1977 DATSUN PICK-UP oil

CLUTCH

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Probable
cause
and

testing

Clutch

slips
Corrective
action

Slipping
of
the

clutch

may
be

noticeable
when

any
of
the

following
symptoms
is

encountered

during
operation

I
Vehicle
will

not

respond
to

engine

speed
during
acceleration

2
Insufficient
vehicle

speed

3
Lack
of

power
during
uphill
driving

Some
of
the

above
conditions
are
also

experienced
when

engine

problem
is

oc

urring
First

de
tennine
whether

engine
or
clutch
is

causing
the

problem

If

slipping
clutch
is

left
unheeded
wear
and
or

overheating
will
occur
on
clutch

facing
until
it
is

no

longer
serviceable

TO
TEST
FOR
SLIPPING
CLlJfCH

proceed
as
follows

During
upgrade
travelling
run

engine
at

about
40
to
50
km

h
25
to
31

MPH
with

gear
shift

lever
in

3rd

speed
position
shift
into

highest
gear
and
at
the
same
time

rev

up
engine
If
clutch

is

slipping
vehicle
will
not

readily

respond
to

depression
of
accelerator

pedal

Clutch

facing
worn

excessively

Oil
or

grease
on
clutch

facing

W

r
d
clut
h
cov
r

pressure
plat
Replace

Replace

tpa
o
e
lace

Dragging
clutch
is

particularly
noticeable
when

shifting
gears
especially
into

low

gear

TO
TEST
FOR
DRAGGING
CLlJfCH

proceed
as
follows

I
Start

engine
Disengage
clutch
Shift
into

reverse

gear
and
then
into
Neutral

Gradually

increase

engine
speed
and

again
shift
into
reverse

gear
If
clutch
is

dragging
gear
grating

is

heard
when

shifting
from
Neutral
into

Reverse
Clutch

drags

2

Stop
engine
and
shift

gear
Conduct
this
test
at
each

gear
position

3
Gears

are
smoothly
shifted
in

step
2
but

drag
when

shifting
to
1st

speed
position
at

idling

a
If

dragging
is
encountered
at
the
end
of

shifting
check
condition
of

synchro

mechanism
in
transmission

b
If

dragging
is
encountered
at
the

beginning
of

shifting
proceed
to

step
4

below

4
Push

change
lever
toward
Reverse
side

depress
pedal
to
check
for
free
travel

a

If

pedal
can
be

depressed
further
check
clutch
condition

b
If

pedal
cannot
be

depressed
further

proceed
to

step
5
below

5
Check
clutch
control

pedal
height
pedal
free
travel
withdrawal
lever

play
etc

If
no
abnonnal

condition
exists
and
if

pedal
cannot
be

depressed
further
check
clutch

condition

Clutch
disc
runout
or

warped

Wear

or
rust

on
hub

splines
in
clutch
disc

Diaphragm
spring
toe

height
out
of
ad

justment
or
toe

tip
worn

Worn
or

improperly
installed

parts

CL10
Repair
or

replace

Clean
and
lubricate
with

grease
or

replace

Adjust
or

replace

Repair
or

replace

Condition

Clutch
chatters

Noisy
clutch

Clutch

grabs
CLUTCH

Probable
cause
and

testing
Corrective
action

Clutch

chattering
is

usually
noticeable
when
vchicle
is

just
rolled
off
with
clutch

partially

engaged

Weak
or
broken
clutch
disc
torsion

spring

Oil
or

grease
on
clutch
facing

Clutch

facing
out
of

proper
contact
or

clutch
disc

runout

Loose
rivets

Warped

pressure
plate
or
clutch
cover

surface

Unevenness
of

diaphragm
spring
toe

height

Loose

engine
mounting
or
deteriorated

rubber

A
noise
is
heard
after
clutch
is

disengaged

Damaged
release

bearing

A
noise
is

heard
when
clutch
is

disengaged

Insufficient

grease
on
the

sliding
surface

of

bearing
sleeve

Clutch
cover
and

bearing
are
not
installed

correctly
Replace

Replace

Replace

Replace

Repair
or

replace

Adjust
or
replace

Retighten
or

replace

I
Replace

Apply
grease

Adjust

A
noise
is
heard
when
vehicle
is

suddei11y
staited
off
with
clutch

partially
engaged

Damaged
pilot
bushing

I
Replace

When

grabbing
of
clutch
occurs
vehicle
will
not
start
off

smoothly
from
a

standing
start
or

clutch
is

engaged
before
clutch

pedal
is

fully

depressed

Oil
or

grease
on
clutch

facing

Clutch

facing
worn
or
loose
rivets

Wear
or
rust
on

splines
in

drive
shaft
and

clu
tch
disc

Warped
flywheel
or

pressure
plate

Loose
mountings
for

engine
or

power

train
units

CLll
Replace

Replace

Clean
or

replace

Repair
or

replace

Retighten

Manual

Transmission

4
SPEED

TRANSMISSION
TYPE

F4W71B

CONTENTS

DESCRIPTION

REMOVAL

DISASSEMBL
Y

TRANSMISSION
CASE

DISASSEMBLY

D

ISASSEMBL
Y
OF
GEAR

ASSEMBLY

REAR

EXTENSION

DISASSEMBLY

ADAPTER

PLATE

DISASSEMBLY

INSPECTION

TRANSMISSION

CASE
AND

REAR

EXTENSION
HOUSING

BEARING
GEARS
AND
SHAFTS

BAULK
RING

Oil

SEAL

ASSEMBL
Y

FRONT

COVER
ASSEMBLY

REAR

EXTENSION
ASSEMBLY

ADAPTER

PLATE

ASSEMBLY

GEAR

ASSEMBLY

TRANSMISSION

ASSEMBLY

INSTALLATION
MT
2

MT
4

MT
4

MT
4

MT
5

MT
B

MT
8

MT

8

MT
B

MT
8
MT
8

MT
9

MT

9

MT
9

MT
9

MT
9

MT
9

MT
9

MT13

MT14

DESCRIPTION

pUshed
the
inner

teeth
of
the

coupling

sleeve
slide
over
the

synchronizer
hub

and
mesh
with

the
outer
teeth

which

are

provided
on
the
mainshaft

gear

The

synchronizer
hub
is
fitted
to

the
mainshaft

by

splines
so
the
main

shaft

gear
turns
together
with
the

mainshaft

The
baulk

ring
serves
to

synchro

nile

the

coupling
sleeve
and
mainshaft

gear

Placing
the
control
lever
in
reverse

position
brings
the
reverse
idler

gear

into

mesh
with
mainshaft
reverse

gear
The
transmission
is
of
a
4

speed

forward

fully
synchronized
constant

mesh

type
that

uses
helical

gears

The

reverse

gear
is
ofa

sliding
mesh

type
using
spur
gears

In
construction
the

main
drive

gear

is
meshed
with
the

counter
drive

gear

which
is

keyed
to

the
countershaft

The
forward

speed

gears
on
the

coun

tershaft

are
in

constant
mesh
with
the

mainshaft

gears
which
ride
on
the

mainshaft

freely
through
the
needle

bearing
When

shifting
is

accom
The
transmission

assembly
consists

of
three
main

parts
a

transmission

case
with
clutch

housing

adapter
plate

to
which
an

gears
and
shafts
are

installed
and
rear
extension

The
cast
iron

adapter
plate

supports

the
mainshaft
countershaft

reverse

idler
shaft
and
three
fork
rods
and

bolted

at
the
front

to
the

transmission

case
and
at
the
rear
to
the
rear

extension

by
means
of

through
bolts

By
removing
these

through
bolts
all

gears
and
shafts
are

stripped

e

TM

858

1

Front
cover

2
Transmission
case

3

Adapter
plate

4

Bearing
retainer

5

Rear
extension

hOUsing

Fig
MT
1
F4W71B
lrammiasion
case

compon
nt

MT
2

Manual
Transmission

o

cCl

4
@

@

fl

t

o

@

Fig
MT
3

MT
3
TM857
1
Main

drive
gear

2
Baulk

ring

3
d
4th

3

Synchronizer
hub
r

4

Shifting
insert

spnng

5
Shifting
insert

6
Coupling
sleeve

7
3rd
main

gear

8
Mainshaft

9
2nd
main

gear

10
1st
main

gear

11
ht

gear
spacer

12
Reverse
main

gear

13
Counter
drive

gear

14
Countershaft

15
Reverse
counter

gear

16
Reverse
idler
shaft

17
Reverse
idler

gear

Fig
MT
2
n
ear

component
F4W71B
transmlsBIO

g

@

f1f@

n
1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27
Striking
lever

Lock

pin

O

ring

Striking
guide

Oil
sea1

Striking
rod

E
ring

Stopper
guide
pm

Return

spring
plunger

Return

spring

Reverse
check

spnng

Return

spring
plug

Check
ball

plug

Check

spring

Check
baD

Interlock
ball

Retaining
pin

k

1st
2nd
shift
or

ht

2nd
fork
rod

3rd
4th
fork
rod

Reverse

fork
rod

3rd
4th
shift
fork

Reverse
shift
fork

Con
trollever

Control
lever
b

shmg

Control
lever

p
n

Control
lever

bushmg

TM045A

I

ponents
shift
contro
com

F4W71

B
transmuswn

REMOVAL

In

dismounting
transmission
from

the
vehicle

proceed
as
follows

I
Disconnect
battery
ground
cable

from
terminal

2

Place
transmission
control
lever
in

neutIal

position

3
Remove
E

ring
and
control
lever

pin
from
transmission

striking
rod

guide
and
remove
control
lever
See

Figure
MT
4

TM335

Fig
MT

4
Remouing
controllelJ
r

4
Jack

up
the
vehicle
and

support

its

weight
on

safety
stands
Use
a

hydraulic
hoist
or

open
pit
if
avail

able

Confirm
that

safety
is
insured

5
Disconnect
exhaust
front
tube

6
Disconnect
wires
from
reverse

lamp
switch
See
Figure
MT
5

7
Disconnect

speedometer
cable

from
rear
extension

housing
See

Figure
MT
5

8
Remove
clutch

operating
cylinder

from
transmission
case
See

Figure

MT5

O

m

J

@

1

Speedometer
cable

2
Reverse

lamp
switch

3
Outch

operating
cylinder

TM774

Fig
MT
5
Bottom
view
of
car
Manual
Transmission

9
Remove
bracket

holding
center

bearing
on
3rd
crossmember

by

loosening
off

attaching
bolts
See

Figure
MT
6

PD219

Fig
MT

6
Removing
center
balring

holding
brucket

10
Uetach

propeller
shaft
from

companion
flange
of

gear
carrier

by

removing
four
bolts

See

Figure
MT
7

Not

a
Remove

propeller
shaft

carefully
so

as
not
to

damage

spline
sleeve

yoke

and
rear
oil
seal

b

Plug

up
the

opening
in
the

rear
of

rear
exteDSion

housing
to

prevent

oil
from

flowing
out

P0220

Fig
MT
7

Remouing
four
bolt

6ecuring
prop
ller

shtJft
to

companion
ltJnge

11

Support
engine
by
locating
a

jacft
under
oil

pan
with
a
wooden

block
used
between
oil

pan
and

jack

12

Support
transmission
with
a

transmissionjack

13
Remove
exhaust

pipe
btacket

by
unscrewing
attaching
bolts
2

California
models

only
See

Figure

MT
8

14
Remove
rear

engine
mounting

insulator

securing
bolts
I
and
rear

mounting
member

securing
bolts
3

See

Figure
MT
8

MT
4
E
A277

Fig
MT
8

Removing
engine
mounting

rear

support

15

Remove
starter
motor

16
Remove
bolt

securing
transmis

sion

to

engine

After

removing
these
bolts

support

the

engine
and
transmission
with

jacks

and
then
slide
tra
ion
rearward

away
from

engine
and
remove
from

the
vehicle

Note
Take
care
in

dismounting
trona

mission
not
to
strike

any
adjacent

parts
and
main
drive
shaft

DISASSEMBLY

TRANSMISSION
CASE

DISASSEMBLY

I
Prior
to

disassembling
transmis

sion

thoroughly
wipe
off
dirt
and

grease
from
it

2

Drain
oil

thoroughly

3
Remove
dust
cover
from
trans

mission
case

Remove
release

bearing
and
with

drawallever

4

Remove
reverse

lamp
switch

5
Move

gear
to
Neutral

6
Remove
speedometer
pinion
and

pinion
sleeve

by

taking
off
lock

plate

7
Remove
E

ring
and

stopper
guide

pin
from
rear
end
of

re
ll
extension

See

Figure
MT

9

TM337

Fig
MT
9

Removing
triking
rod

E

ring
and

topper
pin

REAR

EXTENSION

DISASSEMBLY

Remove
lock

pin
from

striking

lever
and
remove

striking
rod
Manual
Transmission

Note
00

not
diSlssemble

rear
exten

sion
bush
from

rear
extension

ADAPTER
PLATE

DISASSEMBLY

I

Remove
six

6

bearing
retainer

attaching
screws
with
an

impact

wrench
and
remove

bearing
retainer

from

adapter
plate

2

Remove
reverse
idler
shaft

3
Remove
mainshaft

bearing
from

the
rear
extension
side

INSPECTION

Wash
all

parts
in
a
suitable

cleaning

solvent
and
check
for
wear

damage
or

other

faulty
conditions

Notes

a
Be
careful

not
to

damage
any

parts

with

scraper

b

00
not

clean
wash
or
soak
oil
seals

in
solvent

TRANSMISSION
CASE

AND

REAR

EXTENSION
HOUSING

I
Clean
with

solvent

thoroughly

and
check
for

cracks
which

might

cause
oil
leak

or
other

faulty
con

ditions

2

Check

mating
surface
of
the

case

to

engine
or

adapter
plate
for
small

nicks

projection
or
sealant
e
1
Control
lever

2

Striking
rod

guide

3

Striking
rod

4

Striking
lever

5

Return

spring
plug

6

Stopper

pin

TM353

Fig
MT

27

Exploded
view
of
shifting
mechani6m

Remove
all

nicks

projection
or

sealant
with

a
frne

stone

3

If
rear

extension
bush
is

worn
or

cracked

replace
it
as
an

assembly
of

bush
and
rear
extension

housing

BEARING

I

Thoroughly
clean

bearing
and

dry

with
a

compressed
air

2
When
race
and
ball
surfaces
are

worn
or

rough
or
when
balls
are
out

of

round
or

rough

replacebearihg

with
a
new
one
See

Figure
MT
28

I

TM372

Fig
MT
28

l
pecting
ball

bearing

3

Replace
needle

bearing
if

worn
or

damaged

GEARS
AND

SHAFTS

I

Check
all

gears
for
excessive

wear

chips
or
cracks

replace
as

required

MT
8
2

Check
shaft
for

bending
crack

wear
and
worn

spline
if

necessary

replace

3
Measure
backiasii
in

gears

Standard

0
05
to0
10mm

0
0020
to
0
0039
in

If
the
above
limits
are
exceeded

replace
drive
and
driven

gears
as
a

set

4
Measure

gear
end

play

1st

gear

0
32
to
0
39
mm

0
0126
to
0
0154
in

2nd

gear

0
12
to

0
19
mm

0
0047

to
0
0075
in

3rd

gear

0
13
to
0
37
mm

0
0051
to
0

0146
in

TM374

Fig
MT

29

Measuring
end

play

5

Check
for

stripped
or
damaged

speedometer
pinion
gear
If

necessary

replace

BAULK
RI
NG

I

Replace
baulk

ring
if
found
to
be

deformed

cracked
or
otherwise
dam

aged
excessively

2
Place
baulk

ring
in

position
on

gear
cone

While

holding
baulk

ring
against

gear
as
far
as
it

will

go
measure

gap

between
baulk

ring
and
outer

gear

If

gap
is
small
discard
baulk

ring

See

Figure
MT
30

5
lr
1
25

to
1

60
rom

0
0492
to
0

0630
in

Baulk

ring

TM375

Fig
MT
30
Baulk

ring
to

cone

gap

OIL

SEAL

Discard

O

ring
or
oil
seal

which
is

once

removed

Replace
oil

seal
if

sealing
lip
is
deformed

or

cracked

Also
discard

oil
seal

if

spring
is

out
of

position

ASSEMBLY

To
assemble

reverse
the

order
of

disassembly
Observe

ihe

following

instructions

FRON1
COVER
ASSEMBLY

I

Wipe
clean
seal
seat
in
front

cover
then

press
fit
oil
seal
in

place

Coat
oil
seal
with

gear
oil

to

provide
initial
lubrication

Front

J

f

C
J

TM354

Fig
MT
31
Front
cov

oil
eol
Manual
Transmission

2

Apply
sealant
to
withdrawal

lever

ball

pin
screw
Install
withdrawal
lever

ball

pin
to
front
cover
and

tighten

screw
to
1
6
to
2
1

kg
m

12
to
15

ft
lb

torque

REAR

EXTENSION

ASSEMBLY

1

Wipe
clean

seal
seat
in

rear
exten

sion

housing

press
fit
oil
seal
in

place

Coat
oil
seal
and

bushing
with

gear

oil
for
initial
lubrication

Front

h

TM355

Fig
MT
32
Rear
extemion
oil
seal

2

Apply
grease
to
O

ring
and

plung

er

grooves
in

striking
rod

Insert

striking
rod
with

striking
rod

guide
through
rear
extension

3
Install

striking
lever
on
front
end

of

striking
rod
Install
lock

pin
and

torque
screw
to
0
9
to

1
2

kg
m

7
to

9
ft
Ib

ADAPTER
PLATE
ASSEMBLY

1
Place
dowel

pin
mainshaft
bear

ing
and
oil

gutter
on

adapter
plate
and

tap
with
a
soft
hammer
until

they
are

properly
positioned
in

place

Use
a
new
dowel

pin

Bend
oil

gutter
on
front
side
and

expand
on
rear
side
See

Figure

MT33

J

7

r

M356
Upper

Front

Fig
MT
33
Oil

gutter

MT
9
2
Insert
reverse
idler
shaft
in

adapt

er

plate

Make
sure
that
the

cut
out

portion

of
reverse

idler
shaft
is
lined

up
with

inner
face
of

adapter
plate

3
Install

bearing
retainer
in

adapter

plate

Align
bearing
retainer
with
reverse

idler
shaft
at
the
cut
out

portion
of

this
shaft

torque
screws
to
1

9
to

2
5

kg
m
14
to

18
ft
lb

and
stake
each

screw
at
two

poin
Is

with

a
punch
See

Figure
MT
34

TM400

Fig
MT
34
Staking
SCN
W

4
Install
countershaft
rear

bearing

in

adapter
plate
by
lightly
tapping

around
it
with

a
soft
hammer

GEAR
ASSEMBLY

Clean
all

parts
in

solvent
and

dry

with

compressed
air

Synchronizer

888embly

Assemble

synchronizer
assembly

Position

shifting
insert

springs
and

shifting
inserts
in
three
3
slots
in

synchronizer
hub

put
coupling
sleeve

on

synchronizer
hub

r
Front

3rd
4th
15t
2nd

TM351

Fig
MT

35

Installing
synchronizer

hub

Malnshaft

assembly

I

Assemble
2nd

gear
needle
bear

ing
2nd

gear
baulk

ring
1st
2nd

speed
synchronizer
assembly
st

gear

baulk

ring
I
st

gear
bush
needle
bear

ing
I

st

gear
steel
ball
and
thrust

washer
on
mainshaft
Before

installing

a

steel
ball

apply
grease
to

it
See

Figure
MT
36

TM358

Fig
MT

36

l
talling
thrust
washer

2

Set
Transmission
Press
Stand

KV311
00400
and

place
adapter
plate

assembly
on
it

See

Figure
MT
37

For

counterman
and
reverse
idler
shaft

For
main5haft
and
reverse

tdler
haft

V31100400

J
UJ

V
TM438

Holes
for
reverse
Idler

shaft

Fig
MT

37
Tromm
inion
PreS3
S
tond

3
Install
mainshaft

assembly
to

adapter
plate
assembly
Be
sure
to

place
bearing
squarely
against
shaft

and

press
it
into

place
on
shaft

gradu

ally
See

Figure
MT

38

KV31100400

TM439

Fig
MT
38

Installing

mai
haft

em

bly
Manual
Transmission

Countershaft

assembly

I
Place
new
woodruff

keys
in

grooves
in

countershaft
and

tap
them

lightly
until

they
are
seated

securely

Use
a

soft
hammer
to

avoid
dam

aging
keys

2

Place

adapter
plate
assembly
and

mainshaft

assembly
so
that

counter

shaft
rear

bearing
rests
on

Transmis

sion

Press
Stand
KV31100400

prop

erly

3
Install
countershaft

into

adapter

plate
by

pressing
it
See

Figure
MT
39

TM440

Fig
MT
39

l
talling
countersha
t

4
Position

3rd

gear
needle

bearing

fnaiiiSh
ifOfd

gear
baulk

ring
and
3rd

4th

synchronizer
assembly
on
the

front
of
mainshaft

S
Ins
iall
thrust
washer

on
mainshaft

and
e
ure
it
with

snap
ring
of

proper

thickness
that
will
fit
the

groove
in

mainshaft
See

Figure
MT
40

Available

snap
ring

No
Thickness
mm
in

I

2

3
1
4

0
055

1
5
0
059

1
6
0
063

TM441

Fig
MT
40

l
talling
snap
ring

MT
l0
Main
drive

gear
assembly

1

Using
Transmission
Adapter

ST23800000

press
main
drive

bearing

onto
the
shaft
of
main

drive

gear

Make
sure
that

snap
ring
groove
on

shaft
clears

bearing

2
Place
main
drive

bearing
spacer

on
main
drive

bearing
and

secure
main

drive

bearing
with
thicker
snap

ring

that
will
eliminate
end

play
See

Figure
MT
4l

Available

snap
ring

No
Thickness
mm
in

2

3

4

5

6
1
80
0
0709

1
87
0
0736

1

94
0
0764

2
01
0
0791

2
08
0
0819

2
15

0
0846

CD

I

TM364

Fig
MT
41
Installing
snap
ring

3

Position
baulk

ring
on
cone
sur

face
of
main

drive

gear

Apply
gear
oil

to

mainshaft

pilot

bearing
and
install
it

on
mainshaft

Assemble
main
drive

gear
assembly

on
the
front

end
of
mainshafl

4

Press
counter
drive

gear
onto

countershaft

with
Counter
Gear
Drift

ST23860000

by

meshing
gears
and

secure
counter
drive

gear
with
thicker

snap
ring
See

Figures
MT
42
and

MT
43

Note

Be

sure
to
drive
in
counter

drive

gear
and
main
drive

gear

simultaneously