transmission DATSUN PICK-UP 1977 Workshop Manual

Fig
ER
2
ER207

Removing
front
engine

mounting
bolts

20
Place
a

jack
under
transmission

and

jack
it

up

21
Loosen

two
rear

engine
mount

ing
bolts

CD

22
Loosen
two

exhaust
tube

hanger

bolts

V
California
models

only

23
Remove
four
bolts

CID
securing

engine
mounting
rear

support
to
side

member
and
detach
rear

support

j
r

O

1

ER271

Fig
ER
3
Removing
rear

engine

mounting
support

24
Remove

steering
idler
arm
secur

ing
bolts
and

push
down

cross
rod

iC

EA278

Fig
ER

4
Removing
idler
arm

25
Pull

engine
towards
front
as
far

as

possible
and

carefully
raise
if
and

transmission
with
a
hoist
and
cable

Note
In

this

r
an

care
should

always
be
taken
not
to
allow
the

unit
to
hit

against
any

adjacent

parts
Engine
Removal
Installation

INSTALLATION
E
R367

Fig
ER
5
Lifting
engine

Install

engine
with
transmission
in

reverse
order
of

removal

observing
the

following

I
When

installing
first
secure

rear

2

Front

1
Bracket
R
H

2

Insulator
R
H

3
Bracket
LH

4

Heat
shield

plate

5
Insulator

L
H

6
Rear

support

7
Rear
insulator

8
Exhaust
tube

hanger

California
models

only
engine
mounting

support
to

body

2
Refer
to

applicable
section
when

installing
and

adjusting
any
parts

@

E

A279

Fig
ER

6
Structual
view

of
engine
mounting

ENGINE
MOUNTING

INSULATORS

Three
insulators
are
used
to

mount

the

engine
and
transmission

two
are

located
at

the
left
and

right
of
the

cylinder
block
and
one
at
the
transmis

sion

rear
extension

housing
Replace
any
insulator
that
shows

signs
of

separation
or
deterioration

Be
sure
to

keep
insulator
free
from

oil

or

grease

ER
3

Engine
Removal
Installation

FRONT

INSULATOR

Removal
and
installation
7
To

install
reverse
order
of

re

moval

1

Disconnect

battery
ground
cable

2
Remove

hood

3

Suspend
engine
with
wire
or

chain

4
Loosen
front

engine
mounting

insulator

upper
nuts

both
sides

5

Carefully
raise

engine
a
little
with

a
hoist
and
cable

6
Remove
front

mounting
insula

tors
at
front

supports
after

removing

front

mounting
bolts
REAR
INSULATOR

Ramoval
and
Installation

1

Place
a

jack
under
transmission

TIGHTENING

TORQUE

Fixing
bolts
and
nuts

Front

mounting
bracket
to

cylinder
block

Front

mounting
in

lator
to
brac
t

Front

mounting
insulator
to
front

support

Rear

mounting
insulator
to

transmission

Rear

mounting
insulator
to

rear

support

Rear

support
to
frame

Clutch

operating
cylinder
to
transmission

Exhaust
front

tube
to
exhaust
manifold

Center

bearing
bracket
to

crossrnember

Propeller
shaft
to

companion

flange
kg
m
ft
lb

kg
m
ft
Ib

kg
m
ft
lb

kg
m
ft
lb

kg
m
ft
Ib

kg
m
ft
lb

kg
m
ft
Io

kg
m
ft
lb

kg
m
ft
lb

kg
m
ft
lb

ER
4
and

jack
it

up
slightly

2

Loosen
two

rear

engine
mounting

bolts

3

Loosen
two

exhaust
tube

hanger

bolts
California

models

only

4

Remove
rear

mounting
insulator

at
transmission
rear
extension

after

removing
insulator

securing
bolts

5

To
install

reverse
order

of
Ie

moval

2
6
to
3
6
19
to
26

2

6
to
3

6

19
t
o

76

1
4

to
1
8
10
to
13

3

2
to
3
7
23
to

27

1
6
to
2
2

12
to
16

3

2
to
4
3
23
to
31

2
5

to
3

5

18
to
25

1

9
to
2
5
14
to
18

1
6

to
2
2

12
to
16

2
4
to

3
3

17
to

24

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

Release

bearing
and
sleeve

Check
for
abnormal
wear
on
con

tact
surface
of
withdrawal
lever
ball

pin
and

bearing
sleeve

DESCRIPTION

CLUTCH
PEDAL

Removal
and
installation

I

nspection
and

adjustment

CLUTCH
MASTER
CYLINDER

Removal

and
installation

Disassembly
and

assembly

DESCRIPTION

The

hydraulic
clutch
control
con

sists

of
a

pendent
pedal
a

master

cylinder
an

operating
cylinder
and
a

withdrawal
lever

When

the
clutch

pedal
is

depressed

the

piston
of
the
master

cylinder
CLUTCH

Pilot

bushing

Check

pilot
bushing
in
crankshaft

for
wear
or

roughness
If

necessary

replace
it

CLUTCH
CONTROL

CONTENTS
When

bushing
is

faulty
be

sure

to

check
transmission
main
drive

gear
at

the
same
time

CL
5

CL

6

CL

6

CL
6

CL
7

CL
7

CL
7
Inspection

OPERATING
CYLINDER

Removal

and
installation

Disassembly
and

assembly

Inspection

BLEEDING
CLUTCH
SYSTEM
CL
B

CL
B

CL

B

CL

B

CL
B

CL
B

forwards
clutch
fluid
to
the

operating

cylinder
via
a

pipe
line
The
movement

of
the

operating
cylinder
piston
is

transmitted
to
the
withdrawal
lever

through
the

push
rod
thus

disengaging

the
clutch

The

operating
cylinder
is
a
non
adjustable
type
that
uses
no

return

spring
In
this
unit

the
withdrawal
to

push
rod

play
adjustment
is
not
neces

sary
since
the
8
as
shown
in

Figure

CL

15
serves
to

automatically

compen

sate

for
wear

on
the

clutch
disc

2

I

l

1
Clu
tch

pedal
6
Push
rod

2
Return

spring
7

Withdrawal
lever

3
Clutch
master

cylinder
8
Release

bearing

4
Clutch

piping
9
Clutch
cover

5

Operating
cylinder
10
Clutch
disc

CL
5
5

Cl305

Fig
CL

14
Clutch

operating
system

CLUTCH

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Probable
cause
and

testing

Clutch

slips
Corrective
action

Slipping
of
the

clutch

may
be

noticeable
when

any
of
the

following
symptoms
is

encountered

during
operation

I
Vehicle
will

not

respond
to

engine

speed
during
acceleration

2
Insufficient
vehicle

speed

3
Lack
of

power
during
uphill
driving

Some
of
the

above
conditions
are
also

experienced
when

engine

problem
is

oc

urring
First

de
tennine
whether

engine
or
clutch
is

causing
the

problem

If

slipping
clutch
is

left
unheeded
wear
and
or

overheating
will
occur
on
clutch

facing
until
it
is

no

longer
serviceable

TO
TEST
FOR
SLIPPING
CLlJfCH

proceed
as
follows

During
upgrade
travelling
run

engine
at

about
40
to
50
km

h
25
to
31

MPH
with

gear
shift

lever
in

3rd

speed
position
shift
into

highest
gear
and
at
the
same
time

rev

up
engine
If
clutch

is

slipping
vehicle
will
not

readily

respond
to

depression
of
accelerator

pedal

Clutch

facing
worn

excessively

Oil
or

grease
on
clutch

facing

W

r
d
clut
h
cov
r

pressure
plat
Replace

Replace

tpa
o
e
lace

Dragging
clutch
is

particularly
noticeable
when

shifting
gears
especially
into

low

gear

TO
TEST
FOR
DRAGGING
CLlJfCH

proceed
as
follows

I
Start

engine
Disengage
clutch
Shift
into

reverse

gear
and
then
into
Neutral

Gradually

increase

engine
speed
and

again
shift
into
reverse

gear
If
clutch
is

dragging
gear
grating

is

heard
when

shifting
from
Neutral
into

Reverse
Clutch

drags

2

Stop
engine
and
shift

gear
Conduct
this
test
at
each

gear
position

3
Gears

are
smoothly
shifted
in

step
2
but

drag
when

shifting
to
1st

speed
position
at

idling

a
If

dragging
is
encountered
at
the
end
of

shifting
check
condition
of

synchro

mechanism
in
transmission

b
If

dragging
is
encountered
at
the

beginning
of

shifting
proceed
to

step
4

below

4
Push

change
lever
toward
Reverse
side

depress
pedal
to
check
for
free
travel

a

If

pedal
can
be

depressed
further
check
clutch
condition

b
If

pedal
cannot
be

depressed
further

proceed
to

step
5
below

5
Check
clutch
control

pedal
height
pedal
free
travel
withdrawal
lever

play
etc

If
no
abnonnal

condition
exists
and
if

pedal
cannot
be

depressed
further
check
clutch

condition

Clutch
disc
runout
or

warped

Wear

or
rust

on
hub

splines
in
clutch
disc

Diaphragm
spring
toe

height
out
of
ad

justment
or
toe

tip
worn

Worn
or

improperly
installed

parts

CL10
Repair
or

replace

Clean
and
lubricate
with

grease
or

replace

Adjust
or

replace

Repair
or

replace

DATSUN
PICK

UP

MODEL
620

SERIES

I
NIS

J

NISSAN
MOTOR
CO
LTD

TOKYO
JAPAN
SECTION
MT

MANUAL

TRANSMISSION

4
SPEEo
TRANSMISSION

MT
2

TYPE

F4W71
B

5
SPEED

TRANSMISSION

MT
14

TYPE

FS5W71
B

SERVICE
DATA
AND

MT
21

SPECIFICATIONS

TROUBLE
DIAGNOSES
AND

MT
23

toRRECTloNS

SPECIAL
SERVICE
TOOLS

MT
24

Manual

Transmission

4
SPEED

TRANSMISSION
TYPE

F4W71B

CONTENTS

DESCRIPTION

REMOVAL

DISASSEMBL
Y

TRANSMISSION
CASE

DISASSEMBLY

D

ISASSEMBL
Y
OF
GEAR

ASSEMBLY

REAR

EXTENSION

DISASSEMBLY

ADAPTER

PLATE

DISASSEMBLY

INSPECTION

TRANSMISSION

CASE
AND

REAR

EXTENSION
HOUSING

BEARING
GEARS
AND
SHAFTS

BAULK
RING

Oil

SEAL

ASSEMBL
Y

FRONT

COVER
ASSEMBLY

REAR

EXTENSION
ASSEMBLY

ADAPTER

PLATE

ASSEMBLY

GEAR

ASSEMBLY

TRANSMISSION

ASSEMBLY

INSTALLATION
MT
2

MT
4

MT
4

MT
4

MT
5

MT
B

MT
8

MT

8

MT
B

MT
8
MT
8

MT
9

MT

9

MT
9

MT
9

MT
9

MT
9

MT
9

MT13

MT14

DESCRIPTION

pUshed
the
inner

teeth
of
the

coupling

sleeve
slide
over
the

synchronizer
hub

and
mesh
with

the
outer
teeth

which

are

provided
on
the
mainshaft

gear

The

synchronizer
hub
is
fitted
to

the
mainshaft

by

splines
so
the
main

shaft

gear
turns
together
with
the

mainshaft

The
baulk

ring
serves
to

synchro

nile

the

coupling
sleeve
and
mainshaft

gear

Placing
the
control
lever
in
reverse

position
brings
the
reverse
idler

gear

into

mesh
with
mainshaft
reverse

gear
The
transmission
is
of
a
4

speed

forward

fully
synchronized
constant

mesh

type
that

uses
helical

gears

The

reverse

gear
is
ofa

sliding
mesh

type
using
spur
gears

In
construction
the

main
drive

gear

is
meshed
with
the

counter
drive

gear

which
is

keyed
to

the
countershaft

The
forward

speed

gears
on
the

coun

tershaft

are
in

constant
mesh
with
the

mainshaft

gears
which
ride
on
the

mainshaft

freely
through
the
needle

bearing
When

shifting
is

accom
The
transmission

assembly
consists

of
three
main

parts
a

transmission

case
with
clutch

housing

adapter
plate

to
which
an

gears
and
shafts
are

installed
and
rear
extension

The
cast
iron

adapter
plate

supports

the
mainshaft
countershaft

reverse

idler
shaft
and
three
fork
rods
and

bolted

at
the
front

to
the

transmission

case
and
at
the
rear
to
the
rear

extension

by
means
of

through
bolts

By
removing
these

through
bolts
all

gears
and
shafts
are

stripped

e

TM

858

1

Front
cover

2
Transmission
case

3

Adapter
plate

4

Bearing
retainer

5

Rear
extension

hOUsing

Fig
MT
1
F4W71B
lrammiasion
case

compon
nt

MT
2

Manual
Transmission

o

cCl

4
@

@

fl

t

o

@

Fig
MT
3

MT
3
TM857
1
Main

drive
gear

2
Baulk

ring

3
d
4th

3

Synchronizer
hub
r

4

Shifting
insert

spnng

5
Shifting
insert

6
Coupling
sleeve

7
3rd
main

gear

8
Mainshaft

9
2nd
main

gear

10
1st
main

gear

11
ht

gear
spacer

12
Reverse
main

gear

13
Counter
drive

gear

14
Countershaft

15
Reverse
counter

gear

16
Reverse
idler
shaft

17
Reverse
idler

gear

Fig
MT
2
n
ear

component
F4W71B
transmlsBIO

g

@

f1f@

n
1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27
Striking
lever

Lock

pin

O

ring

Striking
guide

Oil
sea1

Striking
rod

E
ring

Stopper
guide
pm

Return

spring
plunger

Return

spring

Reverse
check

spnng

Return

spring
plug

Check
ball

plug

Check

spring

Check
baD

Interlock
ball

Retaining
pin

k

1st
2nd
shift
or

ht

2nd
fork
rod

3rd
4th
fork
rod

Reverse

fork
rod

3rd
4th
shift
fork

Reverse
shift
fork

Con
trollever

Control
lever
b

shmg

Control
lever

p
n

Control
lever

bushmg

TM045A

I

ponents
shift
contro
com

F4W71

B
transmuswn