether
starter

operates
in
N
and
p

ranges
only

and
whether
reverse

lamp
operates
in

R
range
only

Check
whelher

idling
rpm
meet

standard

Check
whether

vacuum

pressure
is

more
than
450

mmHg

in

idling
and
whether
it

decreases
with

increasing
rpm

Check
whether
transmission

engages
positively
by
shifting

N
0
N

2
N

l
I
and
N
R

range

while

idling
with
brake

applied

Check
whether

there
is

any
creep
in
D
2

R

ranges
and

Measure
line

pressures
in
D
2
I
and
R

range
while

idling

Measure

engine

rpm
and
line

pressure
in
D
2
I

and

R

ranges
during
full
throttle

operati
n

Notes

a

Temperature
of

torque
converter
oil
used
in
test
should

be
from
600

to
1000C
1400
to
2120F
i
e

sufficiently

warmed

up
but
not
overheated

b
To
cool
oil

between
each
stall
test
for
D
2
I

and
R

ranges
idle

engine
i
e

rpm
at
about
1
200

rpm
for
more
than
1
minute
in
P

range
Measurement

time
must
not
be
more
than
5
seconds

Same
as
item
I

Check
vehide

speeds
and

engine
cpm
in

shifting
up
Ist

2nd

range
and
2nd
Jo3rd
range
while

running
with
lever
in

D

range
and

engine
vacuum

pressure
of
about
200

I11I1lHg

Same

as
item
1
above

except
with

engine
vacuum
pressure

of
0

mmHg
i

e
in

position
just
before
kickdown

Check
whether
the
kickdown

operates
and
measure
the
time

delays
while

running
at
30
40
50
60
70
km
h
18
25
30

37
43
MPH
in

D3
range

AT

57

Automatic
Transmission

Order
Test
item

4
Shift
down

Dr
O2
0

5

Shift
down

DJ
12
1

6
Shift
down

DJ
2

7
Shift

up

I

12

8
Shift

up
or
down
when

start

iog
in

2

range

9

Parking

Others
Abnormal
shock
oil

leakage
Procedure

Check
vehicle

speeds
and

engine
rpm
in

shifting
down
from

3rd
2nd
I

st

sequentially
while

coasting
with

accelerater

pedal
released
in

D3
range
and

engine
vacuum

pressure
of
about
450

mmHg

Check
for

shifting
down

OJ
12
and

engine
braking
and

further
for

shifting
down

12
I
and

engine
braking
after

shifting
the
lever
into

I

range
with
the
accelerator

pedal

released
and
the

engine
vacuum

pressure
of
0

mmHg
while

driving
at
about
50
km
h

30
MPH
in

OJ
range

Check
for

quick
shifting
down

0
2
and

engine
biaking

after

shifting
the

lever
into
2

range
while

driving
at
about

50
km
h
30
MPH
in

OJ
range

Further
check
for

locking
of
the

transmission
in

2nd

gear

ratio

regardless
of
vehicle

speed

Check
for
failure
of
the
transmission
to
shift

up
during

acceleration
when

starting
in
I

range

Check
the
transmission

for
not

shifting
up
or
down

during

acceleration
or
deceleration
when

starting
in

2

rang

Confirm
that
vehicle
will
not
move
on

grade
when

shifting

to

P

range

Enter
into
record
conditions
observed

during
these
tests

such
as

gear
noise

abnormal
clutch
noise
and

acceleration

performance

AT
58

Automatic
Transmission

SERVICE
DATA
AND
SPECIFICATIONS

General

specifications
AfT

Torque
converter

Type

Stall

torque
ratio
Symmetrica13
element
I

stage

2

phase
torque
converter

2
0
I

Transmission

Type

Control
elements

Multiple
disc
clutch

Band
brake

Multiple
disc
brake

One

way
clutch

Gear
ratio

1st

2nd

3rd

Reverse
3

speed
forward
and

one
speed

reverse
with

planetary
gear
train

2

I

I

I

2

458

1458

1

000

2
182

Selector

positions
P
Park

R

Reverse

N
Neutral
Transmission
is

placed
in

neutral

Output
shaft
is

fIXed

Engine
can
be
started

Backward

running

Transmission
is
in

neutral

Engine
can
be

started

Up
or
downshifts

automatically
to

and
from
I

st
2nd
and

top

Fixed
at
2nd

Fixed
at
low

or
downshifts
from

2nd
o
Drive

2
2nd
lock

I
Lock

up

Oil

pump

Type
Internally
intermeshing
involute

gear
pump

Number
of

pump

Oil
Automatic
transmission
fluid

DEXRON

type

5
5

liters

SUU
s

qt
4Ulmp
qt

Approximately
2
7
liters

2UU
s

qt
2XIrnp

qt

in

torque
converter

Controlled

by
measuring
the

nega

tive

pressure
of
intake
manifold

and
the
revolution
of

output
shaft

Forced
lubrication

by
an
oil

pump

Water
cooled

by
a
circulation

type

auxiliary
cooler

located
at
the

radiator
Capacity

Hydraulic
control

system

Lubrication

system

Cooling
system

AT
59

Automatic

Transmission

Engine

Idling
and

stall

revolution

Idling
revolution

Stall

revolution
rpm

rpm
6S0
ai
0

position

2

000
to

2

200

TIghtening
torque

kg
m
ft
lb

Drive

plate
to

crankshaft

Drive

plate
to

torque
converter

Converter

housing
to

engine

Transmission
case
to

converter

housing

Transmission
case
to

rear
extension

Oil

pan
to
transmission

case

Servo

piston
retaine
T

to

transmission
case

Pislon
slem
when

adjuting
band
brake

Piston

stem
lock
nut

One

way
clutch
inner

race

to
transmission

case

Control
valve

body
to

transmission
case

Lower
valve

body
to

upper
valve

body

Side

plat
to

control
valve

body

Nut
for
control
valve

reamer
bolt

Oil
strainer

to
lower

valve

body

Governor

valve

body
to

oil
distribu
tor

Oil

pump
housing
to

oil

pump
cover

Inhibitor
switch
to
transmission

case

Manual
shaft
lock
nut

Oil
cooler

pipe
to
transmission
case

Test

plug
oil

pressure
inspection
hole

Support
actuator

parking
rod

inserting
position
to

rear
extension

I

Oil

charging
pipe
to
case

Dust

cover

to
converter

housing

Selector

range
lever
to
manual
shaft
14

0
to

16
0
101
to

116

4
0
to
5
0

29
to

36

4
0

to
S
O

29
10

36

4
S
to
5
5

33
to

40

2
0
to

S

14
to
18

O
S
to

0
7

4

to
S

O

S
to

0
7
4
to
S

1
2
to
1
5

9
to
11

1
5
to
4
0

I
I

to
29

1
3
to
1

8
9

to
13

0

5S
to
0
75
4
to
S

0
25

to
O
3S

2
to
3

0

25
to

0
35
2
to
3

O

S
to

0
7
4
to
S

0

25
to
0
35

2
to
3

D
S

100
7
4
to
5

0

6
to
0

8
4
to
6

0
5
to

0
7
4
toS

3
0

to
4

0
22

to
29

3
0
to

S
O

22
to

36

I
4to
2
1

10
to
IS

0
8
to
I
1
6
to
8

O
5S
to
0
7S

4
to
S

O
5S
to

0
75
4
to
S

3
0
to
4

0
22
to
29

Turn

back
two

turns
after

tightening

AT
61

PROPELLER

SHAFT

DIFFERENTIAl

CARRIER

TROUBLE
DIAGNOSES

AND

CORRECTIONS

When
a
differential
carrier
is

sus

pected
of

being

noisy
it
is

advisable
to

make
a

thorough
lest

to
determine

whether
the

noise

originates
in
the

Condition

Noise

on
drive

coast

and
float

Noise
on
turn

Knocking
sound

during

starting
or

gear

shifting
tires

road
surface

exhaust
universal

joint
propeller
shaft
wheel

bearings

engine
transmission

or
differential

carrier

Noise
which

originates
in

other

Probable
cause

Shortage
of
oil

Incorrect
tooth
contact

between

ring
gear

and
drive

pinion

Incorrect
backlash
between

ring
gear
and

drive

pinion

Seized

up
or

damaged
ring

gear
and
drive

pinion

Seized

up
damaged
or

broken
drive

pinion

bearing

Seized

up
damaged
or
broken
side

bearing

Loose
bolts
or
nuts

fIXing
ring
gear
bearing

cap
etc

Seized

up
damaged
or
broken
side
and

pinion
mate

Seized

up
damaged
or
broken

side

gear
and

pinion
thrust
washer

Pinion

mates
too

tight
on

their
shaft

Excessive
backlash

Incorrect

backlash

ring
ar

to
drive

pinion
or
side

gear
to

pinionmate

Worn

gears
or
case

Worn
rear

axle
shaft
and

side

gear
spline

Drjve
pinion

bearing
under

p
reload

Loose
drive

pinion
nut

Loose
bolts

or
nuts

ftxing
ring
gear

bearing

cap
etc

PD

14
places
cannot
be
corrected

by

adjust

ment
or

replacement
of

parts
in
dif

ferential
carrier

Corrective
action

Supply
gear
oil
Rebuild

gear
carrier
if

necessary

Adjust
tooth
contact

or

replace
the

hypoid

gear
set

Adjust
backlash
or

replace
the

hypoid
gear

set

if

necessary

Replace
the

hypoid

gear
set

Replace
the

pinion

bearing
and

faulty

parts

Replace
the

side

bearing
and

faulty
parts

Clamp
them

to

specified

torque
and

replace

faulty
parts

Replace

faulty
parts

Replace

faulty
parts

Replace
faulty
parts

Adjust
backlash

Replace
worn

parts

Replace
worn

parts

Adjust
preload

Repair
or

replace

Clamp
them
or

replace
if

necessary

Note
When

installing
fulcrum

pin

insert
it

from
rearward

of
vehicle

12

Install

tension
rod
shock
ab

sorber

I
stabilizer
torsion

bar

spring

and

knuckle
arm

referring
to
the

related

paragraphs

13

Install
brake
disc

to
knuckle

spindle
and

torque
securing
bolt
to
4
2

to
5

0

kg
m
30

to
36
ft
Ib

14

Install
wheel
and
brake

drum
as

an

assembly
and

torque
knuckle

spin

dle

nut
to
8
0

to
9
0

kg
m
58
to
65

ft
Ib

DISASSEMBLY

AND

ASSEMBLY

Upper
link

I

Detach

upper
link

spindle
from

upper
links
and

remove

clamp
dust

cover
and
dust
seal
Secure

upper
link

in
a
vise
and

loosen
screw

bushing

Assemble
link

spindle
in
reverse

sequence
to

disassembling
noting
the

following
instructions

2

Torque
screw

bushing
on

upper

link
to
3S
to

55

kg
m
253
to

398

ft
Ib

Install
new
dust
seal
and
dust

cover
and
secure
them
with

clamp

3

Coat

grease
to

screw

bushing
in

side
and
the
thread

portion
of

upper

link

spindle

liberally
Screw
front
and

rear
links
to

upper
link

spindle
in
the

same

length
so
as
to
obtain

the

speci

fied

figures
as
shown
in

Figure
FA

23

Unit
mm
in

I

44

6
1
156
FA2

Upper
link

and

upper
link

spindle
Fig
FA
23
Front
Axle
Front

Suspension

4

Make
sure
to

operate
upper
link

spindle
smoothly
after

installation

5

Replace
filler

plug
with

grease

nipple
and

pack
grease
until

grease

comes
out
from

dust
cover

Reinstall
f1ller

plug

Lower
link

When

installing
torque
arm
on

lower
link

tighten
it

to
the

following

specifications

Serration
boss

1
8

to
2

6

kg
m

13
to

19
ft

Ib

Arm

head

2
7

to
3
7

kg
m

20
to

27
ft
tb

INSPECTION

Upper
link

spindle
fulcrum

pin

and
screw

bushing

Apply
screw

bushing
to

upper
link

spindle
or
fulcrum

pin
and
measure

axial
end

play
between

them

When
the
end

play
exceeds
0
35

mm
0

0138
in

replace

upper
link

spindle
or
fulcrum

pin
together
with

screw

bushings

Condition

Vehicle

empty
no

payload

Vehicle
loaded

Notes

a
Vehicle

empty
no

payload
consists

of
the

following
conditions

I
Full

tank
of

gasoline
radiator

f1lled
and

engine
oil
level
full

2

Spare
tire
wheel

jack
and

jack

handle
in

design
position

b
Vehicle
loaded
consists
of
the
fol

lowing
conditions

For
all
models
2

persons
and
SIlO

leg
I
103lb

payload

FA
Check
the
screw
of

upper
link

spindle
fulcrum

pin
and
screw
bush

ing
and

repair
or

replace
if

necessary

Note

Discard
dust
cover
and

dust
seal

when
disassembled

ADJUSTMENT

VEHICLE
POSTURE

Vehicle

posture
may
be
incorrect

due

to
weakened

spring
or

other

faulty

condition
The

following
procedures

are

necessary
when

adjustment
is

Ie

quired

That
is

the
vehicle

posture
can
be

adjusted
by

obtaining
only
the

speci

fied
H

dimension

changing
the

length
of
anchor
bolt

I

Raise
front
of
vehicle

on
stands

2

Adjust
H

dimension
with

turn

ing
nut

adjusting
anchor
bolt
H

dimension

changes
approximately
3
5

mm
0

J38
in

vertically
when

adjust

nut
is
turned

one

complete
turn

3
To

make
the
best

vehicle

posture

H
dimension
must
be
in
the
follow

ing
range

H

dimension
mOl

in

All
models

79
to

84
3

11
to
3
31

54
5
2

15

o
i

Fig
FA

24
FA242

Dimension

for
standard

vehicle

postl4re

Rear
Axle
Rear

Suspension

Spring
front

pin

Spring
shackle

Bearing
cage

fIXing
bolt

Wheel

bearing
lock
nut

Air
breather

Differential

gear
carrier

to
axle
case
nut

Propeller
shaft

flange
bolt

Drain
and
filler

plug

Bumper
rubber

fixing
bolt

Wheel
nut
kg
m
ft
lb

kg
m
ft
Ib

kg
en
ft
lb

kg
m
ft

Ib

kg
m
ft
Ib

kg
m
ft
Ib

kg
en
ft
Ib

kg
m
ft

Ib

kg
m
ft
Ib

kg
m
ft

lb
11
5
to
13
0
83

to
94

11
5

to
13

0
83
to
94

S
4
to
6
4
39

to
46

IS
to
20
108

to
l4S

0
7

to
0

9
S
I

to
6
S

17
to
2
7

12
to
20

2
0
to

2
7

14
to
20

6
to
10
43

to
72

1
6
to
2
2

12
to
16

8
to
9
S8

to
6S

TROUBLE

DIAGNOSES

AND
CORRECTIONS

When

rear
axle
and

suspension
is

suspected
of

being
noisy
it
is

advisable

to
make
a

thorough
test
to
determine

whether
the
noise

originates
in

the

tires

road
surface
exhaust

propeller
shaft

engine
transmission
universal

joint
wheel

bearings
or

suspension

Noise
which

originates
in

other

places
can
not

be
corrected

by
adjust

ment
or

replacement
of

parts
in
the
rear
axle

and
rear

suspension

In
case
of

oil
leak

first
check
if

there
is

any

damage
or

restriction
in

breather

Condition
Probable
cause

Noise
Loose
wheel
nuts

Loose
one
or

more

securing
bolts

Lack
of

lubricating
oil
or

grease

Faulty
shock
absorber

Incorrect

adjustment
of

rear
axle
shaft
end

play

Damaged
or
worn
wheel

bearing

Worn

spline
portion
of
rear
axle
shaft

Broken
leaf

spring

Loose

journal
connections

or
so
no

Wheel
and
tire

unbalance

Damaged
rubber

parts
such
as
leaf

spring

bush
shock
absorber
moun

ting
bush

Faulty
universal

joints

Instability
in

driving
Loose
wheel
nuts

Worn
shock
absorber

Worn

or
broken
leaf

spring

Oil

leakage

Damaged
or

restricted
air

breather

Damaged
oil
seal
in

rear
axle
case
or
differ

ential
carrier

Oil

leakage
from
between
the
differential

carrier

and
axle
case

RA
8
Corrective
action

Tighten
the

wheel
nuts

Tighten
the

bolts
to
the

specified
torque

Lubricate

as

required

Replace
the
shock
absorber

Adjust
the
rear
axle

shaft
end

play

Replace
wheel

bearing

Replace
if

necessary

Replace
leaf

spring

Tighten
to

the

given
torque

Balance
wheel

and
tire

Replace
the

required
parts

Adjust
or

replace

Tighten
to
the

given

torque

Replace
faulty
shock
absorber

Replace
leaf

spring

Clean
or

replace
air

breather

Replace
the

damaged
oil
seal

Tighten
to
the

specified
torque
or

replace

gasket

f

BR317

Fig
BR
23

Gre
ing
point

4

Tightening

torque

Wheel

cylinder

J
S
to
1

8

kg
m

II
to

13ft
Ib

Connector
bolt

1

9
to
2
5

kg
m

14
to
18
ft
Ib

Brake
tube

1
5
to
1

8

kg
m

II

to
13

ft
Ib

Air
bleeder

0
7
to
0
9

kg
m

S

to
7
ft
Ib

Brake
disc

5
4

to
6
4

kg
m

39
to
46
ft

Ib

S

Adjust
brake
shoe
clearance
and

bleed
brake

system
Upon
completion

of

the
above

adjustments
make
sure

that
brake

operates
correctly
and
no

brake
fluid
leaks

MASTER
VAC

DESCRIPTION

A
vacuum

suspended
Master
Vac

is

installed
behind
the

master

cylinder

As
the

brake

pedal
is

depressed
fluid

is

forced
under

high
pressure
through

the
brake

pipes
to
the
wheel

cylinders

to
retard

or

stop
the

vehicle

The
Master
Vac
contains

a

spring

loaded

diaphragm
of
IS2
4

mm
6
in

in

diameter
It

operates
on

negative

pressure

produced
n
the

engine
intake

manifold

The
tandem

master

cylinder
is

capable
of

producing
high
pressure

even
if
the
Master
Vac
is

faulty
Brake

System

Note
The
Master
Vac

diaphragm
dif

fers
from
fonner
ones
for

improved

braking
force
Do
not
install
fonner

Master
Vac
on
1976
models
The

1

Plate
and
seal

2
Push
rod

3

Diaphragm

4

Rear
shell

5

Diaphragm

plate
Master
Vacs

are
identified

by
the

label
color
as
follows

1976
model
Caution

Label

Former
models
YeJlow

BR321

11

Valve

operating
rod

12
Valve

return

spring

13

Poppet
return

spring

14
Exhaust
valve

15
Valve

plunger

16
Reaction

disc

17

Diaphragm
return

spring

18
Front
shell
6
Seal

7

Vacuum
valve

8

Poppet
assembly

9
Valve

body
guard

10
Air

silencer
filter

INSPECTION
OF

OPERATION

Checking
yscuum

pressure

I
Connect

a
vacuum

gauge
in
the

line
between
check
valve

and
Master

2
Start

engine
and
increase

engine

speed
Stop
engine
when
vacuum

gauge
indicates
SOO

mmHg
19
69

inHg

BR
14
Fig
BR
24
Sectionall1iew

of
Master
Vac

Vac
as

shown
in

Figure
BR
25

1

Check
valve

2

Vacuum

gauge

BA169

Fig
BR

25
Air

tight
t
t
t

up

Air

tight
test

I
Fifteen

seconds
after

engine
is

stopped
observe
the

rate
of

drop
in
air

pressure
registered
by
vacuum

gauge

If
a

pressure
drop
of
25

mmHg
0
98

inHg
is

exceeded
refer
to
the
follow

ing
chart
to
determine
the
cause
of

failure

Probable
cause

I
Air

leakago
at
check
valve

2
Air

leakage
a

t

push
rod
seal

3

Air
leakage
between
valve

body
and

seal

4
Air

leakage
at
valve

plunger
seat

5

Damaged
piping
or

joints

2
Fifteen

seconds
after

engine
is

stopped
and
brake

fully
applied
ob

serve
the

rate
of

drop
in
air

pressure

registered
by
vacuum

gauge

Probable
cause

1
Air

leakage
at
check
valve

2

Damaged
diaphragm

3
Reaction
disc

dropped
off

4
Air

leakage
at

and
valve
body
poppet
assembly
seat

Note
When

replacement
of

any
part

is

required
be
sure
to
renew

Master

Vac
as
an

assembly

Inspecting
check
valve

Remove

clip
and
disconnect
hoses

at
connections

The
check
valve

can

now
be
removed

yr

BA3

Fig
BR
26
Location

of
check
valve

2

Using
a
Master

Vac
tester

apply
a

vacuum

pressure
of

200

mmHg
7
87

inHg
to

the

port
of
check

valve
on
the

Master
Vac
side
If
a

pressure
drop
of

10

mmHg
0
39

inHg
is
exceeded
in
1

I

I

17
I

f
I

I
I

Z
I

I
y1
I

I
I
7
I
I
I

I
I
I

I
I
I

I

y1
II

I

I
I
I
I
I

I
L
I
L

5
to
15

20
25
30
35
40

45
50

55
60

22
44

66

88
110
132

Pedal

operating
force

kg
lb
BR772

Fig
BR
28

Performance
curves

of
Master
Vac
Brake

System

Corrective
action

Replace
check
valve

Replace
seal

Repair
or

replace
faulty

partes

Repair
or

replace
seat

Repair
or

replace

If
a

pressure
drop
of
25

mmHg

0

98

inHg
is

exceeded
refer
to

the

following
chart
to
determine
the
cause

of

failure

Corrective
action

Replace
check
valve

Replace

Reinstall
and
check

push
rod

for

proper
turn

Replace

faulty
part
s

15
seconds

replace
check
valve
with
a

new
one

3
When

pressure
is

applied
to
the

Master
Vac
side
of
check

valve
and

valve
does
not

open
replace
check

valve
with
a

new
one

120
I

7IG

110
1
560

100

I
420

i
90
1
280

I

u

80
1
140

70
1
000

II

60
850

0

0

5

a
50
710

40
570

30
430

20
280

10
140

BR
15
1

I

Manifold

side

Master

Yac
side

1

Spring
2

Valve

BA289

Fig
BR

27
Sectional
view

of
check

valve

Operating
test

1
Connect

an
oil

pressure
gauge
in

brake
line

at
connection
on
master

cylinder

2
Install
a

spring
scale
on
brake

pedal

3

Start

engine
and
increase

engine

speed
until

a
vacuum

pressure
of
500

mmHg
19
69

inHg
is

registered
on

vacuum

pressure

gauge
With
a

vacuum

pressure
of
500

mmHg
19
69

inHg

held

measure
an
oil

pressure
with

respect
to

each

pedal

operating
force

Relationship
between
oil

pressure

and

pedal

operating
force
is
illustrated

in

Figure
BR
28
If

test
results
are
not

as

specified
in

Figure
BR
28
check

Master
Vac
for
condition
in

a
manner

as
described
under

Inspection
before

removal
of
this
unit

Also
check
brake
line
for
evidence

of
fluid

leakage

Note
Determine
whether
malfunc

tion
occurs
in
Master
Vac
or
in

check
valve

Always
inspect
check

valve
fiTlit

ST202

Fig
ST
6

Withdrawing

gear
ann

Note

Before

removing
steering

gear

arm

scribe
match
marks
on
arm

and

housing
so

that

they
can

easily

be

replaced
in
their

original
posi

tions
at

assembly

9
Remove
three

bolts

securing

steering
gear
housing
to
frame

10
Withdraw

steering
gear
assembly

toward

engine
compartment

Installation

Install

steering

gear
assembly
in
the

reverse
order

of
removal

observing
the

following
instructions

I
When

installing

steering

gear

housing

securing
bolts
insert
two
bolts

through
gear
housing
to
frame

2
When

installing
steering
gear
arm

align
four

grooves
of

gear
arm

serra

tions

with
four

projections
of
sector

shaft
serrations

3

Tightening
torque

Steering
gear

housing

4

6
to
S
3

kg
m
33
to
38
ft
lb

Gear
arm

13

to
IS

kg
m
94

to
108
ft
lb

Steering
wheel

7

0
to

7
S

kg
m
51

to
54

ft
Ib

4

With
front
wheels
set
in

a

straight

ahead

position
make

sure
that

punch

mark
on
the

upper
end
surface

of

steering
column
shaft
is

at
the

center

of
the

upper
side
in
its

installing

portion

S
When

installing
steering
wheel

apply
grease
to

sliding
parts

6
After

installing
make

sure
that

steering
wheel
turns

smoothly
STEERING
SYSTEM

Disassembly
and

assembly

Disassembly

I
Drain

oil
in

steering
gear
housing

by
unscrewing
fIller

plug

2
Place

steering
gear
assembly
in
a

vise

securely

3

Loosen
lock
nut
and
turn

sector

shaft

adjusting
screw
a
few

turns
coun

terclockwise

Remove
sector
shaft
cover

by
un

screwing
four

fixing
bolts

rn

ST203

Fig
ST
7

Remouing
sector

haft
couer

4

Turn

sector
shaft

adjusting
screw

a

few
turns
clockwise

and

pull
sector

shaft
cover

together
with
sector
shaft

from

gear

housing

ST204

Fig
ST
B

PuUing
out

ector

haft

S

Separate
sector

shaft

adjusting

screw
and

shim
from
cover

6
Remove

jacket
tube

by
unscrew

ing
three

fixing
bolts

7

Remove

steering
worm

assembly

from

gear

housing

8

Detach

worm

bearings
and

worm

bearing

adjusting
shims
from

worm

gear
assembly
and
column

jacket

Note
Be

careful
not
to
allow
ball

nut

to

run
down
to
the

worm
end
If

ball

nut
rotates

suddenly
to

the

worm

end
the
ends
of
ball

guides

may
be

damaged

ST
4
9

Pry
out
sector
shaft
oil

seal
from

gear

housing
and

discard
it

10
Remove

O

ring
from
the

rear

cover
of
column

jacket
and

discard
it

11

Remove
column

jacket
bushing

Notes

a

Do
not

remove
sector
shaft

bushing

from

housing
If

necessary
replace

as
a

gea2

nousing
assembly

b
Do

not
disassemble

ball
nut
and

worm

geir
If

necessary

replace

them
with
new
ones
as
a

worm

gear

assembly

Fig
ST
9

Removing

steering
worm

assem

bly

Assembly
and

adjustment

Apply
recommended

gear
oil
to
all

disassembled

parts

1

Fit
column

jacket
bushing
to

column

jacket
in

place

Note
When

fitting
apply
adhesive
to

bushing
exterior
and

grease
to
in

terior

2
Fill
the

space
between
new
sector

shaft
oil
seal

lips
with

grease
and
fit
it

to

gear

housing

3
Place

steering
worm

assembly
in

position
in

gear

housing
together
with

worm

bearings

4

Install
column

jacket
on

gear

housing
with
O

ring
and

worm

bearing

shims

Be

sure
to

install
thicker
shims
to

the

gear

housing
side

Standard
shim
thickness

1
5
mOl
0
OS9
in

Tightening

torque

1
5
to
2
S

kg
m
11
to

18
ft
Ib