1969 DATSUN 610 Workshop Manual

inter
1D7
J

3

T
T

aj

W

n
J

I

1

T

f
T
7

e

Fig
E
II

Adjustillll
the

height
of
the
release

levers
Fig
E
12
Actuating
the
clutch
to
settle
the

mechanism

Tightening
torque
3
5
to
4
0

kltm

125
to
29

h
lb

Rs

@

A
l

I
l

1
3
fP

I

01
I

8J

I

Jt
I

Lock
A

2

Lock
ul
Bn

Adjwt
by
adjust
of
master

cyl

@
Lubricatic
l

Clutch
dal
full

trek
140
4

mm
5
51
0
16

Clutch

pedal
free
stroke
25
mm
0
98
Pedal

height
175
mm
6
89
nl

Pc

dalfullstrokc
b

135mm
5
JI
n

@
Multi

purpo
greasc

510
series
610
series

Fig
E
l3

Adjusting
the
clutch

pedal

I

48

inter
lliJ
j

flDlJ
l

Jl

iO

n
cxB
L

of

lii
t
hl
9

q
6
15

1

r

8t

r

L
L
I
i

1
2
9

@
7
5I1

9
QlIf12
12J
J
7
ll
I

I

o

Q

1

Cylinder

2

Return

spring

3
Piston

4

Secondary
cup

5
Piston

cup

6

Supply
valve
seat

7

Supply
valve
stem

8

Supply
lIOlve

spring
9

Spring
seat

10
Va
ve

stem

stop

11

Stopper
gasket

12
Gasket

ring

13
Push
rod

14
Push
rod
ht
lld

15
Wdd
nut

16
Lock
nut
17
Piston

stopper

18

Stopper
ring

19
Boots

20
Oil
reservoir

21
Rese1l
Oir
band

22

Reservoir

cop

23

Cap

24

Pipe
seat
J

J

5

9

a

ID

1

Cylinder

2
Return

spring

C1

3
Piston

4

Spring
seat

5
Push
rod

6
Nut

7

Stopper
ring

8

Stopper

9
Dust
cover

10
on
reservoir

1
J
Reservoir
balld

12
Reservoir

cap

Fig
E

14
Section

through
the
clutch
master

cylinder

Adjusting
nut

Fig
E
l
S

Adjusting
the
clutch
withdrawal
lever

49

other
end
of
the

tube
into
a
clean
container

partly
filled
with

brake
fluid

Top

up
the
master

cylinder
reservoir
with
recommended

fluid
and

open
the
bleed
screw

approximately
three

quarters

of
a
turn

Depress
the
clutch

pedal
slowly
and
hold
it

completely

down
re

tighten
the
bleed
screw
and
allow
the

pedal
to
return

slowly

Repeat
the

operation
until
the
fluid

emerging
from
the

tube
is
free
from
air
bubbles
It
should
be
noted
that
assistance
will
be

required
when

carrying
out

bleeding
operations
as
not

only
must
the
fluid

entering
the

glass
container
be
watched
but
also
the
clutch

pedal
has
to
be

operated
and
the
reservoir

topped
up
frequently

throughout
the

procedure

When
the
fluid
is
completely
free
from
air
bubbles
the

bleed
screw
should
be

retightened
on
a
down
stroke
of
the

pedal

Finally
remove
the
bleed
tube
and

replace
the
dust

cap

TechnIcal
Data

Outch

type

Pressure

spring

Free

length

Fitted

length
and
load

Side
distortion

Permissible
deterioration

of

spring
force

Outch
release
levers

Oearance
between
release

bearing
and

diaphragm
spring

release
levers

Height
between
diaphragm
spring
and

flywheel

Height
between
release
levers
and
flywheel

Outch
driven

plate

Outer
diameter

Inner
diameter

Thickness
of

facingS

Total
friction
area

TIrickness
of

clutch
plate

Free

Compressed

No
of
torsion

springs

Permissible
minimum
depth
of
rivet
heads
from

facing
surface

Permissible
run
out
of
clutch

facing

P
rmissible
free

play
of

splines

Outch

pedal
1400
and
1600cc
models

Pedal

height
in
the
rest

position

P
da1
free
stroke

P

da1
effort

Master

cylinder

Diameter

Maximum
clearance
between

piston
and

cylinder

Pressure

plate

Permissible
refacing
limit

Outch

pedal
180Occ
models

P
da1

height

Play
at
clevis

pin

Full
stroke

P
da1
effort

50
Diaphragm
spring
or
coil

spring

52
3mm
2
059
in

29
2mm
44

2kg

1
149
in

197
t

4
4
lb

5mm

per
IOOmm

0
2in

per
3
94
in

15

1
2
I

4mm
0
047
0
055
in

44
t

Imm
1
732
t

0
039
in

50
5
t
0
05mm
1
988
t

0
0197
in

200mm
7
87
in

130mm
5
12in

3
5mm
0
140in

362

sq
cm
56
11
sq
in

8
6
9
0mm
0
3386
o
3543in

7
65
7
95mm
0
3012
o
3130in

6

O
3mm
0
0118

in

0
5mm
0
0197
in

0
4mm
0
0157
in

182mm
7
17in
R
H
D

207mm
8
15in
L
H
D

25mm
0
984in

15kg
33
lb

15
87mm
0
625in

O
13mm
0
005lin

Imm
0
0394in

175mm
6
89in

1
5mm
0
04
0
20in

135mm
5
3lin

10

5kg
23Ib

Gearbox

GEARBOX
Removal

GEARBOX

Dismantling

GEARBOX
Inspection
and
Overhaul

GEARBOX

Assembling

THREE
SPEED
GEARBOX
GEARCHANGE
CONTROL
Removal
and

Adjusting

AUTOMATIC
TRANSMISSION

Gearchange
control

linkage

DESCRIPTION

Three

types
of
transmission
are
available
for
the
Datsun

models
covered

by
this
manual
Either
a
three

speed
gearbox

a
four

speed
gearbox
or
three

speed
automatic
transmission

can
be
fitted

The

three
and
four

speed
gearboxes
are

equipped
with

nchromesh
on
all
forward

gears
with
the
three

speed
gearbox

operated
by
a

steering
column

gearchange
system
and
the
four

speed
gearbox
by
a
floor
mounted

gear
lever

Two

types
of

synchromesh
are
used
in
the
four

speed

gearboxes
Either

Borg
Warner
or
Servo

types
may
be
fitted

The

gearboxes
differ

only
in
the

synchromesh
devices

whereby

the
baulk

rings
synchronize
the

coupling
sleeve
with
the
main

shaft

gear
on

the
Warner

gearbox
This
action
is

accomplished

by
a

synchrcrring
on
the
servo

gearbox

THREE
SPEED
GEARBOX
Removal

I
Jack

up
the
vehicle
and

support
it
on
stands

2
Disconnect
the
hand
brake
cable
at
the

equalizer
bracket

Slacken
the
two
exhaust

pipe
centre

clamps
and
turn
the

centre
section
of
the
exhaust
assembly
to
the
left
as
shown

in

Fig
F
2

3
Disconnect
the

propeller
shaft
from
the
rear
axle
drive

flange
by
removing
the
four

securing
bolts
Seal
off

the

gearbox
extension

housing
to

prevent
the
loss
of
oil
and

withdraw
the
shaft
to
the
rear

4
Disconnect
the

speedometer
drive
cable
from

the
adaptor

in
the

gearbox
extension

housing
Fig
F3

S
Disconnect
the
lower
shift
rods
from
the
shift
levers

Fig
F
4
and
remove
the
cross
shaft

assembly
from
the

gearbox
casing
Remove
the
clutch
slave

cylinder
from
the

clutch

housing
Fig
F
5

6

Support
the

engine
with

ajack
positioned
underneath
the

oil

sump
making
sure

that
the

jack
does
not
foul
the
drain

plug
A
block
of
wood
should
be

placed
between
the

sump

and

jack
to

avoid

damaging
the

sump

7
Remove
the
bolts

securing
the
rear

engine
mounting
to

the
crossmember
Position

ajack
under
the

gearbox
and

remove
the
bolts

attaching
the
crossmember
to
the

body

Lower
the

jack
under
the

engine
so
that
the

engine
is

tilted
to
the
rear
Remove
the
starter

motor
and
the
bolts

securing
the

clutch

housing
to
the

engine
Lower
the

jack

slowly
and
withdraw
the

gearbox
towards
the
rear
of
the

vehicle
THREE
SPEED
GEARBOX

Dismantling

Drain
the

gearbox
oil
Remove
the
dust
cover
release

the
retainer

spring
and
remove

the
withdrawal
lever

complete

with
release

bearing
from
the
clutch

housing
See
section

CLUTCH

Remove
the

gearbox
bottom
cover
the

speedometer
drive

pinion
assembly
and
the
rear
extension

housing
Take
out

the

cross
shaft

retaining
rings
and
unscrew
the
nuts

securing
the

operating
lever
lock

pins
Use
a
hammer
and

punch
to
drive

out
the

pins
and
withdraw
both
cross
shafts

Fig
F
6

Remove
the
fr
mt
cover

and
withdraw
the
counter
shaft

Lift
out

the
countersbaft

gear
cluster

together
with
the
needle

roller

bearings
and

spacers
Fig
F
7
Remove
the
reverse
idler

gear
shaft
lock
bolt
and
remove
the
shaft
and
the
idler

gear

Fig
F
B
Drive
out
the

pins
securing
the
selector
forks
to
the

selector
rods

Unscrew
the
interlock

plug
and
remove
the
detent
ball

and

spring
Fig
F
9
Remove
the
first
reverse

speed
and
second

third

speed
selector
rods
and
lift
out

the
selector
forks

Withdraw
the
main
shaft
assembly
and
the
drive
shaft

assembly
from
the

gearbox
See

Fig
F
1O
and
F
11

To
dismantle
the
mainshaft
release
the

circlip
from
the

front
of
the
mainshaft
as
shown
in

Fig
F
12
and
remove
the

second
and
third

speed
synchronizer
hub
and
second

speed

gearwheel
Fig
F
13
Remove
the

circlip
securing
the
speedo

meter
drive

gear
and
withdraw
the

gear
together
with
the
ball

and

spacer
Fig
F
14
Remove
the
mainshaft

bearing
using
a

press
Hold
the
rnainshaft
reverse

gear
and

tap
the
shaft
on
a

piece
of
wood
to
release
the
reverse

gear
assembly
together

with
the
first

speed
gearwheel

GEARBOX

Inspection
and
Overhaul

Oean
all

parts
thoroughly
and
examine
the

gearbox
case

and
extension
housing
for
cracks

If
the

joint
faces
are
burred
or

pitted
it

may
be

necessary

to

replace
the
units
if

repair
cannot
be
carried
out
satisfactorily

Remove
any
adhesive
which
remains
on

the
faces

The
rear
extension

housing
bush
should
be
renewed
if

worn

unevenly
Clean
the

bearings
and

dry
with
compressed
air

taking
care
that
the
bearings
do
not

spin
Turn
the
ball

bearings

to
make
sure

that
they
run

smoothly
and
without
play
Replace

the
needle

bearings
if
worn
or

damaged
in
any

way

It
is
advisable
to
renew

the
needle
roller

bearings
after

they

have
been
installed
for
a
considerable

period
as
it
is
difficult

51

VP

F
rr

l
I

lip

J

I
I
ii

iI

a

l

Fig
F

1
View

through
the
four

speed
gearbox

It
j

j
4

C
J

f

e

V

tJ

J

I

P

Fig
F
2
The

propeUer
shaft

Fig
F
3
Disconnecting
the

speedometer
cable

Fig
F
4

Disconnecting
the
remote
control

linkage

Fig
F

5

Removing
the
clutch
slave

cylinder

52

jiii
c

c
inteN
I
j

D

p

Fig
F

7

Removing
the

countershaft

gear

Fig
F
6

Removing
the
ero
shaft

tT

l

Fig
F
S

Removing
the
reverse

idler

gear
JO

Fig
F
9

Removing
the
interlock

plug

F
8
F
I
0

Withdrawing
the
mainshaft

gear
assembly

Fig
F
lI

Removing
the
main
drive
shaft

Fig
F
12

Removing
the
2nd
and
3rd

speed

syndlroniur
hub

circlup
f

Ii

ii
jjf

vr

O

Fig
F
13

Removins
the
2nd
and
3rd

speed
hub

and

2nd

speed
gearwheel

S3

i
nte
r
IJ
j
J
D

W

J

Fig
F
14
Rc
the

speedometer
drive

gear

and

spacer

Fill
F

15

Checking
the
IIlJIDlShofllor
ron
ol

Fig
F
I

7

Installing
the

insert

snap
ring

Fill
F
16

Checking
the
clearance
between
baulk

ring
and

gear

Fig
F
18

InsWlins
the

shifting
inserlll

54
Fig
F
19

Fitting
the

synchronizer
hub
to
the

coupling
sleeve

to
ascertain
the
amount
of
wear
that
has
taken

place

Check
the
teeth
of
the

gearwheels
and
the
machined
surfaces

for

signs
of
wear

scoring
pitting
and
burrs
Ensure
that
the

synchronizer
hubs
slide

freely
on
the

splines
of

the
main
shaft

with
minimum
clearance
Check

the
mainshaft
for
run
out

using
V
blocks
and
a
dial

gauge
as
shown
in

Fig
F
15
Renew

the
mainshaft
if
the
run
out
exceeds
0
15mm
0
0059
in

Check
the

synchronizer
rings
for
wear
and
renew
them
if

necessary
Place
the

rings
in

position
on

their

respective
gear

wheel
cones
and
check
the

gap
between
the
end
of
the

ring
and

the
front
face
of

the
teeth
Fig
F
16
The
correct

gap
should

be
within
1
2
1
6mm
0
047
0
063
in
Renew
the
synchronizer

ring
if
the

gap
is
less
than
0
8mm
0
0315
in

Place
the
selector
rods
on
a
flat
surface
and
check
them
for

traightness
Renew

any
rod
which
is
bent
Renew
the

locking

pins
and
interlock
balls
if

they
are
worn
or

damaged
The

standard
clearance
between
the
selector
forks
and

operating

sleeve

groove
is
0
15
0
30mm
0
006
0
012
in

Make
sure
that
the
oil
seals
are

satisfactory
and
discard

the
O

rings

THREE
SPEED
GEARBOX

Assembly

Press
the
main
drive
gear

bearing
onto
the
main
drive
shaft

and
fit
the

spacer
Select
a

snap
ring
of
suitable
thickness
so

that
all

play
is
eliminated
between
the

bearing
and

snap
ring

Seven
sizes
of

snap
rings
are
available
and

vary
in
thickness
from

1
52mm
0
0598
in
to
1
89mm
0
0747in

The

synchromesh
unit
consists
of
a

coupling
sleeve
baulk

ring
spring
synchronizer
hub
and
insert
When

assembling
the

unit
make
sure
that
the
correct
insert

pressure
springs
are
fitted

to

the
relevant

speed
unit
The
first
reverse

gear
synchronizer

should
be
fitted
with
the
three
coil

spring
type
and
the
second

third

gear
synchronizer
with
the
two

expanding
springs

To
assemble
the
fiI3t

speed
synchronizer
insert
the

sliding

insert

snap
ring
onto

the
synchronizer
hub
as
shown
in

Fig
F
17

Fit
the

sliding
inserts

Fig
F
18
and

the
synchronizer
springs

on
the

synchronizer
hub
and
assemble
the

synchronizer
hub

complete
with
inserts
into
the

coupling
sleeve

Fig
F
19

Assemble
the
second
third

gear
synchronizer
hub
and

coupling
sleeve

making
sure

that
the
sleeve
slides

freely
on
the

hub

splines
Fit
the
three

shifting
inserts
and
install
a

spring
ring

on

each
side
of
the
hub
Fig
F
20

To
assemble
the
mainshaft
start
from
the
front
end
of
the

shaft
and
slide
the
second

speed
gearwheel
on
to
the
shaft
with

the

tapered
cone

facing
forwards
Install
the
baulk
ring
on
the

gearwheel
and

place
the
second
third
speed
synchronizer
assembly

on
the
front
end
of
the
shaft
and
retain
it
with
a

snap
ring
which

will

give
an
end

play
of
0
05
0
25
mm
0
002
0
009
in

Snap
rings
are
available
in
five
sizes
from
1
60
1
80
mm

0
063
0
071
in

Fit
the
first

speed
gear
and
baulk

ring
on
the
rear
of

the

shaft
so
that
the

tapered
cone
faces
to

the
rear

Assemble
the

first

speed
synchronizer
and
reverse

gear
on
the
shaft
Fit
the

spacer
and

press
the
mainshaft

bearing
complete
with
retainer

onto
the
shaft
Install
the

spacer
ball
and

speedometer
drive
pinion

Select
a

snap
ring
which
will
give
an
end
float
of
0
05
0
22mm

0
002
0
009
in
on
the
mainshaft
first

gear
Snap
rings
are

available
in

eight
thicknesses
from
1
30mrn
0
0512
in

to

1
70mm
0
0669
in

Secure
the
drive

gear
with
the
selected

snap
ring
and
check

the
end
float
of
the

gearwheels
as

shown
in

Fig
F
21
The
correct

end
float
should
be
as
follows

I
st

speed
gearwheel
0
2
o
3mm

0
008
0
012
in

0
2
0
3mm

0
008
0
012
in
2nd

speed
gearwheel

Fit
the
main
drive

gear
and
mainshaft

assembly
into
the

gearbox
casing
Fit
the
selector
rods
and
forks
as
follows

Turn
the

gearbox
casing
so
that
the
detent
ball
hole

is

uppermost
and
insert
the

spring
and
ball
in
the
bottom
of
the

hole
Hold
the
ball
witb
a

dummy
shaft

and
install
tbe
first

reverse
selector
fork
and
rod
pushing
the

dummy
shaft
out

of

position
Insert
the

interlocking
plunger
and
fit
the
second
third

speed
selector
fork
and
rod

Insert
the
steel
ball
and

spring
and

refit
the

interlocking
plug
after

coating
the
threads
of
the

plug

with

sealing
compound
See

Fig
F
22

Secure
the
selector
forks

to

the
rods

by
inserting
the

retaining
pins

Fit
the
reverse
idler

gear
and
shaft
and
secure

the
shaft

with
the
lock
bolt
and

plate
Insert
the
counter

gear
cluster
and

shaft

using
a
suitable
thrust
washer
to
obtain
an
end
float
of

0
04
0
12
mm
0
0016
0
0047
in
Thrust
washers
are
available

in
five
sizes
from
3
85
4
05
mm
0
1516
0
1594
in
thickness

in
increments
of

0
05
mm
0
002
in

Fit
the
cross
shafts

1
in

Fig
F
23
the
thrust
washers
2

and
the

operating
levers
3
Secure
the
cross
shafts
with
the

retaining
rings
5
and
lock
the

operating
levers
to
the
shafts
with

the

pins
4

Locate
the
rear
extension

housing
on
the

gearbox
case

and

tighten
the
bolts
to
a

torque
reading
of
2
8
4
4

kgm

20

32
Ib
ft
Insert
the

speedometer
drive

pinion
and
retain
it

with
the
set

bolt
and
lock
plate
Check
the
backlash
of
all
the

gears
using
a
dial

gauge
as
shown
in

Fig
F
24
The
backlash

should
be
between
0
05
0
20
mm
0
002
0
008
in
Fit
the

gearbox
front
cover
and

tighten
the
fixing
bolts
to
a

torque

reading
of
1
I
1
7

kgm
8
0
12
3
lb
ft

taking
care
not
to

damage
the
oil
seal
Fit
the
clutch
release
bearing
and
with

drawallever

Fig
F
25

Replace
the
bottom
cover
and
tighten

the
bolts
to
a

torque
reading
of
1
I
1
7

kgm
8
0
12
31b
ft

THREE
SPEED
GEARBOX
Installation

Installation
of
the

gearbox
is
a
reversal
of

the
removal

procedure
noting
the
following

points

Fit
the

gearbox
with
I
7

litre
0
45
US
gall
0
37

Imp

gall
of
MP
90

gear
oil

Adjust
the
clutch
slave

cylinder
push
rod
as
described
in

the
section
CLUTCH
to

provide
a
free

play
of
2
2
mm
0
087in

at
the
withdrawal
lever

55