tow DATSUN PICK-UP 1977 Owner's Manual

3

Jit
f
ng
valve

24

1

3

L
l

r

I
Js

I
i

ilr
t
pressure
6
when

shif
ing
from
3rd

to
2nd
at
D

range
Thus
the

throttle
of
line

pressure
6
reduces

the

shock

generated

fro
shifting

A

plug
in
the

SSV
left

end

readjust

the

throttle

piessu
e
I
6
which
varies

depending
on
the

engine
throttle
con

dition
to
a
throttle
pressure
19

suiled
to
the

sp
ed

change
control

Moreover
the

plug
is
a
valve
which

applies
line

P

esspre
13
in
lieu
of
the

throttle

pressure
to
the
SSV
and
the

FSV
when
kickdowri
is

performed

When
the
throttle

pressure
16
is

applied
to
the

left
side
of
this

plug

and
the

plug
is

epressed
toward
the

right
a

slight

space
is
formed
from
the

throttle

pressure
6
10

19
A

throt

tIepressu
19

w
1iFh
is
lower

by
the

pressure
loss

equivalent
to
this

space
is

rH

1

Pressure
Odifier
valve
PMV

I

Compared
to
the

operating

pressure

required
in

starting
th
vehicle
the

ppwer
trimsinitting
capacity
of
the

clutch
that
is

required
operating

pres

sure

may
be

lower
when
the
vehicle
is

once
started
When
the
line

pressure
is

retained
at

a

high
level

up
to

a

high

vehicle

speed
shock

gerieraled
from

the

shirring
increases
arid
the

oil

pump
loss
also
jncrdases
In
order
to

prevent
his
the
t

lrott
le

pressure
must

be
l

hanged
over

with
the

operation
of

the

governor
pressure
15
to
reduce

Ihe
line

pressure
The
PMV
is
used
for

this

purposc
Automatic

Transmission

generated
the

piessure
loss
is
adde
d
to

the

spring
force

and
the

plug
is
lhus

forced

back
from
the

right
to
the

left

When
this

pressure
19
increases
ex

cessively
the

plug
is
further

depressed

toward
the

left

space
from
the
lhrot

tle

pressure
19
to

the
drain
circuit

13

increases
and
the
throttle

press

ure

19
decreases
Thus
the

plug
is

balanced
imd
the
throttle

pressure

19
is

reduced
to
Ii
certain
value

against
the
throttle

pressure
6

Wheri

performing
kickdowri

the

SDV
moves
a

high
line

pressure
is

led

to
the
circuit

19
from
the
line

pressure
circuit

13
which
had

been

drained

the

plug
is
forced
toward
the

left

and
circuit

19
becomes

equal
to

the
line

pressure
13

I

W
15

I

A
TOgS

Fig
iT
13
2nd
3rd

shift
vallJe

I

When

the

governor
pressuie
IS

which
is

applied
to
the

right
side
of

the
PMV
is
low
the
valve
is
forced

toward

the

right
by
the
throttle

ines

sure
16

applied
to
the
area
differ

ence
of
the
value
and
the

spring
foice

and
t

he
circuit

from
circuit

16
to

circuit
18
is
closed
However
when

vehicle

speed
increases
andl
the

gaver

nor

pressure
15
exceeds
a
certain

level
the

governor
pressure
toward

the

left
which
is

applied
to
the

right
side

exceeds
the

spring
force
and
the

throt

tle

pressure
16

toward
thc

right
the

valve
is

depressed
loward
the
lefi

and

the
throttle

pressure
is
led
from
circuit

AT

9
16
to
circuit

18
This
throttle

pressure
18
is

applied
to
the

top
of

the
PRV
and
the
force
of
the

line

pressure
source
7
is
reduced

Contra

rily
when

the
vehicle

speed
decreases

arid
the

governor

ipressure
15
de

creases
the

force
toward
the

fight

exceeds
ithe

governor
pressure
the

valve
is

forced
back
toward
the

right

and
the

throttle

pressure
18
is

drained
to
the

spring
unit

This
valve
is

sWitched
when
the

throttle

pressure
and
the

governor

pressure
are

high
or
when

tIiey
are

both
Tow
i

i
I
11

18
16

n

r

I

I

15

AT099

Fig
AT
14

Pre
ure

modifier
valve

Vacuum
thro
le
valve
VTV

The

vacuum
t
rottle
valve
is
a

regula
tor
valve

whiCh
uses
the
line

pressure
7

for
the

pressure
source

and

regulates
the

throttle

pressure
16

I

which
is

proportioned
t
the

force
of

the

vacuum

diaphragm
The
vacuum

dia

phragm
yories
depending
on
the

engine
throt
le

condition

negative

pressure
in
the

inta
e
line

When
the
line

pressure
7
is

ap

plied
to
the
bottom

through
the

valve

hole
and
the
v

a
ve
is

forced

upward

space
from
the
line

pressure
7
to
the

throttle

pressure
16
is
dosed
and

the

space
from
the
Ihrottle

pressure

16
to

the
drain
circuit
17
is
about

to

open
In

this

operation
the
throttle

pressure
16
becomes
lower
than

the

linep
s

ureY
btthe
p
e
sur

9
iv

alenl
of
the

loss
of

space
and
Ihe

force

depressing
tlie
rod
if
the

vaeuum

diaphragm
is

balanced
wit

Ii
thethrot

tie

pressure
16
a

pplied
upward
tOlthe

bottom

When
the

erigine

torque
is

high
Ihe

negative
pressure
in
the
intake
iirie

rises

tending
ioward

atmospheric

pressure
and
the
force
of
the
rod
to

depress
the
valve
increases
As
a
result

the
valve
is

depressed
downward
the

space
from
the
throttle

pressure
16

to

the
drain

17
decreases

and
the

space
from
the
line

pressure
7
to

Ihe

throttle

pressure
16
increases

Consequently
the
throttle

pressure

16
increases

and
the

valve
is

bal

anced

Contrarily
when
the

engine

torque
lowers
and
the

negative
pr

sure
in

the
intake
line

lowers

tending

toward
vacuum
the
force
of
the

rod

depressing
the
valve
decreases

and
the

throttle

pressure
16
also
decreases

When

pressure
regulated

by
the
throt

tle

back
p
valve
described
in
the

subsequent
paragraph
is
led
to
circuit

17
a

high
pressure
is

applied
through

the

space
from

the
circuit
17
to
the

throttle

pressure

16
Consequently

the
VTV
is
unbalanced
the

throttle

pressure
16
becomes

equal
to
the

back

up
pressure
17
and
the

valve
is

locked

upward

I

16

III
AT100

Fig
AT
15

Vacuum

throttle
valIN

Throttle

back

up
valve

TBY

Usually
this

valve
is

depressed

downward

by
the

spring
force

and

circuit

17
is

drained

upward

As

soon
as
the
lever
is

shifted
either

to
2

or
I

range
line

pressure
is

led
from

circuit
4

the
line

pressure
is

applied
to
the
area
difference

of
the

valve
the

valve
is
forced

upward
the

space
from

circuit
4
to
circuit

17
is

closed

and
with
the

space
from
circuit
Automatic
Transmission

17
to
Ihe

upper
drain
about
to

open

the
back

up
pressure
17
which
is

lower
than
the

line

pressure
4

by
the

pressure
loss
due
to
the

space
from

circuit
4
to

circuit

17
is
balanced

with

the

spring
force

Further
when

gear
is

shifted
from

2nd

to
Low

at
the

range
I
line

pressure
is

led
from
circuit

12
and

the
line

pressure
is

applied

pward
to

the
bottom
of
the

valve

through
the

valve
hole

Consequently
the
valve
is

forced

upward
and
locked
As
a

result
the

space
from
the
line

pressure

4
to

the
back

up
pressure
17
is

closed

completely
and
the
back

up

pressure
17
is

drained

upward

AT101

Fig
AT

16
Throttle
back

up
lJ
Jlve

Solenoid

downshift
valve

SDY

This
valve

is
a
transfer
valve
which

leads
the
line

pressure
7

to
13

and

transmits
the
same
to
the
FSV
and

SSV
when
a
kickdown

signal
is
re

ceived
from

the
downshift
solenoid

Usually
the
solenoid

push
rod
and

valve
are
locked

upward
by
the

spring

in
the
lower
end
and
the
circuit
from

line

pressure
4
to
line

pressure
13
is

opened

When
kickdown
is

performed
the

push
rod

operates
Ihe
valve
is
de

pressed
downward
and
the

circuit

from
line

pressure
7
to

line

pressure

13

opens
Line

pressure
13

opposes

the

governor
pressure
15
at

Ihe
SSV

and
FSV
thus

accomplishing
the

downshift

operation

AT
10
r

AT102

Fig
AT
17

Solenoid

dow
hift
valve

Second

lock

valve
SLY

This
valve
is
a
transfer

valve
which

assists
the
shift

valve
in

determining

the
fixed

2nd

speed
at

the
2

range

In

the
D

range
the

sum
of
the

spring
force

and
line

pressure
3

APplied

upward
xce
ds
the

linepres

sure
2
which
is

applied
to

the
valve

area
difference

as
a
downward
force

As
a
result

the
valve
is

locked

upward

and
the
circuit
from
line

pressure
8

to
line

pressure
9
is

opened

Consequently
the
FSV

becomes

the
2nd

speed
condition
and
line

pressure
is

led
to

the
band

servo

engaging
circuit
9

only
when
line

pressure

1
is
released

to
line

pressure

8

In
the
2

range
the

upward
force

is

retained

only
on
the

spring
and
the

downward
line

pressure
2

exceeds

the

upward
force

As
a
result
Ihe
valve
is

locked

downward
line

pressure
2
is

released

to

9

regardless
of
the

operating

condition
of
the
FSV
and
the

band

servo

is

engaged

J

2

8

ATl03

3

Fig
AT
18
Second
lock
lJ
Jlve

I
i
0

t
V

iL

1

0

ST25570001

j

w
1
h

AT130

Fig
AT
64

Removing
hex
head
slotted

bolt

19
Blowout
low
and
reverse
brake

piston
by
directing
a

jet
of
air
into

holeJn
cylinder
See
F

igure
AT
65

Fig
AT
65

Removing
piston

20
Remove
band
servo

loosening

attaching
bolts

Note
If

difficulty
is
encountered
in

removing
retainer
direct
a

jet
of
air

toward
release
side

as
shown
in

Figure
AT
66

II

AP

fW
l

1

A
T132

Fig
AT
fiB

Removing
bond
servo

21

Pry
snap

rings
CD
from
both

ends
of

parking
brake
lever

@
and

remove
the
lever

Back
off
manual

shaft

lock
nut

ID
and
remove

manual

plale
@
and

parking
rod

CID
See

Figure
AT
67
Automatic
Transmission

Up

@
J1i

ll
J

t
i
p

lli
l
1

I
l
P
l

1
Ii

@

j
Y

L

l

rr
i

J

ry

j

AT133

Fig
AT
67

Removing
manual

plate

22
Remove
inhibitor
switch
and

manual
shaft

by

loosening
two
secur

ing
bolts

INSPECTION

Torque
c
onverter
housing

transmission
c
ase
and

rear
extension

I

Check
for

damage
or
cracking
if

necessary
replace

2

Check
for
dents
or
score
marks

on

mating
surfaces

Repair
as
nee

essary

3
If
rear
extension
bushing
is
worn

or
cracked
replace
it

as
an
assembly
of

bushing
and
rear
extension
housing

Gaskets
and
O

ring

1

Always
use
new

gaskets
when
the

units
are
to
be
disassembled

2
Check
O

rings
for
burrs
or
crack

ing
If

necessary
replace
with

new

rings

011
distributor

I
Check
for

signs
of
wear
on
seal

ring
and

ring
groove
replacing
with

new
ones
if
found
worn

beyond
use

Check
that
clearance
between
seal

ring
and

ring
groove
is
correct
If
out

of

specification
replace
whichever
is

worn

beyond
limits
Correct
clearance

is
from
0
04
to
0
16
mm
0
0016
to

0
0063
in
See

Figure
AT
68

AT
J8
j
Clearance

1

61
Seal

dng

0

j

J

I

I

AT134

ig
A
r
68
Me

q
sur

ingseal
r

ing
to

ring
groove
clearance

ASSEMBLY

Assembly
is
in

reverse
order
of

disassembly
However
observe
the
fol

lowing
assembly
notes

After

installing
piston
of
low
and

reverse
orake
assemble
thrust

spring

ring
return

spring
thrust
washer
and

one

way
clutch
inner
race

Torque

hex
head
slotted
bolt
to
L3to
1
8

kg
m

9
to
13
ft
ib

using
Hex
head
Ex

tension
ST2SS7000
ST2SS70000

Torque
Wrench
GG93010000
and

Socket
Extension
ST2S490000

ST2SS
12001
See
Figure
AT
69

ST2557000t

ST25490000

I

GG930JOOOO

A
T135

Fig
AT
69

Installing
ont

woy
clutch

inner
race

2
After
low
and
reverse
brake
has

been
assembled
measure
the
clearance

between

snap
ring
CD
and

retaining

plate
@
Select

proper
thickness
of

retaining
plate
to

give
correct

ring
to

plate
clearance
See

Figure
AT
70

Low

and
reverse
brake

clearance

0
80
to
1

05
rom

0
0315
to
0
0413
in

Fig
AT
70

Measuring
ring
to

plate

clearance

Available

retaining
plate

Thickness
mm
in

1l
8
0
465

12
0

0472

12
2
0480

124

0488

12

6
0496

12

8
0
504

For

inspection
procedure
for

low

and

reverse
brake
see

page
AT
42
for

Assembly

3

Install
one

way
clutch
so
that
the

arrow
mark
is
toward
front

of

vehicle
It
should
be

free
to

rotate

only
in

clockwise
direction
See
Figure

AT
71

mITIJ

o

oml

AT137

Fig
AT
71

One

way
clutch

4
After

installing
rear
extension

torque
attaching
bolts
to
2
0
to
2
5

kg
m

14
to
18
ft
lb
Place
manual

lever
in
P

range
and
check
to

be
sure

that
rear

output
shaft
is

securely

blocked

5

Tighten
servo
retainer

temporari

ly
at
this

stage
of

assembly

6
Place

rear
clutch

assembly
with

needle

bearing
on
front
assembly
Automatic
Transmission

7

Install
rear
clutch
hub
and
front

planetary
carrier
as
shown
in

Figure

AT
72

AT142

Fig
AT
72

Installing
planetary
carrier

8
Assemble

connecting
shell
and

other

parts
up
to
front
Clutch
in

reverse
order
of

disassembly

AT143

Fig
AT
73
Installing
connecting
shell

9

Adjust
total
end

play
and

front

end

playas
follows

Front
end

play

L

r

L

CD
I

r

L

11
I
J

Total
end

play
@

Front
clutch

thrust
washer

2

Oil

pump
cover

3
Front
clutch

4

Rear
clutch
AT138

5

Trammission
case

6
Oil
pump

gasket

7
Oil

pump
cover

bearing
race

Fig
AT
74
End

play

1
Measure
the
distance
A

and

C

by
vernier

calipers
as
shown

in

Figure
AT
75

AT
39
i
Rear

c

clutch

N
edle
bearing

Bearing
race

I

Fig
AT
75
AT139

Measuring
the
distance

A

and
C

2

Measure
the
distance
B

and

D
of

oil

pump
cover
as
shown
in

Figure
AT
76

I

L

I
Oiipi
mp

AT140

Fig
AT
76

Measuring
the
distance

B
and
D

Adjustment
of

total
end

play

Select
oil

pump
cover

bearing
race

by

calculating
the

following
formula

TT
A
B
W

where

T

T
Required
thickness
of
oil

pump

cover

bearing
race
mm
in

A

Measured
distance
A
mm
in

B
Measured
distance
B
mm

in

W
Thickness
of

bearing
race

temporarily
inserted
mm
in

Available
oil

pump
cover

bearing

race

Thickness
mm

in

1
2
0
047

I
4
0
055

1
6
0
063

1
8
0
071

2

0
0
079

2
2
0
087

Specified
total
end

play

0
25100
50
mm

0
0098
to
0
0197
in

In

these
cases
the

transmission
must

be

repaired

Notes

a
In

checking
oil

level
use

special

paper
cloth
to
handle
the
level

gauge
and
be
careful
not
to
let
the

scraps
of

paper
and
cloth
stick
to

the

gauge

b
Insert
the

gauge
fully
and
take
it

out

quickly
before

splashing
oil

adheres
to
the

gauge
Then
observe

the
level

c
Use
automatic
transmission
fluid

having
DEXRON
identifications

only
in
the
3N71B
automatic
trans

mission

d

Pay
attention
because
the
oil
to
be

used
differs
from
that
used
in

the

Nissan
Full
Automatic
TranSJTIis

sion
3N71A
Never
mix
the
oils

INSPECTION
AND
REPAIR

OF
OIL
LEAKAGE

When
oil

leakage
takes

place
the

portion
near
the

leakage
is
covered

with
oil

presenting
difficulty
in

detecting
the

spot
Therefore
the

places
where
oil
seals
and

gaskets
are

equipped
are
enumerated
below

11
Converter

housing

Rubber

ring
of
oil

pump
housing

Oil
seal
of
oil

pump
housing

Oil
seal
of

engine
crankshaft

Bolts
of
converter

housing
to
case

2
Trarismission
and
rear
extension

Junction
of
transm
ss
ion

and
rear

extension
J

Oil
cooler
tube
connectors

Oil

pan

Oil

pressure
inspection
holes
Refer

to

Figure
AT
il2

Mounting
portion
of
vacuum
dia

phragm
and
downshift
solenoid

Breather
and
oil

charging
pipe

Speedometer
pinion
sleeve

Oil
se
l
of
rear
extension

To

exactly
locate
the

place
of
oil

leaka
le
proceed
as
follows

Place
the
vehicle
in

a

pit
and

by

sampling
the
leaked
oil
determine
if
it

is
the

torque
converter
oil
The

torque

converter
oil
has
a
color
like
r
d
wine

So
it
is

easily

distinguished
from

engine

oil
or

gear
oil
Automatic
rransmission

Wipe
off
the

leaking
oil
and
dust

and
deiecl
the

spol
of
oil

eakage

l
se

nonflammable

organic
solve
t
s
ch
as

carbon
tetrachloride
for

wiping

Raise

the
oil

tcmperalure
by

op

erating
the

engine
and

shift
the
lever

to
D
to
increase

the
oil

pressure

The

spot
of
oil

lcakage
will
then
be

found
more

easily

Note
As
oil

leakage
from
the
breaih

er
does
not
take

place
except
when

running
at

high
speed
it
is

impos

sible
to
locate
this

leakage
with

vehicle

stationary

CHECKING
ENGINE
IDLING

REVOLUTION

The

engine
idling
revolution
should

be

properly
adjusted

If
the

engine
revolution
is

too
low

the

engine
does
not

operate
smoothly

and
if
too

high
a

strong
shock
or

creep
develops
when

changing
over

from
N
to
D
or

R

CHECKING
AND
ADJUSTING

KICK

DOWN

SWITCH
AND

DOWNSHIFT

SOLENOID

When

the
kickdown

operation
is

not

made

properly
or
the

speed
chang

ing
point
s
too

high
check
the
kick

down
switch
downshift
solenoid
and

wiring
between
them
When
the

igni

li
n

key
is

pqsitioned
a
t

the
I

st

stage

nd
the
accelerator

pedal
is

depressed

deeply
the
switch
contact
should
be

closed
and
the
solenoid
should
click
If

it
does
not
click
it
indicates
a
defect

Then
check
each

part
with
the

testing

instruments
See

Figure
ATl09

d

I

t

AT10S

Fig
AT
109

Downshift
solenoid

Note
Watch
for
oil

leakage
from

transmission
case

AT
4Q
INSPECTION
AND

ADJUSTMENT
OF
MANUAL

LINKAGE

The

adjustmcnt
of

manual

linkage

is

equaUy
important
as

Inspection
of

Oil
Level
for
the
automatic
transmis

sion
Thereforc

great
care
should
be

exercised
because
incorrect

adjustment

will

rcsult
in
the
brcakdown
of
the

transmission

Inspection

Pull
the
selector
lever
toward

you

and
turn
it

as
far
as
P

to
I

range

wherc
clicks
will
be
felt

by
the
hand

This
is
the

detcnt
of
manual
valve
in

the
valve

body
and
indicates
th

correct

position
of
the

lever

Inspect
whether

the

pointer
of

selector
dial

corresponds
to
this

point

and
also
whether
the
lever
comes

in

alignment
with
the

stepping
of

posi

tion

plate
when
it
is
released

Adjustment

This

procedure
can
be

accomplish

ed

by
refcrring
to

page
AT
35

for

Removal
and
Installa
tion

CHECKING
AND

ADJUSTING

INHIBITOR
SWITCH

The
inhibitor
switch

lights
the
re

verse

lamp
in

the

range
R
of
the

transmission

operatio
l
and
also

rotates

the
starter
motor
in
the

ranges
N

and
P

CD

@
b
ell

If

L
t

7
4l

@

1l

j7
@
@

@
dl

AT109

6
Washer

7
Nut

8
Inhibitor
switch

9
Range
select
lever
t
Inhibitor
switch

2
Manual
shaft

3
Washer

4
Nut

5
Manual

plate

Fig
AT
110
Construction

of
inhibitor

switch

spindle
and

torque
bolt
to
10
3

to

12
1

kg
m
75
to

88
ft

lb
Bend

lock

plate
to

engaged
flats
on
boll
head

Note

When
disassembled
discard

used
lock

plate

5

Pack

grea
to
the

upP
r

and

lower

bushings
on

knuckle

spindle

until

grease
c
omes
out

from

gr
ease

seal

6
Fill
wheel
hub
and

cap
with

grease

up
to
the

described
level
See

Figure
F
A
4

FA141

Fig
FA
4

Gre
ing
wheel
hub

7
Pack

roller
and
cone

assembly

and
the

cavity
of

grease
seal

lip
with

grease

8
Coat

grease
to

the
thread
of

knuckle

spindle

bearing
washer
and

bearing
lock
nul

9
Secure
wheel
hub

bearings
bear

ing
washer
and

spindle
nut
on
knuckle

spindle
and

adju
t

bearing

preload

referring
to

the

paragraph
Wheel

bearing
adjustment

Note
Be

sure
to
obtain

correct

pre

load

on
wheel

bearings
for
the

pu
rpose
of

ving
their

long
life

taking
care
to

keep
wheel

be8rlngs

grease
seal

bearing
washer
and

spin

dle
nut
clean
when

installing
them

WHEEL

BEARING

D

TM
NT

Wrong

adjustment
of
wheel
bear

ing
causes
abnonnal
wear
and
score

on
the

bearings
and
knuckle

spindle
Front
Axle
Front

Suspension

To
attain

proper
preload
on
wheel

bearings

proceed
the

following

opera

tions

I

Torque
spindle
nut

to
3

0
to
3
S

kg
m
22
to

25
ft
lb

using

torque

wrench

FA227

Fig
FA
5

Tightening
apindle
nut

2

Rotate
wheel

hub
a
few
turns

clockwise
and

counterclockwise
to

seat

bearings
Then

retighten
spindle

nut
to
the
same

tightening

torque
Be

certain

to
rotate
hub

smoothly

3

Back
off

spindle
nut
in

range

from
40
to
70

degrees
Locate

adjust

ing
cap
on

spindle
nut

so
as
to

align

the
castellation
on

the

cap
with

the

cotter

pin
hole
in

the

spindle

4

Check
the
hub
rotation

If
hub

rotates

properly
measure

bearing
rota

tion

starting
torque
If
measured

torque
is
deviated
from

the

specified

value
r

place
beari

gs
r
re

dju
st

The

starting

torque
can

be
mea

sured

by
a

spring
balance
as
shown
in

Figure
F

A
6

Spring
balance

indication
at
hub
bolt

New

bearing

2
1

kg
4

Ib
o

ess

Used

bearing

1
0

kg
2
2
lb
or

less

Notes

a

When

measuring
the

starting
force

pull
the

spring
balance
toward
tan

gential
direction

against
normal
line

connected
between
hub
boll
and

spindle
center

b

Axial

play
is

permissible
to
exist

in

0
1
mm
0
004
in
or
less

FA
4
fA22S

Fig
FA
6
Mea

uring
bearing
rotation

atarting
torque

S

Install

a
new
cotter

pin
Bend

the

ends
of
coller

pin
around
the

castel

lated

flange
of

adjusting
cap
Then

install
hub

cap

DISASSEMBLY
AND

ASSEMBLY

Knuckle

spindle

I
Drive

spindle
bushing
and

grease

seal
out
of
knuckle

spindle
with

KiTlg

Pin
Bush
Drift

ST3S380000
Discard

bushing
and

grease
seal
when

disas

sembled

2

After

cleaning
king
pin
bores

thoroughly
install

bushing
carefully

by
using
the
above

special

tpol
Posi

tion

bushing
in

accordance
With
the

instructions
fIlled
in

Figure
F
A

7
and

FA
8

34
mm

1
34
in
Upper
side
in

lower
boss

I

I

1

II

I
Pla
ce
this

position
in
line
with

grease
nipple
hole

Upper
side
in
upper
boss

FA229

Fig
FA
7

King
pin
bu

hing

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

Available
worm

bearing
adjusting

shim

No
Thickness

mOl

in

I
0
762
0
0300

2
0
2S4
0
0100

3
0
127
0
0050

4
O

OSO
0
0020

5

Adjust
the
worm

bearing

preload

with

Preload

Gauge
ST3127S000

by

selecting
suitable

bearing
shims
so
that

the
initial

turning

torque
of

steering

column
is

the

specified
value

Initial

turning
torque
of

steering

column
shaft

New
worm

bearing

4

0
to
6
0

kg
em

S6
to
83
in
oz

Used
worm

bearing

2
4
to
4
4

kg
em
33
to
61
in

oz

6

Insert

adjusting
screw
into
the

T

shaped

groove
at
the
sector
shaft

head

and

adjust
the
end

play
between

sector
shaft
and

adjusting
screw
until

it
is
within
0

01
to
0
03
mm

0
0004

to
0
0012
in

by
choosing
suitable

adjusting
shims

Available
sector
shaft

adjusting

screw
shim

No
Thickness
mOl
in

I
1
57S
0
0620

2
1
550
0
0610

3
1
525
0
0600

4
I
S00
0
OS91

S
1
475
0

0581

6
I

4S0
0
0571

7
Rotate
ball
nut

by
hand
until
it
is

in

the
center

of
its
trovel
then
install

sector
shaft

together
with

adjusting

screw
in

gear
housing
ensuring
that

the
center

gear
of
sector
shaft

engages

with
that
of
ball
nut
STEERING
SYSTEM

8

Install
sector
shaft
cover

to

gear

housing
Be
sure

to

apply
sealant
to

each
face
of
sector
shaft
cover

packing

when

installing
cover

9

By
turning

adjusting
screw
coun

terclockwise
attach
sector
shaft
cover

to

gear
housing
and
then

temporarily

secure
it
with
its

fixing
bolts

10
Pull
sector
shaft
toward

cover

approximately
2
to
3
mOl

0
08
to

0
12
in

by
turning

adjusting
screw

counterclockwise
and
tighten
sector

shaft
cover

fixing
bolts
to
l
S
to
2
5

kg
m

11
to
18
ft
Ib

II
Push
sector
shaft

against
ball
nut

gear
by

gradually
turning

adjusting

screw

clockwise
until

sector
shaft

gear

lightly
meshes
with
ball
nut

gear
and

then

temporarily
secure

adjusting

screw
with
lock
nut

12
Install

gear
arm
to
sector
shaft

and
move

sector
shaft
several
times

from
the
side
of

gear
arm
and

make

sure
that
it
turns

smoothly

13

Adjust
the
backlash
at
the
neu

tral

position
of

gear
arm

by
turning
in

or
out

adjusting
screw
so

that
the

movement
of
the

gear
arm

top
end
is

less
than
0
1
mOl
0
004
in

0

ST207

Fig
ST
10
Mea

uring
backlash

14
Turn

adjusting
screw
approxi

mately
1
8
to
1

6
turn
clockwise
and

then

retighten
lock

nut
to
3

0
to
4
0

kg
m
22

to
29

ft
Ib

IS
Fill
recommended
gear
oil

ap

proximately
0
33
liter
X

U
S

pI

X

Imper
pt
into

gear
assembly

through
the
filler
hole
and
install
filler

plug

ST
5
Inspection
and

repair

Wash
clean
all
the
disassembled

parts
in
solvent
and
check
for
condi

tions

Sector

shaft

1

Check

gear
tooth
surface
for

pit

ting
burrs
cracks

or

any
other
dam

age
and

replace
if

faulty

2
Check
sector
shaft
for
distortion

of
its
serration

and
if

necessary
re

place
In

this
case
be
sure
to
check

gear
housing
for
deformation

Steering
column
shaft

assembly

1

Inspect
the
ball
nut

gear
tooth

surface
and

replace
if

pitting
burrs

wear
or

any
other

damage
is
found

2

Ball
nut

must
rotate
smootWy
on

worm

gear
If

found
too

tight
assem

bly
should
be

replaced
Check

as
fol

lows

Move

ball
nut
to
either
end
of

worm

gear
and

gradually
stand
steer

ing
column
shaft

assembly
until
ball

nut
moves
downward
on
worm

gear

under
its

own
weight
In
the
above

test
if
ball
nut
does
no
move

freely

over
entire

stroke
assembly
may
be

damaged
Replace
with

a
new
one
as

an

assembly

Note
In

this

inspection
be
careful

not
to
dama
e

ball
nut

guide
tube

Bearings
and

bushings

I

Replace
worm

bearings
if

pitting

wear

or

any
other

damage
is

found
on

them

2

Repiace
column

bushing
which
is

excessive
worn
or
deformed

3
If
sector
shaft

bushings
in

gear

housing
are
found
worn
or

damaged

replace
as
an

assembly
of

gear
housing

and

bushing

Oil
seal

gasket
and

O

ring

Do
not
reuse
above

parts
which
are

removed
once

Be

sure
to
use
new

parts
at
each

reassembly

Engine
Control
Fuel
Exhaust

Systems

REMOVAL

Non
California
models

I
Remove
exhaust
tube
U

bolt

clamp

2

Break
sealant
off
at
front
tube
to

main
muffler

connectio
n

3
Remove
rear
tube

mounting
bolt

and

remove
muffler

assembly
with

rear

tube

4
Remove

front
tube
heat

insulator

5

Remove
nuts

securing
front
tube

to
exhaust
manifold
and

remove
front

tube

mounting
bolts
Then
detach

front
tube

When

disconnecting
the
exhaust

tube

connections

pay
attention

to
the

following
point

I

Break
old

se
lant
off
at

t
1e

connection

by

lightly
tapping
around

the
tube

witlJ
a
hammer
and

twisting

muffler
See

Figures
FE

7
and
FE
8

2

Using
a
rubber
hammer

tap
on

the
front

end
of
muffler
while

pushing

it

toward
rear
The
mumer

assembly

can
then
be
taken

out
See

Figure

FE
9

FE187

Fig
FE
7

Breaking
Bealant

FEl88

Fig
FE
8

Twisting
muffler
ijl

4

FE189

Fig
FE
9

Tapping
muffler
with

Q
rubber
hammer

California
models

I
Remove

all
heat
insulators

2

Remove
exhaust
tube
U
bolt

clamp

3

Break
sealant
off
at
center
tube

to
main
muffler

connection

4

Remove
rear
tube

mounting
bolt

and
remove
muffler

assembly
with
rear

tube

5
Remove

bolts

securing

catalytic

converter
to
center
tube
and
remove

center
tube

mounting
bolts

Then
detach
center
tube

6
Remove
bolts
and
nuts

securing

catalytic
converter
to
front
tube
and

detach

catalytic
converter

7

Remove
nuts

securing
front

tube

to
exhaust
manifold
and

remove
front

tube

mounting
bolts

Then
detach

front
tube

INSPECTION

I
Check
muffler
and
tubes
for

cracks

Qr

damage

Replace
any

part
that
is

damaged

beyond
limits

2

Replace
bracket
and

mounting

insulator
that
are
cracked

fatigued
or

sweated

FE
8
INSTALLATION

Install
the
exhaust

system
assembly

in

reverse
order
of
removal
Observe

the

following

Notes

a
Insert
front
tube
until
it
touches

emboss

b
When
there
is

110
clearance
between

front
tube
and
floor

or

propeUer

shaft
turn
tube

along
center
line
of

tube

in
the
manifold

connecting

unit
and
obtain

proper
clearance

c
Check
all
tube
connections
for
ex

haust

gas
leaks
and
entire

system

for
unusual
noises

with

engine

running

d
After
installation
check
that

mounting
brackets
and

mounting

rubbers
are
free
from
undue
stress

If

any
of
the
above

parts
is
not

installed

properly
excessive
noises

or
vibrations

may
be
transmitted
to

the
vehicle

body

e

Tightening
torque

Exhaust
manifold
to

front
tube

nut

1
9

to
2
5

kg
m

14
to
18
ft
lb

U
bolt

securing
nut

1
9
to
2
1

kg
m

14
to
15

ft
lb

Mounting
bracket
bolt

1
0
to
1
2

kg
m

710
9
ft
lb

Front

tube

mounting
bracket

bolt

california
models

1
9

to
2
1

kg
m

14
to
15
ft
lb

Catalytic
converter
to
front

and
center
tube
bolt

California
models

3
2

to
4
3

kg
m

23
to
31
ft
Ib

If
exhaust

tubes
are

separated
at

connection

t
renew
muffler

assembly

etc
use
the
Genuine
Nissan

Sealant

Exhaust
Sealant
Kit
20720
N2225

or

equivalent
See

Figure
FE
IO
to

eliminate

gas
leakage
at
the

joint
Be

sure
to
observe
the

following

WINDSHIELD
GLASS

DESCRIPTION

The

windshield

glass
is
retained
in

the

body
glass
opening
through
the

weatherstrip
There
are
twelve

water

drain
holes
one
on
each

side
of
the

bottom
of
the

glass
opening
and
ten

along
the

length
of
the

weatherstrip

1

Weatherstrip

2
Windshield

glass

3

Water
drain
hole

Fig
BF
35
Windshield

glass
and

weatherstrip
BF473A

REMOVAL

1
Place

protective
covers
over
en

gine
hood
front
fender
seat
and
in

strument

panel

2
Remove
inside
rearview
mirror

and
sun
visor

3
Remove
windshield

mouldings
if

so

equipped

4

Using
a

putty
knife
or
similar

flat
bladed
tool

pry
lips
of
weather

strip
out
of

place
from

top
and
side

flanges
of

body
opening

If

weatherstrip
is

to
be
reused
it
is

important
that
it

not
be

damaged

during
this

operation

BF041

Fig
BF
36

Removing
weatherstrip
Body
Frame

WINDSHIELD
GLASS

5

Working
from
inside
vehicle

push

windshield

glass
out

of

body

opening

by
hand

starting
at

right
and
left

upper
COIners
and

working
out
toward

ends

6
After

removing
weatherstrip
from

top
and
sides
of

body
opening
lift

glass

up
sufficiently
to

permit
removal

of

weatherstrip
from
bottom

flange

pry
weatherstrip
out
of

position

This

operation

requires
two
men

INSPECTION

Prior
to

installing
windshield

glass

make
the

following
checks
on
body

glass

opening
and

weatherstrips

I
Clean

weatherstrip
channels
re

placing
those
found
with

cracks
or

signs
of
deterioration

2
Clean

body
openings
noting
if

these
are
distorted
or
corroded

INSTALLATION

L

Fit

weatherstrip
on

glass

making

sure
it
is

properly
seated
and

posi

tioned
Adhesive
need
not
be

applied

0

BF641

Fig
BF

37

Fitting
weatherstrip
on

glass

2

Insert
a
draw
cord

completely

around

weatherstrip
outer
channel

Q
i

I

dYii

1

Windshield

glass

2
Draw
cord

3

Weatherstrip

Fig
BF

38
In8erting
draw
cord
around

weatherstrip
outer
channel
8F648

BF
16
3

With
aid
of
a

helper
press
wind

shield

assembly
against
body
opening

from
outside

being
sure
weatherstrip

lip
aligns
ith

body
opening
flange

4

Slowly

pull
cord
ends
from
inside

to

overlap
weatherstrip
channel
on

body
opening

flange
starting
at
center

top
and

working
out
toward
ends
This

operation
should
be
done
while
one

man
pushes

glass
against
body
opening

from
outside

The

same

technique
should
be

ap

plied
to

right
left
and
bottom

wea
th

erstrips

Fig
BF
39

Fitting
weatherstrip

top

BF650

Fig
BF

40

Fitting
weatherstrip

bottom

5
Install

windshield

moldings
on

weatherstrip
if
so

equipped

6
Install
inside
rearview
mirror
and

sun
visor

BACK
WINDOW

GLASS

AND
SIDE

WINDOW

GLASS

Refer
to
relative

topics
under
Re

moval

Inspection
and
Installa

tion
of
windshield

glass