1969 DATSUN 610 lock

inter

iillu@U

Fig
F
20

Filting
the

spring
rings

Fig
F
21

Olecking
the
end
float
of
lhe

gearwheels

Fig
F
22
The
interlock
mechanism

c

Fig
F
23

Installing
the
cross

shaft

1
crossshil
t

2
l
hnut
washers

3

OperatirJ8levm

4

Lock

pim

5

Retaining
rings

Fig
F

24

Ole
king
the

gear
backlash

hk

rmJ

t
0
o

y

9

Ll

7

1
l

i

A
I

f

0

Fig
F

25
Withdrawal
lever
and
reIe
e

bearing
Fig
F
26
View
of
the
four

speed

gearbox
with

bottom
cover
removed

II

56

FOUR
SPEED
GEARBOX
Removal
and
Installation

The
removal
and
installation

procedures
for
the
four

speed

gearbox
are
similar
to

those

previously
described
for
the

three

speed
gearbox
However
the
floor
mounted

gear
lever
must
be

removed
from
the
controllevef
bracket
in
addition
to

the

operations
already
detailed

FOUR
SPEED
GEARBOX

Dismantling

Drain
the
oil
from
the

gearbox
Remove
the
dust
coveT
and

release
the

spring
securing
the
clutch
withdrawal
lever
Remove

the
withdrawal
lever
and
release

bearing
from
the
clutch

housing

as
described
in
the
section
CLurCH
Remove
the
clevis

pin

securing
the

striking
rod
to
the
control
lever

Remove

the
speedometer
drive

pinion
assembly
and
with

draw
the
rear

extension

housing
Disengage
the

striking
rod
from

the
selector
rod

gates
Remove
the

gearbox
covers
See

Figs
F
26

and
F
27

Unscrew
the
three
detent
ball

plugs
and
remove
the

spriags

and
detent
balls
Drive
out
the

pins
securing
the
selector
forks

to
the
rods
and
withdraw
the
forks
and
rods
Lock
the
main

shaft

by
moving
the
first
second
and
third
fourth

coupling
sleeve

into

gear
at
the
same
time
and
release
the
ffiainshaft
nut

Remove
the
countershaft
and
the
gear
cluster

together

with
the
two
needle
roller

bearings
and

spacers
Remove
the

snap
ring
holding
the
revep
e

idler

gear
and
withdraw
the
reverse

idler

gears
and
shaft

Fig
F
28

Take
off

the
bolts

securing
the
mainshaft

bearing
retainer

to
the

gearbox
case

Fig
F
29
Withdraw
the
mainshaft

assembly
Fig
F
30
and
the
main
drive
shaft

The
mainshaft
can
be
dismantled
in
the

following
manner

Release
the
third
fourth

synchronizer
unit

snap
ring
and
with

draw
the
hub

complete
with

coupling
sleeve
Remove
the
third

speed
gearwheel
and
the
needle
roller

bearing
from
the
main

shaft
Take
off
the
mainshaft
nut
and

locking
plate
Remove
the

speedometer
drive

gear
with
the

retaining
ball
Withdraw
the

mainshaft
reverse

gear
and
the
hub
Press
off

the
mainshaft

bearing
complete
with
the

bearing
retainer

Remove
the
thrust
washer
and
the
first

speed
gear
together

with
the
needle
roller

bearing
taking
care
not
to
lose
the
small

baU
used
to

locate
the
thrust
washer
Slide
off

the
first

speed

gearwheel
bush
Withdraw
the
first
second

synchronizer
and

hub
Remove
the
second

speed
gearwheel
and
needle
roller

bearing

FOUR
SPEED

GEARBOX
Installation

Refer
to

the
instructions

given
for
the
three

speed
gearbox

and
to
Technical
Data
for
the

specifications
applicable
to
the

different

gearboxes

FOUR
SPEED
GEARBOX

Assembly

Assembly
of

the

gearbox
is
similar
to
the

procedures

previously
described
for
the
three

speed
gearbox
with
the

following
exceptions
When

assembling
the
main
drive

gear
bearing
on
the
shaft

insiall

the

spacer
and
select
a
new

snap
ring
to
eliminate
all
end

float

between
bearing
and

snap
ring
Snap
rings
are
available
in

five
thicknesses
from
1
52
1
77mm
0
06
0
07
in

The

assembly
procedures
for

the
Warner

type
synchronizers

are
similar
to
the
instructions

previously
described
for
the
three

speed
gearbox
Refer
to
THREE
SPEED
GEARBOX

Assembly

for
further
details

To
assemble
the
Servo
F4C63

type
synchronizers
proceed

as
follows

Place
the

gear
on
a

clean
flat
surface
and
install
the

synchronizer
ring
on
the
inner
side
of
theclutch
gear
Fit
the

thrust
block
into

place
as
shown
in
Fig
F
31
Place
the
anchor

block
and
brake
band
into

position
and
fit
the

circlip
into
the

groove
in
the

gear
to
secure
the

synchromesh
assembly

When

assembling
the
mainshaft
select
a

snap
ring
which

will

give
an
end
float
between
0
05
0
15
mm
0
002
0
006in

to
the
third

speed
gearwheel
Snap
rings
are

available
in
five

sizes
from
1
40
mm

0
0551
in
to
1
60
mm
0
0630
in
thick

ness

Tighten
the
locknut
at

the
rear

of
the
mainshaft
to
a

torque
reading
of
7
1

kgm
51
87Ib
ft

Assemble
the
reverse
idler

gear
as
shown
in
Fig
F
32
The

reverse
idler
driven

gear
3
should
be

placed
on
the
end
of
the

reverse
shaft
1
with
the

longest
spline
and
retained
with
a

suitable

snap
ring
2
Install
the
reverse
shaft
and

gear
assembly

into
the

gearbox
case
from
the
rear
with
the
thrust
washer
4

between
the

gear
and
the
case

Fit
the
thrust
washer
5
and

idler
gear
6
18
teeth
and
secure
with
a
suitable

snap
ring

2
The
end
float
of
the

gear
should
be
checked
and

adjusted

to

0
1
O
3mm
0
004
0
012
in

by
selecting
a
suitable

snap

ring
2
Five
thicknesses
of

snap
rings
are
available
from
I
lmm

0
043in
to
1
5mm
0
06in
See
Technical
Data
for
F4W63

and
F4C63

gearboxes
Adjust
the
counter

gear
end
float
to

0
05
0
15
mm
0
002
0
006in

by
selecting
a
thrust
washer

of

the

required
thickness
Thrust
washers
are
available
in

five

thicknesses
from
2
40
2
60
mm
0
094
0
102
in

When

assembling
the
selector
mechanisms

Fig
F
33
fit

the
first
second
selector
forks
I
and
the
third
fourth
selector

forks
2
onto
the

coupling
sleeves
and
insert
the
first
second

fork
rod
3

Fit
an

interlock
plunger
4
and
the
third
fourth

speed

selector
rod
5
Do
not

forget
the
interlock

pin
7
A
section

through
the
selector
and
interlock
mechanism
is

given
in

Fig

F
34
Install
an

interlock

plunger
6
and
assemble
the
reverse

selector
fork
8
and
fork
rod
9
Secure
the
selector
forks
to

the
rods
with
the

retaining
pins
10

Place
a
check
ball

and
spring
into
each
of
the
holes
and

screw

the

plug
down
to
a

torque
reading
of
1
7
2
1

Jegm

12
3
15
2
Ib
ft
after

coating
the
threads
with
sealing
com

pound

Install
the
rear
extension

housing
engaging
the

striking
rod

with
the
fork

rod

gates
and

tighten
the

housing
bolts
to

a

torque
reading
of
1
6
2
5

kgm
12
18Ib
ft
Fit
the
front

and
bottom
covers
and

tighten
the
bolts
to

a

torque
reading

of
1
1
1
8

kgm
8
13Ib
ft

57

inter
lli

r@

ig
F
28
Re

oving
the
reverse
idler

gear
q

F
8
F
27
View
of

the
four

speed
gearbox
with

front
cover

removed

F
8
F
29

Removing
the
mainshaft

bearing

retainer
Fig
F
30

Withdrawing
the
mainshaft

assembly

CD

1ib
1

@
II

c

I

@
d
I

Q

n
j2

JJ

I
0

6

r

7

1

L
l
Hv

9

1l

ij07
u

1

1

v

1
ISland
2nd
selector

fork
5
Fork
rod

2
3rd
and
4th
selector

fork
6
Inter
ock

phmgtr

3
Fork
rod
7
Intulock

pin

4

Interlock

plunger
8
Revene
selLetor

fork

9
Fori
rod

10
Retaining
pin

Fig
F
33

Assembly
of
the
selector
forks
1
17uu

t
block

2

md
bruke

3

Synchro
rint
4
Anchor
block

5

Circlip

6
Band

b
ke
r

1
R
nt

shaft

SntJpring

3

R
idler

driving
geor
UT

4
Thrust
washer

5
1
hnat
washer

6

Idlergeor
18T

Fig
F
32

Reverse
idler

gear
F
8
F
31

Syncbromesh
assembly

3rd
4th

Rod

Fig
F
36

Removing
the

steering
wheel
Fig
F
34
Section

tIuough
the

gearbox
showing
the

inlerlock
mechanism

58

THREE
SPEED
GEARBOX

GEARCHANGE
CONTROL
LINKAGE

Fig
F
35

As

previously
described
the
three

speed
gearbox
is

equipped
with
a

steering
column

gearchange
linkage
system

which

incorporates
a

collapsible
control
rod
when
combined

with
the

collapsible
type
of

steering
column

assembly

The
gearchange
linkage
can
be
removed
and

inspected
in

the

following
manner

Remove
the

steering
wheel

Fig
F
36
and
take
off
the

steering
column
shell
cover
Remove
the
turn

signal
and
lighting

switch

Fig
F
37
These
removal
details

can
also
be
found
in

the
section
STEERING
Remove
the
C
washer

I
in

Fig
F
38

and
the
washer
then
remove
the

upper

support
bracket

by

releasing
the

locating
bolt
and
screw
The
control
rod
insert
with

bush
and
return

spring
can
now
be
removed
Remove
the
snap

and

gear
lever

pivot
pin
and
withdraw
the

gearlever

Remove
the
cotter

pin
plain
washer

and

spring
washer
and

disconnect
the
shift
rods
from
the

gear
selector
levers

Fig
F
39

Unscrew
the
bolts
securing
the
lower

support
bracket
and
the

clamp
Remove
the

clamp
and

gear
change
lever
retainer

Remove
the
second
third

speed
selector
lever
the
lower

support
bracket
and
the
first
reverse
selector
lever
from
the

control
rod
Withdraw
the
control
rod
Disconnect
the

gear

change
rods

by
removing
the
cotter

pins
and
remove
the
cross

shaft
bracket
from
the
side
member
Withdraw
the
cross
shaft

assembly
Fig
F
40

Examine
the

components
for

signs
of
wear
and

damage

and
replace
if

necessary

Installation
is
a
reversal
of
the
removal

procedure
noting

the

following
points

Take
care
not
to
strike
or

apply
a
load
to

the
collapsible

type
of
control
rod
or

the
rod
may
be
damaged

The
rod
should
not

be
slack
in

the
axial
direction
when

installed
and
must
be
removed
if
slackness
is
detected
Coat

the

sliding
surfaces
with

grease
before

assembling
them
Acijusting

Set
the
gear
lever
to

the
neutral

position
and

temporarily

connect
the
trunnion
on
the
lower

support
bracket
to
each
rod

Fig
F41

Set
the
rod
on
the
lever
so
that
the
neutral

adjustment

grooves
on
the

upper
surface
of
the
lower
support
bracket
are

aligned
with
the

grooves
on
each
lever

When
the

adjustment
is

completed
operate
the

gear
lever

to
select
each
gear
and
make
sure
that
the
lever
can
be
moved

smoothly
and

positively

AUTOMATIC
TRANSMISSION

Gearchange
control
linkage

The
automatic
transmission

gear
change
control

linkage

can
be
removed
in
a

similar
manner
to
the
three

speed
gearbox

linkage
Carry
out
the

operations
previously
described
under

the
relevant

heading
as
far
as
the
removal
of
the
gear
lever
and

proceed
as
follows

Disconnect
the

upper
selector
rod
from
the
selector
lever

by
removing
the
cotter

pin
plain
washer
and
lock
washer
See

Fig
F
42
Remove
the

speed
range
position
plate
the

snap
ring

at
the
lower
end
of
the
control
rod
and
unscrew

and
remove

the
lower

support
bracket
Release
the

locking
screw
and
with

draw
the
selector
lever

assembly
Withdraw
the
control

rod

disconnect
the
selector
rods
and
remove
the
cross
shaft
bracket

and
cross
shaft

assembly
Clean
all

parts
and

repair
or
renew

any
part
which
is
worn
or

damaged
Installation
is
a
reversal
of

the
removal

procedure
noting
the

following
points

Coat
all

the
sliding
surfaces
with
chassis

grease
prior
to

assembling

Set
the
converter
side
lever
and
the

gear
lever
in
the
neutral

position
Install
the

upper
selector
rod
to

the
selector
lever
and

adjust
the

gear
position
plate
to

give
a
clearance
of
0
5
I
Omm

0
02
0
04
in
between
the
selector
lever

stop
pin
and
the

position
plate
The

adjustment
can

be
obtained

by
turning
the

selector
rod

adjusting
nuts

Finally
tighten
the
nuts
on

each

side
of

the
trunnion

S9

inter
E
lill
j

lll
jIl

1

3

I

i

1r
I
An
t

1
ll

1
11
5
85

1
Sleeve

voke
arsembh

Bearillg
race
assembh

Jvumal
asst

mb
r

4

Snap

ring

5

Prope
ier
shaft
tube
assl

mblv

6
flan

oke
2

O

L

l
OIlU

39
I

JII

I

I

i
i

3

1
378

@
Fig
G
I
Section

through
the

propeller
shaft
Unit

mm
in

@
@

j

c

@

I
I

i

@

@

@

J

q

cJi
y

j

rID

@

62
Fig
G
2
Section

through
the
differential
carrier

1

Supply
rrwlti

purpose
gTet1M
to

oil
seal

lip
when
ass

mb1ing

Pinion

bearing
adjusting
lWSher

Adjust
pinion
ber
uing

X
eload

by

selecting
2
and
3

Pinio

bearing

adjusting
spacer

4
PInion

height
adiustinx
MUS1m

5
Lock

strap

6

Ring
gear
bolts
T
7

0
to

8
0

kgm

50
6
ro
578

bIt

TIghten
by
tapping
bolt
head
with

Jj41b3
hamTMr

7
Lock

pin

8
Rear
cover

9

Ring
gmr

10

Diff
mounting
member

1
J
Bolt

diff
to

diff
mounting
member

T
6
0
to
8

0kKm
43
4
0
7
8

b
ft

12

ShIlf

pinion
m1te

13
Thnl

lWlJIJer

14
Pinion
mate

15
17vust
washer

Adjust
the
backla
h
in

pinion
mate

and
ide

gear
or
the
clearance

betwun
the

differential
ctlSI

and
the

rear

fact
ofridt
gror
to
0
1
to
0
2

mm

0
0039
0
0

0079
bv
16

16
Side
ar

17

BoltsideflilngeT
1
9to

6kgm

13
710
18

8Ib
f

18
Oil
tal

Supply
chassi

grea
e
to
oil

seal

lip
Vtlhen

autmbling

19
Side

flange

20
Side

retainer

21
Bolt
side
retainer
T
0
9
to
1
2

kgm

6
5
to
8
71b

22

ring

23

Side
bearing

24

Diff
Gear
case

25
Pinion
rear

bearing

26
Dril
e

pinion
27
Pinion

front
bearing

28

Spacer
front
pilot
beaTing

29
Front

pilot
bearing

30
Oil
seal

3J

CompanionfliInge

32
Dri

pinion
nut
T
17

to
20

Jwn

122
9
0144

6Ib
fI

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

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

inter
lJIi

@
pl

J

J
Y

e

c

J
r
c

A

Ir

f
1

r
i

ST06J60000

0

i
J

estate
car
r

I

f
o
t
t
iJ
J

I

l

G

L

i

f1

v
f
P

r

5T0631110UO

I
sr
s

s

r

u
h

van

Fig
G
20

Removing
the
side

bearing

Fig
G
19

Mounting
the

differential
carriers

V

1

tj
l
fl4j
P

ff

P

tffST23510000
f

S

I
l
1

rig
G
22

Punching
out

the

pinion
shaft
lock

pin
j
Fig
C

21

Removing
the

crownwheel
bolts

Fig
C
23

Removing
the
drive

pinion
nut

t

1

Fig
G
24

Removing
the

pinion
rear

bearing
inner

race
rig
G
25

Checking
the

crownwheel
for

run
out

I

u
l

o

F
Ice
idth
Ol
1
lction

Ibvr
ti

3
3S6
L

i

1

Fig
G

26
Drive

pinion

markings
Estate
cars
Fig
G

27

Standard

pinion
height
dimension

68