1969 DATSUN 610 ECU

cage
Mcasure
the
clearance
between
the

rear
face
of
thc
side

gear
and
the
differential
cage
as

shown
in

Fig
G
ll

and
if

necessary
use
a

tluust
washer

which
will

given
a

clearance
of

0
1
0
2mm
0
004
0
008
in
Fit
the

pinion
shaft
lock

pin

and
secure
it

by
caulking
with
a

punch
Lubricate
the

gear
teeth

and
check
the

gear
for
freedom
of
rotation

Install
the
crown
wheel
in
the

differential

cage
and
insert

the
bolts
with
new
lock

straps
Tap
the
head
of
each
bolt

lightly

and

tighten
the
bolts
in
a

diagonal

pattern
to
a

torque
reading

of
7
0
8
0

kgm
51
58Ib
ft
Measure
the
width
of

the
side

bearings
before

installing
them
Place
a

weight
of
2
5

kg
5
5
1b

on
the

bearings
and
check
the
nominal
width
which
should
be

20mm
0
787
in
Press
the

side

bearings
into
the
differential

cage

Adjustment
of
drive

pinion

preload

This

adjustment
is
carried
out
without

fitting
the
oil
seal

Press
the
front
and
rear

bearing
outer
races

into
the

gear
carrier

and
fit

the

pinion
height
adjusting
washer

Fig
G
12
the

shims

and
the
rear

bearing
inner
race
onto

a

dummy
shaft

special
tool
ST
31
120000
The
old
washers
and

shims
can

be

re
used
if
the
tooth
contact

pattern
was
found
to
be

correct

on
the

pre
dismantling
check
Fit
the
drive

pinion
bearing
spacer

the
washer
ans

special
collar
5T
312140000
or
5T
31500000

and

the
drive

flange
on
to

the

dummy
shaft

Tighten
the
drive

pinion
nut
to
a

torque
reading
of
17

20

kgm
123
145
Ib

ft

Measure

the
drive

pinion
bearing
pre
load
and
select
washers
and

spacers
to

give
a

pre
load

of
7
1
0

kg
cm
6

9Ib
in
with
new

bearings
or
3

6
kg
cm
2

6
5
Ib
in
with
used

bearings

Adjusting

spacers
are
available
in

lengths
of
56
2
57
2
mm

2
2126
2

2520
in
and

adjusting
washers
in
thicknesses
of

59
2
31
mm
0
1020
0
0909
in

Adjustment
of

pinion
height

The

pinion
height
or
distance

of
the
face
of
the

pinion
to

the
axis
of
the

crownwheel
is

adjusted
by
the
thickness
of
the

adjusting
washer
behind
the
drive

pinion
gcar

The
drive

pinion
has
a

tolerance
mark
etched
on
its
face

this
tokrance
is

accompanied
by
a

or

sign
to
show
the

deviation
from
the
nominal
dimension
Thc

plus
sign
indicates

that

the
nominal
distance
must
be
increased
and

the
minus

sign
that
it
mllst
be
decreased
The
tolerances
are
shown
in

Fig

G
I3

The

pinion
height
can

be

adjusted
using
the

original

adjusting
washer
and
shims
between
the
rear

bearing
cone

and

the

drive

pinion
Install
the

setting
gauge
5T
31210000
on
the

carrier
with
the

dummy
pinion
installed
Sce

Fig
G
14

Measure
the
clearance
between
the
head
of
the

dummy

shaft

and
the
tip
of
the

setting
g
wge
using
a
feeler

gauge
as

shown
in

Fig
G
15
The
clearance
is

also
shown
at
the

point

T
in
Fig
G
14
The

required
thickness
of
the

adj
lsting

washer
can

be
obtained

using
the
following
formula

S
W

T
H
x

0
01
0
20

Where
W

thickness
of
inserted
shims
and
washers

T
Measured
thickness

H
Figure
engraved
on

pinion
head
o

S

Required
thickn
ss
of
washers
and
shims

A

typical
example
is
given
below

w

20
1
20

T

H

S
340
0
24
2
x
0
01

0
20
3
40
mm

0
24
mm

3
46
mm

An
adjusting
washer
rrlust
be
selected
which
is
nearest
in

thickness
to
the
value
of
3
46mm
Adjusting
washers
are
available

in
thicknesses
of
3
09mm
0
01217
in
to
3
66m
0
1441
in

for
the
l800cc
models
and
in
thicknesses
of
O

2
and
2
4mm

0
787
0
866
and
0
945
in

for
the
1400
and
1600
cc
models

Fit
the
selected

adjusting
washer
and
shims
to
the
drive

pinion
and

press
on
the
rear

bearing
inner

race
Install
the
drive

pinion
into
the
differential
carrier

together
with
the

bearing

spacer
and
washer

the
front

bearing
inner
race
and
the
front

bearing
pilot
spacer

Fit
the
drive
flange
and
washer
on
the
drive

pinion
and

secure
them
with
the

pinion
nut

Tighten
the
nut
to
a
torque

reading
of
17
20

kgm
123
145Ib
ft

SIDE
BEARING
SHIMS
Selecting

The
side

bearing
pre
load
must

be
adjusted
with
selected

shims

if
the

differential
carrier
the

cage
the
side
bearings
or

the
bearing
covers
have
been
renewed

The

required
thickness
of

the
shims
can
be
obtained

using

the

following
formula
and

referring
to

Fig
G
l
5

T1
left
side
bearing
A
C
GI
D
E
H
x
0
01

0
76

T2

right
side
bearing
B
D
G2
F
H
x
0
01
0
76

Where

A
B

C
D

E
F
The

figure
on
the
differential
carrier

The

figure
on
the
differential

cage

The
differences
in
width
of
the
left
or

right
hand

bearings
against
the
nominal
width
of
20
0mm

0
7874
in

given
in
units
of
1
100
mm

Gl

G2

H
The

figure
on

the
side
cover

The
figure
on
the
crownwheel

The
A
B
C
D
G
and
H

figures
indicate
the
dimensional

variations
in
units
of
1
100
mm
fr
Jm
the
standard
measurement

An

example
of
the
calculations
to
decide
the
thickness
of
shim

required
is

given
below

Where

A
I
B
2
C
2
D
1
GI
3
G2
1
E
O
Olmm
F

O
02mm
H

Left
side

bearing

Tl
A

C
G
1
D
H
x

0
01
0
76
E

I
3
1
2
x

0
01
0
76
0
01
0
8mm

Right
side

bearing

T2
B
D
G2
H
x
0
01
0
76
F

2

I
I
2

x
0
01
0
76
0
02
0
8mm

67

The

standard
width
of
the
side

bearings
is
20
0mm

0
7874

this
width
must
be

measured
before

attempting
to

calculate
the
thickness

of
the

adjusting
shims
Use
a

dial

gauge

and
surface

plate
to
ohtain

the
measurement
Place
a

weight
of

approximately
2

5

kg
5
5
lb
on
the

bearing
to

obtain

steady

readings

Install
the
differential

cage

assembly
in

the
carrier

Fit
the

sckcted

shims
and
O

rings
into
both

differential
side

bearing

covers

and
install
the
covers

in
the

carrier

using
the

special
tool

ST
33720000

Fig
G
16
l
Make
sure

that
the
side

bearing

outer

races
are
not

damaged

by
the

roller
Measure
the
backlash

between
the

teeth
of

the
crown
wheel

and
drive

pinion
with
a

dial

gauge
as
shown
in

Fig
G
I
Sct
the
dial

gauge
to
0
10

f
O

mm

0
004
0
008
in

I
If
the

backlash
is

less
than
the

specifIed

value
move
he
left
side

adjusting
shim
to
the

right
side
and
vice

versa

if
the
backlash

exceeds
the
specified
figure

Check

that
the
run
out
at
the
rear

of
the

crownwheel
does

not

excecd
O
OSmm
0
002

in
for

the
1800ce
model
or

O
08mm
0

003
in

for
the
1400
Check
the

drive

pinion

turning

torque
Thc

turning
torque
should
be

higher

by
I
3

kg

em

compared
with
the

turning
torque
obtained
before

fitting

the
differential

cage
in
the
carrier
The

higher
value
can

be

provided
if

necessary
by

dmnging
the

jde
cover

shims
Note

howcver

that
any
decrease
or
increase
in

the
thickncss
of
shims

wjJl

alter
tht
budlush

between
the
teeth
of
the
crownwhee1

and

pinion

Check

the
tooth
contact

pat
tern

of
the
crown
wheel
and

pinion
as

described
under
the

appropriate
heading

DIFFERENTIAL

Installation

Secure
the
differential

carrier
on
the
rear

suspension
mem

ber

using
the
four

bolts
and
washers
Fit
the
differential

mounting
member
to
thc

mounting
holes

by
pushing
it
forwards

with
a

suitable
lever

Fig
G
18

Tighten
the

nuts
to
a

torque

reading
of
8

5

kgm
61
5

Ib
ft

Tighten
the
bolts

attaching
the

gear
carrier
to
the

suspension
member
to
a

torque
reading
of

6
7

kg
36
5Ilb
ft
t

The

rcmainder
of
the
installation

operations
are
a
reversal

of

thc
removal

procedure
Fill
the
differential
with

the
correct

quantity
of
recommended
oil

DIFFERENTIAL
CARRIER

Removal
and

Dismantling

Estate
car
alld
Vanl

To

remove
the
differential

carrier
disconnect
and
remove

rhe

propeller
shaft
as

previously
described

and
remove

the
two

rear
axle

shafts
as

described
in

the
section
REAR
AXLL
With

draw

the
nuts

securing
the
differential

and
remove

the
carrier

from
the
rear
axle

Mount

the
unit
on
the

special
attachment
as
shown
in

Fig
G
19
and

carry
out
a

preliminary
check
before

dismantling

Oleck
the
tooth
contact
of
the

crownwheel

and

pinion
by

applying
lead
oxide

to
three
or
four

teeth
of
the

crownwheel

Turn
the
crown

wheel
several
times

to
obtain
an

impression
of

the

tooth
contact

pattern
Check
the
backlash

between
the
teeth

of
the
crownwheel
and

pinion
with
a

dial

gauge
Hold
the
drive

pinion
with
one

hand
and
move

the
crown
wheel

backwards
and
forwards
to

check

that
the
backlash
is
Io

ithin
thL

speL
ified
limits

Shims
and

adjusting
washers
must
bL
altered
if

the
tooth
con

tact

pattern
and
backlash

is

incorre
L
the
neL

cssary
details
for

these

operations
can
be
found
towards
the

end
of

this
section

under
the

appropriate
he
Jdjn

s
Fil1JJly
mark
the

bearing
caps

with
a
hammer

and

punch
to
ensure
correct

t1ignment
on
re

assembly

Remove
the

bearing

caps
nd
withdraw

the
differ

ntial

cage
make

a
note
of

the
left
and

right
hand

positions
so
h
Jt

the

bearing
caps
and
outer
race
can

be
re

assembled
in

their

original
positions

Withdraw

the
side

beJrings
with
the
s

cjal

puller
as

shown

in

Fig
G
20

taking
care
not
to

catch
the

edge
of
the

bearing

inner
races

Place
the

assembly
in
a
vice
and
detach

the
crownwheel

by
slackening
the

retaining
bolts
in
a

diagonal

patter
Fig
G
lf

Drive

out
th

pinion
shaft
lock

pin
from

left
to

right
using
a

suitable

punch
or

special
tool
ST
23520000

Fig
C
22

With

draw
the

pinion
shaft
and
take
out

the

pinions
side

gears
and

thrust
washers

Store
the

gears
and
thrust
washers
so
that

they

can

be
assembled
in
their

original

positions

Check
the
initial

turning
torque
of
the

drive

pinion
with

the

preload
gauge
ST
3190000

and
measure

the

height
of

the

drive

pinion
with
the

special
gauge
ST
31941000

Compare
the

figures
obtained
with
those

givcn
in

Technical
Data
at

the
end

of
this
section

Hold
the
drive

pinion
with

the

speciaJ
wrench
ST
3
J
530000

as
shown
in

Fig
C

23
and
unscrew
the

drivc

pinion
nut

then

pull
out
the
drive

pjnion
flange

Tap
the
drive

pinion
assembly
to
the
rear
with
a

plastic

mallet
and
withdraw
it

together
with

the
rear

bearing
inner
race

bearing
spacer
and
adjusting
washer

Remove

and
discard
the
oil
seal
and

withdraw
thc
front

bearing
inner
race
Drive
out
the
outer
races

of
the
front
and

rear

bearings
with
a
suitable

drift

Fig
G
25

The
drive

pinion
rear

bearing
inncr
race
can
be
removed

with
the

special
tool
ST
300310000
as

shown
in

Fig
G
24

DIFFE
l
ENTlAL

Inspection

Clean
all

components
thoroughly
and

examine
for

signs

of
wear
or

damage

Check
the
teeth
of
the

crownwhcel

and

pinion
for

scoring

and

hipping
Ii
should
be

noted
that
the
crownwhecl

and

pinion
are

supplied
as
a

matched
set
and
if
either

part
is

damaged

the

complete
set
must
be

replaced

Examine
the

inner
faces
of
the
side

gears
and
seats
on
the

differential
case

Inspect
the

bearing
races
and

rollers
and

replace

them
if

necessary

Small
defects

on
the
faces
of

the
thrust

washers
can
be

corrected

using
emery
cloth
however
if

the
clearance
between

side

gear
and

thrust
washer

exceeds
0
1
O
2mm
0
0039

0
0079

in
it
ill
be

necessary
to

replace
the
washer

Various

sizes
of
washers
are
available

and
the
thicknesses
arc
detailed

under
the

heading
DIFFERENTIA
L

GEAR
CAGE

Assembling

69

Rear
Axle
Rear

SuspensIon

DESCRIPTION

REAR
AXLE
AND
SUSPENSION
Removal
Saloons

COIL
SPRINGS
Saloons

REAR
SHOCK
ABSORBERS
Saloons

REAR
SUSPENSION
ARM

Saloons

DESCRIPTION

Saloon
models
are
fitted
with

independent
rear

suspension

with
semi

trailing
arms

suspension
arms
coil

springs
and

telescopic
hydraulic
double

acting
shock

absorbers
The
differ

ential

gear
carrier
and

suspension
member
is
mounted

directly

onto

the

body
structure

via
rubber

mountings
See
Fig
H
I

Estate
cars
and
1800
ce
Vans
are
fitted

with
a
semi
floating

rear
axle
with
semi
elliptic
leaf

springs
and

telescopic
hydraulic

shock
absorbers
mounted
on
rubrer
bushes
See

Fig
H
2

REAR
AXLE
AND
SUSPENSION
Removal

Saloon
models

I
Jack

up
the
rear
of
the
vehicle
and

support
it
on
stands

2
Remove
the
road
wheels
disconnect
the
hand
brake

linkage

and
the
return

spring
Fig
H
3

3
Remove
the
exhaust
tail

pipe
and
silencer

4
Disconnect
the
brake
hoses
and
plug
the
openings
to

prevent

the

ingress
of
dirt

5
Remove
the

propeller
shaft

assembly
as
described
in
the

relevant
section
after

marking
the

propeller
rear

flange

and
differential

pinion
flange

6
Jack

up
the

suspension
ann

and
remove

the
shock

absorber

lower

mountings
taking
care
not
to
lose
the
rubber

bushings

7
Place

ajack
under
the
centre
of
the

suspension
member

and
differential

carrier
and
remove

the
nuts

securing
the

suspension
member
to
the

body
7
in

Fig
H
3
Remove

the
differential

mounting
nuts
8

8
Carefully
lower
and
remove
the

suspension
assembly

REAR
SUSPENSION

Inspection

Saloons

Examine
all

parts
for

wear
and

damage
paying
particular

attention
to
the
rubber
bushes

in
the

suspension
arms
and
the

bump
rubbers
Check
the
condition
of
the

spring
rubber
insulators

in
the

suspension
member

and
differential

mounting
memrer

The
rubber
insulators
must
be

replaced
if
the
dimension
A

in

Fig
H
4
is
less

than
5mm
0
2
in
REAR
AXLE
SHAFTS
BEARINGS
AND
SEALS
Saloons

DRNE
SHAFTS

REAR
AXLE
Removal
Estate
cars
and
Vans

REAR
SPRING
Estate
cars
and
Vans

REAR
SHOCK
ABSORBERS
Estate
cars

and
Vans

REAR
SUSPENSION
Installation

Saloons

Installation
is
a
reversal
of
the
removal

procedures
noting

the

following
points

Ensure
that
the
suspension
member
and
differential
mount

ing
member
are

correctly
aligned
as
shown
in

Fig
U
5
and
insert

the
rubber
insulators
from
the
underside
of

the
vehicle

Tighten
the
differential

mounting
member
the

suspension

member
and
lower
shock
absorber
nuts
to

the
specified
tighten

ing
torques

COIL
SPRINGS
Removal

Saloons

Jack

up
the
rear
of
the
vehicle
and

support
it
on
stands

2
Remove
the
road
wheels
and
disconnect
the
handbrake

linkage
and
return

spring

3
Remove
the
drive
shaft
flange
nuts
at
the
wheel
side

Fig

H
6
and
the

bump
rubber

securing
nuts

4
Place

ajack
under
the
suspension
ann
and
remove
the

shock
absorber
from
the
lower

mounting
bracket
Carefully

lower
the

jack
and
remove

the
coil

spring
spring
scat

and

bump
rubber
Fig
H7

COIL
SPRINGS
Installation

Saloons

Oleck
the
coil

springs
for

signs
of
deformation
or
cracks

Test
the

spring
for
its
free

length
and
height
under
load
and

compare
the

figures
obtained
with
the
information
in
Technical

Data
Inspect
all
rubber

parts
and

replace
any
which
are

damaged

or
deformed

Installation
is
a
reversal
of
the
removal

procedure
making

sure
that
the
flat
face
of

the
spring
is
at
the

top

REAR
SHOCK
ABSORBERS
Removal
and
Installation

Saloons

Remove
the
trim
in
the
boot
trunk
and
take
off
the
two

nuts

securing
the

upper
shock
absorber

mounting
See

Fig
H
S

Detach
the
shock
absorber
from
the
lower

mounting
bracket

The
shock
absorber
should
be
tested
and
the

fIgUres
com

pared
with
the

specifications
in
Technical
Data
Cbeck
for
oil

leaks
and
cracks
Make

sure
that
the
shaft

is
straight
and
that
the

rubber
bushes
are
not

damaged
or
defonned
Renew
all
unsatis

75

factory
parts

Installation

is
a

reversal
of
the
removal

procedure

REAR
SUSPENSION

ARM
Removal
and
Installation

Saloon

I
J
ad

up
the
car
at

the
rear
and

support
it
on
stands

2
Remove
the
road
wheel
and
brake
drum
as
described
in

the

section
BRAKES

3
Disconnect

the
drive
shaft
from
the
axle
shaft

4
Disconnect

the
handbrake
cable
from
the

equalizer
bracket

and
the
wheel

cylinder
lever
Disconnect

the
brake
hose

from
the
brake
line

by
removing
the
lock

spring
and
then

withdrawing
through
the
connector

Plug
the
end
of
the

brake

line
to

avoid
loss

of
fluid
and

ingress
of
dirt

5
Remove
the
wheel

bearing
locknut

Fig
H
9
the
rear

axle

shaft

wheel

bearings
and
oil
seal
Remove
the
rear
brake

assembly
from
the

suspension
ann
See
section
BRAKES

6
Jack

up
the

suspension
arm
to

relieve
the
tension
on
the

shock
absorber
and
disconnect
the
shock
absorber
from

the
lower

mounting
Lower
the

jack
gradually
and
remove

the
coil

spring
seat
and

bump
rubber

7
Remove
the
bolts

securing
the

suspension
arm
to

the

suspension
member

Fig
H
IO
and
withdraw
the

suspension

arm

The
rubber
bushes
can

be
drawn
out

of
the

suspension
arm

if

necessary
using
the

special
tool
ST
38280000

Fig
H
Il

O1eck
the

suspension
arm
for
distortion
or

cracks
and

inspect
the
rubber
bushes
for

signs
of
wear
or

damage
Renew

any
part
which

is

unsatisfactory

Installation

is
a

reversal
of
the
removal

procedure
Tighten

all
the

suspension
arm

mounting
bolts
with
the

weight
of

the

vehicle

resting
on
the
rear
wheels
The
self

locking
nuts
must

be
renewed
at
each
overhaul

REAR

AXLE
SHAFTS
BEARINGS
AND
SEALS

Saloon
Removal
and

Dismantling

I
Raise
the
vehicle
at
the

rear
and

place
stands
under
the

body
member

2
Remove

the
road
wheel
and
brake
drum

3
Disconnect
the
drive
shaft
from
the
axle
shaft
and
remove

the
wheel

bearing
locknut
The

special
wrench
ST
38060001

can
be
used
to
hold
the

flange
as

shownin

Fig
H
12

4
Withdraw

the
axle

shaft

assembly
as
shown
in

Fig
H
13

using
the

special
tool
ST
07640000

and
sliding
hammer

ST
36230000
Remove

the
rear
axle
drive

flange

5
Use
a
suitable
drift
or

special
tool
ST
37750000
See

Fig

H
14
to
drive

out
the
inner

bearing
and
oil
seal

F
6
Remove

the

grease
retainer
and
withdraw
the
outer

bearing
with
a
conventional

puller
DO
NOT
re
use
this

outer

bearing

REAR
AXLE
SHAFTS
BEARINGS
AND
SEALS
Saloon

Assembly
and
Installation

Oleck
the
axle
shaft
for

straightness
make
sure
that
it
is

not
cracked
or

damaged
in

any
way
00
NOT
heat
the
shaft

if

attempting
to
re
straighten

Make
sure
that
the

lip
of
the
oil

seal
is
not

damaged
or

distorted
Check
the

bearing
for
excessive

wear
and

damage

Oean
the
wheel

bearings
the
oil
seal

and
the
inside
of
the

axle

housing

When

installing
the
wheel

bearings
the
sealed
side
of
the

outer

bearing
should
face

the
wheel
and
the
sealed

side
of

the

inner

bearing
should
face
the
differential
See

Fig
H
IS

Pressure
must
be

applied
to
the
inner
race
when

fitting

When

replacing
the

suspension
arm
check
that
the
distance

piece
is
0
05
mm
0
002
in
shorter
than
the

length
of
the

housing
dimension
LI
See

Fig
H
16
The
distance

piece
and

axle

housing
code

markings
must
coincide

The
wheel

bearing
grease
must
be

replaced

every
50
000

km
30
000
miles
Pack
the
wheel

bearings
with

grease
at
the

positions
shown
in

Fig
H
IS
and
coat
the

lip
of
the
oil
seal

Renew
the
locknut
and
oil
seal
at

each
overhaul

Wheel

bearing
adjustment

Tighten
the
locknut
to

the

specified
torque
reading
of

25
33

kgm
181
239
lb
ft
and
check
that
the
rear
axle
shaft

end

play
does
not
exceed
0
15
mm
0
006
in
with
a

turning

torque
of
less
than
7

kg
em
6
11b
in
for
the
1400
and
1600cc

models
510

series
or
4
5

kg
em
3
91b
in
for
the
1800cc

610
series

If
the
correct
end

play
or

turning

torque
cannot
be

obtained
it
will
be

necessary
to

change
the
distance

piece
See

above

DRIVE
SHAFTS
Removal
and

Dismantlill8

Disconnect
the
end

flanges
and
remove
the
shaft
See

Fig
H
17
The
drive
shaft
should

only
be
dismantled
to

lubricate
the

splines
This

operation
will

only
be

necessary
every

two

years
or
50
000
km
30
000
miles

Remove
the
universal

joint
spider
at
the
differential
side

Refer
to
the

propeller
shaft
section
Remove
the

snap
ring

securiilg
the
sleeve

yoke
plug
and
take
out

the

plug
Compress

the
drive
shaft
and

remove
the

snap
ring
and

stopper
Fig
H
17

Disconnect
the
boot
and

split
the
shaft
Make
sure
that
the

balls
and

spacers
are
retained

DRIVE
SHAFTS

Inspection
and

Assembly

The
drive
shaft
should
be

replaced
as
an

assembly
if

any

part
is
found
to

be
defective

Check
the
shaft
for

straightness
damage
or
wear
Old

79

the
steel
balls
and
the
sleeve

yoke
for

damage
or
wear
Renew

the
boots
and
the
sleeve

yoke
plug
0

ring
if

necessary
Renew

the
universal

joint
jf

faulty

Check

the

play
in
the
drive
shaft

using
a
dial

gauge
as

shown
in

Fig
H
18
The
measurement
taken
with
the

dri
le

shaft

fully

compressed
should
not

exceed
O
lmm
0
004
in

Renew
the
drive
shaft
as

embly
if
the

specified
value
is
not

obtained

Oean

the
old
grease
from

the
sleeve

yoke
and
the
drive

shaft
ball

grooves
and
lubricate
with
oil

Asse

bly
of

the
drive
shaft

is
a

reversal
of
the

dismantling

procedure
noting
the

following
points

Align
the

yokes
and
make
sure
that

the
steel
balls

and

spacers
are
fitted

in
the
correct
order
Select
a

snap
ring
which

will

adjust
the
axial

play
of

the

universaIjoints
to
within
0
02mm

0
0008
in

Snap
rings
are
available
in

four
thicknesses
of

1
49
1
52
1
55

and
1
58
mm

0
0587
0
0598
0
0610

0
0622
in

Apply
a

generous

quantity
of
multi

purpose
grease
to
the

ball

groove
and
the
area
shown
in

Fig
H
19

REAR
AXLE
Removal
See

Fig
H
2

Estate
car
and
Van

Jack

up
the
vehicle
at
the
rear

and

support
it
on
stands

Remove

the
road

wheels
and
brake

drums
I

3
Disconnect
the
brake
hose
from
the

brake

pipe
Plug
the

end
of
the
hose
to

prevent
the

ingress
of

foreign
matter

4
Disconnect
the
handbrake
rear
cable
from

the
balance

lever

assembly

5
Disconnect

the

propeller
shaft
from
the
differential

flange

Release
the
lower
shock
absorber

self

locking
nuts
and

slide

the

mounting
eyes
of
the
shock
absorber
from
the

rear

spring
seat

pivot

6

Support
the
rear

axle
with

ajack
loosen
the
U
bolts
and

remove
the
nuts
from
the
rear

spring
shackles
Withdraw

the
shackles
from
the

spring
eyes

7
Remove
the
V
bolt
lock
nuts

completely
and
lower
the

jack
to

withdraw
the
rear
axle

assembly

REAR
AXLE

Dismailtling
and

Inspection

Disconnect
the
brake

pipes
from

the
wheel
cylinders
and

remove

the
brake

pipe
and
three

way
connector
Remove
the

cross
rod

clamp
and
the
balance
lever
from
the
rear
axle
case

Remove
both
cross
rod

ends
from
the

wheel

cylinder
lever

assembly

Unscrew
the
oil
drain

plug
and
drain
the
oil
from
the
axle

case
into
a
clean
container
The
oil

may
be
re
used
if
it
is
in

good
condition

Remove
the
nuts

securing
the
brake

backplate
to
the
axle

case
and
draw
out
the
axle
shaft

assembly
with
the

backpl
te

and
grease
catcher
A

sliding
hammer

ST
36230000
should
be

used
for
this

operation
as
shown
in

Fig
H
2Q

The

bearing
collar
can
be
removed
with
a

press
or

by

cutting
with
a
cold
chisel

and
the

bearing
withdrawn
with
the

puller
ST
3712001
as
shown
in

Fig
H
2t
Remove
the
brake

backplate
and
withdraw

the

gear
carrier
from

the
axle
case

Check
the
axle
shafts
for

straightness
wear
and
cracks

00
NOT

attempt
to

straighten
a
bent
shaft

by
heating
Check

the
oil
seal
lips
for

signs
of

damage
or
distortion
Make
sure

that

the

bearing
is
not
worn
or

damaged
REAR
AXLE

Assembly
and
Installation

Assembly
is
a
reversal
of
the

removal

procedure
noting
the

following
points

Thoroughly
clean
all

parts
and
fit
a
new

gasket
between

the
axle
case

and

gear
carrier

Tighten
the
nuts
in
a

diagonal

pattern
and
to

the

specified
torque
readings

Fit

the
grease
catcher

bearing
spacer
bearing
and
new

bearing
collar
onto
the
axle
shaft
A
load
of
4
5
tons
will

be

required
to

press
the

bearing
onto

the
shaft

Insert
the
wheel

bearing
with
the
seal
side

facing
the

wheel
and
ensure
that
the

oil
seal

lips
are
coated
with
wheel

bearing
grease
prior
to

fitting

Check
and

adjust
the
axial

play
between
the
wheel

bearing

and
the
axle

housing
using
a

dial
gauge
as

shown
in

Fig
H
22

The
axial

play
should
be

adjusted
to
within
0
3
0
5mm

0
0118
0
0197
in

on
the
1400
and
1600cc

models
and
to

within
O
lmm
0
0039
in
on

the
1800cc
models

Fill
the
rear
axle
with
the

specified
amount
of

oil
and

bleed
and

adjust
the
brake

system
as
described
in

the

appropriate

section

REAR
SPRING
Removal
and

Inspection

Estate
cars
aud
Vans

The
rear

springs
can
be
removed
in
the
following
manner

Jack

up
the

vehicle
at
the

rear
until
the
wheels
are
clear

of

the

ground
and

place
stands
under
the
rear
frame

Disconnect
the
shock
absorber
from

the

spring
seat

Fig
H
21a
and

support
the
rear
axle

housing
with

ajack

3
Take
off

the
locknuts

and
remove

the
U
bolts
shown

arrowed
in

Fig
H
2t
the

spring
seat
location

plates
and

seat

pads

4
Remove
the
nuts

securing
the
front
bracket
to
the

body

remove
the
bracket
from

the

spring
eye
and
car

body
and

withdraw
the
rear

spring

5
Remove

the

upper
and
lower

rear
shackle
nuts

Fig
H
23

and
remove
the
rear

spring
from
the
vehicle

Clean
the

spring
leaves

thoroughly
and
examine

them
for

fractures
or
cracks
Renew
the

assembly
if

necessary

Check
the
front

pin
shackle
U
boIts
and

spring
seat

for

signs
of
wear
cracks
and

damaged
threads
Renew
the

components
as

required

REAR
SPRING
Installation

Installation
of
the
rear

spring
is
a
reversal
of
the
removal

procedure
noting
the
following

points

The
front
bracket

pin
front
bracket

bushing
shackle

pin

and
shackle

bushing
should
be
coated
with
a

soapy
solution

prior
to

assembly

Tighten
the
front

pin
securing
nut

and
the
shock
absorber

lower

securing
nut
with
the
vehicle

weight
resting
on
the
rear

wheels

Ensure

that
the
flange
of

the
shackle

bushing
is

clamped

evenly
on
both
sides

The

tightening

torque
values
can

be
found

on
the

page

entitled
TIGHTENING

TORQUES

81

the
castle
nut
and
detach
the
tie
rod
from
the
knuckle
arm

5
Remove
the
tension
rod

securing
nuts

Fig
J
7
remove

the
bolts
and
withdraw
the
tension
rod
Withdraw
the
nut

shown
arrowed
in

FigJ
8
and
remove
the
stabilizer

6

Support
the

engine
with
suitable

lifting
tackle
so
that

the

engine
mounting
bolts
can

be
removed
and
the

suspension

crossmember
detached
from
the

engine
FigJ
9

7
Place

ajack
under
the
crossmember
Remove
the
bolts

indicated
in

Fig
J
IO
and

separate
the
crossmember
from

the

body

8
Remove
the
strut

assembly

upper
attachment
self

locking

nuts
at
both
sides
Fig
J
ll

and
lower

the
front

suspension

assembly
to
remove
it
from
the
vehicle

FRONT
AXLE
AND
SUSPENSION
ASSEMBLY
Installation

Installation
is
a
reversal
of

the
removal

procedure
noting

the

following
points

Make
sure
that
all
rubber

parts
are
free
from
wear
and

deterioration

Any
part
of

the
suspension
assembly
which
has

been

damaged
or
distorted
must
be

replaced
The
front
wheel

alignment
should
be
checked
after

completing
the
installation

a
brief

description
is

given
at
the
end
of
this
section
Camber

and
castor

angles
are

preset
and
cannot
be

adjusted

SPRING
AND
STRUf
ASSEMBLY
Removal
and
Installation

The
strut

assembly
consists
of
the
outer

casing
piston
rod

piston
rod

guide
and
cylinder
etc
An

exploded
view
of
the

components
is

given
in

Fig
J
12

The
inner

components
must

be
replaced
as
a

complete

assembly
Replacement
and
overhaul

procedures
for

the
inner

components
together
with
the
removal
of
the
front

springs

should

only
be
carried
out

by
a
specialist
Datsun

workshop

The
strut

assembly
can
be
removed

prior
to

dismantling
by

following
the

procedures
outlined
below

Jack

up
the
front
of
the
vehicle
and

support
it
on
stands

2
Disconnect
the
brake
hose
from
the
strut

assembly
bracket

as

previously
described
under
the

heading
FRONT
AXLE

and
SUSPENSION
ASSEMBLY
Removal

3
Remove
the
stabilizer
bar
and
tension
rod
from
the
trans

verse
links
Loosen
and
remove

the
knuckle
arm

fixing

bolts

Fig
J
9
And

separate
the

strut
assembly
from
the

ball

joints

4
Remove
the
strut

assembly

upper
attachment
self

locking

nuts

Fig
J
11
and
withdraw
the
strut

assembly
from

the

body
Fig
J
13

Installation
is
a
reversal
of
the
removal

procedure
Ensure

that
the
bolts
are

tightened
to

the
specified
torque
readings

given
under
TIGHTENING

TORQUES
SPRING
AND
STRUT
ASSEMBLY

Dismantling
and

Assembly

Care
must
be
taken
when

dismantling
the
assembly
to

ensure

that
aU

parts
are
maintained
in
a
clean
condition

Clamp
the

suspension
strut

assembly
in
a
vice
and
fit
the

special
attachment
ST
2770000
I
to
the
lower
end
of
the
strut

Prise
off
the
dust
cover

snap
ring
Use
the
coil

spring
compressor

ST
35650001
to

slightly

compress
the

spring
Remove
the
self

locking
nut
and
take
off
the
mounting
insulator
thrust
bearing

spring
seat
and

bump
rubber
Slacken
the

spring
compressor
and

remove

the

spring
Push
down
the
shock
absorber

piston
until
it

bottoms
and
remove

the

gland
packing
with
the

special
tool

ST
35500001

Fig
J
14
Remove
the
O

ring
from
the

piston

rod

guide
and
lift
out

the
piston
rod
and

cy
linder

assembly

00
NOT

separate
the

piston
and

cylinder
which
are
serviced

as
a

complete
assembly
Drain
all
fluid
from
the

suspension
unit

and
shock
absorber

assembly
Wash
all

parts
thoroughly
not

rubber

parts
in

petrol
or
a
suitable
solvent

The

gland
packing
and
0

ring
must
be
renewed
at

each

overhaul

Always
refill
with
the
correct

grade
of
fresh
oil
in

accordance
with
the
information
in
the
table
below

ATSUGI
KAYABA

Part
No

54302
UO
100

UOl10
325
cc
332
cc

54302
3
U0500
1

54302
N
1200
325
cc
300
cc

The
oil

quantity
is
extremely
critical
as
it
will
affect

the

damping

power
of
the
shock
absorber

To
assemble
fit
the
rubber
O

ring
on
the

top
of
the

piston

rod
and
refit
the

gland
packing
Take
care
that
the
oil
seal
does

not
become

damaged
during
the
latter

operation
Lift
the

piston

rod

up
by

approximately
90
mm
3
5
in
before

tightening
the

gland
packing
to
facilitate

bleeding
then

tighten
the
packing

to
a

torque
reading
of
7
13

kgm
51
94Jb
ft
Bleed
the

shock
absorber
by
pumping
the

piston
rod

up
and
down
until

the

pressure
is
the
same

in
both
directions

Position
the
coil

spring
bump
rubber

spring
seat
and
dust

cover
on
the

top
of
the

piston
rod
The

piston
rod
must
be
in

the

fully
extended

position
Compress
the

spring
fit
the
strut

mounting
insulator
and

bearing
assembly
Tighten
the
self

locking
nut
to
a

torque
reading
of

6
7
5

kgm
43
541b
ft

SPRING
AND
STRUT
ASSEMBLY
Installation

Installation
is
a
reversal
of

the
removal

procedure

Thoroughly
grease
the

parts
marked
in

Fig
J
15
Tighten
the

fixing
bolts
to
the

torque
readings
given
in
TIGHfENING

TORQUES

TRANSVERSE
LINK
AND
LOWER
BALL
JOINT
Removal

The
transverse
link
with
rubber

bushing
is
connected
to

the

suspension
crosSlTIember

by
a

mounting
bolt
as
shown
in

Fig
J
11
and
to

the
strut

assembly
via
the
lower
ball

joint

87

Removal
from
the
vehicle
can
be
carried
out
in
the

following

manner

Jack

up
the
front
of
the

vehicle
and
support
it
on
stands

2
Remove
the
stabilizer
bar
and
tension
rod
from

the

transverse
link
as

previously
described
Remove
the
knuckle

arm

fixing
bolts
and

separate
the
ball

joint
from

the
strut

asse
m

bly

3
Remove
the
transverse
link

mounting
bolt

Fig
J
16
and

detach
the
transverse

link
from

the
suspension
member

Remove
the
cotter

pin
from
the
knuckle
arm
castle
nut

and
remove
the
knuckle
arm
from
the
ban

joint
Unfasten
the

ball

joint
securing
nut
and
withdraw
the
ball

joint
from
the

transverse
link

r
The

bushing
can

be
withdrawn
from
the
transverse
link

using
a

press
and
the

special
tools
shown
in

Fig
J
17

TRANSVERSE
LINK
AND
LOWER
BALL
JOINT

Inspection

The
transverse
link

bushing
is
shown
in
Fig
J
18
If
the

rubber
and
inner
tube

joints
are
melted
or
cracked
the

complete

transverse
link

assembly
must
be

replaced

The
ban

joint
cannot
be
dismantled
and
should
be

replaced

if
the
dust
cover

is

split
or
if
the
axial

play
of
the

joint
exceeds

1
0
mm
0
039
in
Oleck
the
axial

play
with
a

spring
balance

The
force

required
at

the

cotterpin
hole
pOsition
is
between

6
6
1
I
3

kg
15
25
lb

Lubricate
the
ball

joint
with
multi

purpose
grease
every

50
000
km
30
000
miles
or
two

year
whichever
comes
first

A
grease

nipple
must

be
installed
in

place
of
the

plug
See

Fig
J
19
and
the
old

grease
completely
replaced
If
a

high

pressure
grease
gun
j
used
make
sure
that
the

grease
is

injected

slowly
and
is
not
forced
out

through
the

joint
clamp

Remove
the
grease

nipple
and

replace
the

plug

TRANSVERSE
LINK
AND
BALL
JOINT
Installation

Installation
is
a
reversal
of

the
removal

procedure
noting

the
following
points

Remove
all
rust
from
the
transverse
link

bushing
interior

with
a

piece
of

emery
cloth
The

bushing
and
transverse
link

bore
should
be
wetted
with

soapy
water
so
that
the

bushing

can
be
more

easily
inserted

Fit
the

bushing
into
the
transverse

link

using
the

special

tool
ST
36700000

Adjust
the

bushing
inner
tubes
so
that
the

distances
from
the
transverse
link
collar
ends
are

equal
at
both

sides

88
Install
the
lower

ball

joint
on
the
transverse
link
and

tighten
the
installation
bolt
to
a

torque
reading
of
1
9

5kgm

14
18Ib
ft

Oean
the
knuckle
arm
and
the
ball

joint
stud
install
the

knuckle
arm
on
the
ball

joint
and

tighten
the
castle
nut
to
a

torque
reading
of
5
5
74

kgm
4o
53Ib
ft
fit
the

cotterpin

and
bend
it
over

Apply
sealing
agent
over
the
ball

joint
castle

nut
to

prevent
the
formation
of
rust

Locate
the
knuckle
arm
beneath
the
strut

assembly
and

tighten
the

mounting
bolts
to
a

torque
reading
of
4
9

63kgm

35
46Ib
ft
Make
sure
that
the
shorter
of
the
bolts
is
fitted

at
the
front

Install
the
transverse
link
on
the

suspension
crossrnember

and

temporarily
tighten
the
mounting
bolts
Make
sure
that
the

nut

faces
the
front
of

the
car
and
not

the
bolt
head
Fit
the

tension
rod
and
stabilizer
bar

Lower
the
vehicle
and
remove
the

jack
Tighten
the
trans

verse

link

mounting
bolts
to
a

torque
reading
of
9
0
10
0

kgm

65
72
Ib
ft
with
the
vehicle
unladen

FRONT
WHEEL
ALIGNMENT

The
castor

and
camber

angles
are

preset
and
cannot

be

adjusted
If
the

angles
do
not

conform
with
the

fIgures
in

Techni
al
Data
then
a
check
must
be
made
for

damage
to
the

uspenSlon
system
Wheel

alignment
is
carried
out
with
the

tyres

mflated
to
the
correct

pressures
and
with
the
vehicle
on
a
level

surface
The
toe

in
should
be
checked
and

adjusted
if

necessary

by
slackening
the
locknuts

FigJ
20

and

turning
the

track
rods

by
an

equal
amount

until
the
correct
toe
in
is
achieved
The

standard

length
between
the
ball

joints
is
309
5
mm

12
19
in

for
the
1400
and
1600
cc
models
and
105
5
mm
4
14
in
for

the
1800
cc

models

ADJ
USTING
THE
STEERING
ANGLE

The

steering
angle
at
the
full
lock

positions
must
be

checked
with
the
front
wheels

placed
on
a
turntable

Adjust

ment
can
be
made

changing
the

length
of

the
stopper
bolt

shown
arrowed
in

FigJ
21
The
clearance
between
the

tyre

and
tension
rod
should
be
30
mm

1
181
in
or
more
and
can

be
increased
if

necessary
by
extending
the
length
of
the

stopper

bolt
The
bolt

length
should
not
exceed
27
5
mm
1
083
in

when
the
adjustment
is

completed

Steering
angle
figures
are

given
in
Technical
Data

at
the

end
of
this
section