1969 DATSUN 610 technical data

Check
the
run
out
at
the

ceac
of
the
crownwheel
if
the
back

lash
or

tooth
contact

pattern
is
incorrect
The
run
out
should

not
exceed
0
08mm
0
003
in
Measure
the

turning
torque

of

the
drive

pinion
which
should
be
within
7

IOkg
cm
6
9Ib
in

Shims
and

adjusting
washers
must
be

changed
if
the
tooth

contact

pattern
and
backlash
is
incorrect
the
necessary
details

for
these

operations
can

be
found
towacds
the
end
of
this

section
under
the

heading
TOOTH
CONTACT
PATTERN

To
dismantle
the
differential
remove

the

flange
clamp
bolt

and
extract

the
side

flange
as
shown
in

Fig
GA

using
the

special
stand
ST
33730000
and

sliding
hammec
ST
36230000

Remove
the

bearing

caps
with
a
suitable

puller
as
shown

in

Fig
G
5
Remove
the
left
hand

cap
first
followed

by
the

right
hand

cap
The

caps
should

be
marked

to
ensure
that

they

are

refitted
in
their

original
positions
Withdraw
the
differential

cage
from

the
carrier

Fig
G
6

Slacken
the
drive

pinion
and
hold
the

flange
with
a

suitable
wrench
as

shown
in
Fig
G
7
Withdraw

the
flange
with

a
standard

puller
Press
the
drive

pinion
out
of
the
differential

carrier

together
with
the
rear

bearing
inner
races
the

spacers

and
the
shims
Place
a

press
plate
between

the
drive

pinion
head

and
rear

bearing
and

press
out
the

pinion
shaft

The
inner
races

need
not
be
removed
if
the
tooth
contact

pattern
is
correct
and
the
crownwheel
drive

pinion
carrier

rear

bearing
and
shims
etc
are
to

be
re
used
The
front
and

rear
outer
races
of
the

pinion
bearings
can
be
removed
with
the

special
tool
ST
30610000
or
with
a

suitable
drift

To
dismantle
the
differential

cage
remove

the

right
hand

bearing
cone
as
shown
in

Fig
G
8
The

special
puller
ST
3306

0000
and

adaptor
ST
33052000
should
be
used
for

this

pur

pose

taking
care
not
to

damage
the

edge
of
the

bearing
innec

race
Flatten
the

lock

straps
slacken
the

crownwheel
bolts
in

a

diagonal
pattern
and
remove

the
crownwheeL

Remove
the
left
hand

bearing
cone
in
a
similar

manner
to

the

right
hand

bearing
cone
Make
sure
that
the

parts
do
not

become
mixed
and
can
be
assembled
in
their

original

positions

Punch
out
the
differential
shaft
lock

pin
from
the
crownwheel

side

using
a

suitable
drift
Great
care
must

be
taken
when

carrying
out
this

operation
as
the

pin
is
caulked
into
the
hole

in
the
differential

cage

Remove
the
shaft
the
differential

pinion

gears
and
the
side

gears
and
thrust
washers

Separate
the
left
and

right
hand

gears

and
washers
so
that

they
can
be
reassembled
in
their

original

positions

Replacing
oil

seals
with

the
differential
installed

The
oil
seals
can

be

replaced
if
necessary
with
the
differ

ential
fitted
to
the
vehicle

Front
oil

seal

Drain
the
oil
from
the
differential

unit
and
jack
up
the

vehicle
at
the
rear
Remove
the

propeller
shaft
from
the

differential

flange
Disconnect
the
handbrake
left
hand
rear

cable
Slacken
and
remove
the
drive

pinion
nuts
whilst

holding

the
drive
flange
with
a
suitable
wrench
or

special
tool
ST

31530000
Withdraw
the
drive

flange
with
a
conventional
two
l

arm

puller
as
shown
in

Fig
G
9
Use
the
oil
seal

puller
ST

33290000
to
withdraw
the
oil
seal
from
the
retainer

Replace

the
oil
seal

using
a
suitable
drift
or

special
tool
ST
33270000

Fill
the
oil
seal

lips
with

grease
when
installing
Fit
the
oil
seal

retainer
and
replace
the
various

parts
in
reverse

order
to

the

removal

procedure

Side
oil
seal

Detach
the
drive
shaft
from
the
side
flange
of
the
differ

ential
carrier
Extract
the
side

flange
with
the
slide
hammer

ST
36230000
and

adaptor
ST
33730000
as
shown
in

Fig
G
lO

Remove
and
replace
the
oil
seal
in
a
similar
manner
to

that

previously
described
for
the
front

oil
seal

taking
care
to

apply

grease
between
the
oil
seal

lips

DIFFERENTIAL

Inspection

Clean
the

parts
thoroughly
and

inspect
them
for

signs
of

wear
or

damage

Check
the
gear
teeth
for
scores
cracks
or

excessive
wear

Check
the
tooth
contact

pattern
of
the
crownwheel
and

pinion
for
correct

meshing
depth
The
crownwheel
and

pinion
are

supplied
as
a
set

and
should
either

part
be

damaged
it
will
be

necessary
to
renew
the

complete
set

2
Check
the

pinion
shaft
and

gear
mating
faces
for
scores
or

wear

Inspect
the
inner

faces
of
the
side

gears
and
their

seating
faces
on

the
differential

cage

3

Any
small
defects
on
the
faces
of
the
thrust
washers
can

be
corrected

using
emery
cloth
The
thrust
washers
must

be

replaced
however
if

the
backlash
between
the
side

gear

and

pinion
exceeds
0
2mm
0
008
in
and
the
clearance

between
the
side

gear
and
thrust
washer
exceeds
O
3mm

0
012
in
Three
sizes
of
washers
are
available
and
the

thicknesses
are
detailed
in
Technical
Data
at

the
end
of

this
section

4
Measure
the
run
out
of
the
crownwheel
at
the
rear
with
a

dial

gauge
Replace
the
crownwheel
and
drive
pinion
as
a

set
if

the
run
out
exceeds
the

permissible
value
of
O
08mm

0
003
in

5
Examine
the
differential
carrier

and

cage
for
cracks
or

distortion
Renew

any
part
found
to

be
defective

It
is

advisable
to
renew
all
oil
seals

DIFFERENTIAL

Assembly
and

Adjustment

Assembly
is
a
reversal
of
the
removal

procedure
noting

the
following
points

Arrange
the
shims
and
washers
etc
in
their
correct

order

and

thoroughly
clean
the
surfaces
to

which
the
shims
washers

bearings
and

bearing
retainecs
are
to
be
installed

Differential

cage

Fit
the
differential
side

gear
and
bevel

gear
in
the

cage

using
the
correct
thrust
washers
Insert
the

pinion
shaft
so
that

the
lock

pin
hole

corresponds
with
the
hole
in
the
differential

65

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

Check
the
run
out
of
the
crownwheel
as

shown
in

Fig
G
15

Position
the

dial
gauge
to

the
rear

of
the
crownwheel
and
check

that
the
run
out
does
not

ceed
0

0
mm
0

0020
10
I
It
the

run
out

limit
is
exceeded

replace
the
crownwheel
and

pinion

as
a
t

Inspect
the
differenti
l
L
arrier
nd
case
for

cracks
or

distortion
and

replace
them
if

necessary

DIFFERENTIAL

GEAR
CAGE

Assembli
g

V
Install
the
differential

side

geaI
5
pinions
and

original
thrust

washers
into
the

cage
and
check
the
clearance

between
side

gears

and
thrust
washers
The

clearance
must
be

adjusted
to

within

0

05
0
20
mm
0
002
0
008

in
for

the
1400
and
1600
cc

models

and
to

within
0
10
0
20
mIT

0
004
0
008
in
for

the

1800
cc
models
Correction
can

be
made
if

necessary
by
replacing

the

thrust
washers
which
are
available
in
the

following
sizes
t

SIDE

GEAR
THRUST
WASHERS

f
1400
and
1600

cc
Estate
car
0
78
0
83
0

88
1
03
1
23
mm

0
0030
0
0327
0
0346

0
0406
0

0484
in

l800cc

Estate
car
0
785
0
835
0
885

1
035

I
185
mm

0
0309
0
0329
0
0348
0
0408

0
0467
in

1800
cc

Van
0

75
0
80
mm
0
80
0

85
mm

0
85

0
90
mm
0
90
0
95
mm

0
0295
0
0315

in
0
0315

0
0335
in
0
0335
in
0
0354
in

0
0354
0

0374
in

Drive
in

the
differential

pinion
lock

pin
from
the

right
hand

side
of
the
case
and

peen
the
rim
of
the
hole

to

prevent
the

pin

from

working
loose

Fit
the
crownwheel

to
the
differential

cage
and

install
the

bolts
and
new
lock

plates
Tap
the
head
of

each
bolt

lightly

and

tighten
the
bolts
in
a

diagonal
pattern
to
the

specified

torque
readings

Press
in
the
side

bearing
inner
race
with
a
suitable
drift

The

crown
wheel

adjusting
shims
must
be

placed
behind
the

bearings
to
obtain

the
correct

pre
load
Press
the

drive

pinion

rear

bearing
outer
race

and
front

bearing
outer
race
into
the

carrier

The
shim
at
the

rear
of
the
outer
race

must
be
increased

or
decreased
to

adjust
the

pinion
height
as
described

below

Adjusting
the
drive

pinion

The

pinion
height
or
distance
from

the
face

of
the

pinion

to
the
axis
of

the
crownwheel
is

adjusted
by
altering
the
thick

ness
of
the

adjusting
shim

between
the

drive

pinion
gear
and

the
rear

bearing
cone
The
drive

pinion
ha

a
tolerance
mark

etched

on
its
face
as

shown
in

Fig
G
26
This
tolerance
is

accompanied
by
a
or

sign
to
show

the
deviation
from
the

nominal
dimension
of

86mm
0
386
in
see

Fig
C

n
The

plus

sign
indicates
that
the

nominal
dimension
must
be
increased

by
the

figure
on

the

pinion
and
the
minus

sign
that
it
must
b

decreased

To
determine
the
thickness
of

the
drive

pinion
shim

press

the
front

and
rear

bearing
outer
races
into
the

carrier
fit
the

70
rear
be

ring
and

dummy
shafr
and

place
the

Ippropriatt
ettil1g

gauge
on

the
carrier
See

Fig
C
2S
l

The

fOllowing
setting

gaUges
and

dUlllmy

shaft
houlJ
bt
llsed
for
th
various

modds

I
OO
and

1600
Estate
c

r

Setting
g
3uge
ST
1941000

Dummy
shaftST
31942000

ISOOce
Estate
car

Setting
gauge
ST
31141000

Dummy
shaftST
1941000

1800cc
V

n

Setting
gauge
5T
3
I
Y41

000

Dummy
sh
ftST

31941000

Measure
the
clearance
N

Fig
C
l8
berween
the

tip
of

the

setting

gauge
and
the
face
of

the

dummy
shaft

with
a
feeler

gauge
Determine
the
thickness
of
shim

required
using
the

following
formula

T
N
H
D

S
x
0
01
0
28
station

wagon

T
N
H
D
S
x
0
01
2
18
Van

Whe
rc

T
The

required
thickness
of

adjusting
shim
mrn

N
The
measured
clearance
mm

H
The

plus
or

minus

figure
on
the

pinion
head

D
The

figure
on

the

dummy
shaft

S
The

figure
on
the

setting
gauge

As
an

example
for

the
Estate
car

N
0
30mm
H

1
D
I
S
O

T
0
30
2
1
0
x
0
01
0
28
0
59
mm

Shims
are

available
in
thicknesses
of
0
050

0
070
0
10

0
20
and
0
50
mID
0
0019
0
0027

0
0039
0
0078
and

0
0196
in
for
the
Estate

cars
and
in
thicknesses
of
2
37
2
97mm

0
0933
0
1169
in
for
the
1800cc
Van

Take
off

the
drive

pinion
and
the
rear

bearing
outer
race

and

adjust
the

position
of

the
drive

pinion
by
installing
shims

of

selected
thicknesses
Fit
the
drive

pinion
and

bearing

spacer

in

the

pinion
housing
and

tighten
the
drive

pinion
nut
to
a

torque
reading
of
14
17

kgm
101
130
Ib
fl
for

the
Estate

cars
or

13
20

kgm
94
145Ib
ft
for
the
1800
cc
Van

Adjusting
the
drive

pinion
preload

The
drive

pinion
preload
on
Estate
car
models
is

adjusted

by
meam
of
the

adjusting
spacer
and
the
shims
between
the

spacer
and
the
front

bearing
inner
race

On
the
1800
cc

van
a

collapsible

pacer
is
u
sed

to

adjust

the

preload

Estate
car

O1eck
the

preload

by
attaching
a

preload
gauge
to

the

pinion

flange
and

adjust
by
selecting
spacers
and
shims
from
the

sizes

given
in
Technical

Data
The
initial

turning

torque
without

the
oil
seal
and
with

the
drive

pinion
nut

tightened
to
a

torque

reading
of
14

17

kgm
101
130
Ib
ft
should
be
10
13

kg
m

138
9
180
5
in
oz
for
new

bearings
If
used

bearings
are

fiued

the
initial

torque
must
be
reduced

by
20
to
40
Cneck

the

pinion
height
as

previously
described
and
re

adjust
if

necessary

Remove
the

pinion
nut
and

nange
Press
the
new
oil
seal

into
the
carrier

ensuring
that
the

lips
of
the

seal
are

thoroughly

greased
Install
the

flange
washer
and

pinion
nut
Tighten
the

nut
to
a

torque
reading
of

14
17

kgm
101
130
Ib
fL
If

the
cotter

pin
hole
is
not

correctly
aligned
a
suitable

washer

should
be
fitted
Do

NOT

adjust
by
overtightening
the

pinion

nul

Van

Lubricate
the
front

bearing
with
oil
and

place
it
in
the

carrier
Grease
the

lip
of
the
oil
seal

and
install
it
to
the
final

drive

housing
Install
the
drive

pinion
the
new

collapsible
spacer

and

the
drive

flange

Fit
the
drive

pinion
nut
and

tighten
temporarily
until
all

slackness
is
eliminated
from
the
front

and
rear
of
the
drive

pinion

NOTE

Ensure
that
oil
and

grease
have
been

completely

removed
from

the
threads
of
the

pinion
gear
the

pinion

nut
and
the
washer

Tighten
the

pinion
nut
and
check

the

preload
with
a

preload

gauge
As
the
nut

is

tightened
to
the

specified
torque

reading
of
13
20

kgm
94
0
144

6Ib
fL

the

preload
must
be

measured
at

every
five
to
ten

degrees
turn
of

the

pinion
nut

As
the

pinion
nut
is

tightened
the

stepped
portion
of
the

spacer

is
deformed
See

Fig
G
29
J
and
the

length
between
the

bearings

adjusted

The
drive

pinion
bearing
preload
with
oil
seal
and
new

bearing
is
7
15

kg
cm
6
1
13
0
lb
in

Turn
the
drive

pinion

to
settle
the

bearing
and
re
check
the

preload
and

tightening

torque
If
the

preload
rate
is
exceeded
it
will
be

necessry
to
fit

a
new

spacer
the
old

spa
cr
cannot
be

reused
and
the
preload

must
not
be

adjusted
by
loosening
the
pinion
nul

Side

bearing

pre
load

adjusting

If

the

original
side

bearings
arc
to
be
used

the
shims
must

be
of
the

same
thickness
as
those

previously
fitted

To
select
shims
for
new

side

bearings
proceed
as
follows

The
standard

width
of
the
side

bearings
is

given
in

Technical
Data
This

width
must

be
measured
before

attempting

to

calculate
the

required
thickness
of
the

adjusting
shims
Place

a

weight
of

approximately
5

kg
5
5
lb
and
of

predetermined

height
onto
the
side

bearing
as
shown

in
Fig
G
30
Mcasure

the

width
of
the

bearing
with
a
dial

gauge
as
illustrated

turning

the

bearing
two
or

three
times

to

gain
an
accurate
meaSurement

Dimensional
variations
from
the
standard
measurements

are
marked
on
the
left

side

bearing
housing
of
the

gear
carrier

on

the

right
side

bearing
housing
of
the

gear
carrier
and
on

the

differential

case
These

variations
are
marked
in

units
of

l
lOOmm

and
are
used
for
the

f
rmula
to

calculate
t1H
thickness
of

the

adjusting
shims
in
the

following
manner

Where
TI

equals
the
left
side

bearing
shim

crownwhecl

side

T2

equals
the

right
side

bearing
shim

pinion
gear
A

equals

the

figure
marked
on

the
left
side

bearing
housing
B

equals
the

figure
marked
on
the

right
side

bearing
housing
C
and
0

equals

the
figure
marked
on

the
differential
case
and

E
and
F
is
the

difference
bctween
the

width
of

the
side

bearings
and
the

standard

bearing
width
H
the

figure
marked
on
the

crownwhcel
Fig
G
31
The
following

formulae
can
now
be
used

to
deter

mine
the

required
shim

thicknessl
s
for

both
side

bearings

I
OOcc
Estate
car

Left

side

bearing
TI
A
C

D
H
x

0
01
0
100
E

Right
side

bearingT2
B
D
H
x

0
01
0
090
F

I800cc

Van

Left
side

bearingTI
A

C
D
H

xO
OI
0
175
E

Right
side

bcaringT2
8
D
H
x
0
01

0
150
F

As
an

example
where
A
1
B
C
2
D
3
E
0
02mm

H
I

The
formula
for
the
left

side

bearing
is

T
I
I
1
3
1

x
0
01

0
175
0
02
0
205mm

1400
and

1600cc
Estate
car

The

required
thickness
of
shim
can
be
found

using
the

following

formula
in

a
similar
manner
to

that

previously
described
for

the
1800cc
models

Left

side

bearing
T
I
A

C
D
E
7

Right
side

bearing
T2
B
D
F

6

Shims
are
available
in
five
thicknesses
of
0
05
0
07
0
10

0
20
and
0
50
mm

0
002
0
0028
0
0039
0
0079
and

0
0197

in

Fit
the
selected
side

bearing
adjusting
shims
on
the

differential

cage
and

press
in
the
side

bearing
inner
races

using

a

suitable
ddfL
nstall
the
differential
cage
into

the
carrier
and

fit
the

bearing

caps
Ensure
that
the
marks
on

the

caps
coincide

with
the
marks
on
the
carrier

Tighten
the

bearing
cap
bolts
to

the

specified
torque
reading
See

Tighte
ing
torques

Measure
the
dimension

between
the
outer

edges
of

the

left

and

right
hand

caps
using
a

large
micrometer
as
shown
in

Fig
G
32
This
dimension
should
be
198
40
198
55
mm

7
8110
7
8169

in
for

the
1400

and
1600
ce
Estate
cars
and

1800
ce

Van
and
173
23
17329
mm
6
8201
6
8244
inl

for

the
1800
cc

Estate
cars

Measure
the
backlash
of
the
crownwhcel
and

pinion
with

a
dial

gauge
The
backlash
must
be

adjusted
to
0
13
0
18
mm

0
005

0
007
in
on

the
1800
CC
models

and
to
0
15
0
20mm

0
006
0
008
in
on
the
1400
and
1600
cc
models

Adjustment

can
be
carried
out

by
moving
side

bearing
shims
from
the

right

hand
side
to
the
left
hand
side
if
the
backlash

is
too

high
or
vice

verca
if
the
backlash
is
too
low

Tighten
the

bearing
cap
bolts

to

the

specified
torque

reading
after

adjusting
Ensure
that
the

run
out
at
the
rear
of
the
crown
wheel

does
not

exceed
O

05mm

0
002
in

Finally
heck
the
tooth
contact

pattern
as
described
below

TOOTH
CONTACT
PATTERN

Checking

The
final
check
on

reassembly
is
an

inspection
of
the

tooth

contact

markings
of

the
crownwhed
and

pinion

Apply
a

coal
of
red
lead
in

oil
to
4
or
5
teeth
of
the
crown

wheel
Turn
the
crownwheel
backwards

and
forwards
several

times
to
obtain
a
clear

impression
of
the
contact
areas

Heel
contact

Fig
G
3
1

71

increase
the
thickness
of
the
drive

pinion
adjusting
shim

and
washer
to
move
the
drive

pinion
closer
to
the
crown
wheel
A
correct

contact

pattern
showing
the

impressioll
ithill

a

range
of
2

3
to
4

of
the

distance
bct
l
en

t
h

tip
lllU
till

root
of
the
teeth

under
no

load

Toe

contact

Fig
G
34

Rcdu
e

the
thickness

of
the
drive

pinion
adjusting
shim
and

washer
to
move
the
drive

pinion
away
from
the
crown
wheel
It
will
be
neCL

ssary
to
rc

check
the
backlash
bl

tW
Cl1
drivt

pinion
and
crown

wheel
if
the

adjusting
shim

1l1d
washer
arc

changed

Flank
contact

Fig
G

35

DIFFERENTIAL
Installation

This

pattern
should
be

adjusted
in

a
similar
manner

to
toe

contact

Face
contact

Fig
G
36
Installation
of
the
differential
carrier
is
J

reversal
of
the

removal

procedure
Reference
should
be

made
to
the
section

REAR
AXLE
AND
REAR
SUSPENSION
for
a
dl

saipIion
of

the

operations
required
to

replace
the
axle

shafts

This

pattern
should
be

adjusted
in

a
similar
manner
to

heel
contact

Correct
contact

Fig
G
37

Technical
Data

PROPELLER
SHAFT

Axial

play
of

spider
journal
0800

Axial

play
of

spider
journal
1400
and
1600
cc
0
Q2
mm

0
0008
in

0
08
mm
0
003
in

Max
run

out
of
shaft

Wear
limit
of

spider
diameter
0
6
mm
0
024
in

0
15
mm

0
006
in

Permissible

dynamic
unbalance

Two

joint
shaft

Three

joint
sh
lft
15
gr
em

0
208
in
oz
at
4000

rpm

35

gr
cm
0
5
in

oz
at
5800

rpm

FINAL
GEAR
RATIOS

1800cc
Saloon
6101

ISOOcc
Estate
Car

610

1800cc
Van
610

1600cl
SJloon
610

1400

and
1600cc

510
4
Door
Saloon
RHO

4
Door
Saloon
LHD

De

Lu
e
4
Door
Saloon
RHO

SSS
4
Door
Saloon
RHO

Door
Saloon
LHO
3700

3
889

4
375

3
900

4375

4111

3
889

3
900

3
700

DRIVE
PINION

InitiJI

turning
torque
without
oil
sea

Saloon
modds

Estate
CJr
models
7

10

kg
em

0
506
0
723Ib
ft

10
13

kg
em
0
723
0
940Ib
ft

Thickness
of

pinion
height

adjusting
washers
1400

and
1600
CC

Saloon

1400
and
1600cc
510

Thickncss
of

pinion
height

adjusting
washers
0800
cc
Saloon
0
4
mm
0
078
0
086
0
094
in

3
09
3
66mm

0
1
17

0
1441
in

in
increments
of
0
03
mm

0
00
I
in

Thickness
of

pinion
height

adjusting
washers
0800
n
Estate
car
0
050
0
070
0
100
0
200
0
500mm

0
0020
0
0028
0
0039
0
0079
0
0197
in

Thickness
of

pinion
height

adjusting
washers

1800
CL
Van
37
97111m
0
0933
0
I
69
in

in
increments
of
0
03
mm
0
00
I
in

73

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

REAR
SHOCK
ABSORBERS

Replacing

Estate
cars
and
Vans

Jack

up
the
reaT
of
the
vehicle
and

place
stands
under
the

rear

axle

housing

Disconnect
the
lower
end
of
the
rear
shock
absorber
from

the

spring
seat

Fig
H
23

Remove
the
shock
absorber

upper
attachment
nuts
and

withdraw
the
shock
absorber
The

upper
attachment
nuts
are

located
behind
the
Tear
seat
backrest
as
shown
in

Fig
H
24
Check
the
shock
absorber
for

leakage
or
cracks
and
make

sure
that

the
shaft
is

straight
Inspect
the
rubber
bushings
for

damage
and
deterioration
Renew
all
defective

components

lnstallation

is
a

reversal
of
the
removal

procedures
Tighten

the

upper
and
lower
shock
absorber
attachment
nuts
to
the

torque
readings
stipulated
in
TIGlITENING

TORQUES

NOTE
The

weight
of
the

vehicle
must
be

resting
on
the
fear

wheels
when

tightening
the
lower

mounting
to

damp
the
rubber

bushes
in
an
unloaded

position

TechnICal
Data

I
Type
Independent
suspension
with
semi
tralllI1g
arms
or

semi

floating

COIL
SPRINGS

14
2mm
0
559
in

14
5mm
0
571
in

90
mm
3
543
in

306
mm

12
047
in

299
mm
II
772
in

290
mm

11417
in

I
1400
and
1600cc

Wire
diameter

Wire
diameter
hard

suspension

Coil
diameter

Free

length
R
H

Free

length
L
H

Free

length
Hard

suspension

1800cc

Wire
diameter

Coil
diameter

Free

length
RHD
R
H

Free

length
RHD
L
H

Free

length
LHD
both

Free

length
Hard

suspension

RHD
R
H

RHD
L
H

LHD
both
14
5
mm

0
571
in

90
3
54
in

321
mm

12
6
in

307
mm

12
1
in

321
mm

12
6
in

306
mm

12
0

in

299
mm

I
1
8
in

306
mm

12
0
in

SHOCK
ABSORBERS

34
56

kg
75
123
lb

21
39

kg
46
86
lb

SHOCK
ABSORBERS

Estate
cars
and
Vans

1400
and
1600cc
estate
cars
and

rigid
axle
sedan

Piston
diameter
2S
mm
0
984
in

Stroke
205
mm

8
071
in

Max

length
518
mm
20
39
in

Damping
force
at
0
3
in
see

Estate
cars

Expansion

Compression

Damping
force

at
0
3m
jsec

Sedan

Expansion

Compression
1400
and
1600
cc

Piston
diameter

Piston
diameter
Hard

suspension

Stroke

Max

length

Damping
force
at
0
3m
sec

Expansion

Compression

1800
cc

Stroke

Max
lengtb

Damping
force
at
0
3
m
sec

Expansion

Compression

82
35
mm
1
378
in

40
mm

1
575
in

206
mm
8
110
in

568
mm
22
362
in

45

kg
99
21b

28

kg
61
7
lb

220
mm
8
60
in

595
mm
23
4
in

90

kg
198
4
lb

50

kg
110
3
lb

75

kg
165
4Ib

40

kg
88
2

lb
1800cc
Estate
cars

Stroke

Max

length

Damping
force
at
O
3m
sec

Estate
cars

Expansion

Compression
205mm
8
071
in

518
mm
20
39
in

63
87

kg
139
192
lb

33
43

kg
73
95
lb

Damping
force
at
0
3
m
sec

Estate
car
and
Van
with
hard

suspension

Expansion

Compression
97
131

kg
214
289
lb

29
43

kg
64
95
lb

REAR
SPRINGS

1400
and
1600cc
Estate
car

Length

Width

Thickness

No
of
leaves

Free
camber

Laden
camber
1200mm
47
2
in

60
mm
f2
362
in

6
mm
0
236
in

4

137
mm
5
394
in

15
mm

265
kg
0
59
in

584
lb

Spring
eye
bolt
diameter

Front

Rear
45
mm

I
772
in

30

mm
U81
in

1400
and
1600
cc

Free
camber

Laden
cam
her
rigid
axle
sedan

100
mm
3
937
in

15mm
250

kg
0
591
in

551

lb

1800cc
Estate

Laden
camber

Turning
torque
15
mm

265
kg
0
591

in
1

584
lb

2
2
kg
mm

123
Ib
in

REAR
AXLE
SHAFT

less
than
4
5

kg
cm
3
91b

in

less
than
0
1

S
mm

0
006
in

DRIVE
SHAFT
AND
JOURNAL
Spring
constant

End

play

Sliding
resistance
1400
and

1600
cc

Sliding
resistance
1800cc
0
15

kg
0
33
lib

less
than
20

kg
44
lb

Radial

play
of
ball

spline
less
than
O
lmm
0
004
in

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