1968 DATSUN 510 clutch

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

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

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

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

110
CHAPTER
FIFTEEN

FOR
MANUAL

IGNITION
KEY

i

I
MADV
Nf
D

BRAKE
POINT

v
sa

tS

57

51
Th
rottle
sWItch

52
Speed
sWItch

relay

53
Speed
detector

assembly
Q
FOR

AUTOMATIC

IGNITION
KEY

AOVANEO

BRAKE
POINT

I
SPEED

DETECTOR

SPEED
SWITCH

I
RELAY
MJsr
I

IQ

52

SOLENOID

VALVE

54

Relay

55
Screw

56
Clutch
sWItch

assembly
57

Relay
assembly

58
Screw

INSTRUMENT
METERS
AND

PANELS

Figure
9
Illustrates
the
instrument

panel
and

gauges
used
on
the
sedan
and

wagon
models

untIl
1970

Figure
10

page
212
shows
the
m

strument

panel
and

gauges
smce
1970

Figure
11

page
213
shows
the
lDstrument

panel
and

gauges
used
on
the

pick

up

HEATER

Figures
12

page
214
and
13

page
215
are

exploded
Views
of
the
heaters
used

on
the
sedan

and

wagon
FigDre
14

page
213
shows
the

heater
used
on
the

pick
up

WINDSHIELD
WIPER

Figure
15

page
216
illustrates
the
wind

shield

Wiper
system
used
on
the
sedan
and

wagon

smce
1969
Earlier
models

were
slrmlar

Figure

16

page
217
shows
the

wiper
motor
wlule

Figure
17

page
2
I
7
shows
the

Wiper
motor

Imkage
on
the

pick
up
WINDSHIELD
WASHER

Figure
18

page
218
is

an

exploded
View
of

the
WindshIeld
washer

system
used
on
the
sedan

and

wagon
smce
1969
The
washer
used
on
the

pick
up
IS
SImilar

HEADLAMP

The

headlamp
units
used
on
the
sedan

wagon

and

pick
up
are
all
similar
to
that
shown
m

Figure
19

page
219

Replacement
of

the
sealed

beam
UnIts

reqwres
that
the

headlamp
trim
be

removed
so
that
the
sealed
beam
unit
can
be

withdrawn

AdJustment
of
the

headlamps
should

be
referred
to

a

qualified
electrical

shop

Lamp
Bulb

Replacement

Bulb

replacement
consIsts
of

removmg
the

retamer

nng
and
lens
from
the
unit

removmg

the
bulb
and

replacmg
It
In
some
cases
the

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

INDEX

237

2

7

30

28
WIrIng
diagrams

WIrIng
harnesses

Electncal

system
engme

Alternator

Chargmg
ClfCUlt

Dlstnbutor

IgmtlOn
coIl

Spark
plugs

Starter

Voltage
regulator

Emission

control
crankcase

DescnptIon

General

mspectIon

SchematIc
vIew

VentIlatIOn

control
valve

EmIssIOn

control
exhaust

AIr

pump

AntI
backfire
valve

Check
valve

DescnptlOn

Engme
modificatIons

system

Exploded
and
schematIc
vIews

Mamtenance
and

testIng

Troubleshootmg

Emission
control

system

evaporatIve

Engme

Camshaft

and

beanngs

Camshaft

sprocket

Component
descnptIons

Componenl

reassembly
and
mstallatIon

CompressIOn

testmg

Connectmg
rod

beanngs

Connectmg
rods

Crankshaft

Crankshaft
and

tImmg
cham

Crankshafl

sprocket

Cylmder
block

CylInder
head

DescnptlOn

Disassembly

Exploded
view

Flywheel

InstallatIOn

LubncatIon

MaIO

bearmgs

PIston

nngs

Pistons
and

connectmg
rods

PiStOns
and

piston
pms

Reassembly

Removal

SectIonal

views

ServIce
data

SpeCificatIons

Troubleshootmg

Valve
rocker

PIvot

Valves

Engme
lubncatlon

DescnptIon
217
222

205
207

98

104

98

105
111

111

112
113

9197

104

122

122

121

38
114

123

115
120

114

15

123

48
54

53

31

38

5759

24

52

51
54

51

57

53

49
55

46
56

31

40

33

53

59

27
30

52

50

45

50
54

53

38

32

60
61

60
61

13

54

47
53
114

114

121

114
LubncatlOn
ClfCUlt

011
filter

011

pump

Engme
tune

up

Checks

miscellaneous

Compression
testIng

DIstributor

Dwell

angle

EqUIpment
usage

ReqUIred
eqUIpment

Spark
plugs

Tlmmg

Tlmmg
dual

pomt
dlstnbutor

Valve
clearances

Exhaust

systems

Exploded
views

InspectIon

InstallatIOn

Removal

pickup

Removal
sedan
and

wagon

F

Fan
clutch

DIsassembly
and

reassembly

OperatIon
and

mspectlon

Flywheel

Fuel

pump

Capacity
test

DescnptlOn

Exploded
views

InspectIOn

InstallatIOn

Reassembly

Removal
an

assembly

StatIc

pressure
test

Fuel
stramer

Fuel

system

Air
cleaner

Carburetor

Fuel

pump

Fuel

stramer

Fuel
tank

Troubleshootmg

Fuel
tank

DescnptIon

Exploded
Views

InspectIOn
and

repaIr

Installation

Removal

sedan

Removal

pick
up

Removal

wagon

Fuses

G

27
General

mformatIon
25

24

21

24

20

20

21

23

24

25

124
126

126

126

126

123

l

89

89

53

68

37
65

66
67

68

58

68

42
68

65

1
2v

62

69

65

68
l

6

7

1
l

76

78
81

82

82

76

82

7
6

2

1

F

l

INDEX
239

Rear

suspensIOn
wagon
Removal
40
92

Servlcmg
161
Termmals
94

Tightening
torques
162
Test

diagnosIs
97

Testmg
96

Troubleshootmg
10

5

Steenng
also
see

Suspension
front

I

Exploded
views
182
185
L

Seats

SpecIfications
186

DescnptIon
228

Troubleshooting
16

Exploded
View
front
4
door
sedan
232

SuspensIOn
front

pick
up

Exploded
VIew
front

pick
up
228

Axle
removal
175

Service
hmts
4

Inspection
and

repair
179

Shock
absorbers
sedan
154

Installation
179

Shock
absorbers

wagon
162

Posture

adjustment
181

Spark
plugs
Removal
177

CondlllOn
chart
21

Wheel

abgnment
182

InspectIon
and

servlcmg
21

Wheel

bearmg
adjustment
177

Recommended

types
112

Suspension
front
sedan
and

wagon

SpecificatIOns
and
tables

Inspection
and

repair
176

Adjustment
and
wheel

alignment
175

InstallatIOn
177

Brake
service
data
203
204

Lower
ball

Jomt
174

Brakes
203
204

Spnng
and
strut

assembly
173

Camshaft

beanngs
48

Stabilizer
173

Caster
and
camber
sedan
and

wagon
175

TenSIOn
rod
173

Clutch
134

Transverse
bnk
174

Clutch
service
data
134

Wheel

beanngs
177

Connectmg
rod

beanng
underslzes
52

Wheel
hubs
and

bearmgs
168
173

Dlstnbutor
112

SWItches

Dnveshaft
147

DescnptIon
205

Dnveshaft
service
dala
147

Exploded
View

through
1969
208

Engme
60
61

Exploded
view
1970
1972
207

Engme
service
data
60
61

General
4

Mam

bearmg
underslzes
52

T

Piston

rmg
gap
50

Rear

suspenSIOn
pick
up
167
Tail

gate
228
233

Rear

suspensIOn
torques
wagon
162

TenSIOn
rod
sedan
and

wagon
173

Steermg
186
Thermostat

TransmiSSion
manual
144

DescnptIon
89

TransmiSSion
service
data
manual
144

Inspection
and

replacement
89

Valve

spnng
47

Removal
89

Sprmg
and

strut

assembly
sedan
and

wagon
173
Tires

Spnngs
sedan
154
Wear

analYSIS
17

Stabilizer
sedan
and

wagon
173

TransmiSSion
automatic

Starter
Downshift

solenOid
147

Armature
95
Inhlbllor
SWItch
148

Beanngs
96
Kick
down
SWitch
147

Brush
holder
96

Lmkage
mspectIon
and

adjustment
148

Brushes
and
lead
WIre
95
011
checks
147

Cleaning
mspectIon
and

repair
94
Oil

leakage
147

Construcllon
92
TransmiSSion
manual

Disassembly
92

DescnptIon
134

Exploded
View
93

Disassembly
138

Field
COIl
94

Exploded
view
138

Magnetic
SWItch
96
Gear

assembly
exploded
view
139

Magnetic
SWItch

assembly
test
97

Inspection
and

repair
141

Operation
91
Installation
143

Overrunnmg
clutch

96

Reassembly
and

adjustment
142

Reassembly
96
Removal
134