weight DATSUN PICK-UP 1977 Owner's Manual

DESCRIPTION

The
rear
axle

assembly
is
of

the

semi

floating

type
in

which
the
vehicle

weight
is

carried
on
the
axle
shafts

through

bearings
enclosed
in
the

bear

ing
cages
on
outer

rear
axle

case
The

axle
case
is
a

pressed
steeJ

Banjo

type
housing

The

rear
axle

assembly
is

attached

to
the
frame

through
semi

elliptic
leaf

springs
and

telescopic
hydraulic
shock

absorbers

Rubber

bushings
at

either

end
of

the
leaf

springs
and
shock

absorbers

are

designed
to
absorb
vibra

tion
and
noise

The
rear

axle
shaft

splines

engage

the
differential

side

gears
with

a
float

ing
fit
The

outer
ends
are

supported

in
the

bearing
cages
by
tapered
roller

bearings

The

bearings
are
lubricated

by

wheel

bearing
grease
The
axle
shaft
oil

seals

are
located

outboard
and

inboard

of
the

bearing
The

bearings
are

se

cured

against
shoulders

on
the
shafts

by
press
fit

and
held
in

place
by
a

large
nuts

The

bearing
cages
hold
the

bearings

against
shoulders
on
the
axle

case

Whee
side
thrust
is
taken

at
the

wheel

bearings

through
the
thrust

block
so
an
axle
shaft

may
be

re

moved

simply
by

removing
the
bolts

holding
the
brake
disc
to
the

bearing

cage
and
the
rear
axle
case

REMOVAL
AND

INSTALLATION

REAR
AXLE

ASSEMBLY

It
is
not

necessary
to
remove
the

reaT
axle

assembly
for

any
normal

repairs

However
if
the

axle
case
is

dam

aged
the
rear
axle

assembly

may
be

removed
and

installed

using
the
fol

lowing
procedures

I

Raise
rear

of
vehicle

high

enough

to

permi
t

working
underneath

Place
a

jack
under
center
of
axle
case

so
it

just

starts
to

raise
rear
axle

assembly

Place
stands

solidly
under
frame

members
on
both
sides
Remove

rear

wheels
Rear
Axle
Rear

Suspension

2

Mark

relationship
across

propeller

shaft

flange
and

companion

flange
of

differential
carrier
so
that
the

original

combination
is
restored
at

assembly

3

Remove
bolts

retaining
center

bearing
bracket
and

connecting
shaft

to

companion
flange
Withdraw

pro

peller
shaft
sleeve

yoke
from

transmis

sion

by
moving
the

shaft
rearward

passing
it
under

rear
axle

4

Disconnect
rear
hand

brake
cable

Q
by

removing
adjusting
nut

@
three

clamps
ID
and

connector

@

Slide
front
cable

rearward
and

discon

nect
rear

cable

@
at
connector

ID
by

removing
three

clamps
ID

5

Disconnect

rear
brake

hose
at

frame

@
Cover
brake
hose

and

pipe

openings
to

prevent
entrance
of

dirt

6

Disconnect

shock
absorbers
at

lower
end

f
and

push
shock
ab

sorbers

up
out

of
the

way

7

Lower

jack
under

axle
case
Re

move
U

bolts

spring

clips
@
to

separate
axle
case
from

spring

8

Place
a

jack
under

center
of
axle

case
Pass
axle

case

through

space

above

spring
and
take
it

out
to
the

side

RA134

Fig
RA
3

Removing
rear

axle

assembly

9
Install

the
axle
case

assembly
in

the
reverse
order

of
removal

RA
3
RA312

Fig
RA
2
Under
view

Tightening
torque

U
bolt

Spring

clip

7
3
to

9
9

kg
m

53
to
72

ft
lb

Shock
absorber

lower
end
nut

1
6
to
2
2

kg
m

12to

16ft
Ib

Brake

pipe
flare

nut

I
S
to
1
8

kg
m

II

to
13
ft
Ib

Propeller
shaft
to

companion

flange
connecting
bolt

2
0
to

2
7

kg
m

14
to
20
ft
Ib

Center

bearing
bracket

fixin
holt

1
6
to
2
2

kg
m

12
to
16
ft
Ib

RA148

Fig
RA
16
Remvoing
spring
pin

6
Remove

rubber
bush
in

spring
if

necessary
and
install
new
bush
Coat

rubber
hush
with
a

soapy
solution

prior
to

assembly

InstaH
rear

spring
in
the

reverse

order

of
removal

noting
the

following

poinc

Vehicle

weight
must
be
on
rear

wheels
when

tightening
front

pin

shackle
and
shock
absorber
lower
end

nut
in

order
to

clamp
rubber
bush
in
a

neutral

or
unloaded

position

Tightening
torque

Spring
fTont

pin
nut

11
5

to
13

0

kg
m

83
to
94
ft
Ib

Spring
shackle
nut

11
5

to
13

0

kg
m

83
t094
ft
b

U

bolt
7
3
to
9

9

kg
m

S3
to
72
ft
lb

Shock
absorber
lower
end
nut

1

6
to

2
2

kg
m

12
to
16
ft
lb
Rear
Axle
Rear

Suspension

SHOCK
ABSORBER

Raise
rear
of

vehicle
and

support

under
axle

case
on
stands
It
is

recom

mended
that
a

hydraulic
hoist
or

open

pit
be
utilized
if

available

2

Disconnect
lower
end
of
shock

absorber

by
removing
nuts

Q
at

spring
seat

3

Disconnect

upper
end
of
shock

absorber

by
removing
nut

2
at
frame

RA146

Fig
RA
J
7

Removing
shock
absorber

Installation
of
shock

absorber
in

the

reverse
order
of

removal

Note
Vehicle

weight
must
be
on

Tear

wheels
when

tigtrtening
shock
ab

sorber

upper
and
lower
ends
in

order
to

clamp
rubber

bushings
in
a

neutral
or
unloaded

position

INSPECTION

REAR
AXLE

SHAFT
AND

WHEEL
BEARING

Inspect
the

following
parts
for

faults
and

replace
as

required

RA
6
I
Check

axle
shaft
for

straightness

cracks

damage
wear

and
distortion

2
Check
the

lip
of
oil
seal
for

damage
deformation
and

wear

3
Check

bearing
for
wear
and

damage

REAR
AXLE

CASE

Check
axle

case
for

yield
deforma

tion

cracks
or
oil

leakage
and

replace

if

necessary

REAR

SPRING

Clean
all

rust
and

dirt
from

spring

leaves

using
a
wire

brush
if

necessary

1

Examine

spring
leaves
for
frae

tures
or

cracks

2

Check
front

bracket
and

pin

shackle
U

bolts
and

spring
seat
for

wear
cracks

straightness
and

damaged

threads
If

faulty

parts
are
found

replace
with

new
ones

3

Inspect
all
rubber

parts
for
wear

damage

separation
and
deformation

Replace
them
if

necessary

SHOCK
ABSORBER

I

Test
shock
absorber
and

compare

with
the

specifications
given
in
Service

Data

and

Specifications

Replace
if

necessary

2
Check
for
oil

leakage
and
cracks

Also
check
shaft
for

straightness

3

Inspect
rubber

bushings
for
dam

age
cracl
s
and
deformation

Replace

parts
if

necessary

REMOVAL

1

Removing
flare

nuts
on

both
ends

and

clips
effects
the

removal
of

brake

tube
and
brake
hose

2

Rear
brake
hose
can
be

removed

by
disconnecting
the
tube
and
then

turning
round
the
hose

Note
When

removing
brake
tubes
and

hoses

use
Flare
Nut

Torque

Wrench
GG943IOOOO

Never
use

an

OpeD
end

or
an

adjust

able
wrench

INSPECTION

1
Examine

all
hoses
for
swell

rubbing
marks
or
ozone
cracking

re

placing
those

found
with

any
of
above

badly
beyond
use
Also

inspect
end

fittings
and
be
sure
that
no
fluid
leak

through
staked
end

has
taken

place

replace
if

necessary
Hose

with

badly

rusted

fitting
should

also
be

replaced

with
a
new
one

2

Clean
all
tubes

to
remove
dust

and

dirt
with

isopropyl
alcohol

check

ing
for

collapse
wear

cracking
swell

or

rusting
Replace
if
foun
d

with

any

of
wove
Use
care
not
to

damage

brake
tubes

while

operation

Check
if
tubes

are

clamped
secure

ly

Mter
all

brake
lines

have
been

installed

retighten
aU
connections
if

necessary
to

assist
in

obtaining
correct

torque
In

retightening
at
front
wheel

cylinder
first
remove
hose

clamp
and

loosen
flare
nut
on

opposite
side
to

avoid

twisting
hose

Hold

pedal
as
far
downward
as

possible
80

kg
176
lb
or
more

examining
evidence
as
to
whether
fluid

is

leaking
through
brake

lines
or

con

nections

Leakage
in

any
manner
can

not
be

permitted
here
In

case
fluid

leaks

tightening
to

specified
torque

tighten
additionally
up
to
2
5

kg
m

J
8
ft
lb
Under

no
circumstances

should
not

be

tightened
over
2
5

kg
m

18
ft
Ib

torque
since
this

elongates

end

fitting
making
it

impossible
to

reuse
brake
tube

Under
no
circumstances
should
rear

brake
hose
and
3

way
connector
be

retightened
over

specified
torques
In
Brake

System

stead

replace

copper
washer
with
a

new
one

after

checking
for

sign
of

damage
on

seating
surface
Never
reuse

an
old

copper
washer

INSTALLATION

Brake
hose

Front
brake

hose

In

installing
brake
hose
first

jack

up
vehicle

to
take
off
the

weight
of

vehicle
from

wheels
so
that

suspension

is
in
rebound

Steering
wheel
should

also
be

kept
in

straight
ahead

position

To
connect
brake

line
first

connect

brake

hose
to
wheel

cylinder
with
the

specified
torque

Tightening
torque

1
7
to
2

0

kg
m

12
to

14
ft
Ib

Then
secure

brake
hose
to
the

bracket
with
lock

plate
so
as
not
to

twist
or

abnormally
bend
the
hose

Note

After

connecting
brake
hose

at

both
eiuIs

pay
keen
attention
not

to
twist
the
hose
when
additional

tightening
is

required

Fig
BR

12
Front
brake

hose

Rear

brake
hose

First
secure
rear
brake
hose
to

3

way
connector
on
rear
axle
case
to

the

specifications
Mter

connecting

hose
do
not

tighten
it

at
3

way

connector

additionally
since
this

oper

ation

causes
hose
to
be
twisted

Tightening

torque

I
7

to
2
0

kg
m

12
to
14
ft
Ib

BR
8
Fig
BR
13
Rear
brake
ho
e

After
brake
hose
has
been
installed

check

to
be

sure
that
there
is

enough

clearance
between
hose
and

adjacent

parts
to
avoid
contact
with
other
ones

The
check
should
be
carried
out
while

moving
wheel

up
and
down

through
its

full

stroke
and

rotating
steering
wheel

between
two
extreme
lock

positions

The
wow
clearance
must
be
as

follows

Hose

to

rotating
or

mOving
parts

such
as
tire
and

rim

40
mm
1
57
in

and
more

Hose
to

stationary

part

2S

mm
0

98
in
and
more

In

case
that
the

above
clearance

cannot
be
obtained
it

may
be
caused

by
the
hose

twisted

Accordingly

carry
out
the
correction
with
hose

connection

again
following
the
above

instructions

Brake
tube

In

installing
a
brake
tube
use
care

to
locate
its

end

squarely
on

mating

seat

noting
the
fact
that
nut
can
be

turned

freely
by
a

light
finger
twist

Then

tighten
to
correct

torque
with
a

Brake

Pipe
Torque
Wrench

GG943
10000

Tightening
torque
Flare
nut

1
5
to
1

8

kg
m

11
to

13
ft
Ib

In
addition
care
should
also
be

exercised
to
avoid

damaging
or
col

lapsing
brake
tube

during
operation

Be
sure
to
make

enough
clearance

between
all
tubes
and
other

adjacent

parts
to
avoid
contact

In

installing
tube

through
hood

ledge

grommet
be
sure
to

position
it

at
the

center
of

grommet

4
To

jack
up
rear

place
jack
under

rear

axle
case
close
to
the
side

of
rear

spring
after

applying
parking
brake

and

blocking
front
wheels

WH077

Fig
WT
7

Jacking

up
rear
side

S

Remove
wheel
nuts
and
wheel

from
drum

6
To

install
wheel

reverse
the

above

steps

Tighten
wheel
nuts
in
criss
cross

fashion
to
8

0
to
9
0

kg
m

S8
to
6S

ft

Ib

Note
Nerer

get
under
the
vehicle

while
it

is

supported
only
by
the

jack
Always
use
S8

fety
stands
to

support
the

side
member
of

body

construction
when

you
must

get

beneath
the
vehicle

INSPECTION

WHEEL
BALANCE

The

wheel
arid
tire

asSembly
should

be

kept
balanced

statically
and

dynam

ically
Wheel
and
Tire

Proper
tire

balance
is

necessary

when

driving
the
vehicle

at

high

speeds

Consequently
the

wheel
and

tire

assembly
should
be

properly
re

balanced
whenever

puncture
is

re

paired

The
wheel
and

tire

assembly
be

comes
out
of
ba1ance

according
to

uneven
tire
wear

Severe
acceleration

and

braking
or
fast

cornering
is
the

cause
of

wear

on
tire

resulting
in

unbalance
of
tire
and
wheel

assembly

The

symptom
of
unbalance

appears

as

tramp
vehicle
shake
and

steering

malfunction

To

correct
unbalance

use

proper

wheel
balancer

Maximum

allowable

unbalance

177

gr
cm
2
5
in

oz

10

gr
O
3S
oz
at
rim

circumferences

Balance

weight

10
to
60

gr
O
3S

to
2
12

oz

at

10

gr
0
3S

oz
intervat

Note
Be

sure
to

place
the
correct

balance

weights
on
the

inner

edge

of
rim
as

shown
in

Figure
WT
S

00
not

put
more
than
two

weights

on
each

side

WHEEL
AND
TIRE

In

order
to
ensure

satisfactory

steering
condition
as

well

as
maximum

tire
life

proceed
as
follows

Check

wheel
rim

for
rust

distor

tion
cracks

or
other
faults

WT
4
Thoroughly
remove
rust
dust

oxidized
rubber

or
sand
from
wheel

rim
with
wire

brush

emery
cloth

or

paper
Use

dial

gauge
to
examine

wheel
rim

for
lateral

run
out

Lateral
run
Qut
limit

Less

tltan
1
5
mOl
0

059

il
total

indicator

reading

WTOO5

Fig
WT

B
Whetl

rim
run

out
check

points

Note
In

replacing
tire

t
e

extra
care

not
to

damage
tire
bead

rim

flange

and
bead
seat

Do

not

use
tire
irons

to
force

beads

away
from

wheel
rim

flange
that
is

always
use
tire

replacement
device

whenever

tire
is
removed

2

Discard
when

any
of

the
follow

ing
problems
occur

1

Broken
or

damaged
bead
wire

2

Ply
o

treairsepanitiori

3

Cracked
or

damaged
side

wall

etc

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

@

I

r

L

c

@

DESCRIPTION

The

door
consists

of
inner

and

outer

panels
welded

together
to

form
a

rigid
structure

The
curved

glass
provides
greater

shoulder
room

A
door

that

incorporates
a

ventila

tor

window
is
also
available

as
an

option

The

weatherstrip
is
inserted
into

the

groove
on
the

door
sash
side
and
is

attached

by
clips
on
the
door

side

DOOR

REMOVAL
AND

INSTALLATION

I
With
door
in
full

open
position

place
a

garage
jack
or
stand
beneath

door
to

support
its

weight
when
bolts

are
removed
Place

rag
between
door

and

jack
or
stand
to

avoid
damaging

painted
surface
Body
Frame

CD

1

@

@

ID

@

AJ

@

@

@
1

Door
sash

2

Window
outside

weatherstrip

3

Window
inside

weatherstrip

4

Door

atherstrip

5
Rear

glass
run

rubber

6
Door
finish
holder

7
Rear
lower

sash

8
Seal
screen

9
Door

weatherstrip
clip

10
Front

glass
run

rubber

11
Lower
door

hinge

12

Upper
door

hinge

13

Front
lower

sash

14
Door

glass

15

Glazing
rubber

16
Door

glass
bottom
channel

11

Lower

support

18

Upper
support

19
Door
ventilator

assembly

BF031B

Fig
BF
22
Door
with
ntilator
window

Optional

BF023

Fig
BF
23

Supporting
door

2

Separate
lower
door

hinge
hole

cover
from
dash

side
trim

3

While

supporting
door
as
above

back
off

body
to

upper
and
lower

hinge

attaching
bolts
accessible

from

inside
cab
three
each
Door

can
now

be
taken
out
from
cab

body

I
t

I

l
f
p1

1
W
JJ

i

Sl
j

Fig
BF

24

Removing
door

hinge

bolt

8F
12
4

To

install
reverse

removal

pro

cedure

ALIGNMENT

Elongated
holes
three
each
in

door

hinge
and
door

lock
striker

pro

vide
for

up
and

down
forward
and

backward
and
or

sideways
adjustment

to

assure

proper
door

fit

to
door

opening

To

adjust
door

alignment
loosen

bolts
and
move
door
to

desired

posi

lion

to
obtain
a

parallel

space
between

door
sides

and
door

opening
Also

check
to

be
certain

that

weatherstrip

contacts

body
opening

evenly
to

pre

vent

entry
of
mud
and
water

DOOR
TRIM
AND

SEAL

REMOVAL
AND

INSTALLATION

1

Remove
screw

securing
inside

door
handle

escutcheon
remove
es

cutcheon

2

Remove

screws
which
hold

pull

handle
and
arm
rest
in

position
Pull

handle
and

arm
rest
can
then
be

taken

out

3

Pull

retaining
spring
off

regulator

handle
Take

out

regulator
handle

and

seat
washer

DESCR

IPTIDN

COMPRESSOR
CLUTCH

REMOVAL

INSTAllATION

DISASSEMBLY

ASSEMBLY

INSPECTION

DESCRIPTION

Model
CF206
is
a
crank

type

compressor
specially
designed
with

minimum
size
and

light
weight
for

use

on

compact
vehicles

The

compressor
crankshaft
is

driven

by
a
belt
from
the
crankshaft

pulley

through
the

electromagnetic
clutch

Two

pistons
positioned
in

line
are

actuated

by
connecting
rods
coo

nected
to
the
crankshaft

Discharge
and
suction
valves
are

mounted
in
the

valve
liner
between
the

crankcase
and

cylinder
head

As
a
lubricant

SUNlSO
NO
5
is

used

Simplified
positive
pressure

lubrication
utilizes

existing
pressure

differential
between
suction

intake

and
crankcase
to

provide
a
film
of

lubricating
oil
to

bearings
All
internal

components
have
been

designed
to

provide
more
than

adequate
lubrica

tion
to

cylinder
walls

connecting
rod

bearings
and
seal

assembly
The
result

is

improved
lubrication
lower

seal

temperatures
reduced
oil

pumping

and
a

reduction
in
the
number

of

moving
parts
Air

Conditioning

COMPRESSOR

AC33

AC34

AC34

AC34

AC35

AC
35

AC35
CONTENTS

SHAFT
SEAL
ASSEMBLY

REMOVAL

INSTAllATION

INSPECTION

CYLINDER
HEAD
AND
VALVES

REMOVAL

INSTAllATION
AC36

AC36

AC36

AC37

AC37

AC37

AC37

AC728

Fig
AC
49
Sectional
view

of
compressor

AC33