1968 DATSUN 510 air condition

154
CHAPTER

tWELVE

move
two
nuts

attachmg
dtfferenual

suspension

member
to
the

body

7

Gently
lower
the

suspension
assembly
from

the

body
by
10wermg
the

jack
Support
the

suspension
so
It

does
not

fall
off
of
the

Jack

See

Figure
11
WIthdraw

Jack
and

suspension

from
vehicle

Rear
Axle
and

Suspension
Inspedion

And

Repair
Sedan

WIth
the
rear

suspension
removed
from
the

vehicle

InSpect
all

parts
for
wear
and

damage

Pay

special
attention

to
the

bushings
in
the

suspensIon
arms
and
robber

bumpers
Check

conditIon

of
the

spring
robber

msulators
in
the

suspensIOn
member
and
drive
unit

mounting

member

Replace
as

required

Rear
Axle

and

Suspension
InstaDation
Sedan

1
Instalation

procedures
are
the

opposite
of

removal

2
Be
sure
that
the

suspension
member
and
dnve

unit

mountmg
member
are
med

up
correctly

3

Tighten
fixing
nuts
and
bolts

as
follows

Suspension
Member

Mounting
Nuts
72
It

Ib
10

kg
m

Dlfferenbal

Mounting
Nuls
62
It
Ib
85

kg
m

Shock
Absorber
Lower
End
Nuts
17
It
Ib
23

kg
m

COIL
SPRING

SEDAN

Coil

Spring
Removal
Sedan

1
Jack

up
rear
of

vehicle
and

support
it
on

stands
2
Remove
wheels

3
Disconnect
handbrake

mkage
and
retl1rn

spring

4
Remove
dnve
shaft

flange
nuts

Figure
12

5
Remove
nuts
from
lower

part
of

bumper

assembly

6
Place
a

Jack
under

suspension
arm
and

re

move
shock
absorber
from

lower

mounting

Lower

Jack
and
remove
coll

spring
spnng
seat

and

bumper
assembly

Coil

Spring
Inspection
and

Repair
Sedan

1
Check
condItIon
of
coll

sprmg
for
wear
and

damage
Replace
if
defective

2
Check

all
robber

parts
for

wear

damage
and

general
condItion

3
Installation
of
the
coll

spnng
assembly
is
the

reverse
of
removal
Make
certam
the
coil

spring

is
installed
With
Its
flat
face
at
the

top

SHOCK
ABSORBER

REMOVAL
REPLACEMENT

INSTALLATION

SEDAN

1

Open
the
trunk
and

remove
the
mer

2
Remove
double
nuts
that
fasten

upper
end

of
rear
shock
absorber
to
the

body
Figure
13

3

DIsconnect
lower
end
of
shock
absorber
from

suspensIon
arm

4
Check

general
conditIon
of
shock
absorber

Check
for
011
leaks
cracks
and

straIghtness
of

shaft

Replaceif
defectIve

5

Inspect
robber

bushmgs
for

damage
wear

and

general
condition

Replace
as

required

6
InstallatIon
IS
the
reverse
of
removal

DIFFERENTIAL
REAR

AXLE
AND
REAR

SUSPENSION
155

i

I

I

I

REAR
SUSPENSION
ARM

SEDAN

Rear

Suspension
Arm
Removal
Sedan

1
Jack

up
the
rear
of
the
vehIcle
and

support
It

on
stands

2
Remove
wheel
and
brake
drum

3
DIsconnect
dnve
shaft
from
axle
shaft

4
Remove
handbrake
cable
from
lever
attached

to
wheel

cylInder

5

Plug
brake
tube
to

prevent
loss
of
brake
flwd

6
Remove
wheel

beanng
lock
nut
rear
axle

shaft
wheel

beanngs
and
OIl
seal
Remove
rear

brake

assembly
from

suspensIOn
arm

7
Place

Jack
under

suspenSIon
arm
remove

shock
absorber
from
lower
bracket
lower

Jack

gradually
remove
coll

spnng
spnng
seat
and

bumper
assembly

8
Remove
two
bolts

secunng
suspensIOn
arm
to

suspensIOn
member
and
remove

suspensIOn
arm

See

Figure
14
9
Remove
rubber

bushmg
from

suspensIon
arm

usmg
a

bushmg
remover
as
shown
In

Figure
15

@

Rear

SllSpension
Arm

Inspection

Repair
and

Installation
Sedan

1
Examme

suspensIOn
arms
for

damage
dents

and
cracks

Replace
tf
defectIve

2
Check
rubber

bushmgs
carefully
for
wear

damage
and

general
condItIon

3
Install

suspensIOn
arm
m
reverse
of
removal

When

Installmg
suspensIOn
arm
to

suspensIOn

member
re

tIghten
the
bolts
after
the
vehIcle

IS

removed
from
stands

Change
self

lockmg
nuts

every
tIme

they
are
removed

dunng
semcmg

REAR
AXLE
SHAFf
WHEEL

BEARINGS
AND
SEALS
REMOVAL

AND
DISASSEMBLY

SEDAN

1
Jack

up
the
rear
of
the
vehIcle
and

support
It

on
stands

2
Remove
wheel
and
brake
drum

3
DIsconnect
dnve
shaft
from
axle
shaft

4
Remove
wheel

bearmg
lock

nut

usmg
axle

shaft

flange
wrench
to
hold
the

companIOn

flange
See

Figure
16

5
Use

a
slIde
hammer
to
Withdraw
the
axle
shaft

assembly
Refer
to

Figure
17

6
Remove
011
seal
and

Inner

bearmg
usmg
rear

axle
shaft

bearmg
dnft
as
shown
In

Figure
18

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

17
CHAPTER
THIRTEEN

CD

7
Remove

bearing
collar
and
extract
the
outer

beanng
cage

8
Use
a
screwdriver
to
remove
front
hub

grease

seal
and
imIer

bearmg
cage

9
Use
a
dnft
to

punch
out
the
outer
and
mner

race
of
the
outer

bearmgs
Punch
out
imIer

bearing

10
Detach
rotor
from
wheel
hub

as
shown
in

FJgUre
7
@
1

Upper
Imk

2
Lower
Imk

3
TenSIOn
rod

4
Knuckle

spindle
support

5

Upper
link

sptndle

6
lower
link

spmdle

7
Fulcrum

pm

8
Fulcrum
bolt

9
Cotter

ptn

10
Shock
absorber

11
Frame

12

AdJustmg
shim

13
Lower

bumper
rubber

14

Upper
bumper
rubber

15
Bracket

Wheel
Hub
nnd
Wheel

Bearing

Inspection
nnd

Repair

1

Inspect
all

parts
for
wear
and

damage
and

clean
with
solvent

2
Rotate

bearmgs
by
hand
to
make
certain

they

move

freely
If

draggnIg
IS

eVident

replace

bearings

3
Check
the
axle
for

sconng
excessive
wear

rust
or
other

daJP

age
Reparr
or

replace
as

requIred

4

Inspect
the
rotor
for

scoring
pIttIng
or
rust

If

damaged
reconditIon
the
rotor

by
haVlDg
It

tumed
or
refaced
Refer
to

Chapter
Fourteen

Wheel

Hub
nnd
Wheel

Bearing
Installation

1

Assembly
is
the
reverse
of

removal

2

Apply
wheel

bearing
grease
to
the
inside
of

hub

cap

3

Replace
grease
seals
with
new
ones
whenever

they
are
removed

4

Torque
bolts
to

specIficatIons
on
next

page

FRONT
AXLE
FRONT
SUSPENSION
AND
STEERING
179

17
Remove
lower
lmk

torque
arm
and

torque

arm
bolt

Separate
torque
arm
from
lower
lmk

18
Dnve
out
lower
lmk

bushmg
from
bracket

Front

Suspension
Inspection
and

Repair

1
Check
the
shock
absorber
for
011

leakage
and

general
conditIon

Replace
1f
defects
are
found

2
Check

upper
and
lower

bushmgs
Replace
If

defective
or
worn

3
Install
screw

bushmg
to

upper
lmk

spmdle

and
fulcrum

pm
Measure
end

play
m

aXial

dIrection
If
end

play
exceeds
000
38
m

0
033mm

replace
upper
lmk

spmdle
fulcrum

pm
and
or
screw

bushmg

4
Check
dust
cover
for

damage
and
detenora

tIon

Replace
as

reqUIred

5
Check
threads
of

upper
lmk

spmdle
fulcrum

pm
and
screw

bushmg
RepaIr
or

replace
If

defective

6
Check
lower
lmk
and

upper
lmk

bushmgs
for

general
condition
and
wear

Replace
1f
defective
7
Check
torsion
bar
for
distortion
weakness

bends
and

general
conmtIon

Replace
If
de

fectIve

8
Check
tensIOn
rod
for
dIStortion
If
the

threaded

part
is

damaged
replace

9
Check
tenSiOn
bar
cushIOn
rubber

Replace
if

defective

10
Check
dust
seal
for
wear
and

damage
Re

place
as

requIred

11
Check
threaded

part
of

upper
lmk

spmdle

fulcrum

pm
and

screw

bushmgs
for
wear
and

damage
Replace
as

required

2
Check
lower
hnk

bushmg
and

upper
hnk

bushmg
for

SignS
of
wear
or

damage
Replace
as

reqwred

13
Check

torsIOn
bar
for
dlstorllon
and

general

condition

Replace
as

reqwred

14

Replace
rubber

bumper
If
weakened
or

damaged

15
Check

upper
and
lower
lmks
for
cracks

thread

damage
and

general
condition

RepaIr

or

replace
If
defectIve

Front

Suspension
Installation

1
Fit
lower
lmk

bushmg
to

lower
lmk

mountmg

bracket

usmg
a
SUItable
drlft

and
hanmIer

2
Install

torque
arm
on
lower
lmk

Torque

bolts
as
follows

181

to
224
fl
lb

25to31

kg
m

58
to
8
7
fl
Ib

08
to
12

kg
m

4

Tighten
screw

bushmg
on

upper
lmk
Install

grease
seal
and
dust
cover

Torque
to
173
5
to

1808
ft
lb
24
to

25

kg
m

5
Refer
to

Figure
27
Fill

upper
lmk
screw

bushmg
With
multi

purpose
grease
as
mdlcated

by
the
m

the
Illustration

Apply
grease
to
bush

mg
mtenor
Thread
on

upper
lmk

spmdle
to
the

dimenSIOn
mdIcated

6
Screw
front
and
rear
lInks

agaJnst
upper
hnk

spmdle
to
the

openmg
Width
mdlcated
Remove

the
filler

plug
while

fittIng
the
front
and

rear

lmks
Check
to
make

cectam
that
the

upper
link

spmdle
operates
smoothly

7
Remove
filler

plug
mstall

grease
mpple
and

inJect
grease
untIl
It
comes
out
from
dust

cover

Reinstall
filler

plug
Arm
Head

Serration
Boss

BRAKES
191

2
Disconnect
the
front
brake
hose
from
the

brake
tube
See

Figure
8
and

plug
the
brake

hne
to
avoid
flwd

loss

3
Screw
out
the
bolts

fixing
the

calJper
to
the

knuckle

flange
and
remove
the

calJper
assembly

as
shown
m

Figure
9

4
Remove
the

spmdle
nut
and
the
dISC
hub

Separate
the
rotor
from
the
hub

assembly
See

Figure
10

Front
Disc
Brake

Disassembly

Figure
11
next

page
IS
an

exploded
diagram

of
the
front
disc
brake

assembly
Refer
to

figure

and
follow
the

followmg
procedures

I
Remove
the
antI
rattle

clip
from
the

calJper

plate
and
remove
the
brake

pads
4

2
Remove
the
tension

spnngs
and

pull
the

cyhnder
out
of
the

caliper

plate
3
Remove
the

piston
by
applymg
air
or

hy

draulJc

pressure
to
the
flwd
mlet
hole
Remove

the
rubber
seal
from
the

groove
on
the

cyhnder

Remove
the
retamer
and

Wiper
seal
The

pISton

can
now
be
removed

Front
Disc
Brake

Inspection
and

Repair

I
Check
the

cyhnder
assembly
for

leakage
and

damage
Replace
If
defects
or

damage
are

apparent

2
Check
the
disc
brake

pads
for
wear
and

cracks

Replace
all

pads
If
It
IS

necessary
to

replace
any

fi

3
Check
the

caliper
for

damage
Replace
as

reqUIred

4
Check
the
rotor
for
scratches

sconng
and

general
conditIon
The
rotor
can
be
resurfaced
If

defects
are
found
Standard
rotor
thiCknesS
IS

o
0394
m

IOmm
The
hm1t
of

reconditIOning

thickness
IS
0
331
m
8
4mm

Replace
rotors
If

recondltIomng
limits
have
been
reached

5
Check
the
rotor
for
TWlout

usmg
a
dial

gauge
as
shown
m

Figure
12
Rnnout

ot
the

rotor
should
be
less
than
0
0024

m
0

06DlIll

BRAKES
193

Front
Disc
Brake
Piston
Seal

Replacement

If
oil

leakage
is
detected
around
the

piston

seal
It
should
be

replaced
as
follows

I
Rinse
the

cyhnder
bore
With
brake
flwd
In

sert
new
seal
into
the

groove
taking
care
not
to

damage
It
Attach
the

wiper
seal
Lubricate

cylinder
bore

lightly
With
brake
fluid

2
Clean
the

piston
Inspect
the

pISton
for
scor

ing
or
other

damage
before

inserting
It
Make

sure
that
the
relieved

portion
of
the

pISton
faces

the

pivot
pin
Prevent

tilting
of
the

piston
when

It
IS
mserted
mto
the

cyhnder
Refer
to

Figure
13

@

4

Front
Disc
Brake

Assembly
and
Installation

I
Clean
the

mounting
surface
and
disc
surface

Attach
the
disc
to
the
hub

2
Install
the
hub
to
the
knuckle

spindle

3
Insert
the

piston
into
the

cylinder
untIl
its

face
is
almost
flush
With
the
face
of
the

wiper

seal
retamer

4
Install
the

cyhnder
mto
the

caliper
plate
and

secure
with
the
torsion

spnngs

5

Assemble
the
hold
down

pm
spring
washer

and

nut
to
the

support
bracket

6

Insert
cotter

pin
into
the
nut

7
Assemble

mounting
bracket
and

calJper
plate

with

pivot
pm
washer

spring
and
nut

Tighten

nut

completely
and
insert
cotter

pin

8

Pry
up
the
hold
down
bracket
with
a
screw

dnver
Hook
it

to
the

upper
end
of
the

mounting

bracket
Turn
the

cal1per
plate
to
make
sure
it

slides

smoothly

9
Install
the

caliper
assembly
to
the

knuckle

flange
10
Attach
shun
to
inner

pad

I
I
Insert
the
inner
dIsc

pad
Pull

the

caliper

plate
outward
and
insert
the
outer
disc

pad

12
Attach
the
anti
rattle

plate

13

Replace
wheel
and
remove
stands

REAR
BRAKE
SEDAN
AND

WAGON

Figure
14
IS
an

exploded
view
of
the
rear

brake

assembly
used
m
the
sedan
and

wagon

Rear
Brake
Removal
and

Disassembly

1
Jack

up
the
rear
of
the
vehicle
and

support
It

on
stands
Remove
the
wheels

2
Release
the

parkIng
brake
DISConnect
the

cross
rod
from
the
lever
of
the
ie
wheel

cylinder

3
Remove
the
brake
drum

4
Remove
the
return

springs
and
take
out
the

brake
shoe
assemblies

5
Disconnect
the
brake
tube
from
the
wheel

cylinder

6
Remove
the
wheel

cylinder
by
removing
dust

cover

plates
and

adJusting
shIms

7
DISassemble
the
wheel

cylinder
by
removing

the
dust
cover
and

snap
nng

8
Remove
the

adJuster
assembly

Rear
Brake

Inspection
d

Repair

Sedan
and

Wagon

I

Inspect
the
brake

druf
1s
for

scoring
signs
of

excessive
heat
and
out
of
round

Repair
or
re

place
the
drums
as

reqUIred
The

following

specificatIons
apply

Drum
Out
of
Round

Inner
Olameter

MaXImum
Diameter
after

IlI1ndmg
Less
than
0
0020
In
0
05mm

8
999
m
228
6mm
1

9040
In
229
6mm

2

Inspect
brake

limngs
for
wear

signs
of
oil
or

grease
and
cracks
If

any
of
these
conditions
are

found

replace
the

linmgs
Have

a
brake

special

ISt
arc
the

limngs
to
match
the
diameter
of
the

drums
after

replacement
If
the
thickness
of
the

limng
is
under
0
0591
m
1
5mm

replace
it

3
Check
the

adjusting
cams
for
smooth

opera

tion

Replace
as

reqUIred

4
Check
the

spnngs
If

they
appear
weak
or

uneven
m
tension

replace
them

v

194

CHAPTER

FOURTEEN

3

Right
hand
rear
brake
disc

4
Left
hand
rear

brake
disc

5
Fore
rear

brake
shoe

6
Aft
rear

brake
shoe

7
Brake

IImng

8
Rear
brake

adjuster

9

Adjuster
wedge

11
Lock
washer

12
Hex
nut

13
Wheel

cylinder

assembly

14
Piston

cup

15
Piston

16
Dust
cover

6
@

5
Check
the
wheel

cylinder
for

wear

rust
and

damage
If

defectIve

replace

6
Check
die
clearance

between
th

cyhnder
and

the

piston
If
the
clearance
18

greater
than

Q
0059
m
0
15mm

replace
the

cylinder
The

cyluiders
can
be
honed
With

a
wheel

cyhnder

hone
If
the
maXImum
dimensIOn
has

not
been

reached

7

Replace
the

piston

cups
whenever
the

cyhn

derds
disassembled

even

though
the

cups
appear

to

be
m

good
condition

Rear
Brake

Assembly

1

Assembly
IS
the
reverse
of

disassembly

2
Be
careful

not
to

get
dirt
or
brake
fluid

on
the

brake

hnnlgs

3

AdJust
shoe
clearance

then
bleed
the

hy

draulIc

system
17
Dust
cover

ring

18
21
Lock

plates

22
Dust
cover

23

Lever

assembly

24

Bleeder
screw

25
Bleeder

cap

26
Return

spring

27
Return

spring
adjuster

slide

29
Anti
rattle

spring

30
Anti
rattle

pin

31
Anti

rattle

spring
set

32
Anti

rattle
retainer

spring

23

22

24

e

17

a
25

FRONT
BRAKE

pICK
UP

Figure
15
shows
the
front
brake

system
for

the

pick
up
Generally
speaking
follow
the
same

procedures
given
for
removal

disassembly
re

pair
and

assembly
of
the
sedan

wagon
rear

brake
The

followmg
specifications
apply
to
the

pick
up
front
brakes

Inner

Drum
Diameter

Drum

Out
of
Round

MaXimum
DIameter
after

gnndlng
10
00
In

254mm

Less
than
0
0008
In
0
02mm

10
04
In
255mm

REAR
BRAKE

pICK
UP

Figure
16
shows
the

rear
brake

system
for
the

pick

up
Generally
follow
the

same

procedures

given
for

removal

disassembly

repaIr
and

assembly
as

given
for
the
sedan

wagon
rear

brake
Pertment

specificatIons
are
the
same
as

for
the
front
brakes