1969 DATSUN 610 torque

inter
M
j

@
jJ

2

t

1
5c

t
J
i
3

jp

7
i
r
4

Ilc
d

I

l

@

l
lb
r

s
ril

1

iF
C

Q
Fig
G
12
Section

through
the
drive

pinion

1
Pinion

height
adjusting
kUsher
4
Fte
Ioad

for
pinion
bearing

2
Pinion

height
ad
usting
shims
without
oil
mlI
and
drive
7
to

3

Tightening
torque
of
nut
dril
e
10

kgt1L
5a

6
to
72
3
lb

jl

pinion
17
to

20kg1n
22
9
to

ffnion
bearing
adjusting
w

uher

44

6Ib
ft
J
6
Pillion
bt
flrillgadjusti

lg
s
Jtu
er

fl

i
Ji
l
I
I

J

lJ

i

V
r
IHei
t

giluge

I
lST31210c
0

l

B
I

0
QJ

DUrnmYPinlOn

Drive

pinion
collar

lST3121QOCX
f
1
L

r

IST315000001

Dummvspacer

ST318500001
I
Fig
G
ll

Measuring
the
clearance
between
the

differential
side

gear
and
thrust
washer

Fig
G
t3
Drive

pinion
markings

Fig
G
14

Adjusting
the

pinion
height

1

Fig
G
t
5

Adjustment
diagram
for
the
dif

feren
tiaI
side
covers
Fig
G

16lnstalling
the
differential
side
covers

fig
G

Checking
the
backlash
of
crownwheel

and

pinion
Fig
G
tS

Fining
the

differential

mounting

member

bb

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

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

inter
T
r

if

J
II
10
4

9

A
I
I

I

s

tf
4

J

y
r

1
Sl
f

n1

2

8wpmsion
arm

3

MountinK
buuJDror

4

DiffomtiDJ

OIl1rtlnt
insulaior

J

CoU

P
inI

6

Bump
rubber

7

Sf1TinI
mzt

8

S1tock
absorber

9

I
Jm

tlrtifi

10

Differentli1l
mount
nlf
ober

II

Differentitzl
CtUTio

Fig
H
I

Independent
rear

suspension
Saloons
7
w

A

i
I

I

l
il

1

t
J1

0

11

I
j

1
I
J

71

Iii

I

1
V

1

A
3

1

DiffomtiDJ
CtUTio

2
R
I1
u
eazu

I
1

3

L
ll

Sf11inI

4

Shock
abJOriJer

FJ8
H
2
Rear

r
utate
cars
and
Vans
FJ8
H
4

OIecking
the

mounting
insulators

wn
0
6

t
iO

T
t

1Vt
1

1

j

J3

J

111
1

Q

i

n
f
I

1
I
J

0

J

I
I

I
0
l

5

i

1
a
c

u
T
11
0
to

lS
Oq
m

80
to

108
ft
lb

J

iI

Front

20mm

1

200
mm

O
787
n

041
2

in1

410mm

16
1
n
Di

member
CD
T
7
0
to
10
0

q
m

51
to

72
ft
lb

T

20
0
to
30
0

kg
m

145
to

217
fHb

j

T

Tilhtening
torque
Om

FJ8
8
3
Rear

suspension
removal

T

7
0

to
10

q
m

5lI072
ft
Ib

Flg
D
S
Rear

suspension
imtallation

i

76