1977 DATSUN PICK-UP clock

2
RANGE
2ND

GEAR
Automatic
Transmission

In
2

range
the

gear
rario
is

IOI
keJ

III
the
2nd

forward

speed
In

this
case

the
rear

dutch
is

engaged
and
the

band

brake
holds

the
front

clutch
drum
the

connecting
shell
and
sun

gear
from

rotating

The

power
flow
takes

place

through

the

input
shaft
inlo

the

rear
clutch

and

the
front
internal

gear
With
Ihe

sun

gear
held

stationary
the
front

planetary

gears
rotate
around

the
sun

gear
carrying
the

front

planet
carrier

with
them
The
front

planet
carrier

being
splined
to
the

output
shaft

causes
clockwise
rotation

of
the
OUI

put
shaft
at
a

reduced

speed

compared

to
the

speed
of
the

input
shaft
with

an
increase
in

torque
As
the
low
and

reverse

brake
is
not

engaged
the
clock

wise

rotation
of

the

output
shaft

causes
clockwise
rotation

of
fear
inter

nal

gear
and

the
rear

planet
carrier
also

rotates
around

the

sun

gear
in
a

clockwise

direction
The

one

way

clutch

will
act

to
allow

clockwise

rotation
of

connecting
drum

When
the

manual
valve

V
is

posi

tioned
at
2

the
line

pressure
7
is

introduced
into

the
line

pressure
cir

cuits
I
2

and
4

The

line

pressure

I
is
led

to

the

governor
rear
clutch

and

I
st

2nd
shift
valve

CID
as
in
the

case
of

D

range
The

line

pressure

2
locks

the
second
lock

valve

@and

is
led
to

thc

tightening
side
of
Ihe

band

servo

The

2nd

gear
is

therefore
fixed

regardless
of
vehicle

speed
When

DJ

range
3rd

gear
is

shifted
to
2

range
the

line

pressure
4
enters
Ihe

throttle

back

up
valve

V
and

produces

a

high
pressure
in
the
circuit
17

increasing
thc

throttle

pressure
li
6

The

line

pressure
7

is

therefore

increased

and

quickly
tightens
the

band

N

e

DJ
range
3rd

gear
to
2

range

If

DJ

range
3rd

gear
is

shifled

to
2

range

during
operation
the

manual
valve

V
is
also
shifted

to
A

T078

Fig
AT

40
Powu

tTansminion
during
2
H

range

A
1079

Fig
AT
41

Operation

of
each
mechanism

during
2

range

Clutch
Low

Band
ser
o
On

Parking
Gw

Ran8t

utio
w

pa

Front
Rear

brake
Operalion
Release

dutch

Pui
on

on

Revtrs
e

2
182
on

on
on

Neutral

01
Low

2
458
on
on

Drive
02
Second

1
458
Oft
Oft

OJ

Top
1
000
on
on

on
on

1
Second

1
458

on
Oft

12
tocond
1458

on
on

J

tt
Low
2
458

on
on

2

position

causing
the
line

pres

sure
circuit
3
to

be
drained

Therefore
the

line

pressure
circuit

10
which
is

situated
at
the

release

side
of
the
front
clutch

and
servo
is

also

drained

through
the
2nd

3rd

shift
val

e
@

forcing
the

speed
to

AT
28
decrease
from
3rd

gear
to
2nd

gear
In

this
case

the

speed

change

quickly
takes

place
because
the
line

pressure
7

and
other

pressure
are

heightened
by
the
action
of
the
line

pressure
4
in

the
same

manner
as

described
under
2

range

1
RANGE

LOW
GEAR
Automatic

Transmission

f
Wilen

slJrting
in
I

range
the

drlvlIlg
gear
is
IOl
ked

to

the
low

gear

fJIIIJ

In
H

range
the

rear

clutch
is

engJged
and

the
low
and
reverse
brake

hulds
he

onnecting
drum
and

feac

planet
carrier
from

rotating
The

power
tlow
lakes

place
through
the

input
shaft
and
into
lhe
rear

clutch

ROlalion

of
the
rear
clutch

drives
lhe

rear
dutch
hub

and
front
internal

gear

The
front

internal

gear
rotates
the

front

planetary
gears
clockwise
to

cause
the

sun

gear
to

rotate
counter

clockwise

Counterclockwise

rotation

of
the

sun

gear
turns
the
rear

planetary
gear

clockwise

The

rear

planet
carrier

splined
to

the

connecting
drum
is
held

from

rotating
by
the

low
and

reverse
brake

The

clockwise
rotation

of
the
rear

planetary

gears
therefore

rotates
the

rear

internal

gear
and

internal

drive

tlange
The

internal
drive

tlange
is

splined
to

the

output
shaft
and
rotates

the

uutput
shaft
clockwise
However

the

output
shaft
rotates

at
a

lower

speed

compared
to
that

of
the

input

shaft

This
is

caused

by
the
fact

Ihat

the

front

planet
carrier

rotates
at

the

same

speed
as
Ihe

OUlput
shaft
in
the

same
direction

since
the
carrier

is

splined
to

the

output
shaft
The
front

internal

gear
and

planetary
gear
assem

bly
are

rotating
in

the

same
direction

but

the

planet
carrier
is

rotating
at

a

speed
slower
than
the

ring

gear
So
the

gear
ralio

of
this

speed
range
is

a

combination
of
the
ratios

provided

by

the
front

and
rear

planetary
gear
as

semblies

When
the

manual
valve

Vis

posi

tioned

at
I

the
line

pressure
7

is

applied
into

the
line

pressure
circuits

I

4

and
5
The
oil

pressure
in
5

actuates
the
luw

and

reverse
brake

after

being
introduced
into

the
circuit

12

through
Ihe

1st
2nd
shift

valve

ID
and

the

line

pressure
I

acts
on
C

A

T076

Fig
AT

43
Power

transmission

during
1
J

range

Fai1

A

TOn

Fig
AT
44

Operation

of
each
mechanism

during
JJ
range

Clutch
Low

Band
servo
On

Parking
Gm

Range
reverse
w

pawl
ratIO

Front
Rur

brake
Operatlon
Release

clulCh

Park

on

on

Reverse
2
182
on
on

on

Neutral

01
low

2
458
on

on

Drive
02
Second

1
458
on
on

03

Top
1000
on
on
on

on

2
Second

1
458
on

on

2
Second

IAS8
on

on

I

1
low
2
458
on
on

the

rear
clutch
and

governor
The

line

pressure
4

acts
in

the
same
manner

as

in
2

range

Similar
to

that
of
the

D

range

the
line

pressure

inr
reases
with
the

degree
of
accelerator

pedal

depression

and
the
line

pressure
decreases
with

the

increase
of
car

speed
The

governor
pressure
15
which
acts

on
the

I

st
2nd
shift
valve
does
not
increase

until
it

overcomes
the

combined
force

of
the
line

pressure
12
and
the

spring

causing
no
st
2nd

speed

cha

nge

AT
30

Fig
AT
70

Measuring
ring
to

plate

clearance

Available

retaining
plate

Thickness
mm
in

1l
8
0
465

12
0

0472

12
2
0480

124

0488

12

6
0496

12

8
0
504

For

inspection
procedure
for

low

and

reverse
brake
see

page
AT
42
for

Assembly

3

Install
one

way
clutch
so
that
the

arrow
mark
is
toward
front

of

vehicle
It
should
be

free
to

rotate

only
in

clockwise
direction
See
Figure

AT
71

mITIJ

o

oml

AT137

Fig
AT
71

One

way
clutch

4
After

installing
rear
extension

torque
attaching
bolts
to
2
0
to
2
5

kg
m

14
to
18
ft
lb
Place
manual

lever
in
P

range
and
check
to

be
sure

that
rear

output
shaft
is

securely

blocked

5

Tighten
servo
retainer

temporari

ly
at
this

stage
of

assembly

6
Place

rear
clutch

assembly
with

needle

bearing
on
front
assembly
Automatic
Transmission

7

Install
rear
clutch
hub
and
front

planetary
carrier
as
shown
in

Figure

AT
72

AT142

Fig
AT
72

Installing
planetary
carrier

8
Assemble

connecting
shell
and

other

parts
up
to
front
Clutch
in

reverse
order
of

disassembly

AT143

Fig
AT
73
Installing
connecting
shell

9

Adjust
total
end

play
and

front

end

playas
follows

Front
end

play

L

r

L

CD
I

r

L

11
I
J

Total
end

play
@

Front
clutch

thrust
washer

2

Oil

pump
cover

3
Front
clutch

4

Rear
clutch
AT138

5

Trammission
case

6
Oil
pump

gasket

7
Oil

pump
cover

bearing
race

Fig
AT
74
End

play

1
Measure
the
distance
A

and

C

by
vernier

calipers
as
shown

in

Figure
AT
75

AT
39
i
Rear

c

clutch

N
edle
bearing

Bearing
race

I

Fig
AT
75
AT139

Measuring
the
distance

A

and
C

2

Measure
the
distance
B

and

D
of

oil

pump
cover
as
shown
in

Figure
AT
76

I

L

I
Oiipi
mp

AT140

Fig
AT
76

Measuring
the
distance

B
and
D

Adjustment
of

total
end

play

Select
oil

pump
cover

bearing
race

by

calculating
the

following
formula

TT
A
B
W

where

T

T
Required
thickness
of
oil

pump

cover

bearing
race
mm
in

A

Measured
distance
A
mm
in

B
Measured
distance
B
mm

in

W
Thickness
of

bearing
race

temporarily
inserted
mm
in

Available
oil

pump
cover

bearing

race

Thickness
mm

in

1
2
0
047

I
4
0
055

1
6
0
063

1
8
0
071

2

0
0
079

2
2
0
087

Specified
total
end

play

0
25100
50
mm

0
0098
to
0
0197
in

spindle
and

torque
bolt
to
10
3

to

12
1

kg
m
75
to

88
ft

lb
Bend

lock

plate
to

engaged
flats
on
boll
head

Note

When
disassembled
discard

used
lock

plate

5

Pack

grea
to
the

upP
r

and

lower

bushings
on

knuckle

spindle

until

grease
c
omes
out

from

gr
ease

seal

6
Fill
wheel
hub
and

cap
with

grease

up
to
the

described
level
See

Figure
F
A
4

FA141

Fig
FA
4

Gre
ing
wheel
hub

7
Pack

roller
and
cone

assembly

and
the

cavity
of

grease
seal

lip
with

grease

8
Coat

grease
to

the
thread
of

knuckle

spindle

bearing
washer
and

bearing
lock
nul

9
Secure
wheel
hub

bearings
bear

ing
washer
and

spindle
nut
on
knuckle

spindle
and

adju
t

bearing

preload

referring
to

the

paragraph
Wheel

bearing
adjustment

Note
Be

sure
to
obtain

correct

pre

load

on
wheel

bearings
for
the

pu
rpose
of

ving
their

long
life

taking
care
to

keep
wheel

be8rlngs

grease
seal

bearing
washer
and

spin

dle
nut
clean
when

installing
them

WHEEL

BEARING

D

TM
NT

Wrong

adjustment
of
wheel
bear

ing
causes
abnonnal
wear
and
score

on
the

bearings
and
knuckle

spindle
Front
Axle
Front

Suspension

To
attain

proper
preload
on
wheel

bearings

proceed
the

following

opera

tions

I

Torque
spindle
nut

to
3

0
to
3
S

kg
m
22
to

25
ft
lb

using

torque

wrench

FA227

Fig
FA
5

Tightening
apindle
nut

2

Rotate
wheel

hub
a
few
turns

clockwise
and

counterclockwise
to

seat

bearings
Then

retighten
spindle

nut
to
the
same

tightening

torque
Be

certain

to
rotate
hub

smoothly

3

Back
off

spindle
nut
in

range

from
40
to
70

degrees
Locate

adjust

ing
cap
on

spindle
nut

so
as
to

align

the
castellation
on

the

cap
with

the

cotter

pin
hole
in

the

spindle

4

Check
the
hub
rotation

If
hub

rotates

properly
measure

bearing
rota

tion

starting
torque
If
measured

torque
is
deviated
from

the

specified

value
r

place
beari

gs
r
re

dju
st

The

starting

torque
can

be
mea

sured

by
a

spring
balance
as
shown
in

Figure
F

A
6

Spring
balance

indication
at
hub
bolt

New

bearing

2
1

kg
4

Ib
o

ess

Used

bearing

1
0

kg
2
2
lb
or

less

Notes

a

When

measuring
the

starting
force

pull
the

spring
balance
toward
tan

gential
direction

against
normal
line

connected
between
hub
boll
and

spindle
center

b

Axial

play
is

permissible
to
exist

in

0
1
mm
0
004
in
or
less

FA
4
fA22S

Fig
FA
6
Mea

uring
bearing
rotation

atarting
torque

S

Install

a
new
cotter

pin
Bend

the

ends
of
coller

pin
around
the

castel

lated

flange
of

adjusting
cap
Then

install
hub

cap

DISASSEMBLY
AND

ASSEMBLY

Knuckle

spindle

I
Drive

spindle
bushing
and

grease

seal
out
of
knuckle

spindle
with

KiTlg

Pin
Bush
Drift

ST3S380000
Discard

bushing
and

grease
seal
when

disas

sembled

2

After

cleaning
king
pin
bores

thoroughly
install

bushing
carefully

by
using
the
above

special

tpol
Posi

tion

bushing
in

accordance
With
the

instructions
fIlled
in

Figure
F
A

7
and

FA
8

34
mm

1
34
in
Upper
side
in

lower
boss

I

I

1

II

I
Pla
ce
this

position
in
line
with

grease
nipple
hole

Upper
side
in
upper
boss

FA229

Fig
FA
7

King
pin
bu

hing

Brake

System

SERVICE
BRAKE

CONTENTS

BRAKE
PEDAL

REMOVAL

INSPECTION

INSTAllATION

MASTER

CYLINDER

REMOVAL

DISASSEMBl
Y
AND
ASSEMBLY

INSPECTION

INSTAllATION

BRAKE
LINE

REMOVAL

INSPECTION

INSTAllATION

N
L
S
V

DESCRIPTION

N
L
S
V
TEST

FRONT
BRAKE
BR
4

BR
4

BR
4

BR
4

BR
5

BR
5

BR
6

BR
6

BR
5

BR
7

BR
B

BR
B

BR
B

BR
9

BR
9

BR
9

BR
lO

BRAKE
PEDAL

REMOVAL

Remove

pedal
return

spring

I

2

3

4
REMOVAL

DISASSEMBl
Y
AND

ASSEMBLY

INSPECTION

INSTAllATION

REAR

BRAKE

REMOVAL

DISASSEMBLY
AND
ASSEMBLY

INSPECTION

INSTAllATION

MASTER
VAC

DESCRIPTION

INSPECTION
OF

OPERATION

REMOVAL

DISASSEMBLY

INSPECTION

ASSEMBl
Y
AND

ADJUSTMENT

INSTAllATION
BR
lO

BR
1O

BR
lO

BR
ll

BR
12

BR
12

BR
13

BR
13

BR
13

BR
14

BR
14

BR
14

BR
16

BR
16

BR
17

BR
17

BR
IB

b

i
t

I
Fulcrum

pin

2
Return

spring

3
Pedal

bushings

4
Clevis

pin

5
Brake

pedal
5

BR766
BR657

Fig
BR
5
Broke

pedal
mounting

2
Remove
cotter

pin
from
clevis

pin
and

separate
pedal
from
Master

Vac

push
rod

3
Remove
fulcrum

pin
and

pedal
INSPECTION
Fig
BR
6
Broke

pedal

INSTALLATION

Check
brake

pedal
for
the

following

items

servicing
as

necessary

I
Check

pedal
bushing
for

wear

deformation
or

damage

2
Check

pedal
shaft

sleeve
for
wear

or
roughness

3
Check
for

bent
brake

pedal

4

Check
for

fatigued
return

spring
Note
Loosen
fulcnun

pin
clockwise
Install
b
rake

pedal
in
the
reverse

sequence
of
removal

paying
attention

to
the

following
instructions

1
Insert
fulcrum

pin
into
hole
in

brake

pedal
and
bracket
from

right

side

2
Install
clevis

pin
from
left
hand

side

BA
4

3

Align
marks
scribed
in
the

rear

shell

and
front
shell

Carefully
turn
the

Master
Vac
Wrench
ST08080000

clockwise
until
it
reaches
notch
in

shell

retainer

Fig
BR
43

Tightenilll
reor
shell

4

After

assembly

adjust
the

length

of

push
rod
to
less
than
the

specified

value
indicated
below

Length
adjust

ment
of

push
rod
is

made
at
the

tip
of

push
rod

HAND
BRAKE
Stick
lever

typ
e

REMOVAL

HAND
BRAKE

Stick

lever

type

The
hand
brake

system
is
of
a
cable

reaction

type
which
actuates
rear
Brake

System

Length
B

10
0

to
10
5
mID

0
394

to
0
413
in

rl

J

BA290

Fig
BR
44

Lelll
th
at

B

Fig
BR
45

Adjusting
push
rod

length

HAND
BRAKE

CONTENTS

BR
18

BR
19
INSPECTION

INSTALLATION

wheel
brake

shoes
All

the
cable
ad

justment
can
be
made

by
operating

BR
18
INSTALLATION

Install
in
the

reverse

sequence
of

removal

Tightening
torque

Master

cylinder
to

Master
Vac

0
8

to
I

1

kg
m

6
to
8
ft
lb

Master

Vac
to

body

0
8

to
1
1

kg
m

6
to

8
ft
Ib

Note

After
Master
Vac
is

properly

installed
on
vehicle
be
sure
to

conduct
an
air

tight
test
and

oper

ation
test

described

previously
in

this
section

BR
19

BR
19

only

adjusting
nut
at
balance
lever

Center

This

wear
is
caused

by
overinflation

of
the
tire
The
inflation

pressure
must

be

kept
at
the

specified
value

Shoulder

The
wear

may
be
caused

by
under

inflation
incorrect
wheel
camber
or

continuous
high

speed
driving
on

curves
In

general
the
former
two

causes
are
common
Underinflation

wear
occurs
on

both
sides
of

treads

d
I

Ii

Toe
in
or

toe
out
wear

nf
I

Underinnation
wear

TIRE
ROTATION

Tires
wear

unevenly
and
become

unbalanced

according
to

running
dis

tance
Uneven
tire
wear
often
results

in
tire
noise

which
is
attributed
to
rear

axle

gears
bearing
etc
Meanwhile
the

front
tires
tend
to
wear

unevenly

because
of

improperly
aligned
front

wheel

Accordingly
to

equalize
tire
wear

it
is

necessary
to

rotate
tires

peri

odically

All
the
tires

including
the

spare
tire

are
of
the

same

type

Right
front

Right
rear

14
1

I

@
Spare

t
t
1

1

Left

front
Left
rear

Fig
WT
2
Tire
rotation
1
Wheel
and
Tire

and

on
the
other
hand
camber
causes

wear

only
on

one
side
of
treads
For

cornering
tread
wear
the

driver
must

operate
vehicle

slowing
down
on

curves

Uneven

Uneven
wear
is
caused

by
incorrect

camber
or
caster

malfunctioning
sus

pension
unbalanced
wheel
out
of

round

brake
drum
or
other
mechani

cal
conditions
To

repair
this
abnormal

wear

correct
the

above

faulty
parts

J

I

II

i

11
I

1

Overinllation
wear

1

I
I

t

Uneven
wear
WT007

Fig
WT
1
A
bnormal
tire
wear

The

spare
lire
has

a
different
brand

from
4
tires
on

the
vehicle

Right
front

Right
rear

I

@
Spare

x

J
r

Left
front
Left
rear

The

pare
tire
should
be
used

in
an

emergency
only

Fig
WT
3
Tire
rotation
2

The
tires
are

provided
with
tread

wear

indicator
at
six

places
around

tire
circumference
indicating
1

6
mm

J
in
tread

depth
When
the
tires

wear
and
then
the
marks

appear
re

place
them
with

new
ones
See

Figure

WT

4

WT3
Tire
tread

0E
I
Tread

wear
indicator

c

WH024

Fig
WT
4
Tread
wear
indicator

CHANGING
TIRE

To

change
tire
with
wheel

using
a

jack
in
the
safe
manner
observe
the

following
procedures

1
To

remove

spare
tire
insert

jack

rod

to

guide
and
then
turn
it
counter

clockwise
When

installing
lighten
a

little

strong
after

lifting
up
and
lock

Fig
WT
5
Removing
spare
tire

2
It
is

necessary
to
remove
wheel

cap
and
temporarily
to
loosen

wheel

nuts
before
vehicle
is

jacked
up

3
To

jack
up
front

place

jack
under

side

frame
about
S20

mOl
20
5
in
at

rear
of
front
axle

center
after

apply

ing
parking
brake
and

blocking
rear

wheels

g
1

WT012

Fig
WT
6

Jacking
up
front
side

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