air condition DATSUN PICK-UP 1977 Repair Manual

Engine
Removal

Installation

ENGINE

REMOVAL
AND
INSTAllATION

REMOVAL

INSTALLATION

ENGINE
MOUNTING
INSULATORS

REMOVAL

It
is
much
easier

to
remove

engine

and
transmission

as
a

single
unit

than

to

remove
them

separately
After
re

moval

engine
can
be

separated
from

transntission

assembly

Notes

a
Be

sure
to
hoist

engine
and

jack
up

transmission
in
a
safe
manner

b
Use

fender
cove
to

protect
vehicle

body

1
Remove

battery

2
Scribe

hood

hinge
location
for

proper
reinstallation
and
remove

hood

Note
Have

an
assistant

help
you
so
as

to

prevent
damage
to

body

3
Drain

radiator
coolant

4

Disconnect

upper
and
lower

radiator
hoses

from

engine

5

Remove

two
oil
cooler
hoses

from
lower

end
of
radiator
Auto

ma
tic
transmission

models

only

6
Remove

radiator

shroud

7

Remove
four

bolts

securing
radia

tor
and

detach
radiator

Note

Always
tighten
securing
bolt
at

upper
right
hand
side

together
with

body
harness

terminal

8

Remove
carburetor
air

cleaner
as

follows

Remove
fresh
air

duct

Remove

hot
air

duct

Loosen
air

cleaner
band

bolt
and
air

cleaner

supporting
bolts

Disconnect
air

cleaner
ta
air

pump

hose

Disconnect
air
cleaner

to
rocker

cover
hose
at

rocker

cover

Disconnect
air

cleaner

to
air

control

valve
hose
California

models

only
CONTENTS

ER
2

ER
3

ER
3
FRONT

INSULATOR

REAR

INSULATOR

TIGHTENING

TORQUE
ER
4

ER
4

ER
4

Disconnect
air

deaner
to

A
B
valve

hose

Disconnect
air

cleaner
ta

vacuum

hoses

Note

Protect
carburetor
from
dust

and

foreign
matter

by

placing
cover

over
air
inlet

opening

9

Disconnect

fuel

pump
to
fuel

fdter
hose
and
return

hose

10

Disconnect
carbon
canister

hose

on

engine
side

II

Disconnect
air

pump
air

C1eaner

to
al

p

p
hose

12

Disconnect

following
cables

wires

and
hoses

Engine
ground
cable

Accelerator
wire
at

carburetor

High
tension

cable
between

ignition

coil

and
distributor

Wire

to
distributor
at

body
ter

minal

Wire
to

oil

pressure
switch

Wires
to
thermal

transmitter

Wires
to

B
C

p
D
cut
solenoid

Non
California

models

only

auto

choke
heater
and

anti

dieseling

solenoid

Wires

to
alternator

Wires
to
starter

motor

Heater
inlet
and
outlet

hoses
if
so

equipped

Vacuum
hose
of

Master
Vac
at
in

taJce
manifold

Wires
for

back

up

lamp
switch

Cable
to

speedometer

13

Remove
transmission

control

linkage
from

transmission

Manual

transmission
models

I

Detach
rubber
boot

2
Remove
E

ring
and
control

lever

pin
from

transmission

striking
rod

guide
and

remove
control
lever

ER
2
Fig
ER
l

Automatic

transmission
models

I

Disconnect

selector

range
lever

from
manual
shaft

2
Disconnect
wires

at
inhibitor

switch
and

down
shift
solenoid

14
Air

conditioner

equipped

models
need

following

procedures

1
After

removing
flexible

hose

support
remove
four

comi
ressor

se

curing
bolts

Then
move
the

com

pressor
to

battery

support

2

Remove

vacuum
hoses
of

F
LC
D
solenoid
valve

3
Remove
F
LC

D
actuator

15
Remove
two
bolts

securing

clutch

operating
cylinder
Then
dis

connect

operating
cylinder
and

flexi

ble
tube

as
an

assembly

Manual

transmission

models

only

16
Disconnect
front

exhaust
tube

from
exhaust
manifold

17
Remove

propeller
shaft

I

Disconnect

propeller
shaft

center

bearing
bracket
from

third

crossmember

2

Disconnect

propeller
shaft
from

companion
flange
of
differential

carrier

3
Remove

propeller
shaft
from

transmission

and

plug

up
rear
end
of

extension

housing
of

transmission
to

prevent
oil

leakage

18
Attach
a
suitable
wire

or
chain

to
lift

engine

19
Remove

front

engine
mounting

bolts

at

engine
mounting
front

sup

port

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

Condition

Clutch
chatters

Noisy
clutch

Clutch

grabs
CLUTCH

Probable
cause
and

testing
Corrective
action

Clutch

chattering
is

usually
noticeable
when
vchicle
is

just
rolled
off
with
clutch

partially

engaged

Weak
or
broken
clutch
disc
torsion

spring

Oil
or

grease
on
clutch
facing

Clutch

facing
out
of

proper
contact
or

clutch
disc

runout

Loose
rivets

Warped

pressure
plate
or
clutch
cover

surface

Unevenness
of

diaphragm
spring
toe

height

Loose

engine
mounting
or
deteriorated

rubber

A
noise
is
heard
after
clutch
is

disengaged

Damaged
release

bearing

A
noise
is

heard
when
clutch
is

disengaged

Insufficient

grease
on
the

sliding
surface

of

bearing
sleeve

Clutch
cover
and

bearing
are
not
installed

correctly
Replace

Replace

Replace

Replace

Repair
or

replace

Adjust
or
replace

Retighten
or

replace

I
Replace

Apply
grease

Adjust

A
noise
is
heard
when
vehicle
is

suddei11y
staited
off
with
clutch

partially
engaged

Damaged
pilot
bushing

I
Replace

When

grabbing
of
clutch
occurs
vehicle
will
not
start
off

smoothly
from
a

standing
start
or

clutch
is

engaged
before
clutch

pedal
is

fully

depressed

Oil
or

grease
on
clutch

facing

Clutch

facing
worn
or
loose
rivets

Wear
or
rust
on

splines
in

drive
shaft
and

clu
tch
disc

Warped
flywheel
or

pressure
plate

Loose
mountings
for

engine
or

power

train
units

CLll
Replace

Replace

Clean
or

replace

Repair
or

replace

Retighten

REAR

EXTENSION

DISASSEMBLY

Remove
lock

pin
from

striking

lever
and
remove

striking
rod
Manual
Transmission

Note
00

not
diSlssemble

rear
exten

sion
bush
from

rear
extension

ADAPTER
PLATE

DISASSEMBLY

I

Remove
six

6

bearing
retainer

attaching
screws
with
an

impact

wrench
and
remove

bearing
retainer

from

adapter
plate

2

Remove
reverse
idler
shaft

3
Remove
mainshaft

bearing
from

the
rear
extension
side

INSPECTION

Wash
all

parts
in
a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

a
Be
careful

not
to

damage
any

parts

with

scraper

b

00
not

clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE

AND

REAR

EXTENSION
HOUSING

I
Clean
with

solvent

thoroughly

and
check
for

cracks
which

might

cause
oil
leak

or
other

faulty
con

ditions

2

Check

mating
surface
of
the

case

to

engine
or

adapter
plate
for
small

nicks

projection
or
sealant
e
1
Control
lever

2

Striking
rod

guide

3

Striking
rod

4

Striking
lever

5

Return

spring
plug

6

Stopper

pin

TM353

Fig
MT

27

Exploded
view
of
shifting
mechani6m

Remove
all

nicks

projection
or

sealant
with

a
frne

stone

3

If
rear

extension
bush
is

worn
or

cracked

replace
it
as
an

assembly
of

bush
and
rear
extension

housing

BEARING

I

Thoroughly
clean

bearing
and

dry

with
a

compressed
air

2
When
race
and
ball
surfaces
are

worn
or

rough
or
when
balls
are
out

of

round
or

rough

replacebearihg

with
a
new
one
See

Figure
MT
28

I

TM372

Fig
MT
28

l
pecting
ball

bearing

3

Replace
needle

bearing
if

worn
or

damaged

GEARS
AND

SHAFTS

I

Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

MT
8
2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure
backiasii
in

gears

Standard

0
05
to0
10mm

0
0020
to
0
0039
in

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4
Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0
0126
to
0
0154
in

2nd

gear

0
12
to

0
19
mm

0
0047

to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to
0

0146
in

TM374

Fig
MT

29

Measuring
end

play

ADAPTER
PLATE

DISASSEMBLY

Same
as

for
the
F4W71

B

Fig
MT
67

Removing
screws

INSPECTION

Wash

all

parts
in

a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

a
Be

careful
not
to

damage
any

parts

with

scraper

b
Do

not
clean
wash
or
soak
oil
seals

in

solvent

TRANSMISSION
CASE
AND

REAR

EXTENSION
HOUSING

Same
as
for
the
F4W71
B

BEARING

Same

as
for
the
F4W7l
B

GEARS
AND
SHA
S

I
Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure

backlash
in

gears

Main
drive
and

counter
drive

gear

0
05
to
0
10

mm

0
0020
to
0
0039
in

1st

2nd
3rd
5th
and

reverse

gears

0
05
to
0
20
mm

0
0020
to
0
0040
in
Manual
Transmission

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4

Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0

0126
to
0
0154
in

2nd

gear

0
12

to
0
19
mm

0
0047
to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to

0
0146
in

OD

gear
on
mainshaft

0
32

to
0

39
mm

0
0126
to
0

0154
in

BAULK
RING

Same
as
for
the
F4W7IB

OIL
SEAL

Same
as
for
the
F4W71
B

ASSEMBLY

To
assemble
reverse
the
order
of

disassembly
Observe
the

following
in

structions

FRONT
COVER
ASSEMBLY

Same
as
for
the
F4W7l
B

REAR
EXTENSION

ASSEMBLY

I

Wipe
clean
seal

seat
in

rear
exten

sion

housing
press
fit
oil
seal
in

place

Coat
oil
seal
and

bushing
with

gear

oil
for
initial
lubrication
See

Figure

MT
68

Front
r

I

TM355

Fig
MT
68
R
ar
extemion
oil
sea

2

Apply
multi

purpose
grease
to

O

ring
and

plunger

grooves
in

striking

rod

Insert

striking
rod
with

striking
rod

guide
through
rear
extension

MT19
3
Install

striking
lever
on
front
end

of

striking
rod
Install
lock

pin
and

torque
screw
to
0
9
to
1
2

kg
m
7

to

9
ft
lb

4

Install

filainshaft
bearing
by

lightly
tapping
around
it
with
a

soft

hammer

5
Insert

reverse
idler
shaft
in

adapt

er

plate

Make
sure
that
the
cut
out

portion

of
reverse
idler
shaft
is

lined

up
with

inner
face
of

adapter

plate

6
Install

bearing
retainer
in

adapter

plate

Align
bearing
retainer

with
reverse

idler
shaft
at
the
cut
out

portion
of

this
shaft

torque
screws
to
1

9
to
2
5

kg
m
14
to
18
ft
lb
and
stake
each

screw
at
two

points
with
a

punch
See

Figure
MT
69

TM764

Fig
MT
69

Stahing
screw

7
Install
countershaft

rear
bearing

in

adapter

plate
by
lightly
tapping

around
it

with
a
soft
hammer

GEAR
ASSEMBLY

Clean
all

parts
in
solvent
and

dry

with

compressed
air

Synchronlz
r
embly

Same
as
for
the

F4W71
B

Ov
rdrlve
r

ynchronlz
r

mbly

I

Assemble
reverse
OD

synchro

nizer

assembly

2
Assemble
overdrive

gear
assem

bly

Position
synchronizer
ring
band

brake
thrust
block
and
anchor
block

on
overdrive
clutch

gear
install

circlip

Manual
Transmission

I

TROUBLE
DIAGNOSES
AND
CORREGTIONS

Condition

Difficult
to

intel11lesh
gears

Causes
Jor
difficu
t

gear
shifting
are
classi

fied
to
troubles

concerning
control

system

and
transniissioo
When

gear
shift
lever
is

heavy
and
it
is
difficult
to
shift

gears
clutch

disengagement
may
also
be
unsmooth
First

make
sure
that

clutch

operates
correctly

and

inspect
transmissi
o

Gear
slips
out
of
mesh

In
most
cases
this
trouble
occurs
when

interlock
b
all
check
ball
and

or
spring
is

worn
or
weakened
or

when
control

system

is

faulty
In
this
case
the

trouble
cannot
be

corrected

by
replacing
gears
and
therefore

trouble

shooting
must
be

carried
out

care

fully
It
should
also
be

noted
that

gear
slips

out

of
mesh
due
to
vibration

generated
by

weakened
fron
t
and
rear

engine
mounts

Noise

When
noise
occurs
with

engine
idling
and

ceases
when

clutch
is

disengaged
or
when

noise
occurs
while

shifting
gears
it
is

an

indicati90
that
th
e
noise
is

from
transmis

sion

t
Transmission

may
fa
ule

during
engine

idling

Check
air

fuel
mixture
and

ignition

timing

After
above

procedure
readjust
engine

idling
Probable

cause

Worn

gear
shaft
and
or

bearing

Insufficient

operating
stroke
due
to
worn
or

loose
sliding

part

Faulty
or

damaged
synchronizer

Worn
interlock
ball

Worn
check
ball

and
or

weakened
or
broken

spring

Wom
fork
rod
ball

groove

Wom
or
damaged
bearing

Worn
or

damaged
gear

Insufficient
or

improper
lubricant

Oil

leaking
due

to

faulty
oil

seal
or

sealant

clogged

breather
etc

Worn

bearing

High
humming
occurs
at
a

high
speed

Damaged
bearing
Cyclic
knocking
sound

occurs
also
at
a

19W
speed

Worn

spline

Worn

bushing

j

MT
23
Corrective
action

Replace

pair
or
replace

Replace

Replace

Replace

Replace

Replace

Replace

Add
oil
or

replace

with

designated
oil

Clean
Of

replace

Replace

Replace

Replace

Replace

Automatic
Transmission

i

r

11

I

@
@
j

A

T290

Assembly

I
Prior
to
assembly
dip
all

parts
in

clean
automatic
transmission
fluid

Reverse
disassembly
procedure
to

assemble
brake

2
Use
extreme
care
to
avoid
dam

aging
rubber

ring
when

installing
seal

lace

3

Blow

compressed
air

from

apply

side
of

piston
to
test

for
definite

piston
operation
as
shown
in

Figure

AT
93

7
i
8

ror
1

1
r

c

f

f
A

J

II
1

0

c
r

1

1
I

@

L
O
j

0
n

iJ

fl
IV
I

AT160

Fig
AT
93

Testing
piston

Apply
side

4
With

apply
side
of

piston
plugged

with
thumb
blow

compressed
air
into

cylinder
from
release
side
as
shown
in

Figure
AT
94
If
retainer

is
raised
a

little
it
is

an
indication
that

attaching

bolts
are
loose

calling
for

retightening
1
Anchor
end

pin

2
Band

strut

3

Apply

4
Release

5
Return

spring

6
Band
servo

piston
stem

7

Band
servo

piston

8
Servo
retainer

9
Brake
band
assembly

10

Transmission
case

Fig
AT
92
Sectional
view

ofseruo
piston

7
o

i
J

1S

I

z
1
Y

i
1

t
9
c
fa

AT161

Fig
AT
94

Testing
piston

Release
side

GOVERNOR

Disassembly

I

Separate
governor
from
oil
dis

tributor

by

unscrewing
attaching
bolts

2
To
disassemble

secondary

gover

nor

remove

spring
seat

spring
and

secondary
governor
valve
from
valve

body
in
that
order

as
shown
in

Figure

AT

95

To
control

val

i
1

3

5MI
n

ID
r

Ii

I

4

From
control
valve

Line

pre
sure

I

I
A
TOgO

4
Oil

distributor

5

Output
shaft
I

Primary
governor

2

Secondary
governor

3
Governor
valve

body

Fig
AT
95

Testing
secondary

govemor

AT
43
3

If

primary
governor
is
to
be

dis

assembled
for

any
purpose
remove

spring
seat

primary
governor
valve

spring
and

spring
seat

Inspection

I
Check
valve
for

faulty
condition

Replace
spring
if
found
weakened

beyond
use
Faulty

piston
should
also

be

replaced
with
a
new
one

2
Examine
to
see
if

primary
gover

nor
slides

freely
without

binding

3
To
determine
if

secondary
gaver

nor
is
in

good
condition
blow
air

under

light

pressure
into
hole
at
A

and
listen
for
noise
like
that
of
a

model

plane

Assembly

Reverse
disassembly

procedure
to

assemble

governor

Note
Do

not
confuse

primary
gover

nor
with

secondary
governor
After

installation
check
that

spring
is
not

deflected

OIL
PUMP

Disassembly

I
Free

pump
cover
from

pump

housing
by
removing
attaching
bolts

2
Take

out
inner
and
outer

gears

from

pump
housing

Inspection

I

Inspect
for
wear
or

damage
to

gear
teeth

Replace
rubber

ring
if

found

damaged
beyond
use

2

Using
a

straight
edge
and
feelers

measure

pump
and

gear
clearances
as

follows

Clearance
between
inner

or
outer

gear
and

pump
cover
See

Figure

AT
96

Standard
clearance

0
02
to
0
04

mm

0
0008100
0016
in

Replace
if
over
0
08
mm
0
00
11

in

Automatic
Transmission

TROUBLE

DIAGNOSIS
AND
ADJUSTMENT

INSPECTION
AND
ADJUSTMENT

BEFORE

TRQUBLE
DIAGNOSIS

TESTING

INSTRUMENT
FOR

INSPECTION

CHECKING
OIL

LEVEL

INSPECTION
AND
REPAIR
OF

OIL
EAKAGE

CHECKING

ENGINE
IDLING

REVOLUTION

CHECKING
AND
ADJUSTING

KICKDOWN

SWITCH
AND

DqWNSHIFT
SOLENOID

N
J
J
CII
Q

t
L
8li
p

JYSTMs
T
OF

MANUAL
LINKAGE

CHECKING
AND

ADJUSTING

INHIBITOR

SWITCH

STALL
TEST

STALL
TEST

PROCEDURES

JUDGEMENT

Since
most
automatic

transmission

troubles

can
be

repaired

by
simple

adjustment
do
not
disassemble
im

mediately

Firstly

inspect
and

adjust
the
auto

matic
transmission

in

place
utilizing

the
Trouble

Shooting
Chart

If
the
trouble
can

not
be
solved

by

this

procedure
remove
and
disas

semble

the
automatic
transmission

It

is

advisable
to
check

overhaul
and

repair
each

part
in
the

order
listed
in

the
Trouble

Shooting
Chart

I
In
the
Trouble

Shooting
Chart

the

diagnosis
items

are

arranged
ac

cording
to

difficulty
from

easy
to

difficult
therefore

please
follow
these

items
The
transmission
should
not

be

removed
unless

necessary

2
Tests
and

adjustments
should
be

made
on
the
basis
of
standard
values

and

the
data

should
be
recorded

INSPECTION

AND

ADJUSTMENT

BEFORE

TROUBLE
DIAGNOSIS

TESTING
INSTRUMENT
FOR

INSPECTION

I

Engine
tachometer

2
Vacuum

gauge
ROAD
TEST

VEHICLE
SPEED

AT
GEAR

SHIFT

CHECKING
SPEED
CHANGING

CONDITION

CHECKING
ITEMS
DURING
SPEED

CHANGE

SHIFT
SCHEDULE

LINE

PRESSURE
TEST

LINE

PRESSURE

governor
feed

pressure

JUDGEMENT
IN

MEASURING
LINE

PRESSURE

At
49

TR6
uBLE
SHOOTINC
CHART

INSPECTING
ITEMS

TROUBLE

SHOOTING
CHART
FOR

3N71B

AUTOMATIC
TRANSMISSION

TROUBLE

SHOOTING
GUIDE
FOR

3N71B

AUTOMATIC
TRANSMISSION
CONTENTS

AT
4B

AT
48

AT
4B

AT

49

AT
49

AT
49

AT
49

AT
50

AT

50

AT
50

3
Oil

pressure
gauge

It
is
convenient

to
install
these

instruments
in
a

way
that
allows
meas

urements
to
be
made
from
the
driver
s

seat

CHECKING
OIL
LEVEL

In

checking
the
automatic
transmis

sion

the
o
illevel
and
the
condition
of

oil
around
the
oil
level

gauge
should
be

examined
This
is

an

easy
and
effective

trouble

shooting

procedure
since

some

changes
in
oil
condition

are
often

linked
with

developed
troubles

For
instance

Lack
of
oil
causes

faulty
operation

by
making
the
clutches
and

brakes

slip
resulting
in

severe
wear

This
is
because
the
oil

pump
sucks

air

causing
oil

foaming
thus

rapidly

deteriorating
the
oil

quality
and

pro

ducing
sludge
and

varnish

Excessive
oil
is

also
bad
because
of

oil

foaming
caused

by
the

gears

stirring

up
the
oil

During
high
speed

driving

excessive

oil
in

the

transmission
often

blows
out

from
the
breather

Measuring
011
level

To
check
the
fluid
level
start
the

engine
and
run
it
until
normal

operat

T
AO
AT
51

AT
51

AT

52

AT
52

AT
52

AT

52

AT

53

AT
3

AT

53

AT

53

AT

54

AT
57

ing
temperatures
o

temperature
SO

to
800C

122
to
l760F

Approxi

mately
ten

minute
of

operation
will

raise
the

temperature
to
this

range

and

engine

idling
conditions

are
stabi

lized
Then

apply
the
brakes
and

move
the

transmission
shift
lever

through
all
drive

positions
and

place
it

in

park
P

position
In

this

inspec

tion
the
car
must
be

placed
on
a
level

surface

The
amount
of
the
oil
varies

with

the

temperature
As
a
rule
the
oil
level

must
be
measured
after
its

temper

ture
becomes

sufficiently
high

1

Fill
the
oil
to

the
line
H
The

difference
of

capacities
between
both

H
and
L
is

approximately
0
4

liter
Ji
V
S

p
Y

Imp
pl
and

therefore
do

not
to
fill

beyond
the

line

H

2
When

topping
up
and

changing

oil
care
should
be
taken
to

prevent

mixing
the
oil
with
dust
and
water

InspectIng
011

condition

The
condition
of

oil

sticking
to
the

level

gauge
indicates
whether
to
over

haul
and

repair
the
transmission

or

look
for
the

faulty

part

If
the
oil
has
deteriorated
to
a

varnish
ike

quality
it

causes
the

con

trol
valve
to
stick
Blackened
oil
indi

cates
a
burned
clutch
brake
band
etc

PROPElli

ER
SHAfT
DIFFERENTIAL
G

ARRIERf

Notes

a
PUller
should
be
handled
with

care

in

catchins
the

edge
of

bearing

inner

race

b
Be
careful

not
to

confuse
left
and

right
hand

parts

2
Remove

ring

gear
by
spreading

out
lock

strap
and

loosening
ring
gear

bolts
in

diagonally

3

Punch
off

pinion
mate

shaft
lock

pin
from

ring

gear
side

using
Solid

Punch
ICV31100300

KV31100300

PD022

Fig
PD

13

Removing
lock

pin

Note

Lock

pin
i
cauIked
at

pin
hole

mouth
on
differential
case

Do
not

punch
it
off

forCibly
without

checkins
how
it
is
uIked

4

Draw

out

pinion
shaft
and

re

move
thrust

block

pinion
mates
side

gears
and

thrust
washers

Note
Put
marks

on

gear
and
thrust

Wasliersotliat

they
can
be
reinstaD

ed
in

their

original
positions
from

which

they
were
removed

INSPECTION

Thoroughly
clean

all
disassembled

parts
and
examine

them
to
see
if

they

8re

worn

damaged
or
otherwise

faulty
and

how

they
are
affected

Repair
or

replace
ail

faulty

parts

whichever
is

necessaiy

I

Check

gear
teeth
for

scoring

cracking
and

chipping
and

make
sure

that

tooth
contact

pattern
indicates

correct

meshing
depth
If

any
fault
is

evident

replace
parts
as

required
Note
Drive

pinion
and

ring
gear
are

supplied
for

replacement
as
a
set

therefore

should
either

part
be

damaged
replace
as
a
set

2

Check

pinion
shaft
and

pinic
m

mate
for
scores

and

signs
of
wear
and

replace
as

required

Follow

the
same

procedure
for

side

gear
and
their
seats

on
differential

case

3

Inspect
all

bearing
races
and

rollers
for

scoring
chipping
or
evi

dence
of
excessive
wear

They
should

be
in

tiptop
condition
such
as
not

worn
and

with
mirror
like

surfaces

Replace
if
there
is
a
shadow

of
doubt

oil

their
efficiency
as
an
incorrect

bearing
operation
may
result
in
noises

and

gear
seizure

4

Inspect
thrust

washer
faces

Small

faults
can

be
corrected
with

sand

paper
If

pinion
mate

to
ide

gear

backlash
or

the
clearance

between

side

gear
and
thrust
washer
exceeds

limits
0

02

to
0
08
nun
0
0008
to

0
0031
in

replace
thrust
washers

S

Inspect
carrier

and
differential

case
for
cracks

or
distortion

If
either

condition
is

evident

replace

faulty

parts

6
As

a

general
rule

oil
seal
should

be

replaced
at
each

disassembly

ASSEMBLY

AND

ADjUSTMENT

Assembly
can
be

done
in

the

reo

verse

order
of

disassembly
The
foDow

ing
directions
for

adjustment
and

usage
of

special
tools
enable
to

obtain

a

perfect
differential

operation

PRECAUTIONS
IN

REASSEMBLY

I

Arrange
shims
w

shers
and
the

like
to
install
them

correctly

2

Thoroughly
clean

the
surfaces
on

which
shims

washers

bearings
and

bearing

caps
are
installed

3

Apply
gear
oil

when

installing

bearings

4

Pack

grease
cavity
between

lips

when

fitting
oil
seal

PD
8
ASSEMBLY
OF

DIFFERENTIAL
CASE

I

Assemble

pinion
mates
side

gears
thrust
block
and

thrust
washers

in
differential

case

2
Fit

pinion
shaft
to
differential

case
so

that
it

meets
lock

pin
holes

3

Adjust

pinion
mate

to
ide

gear

backlash
or
the
clearance

between
the

rear
face
of

side

gear
and
thrust

washer
to
0
02
to

0
08
mOl
0
0008

to
0

0031
in

by

selecting
side

gear

thrust
washer

Side

gear
thrust

WlISber

Thickness

nun

in

Over

0
7S

to
0
80

0
029S
to
0
03IS

Over

0
80
to
O
8S
Om

IS
to
0
033S

Over

0
8S
to
0
90
0

033S
to
0
03S4

Over

0
90
to
0
9S
0
03S4

to
0
0374

4

Lock

pinion
shaft
lock

pin
using
a

punch
after
it

is
secured
into

place

S

Apply
oil
to

gear
tooth

surfaces

and
thrust
surfaces
and
check
if

they

turn

properly

6
Place

ring

gear
on

differential

case

and
install

bolts
and
lock
washers

Torque
bolts
to

specification
and

bend

up
lock

strap

Tightening

torque

7
0
to
8
0

kg
m

S1to
Sifft
Ib

Notes

ao
Use

only
genuine
ring
gear
bolts

and
new
lock

strap

b

Tighten
bolts
in

criss
cross
fashion

lighdy
tapping
fOund
bolt

heac
Js

with
a
hammer

7

When

replacing
side

bearing

measure

bearing
width

using
a

stand

ard

gauge
20
00
nun
0
7874
in

thickness
and
a

weight
block
2
5

kg

S
S
Ib

prior
to
installation
See

Figure
PD

I4

Standard
bearing
width

20
00
nun
0
7874
in

PROPELLER

SHAFT

DIFFERENTIAl

CARRIER

TROUBLE
DIAGNOSES

AND

CORRECTIONS

When
a
differential
carrier
is

sus

pected
of

being

noisy
it
is

advisable
to

make
a

thorough
lest

to
determine

whether
the

noise

originates
in
the

Condition

Noise

on
drive

coast

and
float

Noise
on
turn

Knocking
sound

during

starting
or

gear

shifting
tires

road
surface

exhaust
universal

joint
propeller
shaft
wheel

bearings

engine
transmission

or
differential

carrier

Noise
which

originates
in

other

Probable
cause

Shortage
of
oil

Incorrect
tooth
contact

between

ring
gear

and
drive

pinion

Incorrect
backlash
between

ring
gear
and

drive

pinion

Seized

up
or

damaged
ring

gear
and
drive

pinion

Seized

up
damaged
or

broken
drive

pinion

bearing

Seized

up
damaged
or
broken
side

bearing

Loose
bolts
or
nuts

fIXing
ring
gear
bearing

cap
etc

Seized

up
damaged
or
broken
side
and

pinion
mate

Seized

up
damaged
or
broken

side

gear
and

pinion
thrust
washer

Pinion

mates
too

tight
on

their
shaft

Excessive
backlash

Incorrect

backlash

ring
ar

to
drive

pinion
or
side

gear
to

pinionmate

Worn

gears
or
case

Worn
rear

axle
shaft
and

side

gear
spline

Drjve
pinion

bearing
under

p
reload

Loose
drive

pinion
nut

Loose
bolts

or
nuts

ftxing
ring
gear

bearing

cap
etc

PD

14
places
cannot
be
corrected

by

adjust

ment
or

replacement
of

parts
in
dif

ferential
carrier

Corrective
action

Supply
gear
oil
Rebuild

gear
carrier
if

necessary

Adjust
tooth
contact

or

replace
the

hypoid

gear
set

Adjust
backlash
or

replace
the

hypoid
gear

set

if

necessary

Replace
the

hypoid

gear
set

Replace
the

pinion

bearing
and

faulty

parts

Replace
the

side

bearing
and

faulty
parts

Clamp
them

to

specified

torque
and

replace

faulty
parts

Replace

faulty
parts

Replace

faulty
parts

Replace
faulty
parts

Adjust
backlash

Replace
worn

parts

Replace
worn

parts

Adjust
preload

Repair
or

replace

Clamp
them
or

replace
if

necessary