1968 DATSUN 510 differential

DIFFERENTIAL
REAR

AXLE
AND
REAR

SUSPENSION

161

T
8

0
to
9

0

kg
m
57
8
to
65
11b

ft

@

T
2
8

to
3
9

kg
m

20
2
to
28
2
Ib

ft

Apply
grease
on
the

surface
of
the
collar

when

replacing
oil
seal

Brake
tube

T
1

7
to
2
0

kg
m

23
3

to
14
5
Ib

ft

Tread

1260

Use
the
shims
to

adjust
the

gap
C

between

the
wheel

bearing
and
the

recess
in
the
axle
tube
end
The

gap
should
be
beteewn
0
to
0
1
mm

0

to
0
0039

in

12

Fill
the
differentIal

housmg
With

specmed

lubncabng
011

REAR
SUSPENSION

WAGON

The
rear

suspensiOn
consists
of
semi
elhpnc

leaf

spnngs
hydraulJc
shock
absorbers
and
rub

ber

bumpers
Iso
clamp
deVices

are
used
for

attaching
the
axle

housmg
to
the

spnng
The

leaf

spnngs
shock

absorbers
and
rear
axle
hous

mg
are
mounted
on
rubber

bushmgs
at
each
end

See

Figure
22
REAR
SPRING

REMOVAL

INSPECTION
REPAIR

AND

INSTALLATION

WAGON

1
Jack

up
the
center
of

the
rear
axle
until
the

wheels
are
off
the

ground

Support
th
e
rear
end

With
stands

2
Remove

spare
tIre

3

Disconnect
shock
absorber
bottom

end
from

spnng
lower
seat

4

Loosen
rear

spring
U

bolt
nuts
Remove

bolts

bumper
assembhes

spring
seat
location

plates
and
seat

pads

5
Remove

four

fiXing
bolts

holdmg
the
front

bracket

See

Figure
29

l

6
Lower
the
rear

spnng
and
the
bracket
from

the

body

7
Remove
rear
shackle

upper
and

lower
nut

8

Separate
front
bracket
from

spnng
by
remov

mg
front

pms

9
Exanune
the

spring
leaves
for
fractIires

cracks
or
other

damage
Replace
as

reqwred

10
Check
front

pm
shackle

U
bolts
and

spnng

seat
for
wear
cracks

and
other

damage
Replace

1f
defects
are
found

11

Inspect
all
rubber

parts
for
wear

damage

and

general
condil1on

Replace
as

reqUired

12
Install
the

rear

spnngs
in
the
reverse
of

removal

13

See
that

bumper
is

properly
installed
The

elongated
flange
of

the
rubber

bumper
should

face
the
rear

162

CHAPTER
TWELVE

14
Coat
the
front
bracket

pm
and

bushmg
and

shackle

pm
and

bushing
With
a

soap
solution

pnor
to

assembly

15
The
front

pm
secunng
nut
and
shock
ab

sorber
lower
end

securmg
nut
should
be

re

tightened
after

the
vehicle

is

sittmg
on
the

ground

16

Make
certaJn
the
shackle

bushmg
flange
is

clamped
evenly
on
both
Sides

SHOCK
ABSORBER

REMOVAL
INSPECTION
AND

INSTALLATION

WAGON

1
Jack

up
the

center
of
the
rear
axle
and

sup

port
th
e
axle

housmg
With
stands

2
Reinove
the

lower
end
of
the
rear
shock

absorber
from

spring
seat

3
Loosen
the
four
bolts

secunng
the

upper

bracket
to

body
Remove
shock
absorber
and

upper
bracket

4
Check
shock
absorber
for
leaks
and

cracks

Check
the
shaft
for

straighmess

Replace
1f

defective

5

Inspect
rubber

bushmgs
for

damage
cracks

and

general
condition

Replace
1f
defective

6
Install
the
shock
absorber

by
reversing
the

procedure
used

durmg
removal

DIFFERENTIAL

pICK
UP

The
dlfferenl1al

carner
IS
made

up
of
alum

mum

alloy
and
uses
a

hyp01d
bevel

gear

Proper

lubncatIon
IS
essenl1al
Check
and

replemsh
the

lubncant

every
3
000

mlles
Drain
and
refill

every
30
000
inlles

Figure
30
IS
a
cross
sectional

View
of
the

pick

up
dIfferential
Difterential
Removal

Pick

up

1
Jack

up
the
rear
wheels
and

support
vehicle

With
stands

2
DIsconnect
dnve

pmlOn
companlOn
flange

to

yoke
connectIon

3
Remove

rear
axles

as
descnbed
later
m
thIS

chapter

4
Remove
dlfferenl1al

gear
assembly

Difterential

Inspection
Pick

up

The

followmg

mspection
can
be
done
Without

disassembly
of

the
d1fferenl1al
If
abnormahties

or

damage
eXiSts
refer
further
serVice
and

reparr

to

your
dealer

1
Check
the

tooth
contact

pattern
WIth
lead

OXide
at
two
or
three

pomts
after

remoVlDg
rear

cover
Refer
to

FIgure
5
for

correct
contact

pattern
If
the

pattern
IS

faulty
disassembly
and

adJustment
of
the
dIfIerentialIs

required

2
Measure
backlash
between
dnve

gear
and

pmlOn
With
a
dial
mdlcator
Backlash
should

be

00051
to
0
0071

m
013

to
0
18mm

3
Rotate
the

gears
and
lISten
for

SignS
of
bear

mg
noise

4

Inspect
gear
teeth
for

SIgnS
of

damage
or

cracks

Difterential
Installation

Pick

up

Install
the
differential

by
reversmg
the

pro

cedures
used

dunng
removal

REAR
AXLE
AND

SUSPENSION

pICK
UP

The

rear
axle

IS
of
the

semi

floatIng
type
The

rear
wheels

use

tapered
roller

beanngs
Figure

31

IS
a
cross
sectional
view
of
the
rear
axle

REAR
SUSPENSION

TORQUE
TIGHTENING

SPECIFICATIONS
WAGON

Shock

absorber

upper
bracket
to

body
bolts

Shock
absorber
to

upper
bracket

lock
nuts

Shock
absorber

to
lower
bracket
lock
nuts

Rear

spnng
U
bolt
nuts

Shackle
nuts

Front

pm
nuts

Front
bracket

flxmg
nuts

Brake
dISC
to
rear

housmg
bolts

DifferentIal
carner

to
axle

housmg
bolt

Dnve
shaft

flange
nuts
11
to
18
ft
Ib
1

5
to
2
5

kg
m

12

to
16

ft
db
17
to
2
2

kg
m

25
to
33
ft
Ib
35
to
45

kg
m

43

to
47
ft
Ib
60
to
6
5

kg
m

32
to
36
ft
Ib
45
to
50

kg
m

32
to

36
ft
Ib
45
to
5
0

kg
m

13
to
17
ft
Ib
18
to
23

kg
m

20
to

28
ft
Ib
28

to
3
9

kg
m

14
to
16
ft
Ib
20
to
2
2

kg
m

20
to
28
ft
Ib
28

to
3
9

kg
m

DIFFERENTIAL
REAR
AXLE
AND
REAR

SUSPENSION

163

@

j
@

@

@

1

Companron

flange

2
Front

bearmg

3

Spacer

4
Pmlon

heIght
adjust

shim

5
PmlOn

mate

gear

@
6
Pmlon

mate

gear
11

7
Side

gear
thrust
washer
12

8
Side

bearmg
13

9

Bearing

cap
14

10
Differential
case

15
011
seal

Adjusting
washer

Drive

pmlon

Rear

beanng

Drive

gear
16
Lock

pm

17

AdJustmg
shim

18
Thrust
block

19
SIde

gear

20
Pmlon
mate
shaft
@

1
Axle
case

2
Axle
shaft

3
Wheel

beanng

4
Plam
washer

5
Lock
washer

6
Lock
nut

7
011
seal

8
Beanngcage

9
Shim

10
Grease
seal

11
Brake
drum

12
Wheel
nut

DIFFERENTIAL
REAR

AXLE
AND
REAR
SUSPENSION

165

2
Check

wheel

bearmgs
for

damage
or
noise

Replace
them
If
defective

3
Be

sure
to
use
new
011

seals
and
lockwashers

4
FIt

beanng

cup
and

grease
seal

to

cage
Tap

WIth

a
brass

hammer
while

fittIng
FIll

grease

seal

IIp
With

wheel

beanng
grease
after

fittmg

5
Install
brake

diSC
and

beanng
cage
on

axle

Fit

bearmg
cone
With

brass
bar

6

Tighten
lock
nut

Place
faced
Side
of
nut

to
washer
SIde

so
that

washer
IS
not

damaged

Torque
lock

nut
to
10S
to
145
ft
lb
15

to

20

kg
m

7
Match
washer

IIp
With

groove
m

nut

tIghten

nut
and
bend

washer

carefully
to

prevent

hp

damage

S
Use

a
brass
bar
to
fit
011

seal
to

tube
end

When

fitted

apply
grease
to

the

hp
Be
careful

not
to
deform
seal
or

damage

hp

9

Completely
fill

bearmg
With

grease

10
Install
shaft

AdJust
aXial

clearance
With

shIms
See

Figure
37
Clearance
should

be
0
012

to
0
035
m
0
3
to
09mm

Standard
shIm

thickness
IS
0
059
m
1

5mm

@

11
Install
other

shaft

AdJust
aXlal
clearance

With

shIm
Clearance
should
be
0
OOOS

to
0

0059

m
002
to
0
15mm

12

Install
bolts
and

torque
to

26
to
34
ft

lb

3
6
to
4
7

kg
m

REAR

SUSPENSION

PICK
UP

The
rear

suspension
IS
a

banJO

type
ngId

suspensIOn
With

parallel
semI
elhpnc

leaf
spnngs
Front
and

rear
ends
of
the

springs
are

secured
on
the
frame
with

rubber

bushmgs

Shock
absorbers

are
mstalled

on
the
cross
mem

ber
from
the

spnng
lower

pad
Figure
38
next

page
IS
an

exploded

dIagram
of
the
rear
sus

pensIOn

Rear

Suspension
Assembly
Removal

Pick
up

1
Jack

up
rear
of
vehicle
and

support
It
With

stands
Remove
wheels

2
Refer
to

Figure
39

DIsconnect

handbrake

Wire
and

equalIZer
unit

Separate

bracketJt
r

3
Remove
brake

tube
2
shock

absorller
3

and
dnve
shaft
4

r

r

0

it

1
Bracket
4

Propeller
shaft

2
Brake
tube
5

Spnng

pm

3
Shock
absorber
6
Shackle

assembly

4

Support
axle
case
With
a

Jack
at
the
center

Remove

spnng
pm
5
aJId
shackle

assembly

6
The

sprmg
seat
need
not
be
removed
from

shock

absorber

5
Lower

Jack
slowly
and
remove

susp
nslOn

assembly
as
shown
m

Figure
40

DIFFERENTIAL
REAR

AXLE
AND
REAR
SUSPENSION

167

REAR
SUSPENSION

pICK
UP

Rear

Suspension

Inspection
nnd

Repair
Pick

up

1
Check

spnngs
for
cracks
breaks
and

general

conditIon

Replace
as

reqwred
If

a

spnng
on

one

Side
IS

replaced
also

replace
the
other
one

2
Check

U
bolts
for
bends

stripped
threads

and

general
conditIon

Replace
as

reqUIred

3
Check

rubber

bumpers
and

bushings
for

cracks

wear
and

general
condll1on

Replace
if

defecl1ve

4
Check

shock

absorbers
for
leaks
or

other

damage
Replace
as

required

Rear

Suspension
Installation

Pick

up

1

Replace
the

rear

suspension
components
m

the
reverse

order
of
removal
2
When

msta11mg
rubber

bushmgs
coat
them

hghtly
With

a

soap
solution

3

Torque

parts
as
follows

Shackle
Pin

Spnng
Pm

U
Bolt

Secunng
Nut

Shock
Absorber

Upper
Nut

Shock
Absorber

Lower
Nut

Dnve
Shalt

Secunng

Bolt
83

to
94

It
Ib
11
5
to
13

kg
m

83
to
94
It
Ib
115
to

13

kg
m

61
to
72
ItAb
85
to

10

kg
m

26

to
31
It
Ib
36
t04
3

kg
m

10
to
12
ft
Ib
1
4

to
1
6

kg
m

18

to
22
ft
Ib
25
to
30

kg
m

NOTE

Retighten
bolts
and
nuts

that

hold

bushmgs
after
vehicle
has
been

removed

from

Jack
and
stands

236

INDEX

Clutch

DescnptIon

DIsassembly

Bleedmg

Exploded
vIew

Hydraulic
clutch

control

InspectIOn
and

repair

InstallatIOn

Reassembly

Removal

SpecificatIons
and

service
data

TroubleshootIng

Withdrawal
lever

Clutch
master

cylinder

Exploded
views

InspectIon
and

reassembly

InstallatIOn

Removal

and

disassembly

putch
operatmg

cylinder

J
Inspection

I
jj

ReaSs

mbly
and
mslallatlOn

Removal
and

disassembly

Clutch
wllhdrawal
lever

Condenser

Connectmg
rods

Beanng

mspectIon

Connectmg
rod

bearmg
underslzes

DescrIptIOn

InspestIon

Reassembly

Cooling

system

D

scrIpt
Qn

Fan
clutch

Radlato

Thermostat

yvater
pump

Crankshaft

DescrIptIon

Exploded
View

Inspection

Mam

bearIng
underslzes

iPulley
mstallahon

r
Reassembly

Removal

Sprocket

Tlmmg
cham

Cylinder
block

Bore

measurement

Camshaft
bend

DesCrIpllOn

Exploded
view

InspectIOn

eassembly

Cylinder
head

DescrIptIon

f
DIsassembly

r

Exploded
View

InspectIOn

InstallatIOn
l

or

1
Reassembly

127
Removal

127

133

128
D

129

DifferentIal

pick
up

128

59
InstallatIon

129
Removal
and

mspecllOn

127
SectIOnal
view

134
Differential

sedan

15
Exploded
view

133
Inspection

InstallatIOn

131
132
LubrIcant

level

130
Removal

130
DifferentIal

wagon

130
Exploded
view

InstallatIon

132
Removal
and

mspecllon

133
DistrIbutor

132
Cap
and
rotor
head

133
Condenser

110
ConstructIon

DIsassembly
and

reassembly

52
Dwell

angle

52
Exploded
Views

34
IgmtIon
coIl

51
Inspection
and
service

54
Pomts

Removal

84
SpeCificatIons

89
Tlmmg
dual

pomt
distrIbutor

90
Door
lock
and

regulator

89
Exploded
view

pick
up

85
Exploded
View

sedan
and

wagon

Doors

31
Construction

35
Exploded
view
4
door
sedan

51
Exploded
vIew

pick

up

52
DrIveshaft

58
DescrIptIOn

57
Disassembly

43
Exploded
Views

53
InspectIon
and

repaIr

57
Reassembly

Removal

49
SpeCificatIons
and
service
data

48

31

E

33

49
ElectrIcal

system
body

55
Fuses

Headlamps

34
Heater

45
Instrument
meters
and

panels

36
SWitches
and
fuses

46
Wmdshleld

wipers

56

Wmng
53

43

162

162

163

150

151

151

149

149

157

157

157

106

110

105

110

24

106
109

111

21

110

40

112

24

228

229

225

227

228

144

145

145
146

146

146

144

147

217

210

210

210

205
207
210

210

205

r

t

i

f
If

t
I

DAnUN
SE

1
5
10
AN

l
@
0

i1
rtr
JM
OIi
l
jj

I

I

if

J

I

f

lJ

I
I

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I

I

tflr

f1

h
f

I

v

L

7

I

l1It
l

I

fIr

t

I

r

II
to

E

m

PAIIt
I
lANI

X
I
I

PICK
UP

1968
1972

t

t

I

0

l

1

j
f

r
t
g

I

I

0

r

r

This

completely
new
edition

is

Clymer
s

first

covering
late
model
Dat

ouns
The

popular

pick
up
truck
a

best
seller
in
its
own
is
also
included

Material
has
been

pai
stakingly
prepared
by
a

top
technical
writer

and

tlien

carefully
edited

Major
sections
include
Periodic
Maintenance

Trouble

hooting
Tune

up
Lubrication

Engine
Fuel

System
Cooling

Ele

rical

System
Emissio
ontrols

Clytch
Transmission
and
Drive

shaft
Differential
Rear

Axle

Steering
rakes

1

Body

Wbiie
a

f
re

airs
on
advan
lMI

eauipment
such
as

sophisticated

1
II

emissi

ontruls
are

beyond
e
mechanics
the

simple
tests

I

f
l

1
1

and
t
ubl

shooting
measures
ndtided
can

help
diagnose

problems

Wher
r

lrs
are

practical

cr
mplete
informatfon
is

given
Equally

im
t
nt

ho
gh
thi
autho

frequently
includes

cautioning
gotes

1
f
I

where

proCeduljes
are

confusing
and

occasionally
suggests
that
here
s

b
I

t
1

t

I
a

10

1requ
ring
uea
er
attentloru

Ii
l

I

As
in

ail
C

ymer
books

the

goal
has

j

I
I
1

be
n

to

kelp
owners
understand

th
ir

far
owpr
repair
costs
and

generaUi
i
lnprove
automotive
sat

isfadion

O
Jr
200
other
utomotive

and
motcwc

y
c1e
itles
deal
with

re

pairl
performance
tuning
and

nostalgia
Ask
for
them
at

leading

J

book
stores
and

auto

supply
outlets

I

CLY

PUBLI

ATll
LO
MGELES

1

6
r

I

l

t