1968 DATSUN 510 drain bolt

90

CHAPTER

EIGHT

degrees
C
The
maXImum
WIdth
of
the
thermo

stat

openIng
should
be
0315
In
8mm

3
If
the
thermostat
IS
defectIve
or
If

you
have

an
doubts
about
It
mstall
a
new

one

4
When

Installmg
the
thermostat
m
the
hous

Ing
be
certaIn
to

place
the

spnng
end
down

Coat
both
SIdes
of
the

gasket
WIth
sealer
to

pre

vent
leaks
and

tIghten
the

mountlng
nuts

securely

RADIATOR

The
radIator
IS
of
conventional

desIgn
A

draIn
cock
IS

proVIded
at
the
bottom
back
to

perrmt
drainIng
The

system
IS

pressurized
and

the
rehef
valve

incorporated
In
the
filler

cap

mamtains
the

pressure
at

approximately
12
8

Ib
in
0
9

kg
cm
Coolant

capacity
is
1
691

gallons
6

4
lIters

Figure
8
shows
radIator
com
ponents
Note
that
vehicles

equIpped
WIth
auto

matIc
transmISSIon
have

provlSlons
for
connect

Ing
the
011
cooler
lInes
to
the
bottom
of
the

radiator

Radiator

Removal
Inspection

and

Replacement

1
Remove
the

upper
and
lower
radIator
hoses

to
draIn

coolant

2
Remove
four

machme
screws

securmg
radIa

tor
shroud

3
Remove
four

hex
bolts

secunng
rad1ator
to

mountlng
bracket

4
Remove
shroud
and

radIator
from
vehIcle

5

Inspect
radIator
for

SignS
of
leaks

RepaIr
or

replace
as

required

6
InstallatIon

IS
the

OppOSIte
of
removal

CD
14
1
Radiator

assembly
10
Plain
washer

2
Radiator

assembly
11
Plain
washer

automal1c
12
Hose

clamp

3
RadIator

cap
assembly
13
Hose

clamp

4
Drain
cock
handle
14
Radiator

shroud

5
Drain
cock

packing
15
Machine
screw

6

Upper
hose
16
Plain
washer

7
Lower
hose
17

Spring
washer

8
Hex
bolt
18
Hex
nut

9
Hex
nut
19
011
cooler
hoses

Automatic

only

2

i

7

1213

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

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

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

CHAPTER
TWELVE

DIFFERENTIAL
REAR
AXLE

AND
REAR
SUSPENSION

The
dIfferential
rear
axle
and
rear

suspen

sIon
dIffer
for
the
various
models
ThIS

chapter

deals
WIth
each

separately

Due

to
the
need
for

SpecIal
tools
and

exper

Ience
to
dIsassemble
and

repaIr
these
unItS
the

followmg
procedures
generally
cover
removal

InspectIon
and

replacement
only
If
mechanIcal

dIfficultIes

eXIst
WIthIn
the
dIfferentIal
and
rear

axle

components
refer
servIce
and

repair
to
a

Datsun
dealer
or

competent
garage

DIFFERENTIAL

SEDAN

The
cast
Iron
dIfferentIal

assembly
used

in

the
sedan
is
shown
in

Figure
1
next

page

Proper
lubncatlOn
of
the

gear
housmg
IS
essen

tIal
Check
lubncant

every
3
000
mlles
and
re

plenISh
as

necessary
Drain
and
refill
lubncant

at
least

every
30

000
miles

Differential
Removal
Sedan

1
DISconnect
handbrake
rear
cable
dnve

shaft

and
axle
dove
shafts

by
removing
bolts
shown

by
arrows
of

Figure
2

2

Place
a

Jack
under
the
dIfferential
and

lift

slIghtly
Remove
nuts
on
both
ends

of
dtfferentIal

mountlng
member
See

Figure
3

3
Remove
four

fixIng
bolts
that
hold
dIfferentIal

to
the

suspensIon
member

158

CHAPTER
TWELVE

REAR
AXLE
AND

SUSPENSION

WAGON

The

rear
axle
is

a
semI

f1oatlng
type
The
rear

wheel

bearmgs
are

presealed
and
do
not

require

penodlc

servIcmg
However
whenever
new

bearmgs
are
Installed

they
should
be

packed

v
lth
wheel

beanng
grease
durmg
InstallatIon

Figure
21
IS
an

exploded
view
of
the

rear
axle

whlle

Figure
22
IS
an

exploded
VIew
of
the
rear

suspensIon

Rear
Axle
Removal

Wagon

1
Remove
hub

caps
and
loosen
wheel
nuts

2
Jack

up
rear
of

vehIcle
and

support
it
on

stands

3
Remove
wheel
nuts
and
wheels
Remove

brake
drums
If
drums

are
not
free

or
are
dIffi

cult
to

remove
slacken
off
brake
shoe

adjuster

a
few
notches

4
DISconnect
brake

hose
from
brake
tube

Plug

up
the
hose
to

prevent
f1Uld
loss

@

4

16

6
5
DIsconnect
handbrake

rear
cable
from
bal

ance

lever

assembly

6
Remove
four
bolts

holdmg
dnve
shaft
to
the

dnve

pmlon
compamon
flange

7
Release
both
lower
shock

absorber
self

lockmg
nuts
and

slIde
the

mountlng
eyes
off
the

PIvot
of
the
rear

spnng
seat

8

Support
rear
axle
wIth
a
transrmsslOn

Jack

9
Loosen
the
U
bolt
lock
nuts
Remove
the
nuts

from
both

rear

spnng
shackles
and
remove
the

shackles
from
the
rear

spring
eyes

10
Remove

the
U
bolt
lock
nuts
Lower
the

jack

and
WIthdraw
the
rear
axle

assembly
See

Figure
23

Rear
Axle

Disassembly
and

Inspection
Wagon

1
DIsconnect
brake
lIne
ends
from

wheel

cylIn

ders
and
remove
the
line

complete
with

the
three

way
connector

2
Remove

cross
rod

clamp
and
balance
lever

arm
from
the

rear
axle

case
Remove
both
cross

1
Rear
shaft

assembly
11
Bea

ring

2
Rear
shaft
assembly
12
Bea

ring
colla
r

3
Wheel
hub
bolt
13
Axle
case
rear

shim

4
Rear
axle

assembly
14
Hex
bolt
With
washer

5
Stud
15
Brake
drum

6
011
seal
16
Rear
wheel

7
Axle
case
breather
48
Grease
catcher

9
Drain

plug
assembly
49
Seat

assembly

10
Rear
axle

spacer
53
Wheel
nut

DIFFERENTIAL
REAR
AXLE
AND
REAR

SUSPENSION
159

@

8
69

71

72

70

26
29

32

19
5
T1

31

30

21
4

23
58

20

57

37

45

6463

19
Center
bolt
33

Clip
45

Bushmg
62

Bushing

20
Hex
nut
34
Hex
nut
46
Washer
63
Nut

pin

21
Rebound

clip
35
Spring
washer
47
Self

locking
nut

64
Lock
washer

22
Rebound

clip
36

Locatmg
plate
50
Rear

spring
seat
65
Shackle

23
DIstance

piece
37
Seat

pad
54
Inner

clip
66
Shock
absorber
bracket

26
Front

pm
assembly
38
Lower
seat
assembly
55
Outer

clip
67
Bolt

27

Upper
bushing
39
Shock
kit
56
Center
bolt
68
Lock
washer

28
Lower

bushing
40
Rubber

bushing
57
Nut
69

Stopper
assembly

29
Shackle

assembly
41
Washer
58
Distance

piece
70
Nut

30
Hex
nut
42
Washer
59
Bracket

spring
71
Plam
washer

31

Spnng
washer
43
Hex
nut
60
Bolt
72

Spring
washer

32

Bumper
44
Lock
nut
61
Lock
washer

rod
ends
from
the
wheel

cylInder
lever

assembly

WIthdraw
the
handbrake

lInkage
assembly

3
Unscrew
the
011
dram

plug
and
draIn
011
into

sUItable
contamer

4
Remove
four
nuts

holdmg
brake
back

plate

to
the
axle
case
Draw
out
axle
shaft

assembly

WIth
the
brake
back

plate
and

grease
catcher

Use
a
slIde
hammer
as
shown
In

Figure
24

5
Press
off
the

beanng
collar
or
cut
it
loose

WIth

a
cold
chIsel
as
shown
m

Figure
25
The

removed

collar
should
not
be
reused

6
Use
a

beanng
puller
to
remove
the

bearmg

See

Figure
26
Take

out
brake
back

plate

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