1977 DATSUN PICK-UP recommended oil

PROPELLER
SHAFT
DIFFERENTIAL
CARRIER

Watch
for
oil

leakage
from
trans

mission

end

Notes

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
extension

housing
to

prevent

oil
from

flowing
out

To
install

reverse
the

foregoing

removal

procedure

1

Align
propeller
shaft
with
com

panion
flange

using
reference
marks

prescribed
in
removal

procedure
and

assemble
with
bolts

Tightening

torque

2
4

to
3
3

kg
m

17

to
24
ft
Ib

2

Insert
bolts

through
the
holes
of

center

beariug
bracket
and

torque
nuts

to
retain
center

bearing
on
cross

member

Tightening
torque

1
6

to
2
2

kg
m

12
to
16
ft
Ib

DISASSEMBLY
AND

ASSEMBLY

Primarily
do
not
disassemble

pro

peller
shaft
because
it
is

balanced
as
an

assembly

However
check

propeller
shaft

with

journal
for
movement
When

journal
does
not
move

smoothly
dis

assemble

1
Mark

propeller
shaft
and

journal

so
that
the

original
combination
can

be
restored
at
assembly

2
Remove

snap
ring
with
a
standard

screwdriver

3
Lightly

tap
base
of

yoke
with
a

hammer
and
withdraw

bearing
race

See

Figure
PD
4

PDOO5

Fig
PD
4
Remo

i
bearing
Note
When

removing
journal
from

yoke
be
careful
not
to

damage

journal
and

yoke
bole

When

disassembling
and

repairing

center

bearing
are

required
the
follow

ing
procedures
are

applied

1
Put
match
marks
on

flange
and

front

propeller
shaft
Remove
bolts

connecting

flange
yoke
to

companion

flange

2

Applying
Drive
Pinion

Flange

Wrench
ST3lS30000
loosen
off
lock

ing
nut
and

remove
center

bearing
See

Figure
PD
5

P0172
ST31530000

Fig
PD
5
Remouing
locking
nut

To
assemble
reverse
the
foregoing

procedure
using
reference
marks

pre

scribed
in

disassembly
procedure

New

bearing
need
not
be
lubricated

since
it
is

lubricated
for
life
Fill

joint

with
recommended
multi

purpose

grease
whenever

propeller
shaft
is

overhauled

Use
related

snap
rings
of
the
same

thickness
and
be
sure
that

play
is

below
0
02
mm
0
0008
in

Available

snap
ring

Thickness

mm
in
Color

identification

2
00
0
0787

2
02
0
079S

2
Q4
0
0803

2
06
0
08
II

2
08
0
0819

2
10
0
0827

2
12
0
83S

2
14

0
0843
White

Yellow

Red

Green

Blue

Right
Brown

No

paint

Pink

PD

3
Install
and
assemble

components

correctly
so
that

joint
moves
under

friction
resistance
of
less
than
is
o

kg
em

13
in
lb

When
the

above

steps
are
complete

place
the

shaft
in

a

balancing
machine

and

adjust
unbalance
less
than
3S

gr
cm
0
49
in

oz
at
S
800

rpm

Center

bearing
assembling
pro

cedures
are
as
follows

I
Install
center

bearing
in

center

bearing
insulator

2
Install
center

bearing

assembly

and

companion
flange
on
front
shaft

usiug
reference
marks
established
in

disassembly

procedure

3
Install
washer
and

locking
nut
on

front
shaft

and

tighten
nut

using
Drive

Pinion

Flange
Wrench
ST3IS30000
to

specified
torque

Tightening
torque

20
0

to
24
0

kg
m

I4S
to
174
ft
lb

4
Join

companion
flange
of
front

shaft

with

f1ange
yoke
of
rear
shaft

and

tighten
connect
bolts
to

specified

torque

Tightening

torque

2
4

to
3

3

kg
m

17
to
24
ft
Ib

S
Install
center

bearing
bracket

on

center

bearing

INSPECTION

I
Check

journal
pin
for
dent
or

brinell
marks
and

yoke
hole
for

sign

of
wear
or

damage

Snap
ring
bearing
and
seal

ring

should
also
be

inspected
to
see
if
these

are

damaged
worn
or
deformed
Re

place
if

necessary

2
heck
center

bearing

by
rotating

bearing
race
If
it
is

rough
noisy
or

damaged
discard
Cracked

bearing

insulator
cannot
be
tolerated
here

3
Check

propeller
shaft
tube
sur

face
for
dent
or
crack

Change
if

necessary

ST202

Fig
ST
6

Withdrawing

gear
ann

Note

Before

removing
steering

gear

arm

scribe
match
marks
on
arm

and

housing
so

that

they
can

easily

be

replaced
in
their

original
posi

tions
at

assembly

9
Remove
three

bolts

securing

steering
gear
housing
to
frame

10
Withdraw

steering
gear
assembly

toward

engine
compartment

Installation

Install

steering

gear
assembly
in
the

reverse
order

of
removal

observing
the

following
instructions

I
When

installing

steering

gear

housing

securing
bolts
insert
two
bolts

through
gear
housing
to
frame

2
When

installing
steering
gear
arm

align
four

grooves
of

gear
arm

serra

tions

with
four

projections
of
sector

shaft
serrations

3

Tightening
torque

Steering
gear

housing

4

6
to
S
3

kg
m
33
to
38
ft
lb

Gear
arm

13

to
IS

kg
m
94

to
108
ft
lb

Steering
wheel

7

0
to

7
S

kg
m
51

to
54

ft
Ib

4

With
front
wheels
set
in

a

straight

ahead

position
make

sure
that

punch

mark
on
the

upper
end
surface

of

steering
column
shaft
is

at
the

center

of
the

upper
side
in
its

installing

portion

S
When

installing
steering
wheel

apply
grease
to

sliding
parts

6
After

installing
make

sure
that

steering
wheel
turns

smoothly
STEERING
SYSTEM

Disassembly
and

assembly

Disassembly

I
Drain

oil
in

steering
gear
housing

by
unscrewing
fIller

plug

2
Place

steering
gear
assembly
in
a

vise

securely

3

Loosen
lock
nut
and
turn

sector

shaft

adjusting
screw
a
few

turns
coun

terclockwise

Remove
sector
shaft
cover

by
un

screwing
four

fixing
bolts

rn

ST203

Fig
ST
7

Remouing
sector

haft
couer

4

Turn

sector
shaft

adjusting
screw

a

few
turns
clockwise

and

pull
sector

shaft
cover

together
with
sector
shaft

from

gear

housing

ST204

Fig
ST
B

PuUing
out

ector

haft

S

Separate
sector

shaft

adjusting

screw
and

shim
from
cover

6
Remove

jacket
tube

by
unscrew

ing
three

fixing
bolts

7

Remove

steering
worm

assembly

from

gear

housing

8

Detach

worm

bearings
and

worm

bearing

adjusting
shims
from

worm

gear
assembly
and
column

jacket

Note
Be

careful
not
to
allow
ball

nut

to

run
down
to
the

worm
end
If

ball

nut
rotates

suddenly
to

the

worm

end
the
ends
of
ball

guides

may
be

damaged

ST
4
9

Pry
out
sector
shaft
oil

seal
from

gear

housing
and

discard
it

10
Remove

O

ring
from
the

rear

cover
of
column

jacket
and

discard
it

11

Remove
column

jacket
bushing

Notes

a

Do
not

remove
sector
shaft

bushing

from

housing
If

necessary
replace

as
a

gea2

nousing
assembly

b
Do

not
disassemble

ball
nut
and

worm

geir
If

necessary

replace

them
with
new
ones
as
a

worm

gear

assembly

Fig
ST
9

Removing

steering
worm

assem

bly

Assembly
and

adjustment

Apply
recommended

gear
oil
to
all

disassembled

parts

1

Fit
column

jacket
bushing
to

column

jacket
in

place

Note
When

fitting
apply
adhesive
to

bushing
exterior
and

grease
to
in

terior

2
Fill
the

space
between
new
sector

shaft
oil
seal

lips
with

grease
and
fit
it

to

gear

housing

3
Place

steering
worm

assembly
in

position
in

gear

housing
together
with

worm

bearings

4

Install
column

jacket
on

gear

housing
with
O

ring
and

worm

bearing

shims

Be

sure
to

install
thicker
shims
to

the

gear

housing
side

Standard
shim
thickness

1
5
mOl
0
OS9
in

Tightening

torque

1
5
to
2
S

kg
m
11
to

18
ft
Ib

Available
worm

bearing
adjusting

shim

No
Thickness

mOl

in

I
0
762
0
0300

2
0
2S4
0
0100

3
0
127
0
0050

4
O

OSO
0
0020

5

Adjust
the
worm

bearing

preload

with

Preload

Gauge
ST3127S000

by

selecting
suitable

bearing
shims
so
that

the
initial

turning

torque
of

steering

column
is

the

specified
value

Initial

turning
torque
of

steering

column
shaft

New
worm

bearing

4

0
to
6
0

kg
em

S6
to
83
in
oz

Used
worm

bearing

2
4
to
4
4

kg
em
33
to
61
in

oz

6

Insert

adjusting
screw
into
the

T

shaped

groove
at
the
sector
shaft

head

and

adjust
the
end

play
between

sector
shaft
and

adjusting
screw
until

it
is
within
0

01
to
0
03
mm

0
0004

to
0
0012
in

by
choosing
suitable

adjusting
shims

Available
sector
shaft

adjusting

screw
shim

No
Thickness
mOl
in

I
1
57S
0
0620

2
1
550
0
0610

3
1
525
0
0600

4
I
S00
0
OS91

S
1
475
0

0581

6
I

4S0
0
0571

7
Rotate
ball
nut

by
hand
until
it
is

in

the
center

of
its
trovel
then
install

sector
shaft

together
with

adjusting

screw
in

gear
housing
ensuring
that

the
center

gear
of
sector
shaft

engages

with
that
of
ball
nut
STEERING
SYSTEM

8

Install
sector
shaft
cover

to

gear

housing
Be
sure

to

apply
sealant
to

each
face
of
sector
shaft
cover

packing

when

installing
cover

9

By
turning

adjusting
screw
coun

terclockwise
attach
sector
shaft
cover

to

gear
housing
and
then

temporarily

secure
it
with
its

fixing
bolts

10
Pull
sector
shaft
toward

cover

approximately
2
to
3
mOl

0
08
to

0
12
in

by
turning

adjusting
screw

counterclockwise
and
tighten
sector

shaft
cover

fixing
bolts
to
l
S
to
2
5

kg
m

11
to
18
ft
Ib

II
Push
sector
shaft

against
ball
nut

gear
by

gradually
turning

adjusting

screw

clockwise
until

sector
shaft

gear

lightly
meshes
with
ball
nut

gear
and

then

temporarily
secure

adjusting

screw
with
lock
nut

12
Install

gear
arm
to
sector
shaft

and
move

sector
shaft
several
times

from
the
side
of

gear
arm
and

make

sure
that
it
turns

smoothly

13

Adjust
the
backlash
at
the
neu

tral

position
of

gear
arm

by
turning
in

or
out

adjusting
screw
so

that
the

movement
of
the

gear
arm

top
end
is

less
than
0
1
mOl
0
004
in

0

ST207

Fig
ST
10
Mea

uring
backlash

14
Turn

adjusting
screw
approxi

mately
1
8
to
1

6
turn
clockwise
and

then

retighten
lock

nut
to
3

0
to
4
0

kg
m
22

to
29

ft
Ib

IS
Fill
recommended
gear
oil

ap

proximately
0
33
liter
X

U
S

pI

X

Imper
pt
into

gear
assembly

through
the
filler
hole
and
install
filler

plug

ST
5
Inspection
and

repair

Wash
clean
all
the
disassembled

parts
in
solvent
and
check
for
condi

tions

Sector

shaft

1

Check

gear
tooth
surface
for

pit

ting
burrs
cracks

or

any
other
dam

age
and

replace
if

faulty

2
Check
sector
shaft
for
distortion

of
its
serration

and
if

necessary
re

place
In

this
case
be
sure
to
check

gear
housing
for
deformation

Steering
column
shaft

assembly

1

Inspect
the
ball
nut

gear
tooth

surface
and

replace
if

pitting
burrs

wear
or

any
other

damage
is
found

2

Ball
nut

must
rotate
smootWy
on

worm

gear
If

found
too

tight
assem

bly
should
be

replaced
Check

as
fol

lows

Move

ball
nut
to
either
end
of

worm

gear
and

gradually
stand
steer

ing
column
shaft

assembly
until
ball

nut
moves
downward
on
worm

gear

under
its

own
weight
In
the
above

test
if
ball
nut
does
no
move

freely

over
entire

stroke
assembly
may
be

damaged
Replace
with

a
new
one
as

an

assembly

Note
In

this

inspection
be
careful

not
to
dama
e

ball
nut

guide
tube

Bearings
and

bushings

I

Replace
worm

bearings
if

pitting

wear

or

any
other

damage
is

found
on

them

2

Repiace
column

bushing
which
is

excessive
worn
or
deformed

3
If
sector
shaft

bushings
in

gear

housing
are
found
worn
or

damaged

replace
as
an

assembly
of

gear
housing

and

bushing

Oil
seal

gasket
and

O

ring

Do
not
reuse
above

parts
which
are

removed
once

Be

sure
to
use
new

parts
at
each

reassembly

REFRIGERAi
H
R
12

COMPRESSOR
OIL

MAINTENANCE

PERIODIC
MAINTENANCE
AND

SEASON
IN

INSPECTION

GENERAL
SERVICE
INSTRUCTION

SAFETY

PRECAUTIONS

EV

ACUA
TlNG
AND

CHARGING
SYSTEM

HANDLING

MANIFOLD
GAUGE

HANDLING
SERVICE
VALVE

HANDLING
CAN
TAP

DISCHARGING
SYSTEM

REFRIGERANT
R
12

The

refrigerant
used
in
the
air

conditioner
is

generally
called
Re

frigerant
12

R
12
No
other

refrig

erant
than
the

above

refrigerant
should

be
used

This

refrigerant
is

usually
available

in
a
small
can
or
a

cylinder
In

either

case
it

is

liquefied
under

high
pressure

in
the
container

Refrigerant

evaporates
easily
has
a

low

evaporation
point
and
moreover

since
the
latent

heat
of
the

refrigerant

is

large
it

can
abSorb

a

large
amount

of
heat

wh

err
e

vaporating
Extreme

care
must
be
exercised
when

handling

the

refrigerant

COMPRESSOR
OIL

The
SUNISO
5GS
or
SUNISO

351

should
be
used
as

refrigeration

lubricant

Mixing
of
the

two
is

allowable

The

refrigeration
lubricant
should

be
used
to
assure
the
successful
com

pressor
operation
Use
of
oils
other

than
recommended
or

mixing
of
the

oil

with
other
oils
would
cause

chemical
reaction

or
lead
to
lowered

viscosity
or
deficient
lubrication

The
oil

absorbs
moisture
as
it

con

tacts

the
air
This

points
out
the
need

for

care
not
to

expose
it

to
atmos

phere
for
an

extended

period
of
time
Air

Conditioning

GENERAL
SERVICE

CONTENTS

EVACUATING
SYSTEM

CHARGING
REFRIGERANT

CHECKING
FOR
LEAKS

HALIDE
LEAK

DETECTOR

ELECTRIC
LEAK

DETECTOR

REFRIGERANT
LEVEL
CHECK

SIGHT

GLASS

PERFORMANCE
TEST

COMPRESSOR
OIL
LEVEL
CHECK

PERFORMANCE
TEST

REFRIGERANT

LEAKS
AC
8

AC

8

AC
8

AC
8

AC
8

AC
9

AC
9

AC
9

AC10

AC

11

AC
12

MAINTENANCE

PERIODIC
MAINTENANCE

AND

SEASON
IN

INSPECTION

Both

periodic
maintenance
and

season
in

inspection
are

most
essential

to
enable
the
air

conditioner
to

give

full

performance

Perform
the

following
checks

Start

engine
and

check

refrigerant

level

through
sight
glass
on

receiver

dryer
For

details
refer
to

relative

topics
under

Refrigerant
Level

Check

2
Check
the
entire

sysiein
for

sign

of

refrigerant
leaks

Refer
to
relative

topics
under

Checking
for

Leaks

and

Refrigerant
Leaks

If

any
trace
of
oil
is

noted
at

and

around
connection

fittings
it
is
a

sure

indication

that

refrigerant
is

leaking

This
condition

can
be
corrected

easily

by
retightening
the

joints
If

any
joint

on
line

is

suspected
of
small
amount
of

leakage
use
a
leak

detector
to

locate

leaking
points

3
Check

compressor
drive
belts

for

proper
deflection

Season
off

Observe
the

following
maintenance

tips
to
allow

the
air

conditioner

to

operate

normally
in

the
next

season

I

Keep
the
entire

system
free
from

AC
8
AC12

AC

13

AC15

AC15

AC16

AC

16

AC16

AC
17

AC17

AC
17

AC18

refrigerant
leakage
by

periodically

checking
for

refrigerant
gas
leak

even

out
of
season

2

Turn
the

compressor
for
10

minutes

at
least
once
a
month

by

running
the

engine
at
1

500

rpm

c
ENERAL
SERVICE

INSTRUCTION

The

servicing
of
the
air
conditioner

should
be
carried
out

only
by
well

trained
servicemen
This

chapter
de

scribes
essential

points
of

servicing

Jf

a

Jarge
amount
of

dirt
and
sand

enter

the

system
they
will
be

carried
with

refrigerant
and

may

clog
the

system
or
scratch

rotating

parts
This

points
out
the
need
for

care
in

servicing
the

system
That

is

disconnecting

joints
should
be

carried
out

in
a
dean

place

Water
should
not
be
allowed
to

get

inside
the

system
The

refrigerant

does
not

readily
mix

with
water

However
the

presence
of
even
a

minute

amount
of

water
will
cause

a
chemical
reaction

at

high
tem

perature
which
will
in

turn

produce

hydrochloric
acid

HCl
Since

hydrochloric
acid
is

highly
corro

sive
to
metals
the
aluminum
and

copper
piping
etc
will
become

corroded
and
the

refrigeration

system
will
become

clogged

AC506

Fig
AC

59

Grounding
point

of
coil

5

If
clutch

assembly
must
lie
re

placed
remember
that

break
in

opera

tion
is

necessary
The
break
in

opera

tion

consists
of

engaging
and

disengag

ing
the

clutch

some

tirty
times

SHAFT

SEAL

ASSEMBLY

The

shaft
seal

assembley
of

this

compressor
is
of
a

simplified
design

yet
tight

sealing
and

long
lasting

REMOVAL

It
is

recommended
that
the

com

pressor
be
removed

from
the

vehicle

for

shaft
seal

replacement

I
Remove

oil
filler

plug
with
D

ring

and
drain

the

compressor
oil

Fig
AC

60

Removing
filler
plug

2
Remove

clutch
Refer
to

Com

pressor
Clutch

Removal

3

Remove

shaft

key
Air

Conditioning

jpL

Y
L

I
i
0

I
I

0

Ace07

Fig
AC
61

Removing
s
wft

key

4

Remove
seal

plate

AC80e

Fig
AC

62

Removing
seal

plate

5

With
the

Compressor
Seal

Puller

pull
out

seal

gland
and
discard

Notes

a

Discard
all

parts
of
the
seal

includ

ing
the
O

ring

b
Do

not
use
a

screwdriver
to

pry

shaft
seal
from
shaft

as

damage
to

shaft

may
result

AC809

Fig
A
C

63
Removing
s
wft
eal

INSTALLATION

1
Clean

shaft
and
seal

cavity
with

clean

lint
free
cloth

2

Dip
seal

gland
in

clean

refrigerant

oil

AC
36
3

Push
seal

assembly

except
carbon

ring
over
end
of
shaft
with

carbon

ring
retainer

facing
out

4
Move

seal

assembly
into

position

on
shaft

1

I

Fig
AC
64

Inserting
wft
al

ass

mbly

5

Place
carbon

ring
in

ring
retainer

so
lapped
surface
is

facing
outward

Note

The
indentions
in
outside

edge

of
carbon

ring
must

engage

driving

lugs
and
be

firmly
seated
in

re

tainer

6
Install
new
D

ring
in

groove
of

seal

plate

Note

Use

refrigeration
oil
to

make
it

adhere
to
surface

7

Space
seal

plate
with

equal
clear

ance
around

shaft
and

insert

cap

screws

8

Tighten
these

screws

evenly

Tightening

torque

Seal

plate
securing

cap
screws

0
7
to
1

0

kg
m

5
to
7
ft

Ib

AC811

Fig
AC
65

8p
cing
01

plate
and

tightening
cap
screws

9

Install

clutch
Refer
to
Com

pressor
Clutch
Installation