FOUR
SPEED
GEARBOX
Removal
and
Installation
The
removal
and
installation
procedures
for
the
four
speed
gearbox
are
similar
to
those
previously
described
for
the
three
speed
gearbox
However
the
floor
mounted
gear
lever
must
be
removed
from
the
controllevef
bracket
in
addition
to
the
operations
already
detailed
FOUR
SPEED
GEARBOX
Dismantling
Drain
the
oil
from
the
gearbox
Remove
the
dust
coveT
and
release
the
spring
securing
the
clutch
withdrawal
lever
Remove
the
withdrawal
lever
and
release
bearing
from
the
clutch
housing
as
described
in
the
section
CLurCH
Remove
the
clevis
pin
securing
the
striking
rod
to
the
control
lever
Remove
the
speedometer
drive
pinion
assembly
and
with
draw
the
rear
extension
housing
Disengage
the
striking
rod
from
the
selector
rod
gates
Remove
the
gearbox
covers
See
Figs
F
26
and
F
27
Unscrew
the
three
detent
ball
plugs
and
remove
the
spriags
and
detent
balls
Drive
out
the
pins
securing
the
selector
forks
to
the
rods
and
withdraw
the
forks
and
rods
Lock
the
main
shaft
by
moving
the
first
second
and
third
fourth
coupling
sleeve
into
gear
at
the
same
time
and
release
the
ffiainshaft
nut
Remove
the
countershaft
and
the
gear
cluster
together
with
the
two
needle
roller
bearings
and
spacers
Remove
the
snap
ring
holding
the
revep
e
idler
gear
and
withdraw
the
reverse
idler
gears
and
shaft
Fig
F
28
Take
off
the
bolts
securing
the
mainshaft
bearing
retainer
to
the
gearbox
case
Fig
F
29
Withdraw
the
mainshaft
assembly
Fig
F
30
and
the
main
drive
shaft
The
mainshaft
can
be
dismantled
in
the
following
manner
Release
the
third
fourth
synchronizer
unit
snap
ring
and
with
draw
the
hub
complete
with
coupling
sleeve
Remove
the
third
speed
gearwheel
and
the
needle
roller
bearing
from
the
main
shaft
Take
off
the
mainshaft
nut
and
locking
plate
Remove
the
speedometer
drive
gear
with
the
retaining
ball
Withdraw
the
mainshaft
reverse
gear
and
the
hub
Press
off
the
mainshaft
bearing
complete
with
the
bearing
retainer
Remove
the
thrust
washer
and
the
first
speed
gear
together
with
the
needle
roller
bearing
taking
care
not
to
lose
the
small
baU
used
to
locate
the
thrust
washer
Slide
off
the
first
speed
gearwheel
bush
Withdraw
the
first
second
synchronizer
and
hub
Remove
the
second
speed
gearwheel
and
needle
roller
bearing
FOUR
SPEED
GEARBOX
Installation
Refer
to
the
instructions
given
for
the
three
speed
gearbox
and
to
Technical
Data
for
the
specifications
applicable
to
the
different
gearboxes
FOUR
SPEED
GEARBOX
Assembly
Assembly
of
the
gearbox
is
similar
to
the
procedures
previously
described
for
the
three
speed
gearbox
with
the
following
exceptions
When
assembling
the
main
drive
gear
bearing
on
the
shaft
insiall
the
spacer
and
select
a
new
snap
ring
to
eliminate
all
end
float
between
bearing
and
snap
ring
Snap
rings
are
available
in
five
thicknesses
from
1
52
1
77mm
0
06
0
07
in
The
assembly
procedures
for
the
Warner
type
synchronizers
are
similar
to
the
instructions
previously
described
for
the
three
speed
gearbox
Refer
to
THREE
SPEED
GEARBOX
Assembly
for
further
details
To
assemble
the
Servo
F4C63
type
synchronizers
proceed
as
follows
Place
the
gear
on
a
clean
flat
surface
and
install
the
synchronizer
ring
on
the
inner
side
of
theclutch
gear
Fit
the
thrust
block
into
place
as
shown
in
Fig
F
31
Place
the
anchor
block
and
brake
band
into
position
and
fit
the
circlip
into
the
groove
in
the
gear
to
secure
the
synchromesh
assembly
When
assembling
the
mainshaft
select
a
snap
ring
which
will
give
an
end
float
between
0
05
0
15
mm
0
002
0
006in
to
the
third
speed
gearwheel
Snap
rings
are
available
in
five
sizes
from
1
40
mm
0
0551
in
to
1
60
mm
0
0630
in
thick
ness
Tighten
the
locknut
at
the
rear
of
the
mainshaft
to
a
torque
reading
of
7
1
kgm
51
87Ib
ft
Assemble
the
reverse
idler
gear
as
shown
in
Fig
F
32
The
reverse
idler
driven
gear
3
should
be
placed
on
the
end
of
the
reverse
shaft
1
with
the
longest
spline
and
retained
with
a
suitable
snap
ring
2
Install
the
reverse
shaft
and
gear
assembly
into
the
gearbox
case
from
the
rear
with
the
thrust
washer
4
between
the
gear
and
the
case
Fit
the
thrust
washer
5
and
idler
gear
6
18
teeth
and
secure
with
a
suitable
snap
ring
2
The
end
float
of
the
gear
should
be
checked
and
adjusted
to
0
1
O
3mm
0
004
0
012
in
by
selecting
a
suitable
snap
ring
2
Five
thicknesses
of
snap
rings
are
available
from
I
lmm
0
043in
to
1
5mm
0
06in
See
Technical
Data
for
F4W63
and
F4C63
gearboxes
Adjust
the
counter
gear
end
float
to
0
05
0
15
mm
0
002
0
006in
by
selecting
a
thrust
washer
of
the
required
thickness
Thrust
washers
are
available
in
five
thicknesses
from
2
40
2
60
mm
0
094
0
102
in
When
assembling
the
selector
mechanisms
Fig
F
33
fit
the
first
second
selector
forks
I
and
the
third
fourth
selector
forks
2
onto
the
coupling
sleeves
and
insert
the
first
second
fork
rod
3
Fit
an
interlock
plunger
4
and
the
third
fourth
speed
selector
rod
5
Do
not
forget
the
interlock
pin
7
A
section
through
the
selector
and
interlock
mechanism
is
given
in
Fig
F
34
Install
an
interlock
plunger
6
and
assemble
the
reverse
selector
fork
8
and
fork
rod
9
Secure
the
selector
forks
to
the
rods
with
the
retaining
pins
10
Place
a
check
ball
and
spring
into
each
of
the
holes
and
screw
the
plug
down
to
a
torque
reading
of
1
7
2
1
Jegm
12
3
15
2
Ib
ft
after
coating
the
threads
with
sealing
com
pound
Install
the
rear
extension
housing
engaging
the
striking
rod
with
the
fork
rod
gates
and
tighten
the
housing
bolts
to
a
torque
reading
of
1
6
2
5
kgm
12
18Ib
ft
Fit
the
front
and
bottom
covers
and
tighten
the
bolts
to
a
torque
reading
of
1
1
1
8
kgm
8
13Ib
ft
57
inter
lli
r@
ig
F
28
Re
oving
the
reverse
idler
gear
q
F
8
F
27
View
of
the
four
speed
gearbox
with
front
cover
removed
F
8
F
29
Removing
the
mainshaft
bearing
retainer
Fig
F
30
Withdrawing
the
mainshaft
assembly
CD
1ib
1
@
II
c
I
@
d
I
Q
n
j2
JJ
I
0
6
r
7
1
L
l
Hv
9
1l
ij07
u
1
1
v
1
ISland
2nd
selector
fork
5
Fork
rod
2
3rd
and
4th
selector
fork
6
Inter
ock
phmgtr
3
Fork
rod
7
Intulock
pin
4
Interlock
plunger
8
Revene
selLetor
fork
9
Fori
rod
10
Retaining
pin
Fig
F
33
Assembly
of
the
selector
forks
1
17uu
t
block
2
md
bruke
3
Synchro
rint
4
Anchor
block
5
Circlip
6
Band
b
ke
r
1
R
nt
shaft
SntJpring
3
R
idler
driving
geor
UT
4
Thrust
washer
5
1
hnat
washer
6
Idlergeor
18T
Fig
F
32
Reverse
idler
gear
F
8
F
31
Syncbromesh
assembly
3rd
4th
Rod
Fig
F
36
Removing
the
steering
wheel
Fig
F
34
Section
tIuough
the
gearbox
showing
the
inlerlock
mechanism
58
THREE
SPEED
GEARBOX
GEARCHANGE
CONTROL
LINKAGE
Fig
F
35
As
previously
described
the
three
speed
gearbox
is
equipped
with
a
steering
column
gearchange
linkage
system
which
incorporates
a
collapsible
control
rod
when
combined
with
the
collapsible
type
of
steering
column
assembly
The
gearchange
linkage
can
be
removed
and
inspected
in
the
following
manner
Remove
the
steering
wheel
Fig
F
36
and
take
off
the
steering
column
shell
cover
Remove
the
turn
signal
and
lighting
switch
Fig
F
37
These
removal
details
can
also
be
found
in
the
section
STEERING
Remove
the
C
washer
I
in
Fig
F
38
and
the
washer
then
remove
the
upper
support
bracket
by
releasing
the
locating
bolt
and
screw
The
control
rod
insert
with
bush
and
return
spring
can
now
be
removed
Remove
the
snap
and
gear
lever
pivot
pin
and
withdraw
the
gearlever
Remove
the
cotter
pin
plain
washer
and
spring
washer
and
disconnect
the
shift
rods
from
the
gear
selector
levers
Fig
F
39
Unscrew
the
bolts
securing
the
lower
support
bracket
and
the
clamp
Remove
the
clamp
and
gear
change
lever
retainer
Remove
the
second
third
speed
selector
lever
the
lower
support
bracket
and
the
first
reverse
selector
lever
from
the
control
rod
Withdraw
the
control
rod
Disconnect
the
gear
change
rods
by
removing
the
cotter
pins
and
remove
the
cross
shaft
bracket
from
the
side
member
Withdraw
the
cross
shaft
assembly
Fig
F
40
Examine
the
components
for
signs
of
wear
and
damage
and
replace
if
necessary
Installation
is
a
reversal
of
the
removal
procedure
noting
the
following
points
Take
care
not
to
strike
or
apply
a
load
to
the
collapsible
type
of
control
rod
or
the
rod
may
be
damaged
The
rod
should
not
be
slack
in
the
axial
direction
when
installed
and
must
be
removed
if
slackness
is
detected
Coat
the
sliding
surfaces
with
grease
before
assembling
them
Acijusting
Set
the
gear
lever
to
the
neutral
position
and
temporarily
connect
the
trunnion
on
the
lower
support
bracket
to
each
rod
Fig
F41
Set
the
rod
on
the
lever
so
that
the
neutral
adjustment
grooves
on
the
upper
surface
of
the
lower
support
bracket
are
aligned
with
the
grooves
on
each
lever
When
the
adjustment
is
completed
operate
the
gear
lever
to
select
each
gear
and
make
sure
that
the
lever
can
be
moved
smoothly
and
positively
AUTOMATIC
TRANSMISSION
Gearchange
control
linkage
The
automatic
transmission
gear
change
control
linkage
can
be
removed
in
a
similar
manner
to
the
three
speed
gearbox
linkage
Carry
out
the
operations
previously
described
under
the
relevant
heading
as
far
as
the
removal
of
the
gear
lever
and
proceed
as
follows
Disconnect
the
upper
selector
rod
from
the
selector
lever
by
removing
the
cotter
pin
plain
washer
and
lock
washer
See
Fig
F
42
Remove
the
speed
range
position
plate
the
snap
ring
at
the
lower
end
of
the
control
rod
and
unscrew
and
remove
the
lower
support
bracket
Release
the
locking
screw
and
with
draw
the
selector
lever
assembly
Withdraw
the
control
rod
disconnect
the
selector
rods
and
remove
the
cross
shaft
bracket
and
cross
shaft
assembly
Clean
all
parts
and
repair
or
renew
any
part
which
is
worn
or
damaged
Installation
is
a
reversal
of
the
removal
procedure
noting
the
following
points
Coat
all
the
sliding
surfaces
with
chassis
grease
prior
to
assembling
Set
the
converter
side
lever
and
the
gear
lever
in
the
neutral
position
Install
the
upper
selector
rod
to
the
selector
lever
and
adjust
the
gear
position
plate
to
give
a
clearance
of
0
5
I
Omm
0
02
0
04
in
between
the
selector
lever
stop
pin
and
the
position
plate
The
adjustment
can
be
obtained
by
turning
the
selector
rod
adjusting
nuts
Finally
tighten
the
nuts
on
each
side
of
the
trunnion
S9
Gearbox
mode
Gearchange
type
Gear
ratios
I
st
gear
2nd
gear
3rd
gear
4th
gear
Reverse
Num
ber
of
teeth
on
mainshaft
Drive
gear
3rd
speed
2nd
speed
1st
speed
Reverse
Num
ber
of
teeth
on
counter
shaft
Driven
gear
3rd
speed
2nd
speed
1st
speed
Reverse
Reverse
idler
gear
Speedometer
Drive
gear
Driven
gear
Technical
Data
GENERAL
SPECIFICATIONS
R3W65
L
F4C63
F4W63L
Column
change
Floor
change
3
263
1
3382
1
1
645
I
2
013
1
1
000
1
1
312
1
1
000
1
3
355
I
3
364
1
19
22
27
25
30
31
36
34
39
3N71B
iFloor
change
Column
change
2
458
1
1458
1
1
000
1
2
098
1
30
31
29
24
21
15
15
16
14
16
18
5
19
or
17
16
CLEARANCES
AND
PLAYS
Model
R3W65L
F4W63L
Mainshaft
end
float
0
0
19mm
0
0
008
in
0
08
0
29mm
0
003
0
0
II
in
Max
mainshaft
end
float
0
20mm
0
008
in
0
30mm
0
012
in
Countershaft
end
float
0
04
0
12mm
0
002
0
005
in
0
05
0
15mm
0
002
0
006
in
Max
countcrshaft
end
float
0
20mm
0
008
in
0
20mm
0
008
in
Reverse
idler
gear
end
float
0
20
0
40mm
0
008
0
016
in
0
10
0
30
mm
0
004
0
012
In
Max
idler
gear
end
float
0
50mm
0
020
in
0
50mm
0
020
in
Gearwheel
end
float
I
st
speed
gearwheel
0
20
0
30mm
0
008
0
012
in
0
05
0
15mm
0
002
0
006
in
2nd
speed
gearwheel
0
20
0
30mm
0
008
0
012
in
0
05
0
15mm
0
002
0
006
in
3rd
speed
gearwheel
0
05
0
15mm
0
002
0
006
in
Gear
backlash
all
gears
0
05
0
20mm
0
002
0
008
in
0
05
0
20mm
0
002
0
008
in
Oearance
between
fork
and
coupling
sleeve
0
15
0
30mm
0
006
0
012
in
0
15
0
30mm
0
006
0
012
in
Mallshaft
run
out
0
15mm
0
006
in
0
25mm
OmO
in
Model
F4W63
and
F4663
R3W65
Gear
backlash
all
gears
0
05
0
14mm
0
002
0
0055
in
0
05
0
14mm
0
002
0
0055
in
Gearwheel
end
float
1
st
speed
gearwheel
0
05
0
15mm
0
002
0
0059
in
0
05
O
22mm
0
002
0
0087
in
2nd
speed
gearwheel
0
05
0
15mm
0
002
0
0059
in
0
10
0
22mm
0
0039
0
0087
in
3rd
speed
gearwheel
0
05
0
15mm
0
002
0
0059
in
Max
countershaft
end
float
0
05
0
15mm
0
002
0
0059
in
0
04
0
12mm
0
0016
0
0047
in
Reverse
idler
gear
end
float
0
05
0
15mm
0
002
0
0059
in
0
20
0
40mm
0
0079
0
0157
in
Oearance
between
baulk
ring
and
clu
tch
gear
I
2
1
6mm
0
047
0
0630
in
12
1
6mm
0
0472
0
0630
in
61
Propeller
Shaft
and
DIfferentIaJ
DESCRIPTION
PROPELLER
SHAFT
DIFFERENTIAL
Removal
and
Dismantling
DIFFERENTIAL
Assembly
and
Adj
Jstment
DIFFERENTIAL
Installation
DIFFERENTIAL
Estate
car
and
van
TOOTH
CONTACT
PATTERN
Checking
DESCRIPTION
The
tubular
steel
propeller
shafts
are
shown
in
Fig
G
1
The
shaft
is
connected
to
the
drive
pinion
flange
by
a
yoke
flange
at
the
rear
and
to
the
transmission
output
shaft
by
a
splined
yoke
sleeve
at
the
front
The
Datsum
I800ce
station
wagon
and
van
has
a
three
section
shaft
in
contrast
to
the
two
piece
shaft
used
on
the
other
models
covered
by
this
manual
The
differential
carrier
houses
a
hypoid
bevel
gear
assembly
Although
this
manual
contains
dismantling
and
adjustment
procedures
for
the
differential
assembly
it
must
be
pointed
out
that
only
workshops
with
specialized
tools
and
equipment
will
be
able
to
carry
out
the
work
involved
PROPELLER
SHAFT
Removal
1
Release
the
hand
brake
jack
up
the
vehicle
at
the
fear
and
support
it
on
stands
2
Loosen
the
clamps
and
turn
the
pre
silencer
to
the
left
saloon
only
3
Remove
the
adjuster
nut
from
the
handbrake
cable
rear
adjuster
and
disconnect
the
left
hand
cable
Saloon
only
Remove
the
bolts
securing
the
centre
bearing
bracket
1800
cc
stati
n
wagon
4
Disconnect
the
fear
flange
from
the
rear
axle
flange
With
draw
the
propeller
shaft
to
the
rear
away
from
the
gear
box
mainshaft
Take
care
that
the
shaft
is
not
dropped
during
removal
or
the
balance
of
the
shaft
may
be
altered
5
Plug
the
gearbox
rear
extension
to
prevent
the
loss
of
oil
PROPELLER
SHAFT
Dismantling
and
Inspection
Oean
all
components
and
mark
them
before
dismantling
so
that
they
can
be
reassembled
in
their
original
positions
Correct
reassembly
is
most
important
otherwise
the
balance
of
the
shaft
may
be
affected
Remove
the
four
snap
rings
from
the
journal
assembly
and
withdraw
the
needle
bearing
cap
by
tapping
the
yoke
with
a
wooden
mallet
The
wear
on
the
spider
journal
diameter
must
not
exceed
0
15mm
0
006
in
the
standard
size
of
a
new
journal
is
14
7mm
0
579
in
Check
the
spider
seal
rings
and
replace
them
if
necessary
The
radial
backlash
of
the
sleeve
yoke
splines
to
gearbox
splines
should
not
exceed
0
5mm
0
002
in
Renew
the
sleeve
yoke
if
the
figures
are
in
excess
of
the
specified
value
E
Mount
the
shaft
between
the
centres
of
a
suitable
fixture
and
use
a
dial
gauge
to
check
that
the
run
out
of
the
shaft
does
not
exceed
0
6mm
0
024
in
at
the
centre
of
the
tubular
portion
The
shaft
can
only
be
straightened
with
a
hydraulic
press
it
is
advisable
however
to
renew
the
shaft
if
the
run
out
is
excessive
Check
that
the
dynamic
balance
of
the
shaft
does
not
exceed
15
grm
cm
0
208
oz
in
at
4000
r
p
m
PROPELLER
SHAFT
Assembly
and
11Istallation
r
Assembly
and
installation
is
a
reversal
of
the
removal
and
dismantling
procedures
not
the
following
points
Grease
the
needle
rollers
with
wheel
bearing
grease
before
placing
them
into
the
bearing
race
Lubricate
all
splines
with
gear
oil
Adjust
the
journal
radial
end
float
to
within
0
02mm
0
0008
in
using
a
suitable
snap
ring
Snap
rings
are
available
in
eight
thicknesses
from
2
00mm
0
079
in
to
2
14mm
0
084
in
and
are
colour
coded
as
detailed
in
Technical
Data
at
the
end
of
this
section
DIFFERENTIAL
Removal
Saloons
with
independent
rear
suspension
Remove
the
hand
brake
rear
cable
remove
the
propeller
shaft
and
drive
shafts
as
described
in
their
relevant
sections
2
Support
the
differential
with
ajack
and
remove
the
nuts
securing
the
differential
mounting
crossmemb
er
Fig
G
3
3
Remove
the
bolts
holding
the
differential
to
the
suspension
member
Withdraw
the
differential
and
jack
to
the
rear
4
Support
the
suspension
member
with
a
stand
to
prevent
the
mountings
from
becoming
twisted
or
damaged
DIFFERENTIAL
Dismantling
Before
dismantling
place
the
carrier
assembly
in
a
suitable
mounting
stand
or
special
stand
ST
06270001
and
carry
out
preliminary
checks
as
follows
Check
the
tooth
contact
pattern
of
the
crownwheel
and
pinion
by
applying
lead
oxide
to
three
or
four
teeth
of
the
crownwheel
Turn
the
crownwheel
several
times
to
obtain
an
impression
of
the
tooth
contact
pattern
Check
the
backlash
between
the
teeth
of
the
crownwheel
and
pinion
using
a
dial
gauge
The
backlash
should
be
within
0
10
0
20mm
0
004
0
008
in
63
SteerIng
DEsn
IPTION
S
i
EERlNG
MaintenaDce
STEERING
WHEEL
AND
STEERING
GEAR
Removal
and
Installation
STEERING
GEAR
Dismantling
STEERING
GEAR
Inspection
and
Adjustment
DESCRIPTION
A
worm
and
recirculating
ball
type
steering
system
is
fitted
to
the
vehicle
the
component
parts
of
the
steering
gear
are
shown
in
Fig
K
I
The
steering
linkage
consists
of
the
centre
tie
rod
pitman
ann
idler
arm
outer
tie
rods
and
the
knuckle
arms
as
shown
in
Fig
K
2
A
collapsible
steering
column
assembly
can
be
fitted
to
the
vehicle
to
protect
the
driver
from
injury
in
a
head
on
collision
Details
of
this
type
of
assembly
are
given
under
the
appropriate
heading
STEERING
Maintenance
O1eck
the
oil
level
in
the
steering
box
every
10
000
km
6
000
miles
and
top
up
with
recommended
lubricant
if
necessary
Grease
the
steering
linkage
every
50
000
km
30
OOO
miles
It
will
be
necessary
to
replace
the
plug
in
the
tie
rod
ball
joints
with
a
grease
nipple
for
this
operation
as
previously
described
in
the
section
FRONT
SUSPENSION
Use
a
grease
gun
to
completely
replace
the
old
grease
with
new
grease
making
SUfe
that
the
grease
is
not
forced
from
under
the
cover
clamp
if
a
high
pressure
gun
is
used
STEERING
WHEEL
AND
STEERING
GEAR
Removal
1
Take
out
the
retaining
bolts
and
remove
the
horn
ring
remove
the
steering
wheel
nut
Fig
K
3
and
pull
off
the
steering
wheel
The
special
tool
ST
27180000
should
be
used
if
available
2
Disconnect
the
battery
leads
remove
the
steering
column
shell
covers
and
the
turn
signal
and
lighting
switch
assembly
3
On
vehicles
fitted
with
steering
column
gear
change
assemblies
the
gear
lever
must
be
removed
from
the
control
rod
assembly
Unscrew
the
retaining
boltg
and
disconnect
the
gear
lever
4
Remove
the
bolts
from
the
steering
column
upper
clamp
Fig
K
4
and
the
bolts
holding
the
lower
plate
Fig
K
5
5
If
the
vehicle
is
fitted
with
steering
column
gear
change
remove
the
cotterpin
from
the
trunnion
and
detach
the
gearchange
rod
and
selector
rod
from
the
change
lever
and
selector
lever
STEERING
GEAR
Assembly
and
Adjustment
COLLAPSIBLE
STEERING
COLLAPSIBLE
STEERING
Removal
and
Inspection
COLLAPSIBLE
STEERING
Installation
STEERING
LINKAGE
6
Remove
the
bolts
securing
the
steering
gear
housing
to
the
car
body
Fig
K
6
and
pull
the
steering
gear
towards
the
engine
compartment
Remove
the
gearchange
control
from
the
steering
gear
assembly
as
described
in
the
section
GEARBOX
STEERING
WHEEL
AND
STEERING
GEAR
Installation
Installation
is
a
reversal
of
the
removal
procedure
When
the
installation
has
been
completed
make
sure
that
the
steering
wheel
can
be
turned
smoothly
and
is
correctly
aligned
The
free
travel
of
the
steering
wheel
should
be
between
2S
30mm
0
9B
1
18
in
Tighten
the
steering
wheel
locknut
to
a
torque
reading
of
4
0
5
0
kgm
29
36Ib
ft
and
the
steering
column
upper
clamp
and
plate
bolts
to
a
torque
reading
of
1
3
1
8
kgm
94
1
3
Ib
ft
Ensure
that
the
steering
box
is
topped
up
to
the
correct
level
with
recommended
lubricant
STEERING
GEAR
Dismantling
Remove
the
pitman
arm
retaining
nut
and
pull
out
the
arm
The
special
puller
ST
27140000
should
be
used
if
available
Remove
the
drain
plug
from
the
steering
gear
housing
and
drain
the
oil
Slacken
the
adjusting
screw
nut
and
turn
the
sector
shaft
adjusting
screw
a
few
turns
in
the
anti
clockwise
direction
Remove
the
sector
shaft
cover
retaining
bolts
and
pull
the
sector
shaft
cover
and
sector
shaft
from
the
gear
housing
Fig
K
7
Remove
the
bolts
securing
the
column
jacket
to
the
gear
housing
and
carefully
withdraw
the
main
column
jacket
assembly
from
the
gear
housing
Fig
K
B
NOTE
The
ball
must
not
be
allowed
to
run
to
either
end
of
the
worm
or
the
ends
of
the
ball
guides
will
be
damaged
Pull
the
column
assembly
from
the
column
jacket
Remove
the
sector
shaft
oil
seal
and
take
out
the
rear
bearing
outer
race
from
the
column
jacket
with
a
suitable
puller
Withdraw
the
bearing
inner
races
from
the
front
and
fear
worm
bearings
Remove
the
column
shaft
bearing
91
BRAKE
PEDAL
ADJUSTMENT
The
brake
pedal
height
and
free
play
can
be
adjusted
in
the
following
manner
1400
and
1600
CC
models
Adjust
the
length
of
the
master
cylinder
push
rod
until
the
height
of
the
pedal
pad
is
187
mm
7
36
in
for
manual
gear
boxes
and
202
mm
7
95in
for
automatic
transmission
vehicles
without
brake
light
switch
Fig
L
31
Retighten
the
locknut
Screw
in
the
brake
light
switch
until
the
screwed
part
of
the
switch
is
against
the
front
of
the
stopper
bracket
then
tighten
the
locknut
Screw
in
the
stopper
bolt
until
the
moveable
part
of
the
switch
is
completely
pushed
in
by
the
pedal
and
tighten
the
locknut
in
this
position
Make
sure
that
the
lamp
is
00
when
the
pedal
is
pushed
down
by
1
5mm
0
06
in
1800cc
models
Adjust
the
bolt
of
the
brake
lamp
switch
until
its
end
face
is
flush
with
the
locknut
then
tighten
the
locknut
securely
See
Fig
L
32
Adjust
the
pedal
stopper
until
the
pedal
pad
is
positioned
at
a
height
of
185
mrn
7
28
in
from
the
floor
then
tighten
the
stopper
with
the
locknut
Adjust
the
length
of
the
master
cylinder
push
rod
until
a
pedal
free
play
of
I
5mm
0
04
D
2in
is
obtained
then
retighten
the
locknut
Depress
the
brake
pedal
several
times
to
make
sure
that
a
full
travel
of
145mm
5
7
in
is
available
and
that
the
pedal
moves
freely
and
without
noise
Technical
Data
BRAKE
PEDAL
Pedal
height
1400
and
1600cc
models
I
87mm
7
362in
manual
gearbox
202mm
7
953in
auto
matic
185mm
7
28in
145mm
5
71
in
1800cc
models
Full
stroke
MASTER
CYUNDER
Inner
diameter
Piston
running
clearance
19
05mm
0
75
in
0
15mm
0
006
in
WHEEL
BRAKE
CYLINDERS
Inner
diameter
1400
and
1600cc
Front
drum
Front
disc
Rear
with
front
drum
Rear
with
front
disc
22
22mm
7
8in
50
8mm
2
0
in
22
22mm
7
8in
20
64mm
13
16
in
Inner
diameter
I
BOOcc
Front
drum
20
6mm
13
16in
Front
disc
Rear
50
8mm
2
0in
22
2mm
7
8
in
BRAKE
DRUM
AND
BRAKE
DISC
Drum
inner
diameter
Drum
outer
diameter
Out
of
round
maximum
Repair
limit
of
drum
Maximum
disc
run
out
Repair
limit
of
disc
228
6mm
9
0in
232mm
9
13in
0
05mm
0
002
in
230mm
9
055
in
0
06mm
0
0024
in
8
4mm
0
331
in
BRAKE
UNINGS
Drum
brakes
Width
x
thickness
x
length
40
x
4
5
x
219
5mm
1
575
x
1
772
x
8
642in
Disc
brakes
39
7
x
9
x
86mm
1
563
x
0
354
x
3
386in
Total
braking
area
Front
drum
brake
Front
disc
brake
Rear
351
sq
cn
54
4
sq
in
114
2
sq
cm
17
7
sq
in
351
sq
cm
54
4
sq
in
107
TIghtenIng
Torques
LIB
engines
Three
speed
geabox
ENGINE
2
5
4
0
kgm
18
29
Ib
ft
0
3
0
4
kgm
8
13
IbJI
Ll
1
8
kgm
8
0
12
llbJt
1
6
2
5
kgm
12
18Ib
ft
I
I
1
8
kgm
8
0
12
llbJt
0
7
I
I
kgm
5
1
8
0
IbJt
17
2
lkgm
l2
15IbJI
7
0
12
0
kgm
51
87IbJI
0
8
1
0
kgm
5
8
7
2
IbJI
0
3
0
4
kgm
2
2
2
9Ib
ft
2
3
kgm
14
22IbJI
J
9
2
2
kgm
14
16IbJI
Gearbox
to
engine
Dust
cover
Front
cover
Rear
extension
Bottom
cover
Reverse
idler
shaft
Detent
ball
plug
Mainshaft
nut
Mainshaft
bearing
retainer
Speedometer
pinion
sleeve
lock
plate
Reverse
lamp
switch
Control
lever
nut
Cylinder
head
bolts
1st
stage
2nd
stage
3rd
slage
4
0
kgm
28
9Ib
ft
6
0
kgm
43
4lb
ft
6
5
8
5
kgm
47
0
61
5
Ib
ft
Connecting
rod
big
end
nuts
Ll4
Ll8
engines
Ll6
engine
Flywheel
bolls
Main
bearing
cap
bolts
Camshaft
sprocket
bolt
4
5
5
5
kgm
33
40
Ib
fl
3
2
3
8
kgm
23
27
lb
ft
14
16
kgm
l01
106Ib
ft
4
5
5
5
kgm
33
40Ib
ft
12
16
kgm
86
8
116IbJt
0
6
0
9
kgm
4
3
6
5IbJt
I
I
1
5
kgm
8
0
10
8
Ib
fl
2
3
kgm
14
5
21
7Ib
ft
5
6
kgm
36
43
Ib
ft
0
6
0
9
kgm
4
3
6
5
Ib
ft
12
16kgm
86
8
115
7
IbJt
LIB
engines
Four
speed
gearbox
Oil
sump
bolts
Oil
pump
bolts
Oil
drain
plug
Rocker
pivot
locknuts
Camshaft
locating
plate
bolts
2
5
4
0
kgm
18
29
IbJt
0
8
1
0
kgm
5
8
7
2Ib
ft
Ll
l
7kgm
8
12IbJt
Ll
I
7kgm
8
12Ib
ft
3
3
44
kgm
24
32IbJI
1
7
2
1
kgm
12
15
IbJt
2
3
kgm
14
22Ib
ft
0
5
0
7
kgm
3
6
5
IlbJI
0
8
I
I
kgm
5
8
8
0Ib
ft
0
8
Ll
kgm
5
8
8
01b
ft
0
8
1
0
kgm
5
8
7
2Ib
ft
Gearbox
to
engine
Dust
cover
Front
cover
Bottom
cover
Rear
extension
Detent
ball
plug
Reverse
lamp
switch
Lower
bracket
bolt
Shift
rod
nut
Cross
shaft
bracket
bolt
Gear
change
lever
mounting
bolt
Crankshaft
pulley
nut
Outch
mounting
bolts
L14
Ll6
Ll8
2
4
2
6kgm
174
18
8
Ib
ft
1
6
2
2
kgm
12
16Ib
fl
PROPELLER
SHAFf
AND
DIFFERENTIAL
GEARBOX
17
20kgm
l22
145IbJI
14
17
kgm
101
123Ib
ft
13
20
kgm
94
145Ib
fI
Drive
pinion
nuts
Saloon
Drive
pinion
nuts
Estate
car
Drive
pinion
nuts
Van
Ll4
and
L16
engines
Three
speed
Gearbox
Rear
extension
to
case
bolts
2
8
4
4
kgm
20
32lb
ft
Gearbox
10
engine
2
5
4
0
kgm
18
29Ib
fI
Bnttom
cover
L1
1
7
kgm
8
0
12
3
lb
ft
Ll
1
7
kgm
8
0
12
3
lb
fl
3
5
5
0
kgm
25
3
36
2
Ib
ft
1
8
2
1
kgm
13
0
15
2
Ib
ft
2
4
kgm
14
5
29
Ib
ft
0
7
L1
kgm
5
1
8
0
lb
ft
0
7
Ll
kgm
5
1
8
0
lb
fl
9
11
kgm
65
1
79
51b
ft
Crown
wheel
bolts
1400
and
1600
cc
Saloon
1400
and
1600
cc
Eslale
1800ce
Saloon
I800cc
Estate
1800cc
Van
7
8
kgm
51
58Ib
ft
4
8
5
5
kgm
35
40
Ib
ft
7
8
kgm
51
58Ib
ft
7
8
kgm
51
58Ib
ft
4
8
5
5
kgm
35
40
Ib
ft
0
9
1
2
kgm
6
5
8
7Ib
ft
1
9
2
6
kgm
13
7
18
8
IbJI
1
9
2
6
kgm
13
7
18
8
Ib
f
Front
cover
Drain
plug
Selector
lever
bolts
Side
retainer
bolts
Saloon
Drive
flange
bolts
Saloon
Reverse
lamp
switch
Idler
shaft
screw
Rear
cover
bolts
Cross
shaft
lock
pin
Final
drive
to
mounting
member
1400
and
1600cc
models
6
8
kgm
43
4
57
8IbJI
1800cc
models
5
7
kgm
36
2
50
6Ib
fI
Final
drive
to
suspension
member
6
7
kgm
43
4
51
0
Ib
ft
Final
drive
to
drive
shafls
5
6
kgm
36
431b
ft
Final
drive
flange
to
propeller
shaft
1
6
2
4
kgm
12
17
Ib
ft
Final
drive
flange
to
propeller
shaft
Eslale
1
6
2
4
kgm
l2
17Ib
ft
Mainshafl
locknut
Ll4
and
L16
engines
Four
speed
gearbox
Rearexlension
to
case
bolts
1
6
2
5
kgm
12
18Ib
ft
Gearbox
to
engine
2
5
4
0
kgm
18
29Ib
ft
Bottnm
cnver
L1
1
8
kgm
8
13
Ib
ft
Fronl
cover
L1
1
8
kgm
8
13
IbJI
Drain
plug
3
5
5
0
kgm
25
3
36
2
Ib
f
2
4
kgm
14
5
28
9IbJt
9
11
kgm
65
1
79
5Ib
ft
Final
drive
flange
to
propeller
shaft
l800cc
610
only
Reverse
lamp
switch
Mainshaft
nut
2
0
2
7
kgm
14
5
19
5
lb
ft
4
6
kgm
29
43
Ib
ft
Oil
drain
and
flller
plug
Saloon
129