1968 DATSUN 510 Service Repair Manual

140

CHAPTER

ELEVEN

@

sleeve
into

gear
at

the
same
tune
This
will
lock

the
mam
shaft

Release
the
main

shaft
nut

12

Withdraw
the

counter
shaft
and
remove
the

counter

gear
with

the
two
needle
roller

bearings

and

spacers

13

Refer
to

Figure
27

Release
reverse
idler

gear
snap
ring
Remove
reverse

idler

gears
and

shaft

@
14
Remove

four
bolts

holding
maIn
shaft
bear

Ing
retainer
to
transmissIOn

case
as
shown
in

Figure
28

@

15

Withdraw
the
main
shaft

assembly
from

transmIssion
case
See

Figure
29

16
Release
the

snap
ring

securing
the
3rd
4th

synchronizer
and
hub

Remove
the
hub

com

plete
With

couplIng
sleeve

17

Remove
the

300

speed
gear
and

needle
roller

bearings
from

maIn

shaft

18

Unscrew
the
main
shaft

nut
and

remove
the

nut

and

locking
plate

19
Remove
the

speedometer
drive

gear
and

steel
ball

20
WIthdraw
the

main
shaft

reverse

gear
and

hub

21
Press
off
the
main
shaft

bearmg

complete

With
the

bearing
retainer

CLUTCH
TRANSMISSION
AND
DRlVESHAFI
141

22
Remove
the
thrust
washer
and
mam
shaft

1st

speed
gear
complete
With
needle
roller
bear

mg
Be
careful
not
to
lose
the
small
steel
ball

which
locates
the
thrust
washer
Remove
main

shaft
1st

gear
bushmg

23
Remove
the
mam
shaft
2nd

speed
gear
and

needle
roller

bearmg

24
To
dISassemble

synchronizer
assembly
re

move

sprmgs
from
both
ends

Figure
30
shows

the

synchronIZer
dIsassembled

@

d

@

n

9
cr

1

Coupling
slee
e

3

Synchro
hub

2

Shlftmg
msert
4

Spread
spnng

25
DIsassemble
the
mam
dnve

gear
by
remov

mg
the

snap
nng
Use

snap
nng
phers

26
Remove
mam
dnve

gear
bearmg
With
bear

Ing
puller
and
arbor

press

Transmission

Inspection
and

Repair

1

Thoroughly
clean
all
dtsassembled

parts
With

solvent
Check
all

parts
carefully
for
wear
dam

age
or
other
defects

2
Check
the

mountIng
faces

carefully
for

pittIng

or
burrs
that
could
cause
011
leaks
Make
certatn

to
clean
off
all
old

gaskets
and

gasket
adhesive

3

RepaIr
or

replace
dowel

pm
if
bent
or
dam

aged

4

Inspect
rear
extensIon

bushing
for

SIgnS
of

mtenor
wear

Replace
as

reqUIred

5

Inspect
ball

bearmgs
for

SIgnS
of

damage
to

inner
or
outer
race
Rotate
the
ball

bearmg
and

feel
for

SIgnS
of
fnctIon
or

draggmg
If
ball
bear

mgs
are
defectIve
In

any
way
replace
them

6

Replace
needle

bearIngs
1f
wom
or

damaged

7
Check
the
mam
shaft
and

gears
for
wear
damage
or
cracks

Replace
defectIve

parts
as

required
Check
the
maIn
shaft
for

straIghtness

WIth
a

measurmg
gauge
as
shown
m

Figure
31

MaxImum

runpulls
0
0059
m
0
15mm

@

8
Measure
the
backlasH
of
each

gear
See

Fig

nre
32
Standard
backlash
is
0
0020
to
0
0039

In
0
05
to
0
10mm
Gear
wear
hrmt
IS
0
0079

In
0
20mm
If
the

gears
are
worn

beyond
limtt

both
the
dnve
and
dnven

gears
should
be
re

placed
as
a
set

@

9
Check
the
end

play
of
all

gears
WIth
a
feeler

gauge
End

play
should
be
between
0
0020
to

0
0059

m
005
to
0
15mm
If
end

play
IS
not

correct
Sh1nIS
of
vanous
thicknesses
are
avail

able
to
correct
the
condItIon

10
Check
balk

nngs
for
wear

plttmg
and

burrs

Replace
1f
defective

11
Place
balk

rmg
in

pOSItion
on
cone
of
each

gear
Push
the
balk

rmg
onto
the

gear
and
check

gap
between
balk

nng
end
face
and
clutch
tooth

142

CHAPTER

ELEVEN

face
See

Figure
33
When
the

gap
IS
less
than

o
031
m
0
8mm

replace
the
balk

ring

@
1
2

to
1
6

mm

0047
to
0

063
In

12
Check
the

sh1fnng
msert
for

damage
or

wear

Replace
as

required

13
Check
the

OIl
seal
for
deformatIon
wear

or
cracks

Replace
1f
defectIve

14
Check

the
rear

engme
mount
Insulators
Re

place
1f
worn
or

defectIve

Transmission

Reassembly
and

Adjustment

Reassemble
the
transmISSIon
In
the

reverse

sequence
used
ill

dIsassembly
The

followmg

Items
should
be
observed

dunng

reassembly

1
Be
certaIn
that
the
1st

2nd
and
3rd
4th

syn

chronizer
hubs
are

facmg
ill
the
correct
dIrec

tIon

2
Use
a
brass
dnft

to
fit
the
1
st

gear
needle

bearlOg
collar

to
the
shaft

as
shown
In

Figure
34

il

@
3
Use

a
hollow
dnft
and

press
arbor

to
fit

the

main
shaft

ball

bearmg
to
the
shaft

as
shown

10

Figure
35

4
To
hold

synchronIZer
hub
end

play
to
a
mm

imum

snap
rmgs
of

vanous
thIcknesses

are

available

5
To
lock
the
malO
shaft

m
the
transrmSSlOn

case
double
mesh
the

gears
and
msert
the
as

sembly
10
the

case
Install
the
lockwasher
and

lock
nut

on
the

mam
shaft

Torque
the
lock

nut

to
57
8
to

79
5
ft
lb
8
0
to
11
0

kg
m

Fumly

bend
the

lock
washer
around
the
lock

nut
as

shown

In

Figure
36

1
lock
washer
2
Lock

nut

6
Assorted

thIckness

snap
nngs
and
thrust

washers

are
avallable
to
malOtam

proper
end

play
after

assembly
ThIS

applIes
to
the
main

CLUTCH
TRANSMISSION
AND
DRlVESHAFI
143

dnve

gear
counter

gear
and
reverse
Idler

gear

7
Reassemble
the
shIft
fork
and

operatIng
lever

correctly
Refer
to

Figure
37
Be
certam
there
IS

no

gap
between
fork
rod
and
shUt
fork

8
Install
each
fork
rod

together
with
check
ball

plug
check
ball
check
ball

spnng
and
mterlock

plunger
PosItIon
so
that
fork
rod
check
ball

groove
comcldes
wIth
the
ball
When
mstalled

correctly
the

upper
surface
of

plug
IS
flush
With

upper
surface
of

adapter
Install

a
sUItable
lock

Ing
agent
on
the
threads
of
the

plugs
durmg

assembly
Figure
38
shows
the
check
ball

layout

@
9
Install

operatIng
lever
In
correct

pOSItIon

See

Figure
39
Assemble
thrust

washer

snap

nng
and

operatlDg
lever
m
case
Install
lock

pm

Torque
the
lock

PIDS
to
0
2
to
0
3
In
lb

0
3
to

04

kg
cm

@

Washer

Cross
shall

lock

pm

Transmission
Installation

Install
the
tranSmISSIon
m
the
reverse
order

used

durmg
removal
Make
certam
that
all
bolts

Wires
and

parts
are
remstalled

TRANSMISSION
SERVICE
DATA

AND
SPECIFICATIONS

Table
2

proVIdes
the
servlce
data
and

specm

catIons
for
the
sedan

wagon
an
d

pIck
up

u

1

Operating
lever

assembly

2
Reverse
check

3
Reverse
shift
fork
shift
rod
4
3rd
4th
shift
fork
shift
rod

5
3rd
4th
shIft
fork
shift
rod

6

Operating
lever

assembly

144

CHAPTER

ELEVEN

TAANSMISSlON
SERVICE
DATA
AND
SPECIRCATIONS
Table
2

r

General

SpecificatIOns

Gear
Ratlo

1st

2nd

3rd

4th

Reverse

011

capacity

Detail

SpeCIfications

Gear
backlash

Replacement
standard

Gear
end

play

Balk

ring
cone

clearance

Replacement
standard
5
tl
viV

t
O

5
0

If

3657

2558

1419

1000

3638

3
6

pints

Tightening
Torque
ft
Ib

kg
m

Engine
transmission
installation
bolt

Front
cover

transmission
installation
bolt

Rear
extensIon
transmIssion
installation
bolt

Main
shaft

tlghtel
lng
bolt

Companion
flange
tightening
nut

Rear

engine
mount
installation
bolt

Filler

plug

Drain

plug

Back

up
lamp
sWItch

Bottom
cover
bolt

Speedometer

pinion
bolt

Interlock

plug

Operating
lever

Reverse
check

Control
lever
installatIOn
bolt
00020
to
0
0039
In

005
to
0
10mm

o
0079
In

0
20mm

o

0020
to
0
0059
In
0
05
to
0
15mm

00472
to
0
0630
In

1
2
to
1
6mm

00315
In

08mm

174
to
20
2
24
to
2
8

5
8
to
7
2
0
8
to
1
0

10
1
to
130
1
4
to
1
8

57
8t079
5
80to
11
0

72
3
to
101
2
100

to
140

239

to
27
5
3
3

to
38

18
1
to
25
3
25

to
3
5

14
5

to
21

7
20

to
3
0

14

5
to
21
7
2
0
to
3
0

5
8

to
7
2
0
8

to
1
0

2
2
to

2
9
03
to

0
4

123
to
15
2
1
7
to
2
1

22

to
2
9
0
3

to
0
4

14

5
to
21
7
20
to
3
0

13
7
to

15
9
1
9
to
2
2

DRIVE
SHAFf

Descripti

ll

TIie
dnve
shaft

on
the
sedan
and

wagon
is

a

smgle
plece
tubular

steel
unit
The

pick
up
uses

a
two

pIece
umt

Joined
by
a

Journal
assembly

unIversal

Joint
UnIversal

Jomts
connect
the

drive
shaft
ends
to
the
transmissIOn
and
d1f

ferentIal
The

Jomts
consist
of
the

Journal
as

sembly
yoke
sleeve
and

yoke
flange
Figure
40

is
an

explOded
VIew
of
the
dnve
shaft

used
on

the

sedan
and

agon
Figure
41

page
146

shows
the

dnve
shaft
used
on
the

pIck
up

The

pIck
up
has
a

grease
mpple
on
the

dnve

shaft
to
lubncate
the
dnve
shaft

spline
The

sedan
and

wagon
are
not

so

equipped
The
uni

versal

Jomts
shouldebe
removed
and

lubncated

every
24
000

rmles

Removal

1
Release
the
handbrake

j
2
Jack

up
the
rear
of
the
vehIcle
and

support

on
stands

3
Loosen
the
end

clamps
on
the
exhaust

pipe

and
turn
the
exhaust

pIpe
and

premuffier
to
the

left
so
that
dnve
shaft
can
be

removed
sedan

4
Remove
handbrake
rear
cable

adjustIng
nut

from
the

adjuster
DIsconnect
left
hand
cable

from
the

adjuster
sedan

5
DIsconnect

rear

flange

yoke
from
the
com

panIon
flange

by
removmg
the
nuts
and
bolts

See

Figure
42

CAUTION

Be

careful
not
to
let
end

of
dnve

shaft

drop
to

ground
Lower

It

gently

6
Pull
the
dnve

shaft

backwards

away
from
the

transmISSIon
Remove
the
dnve
shaft

as
soon

as
It
IS
clear
of
the
transmISSIon
Make

cert
n
to

support
both
ends
of
the

shaft

duriftgi
mb

sedan
and

wagon
v

4
1tr
l

t

t

CLUTCH

TRANSMISSION
AND

DRIVESIIAFT

145

r

@

l

S

St

P

t
ii

t

1

1

1

0

8
12

3

5

8
12
13

i

f

p
1
2

5

7

Remove

mounting
bolts
from
both
transmis

sion
and

dllIerential

gear
case
Remove

bearing

mounting
bracket
Lower

drive
shaft
to

ground

pick
up

J
iw

sembly

The
drive

shaft
is
a

balanced
unIt
and
must

be

marked
as
to

parts
location
before
dIS

assembly
Mark
the
relative

positions
of
the

drive

shaft
sleeve

yoke
flange
yoke
and
other

parts
so

they
can
be
reassembled
m
their

origmal

positions

146

CHAPTER

ELEVEN

o

i

fij@
0
@

7
B@

I

l

I

L
J

1
Before

disassembly
clean
all

parts
and

mark

locations

2
Remove
four

snap
gs
from
each

universal

JOInt
as
shown
in

Figure
43

@

3

LIghtly

tap
base
of

yoke
with
a
hammer

WIthdraw

beanng
race
See

Figure
44
Be

care

ful
when

remoVIng
the

bearmg
race
as
the

needle

bearmgs
InSIde
are
loose

and
are

easlly
lost

Inspection
and

Repair

1
Check
each

part
for

SIgnS
of
wear

damage

nlSt
dIStortIOn

and

pItting
Replace
as

reqUIred

If

any
part
of
the

journal
assembly

reqUIres
re

placement
replace
the
entIre

assembly
am
@
t

@

2
If
the
dnve
shaft
tubes
show

SIgnS
of

damage

have
them
checked

for
nmout
and
balance

by
a

dealer

or
an
automotIve
machine

shop

Assembly

1

Apply
wheel

bearing
grease
lIberally
to
the

needle

bearmgs
Insert
them

m
the

bearing
face

and

mstall
onto
the

journal
Replace
snap
ring

Vanous
thIckness

snap
nngs
are
avatlable
to

adjust
aXIal

play
in
the

Journal
assembly

2

Apply

gear
Oil
to

inSIde
of

splIne
and
outside

of

yoke
SlIde
the
dnve
shaft

splIned
yoke
onto

the
transmIssion
maIn
shaft

Sl1hnes
sedan
and

wagon

3

Apply
wheel

bearmg

grease
lIberally
to
the

drive
shaft

center

spline
Fill
the

caVIty
with

wheel

bearmg

grease
through
the

grease

mpple

pick

up

4
FJ
nlSh

assembly
by

reversIng
procedures
used

durmg
removal

CLUTCH
TRANSMISSION
AND
DRIVESHAFI
147

SERVICE
DATA
AND
SPECIFICATIONS

Table
3

gives
the
service
data
and

specIfica

tIons
for
the

dnveshaft

AUTOMATIC
TRANSMISSION

CHECKS
AND
ADJUSTMENTS

Whlle
removal
and

repair
of
the
automatic

transmisSIOn
IS
not

recommended
the

follo
VlIlg

checks
and

adjustments
should

help
prevent

costly
repatrs

Transmission
Oil
Check

Check
the
automatIc
transmission
oil
level
at

least

every
3
000
mlles

Replemsh
With

hIgh

qualIty
automatIc
transmISSIon
flUId
as

reqUIred

Be
careful
not
to
overfill
as

damage
to
the
seals

can
result
To
check
the
011
level

proceed
as

follows

1
Start
the

engme
and

nm
it
untIl
normal

oper

atrng
temperature
IS
reached

2

Apply
brakes
and

move
the
transmission

shut
lever

through
all
drive

pOSItions
and

place

lever
In

park
position

3
WIth

engme
running
remove
tranSmISSIon

dIp
StIck
clean
It
WIth
a
lInt
free
cloth
or

paper

and
return
it
to
the
transmission

4
Remove

dIp
stIck

agam
and
examine
level
on

dIp
stIck

gauge
It
should
be
between
the
low

and
full
marks

Replenish
as

necessary

5

VIsually
InSpect
the
color
and
condItIon
of

the
OIl
on
the

dIp
stIck
Normal
color
of
the
OIl

IS
red
If
the
color
IS
abnormal
dram
and

re

place
If
the
011
has
detenorated

to
a
vamlsh

lIke

qualIty
It

may
cause
the
control
valve
to

stIck
Blackened
oil

may
mdlcate
a
burned

clutch
or
brake
band
6
Should
the
above
condItIons

exist
refer

mamtenance
to
a
transmISSIon

specIalIst

Transmission
Oil

Leakage
Check

011

leakage
may
occur
at
the

Junction
of
the

transmissIon
and
rear
extensIon
011
tube
con

nectors
011

pan
OIl

pressure
mspectIon
holes

downshIft
solenoid
or
breather

pipe

Abnormal
OIl

usage
usually
mdlcates
leaks

that
should
be

stopped
before
severe

damage
IS

done
To

mspect
for
011
leaks

proceed
as

follows

1
LIft
car

up
on
hOISt
or

Jack
up
and

place
on

stands

2
Clean
outsIde
of
transmISSIon
case
With

cleanIng
solvent
to
remove
dIrt
and
011

accumu

latIons

3
Start

engme
and
nm
untIl

operating
temper

ature
is
reached

4
ShIft

gear
lever
to
dnve
to
Increase
011

pres

sure
and
CIrculatIon
WIthin
tranSmISsion

5

Inspect
pOInts
mentIoned
above
for

SIgnS
of

leakage
Leakage
of
transrmSSIOn
011

IS
dIStrnC

tIve

by
its
reddISh
color

6
If
leaks
are
detected
refer
servIce
and

reparr

to

qualIfied
transrmssion

specialISt

Kick
down
Switch

and
Downshift
Solenoid

Checks
and

Adjustment

When
ktck
down

operatIon
IS
not
correct
or

the

speed
changmg
pomt
IS
too

high
check
the

klck
down
SWItch
downshIft
solenOId
and
the

wlDng
between
them

Figure
45
shows
the
loca

tIOn
of
these

parts
To
check

operatIon
proceed

as
follows

Table
3
J

DRIVESHAFT
SERVICE
DATA
AND
SPECIFICATIONS

SpeCifications

Axial

play
of

spider
Journal

Sleeve

yoke
spltne
to
malnshaft

Spline
lash
wear
Itmlt

MaXimum
drive
shaft
runout

Journal
diameter
wear
limit

Penmlsslble

dynamiC
unbalance
at
4
000

rpm

Tightening
Torque

Flange
yoke
to

compaRlon
flange
nuts

CompaRlon
flange
center

bearing
nut
pick

up

Bearing
mounting
bracket
installation
bolt
00315
In
008mm

OtoO
0031
In
OtoO
08mm

00197
In

0
5mm

00236
In
06mm

00059
In

0
15mm

0278
In
oz

15

gr
cm

2893
to

615ft
Ib
40
to
8
5

kg
m

74
to
111
ft
Ib
10
to
15
kg
m

18

to
20
ft
Ib
24
to
2
7

kg
m