wheel bolt torque DATSUN PICK-UP 1977 Owner's Manual

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

Rear
Axle
Rear

Suspension

Spring
front

pin

Spring
shackle

Bearing
cage

fIXing
bolt

Wheel

bearing
lock
nut

Air
breather

Differential

gear
carrier

to
axle
case
nut

Propeller
shaft

flange
bolt

Drain
and
filler

plug

Bumper
rubber

fixing
bolt

Wheel
nut
kg
m
ft
lb

kg
m
ft
Ib

kg
en
ft
lb

kg
m
ft

Ib

kg
m
ft
Ib

kg
m
ft
Ib

kg
en
ft
Ib

kg
m
ft

Ib

kg
m
ft
Ib

kg
m
ft

lb
11
5
to
13
0
83

to
94

11
5

to
13

0
83
to
94

S
4
to
6
4
39

to
46

IS
to
20
108

to
l4S

0
7

to
0

9
S
I

to
6
S

17
to
2
7

12
to
20

2
0
to

2
7

14
to
20

6
to
10
43

to
72

1
6
to
2
2

12
to
16

8
to
9
S8

to
6S

TROUBLE

DIAGNOSES

AND
CORRECTIONS

When

rear
axle
and

suspension
is

suspected
of

being
noisy
it
is

advisable

to
make
a

thorough
test
to
determine

whether
the
noise

originates
in

the

tires

road
surface
exhaust

propeller
shaft

engine
transmission
universal

joint
wheel

bearings
or

suspension

Noise
which

originates
in

other

places
can
not

be
corrected

by
adjust

ment
or

replacement
of

parts
in
the
rear
axle

and
rear

suspension

In
case
of

oil
leak

first
check
if

there
is

any

damage
or

restriction
in

breather

Condition
Probable
cause

Noise
Loose
wheel
nuts

Loose
one
or

more

securing
bolts

Lack
of

lubricating
oil
or

grease

Faulty
shock
absorber

Incorrect

adjustment
of

rear
axle
shaft
end

play

Damaged
or
worn
wheel

bearing

Worn

spline
portion
of
rear
axle
shaft

Broken
leaf

spring

Loose

journal
connections

or
so
no

Wheel
and
tire

unbalance

Damaged
rubber

parts
such
as
leaf

spring

bush
shock
absorber
moun

ting
bush

Faulty
universal

joints

Instability
in

driving
Loose
wheel
nuts

Worn
shock
absorber

Worn

or
broken
leaf

spring

Oil

leakage

Damaged
or

restricted
air

breather

Damaged
oil
seal
in

rear
axle
case
or
differ

ential
carrier

Oil

leakage
from
between
the
differential

carrier

and
axle
case

RA
8
Corrective
action

Tighten
the

wheel
nuts

Tighten
the

bolts
to
the

specified
torque

Lubricate

as

required

Replace
the
shock
absorber

Adjust
the
rear
axle

shaft
end

play

Replace
wheel

bearing

Replace
if

necessary

Replace
leaf

spring

Tighten
to

the

given
torque

Balance
wheel

and
tire

Replace
the

required
parts

Adjust
or

replace

Tighten
to
the

given

torque

Replace
faulty
shock
absorber

Replace
leaf

spring

Clean
or

replace
air

breather

Replace
the

damaged
oil
seal

Tighten
to
the

specified
torque
or

replace

gasket

After

connecting
brake
tube
be

sure
to

check
the
clearance
to

prevent

from

damage
The
clearance
at

the

following
portions
must
be

specified

distance
or

more

Tube
to

body
panel
and

frame

Over
5

mm
0
20
in

Tube

to
edge
of
each

panel

Over
10
mm
0
39

in

Tube
to
tube

Loop
pitch

OVer
5
mm
0
20
in

Between
front
tube
and

rear
tube

Over
9

mOl
0
35

in

Tube
to

moving
parts

Over
10
mm
0
39
in

Loop
tube
to

hood

ledge

panel

Over
10

mm
0
39
in

Notes

a
Brake
tubes
are

shaped
at

factory

to
secure

specified
clearance
and

may
not

require
reshaping
Discard

if

they
call
for
excessive

reshaping

b
In

reshaping
a
brake
tube
take
care

to
avoid

damaging
galvanization
or

collapsing
section

Mter
brake
lines
have
been

asssem

bled
check
to
make
sure
that
all

fittings
and
flare
nu
Is
ale

lightened
to

correct

torques

Tightenint
torque

Brake
tube
to
connector

I
Ston

kg
m

II
to

13
ft
Ib

Brake
tube
to
brake
hose

1
7
to

2
0

kg
m

12
to
14
ft
lb

Connector
and

clip
fixing
bolt

O
3S
to
O
4S

kg
m

2
5

to
3
3

ft
lb

3

way
connector

fixing
bolt

on
rear

axle
case

0
8
to
1
1

kg
m

6
to
8
ft
lb

N
L
S
V

DESCRIPTION

The

Nissan
Load

Sensing
Valve

N
L
S
V

serves
to

change
braking

power
of
the

rear
wheels
in

response

to

changes
in
the
load
and
fluid

pressure
improving
braking
stability

and

shortening

stopping
distances
Brake

System

The
N
L
S
V

is
installed
on
the

frame

being
inclined
at
10

degrees
A
summary
of

the
N

L
S
v

operation
is

given
in

Figures
BR
14

and
BR
15

r
Master

cylinder
TI
II

I

y

1

J

I

l
Attaching
angle

D

Wheel

cylinder

BR928

Fig
BR
14
Construction

of
N
L
S
V

Performance
curve
of
brake
fluid

pressure
is
as

follows

0

S

c
A

0

C

o

l
0
oadea

U1U

Front
wheel

cylinder

fluid

pressure
BR769

Perfonnance
curve

of
fluid

pressure
Fig
BR
15

N
L
S
V
TEST

the

following
occurs

When
rear
wheels
lock

stopping

distance
is
shorter
than
13
1

m
43

0

ft
whether
loaded
or
unloaded

Stopping
distance
should
be

measured

from
the

place
where
the
brake

pedal

is

first

applied
to
the

place
the
vehicle

actually

stops
Front
wheels
lock

simultaneously
with
or
ahead
of
rear

wheels
Operating
test

The

test
should
be
conducted
under

these
conditions

Drive
a
vehicle
with

pay
load
and

then
with

only
driver
on

a

dry
flat

concrete
or

asphalt
road

applying
the

brake
suddenly
at
40
km

h
25
MPH

N
L
S
V
is

functioning
normally
if

BR
9

2
The
allowable
maximum

out
of

round
of
brake
drum
is
0
02

mm

0

0008
in

Re

condition
or

replace
brake
drum

if

specified
limit
is
exceeded

3

Measure
for

tapered
brake
drum

If

specified
limit
of
0

02
mm
0

0008

in
is

exceeded
as
measured
at

a

position
where
the
distance
of
4S
mm

177
in
is

kept
away
from
inlet

re
condition
or

replace
brake
drum

4

Contact
surface
with
which

linings
come
into

contact
should
be

finished
to

such
an
extent
that
it
is

ground
by
a
No
120
to
150
sand

paper

S

Using
a
drum

racer
finish
brake

drum

by
machining
if
it

shows

any

sign
of
score
marks

partial
wear
or

stepped
wear
on
its
contact
surface

Note
After
brake
drum
is

completely

re
conditioned
or
renewed
check

drum
and
shoes
for

proper
contact

pattern

Brake

assembly

I
When
brake
shoe

linings
are

cracked

incompletely
seated
uneven

Iy
worn

andlor
deteriorated
due
to

excessive

heating
or
soiled
with

oil

grease
and
brake
fluid

replace

2

Replace
linings
if
the
thickness
is

worn
down
to
less
than
1
0
mm
0
039

in

Note

When
brake
shoe

lining
is
in

stalled

grind
brake
shoe

lining
face

to
diameter

equal
to
that
of
brake

drum

lining
dimension

Width
x
Thickness
x

Length

4S
x

4
S
x

244
mm

1
77
x
0

177
x

9
61
in

3

Check

adjuster
for
smooth

oper

ation

4

Replace
shoe
return

springs
which

are
broken
or

fatigued
Brake

System

Standard
dimensions
of
shoe

springs

Free

length
Dia

of

spring
No
of
Installed

Item

lengthlload

mOl

in
mOl
in

coils

mm

kg
in
lb

Upper
136
5

2
0
0

079
37
IS9
S
14

to
16

S

37
6
28
31

to
3S

Lower
134
S

2
3
0
091
35
IS9
5
21

to
23

5
30
6
28
46
to

Sl

After
shoe
83
2

1
4
O
OSS
27
S
99
4

to
S

3
28
3

90
9
to
II

Wheel

cylinder

I

Replace

any
cylinder
or

piston

which
is
scratched
scored
or
worn
on

its

sliding
contact
surface

2

Replace
worn

parts
if

piston
to

cylinder
clearance
is

beyond
O
IS
mm

0
OOS9
in

Wheel

cylinder
inner
diameter

19
0S
mOl

Y
in

3

Replace
piston
cup
which
is

worn

or
otherwise

damaged

4

Replace
if

contacting
face
of

cyl

inder
and
shoe
is
worn

locally
or
in

step

S

Replace

damaged
dust
cover

fatigued
piston
spring
or

faulty

threaded

parts

6

Replace
tube
connector
which
is

worn
on
its

threaded

portion

INSTALLATION

Install
front
brake
in
the

reverse

sequence
of
removal

paying
particular

attention
to
the

following
instructions

I

When

assembling
adjuster
assem

bly

apply
brake

grease
to

adjuster

housing
bore

adjuster
wheel
and
ad

juster
screw

When
installing
adjuster

assembly

to
brake
disc

apply
brake

grease
to

disc

adjuster
and

retaining
spring
slid

ing
surfaces

to
slide

adjuster
smoothly

Measure

adjuster
sliding
resistance

Adjust
by
adjuster
shim
when

sliding

resistance
is

in
rrect

BR
ll
Adjuster
sliding
resistance

S
to

12

kg
II
to
261b

2

When

installing
wheel

cylinder
be

sure
to
secure
the

cylinder
with
R

mark

to
right
hand
disc
and
the
one

with
L
mark
to

left
hand
disc

Otherwise
brake
hoses

may
interfere

with
other

adjacent
parts
As

to
the

connecting
instructions

of
brake
hose

no
twist
or

contact
is
existed
on

brake

hose

referring
the

related

topic
Brake

line

Tightening

torque

Wheel

cylinder

SA
to

6
6

kg
m

39
to
48
ft

lb

Connector
bolt

1
9
to
2
5

kg
m

14
to
18
ft
Ib

Brake
hose

1
7
to
2

0

kg
m

12
to
14
ft
lb

Air
bleeder

0
7

to
0
9

kg
m

5
to
7
ft

Ib

Brake
disc

4
2

to
S
O

kg
m

30

to
36
ft
lb

3

Before
installing
brake
shoe
as

semblies

apply
brake

grease
to
wheel

cylinder
and

adjuster
brake
shoe
in

stalling
grooves
and
brake
disc
and

brake
shoe

assembly
contact
faces

two

places
Exercise

care
not
to

allow

grease
to

come
into
contact
with

linings
and

adjuster

f

BR317

Fig
BR
23

Gre
ing
point

4

Tightening

torque

Wheel

cylinder

J
S
to
1

8

kg
m

II
to

13ft
Ib

Connector
bolt

1

9
to
2
5

kg
m

14
to
18
ft
Ib

Brake
tube

1
5
to
1

8

kg
m

II

to
13

ft
Ib

Air
bleeder

0
7
to
0
9

kg
m

S

to
7
ft
Ib

Brake
disc

5
4

to
6
4

kg
m

39
to
46
ft

Ib

S

Adjust
brake
shoe
clearance
and

bleed
brake

system
Upon
completion

of

the
above

adjustments
make
sure

that
brake

operates
correctly
and
no

brake
fluid
leaks

MASTER
VAC

DESCRIPTION

A
vacuum

suspended
Master
Vac

is

installed
behind
the

master

cylinder

As
the

brake

pedal
is

depressed
fluid

is

forced
under

high
pressure
through

the
brake

pipes
to
the
wheel

cylinders

to
retard

or

stop
the

vehicle

The
Master
Vac
contains

a

spring

loaded

diaphragm
of
IS2
4

mm
6
in

in

diameter
It

operates
on

negative

pressure

produced
n
the

engine
intake

manifold

The
tandem

master

cylinder
is

capable
of

producing
high
pressure

even
if
the
Master
Vac
is

faulty
Brake

System

Note
The
Master
Vac

diaphragm
dif

fers
from
fonner
ones
for

improved

braking
force
Do
not
install
fonner

Master
Vac
on
1976
models
The

1

Plate
and
seal

2
Push
rod

3

Diaphragm

4

Rear
shell

5

Diaphragm

plate
Master
Vacs

are
identified

by
the

label
color
as
follows

1976
model
Caution

Label

Former
models
YeJlow

BR321

11

Valve

operating
rod

12
Valve

return

spring

13

Poppet
return

spring

14
Exhaust
valve

15
Valve

plunger

16
Reaction

disc

17

Diaphragm
return

spring

18
Front
shell
6
Seal

7

Vacuum
valve

8

Poppet
assembly

9
Valve

body
guard

10
Air

silencer
filter

INSPECTION
OF

OPERATION

Checking
yscuum

pressure

I
Connect

a
vacuum

gauge
in
the

line
between
check
valve

and
Master

2
Start

engine
and
increase

engine

speed
Stop
engine
when
vacuum

gauge
indicates
SOO

mmHg
19
69

inHg

BR
14
Fig
BR
24
Sectionall1iew

of
Master
Vac

Vac
as

shown
in

Figure
BR
25

1

Check
valve

2

Vacuum

gauge

BA169

Fig
BR

25
Air

tight
t
t
t

up

Air

tight
test

I
Fifteen

seconds
after

engine
is

stopped
observe
the

rate
of

drop
in
air

pressure
registered
by
vacuum

gauge

If
a

pressure
drop
of
25

mmHg
0
98

inHg
is

exceeded
refer
to
the
follow

ing
chart
to
determine
the
cause
of

failure

Brake

System

Tightening

torque

Master

cylinder
to
Master
Vac

kg
m
ft
Ib

0
8
to
l
l
6

to
8

Brake
tube

flare
nut

kg
m

ft
Ib
I
S

to
1
8

II
to
13

Brake

hose
connector

kg
m

ft
lb
1
8
to
2
1
13
to
IS

Air

bleeder
valve

kg
m
ft
lb

0
7
to
0

9
S
to
7

Fulcrum

pin
of
brake

pedal
kg
m

ft
Ib
1
2
to

1
5
9
to
II

Connector
and

clip

fIXing
bolt

kg
m
ft
lb

0
35
to
O
4S

2
5
to
3
3

3

way
connector

fIXing
bolt

kg
m
ft

Ib

0
8
to
l
l

6
to
8

on
rear
axle

case

Brake

pedal
stopper
lock
nut

kg
m
ft
Ib
1
2

to
1
5

9
to
II

N
L
S
V

to

body

kg
m
ft
Ib
0
8
to
l
l

6
to
8

Wheel

cylinder

mounting
nut

Front

kg
m
ft

Ib
S
4

to
6
6
39

to
48

Rear

kg
m
ft
Ib

1
5
to
1

8
II

to
13

Wheel

cylinder
connector
bolt

kg
m
ft
lb
1
9

to
2
5

14
to
18

Brake
disc
Back

plate
nut

Front

kg
m
ft

Ib
4
2
to
S

O
30
to
36

Rear

kg
m
ft

Ib
S
4

to
6
4
39
to
46

Master
Vac

Master

Vac
to

body
nut

kg
m
ft
lb
0

8
to
l
l
6
to
8

Flange
to

shell
cover
nut

kg
m
ft
lb

0
8
to
1
1
6
to

8

Operating
rod
lock
nut

kg
m

ft
Ib
1
6
to
2
2
12
to

16

Push
rod

adjusting
nut

kg
m

ft
Ib
1

9
to
2
4
14
to
17

BR
21

Condition

Brake
chatters

Brake

squeals

Pedal

pulsates

Brakes
fade

Brakes

drag

Unbalanced
brakes
Brake

System

Probable
cause

Groove

or
out
of

round
brake
drum

Loose

or
bent

brake

disc

Distorted
brake
shoes

or

pads

Grease
or
brake
fluid
on

linings

Dirty
or
scored
brake

drums

Distorted
brake
shoes
or
bent

support
plate

Weak
or
broken
brake
shoe

retaining
spring

or

return

spring

Glazed
or
contaminated
brake

lining

Out
of

round
or
off
center
drum

Brake
fluid
has
too
low

boiling
point

Use
of

improper
linings
or
brake

linings
are

contaminated

Brake
drums
are
out
of
round

Hydraulic
connections
master

cylinder
and

wheel

cylinders
are

corroded
or

damaged

Bleed
screw
is

open

Pedal

linkage
is

binding
or

push
rod

adjust

ment
is
too

long

Master

cylinder
compensator
part
is
ob

structed

Seized
master

cylinder
piston

Poor
shoe
condition

Poor

wheel
cylinder
condition

Deformation
of

piston
cups

Hand
brake
will
not
return

Clogged
master

cylinder
return

port

Improper
tire
inflation

Improper
adjustment
of
shoe

to
drum
clear

anee

Grease
oil
mud
or
water
on

linings
or

pads

Mud
in

brake
drum

Deterioration
of

linings
or

pads

Excessive
wear
of

linings
or

pads

BR
23
Corrective
action

Grind
or

replace
as

required

Tighten

support
plate
bolts
to

specified

torque
or

replace
plate

Replace
as

necessary

Replace
linings

Blowout

assembly
with

compressed
air
or

refinish
drum

Replace
faulty
unit

Replace
if

faulty

Cam

ground
lining
to
eliminate

glaze
If

it

doesn
t

replace
linings

Turn

drum
or

replace
as
necessary

Drain
and
fill

system
with

approved
fluid

Replace
linings

Repair
or

replace
as
necessary

Repair
as
necessary

Close
screw
and
bleed

system

Lubricate

linkage
check

pedal
return

spring

for
condition
and

adjust
push
rod

as
neces

sary

Blowout

foreign
matter
with

compressed

air

Disassemble
master

cylinder
and

replace

piston
Bleed

system

Clean
and

repair

Repair
or

replace

Replace

Check
and

repair

Clean

Inflate
to
correct

pressure

Readjust

Clean
brake

mechanism
and
check
for
cause

of

problem
Replace
linings
or

pads

Clean

Replace

Replace

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

STEERING
LINKAGE

Removal
and

installation

Removal

I
Jack

up
the

front
of
vehicle
and

support
it

on
the

safety
stands

2
Remove

cotter

pins
and

nuts
fas

tening
side
rod

ball
stud
to
knuckle

arms

3

To
detach
side
rod
ball
studs

from
knuckle
arms
insert
Ball
Joint

Remover
HT72520000
between
them

and

separate
them

by
striking
the

top

of
this
tool

with
a
hammer
If
this

operation
must
be
done
without
this

tool

strike
the
knuckle
arm
boss
with

a

hammer

backing

up
the

opposite
side

of
it
with
a

large
hammer

and
bail
stud

is
freed
from

knuckle
arm
Must
not

strike
the
baIl
stud
head
the
ball

socket
of

side
rod
and
side

rod
with
a

hammer

and
so
on
in

this

operation

Fig
ST
11
Ball

joints

Ic
ann
side

4

Remove
riut

securing
gear
armOD

sector
shaft

and
remove

gear
arm
with

the

use
of
Pitman
Arm

Puller

ST29020001

See

Figure
ST
6

S

Remove
idler
arm

assembly
from

frame

by
backing
off

fixing
bolt
and

nut

Ffa
ST
12

Removing
idler

ann
STEERING

SYSTEM

6
Cross
rod
both

side
rods

and
the

adjacent
parts
can
then
be
freed
from

the

vehicle
as
an

assembly

7

Then

separate
the
ball

joints
of

steering

linkage
assembly

following
the

procedure
for
removal
of
the
side

rods

ball

joints
at

knuckle
arm

sides

Assembly

Install

steering
linkage
in

the
reo

verse

sequence
of

removal

observing

the

following
notes

Tightening
torque

Ball

stud
S
S
to

10
0

kg
m

40
to
72
ft
lb

Idler
arm

assembly

3
2
to
3
7

kg
m

23
to
27
ft
lb

Cross
rod

adjust
bar
lock
nut

8
to
10

kg
m

72

fL
2
f
2
When

cross
rod
sockets

and
cross

rod
are

separated
adjust
cross
rod

length
correctly

Adjustment
should
be
done
be

tween
the
centers
of
ball

joints
at
the

both
end
of
cross
rod

assembly

Standard
cross
rod

length

516

rom
20
31
in

3

Adjust
toe
in

and

steering

angle

The

procedures
of
toe
in

and
steer

ing

angle
adjustments

Ie
described
in

Section
F

A

Toe
in

1
to
5
mm

0
04
to
0
20
in

Steering
angle

Inner
wheel
3S030
to

36030

Outer
wheel
30030

to
31030

5t6
mm
20
31
in

1
Cro
s
rod

2
Side
rod

3
Cross
rod
socket

4
Idler
arm

assembly

5

Gear

housing

assembly
Mter

adjustment
of

toe
in
be
sure

that
dimension
A

at

both
ends
of
cross
rod
is
not

less
than
20
nun
0
79
in

Idler
ann

assembly
ST210

Fig
ST
13

Adjusting
cross
rod

assembly

@

1
Idler

body

2
Collar

welded
to

idler

body

A

3
Plain

bushing

4

Screw

bushing

T529

ST
6
Fig
ST
14

Sectional
W

of
idler
arm
as
sembly

I

J

L6

3

4

5
1

Apply
recommended

grease
to

screw

bushing
interior

plain
bushing

interior
dust
seal
inside
and

bushing

sliding
surface
of
idler
ann

Screw

bushing
tightening

torque

12

kg
m

87
ft
lb

2

Before

installing
idler
arm
assem

bly

replace
f
iller

plug
with

grease

nipple
and

apply
recommended

grease

to
idler

ann

through
this

grease
nipple

until

grease
is
forced

out
at
the

lower

end
of

the
dust

seal

lip
Remove

grease

I

8
I

II

I

I

FIODt

Inspection
and

repair

Ball

joint

1
When
ball
stud
is

worn
or
axial

play
is
too

excessive

replace
cross
rod

socket
or
side

rod
with
a
new
one

2
When

dust
cover
is

broken
or

defonned

be
sure
to

replace
with
a

new
one

Axial
end

play
0
1
to
0
5

mm

0
004
to
0
020
in

Initial

swing
torque

S
to
15

kg
cm
70
to
209
in
oz
STEERING
SYSTEM

nipple
and
reinstall

filler

plug

3
In

installing
idler
arm

assembly

make

sure
that
the

standard

dimension

A
is

adjusted
correctly

Standard
dimension

A

137
8
to

139
8

mm

S

42S
to
S
504

in

See

Figure
ST

14

Furthermore
be

sure
to

install

washers

correctly
See

Figure
ST
IS

Spring
washer

Frame

Plain
washer

Weld
nut

Self

locking
nut

ST212

Fig
ST
15
Locations

of
washers

Initial

swing
torque
5

to
15

kg
cm

70
to
209
in
oz

ST213

ST
7
sary
To
renew

grease
remove

grease

nipple
cap
and

apply
recom

mended

grease
to
ball

joint

through

grease
nipple
until

grease
is
forced

out
at
the

grease
vent
hole

Idler
arm

3B8embly

Remove
old

grease
and
dirt
and

check
idler

ann

assembly
for
wear

deformation
and

damage

CrOBS
rod
side
rod

and

gear
arm

Check
them
for

bending
damage

and
crack
and

replace
as

necessary

Inspecting
steering
system
on

the
vehicle

which
comes
into

collision

Steering
system
is

very
important

for

driving
a
vehicle
When
the

vehicle

comes
into

collision

especially
the

front
of
the

vehicle
is

damaged
special

inspection
should

be
done

for
the

following
matters

If

any
component
parts
of

steering

system
is

found

to
be

damaged
re

place
them

with
new
ones

1

Steering

angles
correctness

Inspect
side

rods
and

cross
rod
for

bend
and
sector
shaft

for
distortion

2

Level
of

steering
wheel
bar
with

the
front

wheels
in

a

straight
ahead

position

If
its
deflection
is

more
than
about

90

degrees
the

bend
or
distortion
of

sector
shaft

and
column
shaft
can
be

seen

3
Noise

during

operation
of

steering

wheel

Inspect
column
shaft

and

jacket

tube
for
bend

4
Smooth

operation
of

steering

wheel

Inspect
sector

gear
for

breakage

ball

nut
screw
for
dint
and
column

shaft

for
bend

S
Gear
arm

breakage

6
Gear

housing
breakage

In
addition

inspect
gear
housing

f

IXing
bolts
for
looseness

7
Distortion
of
sector
shaft
serra

tion

8
Sector

gear
breakage