DATSUN PICK-UP 1977 Service Manual

S

Apply
wheel

bearing
grease
in

wheel

bearing
and

recess
of
axle

case

end

Lubricating
portion

AA143

Fig
RA
l1

Lubricating
portion
in
and

around
wheel

bearing

6

Apply
gear
oil
to
the

spline
at

the

inner
end

of
axle
shaft

Apply
a

coal

of
wheel

bearing
grease
on
the

seal

surface
of
the
shaft

7

Install
left
or

right
shaft
and

adjust
axial
end

play
by
applying
rear

axle
case
end
shim
indicated

by
arrow

mark

Axial
end

play
0
3
to
0
9
mOl

0
012

to
0
035
in

Standard
shim
thickness

1
5
mm
0
059
in

Tightening
torque
of

bearing
cage
fIXing
nut

54
to
6
4

kg
m

39
to
46
ft
lb

w

AA144

Fig
RA
12
Installing
rear
axle

shaft

Rear

axle
case
end
shim

Thickness
mOl
in

O
OS
0
0020

0
07
0
0028

0

10
0
0039

0
20
0

0079

O
SO
0
0197
Rear
Axle
Rear

Suspension

8
Install
shaft
in

opposite
side

and

adjust
axial
end

play
by
applying
shim

Axial
end

play
0
02
to
O
IS

mOl

0
0008
to
0
0059
in

Tightening

torque
of

bearing
cage

fixing
nut

5
4
to
6
4

kg
m

39
to

46
ft
Ib

Fig
RA
13

Measuring
axial
end

play

9
Install
other

parts
in

reverse
se

quence
to
removal

REAR
AXLE
CASE

Rear

axle

case

may
be
removed

and

installed

using
the

following
pro

cedures

I
Raise
rear
of
vehicle
and

support

securely
under
both
frame
members

with

stands

2
Remove
rear
axle

assembly
See

removal
of

rear
axle

assembly

3
Remove

rear
axle
shaft
at
both

sides
See
removal
of
rear
axle
shaft

and
wheel

bearing

4

Remove
differentiai
carrier

as

sembly

Installing
can
be

proceeded
in
the

reverse
order

of
removal

procedure

Another

procedure
is

available
as

listed
below

I

Raise
rear
of
vehicle
and

support

under
both

frame
members
with

stands

2
Remove
ear
axle
shaft
at
both

sides

3
Remove

differential

gear
carrier

assembly

4
Remove

rear
axle
case

RA
5
Installing
can
be

proceeded
in
the

reverse
order
of
removal

procedure

Tightening
torque

Differential
carrier
to
axle
case

fixing
nut
I
7

to
2
5

kg
m

12
to
18
ft

Ib

Oil
drain
and
fIller

plug

6

to
10

kg
m

43

to
72

ft
lb

REAR
SPRING

1
Raise

rear
of
vehicle
and

support

under
both
frame
members
with

stands

2
Disconnect
shock
absorber
at

lower
end

CD
and
remove
U

bolts

Spring
clips

2

3
Position

jack
under
rear
axle
case

Raise
jack
and
float
axle

case
from

spring

4
Disconnect
rear

spring
shackle

by

removing
nuts

AA147

Fig
RA
15
Removing
spring
shackle

5
Disconnect

spring
from
body
by

removing
spring
front

pin

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

SERVICE
DATA
AND
SPECIFICATIONS

Applied
model

All
models

Item

Rear
shock
absorber

Stroke
x
Maximum

length

mOl
in
190
x
47S
7
48
x

18
70

Damping
force

at
0
3
m
1
0
ft
sec

Expansion
kg
lb
75
to
101
165
to
223

Compression
kg

lb
3S
to
S3
77
to
1l7

Standard
Option

Rear
leaf

spring

Dimensions

Length
x

Width

x
Thickness

Number
of
leaves

mOl
in
1
200
x

60
x
6
3

5
1

13
1

47
24
x
2
36
x
0
24
3

0
20
1

0
51
1
1

200x60x
72

6
1

13
2

47
24
x
2
36
x
0

28
2

0
24
1

0
512

Free

camber
mOl
in
IS3

6
0
140
S
5

Laden
camber

mmlkg
in
lb

6
440
0
24
970
24
440
0
94

970

Spring
constant

kg
mOl

lb
in
2
1

to
S

O
118
to
280
2
6

to
10
0
146
to
S60

Rear

axle

End

play
mOl
in
0
02
to
O

IS
0
0008
to
0
0059

Rear
axle

case
end
shim

thickness
mm
in
O

OS
0
0020

0

07
0
0028

0
10
0
0039

0
20
0
0079

0
50
0

0197

Recommended
for

use
on

heavy
load
under

high
center
of

gravity
such
as

camper
loading

Tightening
torque

Shock
absorber

upper
end
nut

Shock
absorber
lower
end
nut

Rear

spring
U

bolt

Clip
kg
m
ft
lb

kg
m
ft
Ib

kg
m
ft
lb
3
1

to
4

1
22
to
30

1

6
to
2

2
12

to
16

7
3
to

9
9
53
to
72

RA
7

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

Rear
Axle
Rear

Suspension

SPECIAL
SERVICE
TOOLS

Unit
mOl
in
For

use

on
Reference

page
or

Figure
No
No
Tool
number

tool
name
Description

Rear

axle

stand
This
tool
is
used
to
remove
rear
axle
shaft

Use
with

sliding
hammer

ST36230000
All

Fig
RA
S

models
KV40101000

SE402

2
ST36230000
This
tool
is
used
to
remove
rear
axle
shaft
All

Fig
RA
S

Sliding
hammer
Use
with

rear
axle
stand
KV40101000
models

SEll1

3
ST38020000
This
tool
is
used

to
loosen
and

tighten
rear
axle

bearing
lock
nut

620

Fig
RA
7

Bearing
lock

nu
t
wrench

SE238

4
HT72480000
This
tool
is
used

to
drive

out
rear
axle
shaft

bearing
All

rigid
Fig
RA

8

axle
car

models
Rear
axle
shaft

bearing

puller
parts
Iools
are
used
for
other
rear
axle

Iype

SE382

RA
9

DATSUN
PICK
UP

MODEL
620
SERIES

l
4ISSAN
I

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN
SECTION
BR

BRAKE
SYSTEM

GENERAL

DESCRIPTIDN
BR
2

ADJUSTMENT
BR
2

SERVICE
BRAKE
BR
4

HAND
BRAKE
BR
18

SERVICE
DATA
AND

BR
2D

SPECIFICATlDNS

TROUBLE
DIAGNDSES

BR
22

AND

CORRECTIONS

SPECIAL
SERVICE
TOOLS
BR
25

The
620

series
vehicles

are
equip

ped
with

hydraulic
brakes

on
the
four

wheels
and
mechanical
hand
brakes

on

the
rear
wheels
The
front
brake
is

the
uni
servo

type
and
the
rear
the

duo

servo
with
the
built
in

hand

BRAKE
PEDAL

FRONT
BRAKE

REAR
BRAKE

BRAKE
PEDAL

Qi

f

l

II

t

Unit

mm
in

I
Under
the
condition
that
the

push
rod
of
brake

lamp
swi

tch
is

pushed
in

position
the

height
of
brake

pedal
from
toeboard
to
148
mm
5
83

in

operating
the
switch

adjusting

nuts
Then

tighten
nuts

securely

Tightening
torque

1
2

to
1
5

kg
m

9
to
I
I
ft
Ib

2

Adjust
the

length
of

push
rod
Brake

System

GENERAL
DESCRIPTION

brake
The
mechanical
hand
brake
is

controlled

by
a
hand
brake
lever
locat

ed
in
the
driver

s

compartment

For
added

safety
the
tandem

I
1lI3ter

cylinder
Master
Vac
and

Nissan
Load

Sensing
Valve
N

L
S
V

ADJUSTMENT

CONTENTS
are
standard

equipment
on
all
models

The
Master
Vac
is
installed
to
increase

braking
force
The
N
L

S
V
ensures

greater
safety
and

reliability

BR
2

BR
2

BR
3
HAND

BRAKE

Parking
brake

BLEEDING
HYDRAULIC
SYSTEM
BR
3

BR
3

Free

height

Full
stroke
at

pedal
pad
A
148

5
83

B
134

10
140

5
28
to
5
51

C
43
to
49

1
69

to
1
93
Depressed
height

1
Push
rod

adjusting
nut

2
Switch
adjusting
nuts

3
BraKe

lamp
switch

BA765

Fig
BR
l

Adjusting
brake

pedal

with
its

adjusting
nut
so
as
to
become

0
6
to
1
2
mOl
0
024
to
0

047
in
in

play
Then

tigh1en
nut

securely

Tightening
torque

1

6
to
2

2

kg
m

12

to
16
ft
lb

Note
Take
care
not
to
allow
the

push

rod
to

get
into
master

cylinder
in

free
condition

BR

2
3
After
completing

adjustment

operate
brake

pedal
several
times
to

ensure
that
it
travels
over
its
entire

stroke
of
137
mm
5

39
in

smoothly

without

showing
squeak
noise
twist

ing
or
interference

FRONT
BRAKE

1
Raise

vehicle
until
wheel
clear

floor

2

Remove
rubber
boot
from
brake

disc

3

Ughtly
tap
adjuster
housing
and

move
it

forward
Turn
down

adjuster

wheel
with
a

screwdriver
and

spread

brake
shoes

Stop
turning
adjuster

wheel
when
a
considerable

drag
is
Jelt

and
lock

up
brake
drum

Note
For
both

right
and
left
brakes

brake
shoes

spread
when

adjuster

wheel
is
turned
downward

4
Return

adjuster
wheel
12
ratches

to
obtain
correct
clearance
between

brake
drum
and
brake
shoes
Turn

brake
drum
and
make
sure
that
brake

drum
turns
without

dragging
when

brake
shoes
interfere
with
brake
drum

then

readjust
clearance

5

Install
rubber
boot

Fip
BR
2

Adjusting
front
brake

REAR
BRAKE

With
hand
brake

fully
released

adjust
rear
brake
shoe
clearance
For

the
service

procedures
refer
to
Front

Brake

Fig
BR
3
Adjusting
rear
brake

HAND
BRAKE

Parking
brake

I
Raise

vehicle
until
rear
wheels
are

clear
of
the
floor

2

Apply
hand
brake
lever

operate

lock
nuts
to
be
80
to
100

mrn
3
lS
to

3
94
in

in
hand
brake
lever
stroke

and
tighten
lock
nuts

securely

Applying
force
to
hand
brake

lever

20

to
30

kg
44

to
661b
Brake

System

1
t

0
t

6

0

I

o

nJ
c

BA655

Fig
BR
4

Adjusting
lock
nut

3

Fully
release
hand
brake
and

rotate
rear
wheels
No

drag
should
be

present

Notes

a
Before

adjusting
hand
brake
com

plete
the

adjustment
of
rear
brakes

b
After

adjusting
hand
brake

operate

the
brake
lever
to
make
cable

stable

c
Hand
brake
must
be

operated

smoothly
while

being

pulled
and

released
Make
sure

that
no
abnor

mal
noise
dragging
twisting
or

other
faulty
condition
occurs

BLEEDING

HYDRAUL
Ie
SYSTEM

Hydraulic
brake

system
must
be

bled
whenever

any
line
has
been
dis

connected
or
air
has

entered
into

system

When

pedal
action
has
a

spongy

feel
it
is
an
indication
that
air
has

entered
the

system

Bleeding
the

hydraulic
system
is

an

essential

part
of

regular
brake
service

BR
3
I

Clean
all
dirt
around
master

cyl

inder
reservoir

I
remove
cap
and

top
up

reservoir

with
recommended
brake

fluid

2

Thoroughly
clean
mud
and

dust

from
bleeder
valve

so
that
outlet

hole

is

free
from

any
foreign
material

Install
a

bleeder
hose
on
bleeder
valve

Place
the
other
end
of
hose
in

a

container

filled
with
brake
fluid

3

Depress
brake

pedal
two
or
three

times
then

keep
pedal
fully
depressed

4

With
brake

pedal
fully
depressed

open
bleeder
valve
to

expel
air

Notes

a

Pay
attention
to
brake
fluid
level
in

master

cylinder
reservoir

during

bleeding

operation

b
Do
not

reuse
brake
fluid
drained

during
bleeding

operation

c

Bleed
air
as
follows

1
Master

cylinder
front

2
Master

cylinder
rear

3
N
L
S
V

front

4
Front

wheels

S
Rear

wheels
left
one
first

6
N
L

S
V

rear

7
N
L

S
V
center

d
Exercise

care
not
to

splash
brake

fluid
on

exterior
finish
as
it

will

damage
the

paint

5

Close
bleeder
valve

quickly
as

brake

pedal
is
on
down
stroke

6
Allow
brake

pedal
to
return
slow

ly
with
bleeder
screw
closed

7

Repeat
bleeding
operations
until

no
air

bubbles
show
in
hose

Notes

a
Brake
fluid

containing
air
is

white

and

has
visible
air

bubbles

b
Brake
fluid

containing
no
air

nms

out
of
bleeder
valve
in
a

solid

stream
free
of
air

bubbles

8

Repeat
above

steps
on
the

re

maining
brake
lines

to

expel
all
air

Brake

System

SERVICE
BRAKE

CONTENTS

BRAKE
PEDAL

REMOVAL

INSPECTION

INSTAllATION

MASTER

CYLINDER

REMOVAL

DISASSEMBl
Y
AND
ASSEMBLY

INSPECTION

INSTAllATION

BRAKE
LINE

REMOVAL

INSPECTION

INSTAllATION

N
L
S
V

DESCRIPTION

N
L
S
V
TEST

FRONT
BRAKE
BR
4

BR
4

BR
4

BR
4

BR
5

BR
5

BR
6

BR
6

BR
5

BR
7

BR
B

BR
B

BR
B

BR
9

BR
9

BR
9

BR
lO

BRAKE
PEDAL

REMOVAL

Remove

pedal
return

spring

I

2

3

4
REMOVAL

DISASSEMBl
Y
AND

ASSEMBLY

INSPECTION

INSTAllATION

REAR

BRAKE

REMOVAL

DISASSEMBLY
AND
ASSEMBLY

INSPECTION

INSTAllATION

MASTER
VAC

DESCRIPTION

INSPECTION
OF

OPERATION

REMOVAL

DISASSEMBLY

INSPECTION

ASSEMBl
Y
AND

ADJUSTMENT

INSTAllATION
BR
lO

BR
1O

BR
lO

BR
ll

BR
12

BR
12

BR
13

BR
13

BR
13

BR
14

BR
14

BR
14

BR
16

BR
16

BR
17

BR
17

BR
IB

b

i
t

I
Fulcrum

pin

2
Return

spring

3
Pedal

bushings

4
Clevis

pin

5
Brake

pedal
5

BR766
BR657

Fig
BR
5
Broke

pedal
mounting

2
Remove
cotter

pin
from
clevis

pin
and

separate
pedal
from
Master

Vac

push
rod

3
Remove
fulcrum

pin
and

pedal
INSPECTION
Fig
BR
6
Broke

pedal

INSTALLATION

Check
brake

pedal
for
the

following

items

servicing
as

necessary

I
Check

pedal
bushing
for

wear

deformation
or

damage

2
Check

pedal
shaft

sleeve
for
wear

or
roughness

3
Check
for

bent
brake

pedal

4

Check
for

fatigued
return

spring
Note
Loosen
fulcnun

pin
clockwise
Install
b
rake

pedal
in
the
reverse

sequence
of
removal

paying
attention

to
the

following
instructions

1
Insert
fulcrum

pin
into
hole
in

brake

pedal
and
bracket
from

right

side

2
Install
clevis

pin
from
left
hand

side

BA
4

3

Hook
return

spring
to

brake

pedal

assembly
from
accelerator

pedal
side

4

Apply
a

coating
of
recommended

multipurpose
grease
to
the
inner
and

outer
faces
of

pedal
bushing
clevis

pin
and
hooks

of
return

spring

Charge
the
clearances
in

bushings
with

grease

Grease

m
n

L

g

U

BR298

Fig
BH

7
Greasing
place

5

lnstali
brake

lamp
switch

6

Adjust
the
brake

pedal
after
in

stallation
Refer
to
the

instructions

under

Adjustment

Tightening
torque

Fulcrum

pin

1

9
to
2
4

kg
m

14to

17ft
ib

MASTER
CYLINDER

The
diameter
of

cylinder
is
19
05

mm

y
in
for

all
models

The
tandem

master

cylinder
contains
two
fluid

reservoirs
which

connect
the

front
and

rear
brake

lines

independently

Braking
force
is

constantly
main

tained
when
failure
occurs
in
either

the
front
brake

system
or

the
rear

brake

system
Failure
in
the

front

brake

system
will
leave
the

rear
brake

still

operative
or

failure
in
the
rear

brake

system
will
leave
the
front
brake

system
still

operative

The
reservoir
is

eq
ui

pped
with
a

retention

cap

To
remove
this

cap
proceed
as

follows

I
Tum
retention

ring
fully
in
the

REMOVE
direction

2
Pull
out
retention

cap
Brake

System

To
install
it

proceed
as
follows

I
Turn
retention

ring
used
in
the

retention

cap
fully
in

the
REMOVE

direction

Tokico

@

1tr

I

I

I
j
1

Nabco

BR926
2

Align
the

projection
in
retention

cap
with
the
slit
in
the
reservoir
tank

and

push
retention

cap
in
the
tank

3
Turn
retention

ring
fully
in
the

TIGHTEN
direction

00
CD
1
Reservoir

cap

2

Reservoir
tank

3
Secondary

piston
return

5pring

4

Stopper
screw

5

Secondary

piston

6
Primary

piston
return

spring

7
Primary

piston

Fig
BR
B
Sectional
view

of
tandem
master

cylinder

o

BR658

Fig
BR
9
Master

cylinder

BR
5
REMOVAL

1
Disconnect

front
and
rear

brake

tubes
from

master

cylinder

Notes

a
When

removing
brake
tubes
use

Flare
Nut

Torque
Wrench

GG94310000

Never

use

open
end
or

adjustable

wrench

b
When

disconnecting
brake
tubes
be

sure
to
use
a

container
to
receive

draining
brake
flnid
Use
of

rags
is

also

suggested
to

keep
adjacent

parts
and
area
clean

2
Remove
master

cylinder
securing

nut
Then
master

cylinder
can
be

taken

out