1969 DATSUN 610 height

Clutch

DESCRIPTION

CLUTCH
Removal
and

Dismantling

CLUTCH
Inspection
and

Adjustment

CLUTCH
Installation

CLUTCH
PEDAL
Removal
and
Installation

DESCRIPTION

Either
a

diaphragm
spring
or

coil

spring
type
clutch

is

fitted
to

the
vehicle
The

component
parts
of
the

diaphragm

spring
clutch
are
shown
in

Fig
E
l
and
the

component
parts

of
the
coil

spring
clutch
are
shown
in

Fig
E
2

The
clutch
is
of
the

single
dry
plate
type
consisting
of

the
drive

plate
clutch
coveT
and

pressure
plate
and
release

bearing

The
driven

plate
comprises
a

flexible
disc
and

splined
hub

which
slides
on
the

clutch
shaft
Friction
linings
are

rivetted
to

both

sides
of
the
disc

The
clutch
cover

and

pressure
plate
are
combined

by
nine

spring
setting
bolts
The

diaphragm
is
dished
to

maintain
a

constant

pressure
on
the

pressure
plate
which
in
turn
holds

the
driven

plate
in
contact
with
the

flywheel
The
release

bearing

is
a
sealed

type
ball

bearing
mounted
on
a

bearing
sleeve
Both

bearing
and
sleeve
are
operated

by
the
withdrawalleveT
when

the
clutch

pedal
is

operated

The
clutch

pedal
actuates
a
master

cylinder
which
transmits

fluid

under

pressure
to
a
slave

cylinder
The
movement
of

the

slave

cylinder
piston
operates
the
clutch
withdrawal
lever
via

a

push
rod
See

Fig
E
14

CLUTCH
Removal
and

Dismantling

The

gearbox
must

be
removed
from
the
vehicle
before

the
clutch
can

be
withdrawn
The

procedures
for

removing
the

gearbox
can
be
found
in
the
section
GEARBOX

If
a

diaphragm
clutch
is
fitted
insert
a

spare
clutch
shaft

or
a

special
alignment
tool
ST20600000
into
the

splines
of

the
driven

plate
So
that
the
dutch
is

supported
Slacken
the

six
bolts

securing
the
clutch
cover
to
the

flywheel
by
a
single

turn
at
a
time
and
in
a
diagonal

pattern
until
the

spring

pressure

is
relieved
Remove
the
bolts

completely
and
lift

away
the

clutch

assembly

When

removing
the
coil

spring
type
clutch
it
will

be

necessary
to
insert
suitable
hooks

under
the
release
levers
to

restrain
the
tension
of
the
clutch

spring
before

removing
the

clutch
cover
lx
llts

Ensure
that
the
friction

linings
of
the
driven

plate
do
not

become
comtaminated
with
oil
or

grease
when
removing
the

plate
from
the

splined
shaft

Diaphragm
clutch

The
clutch
cover
and

pressure
plate
assembly
should
not

be
dismantled
and
must
be

replaced
if
wear
or

damage
has

occurred
Make
sure
that
the
friction
face
of

the

pressure
plate
CLUTCH
PEDAL
Adjusting

CLUTCH
MASTER
CYLINDER

CLUTCH
SLAVE
CYLINDER

CLUTCH
WITHDRAWAL
LEVER

Adjusting

CLUTCH
SYSTEM

Bleeding

is
perfectly
flat
and
smooth

Coil

spring
clutch

A

special
tool
No
ST200S0000
is
available
to
ensure

that

the
clutch
can
be
dismantled
and

accurately
reassembled
The

tool
shown
in

Fig
E
3
consists
of
a
Base

plate
I
Centre

spigot
2
Distance

pieces
3

Height
gauge
4
Operating
lever

5

Securing
bolts
6

A
chart
is
included
to
indicate
the
various

parts
to
be
used

for
each

type
of
clutch

To
dismantle
the
clutch
place
the
distance

pieces
on

the

base
plate
as
shown
and

arrange
the
clutch
cover
on
the
base

plate
so
that
the
cover
holes
coincide
with
the
threaded
holes

in
the
base

plate
Insert

the

securing
bolts
provided
in
the
kit

and

tighten
them
gradually
and

evenly
in
a

diagonal
pattern

until
the
cover
is

firmly
attached
to
the
base

plate
Mark
the

clutch
cover

the

pressure
plate
lugs
and
the
release
levers
with

a

centre

punch
so
that

they
can

be
reassembled
in
their
original

positions

Remove
the

restraining
hooks
from
the
release
levers
and

unscrew
the
three
nuts
from
the

eye
bolts
Slowly
release
the

pressure
on
the
clutch
coil

springs
by
unscrewing
the
bolts

securing
the
cover
to
the
base

plate
and
lift
off
the
cover

springs

and

pressure
plate

CLUTCH

Inspection
and
Adjustment

Use
a
solvent
to
clean
the
dismantled

parts
with
the

exception
of
the
disc

linings
and
the
release

bearing

Check
the
clutch
cover

diaphragm
spring
and

pressure

plate
assembly
for
wear
or

damage
and
renew
the

complete

assembly
if

necessary
The

pressure
plate
on
the
coil

spring

clutch
can
be

lapped
if
necessary
as
described
below
Ensure

that
the
disc
rivets
are
not
loosened
and

inspect
the

linings
for

contamination
Grease
or
oil
should
be
removed
and
the

linings

dressed

using
a
wire

brush

Check
the
disc
for

run
ut

using
a
dial

gauge
as
shown
in

Fig
E
4
Position
the
dial

gauge
at
a

point
approximately
9Smm

3
74
in
from
the
centre
of
the
disc
and
check
that
the
run

out
does
not

exceed
the
permissible
limit
of
0
5
mm

0
02in

A
slight
deflection
can
be
corrected

by
hand

pressure
with

the
disc
mounted
on
the

gearbox
shaft

The
disc
must
be
renewed
or
relined
if
the
height
of
the

linings
above
the
rivets
is
less

than
0
3mm
0
012
in

Replace

the
bearing
sleeve
if
it
shows

signs
of
wear
at

the
point
of

contact
with
the
withdrawal
lever

Replace
the
release

bearing

if

grease
is

leaking
from
it
or
if
it
is

noisy
when
turned

43

The
coil

spring
clutch

pressure
plate
can

be

lapped
with
a

surface

grinder
to
remove

dents
or

scratches

only
the
minimum

amount
of
metal
should
be
removed
to
restore
the
surface

Check
the

plate
for
distortion

by
placing
it

on
a
surface

plate
with

the
friction
face
towards
the
surface

plate
Press

the
pressure

plate
down
and
insert
a
feeler

gauge
of
1
0mm

0
0039
in

between
the

pressure
plate
and
surface

plate
If
it

is

possible
to
insert
the
feeler

gauge
then
the

pressure
plate
must

be

repaired
or

replaced
The

plate
can
be
skimmed
but
the

maximum
amount
of
metal
that
can
be
removed
is
1
0mm

0
0039in

CLUTCH
SPRING

Diaphragm
clutch

With
the

diaphragm
spring
assembled
to
the

pressure
plate

inspect
the

spring
height
and
load
in
the

following
manner

Place
distance

pieces
of
7
8
mm

0
307
in
on
the
base

plate
as

shown
in

Fig
E
3
and
bolt
down
the
clutch
cover

using
the

special
bolts

provided
with
the
kit
Meas
Jre
the

height
B
in

Fig
E
5

at
a
diameter
of
44mm
1

732
in
The
release

fingers

should
not

exceed
a

height
of
43
45
mm
1
693
1
772
in

from
the
base

plate
Replace
the

spring
if

the

height
is
in
excess

of
the

figures

quoted

Press
the
dutch
down
as

shown
in
Fig
E
6
to
a

depth
of

7
8mm
0
307
in
or
until
the
clutch
driven

plate

upper
surface

lines

up
with
the
clutch
cover

mounting
face
If

the
load

applied

is
less
than
350

kg
770
lbs
it
will
be

necessary
to
renew
the

diaphragm
spring
Do
not

press
the
clutch
disc
down

by
more

than
9mm
0
35
in
or
the

diaphragm
spring
may
be
broken

CLUTCH
SPRINGS
Coil

spring
clutch

The
clutch

springs
must
be

replaced
as
a

set
if

any
of
the

springs
are
found
to
be
defective
Specifications
for
the

springs

are

given
in
Technical
Data
at
the
end
of
this
section

Generally

a

spring
may
be
considered
faulty
if
when
assembled
the
load
is

reduced

by
more
than
15
or
if
the
free

length
has
altered

by

more
than
1
5mm
0
0590
in
or
if
the
deflection
B
to
A

in

Fig
E

7
exceeds
5mm

per
100mm
0
2
in

per
3
94
in

Release

Bearing

The
release

bearing
should
be
renewed
if

excessively
worn

or
if

roughness
can
be
felt
when
the

bearing
is
turned

by
hand

The

bearing
should
also
be
renewed
if
the

grease
has

leaked

away
or
if
the
clearance

between
the
clutch
cover
and
inner

diameter
of

the
sleeve
is
more
than
0
5
mm
0
0197
in

The

bearing
can
be

removed

using
a
conventional

puller

as
shown
in

Fig
E
8
Two

types
of
release

bearings
are

available

and
care
must
be
taken
when

fitting
onto

the
bearing
sleeve

The
release
bearing
should
be

pressed
into

place
on
the

diaphragm

spring
type
of
clutch
with
a
force
of
400

kg
880
lbs

applied

at
the
outer
race
as
shown

in

Fig
E
9
On
the
coil

spring
clutch

the
same

force
must

be

applied
at

the
inner
race
as
shown
in

Fig
E
IO
It
should
be

possible
to
turn
the

bearing
freely
and

smoothly
when
it
is

pressed
into

place
CLUTCH

Assembly

Coil

spring
type

Press
the

pin
into
the

eyebolt
and

through
the

lug
on

the

pressure
plate
Place
the
three
distance

pieces
on
the
surface

of
the
base
plate
of
the

special
tool
ST20050000
and

position

the

pressure
plate

pressure
springs
and
retainers

on
the

plate

Set
the

retracting
springs
on
the
cover

and
insert
the

release
levers

through
the

spring
Place

the
clutch
cover
over

the

pressure
plate
and

springs
making
sure
that
the

retracting

springs
do
not

become
dislodged
or
distorted

Compress
the

pressure
springs
by
screwing
the

special
set

bolts
into
the
holes
in

the
cover

Tighten
the
bolts

gradually

in
a

diagonal

pattern
to
avoid

distorting
the
cover
Place
the

release
levers
on

the

eye
bolts
and
screw
OR
the

securing
nuts

Place

retaining
hooks
under
the
release
levers
and
remove
the

clutch
assembly
from
the
base

plate
slackening
the
set
bolts
in

a

diagonal
pattern

COIL
SPRING
CLUTCH

Adjusting

Screw
the
centre

pillar
into
the
base

plate
and

place
the

high
finger
over
the

pillar
The
height
of
the
release
levers
must

be

adjusted
by
turning
the
eye
bolt
nuts
until
the

tops
of

the

release
levers
are

just
touching
the

tip
of
the
gauge
See
Fig
E

11
Remove
the
centre

pillar
when
the
release
levers
are

correctly
adjusted
and
screw
in
the

actuating
lever
Fig
E
12

Turn
the

actuating
mechanism
several
times
to
bed
down
the

parts
and
then
recheck
the

height
of
the
release
levers
Check

for
run
out
as
near
to
the

edge
as
possible
and

readjust
if
the

deviation
is
more

than
0
5
mrn
0
020
in

CLUTCH
InsWlation

Ensure
that
the
friction
faces
are

free
from

oil
and

grease

and
place
the
driven

plate
on
the

flywheel
The

longer
chamfered

splined
end
of
the

assembly
should
face

the

gearbox
Use
a

spare
drive
shaft
to

align
the
driven

plate
The
shaft
must

be

inserted

through
the
splined
hub
of
the
driven

plate
and
into

the

pilot
bearing
of
the

flywheel

Place
the
clutch
cover
into

position
on

the
flywheel
and

tighten
the
dutch
bolts

gradually
in
a

diagonal

pattern
to
a

torque
reading
of
1
5
2
2

kgm
11
16Ib
ft

Remove
the

dummy
shaft
and
the

restraining
hooks
from
the
release
levers

Refit
the
release

bearing
and
the
bell

housing

CLUTCH
PEDAL
Removal
and
Installation

Remove
the
clevis

pin
from
the
end
of
the
master

cylinder
pushrod
and
disconnect
the
pushrod
Remove
the

return

spring
Remove
the

pushrod
after

slackening
the

pushrod

adjuster
Coil

spring
clutch

only
Remove
the

pedal
lever

securing
bolt
slacken
the
handbrake
bracket
bolts
and
lift
out

the

pedal

Clean
all

parts
thoroughly
and
check
them
for
wear
or

damage
paying
particular
attention
to
the
rubber

parts
return

spring
and

pedal
lever
bush

Installation
of
the
clutch

pedal
is
a
reversal
of

the

removal

procedures

45

J

Ie

T

I

Baseplate

@

2
Czn
e

piUfU

i

y
3
Distance

preces

4

height
iPuge
P

5

Actuilting
mechanl

sQ
6
Set

bolt

I

e
r

ft
I

Fig
E
3
autch

assembly
tool

Fig
E
4

Checking
the
driven

plate
for
run
out

81

I

1
1111
11
I
r

A

I

1

1111111111
if

jI

4
J
J
J

FiB
E
5

Checking
the

height
of
the

diaphragm

spring
Fig
E

6
Olecking
the

load
of

the
d

t
b

spring

I

I

I

A

j

I
1
1

I

l
i
y
8

Fig
E
7
Inspecting
the
clutch

spnngs
for

distortion
Fig
E
8

Removing
the
releaSe
bearing

p

l
0
I
0

W
Illmi
i
hm
17
9

FiB
E
9

Installing
the

lea
bearing

diaphragm

spring
FiB
E
I
0

Installing
the
lease

bearing
coil

spring

46

CLUTCH
PEDAL

Adjusting

400
and
1600
cc
models

Adjust
the

pedal
height
to
209
mm
8
22
in

with
the

pedal

stop
slackened
off

by
altering
the

length
of
the
master

cylinder

push
rod
See

Fig
E
13

Tighten
the

pedal
stop
and
obtain

a

pedal
height
of
207
ffim

8
15
in
for
Left
Hand
drive
models

or
182
mID
7
I7
in
for

Right
Hand
drive
models
Secure
the

stop

by
tightening
the
locknut
and
make
sure

that
the

points

illustrated
are

correctly
greased

CLlTfCH
PEDAL

Adjusting

1800cc
models

Adjust
the

pedal
height
to

175
mm
6
89
in

by
adjusting

the

pedal

stop
See

Fig
E
13
then

retighten
the
locknut
A

to
a

torque
reading
of
0
79
1
07

kgm
6
8Ib
ft
Turn
the

master

cylinder
push
rod
to
obtain
a

play
between
1
Smm

0
04

0
2
in
at

the
clevis

pin
then

tighten
the
locknut
B

to

a

torque
reading
of
0
79
1
07

kgm
6
8
Ib
ft
Ensure
when

adjusting
the

play
that
the

port
on
the

master

cylinder
is
not

blocked

too
small
a

play
at
the
clevis

pin
may
block
the

port

Bend
the
clevis

pin
over

completely

CLlTfCH
MASTER
CYLINDER
Removal

and

Dismantling

Disconnect
the

push
rod
from
the
clevis

Fig
E
14

Detach
the
fluid
line
from
the
master

cylinder
and

pump

the
fluid
into
a
suitable
container

3
Withdraw
the

retaining
bolts
and
remove
the
master

cylinder
assembly
from

the
vehicle

To

dismantle
the
master

cylinder
remove

the
filler

cap
and
drain

away
the
fluid

Pull
back
the
dust
cover

and
remove

the

snap
ring
the

stopper

push
rod

piston
assembly
and
return

spring

Oean
the

components
in
brake
fluid

and
check
them
for
wear

or

damage

Renew
the

cylinder
and

piston
if
uneven
wear
has
taken

place

the
clearance

between
the

cylinder
and

piston
must
not
exceed

0
13
mm
0
005
in

Renew
the
dust
cover
oil
reservoir
filler

cap
and
fluid
line
if

necessary

Reassembly
of
the
master

cylinder
is
a
reversal
of

the
dismantling

procedure
take
care
to

soak
the

components
in
brake
fluid
and

assemble
them
while
still
wet

When
the
master

cylinder
is
installed
in
the
vehicle
make
sure

that
the

pedal
height
is

adjusted
as

previously
described
and

bleed
the
hydraulic
system

by
following
the

procedures
given

under
the

heading
CLlTfCH
SYSTEM

Bleeding

CLlTfCH
SLAVE
CYLINDER
Removal
and

Dismantling

Remove
the
return

spring

2
Disconnect
the
fluid
line
from
the
slave

cylinder

D
3
Disconnect
the
push
rod
from
the
clutch
withdrawal
lever

4
Take
out

the
mounting
bolts
and
withdraw
the
slave

cylinder
from
the
clutch
housing

To
dismantle
the
slave
cylinder
remove
the
dust
cover

and

snap
ring
and
withdraw
the

remaining
parts
from

the
cylinder

Oean
all

components
carefully
and
check
them
for

signs

of

damage
or
wear
renew

any

part
found
to

be
defective
and

fit
a
new

piston
seal

CLUTCH
SLAVE
CYLINDER

Assembly
and
Installation

Reassembly
is
a
reversal
of

the
dismantling
procedure

Ensure
that
the

parts
are

dipped
in

brake
flu
d
before

assembling

and
that
the

piston
seal
is

correctly
installed

When
the
slave

cylinder
is
installed
in
the
vehicle
bleed

the
hydraulic
system
by
following
the

procedures
given
under

the

heading
CLlTfCH
SYSTEM

Bleeding

The

push
rod
must
be

adjusted
so
that
the
withdrawal

lever

has
an
end

play
of
2
0
2
3
mm
0
078
0
091
in
details

of
this

operation
are

given
below

CLlTfCH
WITHDRAWAL
LEVER

Adjusting

The
correct

adjustment
of
the
clutch
withdrawal
lever
is

most
essential
as
insufficient

clearance
between
the
clutch

release

bearing
and
the

diaphragm
will
cause
the
clutch
to

slip

On
the
other
hand
an
excessive
clearance
will

prevent
the
clutch

from

disengaging
correctly

The
clearance
between

the
release

bearing
and

diaphragm

or
release
levers
can
be

adjusted
in
the

following
manner

Slacken
the
locknut

Fig
E
IS
and
screw

the

push
rod

fully
home
with
the

adjusting
nut
Return
the

adjusting
nut

I
3
4
turns

to
adjust
the

play
at
the
end
of
the
clutch
withdrawal

lever
to

2
0
2
3
mm
0
078
0
091
in
This
will

give
a
clear

ance
of

approximately
1
3
mm

0
051
in

between
the
release

bearing
and
the

diaphragm
spring
or
release
levers

NOTE
When

adjusting
clutch

pedal
free
travel
at

the
withdrawal

lever
it
is
essential
to
check
that
the
clutch
driven

plate

has
not
worn

by
more
than
2mm
0
08
in
otherwise

the
clutch
will

slip
even
if

it
is

correctly
adjusted
See

Technical
Data
for
the
relevant
clutch
driven

plate

thickness

CLUTCH
SYSTEM

Bleeding

The
clutch

system
must
be
bled
after
it
has
been
dismantled

or
if

any
part
of
the
circuit
has
been

opened
This

operation

should
also
be
carried
out
if
the
fluid
level
in

the
reservoir
has

been
allowed
to
fall
and

pennit
air
to
enter
the

system

The

presence
of
air
in
the

system
may
be
noticed

by

incorrect
disengagement
of
the
clutch
but
in
any
case
if
air
is

suspected
the
clutch
must

be
bled
in

the
following
manner

Remove
the
dust

cap
from
the
slave

cylinder
bleed
screw

Connect
a

length
of
tube
to
the
bleed
screw
and
immerse
the

47

inter
1D7
J

3

T
T

aj

W

n
J

I

1

T

f
T
7

e

Fig
E
II

Adjustillll
the

height
of
the
release

levers
Fig
E
12
Actuating
the
clutch
to
settle
the

mechanism

Tightening
torque
3
5
to
4
0

kltm

125
to
29

h
lb

Rs

@

A
l

I
l

1
3
fP

I

01
I

8J

I

Jt
I

Lock
A

2

Lock
ul
Bn

Adjwt
by
adjust
of
master

cyl

@
Lubricatic
l

Clutch
dal
full

trek
140
4

mm
5
51
0
16

Clutch

pedal
free
stroke
25
mm
0
98
Pedal

height
175
mm
6
89
nl

Pc

dalfullstrokc
b

135mm
5
JI
n

@
Multi

purpo
greasc

510
series
610
series

Fig
E
l3

Adjusting
the
clutch

pedal

I

48

other
end
of
the

tube
into
a
clean
container

partly
filled
with

brake
fluid

Top

up
the
master

cylinder
reservoir
with
recommended

fluid
and

open
the
bleed
screw

approximately
three

quarters

of
a
turn

Depress
the
clutch

pedal
slowly
and
hold
it

completely

down
re

tighten
the
bleed
screw
and
allow
the

pedal
to
return

slowly

Repeat
the

operation
until
the
fluid

emerging
from
the

tube
is
free
from
air
bubbles
It
should
be
noted
that
assistance
will
be

required
when

carrying
out

bleeding
operations
as
not

only
must
the
fluid

entering
the

glass
container
be
watched
but
also
the
clutch

pedal
has
to
be

operated
and
the
reservoir

topped
up
frequently

throughout
the

procedure

When
the
fluid
is
completely
free
from
air
bubbles
the

bleed
screw
should
be

retightened
on
a
down
stroke
of
the

pedal

Finally
remove
the
bleed
tube
and

replace
the
dust

cap

TechnIcal
Data

Outch

type

Pressure

spring

Free

length

Fitted

length
and
load

Side
distortion

Permissible
deterioration

of

spring
force

Outch
release
levers

Oearance
between
release

bearing
and

diaphragm
spring

release
levers

Height
between
diaphragm
spring
and

flywheel

Height
between
release
levers
and
flywheel

Outch
driven

plate

Outer
diameter

Inner
diameter

Thickness
of

facingS

Total
friction
area

TIrickness
of

clutch
plate

Free

Compressed

No
of
torsion

springs

Permissible
minimum
depth
of
rivet
heads
from

facing
surface

Permissible
run
out
of
clutch

facing

P
rmissible
free

play
of

splines

Outch

pedal
1400
and
1600cc
models

Pedal

height
in
the
rest

position

P
da1
free
stroke

P

da1
effort

Master

cylinder

Diameter

Maximum
clearance
between

piston
and

cylinder

Pressure

plate

Permissible
refacing
limit

Outch

pedal
180Occ
models

P
da1

height

Play
at
clevis

pin

Full
stroke

P
da1
effort

50
Diaphragm
spring
or
coil

spring

52
3mm
2
059
in

29
2mm
44

2kg

1
149
in

197
t

4
4
lb

5mm

per
IOOmm

0
2in

per
3
94
in

15

1
2
I

4mm
0
047
0
055
in

44
t

Imm
1
732
t

0
039
in

50
5
t
0
05mm
1
988
t

0
0197
in

200mm
7
87
in

130mm
5
12in

3
5mm
0
140in

362

sq
cm
56
11
sq
in

8
6
9
0mm
0
3386
o
3543in

7
65
7
95mm
0
3012
o
3130in

6

O
3mm
0
0118

in

0
5mm
0
0197
in

0
4mm
0
0157
in

182mm
7
17in
R
H
D

207mm
8
15in
L
H
D

25mm
0
984in

15kg
33
lb

15
87mm
0
625in

O
13mm
0
005lin

Imm
0
0394in

175mm
6
89in

1
5mm
0
04
0
20in

135mm
5
3lin

10

5kg
23Ib

inter
E
lill
j

lll
jIl

1

3

I

i

1r
I
An
t

1
ll

1
11
5
85

1
Sleeve

voke
arsembh

Bearillg
race
assembh

Jvumal
asst

mb
r

4

Snap

ring

5

Prope
ier
shaft
tube
assl

mblv

6
flan

oke
2

O

L

l
OIlU

39
I

JII

I

I

i
i

3

1
378

@
Fig
G
I
Section

through
the

propeller
shaft
Unit

mm
in

@
@

j

c

@

I
I

i

@

@

@

J

q

cJi
y

j

rID

@

62
Fig
G
2
Section

through
the
differential
carrier

1

Supply
rrwlti

purpose
gTet1M
to

oil
seal

lip
when
ass

mb1ing

Pinion

bearing
adjusting
lWSher

Adjust
pinion
ber
uing

X
eload

by

selecting
2
and
3

Pinio

bearing

adjusting
spacer

4
PInion

height
adiustinx
MUS1m

5
Lock

strap

6

Ring
gear
bolts
T
7

0
to

8
0

kgm

50
6
ro
578

bIt

TIghten
by
tapping
bolt
head
with

Jj41b3
hamTMr

7
Lock

pin

8
Rear
cover

9

Ring
gmr

10

Diff
mounting
member

1
J
Bolt

diff
to

diff
mounting
member

T
6
0
to
8

0kKm
43
4
0
7
8

b
ft

12

ShIlf

pinion
m1te

13
Thnl

lWlJIJer

14
Pinion
mate

15
17vust
washer

Adjust
the
backla
h
in

pinion
mate

and
ide

gear
or
the
clearance

betwun
the

differential
ctlSI

and
the

rear

fact
ofridt
gror
to
0
1
to
0
2

mm

0
0039
0
0

0079
bv
16

16
Side
ar

17

BoltsideflilngeT
1
9to

6kgm

13
710
18

8Ib
f

18
Oil
tal

Supply
chassi

grea
e
to
oil

seal

lip
Vtlhen

autmbling

19
Side

flange

20
Side

retainer

21
Bolt
side
retainer
T
0
9
to
1
2

kgm

6
5
to
8
71b

22

ring

23

Side
bearing

24

Diff
Gear
case

25
Pinion
rear

bearing

26
Dril
e

pinion
27
Pinion

front
bearing

28

Spacer
front
pilot
beaTing

29
Front

pilot
bearing

30
Oil
seal

3J

CompanionfliInge

32
Dri

pinion
nut
T
17

to
20

Jwn

122
9
0144

6Ib
fI

inter
M
j

@
jJ

2

t

1
5c

t
J
i
3

jp

7
i
r
4

Ilc
d

I

l

@

l
lb
r

s
ril

1

iF
C

Q
Fig
G
12
Section

through
the
drive

pinion

1
Pinion

height
adjusting
kUsher
4
Fte
Ioad

for
pinion
bearing

2
Pinion

height
ad
usting
shims
without
oil
mlI
and
drive
7
to

3

Tightening
torque
of
nut
dril
e
10

kgt1L
5a

6
to
72
3
lb

jl

pinion
17
to

20kg1n
22
9
to

ffnion
bearing
adjusting
w

uher

44

6Ib
ft
J
6
Pillion
bt
flrillgadjusti

lg
s
Jtu
er

fl

i
Ji
l
I
I

J

lJ

i

V
r
IHei
t

giluge

I
lST31210c
0

l

B
I

0
QJ

DUrnmYPinlOn

Drive

pinion
collar

lST3121QOCX
f
1
L

r

IST315000001

Dummvspacer

ST318500001
I
Fig
G
ll

Measuring
the
clearance
between
the

differential
side

gear
and
thrust
washer

Fig
G
t3
Drive

pinion
markings

Fig
G
14

Adjusting
the

pinion
height

1

Fig
G
t
5

Adjustment
diagram
for
the
dif

feren
tiaI
side
covers
Fig
G

16lnstalling
the
differential
side
covers

fig
G

Checking
the
backlash
of
crownwheel

and

pinion
Fig
G
tS

Fining
the

differential

mounting

member

bb