1968 DATSUN 510 handbrake

CHAPTER

TWELVE

DIFFERENTIAL
REAR
AXLE
AND
REAR
SUSPENSION
149

DIfferentIal

Rear
axle
and

suspension

Codspnng

Shock
absorber

Rear

suspensIOn
arm

Rear
axle

shaft
Wheel

beanngs

Seals

Rear

spnng

Axle
case

SpecificatIons

CHAPTER
THIRTEEN

FRONT

AXLE
FRONT
SUSPENSION
AND
STEERING
168

Wheel
hub
and

bearmg

StabilIzer

TenSion
rod

Spnng
and
strut

assembly

Transverse
lInk

Lower
ball

Jomt
Front

suspension
adjustment

Wheel

alignment

Posture

adJustment

Steenng
system

SpeCificatIons

CHAPTER
FOURTEEN

BRAKES
187

Brake

pedal

Master

cylInder

Front
diSC
brakes

Rear
brakes

Front
drum
brakes
Wheel

cylInders

Brake

system
bleedIng

Handbrake

Service
data
and

speCificatIons

CHAPTER
FIFTEEN

BODY
ELECTRICAL
SYSTEM

Wmng

SWitches
and
fuses

Instrument

meters
and

panels

Heater
205

Wmdshleld

wipers

Wmdslueld
washers

Headlamps

WIrIng
diagrams

CHAPTER

SIXTEEN

BODY

223

Front

body
trIm

Bumpers

Hood
lock
control

Doors
Door
locks
and

regulators

Trunk
lId
and

rear

bumper

Seats

Tad

gate

INDEX

235

I

TROUBLESHOOTING

15

5

Stumbling
when

acceleratmg
from
Idle

Check

accelerator

pump
diaphragm
and
Idle

speed
adjustment

6

Engine
mISses
at

hIgh

speed
or
lacks

power

This
mdlcates

pOSSible
fuel
starvatIon
Check

fuel

pump
pressure
and

capacIty
Clean
main

Jet

and
float
needle

valve

7
Black
exhaust
smoke

Black
exhaust
smoke
means
a

badly
ovemch

nuxture
Check
Idle

mIXture
and
Idle

speed
ad

Justment
Check
for
excessive
fuel

pump
pres

sure
or
blocked
return
hne
from
carburetor

to

fuel
tank
Check
for

leaky
float
or
worn
needle

valve

8
ExceSSIve

fuel

consumptIOn

ThIS

may
be
another
mdIcatIon
of

an
ovemch

fuel
mixture
Check
that
automatIc
choke

oper

ates

If
so

eqUIpped
or
that
the
manual
choke

contraIlS
not

being
left
out
Check
Idle
mIXture

and
Idle

speed
Check
for
excessIve
fuel

pump

pressure
leaky
float

or
worn
needle

valve
Make

certam
that

jets
are
the

proper
SIZe

Fuel

Pump
Pressure

Testing

1
Install
a
T

fittmg
m
the
fuel
hue

close
to
the

carburetor

2
Connect
a
fuel

pressure

gauge
to
the

fittmg

WIth
a
short
tube

3
Check
fuel

pump
pressure
as
described

in
the

Fuel

System
chapter

EXHAUST
EMISSION
CONTROL

The

followmg
symptoms
as
ume

you
have
ad

justed
the

Ignition
and
carburetor

to

specdicatIon

and
that

you
have
checked

the
results
on
an

accurate
exhaust

gas
anajyzer

1
CO

content
too
low

Make

sure
Idle

speed
IS
not
too
low
Check
Idle

mIXture

adjustment
too
lean
Check
carbu

retor

Jets
and

channels
Clean
and
or

replace
as

necessary
Check

engme
condition
With
a
com

pressIOn
and
vacuum
test

2
CO
content
too

hIgh

Check
Idle
mixture

adjustment
too

nch
Check

for

dIrty
air
cleaner

and
defectIve

automatIc

choke
If
so

equipped
Check
carburetor

Jets
and
channels
Clean
and
or

replace
as

necessary

Check

engme
condItIon
WIth

compression
and

vacuum
test

3

Hydrocarbon
level
too

hIgh

Check
that

Idle

speed
and
mIXture

adjustments

are

to

specIfication
Check

spark
plug
condItIon

and

gap
Check
breaker

pomts
Check

IgnItIon

tnumg
too

early
Check
mtake

mamfold
for

leaks
Check

valve
clearance
too

small
Check

condItIon

of
valves
With

compressIOn
test

MANUAL
CLUTCH

1

SlIppage

ThiS

is
most

noticeable
when

acceleratIng
m
a

hIgh
gear
at

relatIvely
slow

speed
To

check

slip

page
park
the
car
on

a
level
surface

WIth
the

handbrake

set
ShIft
to
2nd

gear
and
release
the

clutch

as
If

drlVing
off
If
the

clutch
is

good
the

engme
will
slow
and
stall
If
the

clutch

shps
con

tInued

engme
speed
will

gIve
It

away

CAUTION

ThIS
IS
a
severe

test

Perform

only

when

slippage
IS

suspected
not

penodlcally

Shppage
results
from
IDSufliclent
clutch

pedal

free

play
all
or

grease
on
the

clutch
disc

worn

pressure
plate
or
weak

sprmgs
Also
check
for

bIndIng
m
the
clutch
cable

and
lever
arm
which

may

prevent
full

engagement

2

Drag
or

failure
to
release

ThIS

problem

usually
causes
dIfficult

shIftIng
and

gear
clash

espeCially
when

downshIftmg
The

causes

may
be
excessive
clutch

pedal
free

play

warped
or
bent

pressure
plate
or
clutch
dISC
ex

cessive
clutch
cable

guide
sag
and
broken
or

loose
clutch

lmings
Check
conditIOn
of

mam

shaft

splines

3
Chatter
or

grabbing

A
number
of

thmgs
can
cause

tIns
Check

cable

gUIde
sag
and

tIghtness
of
transnusslOn
to
frame

and

engme
to
transmlSslon

mountIng
bolts

Check
for

worn
or

mISaligned
pressure
plate
and

misalIgned
release

plate

4

Other
nOIses

NOISe

usually
mdlcates
a

dry
or
defective
release

bearIng
Check
the

beanng
and

replace
If
neces

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

ENGINE
39

Figure
11
Remove
the
clutch
return

spnng
from

Its

holdmg
bracket
and
the
clutch

operatmg

cylmder
from
the
clutch
withdrawal
lever

19
Disconnect
the

speedometer
cable
from
the

side
of
the
transnnsslOn
as
shown
m

Figure
12

20
Disconnect
the
flat

attachmg
plug
connector

from
the
reverse

lamp
sWitch
on
the

translDlSSlon

housing

21
At
the
transnnsslOn

housmg
disconnect
the

shIft

and
the
select
rods
Remove
the
cross
shaft

assembly
by
remOVIng
Its
bracket
from
the
Side

member

22
DISconnect
the
front
exhaust

pipe
from
the

exhaust
manIfold

by
remoVing
the
two
connect

mg
bolts

23
Disconnect
the
center
exhaust

pipe
from
the

rear
exhaust

pipe

24
Remove
the
front
exhaust

pipe
the

pre
muffler
and
the
center
exhaust

pipe
from
the

vehicle

25
Disconnect
the
dnve
shaft
from
the

matIng

flange
of
the

gear
carner

26
Insert
a

Jack
under
the
transmiSSIOn
and

jack
It

up
Just
a
little
to
remove
some
of
the

tension
from
the
rear
motor
mounts

CAUTION

Use
care
m
the

placement
of
the

lack

head
to

prevent
transmiSSIOn

housmg

damage
A
block

of
wood
can
be
m

serted

between
the

Jack
head
and

transmISSIOn

for

protection
The
block

of
wood
should
be

long
enough
to

span
the
transmiSSion

housmg

27
Remove
the
rear

engine
mountIng
cross

member

by
remoVing
the
bolts

holdmg
the
en

gine
mountIng
msulator
the

mountIng
cross

member
and
the
handbrake

clamp

28
Remove
the
bolts

secunng
the
front

engine

mountmg
msulators
to
the
front
cross
member

NOTE
At
thiS
time
all
Wires
hoses

and

lmkages
should
have
been
dIScon

nected

from
the

engme
and
transmIS

sIOn

Recheck
thiS
and

make
sure
that

no
loose

ends
Will

hamper
actual
en

gme
removal

29

RIg
a
cham

or
cable
hOist
to
the

lifting
eyes

stnngers
located

on
the

nght
front
and
left

rear

of
the

cylmder
head
Take

up
slack
m
the
hOist

30

Figure
13
shows
the

engme
bemg
lifted
Re

move
the

engine
slowly
by
lowenng
the

jack

beneath
the
transnnssion

gradually
until
It
can

@

136
CHAPTER
ELEVEN

5
DIsconnect
and
remove
starter
motor
from

flywheel
housmg
as
descnbe4
In

Chapter
NIne

6

Dls
onnect
handbrake
WIre
at

equalIzer

pIVOt
See

Figure
15
sedan
and

wagon

I

j

7
Loosen
the
two

exhaust
center

p1pe
clamps

and

turn
the

premuffier
complete
With
center

pIpe
to
the
left
as
shown
m

FJgure
16
sedan
and

wagon

f

W

y
I

0
Y
h

0

ilo

8
DIsconnect
front
exhaust
tube
from
exhaust

man1fold

pICk
up

9
Rem

ye
four
bolts
from

companion
flange

of

gear
carner
and
detach

dnve
shaft
See

Figure

17
Seal
the
end
of
rear
extensIon

housmg
to

prevent
011

leakage

1
0
Dlsconn

i
gpeedometer
drive
cable
from

rear
extensIOn
as
shown
In

Figure
18

11
On
models
s

quipped
disconnect
neutral

gear
sWitch
third

gear
sWitch
and
reverse

gear

sWItch
as
shown
in

Figure
19
next

page

f
t

iT
l
t

t

W
12
Refer
to

Figure
20
whIch

IS
an

exploded

View
of

the

gear
shIft
lever
and
control

system

DependIng
on
the
model
dISconnect
the
shift

lever
as
shown

13
Remove
cross
shaft

assembly
from
trans

rmsslOn
case
See

Figure
21

14
Remove
clutch

operating
cylinder
from

clutch

housmg

15
Place
a

Jack
beneath
the

engme
011

pan
and

SuppOFt
the

engme
Do
not

apply
Jack
pressure

144

CHAPTER

ELEVEN

TAANSMISSlON
SERVICE
DATA
AND
SPECIRCATIONS
Table
2

r

General

SpecificatIOns

Gear
Ratlo

1st

2nd

3rd

4th

Reverse

011

capacity

Detail

SpeCIfications

Gear
backlash

Replacement
standard

Gear
end

play

Balk

ring
cone

clearance

Replacement
standard
5
tl
viV

t
O

5
0

If

3657

2558

1419

1000

3638

3
6

pints

Tightening
Torque
ft
Ib

kg
m

Engine
transmission
installation
bolt

Front
cover

transmission
installation
bolt

Rear
extensIon
transmIssion
installation
bolt

Main
shaft

tlghtel
lng
bolt

Companion
flange
tightening
nut

Rear

engine
mount
installation
bolt

Filler

plug

Drain

plug

Back

up
lamp
sWItch

Bottom
cover
bolt

Speedometer

pinion
bolt

Interlock

plug

Operating
lever

Reverse
check

Control
lever
installatIOn
bolt
00020
to
0
0039
In

005
to
0
10mm

o
0079
In

0
20mm

o

0020
to
0
0059
In
0
05
to
0
15mm

00472
to
0
0630
In

1
2
to
1
6mm

00315
In

08mm

174
to
20
2
24
to
2
8

5
8
to
7
2
0
8
to
1
0

10
1
to
130
1
4
to
1
8

57
8t079
5
80to
11
0

72
3
to
101
2
100

to
140

239

to
27
5
3
3

to
38

18
1
to
25
3
25

to
3
5

14
5

to
21

7
20

to
3
0

14

5
to
21
7
2
0
to
3
0

5
8

to
7
2
0
8

to
1
0

2
2
to

2
9
03
to

0
4

123
to
15
2
1
7
to
2
1

22

to
2
9
0
3

to
0
4

14

5
to
21
7
20
to
3
0

13
7
to

15
9
1
9
to
2
2

DRIVE
SHAFf

Descripti

ll

TIie
dnve
shaft

on
the
sedan
and

wagon
is

a

smgle
plece
tubular

steel
unit
The

pick
up
uses

a
two

pIece
umt

Joined
by
a

Journal
assembly

unIversal

Joint
UnIversal

Jomts
connect
the

drive
shaft
ends
to
the
transmissIOn
and
d1f

ferentIal
The

Jomts
consist
of
the

Journal
as

sembly
yoke
sleeve
and

yoke
flange
Figure
40

is
an

explOded
VIew
of
the
dnve
shaft

used
on

the

sedan
and

agon
Figure
41

page
146

shows
the

dnve
shaft
used
on
the

pIck
up

The

pIck
up
has
a

grease
mpple
on
the

dnve

shaft
to
lubncate
the
dnve
shaft

spline
The

sedan
and

wagon
are
not

so

equipped
The
uni

versal

Jomts
shouldebe
removed
and

lubncated

every
24
000

rmles

Removal

1
Release
the
handbrake

j
2
Jack

up
the
rear
of
the
vehIcle
and

support

on
stands

3
Loosen
the
end

clamps
on
the
exhaust

pipe

and
turn
the
exhaust

pIpe
and

premuffier
to
the

left
so
that
dnve
shaft
can
be

removed
sedan

4
Remove
handbrake
rear
cable

adjustIng
nut

from
the

adjuster
DIsconnect
left
hand
cable

from
the

adjuster
sedan

5
DIsconnect

rear

flange

yoke
from
the
com

panIon
flange

by
removmg
the
nuts
and
bolts

See

Figure
42

CAUTION

Be

careful
not
to
let
end

of
dnve

shaft

drop
to

ground
Lower

It

gently

6
Pull
the
dnve

shaft

backwards

away
from
the

transmISSIon
Remove
the
dnve
shaft

as
soon

as
It
IS
clear
of
the
transmISSIon
Make

cert
n
to

support
both
ends
of
the

shaft

duriftgi
mb

sedan
and

wagon
v

4
1tr
l

t

t

CHAPTER
TWELVE

DIFFERENTIAL
REAR
AXLE

AND
REAR
SUSPENSION

The
dIfferential
rear
axle
and
rear

suspen

sIon
dIffer
for
the
various
models
ThIS

chapter

deals
WIth
each

separately

Due

to
the
need
for

SpecIal
tools
and

exper

Ience
to
dIsassemble
and

repaIr
these
unItS
the

followmg
procedures
generally
cover
removal

InspectIon
and

replacement
only
If
mechanIcal

dIfficultIes

eXIst
WIthIn
the
dIfferentIal
and
rear

axle

components
refer
servIce
and

repair
to
a

Datsun
dealer
or

competent
garage

DIFFERENTIAL

SEDAN

The
cast
Iron
dIfferentIal

assembly
used

in

the
sedan
is
shown
in

Figure
1
next

page

Proper
lubncatlOn
of
the

gear
housmg
IS
essen

tIal
Check
lubncant

every
3
000
mlles
and
re

plenISh
as

necessary
Drain
and
refill
lubncant

at
least

every
30

000
miles

Differential
Removal
Sedan

1
DISconnect
handbrake
rear
cable
dnve

shaft

and
axle
dove
shafts

by
removing
bolts
shown

by
arrows
of

Figure
2

2

Place
a

Jack
under
the
dIfferential
and

lift

slIghtly
Remove
nuts
on
both
ends

of
dtfferentIal

mountlng
member
See

Figure
3

3
Remove
four

fixIng
bolts
that
hold
dIfferentIal

to
the

suspensIon
member

DIFFERENTIAL
REAR
AXLE
AND
REAR
SUSPENSION
151

4
Lower
the

Jack
and

r
move
dIfferentIal
from

rear
of
vehIcle
See

Figure
4
After
removal

sup

port
suspensIon
member
wIth

a
stand
to

prevent

distortlon
and

damage
to
the
Insulators

Differential

Inspection
Sedan

The

followmg
mspectIon
can
be
done
WIthout

disassembly
of
the
dIfferential
If
abnormalitIes

or

damage
eXiSts
refer
further

servIce
and

reparr

to

your
dealer

1
Check
the
tooth
contact

pattern
With
lead

oXide
at
two
or
three

pomts
after

removmg
rear

cover
Refer
to

Figure
5
which
shows
the

cor

rect
contact

pattern
If
the
contact

pattern
IS
m

correct

dIsassembly
and

adjustment
of
dIffer

entlalls

reqUIred

CD
TOE

HEEL
DRIVE

SIDE
HEEL
COAST

SIDE

2
Use
a
dIal
mdtcator
to
measure
backlash
be

tween
the
dnve

gear
and

pmIOn
Backlash

should
be

0
0039
to
0
0079
m
0
10
to

o
20mm
Check

all

gear
teeth
for

damage
and

cracks

3
Check
runout
at
the
rear
of
the
dnve

gear

If
the
tooth
contact

pattern
or
backlash

IS
ab
normal
Runout
should
be
less
than
00031

m

0
08mm
See

Figure
6

4
Rotate
the

gears
and
lIsten
for

SignS
of
de

fective

bearmgs
If
noises
are
eVIdent
the
dIf

ferential
must
be
dIsassembled
and

repaired

CD

Diflerentiallnstallation

Sedan

1
Mount
the
dIfferentIal

assembly
to
the
rear

suspensIOn
member

2
FIt
the
dIfferentIal

mountlng
member
to
the

fittmg
hole

by
pushIng
It
forward
with

a
bar

Torque
the

nuts
to
61
ft
lb

8
5

kg
m

3
Install
axle
dnve
shafts
dnve

shaft
and

handbrake

rear
cable

REAR

AXLE
AND
SUSPENSION

SEDAN

Figure
7
and

Figure
8

page
153
are
ex

ploded
dIagrams
of
the
sedan
rear
axle
and

suspensIOn
The

fully
independent
rear

suspen

SIon
IS
a
semI

traIlIng
arm

deSIgn
With
a
sus

penSIOn
member

suspensIOn
arms
coIl

spnngs

and

hydraulIc
shock
absorbers
The
wheel

bearings
are
lIfetime
lubncated

Rear
Axle

and

Suspension
Removal
Sedan

1
Jack

up
the

rear
of
the
veh1cle
and

support

It
on
stands

2
Remove
wheels

3
Refer
to

Figure
9
and
dtsconnect
handbrake

lInkage
and
rerum

sprmg
Remove
tall

pIpe
and

muffler

4
DISconnect
brake
hose
from
brake
tube
Re

move
four
bolts

holdmg
dnve
shaft
to
dIf

ferential

Lower
dnve

shaft

gently
to

ground