brake light DATSUN PICK-UP 1977 Service Manual

3
If
there

is
a
leak

remove

top

cover
from

purge
contiol
valve
and

check

for
dislocated
or

cmcked
dia

phragm
If

necessary
replace
dia

phmgm
kit

which
is
made

up
of
a

retainer

diaphragm
and

spring

I
@

1
Cover

2

Diaphragm

3
Retainer

4

Diaphragm
spring

Fig
ET
47
ET350

Carbon
caniater

purge

control
valve

Carbon
unlster

filter

Check
for
a
contaminated

element

Element
can
be
removed
at

the

bottom
of
canister

installed
on
vehicle

body

Fig
ET
48

Replacing
carbon

canister

filter

Fuel
tank

vacuum
relief

valve

operation

Remove
fuel
filler

cap
and
see
it

functions

properly

I

Wipe
clean
valve

housing
and
have

it
in

your
mouth

2

Inhale
air
A

slight
resistance

ac

companied
by
valve
indicates
that

valve
is
in

good
mechanical
condition

Note
also
that

by
further

inhaling
air

the
resistance
should
be

disappeared

with
valve
clicks
Engine
Tune

up

3
If
valve

is

clogged
or
if
no
resist

ance
is

felt

replace
cap
as
an
assem

bled
unit

r

u

ET369

Fig
ET
49
Fuel

filler
cap

CHECKING

CATALYTIC

CONVERTER

INSPECTION

Preliminary
inspection

Visually
check
condition
of
all

component
parts
including
hoses

tubes
and
wires

replace
if

necessary

Refer
to

Inspection
of
A
I

S
on

page
EC
17

Catalytic
converter

Whether

catalytic
converter
is
nOf

mal
or
not
can
be
checked

by
ob

serving
variation
in
CO

percentage

The

checking
procedure
is

as
follows

Apply
parking
brake
Shift

gears

into

Neutral
for
manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Visually
check

catalytic
converter

for

damage
or
cracks

2
Remove
air

hose
between
5

way

connector
and
air

check
valve

Plug
the

disconnected
hose
to

prevent
dust

from

entering
Refer
to

page
ET
12

3
Check
carburetor

pipes
for

proper

connection

4

Warm

up
engine
sufficiently

5
Race

engine
1
500
to
2
000

rpm

two

or
three
times
under
no
load
then

run

engine
for

one
minute
at

idling

speed

6

Adjust
throttle

adjusting
screw

until

engine
attains
to

specified
speed

Refer
to

page
ET
12

7

Check

ignition
timing
If

neces

sary

adjust
it
to

specifications
Refer

to

page
ET
10

ET
23
8

Adjust
idle

adjusting
screw
until

specified
CO

percentage
is

obtained

Refer
to

page
ET
12

9

Repeat
the

adjustment
process
as

described
in

steps
5
to

8
above
until

specified
CO

percentage
is

obtained

Note

Adjustment
in

step
9
should
be

made
ten
minutes
after

engine
has

warmed

up

10
Race

engine
1
500
to
2
000

rpm
two
or
three
times
under

no
load

and
make

sure
that

specified
CO

per

centage
is
obtained

I
1
Remove

cap
and
connect
air

hose
to
air
check
valve

If

idling

speed
increases

readjust
it

to

specified
speed
with
throttle
ad

justing
screw

12
Warm

up
engine
for
about
four

minutes
at
2
000

rpm
under
n
load

13
Measure

CO

percentage
at

idling

speed
After

step
12
has
been
com

pleted
wait

for
one
minute
before

making
CO

percentage
measurement

14

If
CO

percentage
measured
in

step
13
is
less
than
0
3
the

catalylic

converter
is

normal

15
If
CO

percentage
measured
in

step
13
is

over
0
3
recheck
A
I
S

and

replace
air

check
valve
Then

perform
inspection
steps
12

and
13

16
If
CO

percentage
is
still

over

0
3
in

step
15

catalytic
converter
is

malfunctioning
Replace
catalytic
con

verter

CHECKING
FLOOR

TEMPERATURE

WARNING
SYSTEM

INSPECTION

Floor

warning
temperature

system

Apply
parldng
brake
Shift

gears

into
Neutral
for

manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Ensure
that
floor
tern

perature

warning

lamp
lights
when

ignition

switch
is

turned
to
the
S

position

If
not
check

lamp
for
burned

bul
bs

ELECTRIC
AUTOMATIC

CHOKE

An
electric
heater
wanns
a
bi
metal

interconnected
to
the
choke
valve
and

controls
the

position
of
choke
valve

and
throttle
valve
in
accordance
with

the

time

elapsed
the
warm

up
condi

tion

of
the

engine
and
the

outside

ambient

temperature

When
outside
ambient

temperature

is

above

operating
temperature
the

automatic

choke
control
serves
to
fur

ther
reduce
exhaust

gasemission

during
warm

up
by
automatically

selecting
one
of
the
two

choke

opera

tion
modes
fast

acting
or
slow

acting

Slow

acting
choke

operation

When
ambient

temperature
is
low

electric
current
flows

through
the

automatic

choke

relay
to
the
P
T
C

heater
A

and

gradually
warms
the

bi

metal
This
causes
the
choke
valve

to

open
slowly

Fast

acting
choke

operation

When
ambient

temperature
is

high

the
bi
metal
switch
is
in

on
This

causes
electric

current
to
flow

through

the
automatic

choke

relay
to
the

P

T
C
heater
A
and
heater

B
result

ing
in

quick

opening
of
the

choke

valve

r

@@

r

@
Engine
Fuel

The

construction
and

function
of

each

part
of

this
carburetor
are
as

follows

l
Bi
metal
and
heater
in
choke

cover

Electric
current

flows

through
the

ttea
r
as

t
le
engine
tl

1
SI
nd
war

the
bi
metal

The
deflection
of
the

bi
metal
is
transmitted
to
the
choke

valve

through
the
choke

yalve
lever

2
Fast
idle
cam

The
fast
idle

cam
determines
the

opening
of
the
throttle
valve

so
that

the

proper
amount
of

mixture
cor

responding
to
the

opening
of
the

choke
valve
will
be
obtained
The

opening
of
the

choke
valve
is

depend

ent

upon
the
warm

up
condition
of

the

engine

3

Fast
idle

adjusting
screw

This

screw

adjusts
the

opening
of

the
throttle

valve
of
the
fast

idle
earn

4
U

nloader

When

accelerating
the

engine
during

the

warm

up
period
that
is

before
the

choke

valve

opens
sufficiently
this

unloader
forces

the
choke
valve

open
a

liUle
so

as
to
obtain

an

adequate

air
fuel

mixture

5

Vacuum

diaphragm

After

the

enginThas
been

started

by
cranking
this

diaphragm
forces

the

choke
valve

open
to
the

predetermined

extent
so

as
to

provide
the

proper

air
fuel
ratio

6
Bi
metal

case
index
mark

The
bi
metal

case
index
mark
is

used

for

setting
the

moment
of
the

D

Il

EF232

1

Alternator

2
Automatic
choke

relay

3
Automatic
choke
cover

4
P

T
C
heater
A

5
Bi
metal
switch

6
P

T
C
heater
B

7
Bi
metal

8
Choke
valve

Fig
EF
33
Schematic

drawing
of
electric
automatic
choke
heater

EF

20
bi
metal
which

controls
the
air

fuel

mixture
ratio

required
for

starting

DASH
POT

SYSTEM

These
carburetors
are

equipped

with

a
dash

pot

interl
ked
wi
h

the

primary
throttle

valve

through
a
link

mechanism
The

dash

pot
is
intended

to

prevent

engine
stall

resulting
from

quick
application
of
the
brake
or

from
the

quick
release
of
the
accele
ra

tor

pedal
after

treading
it

slightly

In

such
a

situation
a
throttle
lever

strikes

against
the
dash

pot
stem
and

makes
the

primary
throttle
valve
close

gradually
thus

keeping
the

engine

running

ALTITUDE
COMPENSATOR

California
models

The

higher
the
altitude
the
richer

the
air

fuel
mixture
ratio
and
there

fore
the

higher
exhaust

gas
emissions

even

though
the

engine
is

properly
ad

justed
for
low

altitude

driving

The
altitude

compensator
is

design

ed

to
meet
EiiriSSion
S13ndards
for

driving
in
both
low
and

high
altitudes

At

high
altitudes
additional
air
is

sup

plied
to
the
carburetor

by
the
altitude

compensator
When
the
altitude

com

pensator
lever

is
set
at
H
air
is

conducted

through
an
air

passage
to

the

carburetor
The
air

passage
is

closed
when
the
lever

is
set
at
L

H

L
Lever

When

operating
the
H

L
lever
fol

low
these

instructions

H

position

Should
be
used
for

general
driving

in

those
areas

designated
by
law

as

High
Altitude
Counties

L

position

For
use
outside
those
areas

desig

nated
as

High
Altitude
Counties

REMOVAL

AND

INSPECTION

Removal
and

inspection
can
be

done

as
follows

Removal

Catalytic
converter

1

Apply
parking
brake

2

Place
wheel
lock
under
each
tire

3

Jack

up
the
vehicle

4
Remove
lower
shelter
of

catalytic

converter

5
Dismount

catalytic
converter

EC453

Fig
EC
69
Removing

catalytic

conuerter

Inspection

Preliminary
inspection

Visually
check
condition
of
all

component
parts
including

ho
s

tubes
and
wires

replace
if

necessary

Refer
to

Inspection
of
A
I
S
on

page
EC
17

Catalytic
converter

Whether

catalytic
converter
is
nor

mal
or
not
can
be
checked
by
ob

serving
variation
in

CO

percentage

The

checking

procedure
is

as
follows

Apply
parking
brake
Shift

gears

into
Neutral
for
manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1

Visually
check

catalytic
converter

for

damage
or
cracks
Emission
Control

System

2
Remove
air
hose
between

5

way

connector
and
air
check
valve

Plug
the

disconnected
hose
to

prevent
dust

from

entering
Refer
to

page
ET
12

3

Check
carburetor

pipes
for

proper

connection

4

Warm

up
engine
sufficiently

5

Race

engine
1

500
to
2
000

rpm

two
or
three
times

under
no
load
then

run

engine
for
o
e
minute
at

idling

speed

6

Adjust
throttle

adjusting
screw

until

engine
attains
to

specified
speed

Refer
to

page
ET
10

7
Check

ignition
timing
If
neces

sary
adjust
it
to

specifkations
Refer

to

page
ET
10

B

Adjust
idle

adjusting
screw
until

specified
CO

percentage
is

obtained

Refer
to

page
ET
12

9

Repeat
the

adju
stment

process
as

described
in

steps
5
to
8
above

until

specified
CO

percentage
is
obtained

Note

Adjustment
in

step
9
should
be

made
ten

minutes
after

engine
has

wanned

up

10
Race

engine

1
500
to
2
000

rpm
two
or
three
times

under
no
load

and
make
sure
that

specified
CO

per

centage
is
obtained

11
Remove

cap
and
connect
air

hose
to

air
check
valve

If

idling

speed
increases

readjust
it

to

specified
speed
with
throttle
ad

justing
screw

12
WaRn

up
engine
for

about
four

minutes
at
2
000

rpm
under
no
load

13
Measure
CO

percentage
at

idling

speed
After

step
12
has
been
coin

pleted
wait

for
one
minute
before

making
CO

percentage
measurement

14
If
CO

percentage
measured
in

step
13
is
less
than
0
3

the

catalytic

converter

is
normal

15
If
CO

percentage
measured
in

step
13
is
over
0
3

recheck
A
I
S

and

replace
air
check
valve
Then

perform
inspection
steps
12
and
13

EC
27
16
If
CO

percentage
is

still
over

0
3
in

step
15

catalytic
conyerter
is

malfunctioning
Replace
catalytic
con

verter

INSTALLATION

To
install

reverse
the
removal

pro

cedure

Bolt

lightening

torque

specifications

Tightening

torque

Catalytic
converter

2
6
to
3
4

kg
m

19
to
25
ft
Ib

FLOOR

TEMPERATURE

WARNING
SYSTEM

DESCRIPTION

The
floor

temperature
warning

system
consists
of
a
floor

temperature

sensing
switch
installed

on
the
vehi

cle
s
floor
floor

temperature
relay
and

a

warning

lamp
on
the
instrument

panel
and
wires
that
connect
these

parts

When
the
floor

tempera
ture
rises
to

an
abnormal
level
the

warning
lamp

will

light
to
call
the
attention
of
the

driver
The

wiring
diagram
of
this

system
and
location
of
the

floor

temperature
sensing
switch
are
ilIus

trated
in

Figures
EC
70
and
EC
71

Floor
temparature
warning

lamp

Refer

to

Figure
EC
74

for
the

loca

tion
of
this

part

L

1t

1

RAt

Fig
EC
74
Location
of
floor

temperature
warning
lamp

INSTALLATION

To
install
reverse
the
order
of

rem
ovaL

INSPECTION

Floor
warning
temperature

system

Apply
parking
brake
Shift

gears

into
Neutral
foI
manual
transmission

and
Neutral
or
Park
for
automatic

transmission

1
Ensure
that
floor

temperature

warning

lamp
lights
when

ignition

switch
is
iumed

to
the
S

position

If

not
check

lamp
for
burned

bulbs

Replace
bulb
if
bulb
is
burned
out

If

bulb
is

not
burned
trace
wire
s

back
to

ignition
switch

Repair
or

replace
if

necessary

2
Be

sure
that
floor

temperature
is

cool
below
800C

1760Fj
before

carrying
out
the

following
procedure

I
Remove
rearseat

2

Ignition
switch
is

turned
to
the

IG

position

3
Ensure
that
floor

temperature

warning
lamp
goes
out

4
Heat

surrounding
areas
of
floor

temperature
sensing
switch
with
a

proper
heater
to
ensure
that
floor

temperature
warning
lamp
glows
when

floor
is
heated

to
the

specifications
as

shown
in
the
table
below
Emission
Control

System

Temperature

sensing
switch

Contact
close
Temperature

warning
lamp

Off

Contact
open
On

Note

Avoid

heating
floor

tempera

ture

sensing
switch

directly

If

lamp
does

not
glow
check
floor

temperature
sensing
switch
connector

for

continuity
with

a
circuit
tester

If

continuity
should
exist
after

heated

surrounding
areas
of
floor
tem

perature
sensing
switch

replace
tem

perature
sensing
switch

If
con

tinuity
does

not
exist

trace

the

wiring
back
to

relay
or
check
the

following
step
3

Repair
or

replace

wire
s
if

necessary

Note
The

floor

temperature
sensing

switch

may
be
heated

through
the

floor

by
a

proper
heater

3
Turn

ignition
switch
to
the

IG

position
and
disconnect
floor

temper

ature

sensing
connector
The

lamp

should
remain

on
If

not
check
floor

temperature
relay
for

continuity
with

2
00

r
I

141

J

To
floor

temperatwe

warning
lamp

2
From

S

position

3
From

IG

position

4

From

ignition
switch

5
To
floor

temperature

sensing
switch
O

When
floor

temperature

warning
lamp
lights

Check
floor

temperature
warning

lamp

1

Open
or

shorj
circuit
in

wiring

harness

2

Check
fuel

system
with

regard
to

the

following
items

Refer
to

Inspec

lion
of
Fuel

System

EC
29
Floor

temperature

Below
1050C
221
OF

Above

1050C
221
OF

a
circuit

tester

Referring
to
the

following
floor

temperature
relay
if

relay
is
normal

trace
wire
s

back
to

ignition
switch

Repair
faulty
wiring

Floor

temperature
relay

When

checking
floor

temperature

relay
for
unit

remove
it
and

proceed

as
follows

1

Check
for

continuity
between

@

and

ID
Continuity
should
exist

Check
for

continuity
between

CD

and@
Continuity
should
exist

Check
for

continuity
between

CD

and

@
Continuity
should
not

exist

2

Apply
a
12

volt
doc
across

@
and

ID
to

ensure
that

continuity
exists

between

CD
and

@
and
that

con
ti

nuity
does

not
between

CD
and

@
If

test
results
dn

not

satisfy
the
above

replace
the

floor

temperature
relay

EC344

Fig
EC
75

Checking
floor
temperature
relay

1
Float
level

2
Choke

3

Normal
fuel

supply
system
Prima

ry
and

secondary

4
Accelerator

pump

5
Power
valve

6
B
C
D
D

7
Fuel
strainer

8
Air
cleaner

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

The
control
valve

assembly
consists

of

the

following
valves
See

Figure

AT

20

I
Pressure

regulator
valve

PRV

2

Manual
valve

MNV

3
I

st
2nd

shift
valve

FSV

4

2nd
3rd

shift
valve

SSV

5

Pressure
modifier
valve

PMV

6
Vacuum
throttle
valve

VTV

7

Throttle
back

up
valve

TBV

8
Solenoid
downshift
valve
SDV

9

Second
lock
valve
SL
V

10
2nd
3rd

timing
valve

TMV

Pressure

regulator
valve

PRV

The

pressure
regulator
valve
re

ceives
valve

spring
force
force
from

the

plug
created

by
the
throttle

pres

sure
16
and
line

pressure
7

and

force
of
the
throttle

pressure

18

With
the
interaction

of
those
forces

the
PRY

regulates
the

line

pressure
7

to
that

most
suitable
for
individual

driving
conditions

The
oil
from
the
oil

pump
is

ap

plied
to

the

ring

shaped
area

through

orifice
20
As

a
result
the
PRV
is

depressed
downward
and
moves
from

port
7

up
to
such
extent
that
the

space
to
the
next
drain

port
marked

with
X
in

Figure
AT
10

opens

slightly
Thus
the

line

pressure
7
is

balanced
with
the

spring
force
there

by
balancing
the
PRV
In
this

opera

tion
Ihe

space
from

port
7
to
the

subsequent
converter
oil

pressure
14

circuit
has
also
been

opened
As
a

result
the
converter
is
filled

with

pressurized
oil
in
circuit
14
and
this

oil
is
further
used
for
lubrication
of

the
rear
unit
Moreover

part
of
the
oil

is
branched
and
used
for
lubrication

of

the
front
unit
for
the
front
and
rear

clutches

When
Ihe
accelerator

pedal
is
de

presscd
the
throttle

pressure
16
in

creases
as
described
in
the

preceding

paragraph
oil

pressure
is

applied
to

the

plug
through
orifice
21

and
this

pressure
is

added
to
the

spring
force

As

a
result
the
PRV
is

contrarily

forced

upward
space
to

the
drain

port

is
reduced
and
Ihe

line

pressure
7

increases
Automatic

Transmission

11

AT095

Fig
AT
10
Pressure

regulator
ualue

When

the

range
is
selected
at
R

Reverse

the
line

pressure
6
is

applied
10

the

plug
in
a
manner
identi

caito
the

throttle

pressure
16
and

is

added
10
the

spring
force

Consequent

ly
the
line

pressure
7

further
in

creases

When
vehicle

speed
increases

and

the

governor
pressure
rises
the

theot

tle

pressure
18
is

applied
to
the

port

on
the

top
of
the
PRV

and

pressure
is

applied
contrarily
against
the

spring

force
As
a

result
the
line

pressure
7

decreases
Moreover
at
individual

con

ditions
the
line

pressure
7

is

equal
to
the
line

pressure
6

and
the
throttle

pressure
16
is

equal
to
18

Manual
valve
MNV

The
manual
lever

turning
motion
is

converted
to

reciprocating
motion

of

the
manual
valve

through
a

pin
and

the
MNV
is

positioned
so
that
the
line

pressure
7
is
distributed
to
the

indi

vidual
line

pressure
circuits
at
each

P

R
N

D
2
or
I

range

as

shown
below

P

range

7
4
SDV
and
TBV

5

FSV
12
TBV
and

Low

reverse
brake

R

range

7
4

same
as
above

5

same
as
above

6

PRY
and

SSV
F
C

and
band
release

N

range

D

range

7
7

None

I

Governor
valve

FSV

and
rear
clutch

2

SLY

3

SL
V

and
SSV

2

range

7
I
Same
as
above

2

SL
V
9
Band

applied

4
SDV
and
TBV

I

range

7
I
Same
as
above

4
Same

as
above

5

FSV

Moreover
1

2
3
4
5

and

6

are

always
drained
at
a

position

where
the
line

pressure
is

not
dis

tributed
from
7

u
JJX
g4Vhl

dIillillt
1
dlMIi
W
ld

IiIb
It
i
B
J

jd
l
tJj
fitMi
td

j
L@

x
x

j
j

P
R
N

17
l

AT7
AT096

Fig
AT
11

Manual
ualvp

Starter

should
be

brought
into

op

eration

only
when
selector

lever
is
in

P

and
N

positions
it

should
not

be
started

when
lever
is
in
D
2

I

and
R

positions

Back

up
lamp
should
also

light

when

selector
lever
is

placed
in

R

position

S
After

converter
is
installed

rotate

10

Check
level
of
oil
in
transmis

crankshaft
several
turns
and
check

to

be
sure
that
transmission

rotates

freely
sion

For
detailed

procedure
see

page

AT48

without

binding

6
Pour

recommended
automatic
II

Move
selector
lever

through
aU

positions
to
be

sure
that
transmission

transmission

fluid

up
to
correct
level

operates
correctly

through
oil

charge
pipe

verter
to
transmission
measure

dis

With
hand

brake

applied
rotate

tan
A

to
be
certain

that

they
are
7

Connect
manual
lever
to
shift

engine
at

idling
Without

disturbing

correctly
mbi
d

S
F
rod

Opeiationsliould
oecaTrie
f
bue

the
above

sclUng
ffiovTSelector
lever

AT

50
with

manual
and
selector
levers
in

through
N

to
D
to
2

to
I

Distance
A
N

and
to
R
A

slight
shock
should
be

More
than
21

5
mm
0
846
in
8
Connect

inhibitor
switch
wires

felt

by
hand

gripping
selector

each

time
transmission
is
shifted
Automatic
Transmission

4
Bolt
converter
to
drive

plate

Note

Align
chalk
marks

painted
a

cross
both

parts
during
disas

sembling

processes

AT116

Fig
AT
49

Torque
converter

aligning
cu
t

3
When

connecting

torque
can

A

ATl17
Notes

a
Refer
to

covering
topic

under

Checking
and

adjusting

inhibitor
switch
n

on

page

AT
49

b

Inspect
and

adjust
switch
as

above
whenever
it
has
to

be

removed
for
service

Fig
AT
50

Installing

torque
converter
9
Check
inhibitor
switch
for

op

eration

AT
34
Note

See

page
AT

49
for

checking

engine
idling

12

Check

to
be

sure
that
line

pres

sure
is

correct
To
do
this

refer
to

relative

topic
under

Testing
line

pres

sure
on

page
AT

52

13

Perform

stall

test
as

per
the

instructions

on

page
AT

50

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

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

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