1968 DATSUN 510 brake rotor

16

CHAPTER

TIlREE

sary
Also
check
all

parts
for

mlSaltgnment
and

uneven
wear

TRANSMISSION

1

Difficult
to
mesh

gears

Make
certam
the

clutch

pressure
plate
and
re

lease

beanng
are
m

good
condItion
The
trouble

can
be

caused

by
worn

gears
shaft
and
or
bear

mgs
DISassemble
and

repaIr
as

requIred
Also

can
be
caused

by
msufficlent

operatmg
stroke

due

to
worn
or
loose

sltdmg
parts
or
a
defective

synchronIZer
DIsassemble

carefully

InSpect
and

replace
as

requIred

2
Gears

slip
out

of
mesh

Generally
thIS
trouble
occurs
when

the
mterlock

plunger
check
ball
and

or

spnng
IS
weakened

or
worn
The
trouble
can

also
be
caused

by
worn

fork
rod
ball

groove

damaged

bearings
or
dam

aged

gears
DIsassemble

carefully
mspect
and

replace
as

required

3
NOIse

If
nOISes
are
heard

wIth
the

engme
idlmg
and
the

clutch

disengaged
the
nOIse
IS

probably

conung

from
the

transmISSIOn
Several
Items

can
cause

nOISes

either

smgly
or
m
combmatIon

Check
the

qualIty
and

quantity
of
lubrIcant

in
the
trans

mISSIon

Replace
or

replenISh
as

necessary
Worn

bearIngs
wIll

usually
produce
a

lugh
humming
at

hIgh
speed
and

a

cycltc
knockIng
sound
at
low

speed
Worn

or

damaged
splInes
and

bushmgs

will
also
cause

nOIse

BRAKES

1
Brake

pedal

goes
to

floor

There

are
numerous
causes
for
thIS

includIng

excessIvely
worn

Itnmgs
aIr
in
the

hydraultc

sys

tem

leaky
brake
lmes

leaky
wheel

cylmders
or

leaky
or
worn

master

cylmder
Check
for
leaks

and
thIn
brake

linmgs
Bleed
and

adjust
the

brakes
If

thIS
doesn
t
cure
the
trouble

rebwld

wheel

cylmders
a
nd
or
master

cylmder

2

Spongy

pedal

Normally
caused

by
aIr
m
the

system
blee
d
and

adjust
the
brakes

3

Brakes

pull

Check

brake

adjustment
Also
check
for
contam
inated

brake

Itmngs
from
leaks

leaky
wheel

cyltnders
loose

caltpers
frozen

or
seIZed

pIstons

and
restrIcted
brake
lmes

or
hoses
In
addItion

check
front
end

alignment
and

suspensIOn
dam

age
such
as
broken
front

or
rear

sprmgs
shocks

etc
Check
condItIon

of
tIres

4
Brakes

squeal
or
chatter

Check
brake

lmmg
thickness

and
brake
drum

roundness
Ensure

that
the
shoes
have
cham

ferred
ends

and
are
not
loose

Inspect
the
condI

tion
of

the
rotors
on
the
front
wheel
dISC

brakes

to
make

certain

they
are
not
scored

or

damaged

Clean

away
all
dIrt
on
shoes

pads
rotors

or

drums

5

Draggmg
brakes

Check

brake

adjustment
includmg
handbrake

Check
for
broken
or

weak
shoe
return

springs

swollen
rubber

parts
due
to

unproper
brake
flUId

or
other
contammatIon

Clean
or

replace
de

fectIve

parts

6
Hard

pedal

Check
brake

linmgs
for

contammation
Also

check
for

restrIcted
brake
lines

and
hoses

7

High
speed
fade

Check

for
dIstorted
or
out
of
round
drums

and

contamInated
brake

lmmgs
Make

certam
the

recommended
brake
flUId
IS

used
Dram
entIre

system
and
refill
If
In
doubt

8

Pulsatmg
pedal

Check
for
dIStorted
or
out
of
round
drums

or

rotors
Check
for

excessIVe
brake

dISC
run
out

STEERING
AND

SUSPENSION

NOTE
Unusual

steermg
pullmg
or

wandermg
IS

usually
caused

by
bent

or
otherwise

mIsaligned

suspenszon

parts
Because

of
the

speCialized
equIp

ment

reqUired
to
evaluate
and

correct

these

faults
It
IS
recommended

t
tat

servIce
to

the

steermg
and

suspension

system
be

referred
to

your
Datsun

dealer

oca

quallfied
specrallst
m

thiS

field

1
VibratIOn

felt
m

steermg
wheel

VIbratIon
can
be
caused

by
several

thmgs
includ

ing
lll1proper
aIr

pressure
m
tIres

uneven
wear

CHAPTER
THIRTEEN

FRONT
AXLE
FRONT

SUSPENSION

AND
STEERING

A
strut

type
front

suspension
IS
used
on

sedans
and

wagons
The
shock
absorber
and
the

spmdle
are
a

smgle
urnt
which
is

supported
by

a
coIl

spnng
on
the

upper
end

and

by
the
trans

verse
lInk
on
the
lower
end

Figures
1
2
nnd
3

are

exploded
dIagrams
of
the
axle
and

suspen

SIon

system
used

FIgure
1
Illustrates
the
axle

Figure
2
shows
the
sedan

suspenSlOn
and

FIgure

3
covers
the

wagon

Front

suspensIOn
on
the

pIck
up
IS
a
double

wIShbone

mdependent
deSign
which
uses
torsIon

bars

Figure
4
IS
a
cross
sectional
view

WHEEL
HUB
AND
WHEEL
BEARING

SEDAN
AND

WAGON

Wheel
Hub
nnd
Wheel

Bearing
Removal

Sednn
aud

Wagon

1
Jack

up
the
front
of
the
vehicle
and

support

It
on
stands

2
Remove
the
wheels

3
Detach
brake
hose
connector
at
frame

4
Remove

calIper
fiXlng
bolts
and
then

cahper

See

Figure
5

5
Remove
hub

cap
cotter

pin
and
front

spindle

nut
See

Figure
6

6
Remove
front
wheel

bearmg
washer
Detach

front
wheel
hub
and
rotor
ft

V

0

y

F
I

I

J

j

0
l
l

4

f

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

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

INDEX

A
Inspection
and

repair
191

Air
cleaner
Pad

replacement
190

Exploded
views
63
64
Piston
seal

replacement
193

Removal
and

replacement
62
Reassembly
and
installation
193

Removal
190

Air

pump
40

Brakes
front

pick
up

Alternator

Brushes
104
Adjustment
201

Diode
103
Exploded
View
195

Disassembly
98
ServiCing
194

SpecdicatIons
194
203
204

Exploded
Views
41
99

Brakes
rear

pick
up

Inspection
and

repair
101

Adjustment
202

Output
checks
104

Exploded
View
195

Reassembly
104

Servicing
194

Removal
40
98

Brakes
rear
sedan
and

wagon

Rotor
102

Adjustment
202

Stator
102

Exploded
view
194

Axle
removal

pick
up
175

Inspection
and

repair
193

Reassembly
194

B
Removal
and

disassembly
193

Breaker

points
110

Ball

JOint
lower
sedan
and

wagon
174
Bumpers

Battery
Exploded
view
front

pick
up
223

Inspecllon
aiii
I

servicing
21
Exploded
View
front
sedan
and

wagon
224

SpeCific
gravity
21
Exploded
view
rear
sedan
230

Body
Exploded
view
rear

wagon
231

Body
Irlm
and

bumpers
223
224

Door
lock
and

regulator
225

C

Doors
225

Hood
lock
control
225
Camshaft

Seats
228

DeSCription
34

Tail

gate
228

Exploded
view
37

Trunk
hd
and

bumper
228

Inspection
48

Brake

pedal
Reassembly
54

Inspection
and

repair
187

Sprocket
53

Installation
188

Tlmmg
chain
57

Removal
187
Carburetor

Brakes
Cleaning
and

inspection
75

Adjustment
201
202
Dash

pot
adjustment
71

Bleeding
196

DesCription
37
69

Brake

pedal
187
Disassembly
71

Front
diSC
sedan
and

wagon
190
193

Exploded
Views
74
75

Front
drum

pick
up
194
Fuel
level

adjustment
69

Handbrake
197
201

Idhng
adjustment
69

Master

cyhnder
188
Interlock
valve
70

Rear

pick
up
194

Reassembly
76

Rear

sedan
and

wagon
193
Removal
40
71

SpeCifications
and
service
data
203
204
Sectional
view
69

Troubleshooting
16

Throttle
valve
70

Wheel

cyhnders
pIck
up
196
Charging
system

Brakes
front
diSC
sedan
and

wagon
Troubleshooting
12

Adjustment
201
Choke
and
accelerator

Disassembly
191

Disassembly
and

installation
82

Exploded
view
192

Exploded
view
83