1968 DATSUN 510 brake

174

CHAPTER

THIRTEEN

Spring
and
StnJt

Assembly

Removal

nnd
Installation

1
Jack

up
the
front
of
the

car
and

support
it

on
stands

2
Remove

front
wheel

3
Detach
brake

hose
connector
at

frame
Re

move
lock

spnng
and
disconnect
brake
hose

from
brake

tube

Plug
up
end
of
tube

so
that

brake

f1wd
will
not
leak
out

4

D
etacb
tensiQn
rod
fi

g
bolts

lld
stabilizer

fixmg
nut
Remove
from
transverse
hnk

5
Detach
two
bolts

connectmg
strut

assembly

and
knuckle
arm
as
shown
in

Figure
10

6
Place

a

Jack
at
the

bottom
end
of
the

strut

assembly

7

Open
the
hood
and
remove
the

strut

fixing

nuts
Refer
to

Figure
11

8
Lower

the

Jack
slowly
The
strut

assembly

With

spnngs
attached
can

now
be

removed
from

the

body
frame

9
Install
strut

assembly
m
the
reverse
of

removal
10

Torque
fiXlng
bolts
as
follows

Strut

Assembly
to

Body
Nuts
282
to
37
6
fl
Ib

3
9

to
5
2

kg
m

434

to
578
fl
Ib

60

to
80

kg
m

35

4
to
45
6
flAb

49
to

6
3

kg
m

8
7
to
123
fl
Ib

12
to

17

kg
m

13
7
to
18
1
flAb

19
to
25

kg
m

TRANSVERSE
l
INK
REMOV
AL
AND

INSTALLATION

SEDAN
AND

WAGON

1
Jack

up
the
vehicle

and

supportIt
With
stands

2
Refer
to

Figure
12

Separate
the
tensIOn
rod

1
and
the
stabIlIzer

2
from
the
transverse

hnk
3
Remove

lower
ball

Jomt
fixmg
bolts

4
Knuckle
Ann
to
Strut
Bolts

TenSion
Rod
to
Transverse

L
mk
Nut

Transverse
Unk
Bracket
Bolts

Frame
Bracket

Bolts

3
Remove

nut
and
take
out
transverse
link

4

Inspect
transverse
hnk
and
rubber

parts
for

wear
and

damage
Replace
as

reqwred

5
Install
transverse
hnk

III
the

reverse
of

removal

6

Torque
bolts

as
follows

Transverse
L

mk
to
Cross

Member

L
ower
Ball
Jomt
882

to
976
fl
lb

122

to
13
5

kg
m

13
7
to
18
1
flAb

19
to
25

kg
m

TenSion
Rod

to
Transverse

354
to
45
6
fl
lb

L
lnk

49

to
63

kg
m

Stabilizer
to
Transverse
8
7

to
123
fl
lb

L
lnk

1
2
to
17

kg
m

LOWER

BALL
JOINT

REMOVAL

REPAIR

INSTALLATION

SEDAN
AND

WAGON

1

Separate
tensIOn

rod
and
stabilizer
from
the

transverse

hnk

FRONT
AXLE

FRONT
SUSPENSION
AND
STEERING
175

2
Remove
bolt

cormectIng
strut
and
knuckle

arm

3
Remove
cotter

pm
and
lower
ball

Joint

4

Separate
lower
ball

Jomt
from
knuckle
arm

5
Remove
bolts
for
lower
ball

Jomt
Separate

transverse
lmk
from
lower
ball

Joint

6

Inspect
ball

Jomt
and
dust
cover
for
wear
or

damage
Replace
as

requIred
If
end

play
m
the

aXial
dIrectIon
of
the
ball

Jomt
exceeds
00012

to
0
0136
m
0
03

to
0
6mm

replace
It

7
Install
ball

Jomt
m
the

reverse
of
removal

Grease
It

through
the

grease
mpple
Take

care

to
fill
the

caVity
slowly
so
that

grease
does

not

come
out
from
the

clamp

portIon

8

Torque
bolts
as
follows

Lower
Ball

JOint
to

Transverse
Link

Ball
Stud
Nut
13

7
to
18
1
fl
Ib

19
to
25
kgfm

398

to
55
0
fl
Ib

55

to
76

kgfm

43
4

to
57
8
flAb

60

to
80

kgfm

35
4
to
45
6
flAb

49
to
63
kgfm

87
to
12
3
fl
lb

12
to
17

kgfm
Knuckle
Ann
to
Strut

TenSion
Rod
to
Transverse

Link

Stabilizer
to
Transverse

Link

FRONT
SUSPENSION
ADJUSTMENT

AND
WHEEL
ALIGNMENT

SEDAN
AND

WAGON

Due
to
the

speclahzed
eqUIpment
required

front

suspensIOn
adJustment
and
wheel

ahgn

ment
should
be
referred
to
a
Datsun
dealer
or

front
end

speciahst
The

followmg
specmcations

apply
to
the
sedan
and

wagon

Sedan

Wagon

Caster
1
40
20
00

Camber
1
00
20
10

King
Pin
Incllnallon
8000
7050

Toe

In
0236
to
0
354
In
0118
to
0
236
In

6

to
9mm
3
to
6mm

Steenng
Angle
In
38
to
390
38

to
390

Steenng
Angle
Out
22030

to
330
30
220
30
to
330
30

Front
Axle
Removal

Pick
up

Refer
to

Figure
13
and

proceed
as
follows

1
Jack

up
vehIcle
and

support
it
With

stands

2
Remove
wheel
nuts
and
wheels

3
Remove
brake
hose
from
wheel

cylinder
@

@

1
Knuckle

spindle

2
Inner
wheel

beanng

3

Outer
wheel

beanng

4
011
seal

5
Wheel
hub

6
Washer

7
Spindle
nut

8

Beanng
cap

9
Brake
drum

10
Wheel
nut

11
Knuckle
spindle
support
12

KUlg
pin

13
Thrust

beanng

14
fulaum
bolt

15
Fulcrum
pin

16
Fulaum
bolt

17

King
pin
lock
bolt
or

nut

18
Collar

19
Knuckle
ann

20

King
pin
busllIng

4
Remove
the
brake
drum
Refer
to

Chapter

Fourteen

5
Remove

bearmg
cap
cotter

pin
and

spmdle

nut
from

spmdle
knuckle

6
Remove
wheel
hub
wheel

bearings
011
seal

and
collar
from

spmdle
knuckle

7
Remove
brake

assembly
from
knuckle

spin

dle

flange

8
Remove
knuckle

arm
from

spmdle
knuckle

See

Figure
14

9
Remove

kmg
pm
lock
bolt
See

Figure
15

10
Remove

plug
from
the

top
of

kmg
using
a

rod
or
other
SUItable
tool
The

plug
can
be

FRONT
AXLE
FRONT
SUSPENSION
AND

STEERING
177

5
Check
front
hub
for
cracks
and

damage
Re

place
1f
defectIve

6
Check
thrust

bearmg
for
wear

damage
rust

and
ease
of
rotatIon

Replace
1f
defectIve

Front

Suspension
Installation

1
Remstallation
is
the
reverse
of

removal

2

Apply
hght
coatIng
of
multI

purpose
grease

to
all

shdmg

parts

3
Install

bushmg
carefully
so
that

grease
groove

IS
on
the

upper
Side
and
the

bushmg
Joint
is
faced

rearward
Remove

grease
mpple
and
dn11

grease

hole

through
bushmg
through
hole
With
an

0
1181

m
3mm
dn11
Remove
metal

shaVlDgs

and
burrs
Ream
the
mner
d1ameter
of
the

bushing
to
07878
to
0
7888
m
20
010
to

20035mm

4
Install
thrust

bearmg
so
that
the
covered
face

Side
is

upward

5
Push

up
the
bottom
of
the

spmdle
hghtly

Measure
clearance
and
select
a

spmdle
shim
to

prOVide
the

followmg
clearance

standard
Clearance
0
001
In

004mm

ShIms
are
available
m
vanous
thicknesses

6
FIt

kmg
pm
and
make
certam
It

operates

smoothly

7

Apply
sealer
to
new

plug
and
install

8
Install

bearmg
outer
race
Fill
wheel
hub
and

hub

cap
With
multI

purpose
grease
Fill

space

between
wheel

bearing
rollers

and

grease
seal

hp
pocket
With
multI

purpose
grease
Make
cer

tam
wheel

beanngs
are
coated

completely

9

Apply
multI

purpose
grease
to

spmdle
shaft
wheel

bearmg
washer

and
to
the
wheel

bearmg

lock
nut

10
Make
certam
that
no
dIrt
or

foreign
matenal

IS

permitted
m
contact
with

parts
or

grease

dunng
assembly

Wheel

Bearing
Adjustment

1
Install

spindle
nut
and

torque
to
23
1
to
24
6

ft
lb
3
2
to
3

4

kg
m

2
Turn
wheel
hub

a
few
tImes
m
both
the
clock

Wise
and
counterclockwISe
directIon
Recheck

the

spmdle
nut

tighmess

3
Back
off

spmdle
nut
from
40
to
70

degrees

until
hole
m

spmdle
and
nut
COinCIde
Insert

cotter

pm
and
bend
over
around
nut

4
Turn
wheel
hub
a
few
turns
in
both
d1rectIons

to
seat

bearmg
Check
the

startmg
torque
of
the

hub
With
a

spring
gauge
as
shown

Figure
20

Startmg
torque
should
be
as
follows

New

Beanng
and
Seal
130
In

Ib
or
less

15
kgl
an

or
less

i

Used

Beanng
and
Seal
6
1
In
Ib
or
less

7
kgl
an
or
less

5

ReadJust
spmdle
nut
as

necessary
to
achieve

proper
startmg
torque
When
correct
mstall
the

hub

cap

Front

Suspension
Pick

up

Durmg
the

followmg
procedures
refer
to

FIg

ure
4
at
the

begmning
of
this

chapter

Front

Suspension
Removal

1
Jack

up
the
vehicle
and

support
It
With
stands

2
Remove
wheels
Remove
front
axle
as

pre

Viously
described

3
Remove
brake
hose
from
wheel

cylinder

CHAPTER
FOURTEEN

BRAKES

The
sedan
and
station

wagon
are

equipped

With
disc
brakes
on
the
front
wheels
drum

brakes

on
the

rear
wheeis
and
a
tandem
master

cyhnder
The

pIck

up
has
drum
brakes
on
all

four
wheels
and

a

single
master

cylmder
All

vehicles
have

a
mechanIcal
handbrake
that

works

on
the

rear
wheels

only

BRAKE

PEDAL

Figures
1
and
2
show
the

mounting
location

and
the

components
of
the
brake

pedal
for

sedans
and

wagons
The

pick
up
is
smlliar

Brake

Pedal
Removal

1
Remove

pedal
return

spring

2
Remove
cleViS

pm
on
the

push
rod
CD

3
Disconnect
brake

pedal
from
the
master

cyhnder

4
Remove
the
fulcrum

pm
Remove
the
brake

pedal

Brake
Pedal

Inspection
nnd

Repair

Check
all

parts
for
wear

damage
and
defor

matIon

Replace
defective

parts
as

reqwred

J

188

CHAPTER
FOURTEEN

Brake
Pedal
Installation

1

Apply
pedal
grease
to
the

pedal
shaft
sleeves

and

push
rod
cleVIS

pm

2
Installation
is
the

reverse
of

removal

3

Torque
the
fulcrum

pm
to

25
3
to

28
9
ft
lb

3
5
to

4
0

kg
m

MASTER
CYLINDER

FIgure
3
is

an

exploded
view
of
the
tandem

master

cyhnder
used
on
the
sedan
and

wagon

starting
m
1969
Earher
models
are
sinnlar

Figure
4
IS
an

exploded
View
of
the
master

cyhn

der
used
on
the

pIck
up

Master

Cylinder
Removal

1
Remove
reservOIr

cap
and
drain
brake
f1wd

2
DISconnect
brake

pedal
return

spring

3
Disconnect
brake
tube
from
master

cyhnder

4
Remove
two
bolts

holdmg
master

cyhnder
to

front
dash

assembly

5
Remove
master

cylinder

Master

Cylinder
Disassembly

1
Remove

dust
cover
and

piston
stopper
screw

2
Remove

snap
nng
and

stopper
ring
then

pllShrod
3
Remove
the

piston
and
related

parts
from

cyhnderbody

4
Remove

valve

cap
gasket
check
valve
and

check
valve

spring

NOTE
DISassemble
master

cylmder

carefully
Don
t

damage
the

slldmg

surfaces

of
pISton
and

pISton

cup
Do

not
remove

flUId
reservOlT

unless
ab

solutely
necessary
Remove

pISton
cup

only
If

pISton
must
be

replaced

r

Master

Cylinder
Inspection
nnd

Repair

1
Clean

all

parts
thoroughly
with
clean
brake

fiwd

2
Check

cyhnder
and

piston
for
abnormal
side

wear
and

damage
Replace
as

reqUIred

3
Check
all

spnngs
for
weakness
and

damage

Reparr
as

reqUIred

4
As
a
matter
of
sound

practIce
replace
all

cups
and
valves
whenever
the
master

cyhnder
is

dISassembled

DefinItely
replace
them
1f

they
are

deformed
due
to

swellmg
wear
and

age

5

Inspect
all
other

parts
Replace

any
that

are

defective

CD
1
Valve

cap

2
Valve
cap

gasket

3
Check
valve

4
Check
valve

spnng

5
011

reservoIr

cap

6
Reservoir

7
ReservOir
band

8

Paclang

9

Stopper
bolt

10

PIston
return

spnng
11

Sprmg
seat

12

Spnng

13
Valve

14
PIston

15

Pnmary
pIston
cup

16

Secondary
piston

cup

17

Stopper
nng

18

Snap
nng

19
Rubber
boot

20
Push
rod

190

CHAPTER
FOURTEEN

Master

Cylinder
Assembly
and
Installation

I
Assemble
the
master

cyhnder
m
the

reverse

order
of

dIsassembly

2
Pnor
to

assembly
soak

piston
cap
m
brake

flwd

Install

piston
so
that
It
seats

firmly
on
the

piston

cup

3
Coat
the

cyhnder
bore

and

pISton
assemblies

With
clean

brake
flwd
before

assembly

4
When

assembly
IS

complete
mount
master

cylmder
on
dash

wall
and
hook

connecting
rod

to
brake

pedal
Replace
return

sprmg
Fill
the

reservOir
With

clean
brake
flUid

5
If

aIr
has

seeped
mto
the
brake
Imes
bleed

the

brakes
as
descnbed
later
m
thIS

chapter

FRONT
DISC
BRAKES

SEDAN
AND

WAGON

Brake

Pad

Replacement

Pad
wear
should
be
checked

every
4
000

nuIes
Clearance
between

the

pad
and
the
rotor

IS

adjusted

automatIcally
and
therefore
IS
not
a

wear
mdlcator

Pad
thiCknesS
IS
checked

by
re

movmg
the
antI

rattle

clJp
When
the

pad
hning

becomes

worn
to

0
04

Imm
replace
all

pads
on
the

front
wheels

I
Remove

the
hub

cap
loosen
the
hub
nuts

jack

up
the
vehicle

support
with

stands
and

remove
the
front
wheels

2
Remove

the
antI
rattle

clJp
from

the

caliper

plate
as
shown
m

Figure
S

jty

3
Loosen
the
bleed
screw
Pull
the

calJper
plate

outward
4
Push
the

pISton
m

approximately
0
157
in

4mm

as
shown

m

Figure
6

5
The
outer

plate
should

be
loose

enough
to
be

removed
See

Figure
7

6

Dra
y
the

calJper
plate
rlfward

and
remove

the
inner

pad

7

Wipe
exposed
surface
of

piston
thoroughly

8
Push
the

piston
mto
the

cyhnder
bore
untJI

the

new

pads
can
be
mstalled
onto
the

calJper

plate

9
After

instl
llatIon
test
the
brakes
at
slow

speed
to
make
certam

they
are
fitted

properly

and
that

no
au
entered
the

hydraul1c
hnes
Bleed

the
brake

system
If

required

Front
Disc
Brake
Removal

I
Jack

up
the
vehicle

place
It
on
stands
and

remove
the
wheels

P

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