1968 DATSUN 510 brake

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

BRAKES
195

@
@

r
@

I

1
Brake
disc
9

Adjuster
wheel

2
Front
brake
shoe
10

Adjuster
scre

assembly
leadmg
11

Adjuster

lead

3
Front
brake
shoe
12
Shim

assembly
trallmg
13
Lock

spring

4
Return

spring
14

Spring
plate

5

Trailing
shoe
return

spring
15
Lock

plate

6
Wheel
cylinder
assembly
16
Shim

7

Adjuster
assembly
17
Rubber
boot

8

Adjuster
housmg

@

j

@@

1
Brake
disc
7

Adjuster
assembly
13
Lock

spring
19

Spring
seat

2
Rear
brake
shoe
8

Adjuster
housmg
14

Sprmg
plate
20
Ant
rattle
spring

assemblies
9
Adjuster
wheel
15
Lock

plate
21
Retamer

3

Upper
return
spring
10
Adjuster
screw
16
Shim
22
Extension
link

i
l

4
Lower
return

spring
11

Adjuster
head
17
Rubber
boot
23
Toggle
lever

5
After
shoe
return

sprmg
12
Shim
18

Anti
rattle

pm
24
Return
spring

6
Wheel
cylinder
assembly

196
CHAPTER
FOURTEEN

WHEEL

CYLINDERS

pICK
UP

Figures
17
and

18
illustrate
the
front
and
rear

wheel

cylinders
used
on
the

pick
up
Mainte

nance

procedures
are

essentially
the
same
as

specIfied
for
the
sedan

wagon

BRAKE
SYSTEM

BLEEDING

Brakes

require
bleeding
whenever
air
enters

the

system
lowering
the
effectIve

braking
hy

draulic

pressure
This
can

happen
when
the

@

@

@

@

D

1
Wheel

cylmder
hOUSing

2
Piston

3
Piston

cup

4
Piston
head

5
Dust
cover
6
Connector

7

Connector
bolt

8

Paclang

9
Bleeder

screw

10
Bleeder

cap
master

cylinder
or
wheel

cylinders
are
serviced

or
If
the
fluid
m
the
reservoir

TWlS

dry
Air
can

also
enter

through
a

leaky
brake
line
or

hose

Find
the

leaky
line
or
hose

and

replace
it
before

bleeding

When

handling
brake
fluid
be
careful
not
to

get
any
on
the
brake
shoes
or

body
paint
Brake

shoes
will
be

permanently
damaged

requiring

replacement
Body

pamt
can
be

damaged
unless

you
Wipe
the
area
with
a
clean
cloth
immedi

ate
then
wash
it
with
a

soapy
solution

r

@

@

1
Wheel

cyhnder
hOUSing

2
Piston

3
Piston

cup

4
Dust
cover

5

Snap

ring

6
Connector

7

Packmg

8
Connector

bolt

9
Bleeder
screw

10
Bleeder

cap

@

BRAKES
IV

197

I
Ensure
that
the
brake

flUid
reservOir

at
the

master

cylmder
IS
full

and
that
the
vent

m
the

cap
is

open

2
Connect

a

plastIc
or

rubber
tube
to
the

bleeder
valve

on
the

nght
rear
wheel

Suspend

the
other
end
of
the

tube
m
a

Jar
or
bottle
filled

With
a
few
Inches
of
clean

brake
flwd

During
the

remaInIng

steps
keep
thiS

end

submerged
at
all

times
and
never
let
the
level

in
the

brake
flUid

reservoir

drop
below
full

3

Open
the

bleeder
valve
on
the

nght
rear

wheel
about

one
turn
Have
an
asSistant

depress

the
brake

pedal

slowly
As
soon
as
the

pedal
is

all
the

way
down

close
the
bleeder
valve
and
let

the

pedal

up
Repeat
thiS

step
as

many
tImes
as

necessary
until

pure
flUid
WithOUt
au
bubbles

comes
from
the

tube

4
Bleed
the

remammg
wheels
m
the

followmg

order
left
rear

nght
front
and
left
front

Keep

checkmg
the

brake
flUid
reservoir
to
make

cer

tam
It
doesn
t
TWl

out
of
flUId

5
When
all
wheels

are
bled
fill
the
reservOIr
to

the
full
level

Never
reuse
the
brake
flwd

bled

from
the

system
or

any
that

has
been

lymg

around
Start

With
a
fresh
contaIner

HANDBRAKE

Figures
19
next

page
and
20

page
199

are

exploded
views
of
the
handbrake

system
used
on

the

sedan
and
statIon

wagon
respectively
F1gDre

21

page
200

shows
the

pick
up
handbrake

system

Front

Cable
Removal
Sedan
and

Wagon

I
Release

handbrake

completely
Disconnect

the
front

cable

by
removmg
the
cleVIS

pm
that

connects
to
the
handbrake
control
stem

2
Screw
out
the

adJusting
nut

from
the

rear

end
of
the
front
cable
Disconnect
the
cable
from

the
center
lever

4
Remove
the

hand
brake

cable

clamp
from

under
the
verucle

Pull
out
the
lock

plate
fixmg

the
front

cable
to
the
front
cable
retamer
Ex

tract

the
front
cable

5

Unfasten
the
front
cable
outer

casing
from

the
bracket
Remove
the
cable

Front
Cable
Removal

Pick
up

I

Loosen
handbrake
2
Remove
cleVIS

pm
and

separate
cable

from

outer
lever
See

Figure
22

p

3
Remove
cleVIS

pm
and

eparate
cable
from

front
lever
Removecable

4
Remove
center
cable
from

control

levers

by

removmg
cleViS

pms

Rear
Cable
Removal
Sedan

I
Remove

adJusting
nut
from

adJuster
DIScon

nect
left
hand
rear
cable

from
handbrake
ad

Juster

2
Pull
out
lock

plates
see

Figure
23
and
re

move
cleVIS

pms
that

connect
rear
cable
With

rear
wheel

cylJnder
levers
Remove
cable

Rear
Cable

Removal

Wagon

1
Remove
both

cleVIS

pins
at
the
ends
of
the

rear
cable

2
Remove
cable

BRAKES

ZOI

Cross
Rod

Removal

Wagon

I
Remove
the

pull
off

spnngs
at
each
end
of

the

cross
rods

2

RelI
ove
clevis

pms
and

cross
rods

Rear
Cable

Removal

Pick
op

1
Remove

cleVIS

pm
and

disconnect

equalizer

from

equal1zer
link

2
Remove
lock

plate
1
and
cable

spring
2

as
shown

ill

Figure
24

3
Remove
both

rear
brake
drums
DISConnect

rear
cable
from

toggle
lever
3

Separate
cable

connecting
flange
4
from
brake
dIsc
See

Figure
25

4
Remove
rear
cable

Handbrake

Inspection
and

Repair

1

Inspect
all

cables
and

parts
for

damage
ex

cessive

elongation
and

general
wear

Replace
as

reqUlred
I

2

Inspect
ratchet

pawl
and
teeth
on

control

stem
for
excessive

wear

Replace
as

reqUIred

3
Check

springs
for

weakness

Replace
as

reqUIred

Handbrake

Installation

I

Install

parts
of
the
handbrake

system
m
the

reverse
of

removal
Make
certam
all

connections

are

tight

2
Lubncate
all

slIdmg
parts
With

muItl

purpose

grease

Front
Brake

Adjustment
Sedan
and

Wagon

AdJustment
of
the

front
dIsc
brake
units
18

not

reqwred
as
it

18
made

automatIcally
Re

place
the
front
dISC
brake

pads
and
rebwld
the

pISton
assemblJes
If
the

brakes
are

defective

Front
Brake

Adjustment
Pick

up

I
Refer
to

Figure
26
Jack

up
vehicle
to
lIft

wheel

requiring

adJustment

2

Remove
rubber
boot

from

brake
disc

3

Lightly
tap
adJuster

housmg
and
move
It
for

ward
Turn

adJuster
wheel

with
a
screwdriver

and

spread
brake
shoes

Stop
turnmg
adJuster

wheel
when

a

considerable

drag
is

felt
on
brake

drum

NOTE
For

both

left
and

right
brakes

brake
shoes

spread
when

adJuster

wheelIS

turned
downward

4
Return

adJuster
wheel
12
ratchet
teeth
to

obtam
correct
clearance

between
brake
drum

and

shoes

5

Turn

brake
drum
to
make

sure
that
drum

turns
Without

draggmg
If

draggmg
exists

readJust

202
h

l
CHAPTER

FOURTEEN

Rear

Brake

Adjustment
Sedan

and

Wagon

I
Jack

up
the
rear
wheel

2
Release
the

handbrake

completely

3

Figure
27
shows

the

adJustmg
screw
for
the

sedan

Figure
28
for
the

wagon
Depress
the

I
rake

pedal
several
tImes
and
turn
the

adJusting

screw

clockWise
untIl
the
drum

cannot
be
moved

I

by
hand

4
Return

adJusting
screw
counterclockwISe

untIl
the

shoes
are

Just
clear
of
the

drum
ThIS

should
be

about
three
notches

5
Rotate

the
drum
to
see
If
the
shoes

are

draggmg
It
so

readJust
untIl
the

drag
IS

gone

Rear
rake

Adjnstment

pick
np

I
Jack

up
rear
wheel

2
Release
handbrake

AdJust
the
wheel

usmg

the

same

procedure
given
for
the
front

wheel

See

Figure
29
Handbrake

Adjnstment
f

I
Release

handbrake
and

adJust
rear
brakes
as

preViously
descnbed

2

AdJust
the
front

and
rear
handbrake
cable

by

adJustIng
nuts

shown
m

Figure
30
The
stroke

of
the
handbrake

control
stem
should
be
3
346

to
3
740
m

85
to
95mm
sedan

only

3
Refer
to

Figure
31

AdJust
the
front
cable

by

turnmg
the

adJusting
nut
so
that
the

control

stem
stroke

IS
4
330
to
4724
m
110
to

120mm

wagon

only

BRAKES

203

4

32
shows
the

adJusting
pomts
for
the

pick
up
With

rear
cable
stretched

adJust

equal

IZer
link

With

adJust
screw
A

so
that

L

dimensiOn

Is
1
161
m
295mm

Lock

adJust

screw
wlth

locknut

5

AdJust
front
cable

adJust
screw

8
so
that

control

stem
stroke
IS
3

15
to

394
m
80
to

100mm

Lock

adJust
screw
With

lock
nut

SERVICE
DATA
AND
SPECIFICATIONS

Table
1

prOVides
the

servIce
data
and

specm

catIons
for
the
sedan
wa

n
and

pick

up

Table
1
BRAKE
SERVICE
DATA

AND
SPECIRCATlONS

Brake

Pedal

m

Pedal

free

height

Full
stroke
of

pedal
ead

Master

Cylinder

Inner
diameter

MaXImum
clearance
between

cylinder
and

piston

Wheel

Cylinder

Inner
diameter
front

Inner
diameter

rear

MaXimum
clearance
between

cylinder
and

piston

Brake
Drum
and
Rotor

Drum
brake

Inner
diameter
front

DISC
brake
outer
diameter

front

Drum
brake
outer
diameter
rear

MaXimum
allowable

out
of
round

LImit
of
drum

reconditioning

Inner

diameter

MaXimum
rotor

runout

MInimum
rotor
thickness

A

Lining
DImenSion

Front
WIdth
x
thIckness

x

length

Front
dISC

pad

Width
x
thickness

x

length

Rear
Width
x
thickness
x

length

Total
friction
ar
a
drum

type

Total
friction

area
front
diSC
Sedan
Wagon
Pick

up

8

150
In

207mm
533m
135
5mm

5
709
In

145mm

f

o
75
In
1905mm
o
75
In

1905mm

00051
In

0
l
mm

o
006
In
0
15mm

i

20m
508mm

08125
m
20
64mm

o
8
2
In

20
64mm
o
8125
In

20
64mm

il

0007
In

0
18mm

0006
In
015mm

1000
In
254mm

9
130
In
232mm

900
In
228

imm
1000
In
254mm

o
002
m

0
05mm
o
008
In
0
20mm

9
039
In
229
6mm
1004
m
255mm

00024
In

006mm

0331
In
84mm

18x02x96m

45
x

4
5
x
244mm

1
563
x
0
354
x
3
386
In

39
7
x
9
x

86mm

1
575
x
0
18
x
8
642
m

40
x
4

5
x
219

5mm

54
4

sq
In

351

sq
cm
18x02x96m

45

C
4
5
x
244mm

682sq
m

440

sq
cm

1777

sq
In

1142

sq
cm

continued

204
CHAPTER
FOURTEEN

Table
1
BRAKE
SERVICE
DATA
AND
SPECIFICATIONS
continued

Sedan
Wagon
Pick

up

Tightening
Torque
ft
lb

Ikg
m

Fulcrum

pm
25
3
to
28
9
253to289

3
5
to
4
0
3
5
to
4
0

Master

cylinder

mounting
bolts
15
2
to
18
1
152
to
18

1

2
Ito
2
5
2
1
to
2
5

Front
brake
wheel
cylinder
108
to
152
30

4
to
37

6

1
5
to
2
1
4
2
to
5
2

Rear
brake
wheel

cylinder
10
8

to
15
2
10
8
to
13
0

1
5
to
2
1
1
5
to
1
8

Rotor

fixing
bolts
28
2
to
38
3

39to53

Brake

hose
to
wheel

cylinder
123
to
14
5
123

to
14
5

1
7
to
2
0
1
7
to
2
0