1968 DATSUN 510 Service Repair Manual

2
@

24

11
3

10
9
r

7
8

JI
4
J

c
U
12
24
22
19
18
@

20
ta

21
1
frontBxhaust
tube

2
Exheust
gasket

3
Plein
wesher

4
Spnng
wesher

5
fixing
nut

6
Center
exhaust
tube

7
Exhaust
tube
U
bolt
clamp

8
Exhaust
tube
U
bolt
clamp

9
Spring
wesher

10
Hex
nut

11
Reer
exheusttube

12
Exhaust
rubber

13
Plain
washer

14
Lock
washer

15
Spnng
washer

16
Hex
bolt

17
Muffler
essembly

18
Exhaust
tube
U
bolt
clamp

19
Exhaust
tube
U
bolt
clamp

20
spring
wesher

21
Hex
nut

22
Rear
mount
bracket

23
Rear
mount
brecket

24
Rubber
henger
i

22
rnL
T
II

19

2
16

rr

I
II
l
r
@

1
Front
exhaust
tube

2
Exhaust
tube
clamp
assembly

3
Exhaust
tube
clemp
assembly

4
Muffler
clamp

5
1
Front
lower
hook

5
2
Front
lower
hook

5
3
Hex
bolt

5
4
Hex
nut

5
5
Lockwasher

5
6
Extenor
mounting
rubber

Insulator

5
7
Extenor
mounting
rubber

Insulator

5
8
Extenor
mounting
shim

5
9
Extenor
mounting
shim

10
U
bolt

11
Clamp
plate

12
Hex
bolt

13
Hex
nut

14
Plain
washer

15
lockwasher

16
Rubber
hanger

17
Hanger
strap

18
lock
plate

19
Hex
bolt

20
Hex
nut

21
lockwasher

22
Exhaust
gasket

23
Hex
nut

24
Plain
washer

25
lockwasher

26
Muffler
kit
l
o

o
t
I
N
III

126
CHAPTER

TEN

@

r

Removal

Pick

up

1
Remove

mountlng
clIps
and

U
bolt
See

FIgure
16

2
Disconnect
front
tube
and

exhaust
manuold

flange
connectIon

3
Remove
exhaust

system
from
vehicle

Inspection

1
Check
for

damage
at
tube

flanges
Replace
u

defectIve
2
Check
for
dIstortIon

damage
or
detenora

tIon
of
tubes
and
mufHers

Replace
or

reparr
as

required

3
Check
for

damage
to

hanger
straps
mounting

clIps
U
bolts
and
rubber
Insulators
Remove

and

replace
as

requrred

Installation

Install
the
umts

m
the

reverse
of
removal

After
InstallatIon

nm
the

engme
and
check
for

exhaust

gas
leaks

CHAPTER
ELEVEN

CLUTCH
TRANSMISSION
AND
DRIVESHAFf

CLUTCH

i
es

ription

Datsun
uses
a

single
dry
dtsc
clutch
with

dIaphragm
spring
The

major
components
are

clutch
cover

pressure
plate
dIaphragm

spring

and
WIre

nngs
The
clutch
dISC
has
riveted

plates

on
both
surfaces
and
coll

spnngs
arranged
in
a

link
The
coll

springs
absorb

shock
to
soften
and

smooth
clutch

engagement
Figure
1
next

page

is
an

exploded

diagram
of

the
clutch

assembly

Clutch
Removal

The
transmIssion
must
be

separated
from
the

engme
to
remove
tlte
clutch

assembly
This
can

be
done

by
removmg
the
transmISSIon
and

engme

from
the
vehicle
as
a
umt
or

by
remoVIng
the

transmiSSIon

separately
Removal
of
the

engine

and
transmissIOn
IS
descnbed
In

Chapter
Six

Removal
of
the
transmISSIon

only
IS
descnbed

later
in
tills

chapter

Outcb

Disassembly

1

Separate
clutch

assembly
from

flywheel

Loosen
and

remove
bolts

dIagonally
and

gradu

ally
as
shown
m

Figure
2

2
Remove
dust
cover
from
clutch

housmg

3
Remove
return

spnng
from

beanng
sleeve

Separate
the
Withdrawal
lever
from

bearing

sleeve
w

1

4
Remove
release

bearmg
and

bearing
sleeve

from
front
cover
Remove
wIthdrawal
lever

ball

pm
Figure
3

CD

1
Withdrawal
lever

ball

pin

2
Withdrawal
lever

3
Return

spnng

4
Release

beanng
4

128

CHAPTER
ELEVEN

1
Clutch
disc

assembly

2
Clutch
cover

3
Hex
bolt

4
Lock
washer

5
Withdrawal
lever

6
Withdrawal
lever

ball

pin

7
Lock
washer

8
Retainer

spnng

9
Clutch
sleeve

10
Release

bearing

11
Holder

spring

12
Dust
cover

13
Return

spring

14
Push
nut

15
Hex
nut
CD

9

11

8

6

7

1
Release

beanng
2

Beanng
sleeve
2

5
13

12

15

14

Clutch

Inspection
and

Repair

1

Thoroughly
clean
all
dISassembled

parts
ex

cept
for
the

dISc

assembly
and
release

bearmg

In
a
SUItable
solvent

2
Check

all

parts
carefully
for
wear
cracks

and
other
defects

3
Check
the
clutch
disc
for
oil
soaked

or

cracked

faCIngs

warpmg
loose
nvets

exceSSIve

wear
and
broken

spnngs

4
Check
the

pressure
plate
for

sconng
bum

marks
blue
tlnted
areas
and
cracks

If

any
of

the
above
condItIons
are
found

re

place
the
clutch
dISC
and
or
the

pressure
plate

Replace
dISC

assembly
1f

facmg
IS
worn
so
that

the

facmg
heIght
above
the

nvet
IS
less
than

00118m
03mm

Very
mmor
bum

marks
and

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
129

scratches
on
the

pressure
plate
may
be

removed

with

crocus
cloth

If
the
source
of
clutch
trouble
IS
still
not
evl

dent
take
the

pressure
plate
and
disc
to
a

compe

tent

garage
to
check
the

pressure
plate
finger

release

height
and
nmout
Never

attempt
to
ad

just
the

fingers
or
dismantle
the

pressure
plate

Without

proper
tools
and

experience

Check
the
release

bearing
by
holdmg
the
Inner

race
and

rotatmg
the
outer
race
With

hght
pres

sure

applied
If
the

bearing
is

rough
or

noisy

replace
it

CAUTION

Never
clean
the
release

bearing
In

solvent
It
IS

prelubriCflted
at

the

fac

tory
Simply

wipe
with
a
Unt

free
cloth

If
the
release

bearing
shows

any
signs
of
loss

of

lubncant
install
a
new

bearing
Replace
the

sleev
lu
SignS
of
wear
are
evident

Clutch

Reassembly

1
Be

sure

your
hands
are
clean
for
the
initIal

assembly

2

Inspect
the
clutch

facings
pressure
plate
and

flywheel
to
be
sure

they
are
free
from

grease
oil

and
other

foreIgn
material

3

TIghtly
fit
release

bearmg
onto
the

bearing

sleeve
When

beanng
IS
mstalled
turn

bearmg

With

a

finger
to
make
sure
It

operates
smoothly

4

Apply
multI

purpose
grease
to
the

bearmg

sleeve
InSIde

groove
See

Figure
5

CD
Ji

rot

Pac
thiS
r

r
r

1
1i

QI
ecess

5

Apply
multi

purpose
grease
to
the

WIth

drawallever
and

bearing
sleeve
contact

point
and
to
the
Withdrawal
lever
ball

pm
and
with

drawallever
contact

point

f

6
Clean
the
clutch

pllot
bushmg
and
fill
It

With
multi

purpose
grease

7
Mount
the
WithdraWal
lever
release

bearing

and

bearing
sleeve
to
the
clutch

housing
Install

dust
cover
on
clutch

housing
and
connect
return

spring
to
WithdraWal
lever

8
Place
the

pressure
plate
and
clutch
disc
in

positIon
on
the

flywheel
Make
certain
the

pres

sure

plate
is
In
the
same

positIon
relative
to

fly

wheel
as
when
removed
Use
a
clutch

alIgning

bar

Special
Tool
ST20630000

FIgDfe
6
to

alIgn
the
clutch
dISc

splIne
to
the

pllot
bearing

CD

NOTE

If
the

special
tool
is
not
avail

able

cut
an

input
shaft
from
a

Junk

transmission

9
Install
the

pressure
plate
mounting
bolts

Tighten
the
bolts

dIagonally
opposite
each
other

one
turn
at
a
time
to

prevent
warpmg
Torque

the
bolts
to
10
8
to
15
9
ft
lbs
1
5
to
2
2

kg
m
Remove

durmny
shaft

10
Install
the
clutch

housing
to
the

engme

Clutch
ntrol

Datsuns
have
a

hydraulic
clutch
control

system
It
consISts
of
a

pendant
clutch

pedal

130

CHAPTER

ELEVEN

master

cylInder

operatlng
cylinder
and
with

drawal
lever

Figure
7
shows
all

components

whlle

Figures
8
and
9
are

exploded
VIews
of
the

master

cylmder
and

operatIng
cylinder
for

models
smce
1970
Prior
models

are

similar
In

construction

MASTER

CYLINDER

Master

Cylinder
Removal

Sedans
and

Wagons

1
Remove
cleVIS

pin
mstalled
at
the

pushrod

2

Disconnect
clutch
hose

from
the
master

cylin

der
and
dram
flwd

3

Remove
bolts
to
free

master

cylinder

Master

Cylinder
Removal

Pick
up

1
DIsconnect

pushrod
from
clutch

pedal

2
DIsconnect
clutch
hose
from
master

cylInder

and
drain
fluid

3
Remove
bolts
to
free
master

cylInder

Master

Cylinder
Disassembly

1
Remove
filler

cap
and
drain
fluid

2
Pull
back
dust
cover
and

remove

snap
ring

3
Remove

stopper
pushrod
piston
assembly

cup
and
return

spnng

CD

i
Master

Cylinder
Inspection

1
Clean
all

parts
thoroughly
In
clean
brake

flwd

2
Check

cylInder
and

pISton
for

wear
or
dam

age
Replace
as

required

3
Check
the

clearance
between

cylInder
and

pIston
If
clearance
is

larger
than

0
005
in

0

13mm

replace
the

cylinder

4

Replace
the

pISton
cup
whenever
it
is
re

moved
from

the

cylInder
or
when
It
shows

SIgnS

of

wear
or

damage

5
Check
all
other

parts
for
wear
or

damage

and

replace
as

required

Master

Cylinder
Assembly

1
Soak

piston
cup
m
brake
fluid

2
Install

pIston
cup

3
Coat
the

cylinder
and

pIston
thoroughly
WIth

brake
flwd
and
assemble

4

Replace
other

parts
in
the

reverse
order
of

removal

Master

Cylinder
Installation

1
Bolt
the
master

cylInder
into

pOSItion

2

Adjust
clutch

pedal
heIght
by
adjusting
the

pushrod
length
Pedal

heIght
from
floorboard

e
j

11
i
Il
Il

15
2
Tl

CTOKICO
2
Piston
assembly

3
Piston
cup

4
Valve
assembly
CI

5
Val
e
spring
I

6
Spnng
seat

7
Return
spring

8
Spnng
seat

9
Push
rod
assembly

10
Push
rod
head

11
Nut

12
Stopper

13
Stopper
ring

14
Dust
cover

15
0
reservoir

2
rl
16
Reservoir
bend
assembly

17
ReservOir
cap

NABCO

1
k
IN