wheel DATSUN PICK-UP 1977 Owner's Manual

DESCRIPTION

REMOVAL
AND
INSTAllATION

Removal

Installation

DESCRIPTION

The
clutch
is

a
single
dry
disc

type
CLUTCH

CLUTCH

CONTENTS

CL
2

Cl2

CL
2

CL
3
DISASSEMBLY
AND
ASSEMBLY

D

isassemb
I

y

Assembly

INSPECTION
CL
3

Cl3

CL
3

CL
4

using
a

diaphragm
spring
It
consists
of

the

clutch
disc

pressure
plate
dia
phragm
spring
thrust

rings
clutch

cover

I
and
clutch
release

bearing

e

M

0

s
8

o

8

l150
5
91
dia

225
8
86
dia

REMOVAL
AND

I
NSTALLATIO

Removal

1
Remove
transmission
from
ve

hicle

For
details
of
transmission
removal

refer
to
Transmission
Section

2

Insert
Clutch
Aligning
Bar

KV30100200
into
clutch
disc
hub

until
it
will
no

longer
go
It
is
im
A

u

o

6

o

C
62

2
44

dia

I

260

10
2
dia

CL231

Fig
CL
l

Construction
of
clutch
disc
and
COller
assembly
Unit
mm
in

portant
to

support

weight
of
clutch

disc

during
further

steps
See

Figure

CL
2

3

Loosen
six
screws

attaching

clutch
cover
to

flywheel
one
turn
at
a

time

each
un
til

spring
pressure
is

re

leased
Be
sure
to
turn
them
out
in
a

crisscross
fashion

Note
Exercise

special
care
to
avoid

grease
or
on

getting
on
clutch

linings

CL2
Fig
CL
2

Supporting
clutch

assembly

Installation

I

Apply
a

light
coat
of
lithium
base

grease
containing
molybdenum
disul

phide
on
transmission
main
drive

gear

splines

Slide
clutch
disc
on
main

drive

gear

several
times
Remove

clutch
disc
and

wipe
off
excess
lubricant

pushed
off

by
disc
hub

2
Install
clutch
disc
and
clutch

cover
assembly
on

flywheel
Support

two
assemblies
with
Clutch

Aligning

Bar
KV30100200
See

Figure
CL
3

Note
Be
sure
to

keep
disc

facings

flywheel
and

pressure
plate
clean

and

dry

7
00

R

rr

CL109

Fig
CL
3

l
talling
clutch
cover

assem

bly

3
Install
six

bolts
to

tighten
clutch

cover

assembly
to

flywheel
squarely

Each
bolt
should
be

tightened
one

turn
at
a
time

to
the

specified
torque

15
to
2
2

kg
m
II

to
16
ft
Ib

Note
Three
dowels
are

used
to
locate

clutch
cover
on

flywheel
properly

4
Remove

Clutch

Aligning
Bar

KV30100200
after

tightening
the

bolts

securely

5
Install
transmission

Note
Make
certain
that
withdrawal

lever

engages
lever
ball

pin

6
Connect

push
rod
of
clutch

op

erating
cylinder
to
withdrawal
lever

DISASSEMBLY
AND

ASSEMBLY

Disassembly

I

Clutch
cover

assembly
can

not
be
CLUTCH

disassembled
since

diaphragm
spring
is

securely
reveted
to
clutch
cover
and

clutch

cover
assembly
is
balanced

If

necessary
replace
clutch
cover

assembly
as
a

complete
unit

2

Remove
clutch
release
mechanism

as
follows
See

Figure
CL4

1
Remove
dust
cover
from
clutch

houisng

2
Remove

withdrawal
lever
from

clutch

housing

3
Remove

retainer

spring
from

withdrawal
lever

4

Remove
release

bearing
bearing

sleeve
and

holder

spring
from
clu
tch

housing
as
an

assembly

1

lo

1

Release

bearing

2
Release

bearing

sleeve

3
Holder

spring

4
Dust

cover

5
Withdrawal

lever

6
Retainer

spring
CL119

Fig
CL
4

Exploded
view

of
clutch

releaae
mechaniam

3
Take

out
clutch
release

bearing

from

bearing
sleeve

using
a

universal

puller
See

Figure
CL
5

C
L014

Fig
CL
5
D

embling

rele
e

b

aring

4

Remove

pilot
bushing
in
crank

shaft

by
Pilot

Bushing
Puller

ST16610001
if

necessary
See

Figure

CL
6

CL3
CLOSS

Fig
CL
6

Removing
pilot
bu

hing

Asse

bly

Release

mechaniam

1
When

assembling
release

bearing

on
sleeve

use
a

press
and
seat

bearing

squarely
on

sleeve
See

Figure
CL
7

l
J

I

CL215
I

1

J

1

Fig
CL
7
1

tailing

rele
e

bearing

2
Before

or
during

assembling
lu

bricate
the

following
points
with

a

light
coat
of
multi

purpose

grease

I

Inner

groove
of
release

bearing

sleeve
See

Figure
CL
8

Lf

I

n

JQt
CL216

Fig
CL

B
Lu

bricating
ee

of

bearing
slee

2
Contact
surfaces
of

withdrawal

lever
lever
ball

pin
and

bearing
sleeve

3
Contact
surfaces
of

transmission

front
cover
See

Figure
CL

9

l
t

tJ
I

P

o

CUll

Fig
CL
9

Lubricating
poinu
of

withdrawal
lever
and

front
cover

4

Contact
surfaces
of
transmission

main

drive

gear
splines
lithium
base

grease
including
molybdenum
disul

phide

Note

Very
IIIIJllII
amount
of

grease

should
be
ated
to
the
above

points
If
too
much
iubricant
is

applied
it
will
run
out
on
the

friction

plates
when
hot

resulting

in
d

gi
dutch
disc

facings

3
Install
retainer

spring
to
with

drawal
lever
Fit
holder

spring
to

release

bearing
and
sleeve

assembly

then
assemble
withdrawal
Iever
and

bearing
sleeve
as
a
unit
Install
this

assembly
on

transmission
case
Then

install
dust

cover

Pilot

bushing

Before

installing
a
new

bushing

thoroughly
clean

bushing
hole
Install

bushing
in
crankshaft

using
a
soft

hammer

Bushing
need
not
be
oiled

INSPECTION

Wash
all
the
disassembled

parts

except
release

bearing
and
disc
assem

bly
in
suitable

cleaning
solvent
to

remove
dirt
and

grease
before

making

inspection
and

adjustment

Flywheel
and

pressure
plate

Check
friction
surface
of

flywheel

and

pressure
plate
for

scoring
or

roughness
Slight
roughness
may
be

smoothed

by
using
fme

emery
cloth

If
surface

is

deeply
scored
or

groov

ed
the

part
should
be

replaced

Clutch
disc
at
llembly

Inspect
clutch
disc
for

worn
or

oily

facings
loose

rivets
and
broken

or

loose

torsional

springs
CLUTCH

I
If

facings
are

oily
the
disc
should

be

replaced
In
this
case

inspect
trans

mission
front
cover
oil
seal

pilot

bushing
engine
rear
oil
seals
and
other

points
for
oil

leakage

2
The
disc
should

also
be

replaced

when

facings
are
worn
locally
or
worn

down
less
than
0
3
mm
0
0118
in

at

revels
See

Figure
CL
IO

DePth

ll
I

gauge

II

1
i
h

1

j1
t

f

Above

0
3
rom

10
012
in

CL089

Fig
CL
I0
Me
JIuringclutch

lining

3
Check
disc

plate
for
runout
when

ever
the
old
disc
or
a

new
one
is

installed

4
If

runoutexceeds
the

specified

value
at

the
outer
circumference
Ie

place
or

repair
disc
See

Figure
CL
II

Runou

t

0
5
mm
0
020
in

total
indicator

reading

R

from
the

hub
center

107
5
mm
4

23
in

CL112

Fig
CL

ll

MeOlUring
disc
runout

5
Check
the
fit
of
disc

hub
on

transmission
main
drive

gear
for

smoothly
sliding
If

splines
are
worn

clutch
disc
or
main
drive

gear
should

be

replaced
that

is
backlash
exceeds

0
4

mm
0
016
in

at
the
outer

edge
of

clutch
disc

Clutch

cover

assembly

I
Check

the
end
surface
of

dia

phragm
spring
for
wear

CL
4
If
excessive
wear
is

found

replace

clu
tch
cover
as
an

assembly

2
Measure
the

height
of

diaphragm

spring
as
outlined
below

See

Figure

CL
12

a
Place
Distance
Piece
ST20050100

on
Base
Plate
ST20050010
and

then

tighten
clutch
cover

assembly

on
the
base

plate
by
using
Set
Bolls

ST20050051

b
Measure

diaphragm
spring
toe

height
A

at
several

points
with
a

vernier

caliper

depth
gauge

STl0050100

rJrf
I
Tl

05001O

f

7

C
L23

STl005Q051

Fig
CL
12

Me
uring
the

height
of

diaphragm
pring

If
the

height

A
of

spring
end
is

beyond
the

specified
value
of
33
to
35

mm
1
23

to
1
38
in

adjust
the

spring

height
with

Diaphragm
Adjusting

Wrench
ST20050240
See

Figure

CL

13

If

necessary
replace
clutch

cover
as

an

assembly
Also
unevenness
of
dia

phragm
spring
toe

height
should
be

less
than
05
mm
0
020
in

ST20050240

CL152

Fig
CL
13

AdjlUting
the

spring
height

3

Inspect
thrust

rings
for
wear
or

damage
As
these

parts
are
invisible

from
outside
shake
cover

assembly
up

and
down
to
listen
for

chattering

noise
or

lightly
hammer
on
rivets
for
a

slightly
cracked
noise

Any
of
these

noises
mean

requirement
for

replace

ment
as
a

complete
assembly

CLUTCH

SERVICE

DATA
AND

SPECIFICATIONS

Clutch
cover

Clu
tch

cover

type

Diaphragm
spring
to

flywheel
distance

Unevenness
of

diaphragm
spring
toe

height

Full
load

Out
of
flatness
of

pressure
plate

Allowable

refacing
limit
of

pressure
plate

Clutch
disc

Facing
size

Outer
dia
x
inside
dia
x
thickness

Thickness
of
disc

assembly

Free

Compressed

Number
of
torsion

springs

Allowable
minimum

depth
of

rivet

head
from
surface

Allowable

facing
run
out

Allowable
free

play
of

spline

at
the
outer

edge
of
disc

Clutch

pedal

Pedal

height

Play
at

clevis

pin

Full

stroke

Clutch
master

cylinder

Dia
of
master

cylinder

Allowable
maximum
clearance

between

cylinder
and

piston

Clutch

operating
cylinder

Dia
of

operating
cylinder

Tightening
torque

Clutch

assembly
to

flywheel
securing
bolt

Pedal

installation
bolt
Fulcrum

pin

Pedal

stopper
lock
nut

Push

rod
lock

nut

Master

cylinder
to
dash

panel
securing
bolt

Clutch

tube
connector
Flare
nut

Clutch

hose
connector

Operating
cylinder
to

clutch

housing
securing

bolt

Bleeder
screw
mm
in

mm
in

kg

Qb

mm
in

mm
in
Diaphragm
C225S

33

to
35
1
23

to
1
38

less
than
0
5

0
020

400

882

0
1

0
004

1

0
0
040

mm
in
225
x

150
x
3
5
8

86
x

5
91
x
0

138

mm
in

mm
in
8
3
to

8
9
0
327
to
0

350

7

6
to
8
0
0
299

to
0
315

6

0
3
0
012

0
5

0
020

0
4
0
016
mm
in

mm
in

mm
in

mm
in

153
6
02

mm
in
I

to
3

0
039

to
0
118

mm
in
117

to
123
4

61
to
4
84

mm
in

15

87
5
8

mm
in

0
15

0
0059

mm
in

19

05

Yo

kg
m
ft
lb
1

5
to
2

2
lito

16

kg
m
ft

Ib

1
9
to
2
4

14
to
17

kg
m
ft
b
0

8
to
1
2
5

8
to
8
7

kg
m

ft
lb

0
8
to

1
2
5
8
to
8
7

kg
m
ft
Ib
0
8
to
1
2
5
8
to
8

7

kg
m
ft
lb

1
5
to

1
8
11
to

13

kg
m
ft
lb

1
7
to
2
0
12
to
14

kg
m
ft
lb

2
5
to
3
5
18
to
25

kg
m
ft
Ib

0
7
to
0
9
5
1

to
6
5

CL
9

Condition

Clutch
chatters

Noisy
clutch

Clutch

grabs
CLUTCH

Probable
cause
and

testing
Corrective
action

Clutch

chattering
is

usually
noticeable
when
vchicle
is

just
rolled
off
with
clutch

partially

engaged

Weak
or
broken
clutch
disc
torsion

spring

Oil
or

grease
on
clutch
facing

Clutch

facing
out
of

proper
contact
or

clutch
disc

runout

Loose
rivets

Warped

pressure
plate
or
clutch
cover

surface

Unevenness
of

diaphragm
spring
toe

height

Loose

engine
mounting
or
deteriorated

rubber

A
noise
is
heard
after
clutch
is

disengaged

Damaged
release

bearing

A
noise
is

heard
when
clutch
is

disengaged

Insufficient

grease
on
the

sliding
surface

of

bearing
sleeve

Clutch
cover
and

bearing
are
not
installed

correctly
Replace

Replace

Replace

Replace

Repair
or

replace

Adjust
or
replace

Retighten
or

replace

I
Replace

Apply
grease

Adjust

A
noise
is
heard
when
vehicle
is

suddei11y
staited
off
with
clutch

partially
engaged

Damaged
pilot
bushing

I
Replace

When

grabbing
of
clutch
occurs
vehicle
will
not
start
off

smoothly
from
a

standing
start
or

clutch
is

engaged
before
clutch

pedal
is

fully

depressed

Oil
or

grease
on
clutch

facing

Clutch

facing
worn
or
loose
rivets

Wear
or
rust
on

splines
in

drive
shaft
and

clu
tch
disc

Warped
flywheel
or

pressure
plate

Loose
mountings
for

engine
or

power

train
units

CLll
Replace

Replace

Clean
or

replace

Repair
or

replace

Retighten

Cl
Ul
CFf

SPECIAL
SERVICE
TOOLS

Tool
number

For
Reference

No

Description
use
page
or

tool
name

on

Figure
No

Unit
mm
in

ST20050010
620

Fig
CL
12

Base

plate

00
B210

710

610

y
S30

2
ST20050051

Set
bolt

SE002

q

3
ST20050
100

Distance

@

piece
7
8
mm

0
31
in

@1
@J

SEOQ3

4
ST20050240
620

Fig
CL
13

Diaphragm
B210

adjusting
710

wrench
610

S30

SE032

5
KV30100200

Clutch

aligning
bar
This

tool
is

used
to

conduct
disc

centeril

g
by

inserting
the
tool

into

pilot
bush
in

flywheel
when

installing
clutch

assembly
to

flywheel
620

710

610

S30
Fig
CL
2

Fig
CL
3

SEaOl

6
STl6610001

Pilot

bushing

puller
Fig
CL
6
620

710

610

S30

SE191

CL
12

Adjustment
of
front
end

play

Sele
t
front
dutch
thrust
washer

by

calculating
the

following
formula

T

F
C
D

0
2
mm

where

T

F
Required
thickness
of
front

clutch
thrust
washer
mm
in

C
Measured
distance
C
mm
in

D
Measured
distance
D
mm
in

Available
front
clutch
thrust

washer

Thickness
mm
in

1
5
0
059

I
7
0
067

1
9
0
075

2
1
0
083

2
3
0
091

2
5
0
098

27
0
106

Specified
front
end

play

0
5
to
0

8
mm

0
020
to
0

031
in

Notes

a
Correct
thickness
of

bearing
race

and
thrust
washer
is
always
the
one

which
is
nearest
the
calculated
one

b
Installed
thickness
of
oil

pump
gas

ket
is
0
4

mm
0
016
in

10
Check
to
be
sure
that
brake

servo

piston
moves
freely
For
detailed

ptocedure
refer
to

page
AT
42
for

Servo
Piston
Use
care
to

prevent

piston
from

coming
out
of

place
dUI

ing
testing
since
servo
retainer
is
not

tightened
at
this

point
of

assembly

II
Make
sure
that
brake
band
strut

is

correctly
installcd

Torque
piston

stem
to
1
2
to
1
5

kg
m
9
to
11

f1
lb
Back
off
two
full
lurns
and

secure
with
lock
nut
Lock
nut

tight

ening
torque
is
1
5
to
4

0

kg
m

II
to

9

f1
lb
Automatic
Transmission

12
After
inhibitor
switch
is
in

stalled
check
to
be
sure
that
it

op

erates

properly
in

each
range
For

detailed

procedure
refer
to

page
AT

49
for
Checl
ing
and

Adjusting
Inhibi

tor
Switch

13
Check
the

length
L
between

case
end
to
rod
end
ofvacuum
throllle

valve
fully

pushed
in
Then
select

adequate
diaphragm
rod
of
corre

sponding
measured
length
See
Figure

AT
77

Available

diaphragm
rod

Distanl
e

measured
L
ITIm
in

Under25
55

l
OO59

25
65

to
26
05
1

0098
to
1
0256

26
15
to
26
55
1

0295
to
1

0453

26

65
to
27
05
1
0492
to
1

0650

Over
27
15
1
0689

COMPONENT
PARTS

The
transmission
cons
sts
of

many

small

parts
that
are

quite
alike
in

construction
yet
machined
to

very

close
tolerances
When
disassembling

parts
be
sure
to

place
them
in

order
in

part
rack
so

they
can

be
restored
in

the

unit
in
their

proper
positions
It
is

also

very
important
to

perform
func

tianal
test
whenever
it
is

designated

FRONT
CLUTCH

Disassembly

Front

clutch
drum

I

Pinon

lcz

t

AT146

1

Snap
ring

2

Retaining
plate

3
Drive

plate

4

Driven

plate

Fit
AT
78
S
Dished

plate

6

Snap

ring

7

Spring
retainer

8
Coil

spring

Sectional
view

of

front
clu
tch

AT
40
i

i
n
H

I
I

ni
c
A
i

iif

L

1

AT145

Fig
AT
77

Measuring
the
distance

L

Diaphragm
rod

length
mm
in

29
00
142
u

29

5
1161

30
0
1
81

30
5
1201

31
0
I
O

I

Pry
off

snap
ring
D
with

a

suitable
screwdriver
or

a

pair
of

pliers

Remove
a

retaining
plate
@
drive

plate
CID
driven

plate
@
and
dished

plate
@
in

the
order
listed
as
shown

in

Figure
AT
78

I

2

Compress
clutch

springs
using

Clutch

Spring
Compressor

ST25420001
or

51
25420000
Re

move

snap
ring
@
from

spring
re

tainer

using
Snap
Ring
Remover

ST2532000
I

See

Figure
AT
79

AT147

Fig
AT
79

Removing
snap
ring

Note
When
Clutch

Spring
Compres

sor
ST25420000
is
to
be
used
cut

the

toe

tips
of
three

legs
by
a

grinding
wheel
See

Figure
AT
80

Using
the

tester
check
the

two

black

yellow
BY
wires
from
the
in

hibitor
switch
in
the

ranges
N

and

I
and
the

tw
re
d

black

RBj
wir
s

in

the

range
R
for

continuity
Turn

range
select
lever
in
both

directions

from

each
lever
set

position
and
check

each

continuity

range
It

is
normal
if

the

electricity
is

on
while
the
lever
is

within
an

angle
of
about
30

on
both

sides
from
each
lever
set
line
How

ever
if
its

continl
ity

range
is
obvious

ly
unequal
on

both
sides

adjustment
is

required

If

any
malfunction
is

found
un

screw
the

fastening
nut
of
the

range

selector
lever

and
two

fastening
bolts

of
the
switch

body
and
then
remove

the
machine
screw
under
the
switch

body
Adjust
the
manual
shaft
correct

ly
to
the

position
N

by
means
of
the

selector
lever

When
the

slot
of
the

shaft

becomes
vertical
the
detent

works
to

position
the
shaft

correctly

with
a

clicking
sound

MSlVe
the

switch

slightly
asj
Je
so

that
the
screw
hole
will
be

aligned

with
the

pin
hole
of
the
internal
rotor

combined
with
the
manual
shaft
and

check
their

alignment
by
inserting
a

1
5
mm
0
059
in
diameter

pin
into

the
holes
If

the

alignment
is
correct

fasten

the
switch

body
with
the
bolts

pull
out
the

pin
tighten

up
the
screw

in

the
hole
and
fasten
the
selector

lever
as
before
Check
the

continuity

again
with
the
tester
If

the
malfunc

tion
still

remains

replace
the
inhibitor

switch
Chcck
whether
the

reverse

lamp

and
the
starter
motor

operate
normal

ly
in
these

ranges
If
Ihere
is

any

lrouble

first
check
the

linkage
If

no

fault
is
found
in

the

linkage
check
the

inhibitor
switch

Separate
the
manual
lever
from
Ihe

remote
control
selector

rod
and
turn

the

range
selcct

lever
to

N

Note

In
the

position
N

the
slot
of

the

manual
shaft

is
vertical

STALL
TEST

The

purpose
of
this
test
is
to
check

the
transmission

and

engine
for
trou

ble

by
measuring
the
maximum
num

bers
of
revolutions
of

the

engine
while
Automatic

Transmission

vehicle
is
held
in
a

stalled

condition

The
carburctor
is
in

full
throttle

opera

tion
with

the
selector
lever
in

ranges

f
2

and
I

respectively
Com

pare
the

measured
results
with
the

slandard

values

Components
to

be
tested

and

test

items

I
Clutches
brake

and
band
in
trans

mission
for

slipping

2

Torque
converter

for

proper
fune

tioning

3

Engine
for
overall

properly

STALL
TEST

PROCEDURES

Before

Icsting
c
heck
the

engine
oil

and

torque
converter

oil
warm

up
the

engine
cooling
water
to
suitable
tem

perature
by
running
at

1
200

rpm
with

the
selector
lever
in

the

range
P
for

several
minutes
Warm

up
the

torque

converter
oil
to
suitable

temperature

6010
1000C
140
to

2l20F

I

Mount
the

engine
tachometer
at
a

location
that
allows

good
visibility

fro

the
dri
er
s
seat
and

put
a
mark

on

specified
revolutions
on
the
meter

2

Secure
the
front
and
rear
wheels

with
chocks
and

apply
the
hand
brake

Be
sure
to

depress
the
brake

pedal

fumly
with
the
left
foot
before
de

pressing
the
accelerator

pedal

3
Throw
the
selector
lever
into

the

range
1

4

Slowly
depress
the
accelerator

pedal
until
the

throttle
valvc
is

fully

opened

Quickly
read
and
record
the

engine
revolution
when

the

engine

begins
to
rotate

steadily
and
then

release
the
accelerator

pedal

5

Shift
the
selector
lever
to
N

and

operate
the

engine
at

approxi

mately
1
200

rpm
for
more
than
one

minute

to
cool
down
the

torque
con

ver
ter
oil

and
coolant

6

Make
similar
stall
tests
in

ranges

2
I
and
RIO

Note
The
stall
test

operation
as

speci

f
d
in
item
4

should
be

I
l3de

wiihin
five
seconds
If
it

takes
too

long
the
oil
deteriorates
an

the

clutches
brake

and
band
are
ad

versely
affected
Sufficient
cooling

time
should
be

given
between
each

AT
5O
test
for
the
four

ranges
0
2

I
and
R

JUDGEMENT

High
stall
revolution
more

than

standard
revolution

If
the

engine
revolution
in
stall

condition
is

higher
than
the
standard

values
it

indicates
that
one

or
more

clutches
in

the
transmission
are

slipping
and
therefore
no
further
test

is

required

For
the

following
abnormalities

the

respective
causes
are

presumed

High

rpm
in

all

ranges
low
Iine

pressure

High
rpm
in
D
2
and
I

and

normal

rpm
in
R
Rear
clutch

slipping

High
rpm
in
0

and

normal

rpm
in
I

clutch

slipping

High
rpm
in
R

only
Front

clutch
or
low
and
reverse

brake

slipping

To

determine
which
is

slipping

front
clutch
or
low

and
reverse
brake

a
road
test
is
nceded

If
whilc

coasting
after

starting

with
the
lever
in
1

range
engine

braking
does

not
work

properly
the

low
and

reverse
brake
is

slipping

Otherwise
the
front
clutch
is

slipping

Slipping
of
the
band
brake
is

diffi

cult
to
ascertain

However
if
it

occurs

with
the
lever
in
2

range

engine

revolution
increases

Jp
to
thesarne

level
as
in

I

strange
It

is

impossible

to
check

it
in
the
stall
test
2
and

One

way

2
Standard
stall
revolution

If
the

engine
revolution
in

stall

condition
is
within

the
standard

values
the
control
elements
are

nor

mally

operating
in
the

ranges
0

2
I

and
R

Also

tIle

engine
and
one

way

clutch
of
the

torque
converter
are

normal
in

performance
and

operation

The
one

way
clutch
of

the

torque

converter
however
sometimes

sticks

This
is
determined
in

the
road
test

3
Lower
stall
revolution
than
stand

ard
revolution

If
the

engine
revolution
in
stall

condition
is

lower
than
the
standard

PROPElLER
SHAFT
DIFFERENTIAL

CARRIER

PROPELLER
SHAFT

AND
CENTER

BEARING

CONTENTS

DESCRIPTION

REMOVAL
AND
INSTALLATION

DISASSEMBLY
AND
ASSEMBLY

INSPECTION

i

t

I
tl
J

I

O

148
5
5
85
PD
2

PD
2

PD
3

PD
3
CHECKING
AND

CORRECTING

UNBALANCED

PROPELLER
SHAFT

SERVICE
DATA

TROUBLE

DIAGNOSES
AND

CORRECTIONS

PD
4
PD
3

PD
4

2

483
19
02
750
29
53

987
38
86

Long
wheelbase
and

Deluxe
cab

models

Unit
mm
in
35

1
38

Front

5

Companion
flange

6
Plain
washer

7
Self

locking
nut

8

Flange

yoke
Rea

1
Sleeve

yoke

assembly

2
Center

bearing

3
Center

bearing
insulator

4

Center

bearing
bracket

DESCRIP
TION

The

propeller
shaft

on
the
620

series
is
3

joint

type

The

propeller
shaft

and
universal

joint

assembly
is

carefully
balanced

during
original

assembly
that
is
the

dynamic
unbalance
is
under
35

gr
cm

0
49
in

oz
at
S

800

rpm

If
the

propeller
shaft

has
to
be

assembled
it
must
be

made

carefully

so
that
the

above
limit
is
not
ex

ceeded
Therefore

when
the
vehicle
is

to
be
undercoated

cover
the

propeller

shaft
and

universal

joints
to

prevent

application
of
the

undercoating
ma

terial
9

Bearing
race

assembly

10

Snap
ring

11
Journal

assembly

PD218

Fig
PD

l

Crou
ctional
v
w

of
propelkr
hafl

REMOVAL
AND

INSTALLATION
3
Remove

bolts

connecting
shaft
to

companion
flange
of
differential

car

rier
See

Figure
PD
3

I
Raise
vehicle
on

hoist
Put
match

marks
both
on

propeller
shaft

and

companion

flange
so
that
shaft

can
be

reinstalled
in

the

original

position

2

Remove
bolts

retaining
center

bearing
bracket
See

Figure
PD
2

PD220

Fig
PD
3

Removing
propclkr
cha
t

PD219

Fig
PD
2

Removing
center

bearing

bruckel
4

Withdraw

propeller
shaft
sleeve

yoke
from

transmission

by

moving

shaft
rearward

passing
it
under

rear

axle

PD
2

PROPELLER
SHAFT

8l

DIFFERENTIALCAAR
ER

CHECKING
AND

CQRRECTING

UNBALANCED

PROPELLER
SHAFT
anced

propeller
shaft

proceed
as

follows

I
Remove

undercoating
and
other

foreign
materials
which
could

upset

shaft
balance
and

check
shaft

vibra

tion

by
road
test

2
If

shaft
vibration
is

noted

during
To
check

and
correct
an
unbal

SERVICE
DATA

Pe
issible

dynamic
unbalance

Axi

play
of

spider

journal

Journal

swinging

torque

Propeller
shaft
front

and
rear
out
of

round

Tightening
torque

Shaft
to

conipanion
flange
Gear
carrier
bolt

Self

locking
nut
front
shaft

Flange
yo
e
rear
shaft
to

companion
flange

front
shaft
bolt

Center

bearing
bracket
to
cross
member
bolt
road

test
disconnect

propeller
shaft
at

differential
carrier

companion

flange

rotate

companion

flange
180

degrees

and

reinstall

propeller
shaft

3

Again
check

shaft
vibration
If

vibration
still

persists
replace

pro

peller
shaft

assembly

gr
cm
in
oz

3S
0
49
at
S
800

rpm

mm
in

Less
than
0
02
0
0008

kg
em
in

Ib
Less
than
IS
O
13

mm
in

Less
than
0
6
0
024

kg
m

ft
lb

kg
m

ft
Ib

kg
m
ft
lb

kg
m
ft
lb
2

4
to
3
3
17

to
24

20
0
to
24
0

l4S
to
174

2
4
to

3
3
17
to
24

1

6
to
2
2

12
to
16

TROUBLE

DIAGNOSES
AND

CQRRECTIONS

Condition

Probable

cause

Vibration

during
at

medium

or

high
speed
Worn

or

damaged
universal

joint
needle

bearing

Unbalance

due
to
bent
or

dented

propeller

shaft

Loose

propeller
shaft

installation

Worn
transmission
rear

extension

bushing

Damaged
center

bearing
or
insulator

Tight
universal

joints

Undercoating
or
mud
on
the
shaft

causing

unbalance

Tire
unbalance

Balance

weights
missing

PD
4
Corrective

action

Replace

I
l
eplace

Retighten

Replace

Replace

Impact
yokes
with
hammer
to
free

up

Replace
joint
if
unable
to
free

up
or
if

joint

feels

rough
when

rotated

by
hand

Clean

up
shaft

Balance
wheel
and
tire

assembly
or

replace

from
known

good
vehicle

Replace