1973 DATSUN B110 clutch

CHASSIS

SERVICE

DATA
AND

SPECIFICATIONS

Clutch
release

lever

Release

bearing
ta

diaphragm
spring

withdrawal
lever
clearance

Diaphragm

spring
to

flywheel
height

Gutch
disc

Facing
size

Outer

dia
x
inside
dia

x
thickness

Total

friction
area

Thickness

of
disc

assembly

Free

Compressed

Number
of
torsion

spring

Allowable
minimum

depth
of
rivet

head

from

facing
surface

Allowable

facing
run

out

Allowable

free

play
of

spline

Clutch

pedal

Pedal

height
when
not

depressed

Free

travel
of

pedal
head

Pressing

strength
at
full
stroke

Master

cylinder
clutch

Master

cylinder
diameter

Allowable
maximum
clearance

between

cylinder
and

piston
Hydraulic
clutch

0
7

to
I
4
mm

0
0276
to

0
055
in

29

to
31

mm

I
142
to
1
220
in

180
x
125
x
3
5
mm

7
09
x
4
92

x
0
140
in

264
cm2
40
92

sq
in

7
6
to
8

0
mm

0
2992

to
0
3150

in

6
7
to
7

0
mm

0

2638
to
0
2756
in

6

0
3

mm
0
0118
in

0
5

mm
0
0197
in
at

radius
85
mm
3
346

in

0
4

mm
0
0157
in

141
5
mm
5
57
in

30

mm

J
181
in

10
8

kg
23
8
Ib

15

87
mm
5
8
in

0
15

mm
0
0059

in

CL12
Mechanical
clutch

0

9
to
I
2
mm

0
0354
to
0
0472
in

136
5
to
146
5
mm

5

4
to
5
8
in

II
to

15mm

0
433
to
0
591
in

8
3

kg
18
31b

CLUTCH

Operating
cylinder
clutch

Operating
cylinder
diameter

T
Ilhtening
torque
19
05
mm
0
750
in

Clutch

assembly
securing
bolt
1
5
to
2
2

kg
m

10
8
to
15
9

ft
Ib

TROUBLE
DIAGNOSES
AND

CORRECTIONS

Condition

Noises
audible

on

pedal

depression

Noises
audible

on

pedal
release
Probable
cause

Excessively
worn

damaged
or

poorly
lubri

cated
release

bearing

Seized
release

bearing
and

diaphragm

spring

fingers

Insufficient

pedal
free
travel

Weakened

unhooked
or
broken
clutch

pedal

return
and
control

springs

Weakened
clutch
withdrawal
lever
return

spring
broken
or
unhooked

Excessive

play
between
clutch
disc
hub
and

drive
shaft

spline

Misalignment
of
clutch
disc
to

flywheel

causes

slight
movement
of

disc
hub
in

respect
of

facings

This
noise
is

especially
audible
with

engine

idling
or

at
low

speed

Broken
or
weakened
clutch
disc
cushion

springs

Insufficient

pedal
free
travel

Weakened
unhooked
or
broken
clutch
con

trol
and

pedal
return

prings

CL
13
Corrective
action

Replace
the

bearing
which

being
cased

cannot
be

greased
inside

Replace
the
release

bearing
Clean

diaphragm

spring
fingers
with
metal
brush
and
smooth

out

bearing
contact
faces
with
felt

polishers

Readjust
pedal
free
travel

correctly

Set

springs
in

position
or

replace
them
if

weakened
or

snapped

Replace
the

spring
or
hook
it

up
as

required

Replace
the
clutch
disc
and

ensure
that

clearance
between

hub
of
new

clutch
and

drive
shaft
is

within
0
50
mm
0

0197
in

endwise
and
0

20
mm
0

0079
in
crosswise

When
clearances
exceed
above
limits

replace

the
drive
shaft
also

Set
level
of
clutch
disc
with
clutch
disc
in

place
on

drive
shaft
set
it
under

slight

rotation
and
check
for
no
run

out

using
a

scriber

Replace
the
clutch
disc

Set

pedal
free
travel

correctly

Check
the

springs
for
correct

position
and

replace
them
if

necessary

The
clutch

drags
CHASSIS

Weakened
broken

ur
unhooked
clutch
with

drawallever
return

spring

Distorted
or
worn
drive

shaft

Excessive

play
of
release

bearing
on

slip

sleeve

Insufficient

push
rod

length

Excessive

pedal
free
travel

Warped
clutch
disc

Roughened
linings

Improperly
fitted
loose
or

broken

lining

Incorrect
release

bearing
to
diaphragm

spring

fmger
clearance

Clutch
disc
hub

forcing
on
drive
shaft

Damaged
drive

shaft

splines
prevent
the

clutch
disc

from

sliding

Oil
or

grease
on

linings

Warped
or

damaged
pressure
plate
or

clutch

cover

Air

pockets
in
the

hydraulic
system
not

bled

correctly

Dirt
or

foreign
matter
on

sealing
faces
of

master

cylinder
piston
cup

Air

pockets
in
master

cylinder
due
to
loose

piston

Fluid

leakage
from
cylinder

Low
fluid
level
in
reservoir

CL14
Replace
the

spring
or
hook

it

up
as

required

Replace
the
drive
shaft

and
clutch
disc
if

necessary

Replace
the
worn

parts

Adjust
the

push
rod

length
correctly

Adjust
free
travel
correctly

Set
level
of
clutch
disc
if

possible

Maximum

plate
run
out
0
25

mm
0

0098

in

Repolish
linings
with

a
metal
brush
or

replace
them
if

necessary

Replace
linings
Lining
rivets

should
be

clenched
with

no

protrusion
to
avoid

damaging

pressure
plate
and

flywheel

Adjust
correctly

Locate

cause
of
trouble
and

remove
it
if

possible
Otherwise

replace
the
clutch
disc

Replace
the
drive

shaft
also
the
clutch
disc

if

required

Locate
the
cause
of
oil
or

grease
leakage
and

correct
it
as

required

Clean
or

replace
linings

Replace
defective

parts

Bleed
out

completely

Clean

replace
piston
cup
if

damaged
and

bleed
the

system

Replace
piston
cup
and
bleed
the

system

Replace
piston
cup
if

damaged
bleed
the

system

Top
up
with
brake

fluid
and
bleed
the

system
if

necessary

CLUTCH

Clogged
vent
hole
in
reservoir

cap
promotes

vacuum

in
master

cylinder

allowing
air

to

inf1ltrate

past
the
seal

Abnormal

lining
wear

Insufficient

pedal
free
travel

The
clutch

grabs

The
clutch

slips
Driver

steps
unnecessarily
on

pedal
this

causes
lin

jog
wear

and

damage
to
release

bearing

Weakened

or

snapped
pressure
springs

Incorrectly
installed

linings

Oil
or

grease
on

flywheel
pressure
plate
and

linings

Loose

disc

linings
due

to

poor
rivet

tightness

Clutch
disc

hub
does
not

slide

freely
on

drive
shaft

spline

Warped
or
cracked

pressure
plate

Misalignment

Stiffened

hydraulic
control
mechanism

Wom
out

lining

Insufficient
clutch

pedal
return

travel
due

to
the
control
and

pedal
return

springs
being

weak
or

misadjusted

Weakened
or
broken

diaphragm
spring

Oil
or

grease
on

linings

eLl5
Clean
reservoir

cap
unclog
the
vent

hole
and

bleed

the

system

Adjust
clutch

pedal
free
travel

correctly

Advise
driver

to
discontinue

wrong

practice

and

step
on

clutch

pedal
only
when
ne

cessary

Check

pressure
springs
for
tension
as

speci

fied
and

replace
springs
if

they
are

unserviceable

Replace

linings
with
new
ones

and
install

them

correctly
Check
clutch
disc
for
center

alignment

Remove
cause

of

leakage
clean

flywheel
and

pressure

plate
thoroughly
replace
linings

If

linings
are
not
worn

replace
defective

rivets

Otherwise

replace
linings
and
clench

rivets

securely

Remove

any

foreign
matter
or

dirt

deposits

from
shaft

splines
When
trouble
is

still

present
replace
damaged
parts

Replace
pressure

plate

Locate
the
defective

point
and
if

possible

adjust
alignment
or

replace
distorted

parts

Check

spring
tension

If

necessary
take

down

pedal
and

lubricate

components

Install
new

linings
and

make
sure
tha

t
the

clutch

disc

pressure
plate
and

flywheel
are

not

damaged

Locate

cause
of
failure
and

replace
defective

springs

Overhaul
clutch
and

replace
springs

Remove
cause
of

leakage
and

replace
linings

if

cleaning
is

ineffective

TRANSMISSION

I

Jack
up
the
vehicle
and

support
it
with
four
stands

If
available
recommend
a

hydraulic
hoist
or

open
pit
be

utilized

2

Disconnect
the
front
exhaust
tube

D
from
the

exhaust
manifold

Fig
TM
4
Underside

of
vehiJ
1e

3
Remove
the

propeller
shaft

@
by
removing
four

securing
bolts
from
the

companion
flange
of
the

gear

carrier
Seal
the
end
of
the
rear
extension

housing
to

prevent
oil

leakage

Fig
TM
5

Removing
propeller
haft
4
Disconnect
the

speedometer
drive
cable

ID
and

back

up
lamp
switch
cable
from
the
transmission
ex

tension
housing

s
Disconnect
the
shift
rods
from
the

shift
levers

by

removing
the
cotter

pin
and
remove
the
cross
shaft

assembly
@
from
the
transmission
case

r

J
f

f

1

I
Speedometer
cable

I
2

I
Cotter

pin

Fig
TM

6

Disconnecting
speedometer
cable

and
remote

controllinkag

6

hydraulic
clutch
control

Remove
the
clutch

operating
cylinder
from
the

clutch

housing

7
mechanical
clutch
control

Disconect
the
clutch
control
cable
from
the
withdrawal

lever

1

1
Withdrawal
lever
2

I
Clutch
control
cable

Fig
TM
7

Disconnecting
clutch
control
cable

8

Support
the

engine
with

ajack
placed
under
the
oil

pan
Do
not
loca

1
f
nder
the
oil

pan
drain

plug

I

i
l

TM
3

CHASSIS

To

prevent
the
oil

pan
from

damaging
insert

a
wooden

block

between
the

pan
and

jack

9

Remove
two
nuts

@
used
to
attach
the

transmission

to

the

rear

engine

mounting
member

Place

a

jack
under

the

transmission
and

remove
two
bolts

@
used
to

fix
the

rear

engine
mounting
member
to

the

body

It

I
Rear

engine
mou

ting

installation

bolts

I
Rear

engine
mounting

bolts

I
2

Fig
TM
8
C

oss

Fberremoval

10

Raise
the

jack
supporting
the

engine
to
incline
the

engine
in
a
rearward

direction
A

sufficient

space
will
be

provided
for
transmission

removal

I
Remove

the

starting
motor
a
d
the

bolts

attaching

the
clutch

housing
to
the

engine

12

Lower
the

jack
under
tlie

and
withdraw
thS
transmission

iJ

DISASSEMBI
Y
trans
fljssion
gradu3Ily

1

j

I
When

disassembling
the
transmission

the

following

procedure

sh
ould
pe
adopted
Since
the

casings
are
made

of
aluminum

alloy
be

careful
not
to

damage
any
of
the

castings
C

t

l
t1
Drain

gear
o

frqrP
the
transmission

I

2
Rc

ove
the

dust

cover
release
the

withdrawal
lever

n
turn

sprin
and
remove
the

withdrawal
lever
and
release

bC
lring
from
the
clutch

housing

h

IF
i

Iii

h

l
11
I
W

ithdrawallever

I
Return

spring

1

31
Release

bearing

Fig
TM
9

Removing
release

bearing
and

withdrawal

lever

3

Remove
three
bolts

securing
the

front
cover
and

remove
the

front
cover

II
I
Front
coveT

L
I
Bolt

Fig
TM
10
Remd

ving

fron
cover

4
Remove

the

spced
omcter

pinion
assembly

1f

SPEEDOMETER

PINION

ASSEMB
Y

w

Fig
TM

11

Removing
speedometer

pinion

TM

4

TR

ANSMISSION

Baulk

ring

I

Check
the
baulk

rings
for
wear

pitting
chips
or

burrs

If

any
abnormal
conditions
are
detected

they
must

be

replaced
with
new
ones

2

Place
the
baulk

ring
in

position
on
the
cone
of
each

gear
Push
the

ring
to
the

gear
and
check
the

gap
between

the
end
face
of
the
bauIk

ring
and
the
front
face
of

the

clutch
teeth
This

gap
should
be
within
1
05
to

I
4

mm

0

0413
to
0
0551
in

If
it
is
less
than
0
5
mm
0

0197

in
a

worn
bauIk

ring
may
be
the

cause
and

a
new

ring

should
be
fitted

ii
V

ilillltII

l
A

1
05
to
1
4

mm

0
0413
to
0
0551
in

Fig
TM
28

ulk

ring
to

cone

installing
dimension

ShiftiAg
insert

Replace
if
worn

excessively
worn

unevenly
de

formed
or

damaged

Oil
seal
i

T

l
l

11

tT

Replace
the
oil
seal
with
a
new
one
if

lip
is
deformed

f

worn
or
cracked
or
when
the

spring
is

dropped
off

When
it
is

necessary
to

replace
the
transmission
rear

oil

seal
use
the

following

procedurecto
prevent
d

age
to
the

extension

l

1
Insert
the
transmission

rear
oil

seal
remover

ST23850000
into
the
dust
cover

2
Attach

a
pipe
wrench
to
the
dust

cover
and
drive
out

the
dust

cover

together
with
the

oil
seal

by

rotating
the

wrench
four
or
five
turns

I
Oil
seal

Extension
IJ

y

Fig
TM
29

Removing
rear
oil
seal

r

VI
1

3

Apply
a

coating
of

sealing
material

to
the

periphery

of
the
dust
cover
when

pressing
a
new
oil

seal
into

position
Never

apply
an
adhesive

caulking
material

Rear

engine
mounting
insulator

Replace
rear

engine
mounting
insulator

if

weakened

a

deteriorated
or

cracked

7i
1

rt

REASSEMBLY
AND
AD
JUSTMENT

Selecting
counter

bearing
thrust

washer

l
Fit
the
counter

bearings
to
the

counter
shaft
both

front
and

rear

by
the

use
of

a
counter
shaft

bearing
press

stand

special
tool

ST23030000
and

by
means
of

pressing

r

j

Itf

Fig
TM

JO

Fitting
counter

shaft

bearing
r

JJff
i

it

l
t

i

j

IlK

Ji
t

l
k

TM
9

CHASSIS

Front

cover

Part
number
Thickness

mm

Un

Adjusting
shim

32208
18000

32208
18001

32208
18002
0
5
0
0197

0
2
0
0079

0
1
0
0039

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Symptom
and

possible
cause
Corrective
action

Difficult
to
intermesh

gears

Causes
for
difficult

gear
shifting
are
classified
to

troubles

concerning
the
control

system
and
transmission

When
the

gear
shift
lever

is

heavy
and
it
is

difficult
to
shift

gears
clutch

disengagement
may
also
be

unsmooth
First

make

sure
that
the
clutch

operates
correctly
and

inspect
the
transmission

Worn

gears
shaft
and
or

bearing
Replace

Insufficient

operating

strokfdue
to
wom
or
loose

sliding
part
Repair
or

replace

Defective

or
damaged
synchronizer
Replace

Gear

slips
out
of
mesh

In
the
most

cases
this
trouble
occurs
when
the

interlock

plunger
check
ball
and

or

spring
is
wuro
or

weakened
or

when
the
control

system
is
defective
In
this

case
the
trouble

cannot
be
corrected

by
replacing
gears
and
therefure

trouble

shooting
must
be
carried
out

carefully
It

should
also
be

noted
that

gear
slips
out
of
mesh
due

to
vibration

generated
by
weakened
front
and
rear

engine
mounts

Worn

interlock

plunger

1
Replace

Worn
check

ball
and
or
weakened

or
broken

spring
Replace

Worn
fork
rod
ball

groove
Replace

Worn
or

damaged
bearing
Replace

Worn
or

damaged
gear
Replace

Noise

When
noise

occurs
under

engine
idling
and

stops
while
the

clutch
is

disengaged
or
when
noise
occurs
while

shifting

gears
it

may
judged
that
the
noise
is

from
the
transmissiun

TM
22