1969 DATSUN 610 wheel size

STEERING
GEAR

Inspection
and

Adjustment

Thoroughly
clean
all

parts
and
examine
them
for

signs

of
wear
or

damage
Replace
any
comIK
nent
found
to
be
un

satisfactory

It
is
advisable
to
renew
the
assemblies
if
the

steering
column

or
ball
nut

assembly
is
defective
as

the

adjustment
procedures

required
to
overhaul
the
units
are
rather
involved

The

dismantling
and

adjustment
procedures
for
the
ball

nut

assembly
can
be
carried
out
in

the
following
manner
if
it

is

decided
that
overhaul
procedures
are
to

be
carried
out

Ball
nut

Remove
the
ball

guide
tube

clamp
withdraw
the

guide

tubes
from
the
ball
nut
and
collect
the
steel
balls

Turn
the
nut

upside
down
and
rotate

the
steering
column

backwards
and
forwards
until
all

36
steel
balls
have

dropped

out
of
the
ball
nut
Pull
the
ball

nut
from
the
column

Inspect
the
ball

guide
tubes

and
make
sure

that

they
are

not

damaged
Pay
particular
attention

to
the
ends
of
the
tubes

that

pick
up
the

balls
from
the
helical

path
Renew
the
tubes
if

they
are

unsatisfactory
Check
the
steel
balls
and

the
ball
nut

for
wear
and

replace
the

complete
unit
if

necessary

Assemble
the
ball
nut
on

the
worm
with
the
ball

guide

holes

upwards
Drop
18
balls
into
each
of

the
two
holes
on
the

same
side
of
the
ball
nut

until
all
36
balls
are
installed
The

column
should
be

gradually
turned

away
from
the
hole

being

filled
and
if
the
balls
are

stopped
by
the
end
of
the
column
hold

down
those

already
installed
with
a

clean
rod
or

punch
while

turning
the
column
several
times
in
the
reverse
direction
The

filling
of
the
circuit
can
then
be
continued
but
it

may
be

necessary
to
turn
the
column
backwards
and
forwards

holding

the
balls
down
first
in
one

hole
and
then
the
other
to
close
the

spaces
and

completely
fill
the
circuit

Place
the

remaining
22
balls
in
the
ball

guide
halves
11

balls
for
each
half
Fit
the
other
half
of

the

guide
tube
to
each

f11led
half

hold
the
two
halves

together
a
ld

plug
each

open
end

with
vaseline
to

prevent
the
balls

falling
out

Push
the

guide
tubes
into
the

ball
nut

guide
holes
and

assemble
the

guide
tube

clamp

Inspection

Oteck
the
axial

clearance
between
the
ball
nut
and
the

balls
If
the
clearance
exceeds
0
08
mrn
0
003
in
the

complete

unit
must
be
replaced
Inspect
the

gear
teeth
of
the

sector

shaft
for
wear
or

damage
Replace
any
worn
or

imperfect

bearings
Examine
the

steering
column
shaft
for

straightness

and
check
that
the
maximum
deflection
does
not
exceed
0
2mm

0
008
in
at

point
C
in

Fig
K
9
when
the
shaft

is

supported

at

points
A
and
B
Check
the
sector
shaft
and

steering

column
shaft
serrations
for
wear
Renew
the

parts
as

necessary
STEERING
GEAR

Assembly
and

Adjustment

Grease
the

lip
of
the
oil
seal
and

press
it
into
the

housing

Insert
the
column

assembly
into

the
column

jacket
and
fit

the
worm

bearing
shims
to
the

gear
housing
Install
the

flange

securing
bolts
and

tighten
them
to
a

torque
reading
of

1
8

2
5

kgm
13
18lb
ft
If
a

new
column

bearing
assembly
is

fitted
it
must
be
filled
with

bearing
grease
and
cemented
to
the

column

The

preload
of
the
worm

bearing
can
be

adjusted
by

altering
the
thickness
of
the
worm
bearing
shim
Four
shim

thicknesses
are
available
in
sizes
of
0
76
0
254
0
127
0
050mm

0
0300
0
100
0
005
in
0
002
in

This

adjustment
check
is
carried
out
without

the
sector

shaft
fitted
and
with
the
worm

bearings
oiled

Install
the

steering
wheel
as
shown
in

Fig
K
9
use
a

spring

balance
as
indicated
to
check
that
the
force
required
to
turn

the
wheel
is
between
4
0
8
0

kg
cm
56
l120z

inch

Select
a
suitable
shim
from
the
sizes

given

Assemble
the
selector
shaft

adjuster
with
a
shim
into
the

sector
shaft
Measure
the
end
clearance
of
the

adjuster
with
a

feeler

gauge
as

shown
in
Fig
K
1
O

The
correct
clearance
is
0
01
0
03mm
0
0004
O
0012in

and
can
be

adjusted
by
varying
the
thickness
of
shim
Four

thicknesses
of
shim
are
available
as

follows

1
57
mm
0
0618
in

1
55
mm
0
0610
in

1
52
mm
0
0598

in

1
50
mm
0
0591
in

To
assemble
the
sector
shaft
into
the
gear
housing
rotate

the
column

by
hand
until
the
ball
nut
is
at
the
central

position

of
its
travel
so
that
the
centre
tooth
of
the
sector
shaft
enters

the
centre
tooth

space
of

the
ball
nut
Fit
a
new

gasket
and

push

the

sector
shaft
cover

and
sector
shaft
into

place

Ensure
that
a
certain
amount
of

play
is

present
between

the
rack
and
sector
teeth
before

tightening
the
cover

bolts
to

a

torque
reading
of
1
5
2
5

kgm
10
9
18
llb
ft

Temporarily
lock
the

adjusting
screw
with

the
locknut

Move
the
sector
shaft
several
times
from

the

pitman
arm
side

to
make
sure
that
it
turns

smoothly

Connect
the

pitman
arm
to
the
sector
shaft

taking
care

that
the

alignment
marks
on

the
arm
and
shaft
coincide

Adjust
the
backlash
with

the
steering
in

the
central

position
using
a
dial

gauge
as
shown
in

Fig
K
II
Turn
the

adjusting
screw
with
a
screwdriver
until
the
amount
of
free

movement
at
the

top
of
the

pitman
arm
is

within
O
lmm

0
0039
in
at
a

radius
of

127
mm
5
0
in
Lock
the

adjusting

screw
with
the
locknut
Fig
K
12
and
recheck
the
free
move

ment

Fill
the

steering
gear
housing
with
the
correct
amount
of

recommended
lubricant

Refit

the

steering
gear
to
the
vehicle
as

previously
described

Make
sure

that
the
steering
wheel
is

correctly
aligned
and
that

93

ENGINE

Dismantling

Remove

the

engine
from
the
vehicle
as

previously
described

and

carefully
clean
the
exterior

surfaces
The
alternator

distribu

tor

and
starter
motor
should
be
removed
before

washing
Plug

the
carhurettor

air
horn
to

prevent
the

ingress
of

foreign
matter

Place
the

engine
and
transmission
on

the
engine
carrier
ST4797

0000
if

available
and
dismantle
as
follows

Remove
the

gearbox
from
the

engine
Disconnect
the
intake

manifold

water
hose
the
vacuum

hose
and
the
intake
manifold

to
oil

separator
hose
Remove
the
intake
manifold
with
the

carburettor
Fit
the

engine
attachment
ST3720OG18
to
the

cylin

der
block
and

place
tre

engine
on
the
stand
ST371
00000

Remove
the
clutch

@
Ssembly
as
described
in
the
section

CLUTCH
Remove
the
exhaust
manifold
and
heat
baffle

plate

Take
off
the
fan
blades
and
remove
the
water

pump
pulley
and

fan
belt
Remove
the
rocker
cover
hose
manifold
heat
hose
and

by
pass
hoses

Remove
the

generator
bracket
and
the
oil
fIlter
Extract
the

engine
breather

assembly
from
above
Note
that
the
breather

is
fitted
to
the

guide
and
is
installed
with
a
O

ring
which
is

pressed
into
the

cylinder
block

Flatten
the
10ckwasher
and
unscrew
the
crankshaft
pulley

nut
Withdraw
the

pulley
with
the

puller
ST44820000
if
available

but
do
not
hook
it
in
the
V

groove
of
the

pulley

Remove
the
rocker
cover
and
take
off
the
rubber

plug

located
on
the
front
of
the
cylinder
head

Straighten
the
lock

ing
washer
and
remove
the
bolt

securing
the

distributor
drive

gear
and
camshaft

sprocket
to
the
camshaft
Remove
the
drive

gear
and
take
off
the

sprocket
See

Fig
A
3

Remove
the

cylinder
head
bolts
in
reverse

order
to
the

tightening

sequence
sOOwn
in

Fig
A
18
and
lift
off
the

cylinder

head
as
an

assembly
See

Fig
A
4
Note

that
in
addition
to
the

ten

cylinder
head
bolts
there
are
also
two
bolts

securing
the

chain
cover
to

the
head
Invert
the

engine
and
remove
the
oil

sump
Remove
the
chain
cover
and
oil

flinger
Take
off
the
nut

securing
the
oil

pump
sprocket
and
withdraw
the

sprocket
with

the
chain
in

position
as
shown
in

Fig
A5
Remove
the
oil

pump

and
stramer
Note

that
two
of
the

pump
mounting
bolts
are

pipe
guides

Remove
the

timing
chain
crankshaft

sprocket
chain
ten

sioner
and
chain

stop

Remove
the

connecting
rod

caps
and

push
the

piston
and

connecting
rod
assemblies

through
the
tops
of
the
bores

Keep

all

parts
in
order
so

they
can
be
assembled
in
their

original
posi

tions

Take

out
the

flywheel
retaining
bolts
and
withdraw
the

flywheel
Remove
the
main

bearing

caps
but
take
care
not
to

damage
the

pipe
guides
Lift
out

the
crankshaft
and
main
bear

ings
noting
that
the

bearings
must
be
reassembled
in
their

original

positions
Remove
the

piston
rings
with
a
suitable

expander
and

take
off
the

gudgeon
pin
clips
The

piston
should
be
heated
to

a

temperature
of
50
to
600
122
to
1400F
before

extracting

the

gudgeon
pin
Keep
the
dismantled

parts
in
order
so

they

can
be
reassembled
in
their

original
positions

Remove
the
camshaft
rocker
ann
shaft
and
rocker
ann

assemblies
from
the

head

by
taking
off
the
cam

bracket

clamp

ing
nuts
It
is
advisable
to
insert
disused
bolts
in
the
No
1

and

No
5
bracket
holes
as
the
cam
bracket
will
fall
from
the
rocker

ann
shaft
when

it
is
removed
Remove

the
valve

cotters

using

the

special
tool
ST47450000

and
dismantle
the
valve
assemblies
Keep
the

parts
together
so

they
can
be
installed
in
their

original

order

ENGINE

Inspection
and
Overhaul

Cylinder
head
and
valves

Inspection
and
overhaul

procedures
can

be
carried
out

by

following
the
instructions

previously
given
for
the
L14
LI6

and
LIB

engines
noting
the

following
points

Measure
the

joint
face
of
the

cylinder
head

using
a

straight

edge
and
feeler

gauge
The

permissible
amount
of
distortion
is

0
03
mm
0
0012
in
or
less
The
surface
of
the
head
must
be

reground
if
the
maximum
limit
of
0

1
mm

0
0039
in
is

exceeded

Oean
each
valve

by
washing
in
petrol
then

carefully
examine

the
stems
and
heads
Discard

any
valves
with
worn

or

damaged

stems
Use
a

micrometer
to
check
the
diameter
of
the
stems

which
should
be
8
0
mm
0
315
in
for
both
intake
and
exhaust

valves
If

the
seating
face
of
the
valve
is

excessively
burned

damaged
or
distorted
the
valve
must
be
discarded
The
valve

seating
face
and
valve

tip
can
be
refaced
if

necessary
but

only

the
minimum
amount
of
metal
should
be
removed
Check
the

free

length
and
tension
of
each
valve

spring
and

compare
the

figures
obtained
with
those

given
in
Technical
Data
at
the
end

of
this
section
Use
a

square
to
check
the

springs
for
deformation

and

replace
any
spring
with
a
deflection
of
1
6
mm
0
0630
in

or
more

Valve

guides

Measure
the
clearance
between
the
valve

guide
and
valve

stern
The
stem
to

guide
clearance
should

be
0
025
0
055
mm

0
0010
0
0022
in
for
the
intake
valves
and
0
04
0
077
mm

0
0016
0
0030
in
for
the
exhaust
valves
The
maximum
clear

ance

limit
is
0
1
mm
0
0039
in
The
valve

guides
are
held
in

position
with
an
interference
fit
of
0
040
0
069
mm
0
0016

0
0027
in
and
can
be
removed

using
a

press
and
valve

guide

replacer
set
ST49730000
under
2
ton

pressure
This

operation

can

be
carried
out
at
room

temperature
but
will
be
more
effec

tively

performed
at
a

higher
temperature
Valve

guides
are

available
with
oversize
diameters
of
0
2
mm
0
0079
in
The

cylinder
head
guide
bore
must
be
reamed
out
at

normal
room

temperature
and
the
new

guides
pressed
in
after

heating
the

cylinder
head
to
a

temperature
of

approximately
800
C
1760F

The
standard
valve

guide
requires
a
bore
of
14
0
14
018
mm

0
551
0
552

in
and
the
oversize
valve

guide
a
bore
of
14
2

14
218
mm
0
559
0
560
in
Ream
out
the
bore
of
the

guides

to
obtain
the
desired
finish
and
clearance
Use
the
reamer
set

ST49710000
to

ream
the
bore
to
8
000
8
015
mm
0
3150

0
3156
in
The
valve
seat

surface
must

be
concentric
with
the

guide
bore
and
must
be
corrected
if

necessary
using
the
new

valve

guide
as
axis

Valve
seat
inserts

Check
the
valve
seat

inserts
for

signs
of

pitting
The

inserts

cannot
be

replaced
but

may
be
corrected
if

necessary
using
a

valve
seat
cutter

ST49720000

Scrape
the
seat

with
the
450

cutter
then

reduce
the
width
of
the

contacting
faces

using
the

150
and
600
cutters
for
the
intake
valve
inserts
and
150
cutter

for
the
exhaust
valve
inserts
Seat
correction
dimensions
are

shown
in
millimeters
in

Fig
A
6

Lap
each
valve
into
its
seat
after

correcting
the
seat
inserts

Place
a
small

quantity
of
fme

grinding
paste
on

the

seating
face

of
the
valve

and
lap
in
as

previously
described
for
the
Ll4
LI6

and
L
18

engines

S5

that
it
is
clear
of
the
oil
hole
Install
the

bearing
caps
and

tighten
the

bolts
to
a

torque

reading
of
10
0
1
LO

kgm
72
3

79
51b
ft

The
standard
main

bearing
clearance
is
0
03
0
06
mm

0
0012
0
0024

in
with
a
wear
limit
of
0
1
mm
0
0039

in

If
the

specified
limit
is
exceeded
an

undersize
bearing
must

be

fitted
and
the
crankshaft

journal
ground
accordingly
Bearings

are
available
in
four
undersizes
See
Technical
Data

Connecting
rod

bearing
clearance

Check
the

connecting
rod

bearing
clearances
in
a
similar

manner
to
the
main

bearing
clearances
The
standard
clearance

is
0
03
0
06
mm
0
0012
0
0024
in
with
a
wear
limit
of
0

1

mm
0
0039
in
Undersize

bearings
must
be
fitted
and
the

crankpins
reground
if
the

specified
limit
is
exceeded
Bearings

are
available
in
four
undersizes
See
Technical

Data

Fitting
the
crankshaft

bearings

Check

the
fit
of
the

bearing
shells
in
the

following
manner

Install
the

bearings
on
the
main

bearing
caps
and

cylinder
block

bearing
recess
and

tighten
the

cap
bolts
to
the

specified
torque

reading
of
10
0
11
0

kgm
72
3
79
5
Ib
ft
Slacken

one
of
the

cap
baits
and
check
the
clearance
between
the

cap
and

cylinder

block
with
a
feeler

gauge
as
described
for
the
L14
Ll6
and

LIS

engines
The

bearing
crush
should
be
from
0
to
0
04
mm

0
to
0
0016
in

Replace
the

bearing
if
the
clearance
is
not
correct

Check
the

connecting
rod

bearings
in
a

similar
manner

after

tightening
the
rod

cap
bolts
to
a

torque
reading
of

4
5
5
0

kgm
32
6
36
2
Ib
ft

ENGINE

Assembling

Make
sure
that
all

components
are

perfectly
clean
before

starting
to
assemble
the

engine
Refer
to

the
instructions

given

for
the
L14
U6
and
LIS

engines

Cylinder
Head

Install
the
valve

spring
seats
and
valves
Fit
the
oil
seal

rings
on
the
valve
stems

and

place
the
seal

ring
covers
over

the

oil
seal

rings
Note

that
a

gap
of
from
0
3
to
0
7
mm
0
0118

to
0
0276
in
should
be

present
between
the
seal

ring
cover
and

spring
seat

If
the

gap
is
less
than
0
3
mm
0
0118
in

the
oil

seal

ring
or
the
cover
must
be

replaced
Assemble
the
valve

springs
and
retainers

Compress
the
valve

springs
and
install
the

cotters
See
instructions
for
the
LI4
U6
and
Ll8

engines

Assemble

the
camshaft

brackets
valve
rockers
seats

spacers

and

springs
on
the
rocker
shafts
in
the
order
shown
in

Fig
A
l
O

Note

that
the
exhaust
rocker
shaft
has
identification
marks

but

the
intake
rocker
shaft
has
not
Make
sure
that
the
oil
holes

point
in
the
direction
shown
It

may
be
advisable
to
insert

any

convenient
bolts
into
the
bolt
holes
of
the
front
and
rear
cam

shaft
brackets
to

prevent
the

assembly
from

being
displaced

Mount
the
camshaft
on

the
head
fit

the
rocker

assembly

and

tighten
the

nuts
Make
sure
that
the
mark
on
the

flange
of

the
camshaft
is

aligned
with
the
arrow
mark
on
the
No
I
earn

shaft
bracket
as
shown
in

Fig
A
II

Pistons
and

connecting
rods

Assemble
the

pistons
gudgeon
pins
and

connecting
rods

in
accordance
with
the

cylinder
numbers
Heat
the

piston
to
a

temperature
of
500
to
600
1220
to

1400F
and

press
the

gudgeon
pin
in

by
hand
The

pistons
and

connecting
rods
must
be
assembled
as
shown
in

Fig
A
12
with

the
arrow
mark
on
the
head
of
the

piston
pointing
to
the
front

of
the

engine

Fit
new

clips
to
both
ends
of
the

gudgeon
pins
as
indicated

in
Fig
A
13
Fit
the

piston
rings
with
the
marks

facing
upwards

Place
the

bearings
on
the

connecting
rods
and

caps
making
sure

that
the
backs
of
the

bearing
shells
are

perfectly
clean

Assembling
the

engine

Insert
the
oilscal
into
the

grooves
of
the

cylinder
block

and
rear

bearing
cap
Fit
the
seal
down
with
the

speCial
tool

ST49750000
if
available
as
shown
in

Fig
A
14

and
trim
off

the
excess
with
a
knife

Apply
sealing
agent
to

the
oil

plug
and

install
it
in
the
cylinder
block

Fit
the
main

bearings
lubricate
with
clean

engine
oil
and

install
the
crankshaft
Fit
the

bearing
caps
and

tighten
the
bolts

to

a

torque
reading
of
10
0
to
I
LO

kgm
72
3
to
79
5
Ib
ft

Note
that

liquid
packing
should
be

applied
to

the
rear
bear

ing
cap
surfaces
as
shown
in

Fig
A
15

Fit
the
thrust
washers
at
both
sides
of
the
No
2

bearing

with

the
oil
channel
in

the
washers

facing
the
thrust

face
of
the

crankshaft
Install
the
rear

bearing

cap
side
seal
so

that
is

projects

0
2
to

0
6
mm
0
008
to

0
024
in

from
the
lower
surface
of

the

cylind
r

block
then

apply
liquid
packing
to
the

projecting

tip

Install
the

engine
rear

plate
Fit
the

flywheel
and

tighten

the
bolts
to
a

lorque
reading
of
10
0
to
11
0

kgm
72
3
to
79
5

ib
ft

using
new
lock
washers

Lubricate
the
crankshaft

journals
pistons
and
cylinder

bores
with
clean

engine
oil
and
install
the

piston
and

connecting

rod
assemblies
The

pistons
should
be

arranged
so
that

the
arrow

marks
face
towards
the
front
and
with
the

piston
ring
gaps
at

1800
to
each
other
Make
sure
the

gaps
do
not
face
to
the

thrust
side
of
the

piston
or
in
the
same
axial
direction
as
the

gudgeon
pin

Install
the

connecting
rod

caps
o
that
the
marks
face
the

same

way
and

tighten
the
bolts
to
a

torque
reading
of
4
5
to

5
0

kgm
32
6
to
36
2
Ib
ft
Bend
the
lock
washers
as
shown

in

FigA16

Fit
the
oil

jet
to
the
front
of
the

cylinder
block
Install

the
chain
tensioner
and

stopper
crankshaft

sprocket
and
timing

chain

Note
that
the

timing
mark
on
the
chain
must
be

aligned

with
the
mark
on
the

sprocket
as
shown
in

Fig
A
17

Smear
the

mounting
face
of
the
oil

pump
with

sealing
agent

Three
Bond
No
4
or

equivalent
install

the

pump
and

tempora

rily
tighten
the

mounting
bolts

Adjust
the
tension
of
the
oil

pump
chain

using
the

pin
as
the
central

point
then

tighten
the

mounting
bolts

Install
the
oil
thrower
Fit
the
chain
cover
into

position

after

coating
the
new
cover

gasket
with

sealing
compound
Cut

off
the

projecting
parts
of
the

gasket

Fit
the
crankshaft

pulley
and

tighten
the

pulley
nut
to
a

torque
reading
of
15
0
to
20
0

kgm
108
5
to
144
61b
ft
Bend

the
lock
washer
Install
the
oil
strainer
and
oil

pump

Invert
the

engine
and
set
the
No
I

piston
to

T
D
C
of
the

compression
stroke
Note

that
the
notch
on
the
crankshaft

S9

Gean
all

parts
thoroughly
and
renew
if

damaged
If
the

column
shaft
or

jacket
is

excessively
damaged
the

steering
gear

housing
must

be
checked
A

damaged
bearing
must

be

replaced

together
with
the
column

jacket
assembly

Assembly
is
a

reversal
of
the

dismantling
procedures
The

column
shaft

journal
should
be
lubricated
with

multipurpose

grease
which
can
also
be
used
to
fill

up
the
dust
cover
Grease

the
needle

bearing
when

assembling
the
universal

joint
Use

the

tightest
snap

ring
available
when

fitting
the
needle

bearing
Snap

rings
are

supplied
in
oversizes
of
0
95
mm
05
mm
and
1

5

mm

0
0374
0
0413
and
0
0453

in

Installation
of
the
column

assembly
is
a
reversal
of
the

removal

procedures
Tighten
the
rubber

coupling
bolts
to
a

torque
reading
of
I
S
to
1
8

kgm
I
0
8
to

13
0
Ib
ft
Refit
the

steering
wheel
and

tighten
the
nut
to
a

reading
of
4
0
to
5
0

kgm
28
9
to
36
2Ib
ft

RACK
AND
PINION
AND
TIE
ROD

Removing
and

Dismantling

1

Jack

up
the
vehicle
and

support
it
on
stands
Remove
the

road
wheels

2
Slacken
the
bolts

connecting
the

pinion
to
the

steering

lower

joint
See
Figs
C

16

3
Remove
the
bolts
from
the
steering
column
rubber
coupl

ing
See

Fig
C
15
and
remove
the

splash
board

Fig
C
17

4

Remove
the
tie
rod
ball
stud
nut
and
disconnect
the
tie

rod
from
the
knuckle
arm

Fig
C
I8

5
Lift
the

engine
slightly
with
suitable
tackle
but
take
care

not
to

damage
the
accelerator
or
remote
control

linkage

Remove
the
bolts

securing
the
steering
gear
housing
to
the

suspension
member
Withdraw
the
rack
and

pinion

assem

bly

Dismantle
as
follows

Detach
the

steering
lower

joint
from
the
rack
and

pinion

assembly
Clamp
the
unit
in
a
vice

taking
care
not
to

damage

the

steering
gear
housing

Refer
to

Fig
C
16
and
take
off
the
dust
cover
and
boot

clamps
at

both
sides
Slacken
the
stopper
nut

remove
the
tie

rod
inner
socket
and
disconnect
the
tie
rods
from
the
rack

Withdraw
the

spring
seat
and
tie

rod

spring
Take
off
the

steering

gear
boots
at
both
sides
Slacken
the
locknut
and

disconnect
the
tie
rod
outer
socket
from
the
ball

Slacken
the
locknut
remove
the
retainer

adjusting
screw

and
withdraw
the
steering

gear
retainer
See

Fig
C
19

Take
off
the
oil
seal
remove
the
snap
ring
and
withdraw

the

pinion
Remove
the

snap
ring
and
withdraw
the

bearing
from

the

pinion
Remove
the
filler

plug
and
take
out
the
rack
Remove

the

grease
reservoir

Clcan
all

parts
thoroughly
and

replace
any
which
show

signs
of
wear
or

damage
Check
the
axial
play
of
the
inner

and

outer
ball

joints
The

play
should
be
0
06
mm
0
0024
in
for

the
inner
ball
joint
and
from
0
1
to
0
5
mm
0
0039
to
0
0197

in
for
the
outer

joints
Use
a

spring
balance
to
check
the
force

required
to

swing
the
ball

joints
this
should
be
between
0
8
to

LS

kgm
5
8
to
10
8Ib
ft
Renew
the
oil
seal
Examine
the
retainer
and

tie
rod

springs

and

compare
them
with
the
values

given
in

Figs
C
20
and
c
n

RACK
AND
PINION
AND
TIE
ROD

Assembling
and
Adjusting

Press
the

bearing
on
to

the
pinion
gear
and
fi
t

the
tigh
test

snap
ring
available

Snap
rings
are

supplied
in
the

following
over

sizes

Snap

Ring
Thicknesses

1
04
to
1
09
mm
0
0409
to
0
0429
in

1
09
to
I
14
mm

0
0429
to
0
0449
in

1

14toI19mm
0
0449toO
0469in

Ll9
to
1
24
mm

0
0469
to
0
0488
in

1

24
to
1
29
mm
0
0488
to
0
0502
in

Clamp
the

steering
gear
housing
in
a

vice
Grease

the
teeth

and
friction
surfaces
of
the
rack
with

multipurpose
grease

Lubricate
the

gear
housing
from
the

pinion
housing
side

Ensure
that
the
rack

projects
by
an

equal
amount

of

96
mm

3
8
in
in
both
ends
of
the

housing
with
the
rack

teeth

directed
towards
the

pinion
shaft

Grease
the
pinion
teeth
end

bushing
and

pinion
bearing

Engage
the
tccth
of
the

pinion
with
the
rack
and
insert
the

pinion
Make
sure
that
the

bushing
does
not
become
damaged

The
rack
must

project
from
the

housing
by
an

equal
amount

at
each
side
with
the

groove
on
the

pinion
serration

facing

upwards

Fit
the

snap
ring
into
the
housing
groove
to
hold
the

bearing
outer
race

in

position
The

snap
ring
must

fit

tightly

and
can
be
selected
from
the

following
oversizes

Snap
Ring
Thicknesses

LS5
to

1
60
mm
0
0610
to
0
0630
in

1
60
to
1
65
mm
0
0630
to
0
0650

in

1
65
to
I
70
mm
0
0650
to
0
0669
in

1
70
to
I
75
mm
0
0669
to
0
0689

in

Fit
the
oil
seal
Use
a
dial

gauge
as

shown
in

Fig
C
22
to

check
the
thrust

play
of
the
pinion
The

play
should
be
less

than
0
09mm
0
0035
in

Grease
the
retainer
and
insert
it

with
the
spring
Tighten

the
retainer
adjusting
screw

fully
then
back
it
off

by
20
to

25

degrees
Tighten
the
locknut
to
a

torque
reading
of
4
0
to

6
0

kgm
28
9
to
43
4lb
ft
Coat
the
locknut
with

liquid
pack

ing
Three
Bond

When
the
rack
and

pinion
is
assembled
measure
the
force

required
to
rotate

the
pinion
and
also
the

preload
of
the
rack

Use
a

spring
balance
as
shown
in
Figs
C
23
and
C
24
and
check

that
the

pinion
torque
is
8
to
20

kg
cm
7
to
17
Ib
in
and
the

rack

preload
is
from
8
to
18

kg
17
6
to
39
7Ibs
Take
care

to
slide
the

assembly
over
the

complete
range
of
the
stroke

Fit
a
dust
cover

clamp
at

each
end
of
the
housing
Install

the

stop
nut
on
the
threads
of
the
rack

Liberally

grease
the
ball
joint
friction
area
of
the
tie
rod

assembly
Assemble
the
spring
and
ball
seat
and
fit
the
inner

socket

part
of
the
tie
rod

assembly
to
the
rack
Make
sure
the

boot
is

positioned
at
the
ball
stud
end
Note
that
the
left
hand

tie
rod
is
marked
with
an

L
the

right
hand
rod
is
not
marked

527