1968 DATSUN 510 Service Repair Manual

132
CHAPTER

ELEVEN

CD

NAnCO
22
20
21

r

i

T

l
C

r
Jl

i

i

18
Clutch

operating
cylinder

19
Piston

cup

20
PIston

21
Dust
cover

22
Push
rod

23
Bleeder
screw

24
Bleeder
cap
22

I

should
be
8
150
m
207mm
for
the
sedan
and

wagon
Pedal

heIght
should
be
591
m

150mm

for
the

pick
up

3

Apply
multI

purpose
grease
to
all

PIvot

pOInts

4
Bleed
all
aIr
out
of
the

sy
tem
as

dIscussed

below

OPERATING
CYLINDER

Operating
CyHnder
Removal

1
Remove
retum

spring

2
Disconnect
clutch
line
from

operating
cyl

inder
18

Ii

TOKICO

21

I

LL

18
23
24

I
I

3
Disconnect

pushrod
from
wIthdrawal
lever

4
Release
two
bolts

holdmg
operating
cylInder

to
clutch

hOUSIng

5
Remove

operating
cymder
from
clutch
hous

mg

Operating
CyHnder
Disassembly

1
Remove
dust
cover

2
Remove

snap
ring
All
other

parts
can
now

be
removed
See

Figure
10

Operating
CyHnder
Inspection

Check
all

parts
especIally
the

pIston
cup
for

wear
and

damage
Replace
if
defects
are
found

CLUTCH
TRANSMISSION
AND
DRlVESIIAFI
133

C
8

Q@J

@

C

Operating
Cylinder
Reassembly

1
Soak

pISton
cup
m
brake
flUid
and
Install
It

In
the
same

pOSitIOn
as
before
removal

2

Apply
brake
flUid

to
the

cylInder
and

pIston

before

mstalImg
piston

3

Replace
all

parts
m
the
reverse
order
of

removal

Operating
Cylinder
Installation

1
RemstallatIon
IS
the
reverse
of
removal

2
Bleed
aIr
from
the

hydraulIc
system

3

Adjust
the

pushrod
so
that
withdrawal
lever

end

play
IS
0
0787
to
0
1181
In
2

0
to
3
Omm

Procedures
for

the

adjustment
are

given
below

WITHDRAWAL
LEVER
AD
JUSTMENT

Correct

adjustment
of
the
clutch
withdrawal

lever
IS
essentIal
InsufficIent
free
travel
between

the
release

bearmg
and

dIaphragm
fingers
can

cause
the
clutch
to

slIp
ExceSSIve
free
travel
can

prevent
full

dISengagement
of
the
clutch
Refer

to

Figure
11

1
Loosen
lock
nut

2
SCrew
In
the

pushrod
fully
with
the

adjustmg

nut

3
Unscrew

adJustmg
nut
1
turns

TIghten

lock
nut

J

4
Check
the
end

play
of
the
wIthdrawal
lever

End

play
should
be
0
0787
to
0
0906
in
2
0
to

2
3mm
The
correct
end

play
will

give
a
clear

ance
of
0
0512
m

1
3mm
between
the
release

bearmg
and

diaphragm
fingers
@

1
Lock
nut

2

AdJustmg
nut

3
Wrthdrawal
ever

4
Release
beer

ng

5

Diaphragm
spnng
20
to
30

0
079
to
0
11

B

Unit
mm
m

5
If
the
above

adjustment
does
not
result
in

satIsfactory
clutch

operatIon
the
clutch
dISC
is

probably
worn

excessIvely
and
will

reqUire
re

placement
as

preVIously
dIScussed

BLEEDING
CLUTCH
SYSTEM

AIr
In
the
clutch

hydraulIc
system
makes
shIft

Ing
gears
extremely
difficult
1f
not

impOSSIble

To
bleed
the

system
proceed
as
follows

1
Remove
the
bleed
screw
dust

cap
from
the

operating
cylInder

2
Attach
a
bleeder
hose
to
the

bleed
screw

Immerse
the
other
end
of
the
hose
m
a
container

f

hydraulIc
brake
fluid

3
Check
to
see
that
clutch
master

cylInder

reservoir
IS
full
of
brake
flUid

ReplenISh
if

necessary

4

Open
the
bleeder
screw

three
quarters
of
a

tlIrn
and
have
an
assistant

pump
the
clutch

pedal
slowly
Pump
the
clutch
until
the

flUid

entenng
the

contatner
is
clean
and
free
from

bubbles

5

TIghten
bleed
screw

Replace
dust

cap
Refill

the
flUid

reservoir

134

CHAPTER

ELEVEN

CLUTCH
SERVICE
DATA

AND

SPECIF1CATIONS

Table
1

proVIdes
serVIce
data

and

specifica

tIons
for
the
clutch

system

TRANSMISSION

Description

Datsuns
are

eqUIpped
with
either

an
auto

matic
or
manual
transrmSSIOn

Due
to
the
com

pleXity
of
the
unIt
and

the
need
for

special
tools

and

knowledge
overhaul

of
the
automatic
trans

mISSIon
is
not

covered
In
thIS
manual
Auto

matIc
transmISSIOn

checks
and

adjustments
are

given
later
m
thIS

chapter
Reparr
and
mainte

nance

should
be
referred
to

a
Datsun
dealer

or

qualIfied
mechamc

The
manual
transmission
is

a
four
forward

Table
1
speed
unlt
controlled
With
a
floor

mounted
lever

It
consIsts
of
transrmSSIOn

case
rear
extensIOn

housing
and

gear
assembly
The
clutch

housmg

and
transmissIOn

case
are
a

sIngle
unIt
The

rear

extension

housmg
is

detachable

Figure
12
shows

the
4
forward

speed
transmission

Transmission

Removal

Removal
of
the

transmIssion
from
dIfferent

models

Varles

accordmg
to
the

dIfferent
struc

ture
Involved
The

following
procedures

gen

erally

apply
to
all

types

Important
dIfferences

are
noted

1
Prom

InsIde
the
vehicle

remove
the
floor

covenng
around
the

gear
shift

so
that
the
shIft

lever
can
be
removed

2
Jack

up
the
vehIcle
and

support
it
with
four

CLUTCH
SERVICE
DATA
AND
SPECIFICATIONS

Pressure

Spring

Free

length

Fitted

length
and
load

Out
of

rlght

angle

MInimum

sprmg
force

Clutch
Release
Lever

Release

bearlng
to

dlaphragm
clearance

Diaphragm
sprlng
to

flywheel
height

Release

lever
to

flywheel
height

Clutch
DISC

FaCing
size

Outer

dIameter
x
inSide
diameter

x
thlckness

Thickness

Free

Compressed

Number
of

tOrslO
1
springs

Minimum

depth
of
rivet
head

from

faCing
surface

Allowable

facmg
runout

Allowable

spline
free

play

Pressure

Plate

Allowable

refacmg
limit

Clutch
Pedal

Height
when
not

depressed

Free
stroke
of

pedal
head

Pressmg
strength
at
full

stroke

Clutch
Master

Cylinder

Diameter

MaXimum

clearance
between

cylinder
and

pIston

Tightening

Torque

Clutch

assembly

securing
bolt
2
059
In
52
3mm

1
149
In
197
4
4
Ib
29
2mm
44
2

kg

o
1968

per
3
937
In
5

per
100mm

15

00472
to
0
0551
In

1
2
to
1
4mm

1732
0
0394
m

44
O
1

Omm

1
988

0
0197
In

505
0
05mm

787
X

5
120
x
0
0140
In
200
x
130
x
3
5mm

o
3386
to
0
3543
m
8
6
to
9
Omm

03012
to
0
3130
m
765

to
7
95mm

6

00118
In
03mm

o
097
In
0
5mm

00157
m
04mm

o
0394

In
1
Omm

8
150
m
207mm

o
984
m
25mm

33
Ib
15

kg

0625
m

15
87mm

00051
m
0
13mm
J

i

r

174
to
188ft
Ib
24

to
2

6

kg
m

CLUTCH
TRANSMISSION
AND
DRIVESIIAFI
135

stands
If

possible
the
use
of
an

open
pit
or

hydraulIc
hOISt
IS
recommended

3

Figure
13
shows
the
underside
of
the

sedan

and
statIon

wagon
Figure
14
IS
the

pick
up

4
DIsconnect

negatIve
battery
cable
from

termInal

r

j

7T
@

r

1
Cross
shall

2
Back
up

lamp
sWitch

cable
3

Speedometer
dn
e
cable

4
Exhaust
manifold

5

Propeller
shall

136
CHAPTER
ELEVEN

5
DIsconnect
and
remove
starter
motor
from

flywheel
housmg
as
descnbe4
In

Chapter
NIne

6

Dls
onnect
handbrake
WIre
at

equalIzer

pIVOt
See

Figure
15
sedan
and

wagon

I

j

7
Loosen
the
two

exhaust
center

p1pe
clamps

and

turn
the

premuffier
complete
With
center

pIpe
to
the
left
as
shown
m

FJgure
16
sedan
and

wagon

f

W

y
I

0
Y
h

0

ilo

8
DIsconnect
front
exhaust
tube
from
exhaust

man1fold

pICk
up

9
Rem

ye
four
bolts
from

companion
flange

of

gear
carner
and
detach

dnve
shaft
See

Figure

17
Seal
the
end
of
rear
extensIon

housmg
to

prevent
011

leakage

1
0
Dlsconn

i
gpeedometer
drive
cable
from

rear
extensIOn
as
shown
In

Figure
18

11
On
models
s

quipped
disconnect
neutral

gear
sWitch
third

gear
sWitch
and
reverse

gear

sWItch
as
shown
in

Figure
19
next

page

f
t

iT
l
t

t

W
12
Refer
to

Figure
20
whIch

IS
an

exploded

View
of

the

gear
shIft
lever
and
control

system

DependIng
on
the
model
dISconnect
the
shift

lever
as
shown

13
Remove
cross
shaft

assembly
from
trans

rmsslOn
case
See

Figure
21

14
Remove
clutch

operating
cylinder
from

clutch

housmg

15
Place
a

Jack
beneath
the

engme
011

pan
and

SuppOFt
the

engme
Do
not

apply
Jack
pressure

M

I

CL
SMISSION
AND
DRIVESIIAF1
137

i@

v

l
ll
r

1
Neutral

gear
swrtch

2
TransmISSIon
swllch

thud

geu

3

Reverse
gear
SWitch

@1
Control
arm
14
Return
spnng

2
StnkBr

bushmg
15
Re
erse
check
ball

3
O

nng

cep
16
Check

spnng

4
O

nng
17
Retalmng
pm

5
Control
O

nng
18
Slnlung
rod

6

First
and
second
fork
rod
19
Slnlung
pm

7
First
and
second
shill
fork
20
O

nng

8
Thud

and
fourth
lork
rod
22
Control
arm

pm

9
Third

and
fourth
shill
fork
23
Control
washer

10
Reverse
fork
rod
24
Control
arm

bushmg

11
Reverse
shill
fork
25
Control

spnng

12
Rolled

pm
26
Thrust
wesher

13
Reverse
fork

pm
27
Retammg

pm

9

0

11

f
Ir

foUr

1
i

1
k

jl

n

1

1
l

28
Control
lever
35
Lower
washer

29
Control
lever
knob
36
Self

lockmg
nut

31
Washer
37
Rubber
boot

32
Controlle
er
rubber
41
Tnmsmlsslon
hole

cover

33
Washer
42
Tappmg
screw

34

Upper
washer

29

c

28

37

16
t

f

f

1

I
13

1

12
5

T

2V

T
19

25
26

20
31

e
32

@
35

@
36

138
CHAFfER
ELEVEN

to
dram

plug
Use
a

block
of
wood
between
the

011

pan
and
the

Jack

16
Remove
two
bolts

attaching
the
transmIS

sion
to
the
rear

engine
mount
Place
a

Jack
under

the
transmISSIon
and

support
the

transmissIOn

Remove
four
bolts

holdmg
the
rear

engme
cross

member
to
the

body
sedan
and

wagon

17
Place
a

Jack
under
the
transmISSIon
and

sup

port
the
transmISSIon
Remove
rear

engine

mount
from
transmlssiod
and
cross
member
as

shown
In

Figure
22

pIck
up

18
Lower
the

supporting
jacks
to
mclme
the

engine
downward
and
there
IS
sufficient
room

to
remove
the
transmission

19
Pull
the
transmission
towards
the
rear
until

the
dnve
shaft

splme
IS
clear
of
the
clutch

pres

sure

plate
Be
careful
not
to

damage
the

splines

or
the

pressure
plate

6

40

t

I
j

fI
1
2

fr

l

3332

3

1
TransmiSSion
case

2
TransmiSSion
case

3

Thread
taper
plug
t

4
TransmiSSion
Iront
cover

5
Front
cover
011
seal

6
Front

cover
gasket

7

fixmg
bolt

8

Flxmg
bolt

9

Spnng
washer

10
Rear
extension

11
Reer

extenSIon
011
seal

12
Breather

assembly

13
Extension
bushmg

14
Extension

gasket

15
Hex
bolt

16
Hex
bolt
17

Spllng
washer

18
Dowel

pm

19

Beallng
retainer

20
Hex
bolt

21

Spnng
washer

22
Bottom
cover

23
Bottom
cover

gasket

24
Bottom
cover
hex
bolt

25

Spnng
washer

26
Drem

plug
essembly

27
Dram

plug
assembly

29
SwItch

30
Hex
bolt
l
r

I

J

J
I
n

S
T

r
re
l

1
Rear
extension
mountmg
bolts

2
Rear

engme
mounting
bolts

20
Remove
the
transmISsion

by
lowenng
the

transmISsion

Jack

Transmission

Disassembly

Figures
23
and
24
are

exploded
views
of
the

transrmSSlon
case
and

gear
assembly

@

46

47
6

i

4826J

1
41

44

5

31

Spring
washer

32
Hex
bolt

33

Spnng
washer

34
Check
ball

35
Check
ball

spnng

36

Plunier

37

Plug

r

38

P1
g

39
Washer

o
12

10

13

11

40
MaIO
dllve

beanng
retamer

41
Pinion

42
PInion
sleeve

43
Sleeve
011

seal

44
O

lIng

45
Retamer

46
Lock

plate

47

Spnng
washer

48
Hex
bolt

50
Neutral
SWitch

51
Dust
co
er

52
Hex
bolt

53

Sprmg
washer

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
139

@
1
Re
erse

gear

2
Re
erse
shaft

3
Reverse

gear

4

Snep
nng

5
Thrust
washer

6
Reverse

gear
needle

beanng

7
Counter

gear

8
Counter
shaft

9
Counter

spacer

10
Needle
bearing
assembly

11
Thrust
washer

12
Thrust
washer
J

f

I

I

I

I

I

I

I

I

I

I

J

I

I

i

I
f

4
rm

9
13
MaIO
dnve

gear

14
MaIO
dn
e

beanng

15
MaIO
drl
e

spacer

16
MelO
drl
e

snap
ring

17
MaIO
shaft

18
steel
ball

19
Thrust
washer

20
MaIO
shaft
needle
bearing

21
Meln
shaft

bushlOg

22
MaIO
shaft
flm

gear

23
Baulk

nng

24
Sh

ftlOg
Insert

25

Spread
sprlOg

9

1
Remove
the
drain

plug
and
dram
the
trans

rmSSlon

gear
011
Into

a
SUItable
container

2
Remove
the
dust
cover
and
release
the

re

tainer

spring
securing
the

Withdrawal
lever
Re

move
the
lever
and
release

bearing
from
the

clutch

housmg

3
Remove
the

pIn
securing
the

strikmg
rod
to

the
control
lever
and
remove
the
control
lever

4
Remove
five
front
cover

securing
bolts
and

the
front

cover

i

j

5
Remove
14
hex
bolts

and
washers
from
bot

tom
cover
Remove
bottcifu
cover
from
trans
I

I

I

I

I

I

i

i

J
34

34
26
Synchronize
hub

27
CoupllOg
slee
e

28
MaIO
shaft
needle

beanng

29
Second

gear
assembly

30
MaIO
shaft
needle

beanng

31
Third

speed
gear

32
Baulk

nng

33

ShlftlOg
IOsert

34

Spread
spring

35

Synchro
hub

36
Slee
e

coupllOg

37

Snep

nng

38
MaIO
shaft

pilot
beanng

39
Main
shaft

bearing

40
MaIO
shaft

snap
ring

41
Re
erse
maIO

gear
and
hub
set

42
Rwerse
hub
maIO
shaft

43

Speedometer

gear

44
Steel
ball

45
MaIO
sheft
loc
l
washer

46
MaIO
shaft

nut

28
iy

25

25

21

rmssion
case

Figure
25
shows
the
tranSmISSIon

With
the
bottom
cover
removed

6
Remove

speedometer
dnve

pmion
assembly

7
Remove
hex
bolts

holdmg
rear
extension

housmg
to
transmISSIon
case
Remove
rear
ex

tenSIon

housing
as
shown
m

Figure
26

8

fDlsengage
stnkmg
rod
from
fork
rod

gates

9
Unscrew
three
check
ball

plugs
and
remove

sprmgs
and
balls

10
Drive
out

retatnmg
pms
used
to
secure
forks

to
fork
rods
and
remove
rods
and
forks

11
Move
the
1st
2nd

and
3rd
4th

coupling