DATSUN PICK-UP 1977 Service Manual

Manual
Transmission

CD
t

e
I

2

3

4

5

6

7

8

9

10

11

12

13

14

17

18

19

O
20

o

21

24

25
j

@
Striking
lever

Lock

pin

Q

ring

Striking
guide

Oil
seal

Striking
rod

Expansion
plug

Stopper
guide
pin

Return

spring

Return

spring
plug

Return

spring
plunger

Check
ball
plUS

Check

spring

Check
ball

Retaining
pin

Interlock
ball

ist
2nd
shift
fork

1st
2nd
fork
rod

3rd
4th
fork
rod

Reverse
OD
fork
rod

3rd
4th
shift
fork

Revene
OD
shift
fork

Con
trol1ever

Con
trol1cver
pin

Con
trollever
bushing

TM048A

Fig
MT
58
FS5W71B
trammi
ion

shift
control

component

3
Draw
out
counter
drive

gear
com

plete
with
main
drive

gear
assembly
by

means
of

a

gear
puller

When

drawing
out
main
drive

gear

assembly
be
careful
not
to

drop

pilot

needle

bearing
onto
floor
from
the

front
end
of
mainshaft
See

Figure

MT
60
REMOVAL
Same

as
for
the
F4W71B

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

Same
as
for
the
F4W71
B

DISASSEMBLY
OF

GEAR

ASSEMBLY

Fork
rod

Same
as
for
the
F4W71
B

Geer
sembi

I

With

gears
doubly
engaged
draw

out

counte
haft
front

bearing
using
a

suitable

gear
puller
See

Figure
MT
59

2
Remove
counter
drive

gear

snap

ring
TM398

Fig
MT
59

Removing
countershaft

front
bearing

MT
17
TM756

Fig
MT
60
Removing
counter
drive

gear
and
main
drive

gear

4

Rem6vesnap
ring
and
then
thrust

washer
from
mainshaft
front
end

Draw
out
3rd
4th

synchronizer

assembly
and
remove
3rd

gear
assem

bly

5
Remove

snap
ring
and
then
draw

out

speedometer

gear
and

bearing

from
mainshaft
rear
side

6
With

gea
doubly
engaged
re

lease

caulking
on
countershaft
and

mainshaft

nuts
then
loosen
them

Remove
countershaft
nut

TM757

Fig
MT
61

Removing
counterahaft

nut

Note

When

removing
mainshaft
as

sembly
loosen
mainshaft
nut

7
Draw

out
counter
overdrive

gear

and

bearing
from
countershaft
rear

end

by
using
a
suitable

gear
puller
See

Figure
MT
62

TM758

Fig
MT
62

Removing
count
r

overdriv

gear
and

bearing

8
Remove
counter

reverse
idler

gear

and

spacer

9
Remove
countershaft

by
lightly

tapping
the
rear
end
with

a
soft

hammer

Be
careful
not
to

drop
off

gear

shaft

10
Remove
reverse
idler

gear
snap

ring

TM759

Fig
MT
63

Removing
reverse
idler

gear

nap
ring
Manual

Transmission

II
Remove

reverse
idler

gear

12
Remove

snap
ring
of

mainshaft

end

bearing
Draw
out

bearing
using

Mainshaft

Rear

Bearing
Puller

KV32101330

Remove
other

snap
ring

of

mainshafl
end

bearing
See

Figure

MT

64

tw

KV32101330

TM160

Fig
MT
64

Removing

mai
haft

nd

bearing

13

Remove

mainshaft
nut

thrust

washer

mainshaft
reverse

gear
OD

synchronizer
and

overdrive

gear

14
Draw
out

mainshaft

gear
assem

bly
together
with

countershaft

by

lightly
tapping
the

rear
end

with
a

soft

hainmer
Me

holding
the
front

of

mainshaft

gear
assembly
by
hand

Be
careful

not
to

drop
off

gear

shaft
See

Figure
MT
65

k

r
IT

TM761

Fig
MT
65

Driving
out

gear
sembly

Malnahaft

Same
as
for
the
F4W7IB

Main

drive
ear

Same
as
for
the
F4W71

B

Counterahaft

aaaembly

Same
as
for
the

F4W7l
B

REAR
EXTENSION

DISASSEMBLY

Remove
lock

pin
from

striking

lever
and
remove

siriking
rod

Note
Do
not
disassemble

rear
exten

sion

bushing
from
rear
extension

J

l

J

@

1

Striking
lever

2

Striking
rod

3

Stopper

pin

4

Control

lever

5

Striking
rod

guide

6
Reverse
select

plunger

7
Reverse
select

plug

TM767

Fig
MT
66

Exploded
view

of

shifting
mechanilm

MT1B

ADAPTER
PLATE

DISASSEMBLY

Same
as

for
the
F4W71

B

Fig
MT
67

Removing
screws

INSPECTION

Wash

all

parts
in

a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

a
Be

careful
not
to

damage
any

parts

with

scraper

b
Do

not
clean
wash
or
soak
oil
seals

in

solvent

TRANSMISSION
CASE
AND

REAR

EXTENSION
HOUSING

Same
as
for
the
F4W71
B

BEARING

Same

as
for
the
F4W7l
B

GEARS
AND
SHA
S

I
Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure

backlash
in

gears

Main
drive
and

counter
drive

gear

0
05
to
0
10

mm

0
0020
to
0
0039
in

1st

2nd
3rd
5th
and

reverse

gears

0
05
to
0
20
mm

0
0020
to
0
0040
in
Manual
Transmission

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4

Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0

0126
to
0
0154
in

2nd

gear

0
12

to
0
19
mm

0
0047
to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to

0
0146
in

OD

gear
on
mainshaft

0
32

to
0

39
mm

0
0126
to
0

0154
in

BAULK
RING

Same
as
for
the
F4W7IB

OIL
SEAL

Same
as
for
the
F4W71
B

ASSEMBLY

To
assemble
reverse
the
order
of

disassembly
Observe
the

following
in

structions

FRONT
COVER
ASSEMBLY

Same
as
for
the
F4W7l
B

REAR
EXTENSION

ASSEMBLY

I

Wipe
clean
seal

seat
in

rear
exten

sion

housing
press
fit
oil
seal
in

place

Coat
oil
seal
and

bushing
with

gear

oil
for
initial
lubrication
See

Figure

MT
68

Front
r

I

TM355

Fig
MT
68
R
ar
extemion
oil
sea

2

Apply
multi

purpose
grease
to

O

ring
and

plunger

grooves
in

striking

rod

Insert

striking
rod
with

striking
rod

guide
through
rear
extension

MT19
3
Install

striking
lever
on
front
end

of

striking
rod
Install
lock

pin
and

torque
screw
to
0
9
to
1
2

kg
m
7

to

9
ft
lb

4

Install

filainshaft
bearing
by

lightly
tapping
around
it
with
a

soft

hammer

5
Insert

reverse
idler
shaft
in

adapt

er

plate

Make
sure
that
the
cut
out

portion

of
reverse
idler
shaft
is

lined

up
with

inner
face
of

adapter

plate

6
Install

bearing
retainer
in

adapter

plate

Align
bearing
retainer

with
reverse

idler
shaft
at
the
cut
out

portion
of

this
shaft

torque
screws
to
1

9
to
2
5

kg
m
14
to
18
ft
lb
and
stake
each

screw
at
two

points
with
a

punch
See

Figure
MT
69

TM764

Fig
MT
69

Stahing
screw

7
Install
countershaft

rear
bearing

in

adapter

plate
by
lightly
tapping

around
it

with
a
soft
hammer

GEAR
ASSEMBLY

Clean
all

parts
in
solvent
and

dry

with

compressed
air

Synchronlz
r
embly

Same
as
for
the

F4W71
B

Ov
rdrlve
r

ynchronlz
r

mbly

I

Assemble
reverse
OD

synchro

nizer

assembly

2
Assemble
overdrive

gear
assem

bly

Position
synchronizer
ring
band

brake
thrust
block
and
anchor
block

on
overdrive
clutch

gear
install

circlip

Malnshaft

assembly

Same
as
for
the
F4W7IB

Countershaft

assembly

Same
as
for

the
F4W71
B

Main
drive

gear
assembly

Procedures

are
the

same
as
for
the

F4W7IB
trans
i

n

except
as

follows

I

Insert
countershaft
and
mainshaft

into

adapter

plate
and

place
adapter

plate
in

a
vise
with

setting
plate
Manual
Transmission

Synchro

ring

8andbrake

Circlip

Anchor

block

TM449

Fig
MT
70

Imtalling
overdrive

gear
assembly

Install

snap
ring
spacer
needle

roller

bearing
reverse
idler

gear
spacer

and

snap
ring

h
I

L

TM4S1

Fig
MT
71
R
lJerse
idler

gear

MT

20
2

Assemble
OD
reverse

synchro

nizer

assembly
OD

gear
bushing

needle

bearing
OD

gear
assembly

sreel
ball
and

thrust
washer

on
main

shaft
rear
side
Before

installing
steel

ball

apply
grease
to

it

3

Install
new
mainshaft

nut
and

tighten
it

temporarily

4

Install
counter
reverse

gear

counter
5
th

gear

bearing
and
new

countershaft
nut

Tighten
nut
tem

porarily

5

Tighten
mainshafl
and
counter

shaft
nuts
and
stake
nuts
at

groove
in

shafts
with

a

punch
Tightening

proce

dures

for
mainshaft
nut
are
the
same

as
those
for
the
F4W7IB

Shift
forks
and
fork

rods

assembly

Same

as
for

the
F4W71
B

u
TRANSMISSION

ASSEMBLY

Same
as
for

the
F4W71
B

INSTALLATION

Same

as
for

the
F4W71
B

Manual
Transmission

SERVICE
DATA
AND
SPECIFICATIONS

GENERAL
SPECIFICATIONS

Transmission

type
F4W71B
FS5W71B

Synchromesh

type
Warner
1st
to
4th
Warner
5th
Servo

Shift

type
1
3

T

i
i

2
4
R
1
3
5

II

1

2

4
R

Gear
ratio

1st

2nd

3rd

4th

5th

Reverse
3
592

2
246

1
415

1

000

3
657
3
321

2
077

1
308

1
000

0
864

3
382

Final

gear
ratio
4
375
4
375

Speedometer
gear
ratio
20
6

I

7
3
3
20
6

2
0
4X
3
f

Oil

capacity
US

pt
Imp
pt

MT
21

Manual

iTransmission

TIGHTENING
TORQUE

Installa
tion

Engine
to
transmission

installation
bolt

Transmission
to

engine
rear

plate
bolt

Clutch

operating
cylinder
installation

bolt

Rear

mounting
insulator
to

transmission
installation
bolt

Crossmember

mounting
bolt

Propeller
shaft
to
diff
installation
bolt

Gear

assembly

Rear

extension
installation
bolt

Front
cover

installation
bolt

Bearing
retainer
to

adapter

plate
screw

Main
haft
nut

Check
ball

plug

Stri
lever

lock

pin

Reverse
select

return

plug

Speedometer
sleeve

locking

plate
nut

Reverse

lamp
switch

year
oil
Ier

pl
g

Ge
r
oil
drain

plug
Unit

kg
m
ft
lb

4
4

to
5

9
32

to
43

0

9

to
1
2
7
to
9

2
5

to
3
0

18
to
22

0
8
to
1
1
6

to
8

3

2
to
43

23
to
31

2
4

to
33

17
to

24

1

6

to
2
1

12
to
IS

1
6
to
2
1

12to
IS

1
9
to
2
S
14
to
18

14

0
to
17
0

101
to
123

1
9
to
2
S

14
to
18

0
9
to
1
2

7
to
9

0
9
1
2
7

to
9

0
4

to
O
S

3

to
4

2
0
to
3
0

14
to
22

2
S

to
3
5

18
t02S

2
S

toTS

l8
to
2S

or

SPECIFICATIONS

Gear
backlash

Maindrive

gear
to
counter
drive

gear

1st

gear

2nd

gear

3rd

gear

OD

gear

Gear

end

play

1st

gear

2nd

gear

3rd

gear

OD

gear

Counter

gear

Reverse
idler

gear

Clearance

between
baulk

ring
and

gear

All

gears

Counter

bearing

adjusting
shim
Unit

mm
in

0
05
to
0

10
0
0020
to

0
0039

0
05
to
0

20
0
0020
to
0
0079

O
OS
to
0
20
0

0020
to
0
0079

0
05
to
0
20
0
0020
to
0
0079

0
05
to
0

20
0
0020
to
0
0079

0
32
to
0
39

0
0126
to
0
0154

0
12
to
0
19

0
0047
to
0

0075

0
13
to
0
37
0
0051
to
0
0146

0
32
to
0
39

0
0126
to
0

0154

0
01
to
0
21

0
0004
to
0
0083

0
05

to
0
20
0
0020

to
0
0079

1
25
to
1

60
0
0492
to
0
0630

0
6
0
024

0
5
0
020

0
4
0

016

0
3
0
012

0
2
0
008

0
1

0
004

MT
22

Manual
Transmission

I

TROUBLE
DIAGNOSES
AND
CORREGTIONS

Condition

Difficult
to

intel11lesh
gears

Causes
Jor
difficu
t

gear
shifting
are
classi

fied
to
troubles

concerning
control

system

and
transniissioo
When

gear
shift
lever
is

heavy
and
it
is
difficult
to
shift

gears
clutch

disengagement
may
also
be
unsmooth
First

make
sure
that

clutch

operates
correctly

and

inspect
transmissi
o

Gear
slips
out
of
mesh

In
most
cases
this
trouble
occurs
when

interlock
b
all
check
ball
and

or
spring
is

worn
or
weakened
or

when
control

system

is

faulty
In
this
case
the

trouble
cannot
be

corrected

by
replacing
gears
and
therefore

trouble

shooting
must
be

carried
out

care

fully
It
should
also
be

noted
that

gear
slips

out

of
mesh
due
to
vibration

generated
by

weakened
fron
t
and
rear

engine
mounts

Noise

When
noise
occurs
with

engine
idling
and

ceases
when

clutch
is

disengaged
or
when

noise
occurs
while

shifting
gears
it
is

an

indicati90
that
th
e
noise
is

from
transmis

sion

t
Transmission

may
fa
ule

during
engine

idling

Check
air

fuel
mixture
and

ignition

timing

After
above

procedure
readjust
engine

idling
Probable

cause

Worn

gear
shaft
and
or

bearing

Insufficient

operating
stroke
due
to
worn
or

loose
sliding

part

Faulty
or

damaged
synchronizer

Worn
interlock
ball

Worn
check
ball

and
or

weakened
or
broken

spring

Wom
fork
rod
ball

groove

Wom
or
damaged
bearing

Worn
or

damaged
gear

Insufficient
or

improper
lubricant

Oil

leaking
due

to

faulty
oil

seal
or

sealant

clogged

breather
etc

Worn

bearing

High
humming
occurs
at
a

high
speed

Damaged
bearing
Cyclic
knocking
sound

occurs
also
at
a

19W
speed

Worn

spline

Worn

bushing

j

MT
23
Corrective
action

Replace

pair
or
replace

Replace

Replace

Replace

Replace

Replace

Replace

Add
oil
or

replace

with

designated
oil

Clean
Of

replace

Replace

Replace

Replace

Replace

No
Tool
number

tool
name

ST23540000

Fork
rod

pin

punch

2
ST22360002

Drift
C

3
ST23800000

Transmission

adapter

4
ST238
10001

Setting
plate

adapter
Manual
Transmission

SPECIAL
SERVICE
TOOLS

Description

Unit

mm
in

For
removal
of
fork
rod

retaining
pin

L

i
150
5
91

10
0
39
dia

For

assembly
of
counter
drive

bearing

oOler
dia
32
1
26

inner
dia
23
0
91
SE034

For

assembly
of
main

bearing

480

18
90

outer
dia
44

1
73

inner
dia
31
1
22
SE037

For

setting
adapter
plate
in
a
vise

SE132

74
2

91

MT
24
For

use

on
Reference

page
or

Figure
No

All

Fig
MT
15

models

llBT
M

Fig
MT
44

FS5W

63A

All

Page
MT
1O

models

71BT
M

Fig
MT
14

Fig
MT
15

Fig
MT
45

Manual
Transmission

No
Tool
number

tool
name
Description

Unit
mm
in
For

use

on
Reference

page
or

Figure
No

5

ST22520000

Wrench

38mm

1
50
in
For
removal
and

assembly
of
mainshaft
nut
71BT
M
Fig
MT46

63A

TIM
Fig
MT47

SE313

6
ST23860000
For
assembly
of
counter

drive

gear
7IBT
M

Fig
MT42

Counter

gear

drift

outer
dia
38
50

inner

dia
33
1
30

SE039

7

KV31100400
For
assembly
of
rnainshaft
countershaft
counte
drive

gear
and
7IBT
M

Fig
MT
37

Transmission
counter
drive

bearing
Fig
MT
39

press
stand
4
8
1
89
75
2
95
Fig
MT44

0

Q
0

J

I

0

TM438

8
STJ0031000
For

replacing
bearing
All

Fig
MT
21

Bearing
puller
models

Fig
MT
23

Fig
MT
25

80

3
15

50
1
97

SE041

MT
25

Manual
Transmission

No
Tool
number

tool
name
Unit
mm
in
Description

9
KV32101330
For
removal
of
mainshaft
end

b

ari
lg
counter
overdrive

gear
and

Bearing
puller
bearing

300
11
81

SE308

MT

26
For

use

on
Reference

page
or

Figure
No

63A

l
fM
Fig
MT
64

FS5W

7IBT
M