light DATSUN PICK-UP 1977 Workshop Manual

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

Watch
for
oil

leakage
from
trans

mission

end

Notes

a
Remove

propeller
shaft
carefully

so
as
not
to

damage

spline
sleeve

yoke
and
rear
oil
seal

b

Plug
up
the

opening
in
the
rear
of

rear
extension

housing
to

prevent

oil
from

flowing
out

To
install

reverse
the

foregoing

removal

procedure

1

Align
propeller
shaft
with
com

panion
flange

using
reference
marks

prescribed
in
removal

procedure
and

assemble
with
bolts

Tightening

torque

2
4

to
3
3

kg
m

17

to
24
ft
Ib

2

Insert
bolts

through
the
holes
of

center

beariug
bracket
and

torque
nuts

to
retain
center

bearing
on
cross

member

Tightening
torque

1
6

to
2
2

kg
m

12
to
16
ft
Ib

DISASSEMBLY
AND

ASSEMBLY

Primarily
do
not
disassemble

pro

peller
shaft
because
it
is

balanced
as
an

assembly

However
check

propeller
shaft

with

journal
for
movement
When

journal
does
not
move

smoothly
dis

assemble

1
Mark

propeller
shaft
and

journal

so
that
the

original
combination
can

be
restored
at
assembly

2
Remove

snap
ring
with
a
standard

screwdriver

3
Lightly

tap
base
of

yoke
with
a

hammer
and
withdraw

bearing
race

See

Figure
PD
4

PDOO5

Fig
PD
4
Remo

i
bearing
Note
When

removing
journal
from

yoke
be
careful
not
to

damage

journal
and

yoke
bole

When

disassembling
and

repairing

center

bearing
are

required
the
follow

ing
procedures
are

applied

1
Put
match
marks
on

flange
and

front

propeller
shaft
Remove
bolts

connecting

flange
yoke
to

companion

flange

2

Applying
Drive
Pinion

Flange

Wrench
ST3lS30000
loosen
off
lock

ing
nut
and

remove
center

bearing
See

Figure
PD
5

P0172
ST31530000

Fig
PD
5
Remouing
locking
nut

To
assemble
reverse
the
foregoing

procedure
using
reference
marks

pre

scribed
in

disassembly
procedure

New

bearing
need
not
be
lubricated

since
it
is

lubricated
for
life
Fill

joint

with
recommended
multi

purpose

grease
whenever

propeller
shaft
is

overhauled

Use
related

snap
rings
of
the
same

thickness
and
be
sure
that

play
is

below
0
02
mm
0
0008
in

Available

snap
ring

Thickness

mm
in
Color

identification

2
00
0
0787

2
02
0
079S

2
Q4
0
0803

2
06
0
08
II

2
08
0
0819

2
10
0
0827

2
12
0
83S

2
14

0
0843
White

Yellow

Red

Green

Blue

Right
Brown

No

paint

Pink

PD

3
Install
and
assemble

components

correctly
so
that

joint
moves
under

friction
resistance
of
less
than
is
o

kg
em

13
in
lb

When
the

above

steps
are
complete

place
the

shaft
in

a

balancing
machine

and

adjust
unbalance
less
than
3S

gr
cm
0
49
in

oz
at
S
800

rpm

Center

bearing
assembling
pro

cedures
are
as
follows

I
Install
center

bearing
in

center

bearing
insulator

2
Install
center

bearing

assembly

and

companion
flange
on
front
shaft

usiug
reference
marks
established
in

disassembly

procedure

3
Install
washer
and

locking
nut
on

front
shaft

and

tighten
nut

using
Drive

Pinion

Flange
Wrench
ST3IS30000
to

specified
torque

Tightening
torque

20
0

to
24
0

kg
m

I4S
to
174
ft
lb

4
Join

companion
flange
of
front

shaft

with

f1ange
yoke
of
rear
shaft

and

tighten
connect
bolts
to

specified

torque

Tightening

torque

2
4

to
3

3

kg
m

17
to
24
ft
Ib

S
Install
center

bearing
bracket

on

center

bearing

INSPECTION

I
Check

journal
pin
for
dent
or

brinell
marks
and

yoke
hole
for

sign

of
wear
or

damage

Snap
ring
bearing
and
seal

ring

should
also
be

inspected
to
see
if
these

are

damaged
worn
or
deformed
Re

place
if

necessary

2
heck
center

bearing

by
rotating

bearing
race
If
it
is

rough
noisy
or

damaged
discard
Cracked

bearing

insulator
cannot
be
tolerated
here

3
Check

propeller
shaft
tube
sur

face
for
dent
or
crack

Change
if

necessary

PROPELLER

SHAFf
DIFFERENTIAL

CARR
IER

Ex

2

A

0
B
3

C
I

0

0

E
0

20
mOl
F

0
17
mOl

H
2

Left
side

T

I
A
C

D
H
x
om

0

17S
E

0
I

0
2
x
0
01

0
I7S

0
20

0
I
0
2

x
0

01

0
17S
0
20

3

Om
0
17S

0
20

0
03
0
17S
0
20

O

34S
mrn

The
correct

shinjs

are
O

OS

plus

0
10

plus
0
20
mrn
thick

Right
side

T2
B
D
H

xO
0l

O
ISO
F

3
0
2
x

om

O
ISO

0
17

3

0

2
x

om

0
150
0
17

S
x
0
01

0
ISO
0
I7

O
OS

0
1S0
0
17

0
37

mrn

The

correct
shims
are
0
07

plus

0
1
0

plus
0

20
mm
thick

Note
If

w1ues

signifying
A

B
C
0

and

H
are
not

given
regard
them

as

zero
and

compute

Aft
assembly
check
to

see
that

preload
and
backlash

are
correct
If

not

readjust

Side

bearing

adjusting
shim

Thickness
mm
in

O
OS
0
0020

0
07
0
0028

0
1

0
0
0039

0
20
0
0079

0
50
0
0197
2

Fit
determined

side

bearing

adjusting
shim
on
differential
case
and

press
fit
left

and

right
side

bearing

inner

races
on
it

using
Side

Bearing

Drift
ST33230000
and

Adapter

ST33061000

3

Install
differential

case

assembly

into

gear
carrie

tapping
with
a
rubber

mallet

4

Align
mark

on

bearing
cap
with

that
on

gear
carrier

and
install

bearing

cap
on
carrier
And

tight
n
bolts
to

specified
torque

Tightening

torque

4
0
to
S
O

kg
m

29
to
36
fHb

S

Measure

ring

gear
to
drive

pinion

backlash

If
backlash
is
too

small
remove

shims
from
left
side
and

add
them
to

right
side
To
reduce

backlash
remove

shims
from

right
side
and

add
them
to

left

side

Backlash

O
1S
to
0
20

mrn

0
00S9
to
0
0079
in

Fig
PD

22

Mccuuring
back1aah

6
At

the
same
time

check

side

bearing
preload

Bearing
preload

should

read
12

0
to
20
0

kg
cm
10
to

17

in
lb
of

rotating
torque
3
S

to

S
8

kg
7
7

to
12
8

Ib
at

ring

gear
bolt

hole

PD
12
If

preload
does

not
accord
with

this

specification
adjust
it

with
side
bear

ing
shims

7

Check
and

adjust
the
tooth

con

tact

pattern
of

ring
gear
and

drive

pinion

I

Thoroughly
clean

ring
and
drive

pinion

gear
teeth

2
Paint

ring
gear
teeth

lightly
and

evenly
with
a

mixture
of
ferric

oxide

and

gear
oil

to

produce
a
contact

pattern

3
Rotate

pinion
through
several

revolutions
in

the
forward

and
reverse

directions
until

a
defmite
contact

pat

tern
is

developed
on

ring

gear

4
When

contact

pattern
is

incor

rect

readjust
thickness
of

adjusting

washer

S

Incorrect
contact

pattern
of

teeth
can
be

adjusted
in
the

following

manner

a
Heel
contact

To
correct
increase
thickness
of

pinion
height

adjusting
washer

in
order

to

bring
drive

pinio
close
to

ring

gear

P0193

Fig
PD
23
Hul

contact

b
Toe
contact

To

correct
reduce
thickness
of

pinion
height

adjusting
washer
in
order

to
make

drive

pinion

go
away
from

ring

gear

P0194
1

Fig
PD
24
To
contact

The

design
of
the
front

suspension

adopts
the

independent
double

wishbone

type
suspension
used
the

torsion
bar

spring
Both
the

upper
and

lower
links

are
installed
on
the
bracket

which
is
welded
on
the
frame

A
1d
the

above
links

swing
to
allow
the
knuckle

spindle
to
move

freely
in
a
vertical

dimension

The

top
and
bottom

of
the
knuckle

spindle

support
are
connected
to
the

upper
link

through
rubber

bushing
and

to
the
lower
lick

through
screw

bushing

The
tension

rod
held

by
the
brack

ets
on
the
chassis
frame
and
lower
lick

wiih
rubber

bushings
bears
the
force

of
fore
and
aft
direction

The
front
end

of
the
torsion

bar

spring
is

installed
to
the

torque
arm

which

attaches
to
the
lower
link
The

opposite
end
is

installed
to
the

spring

anchor
that

secures
to
chassis
frame

firmly
The
both
ends
of

the
torsion

bar

spring
are
serrated

The

shock
absorber
is

double

action

telescopic

hydraulic
type

The

upper
stem
is
attached
to
the

bracket
of
the
chassis
frame
The

lower
insulated
bracket
is

bolted
to

the
lower
lick

The

bumper
rubber
secured
to
the

bracket
Of
the
frame
limits
the
verti

cal
motion
of
the

suspension
lick

The
knuckle

spindle
is

connecied
to

the
k

ufkle
spindle
arm

by
the

king

pin
The

king

pin
bushings
are
fitted

to

the

upper
and
lower
arm

portIOns
of

the
knuckle

spindle
and

seals
are

provided
at
the

portions
mentioned
to

keep
water
and

dirt
from
enteri

g

The
knuckle
arm
is

connected
to

the
lower
end
of
the
knuckle

spindle

to
transmit

ttLe
movement
of
the

steering
wheel
to
the
knuckle

spindle

The
wheel
hub
is

supported
by
two

taper
roller

bearings
on
the

knuckle

spindle
Tlie
brake
drum
and
wheel
are

secured
to
ihe
hub

by
the

hub
bolts
Front
Axle
Front

Suspension

FRONT
AXLE

REMOVAL
AND

INSTALLATION

Removal

I
Jack

up
and

support
vehicle
on

the
stands

at
the
frame
in

a
safe

manner

2
Remove

front
wheel

3
Re

ove
brake
hose

together
with

connector
from
wheel

cylinder

4
Remove

brake
drum

S

Remove
hub

cap
and
then

remove

cotter

pin
adjusting
cap
and

spindle

nut
from
knuckle

spindle

6
Remove
wheel
hub
outer
and

inner

wheel

bearings
bearing
washer

and

grease
seal
from
knuckle

spindle

7
Remove
brake
disc

assembly
from

the

flange
of
knuckle

spindle

8

Remove
knuckle
arm
from

knuckle

spindle

9
Remove

king
pin
lock
bolt

FA225

Fig
FA
R

mol1ing
king
pin
loch
nut

10
After

removing
air
breather
re

move

plug
from
the

top
of

king
pin

with
the

following
method
Drill
a

10
5
mm
0
413
in

diameter
hole
on

the

plug
thread
hole
with
a

tap

M
12
1
2S
screw
a
bolt
into
threaded

hole
and

pull
out
the

plug

II

Apply
drift
to
the

top
of

king

pin
and
drive
out

king
pin
along
with

lower

plug

12

Tap
spindle
with
a
soft
haJnmer

and

detach
it
from
knuckle

spindle

support
Take

care
not
io

drop
thrust

bearing

FA
3
FA226

Fig
FA
3
R

moving
knuckle

piridle

Installation

Install
front
axle
in
reverse
se

quence
to
removal

by

noting
the
fol

lowing
matters
Furthermore

when

installing
front
axle

lightly
coat

grease

to

sliding
parts

I
Insert

O

ring
on
the
lower
end
of

knuckle

spindle
support
Install
thrust

bearing
and

spindle
shim

together
with

knuckle

spindle
to
knuckle

spindle

support

In

this

operation
select

spindle

shims
to
obtain
the

specified
clearance

between
knuckle

spindle
and
knuckle

spindle
support
To

measure
the
Clear

ance
with

a
filler

gauge
jack
up
the

bottom
of

spindle
slightly

Standard
clearance

0
1

mOl
0
004
in
or
less

Note
Be

sure
to
iristsll
thrust

bearing

to
face
coverea
side

upward

2
Line

up
locking
bolt
hole
of

knuckle

spindle
support
with
the

notch
in

king
pin
and

secure
lock
bolt

Be
sure
to
check
killJckle

spindle
for

smooth
movement
Be

certain
to
move

knuckie

spindle
smoothly
and

reailjust

shim
if

necessary
In
addition
check

bushings
and

king
pin
as

required

3
Press
fit

plug
to
the

upper
of

knuckle

spindle
Then
install
lower

plug
to
the
lower
knuckle

spindle

Note
Make
sure
to

place
lower

plug

conectly

4

Secure
knuckle

arm
to
knuckle

Level
line

Level
line

FA230

Fig
FA
8

Bushing
location

3
Remove

grease
nipple
and
drill

grease
hole
on

bushing
through
thread

ed

grease
nipple
hole
When

grease

hole
is
drilled
remove
metal

chip
and

burr

thoroughly

Drilling
diameter

approximate
3
mOl
0
118
in

Note
When
a

spindle
bushing
has
a

grease
nipple
hole
in
it

an
ad

ditional
hole
need
not
be

drilled

When

pressing
it
into

position
align

grease
nipple
hole

with
that
in

spindle
bushing

4
Ream
the

inside
of

bushing
to
the

specified
value
with

King
Pin

Bush

Reamer
HT56802000

Bushing
inner
diameter

when

fitted

20
010

to
20
03S
mOl

0
7878

to
0
7888
in

Note

Carry
out

reaming
from
both

upper
and

lower

bushings
When

reaming
upper
side
use
lower
side

as

reaming

guide
and
when
reaming

lower
side
use

upper
side
as
ream

ing

guide
to

align
the
center
line

correctly

5
Press

fit

grease
seal
on

upper
arm

with

King
Pin

Grease
Seal
Drift

ST35390000
In

installing
grease
seal

take
care
not
to

damage
seal

lip

51
35390000

FA231

Fig
FA
9

Installing

grease
seal
Front
Axle
Front

Suspension

Wheel
hub

1
After

removing
grease
seal
with

screwdriver
lightly
tap
outer

race
cir

cumference
with
a
hammer

by
ap

plying
a
brass
bar
and

remove
outer

bearing
race
from
hub
When

tapping

outer
race
circumference

tap
evenly

2
Remove
all
traces
of
old

grease

from

bearings
hub
and

knuckle

spindle

3

Install
inner
and
outer

bearing

races
in

hub
with
a

suitable
tool
Be

sure
to

seat
the
races

properly
in
hub

4

Pack
the
inside
of
hub
and
hub

cap
with

specified
grease
to
the
de

scribed
level
See

Figure
FAA
Also

pack
the

bearing
cone
and
roller
as

semblies
with
the
same
lubricant

FA009

Fig
FA
10

Greasing
bearing
cone
and

roller
assembly

5
Place
inner

bearing
cone
and
rol

ler
assembly
in
hub

Coat

grease
slight

ly
to
the

lips
of
new

grease
seal
and

seat
it

properly
INSPECTION

King
pin
and

bushing

Check
and

replace
king
pin
andlor

bushing
if
tne

following
faulty
condi

tion
is
detected

deformation
scores

partial
wear
and

excessive
clearance

between

king
pin
and
bushing
in
dia

meter
direction

exceeding
limit

listed

below

Clearance
limit

0
15
mOl
0

00S9
in

Standard
dimensions

King
pin
outer
diameter

19
979

to
20
000
mm

0
7866
to
0

7874
in

Bushing
inner
diameter

20
010

to
20
035
mOl

0

7878
to
0
7888
in

2
Wheel

bearing

ThorougWy
clean

grease
and
dirt

from
wheel

bearing
with

cleaning
sol

vent
and

dry
with

compressed
air
free

of
moisture
Check
wheel

bearing
to

see
that
it
rolls

freely
and
is
free
from

noise

crack

pit
ing
or
wear
Also

check
outer
race

for
condition
Re

moval
of
outer
race
from
drum
is
not

necessary

Shown
below
is
the
cha
rt
which

furnishes
the

necessary
information
on

Visual
Serviceability
Standard
for

Wheel

Bearing

Visual

serviceability
standard
for
wheel

bearing

@

J

@

@

@

@

@
A

Q
jJ

2

@

CD

FA
5
1
Outer
race

2
Roller

3
Small
collar

4
Inner
race
fitted
surface

5
Collar

surface

6
Inner
race
surface

7
Outer
race

tilted
surface

8
Outer
race
surf
lcc

9
Roller

rolling
surface

10
Inner
race

11

Large
collar

12

Supporter

FADD6

Fig
FA
11
Wheel

bearing
assembly

Components

Rust

Discoloring
Race
and
roller

u

u

e

2

2
0

3

0

t
c

6
6
6

Fig
h

The
wheel

bearing
is
serv

iceable
if

discoloring
can

be

removed
with

solvent

or

by

polishing

f

a
Inner
race

flaking

t

d

Cracked
roller

iT

t
j

t

11
1

1
t

t

I
l

1
t

F
1ll

JJ
J

t
I

1

ollf

oe
c

g
Recess
on

foDer
Front
Axle
Front

Suspension

Cause

Temperature
increased

during
operation
lowers
when
the

bearing

stops
moisture

inside
the

bearing
is

condensed

becoming
fine

drips

and
the

grease
is

moistened

The

bearing
has
been

placed
in
a

highly
moistened

place
for
a

long

period
of
time

Intrusion
of
moisture
chemicals
etc
or

the

bearing
is

touched
with

bare
hand
and
no

rustproof
action
has

been
taken

Slight
discoloring

may
become
like

oxidized
oil
stain
due
to

grease

In
the

most
cases
this

occurs
when

preliminary

pressure
is
too

high

I
I

I

1

v

i
n

dJ

b
RoUer

flaking

c
Cracked
inner

race

c

f

J
Jt

v

l

e
Recess
on

inner
race

f
Recess

on
outer
race

h
Rust
outer
race

F
A007

Fig
FA
12

Defective
conditions

of
bearing

FA
7

Front
Axle
Front

Suspension

SERVICE
DATA
AND
SPECIFICATIONS

King
pin

Clearance
limit
between
the

king
pin

and

bushing
mm
in
0
15
0
0059

Bushing
inner
diameter
when
fitted

mm
in
20
010
to
20
035

0
7878
to
0
7888

Clearance
between
the
knuckle

spindle

support
and

spindle
mm
in
less
than

0
1

0
004

Wheel

bearing

Tightening
torque
kg
m
ft
Ib
3
0
to
3
S

22
to
2S

Spindle
nut

returning

angle
40
to
700

Wheel

bearing
rotation

starting
torque

When

both

bearing
and
seal
are

new

kg
em
in
Ib
less
than
IS
13

0

When

readjusted
kg
em
in

lb
less
than
7

6
1

At
the
hub

bolt

When

both

bearing
and
seal
are
new

kg
lb
less
than
2
1
4

6

When

readjusted
kg
lb
less
than
1
0
2
2

Suspension
link

Upper
link

sliding
resistance
kg
m
ft
Ib
less
than
O
S
3

6

Lower
link

sliding
resistance

kg
m
ft
lb
less
than
O
S
3
6

lightening
torque

kg
m
ft
Ib

Brake
hose

connecting
nut
1
9
to
2
S
14

to
18

Wheel

bearing
lock

nu
t
3
0
to
3
5
22
to
2S

Brake
disc
fIXing
bolt
4

2
to
S
O
30

to
36

Knuckle
arm

fixing
bolt
10
3
to
12
1
74

to
88

King
pin
lock
bolt
2
1
to
2
S

IS
to
18

Torque
arm

Arm
end
2
7
to
3
7

20
to
27

Serration
boss
1
8
to
2
6

13
to
19

Lower
link

spindle
nut
74

to
8
0
S4

to
58

Upper
link
screw

bushing
24

to
35

174
to
2S3

Upper
link

spindle
bolt

fIXing
to
bracket
7
to
9
51

to
6S

Cotter

pin
lock
nut
0
8

to
l
l
5
8
to
8
0

Lower
link
screw

bushing
25
to
32

181
to
231

Fulcrum
bolt
3
9
to
S
3
28
to
38

Tension
rod

Lock
nut
1
6
to
2
2
12
to
16

Bracket
bolt
1
6
to
2
2
12

to
16

Shock
absorber

Lock
nut

of
the

upper
end
1
6
to
2
2

12
to
16

Lower
end
3
1
to
4
1

22
to
30

Stabilizer

Bracket
bolt
1
6

to
2
2
12
to
16

Lock
nut
of
the

anchor
bolt
3
1

to
4
1

22
to

30

Bumper
rubber
bolt
0
8
to
l
l
5
8
to
8
0

FA

13

Condition

Vehicle

puBes
to

right
or
left

Instability
of
vehicle

Stiff

steeirng
wheel

Excessive

steering
wheel

play

Noise
Front
Axle

Front

Suspension

Probable
cause

Deformed
of

steering

linkage
and

suspension
link

Unbalanced

vehicle
level

Improper
air

pressure
of
tire

Worn
or

loose

suspension
link
screw

bushing

Incorrect
wheel

alignment

Worn
or
deformed

steering

linkage
and

suspension

link

Incorrect

adjustment
of

steering
gear

Deformed
unbalanced
wheel

Check

and
correct
in
the

following
manner

Jack

up
front

wheels
detach
the

steering
gear
and

operate
the

steering
wheel
and

a

If
it
is

light
check

steering
linkage
and

suspension

groups

b
If
it
is

heavy
check

steering

gear
and

steering

column

groups

Improper
air

pressure
of
tire

Insufficient
lubricants
or

mixing
impurities
in

steering

linkage
or

excessively
worn

steering

linkage

Insufficient
lubricant
in

gear
box
or
contaminated

lubricant

Unsmooth

king
pin
damaged
part
Or
insufficient

lubrication

Worn

or

incorrectly
adjusted
wheel

bearing

Worn

damaged

steering
gear
and

bearing

Incorrectly
adjusted

steering
gear

Deformed

steering
linkage

Incorrect
wheel

alignment

Interference
of

steering
column
with
turn

signal

switch

Incorrectly
adjusted
steering
gear

Worn

steering
linkage
idler

arm

Improperly
fitted
of

gear
box

Incorrectly
adjusted
wheel

bearing

Worn
or
loose

suspension
link

screw
bushing

Improper
air

pressure
of
tire

Insufficient

lubricating
oil
and

grease
for

suspension

link
screw

bushing
and

steering
linkage
or
their

breakage

FA

15
Corrective
action

Replace

Correct

the
unbalance

Adjust

Replace

Adjust

Replace

Adjust

Correct

or

replace

Adjust

Replenish
grease
or

replace

the

part

Add

or

replace
gear
oil

Replace

Replace
or

adjust

Replace

Adjust

Replace

Adjust

Adjust

Adjust

Replace

Retighten

Adjust

Replace

Adjust

Replenish
lubricating
oil
and

grease
or

replace

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

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