1977 DATSUN PICK-UP differential

PROPELLER
SHAFT
DIFFERENTIAL
CARRIER

Drive

pinion
bearing
adjusting
washer

Thickness
mm

in

over
3
80

to
3
82
0

1496
to
O
lS04

over
3
82

to
3
84
O
lS04

to
0
ISI2

over
3
84
to
3
86
O
lSI2

to
0
IS20

over
3
86
to
3
88

O
lS20
to
O
IS28

over

3
88
to
3
90
O
lS28
to
0
IS3S

over
3
90
to

3
92
0
IS3S
to
O
IS43

over
3

92
to

3
94
0
IS43
to
O
lSS
I

over
3

94
to
3
96
O
lSSI
to
O
lS59

over
3

96
to
3
98
O
lSS9

to
0
IS67

over
3
98

to
4

00
O
lS67
to
O
lS7S

over

4
00
to
4
02
0
S7S
to

O
lS83

over

4
02
to
4
04
O
lS83
to
0
IS91

over

4
04
to
4
06
O
lS9I
to
0
IS98

over

4
06
to
4
08
O
lS98
to
0
1606

over
4

08
to
4
10
0
1606
to

0
1614

3
Check
and

adjust
tooth
contact

pattern
when

former

adjustment
of

bearing

preload
is

completed
Unless

anything
wrong
is

found
remove
drive

pinion
nut
and

companion
flange
and

press
n
oil
seal
into

gear
carrier

using
Oil
Seal

Fitting
Tool

KV38I02SS0

Apply
grease
cavity
be

tween
seal

lips

4

Again
install

companion
flange

and
washer
and

tighteh
nut
to

speci

fied

torque
14
0

to
17
0

kg

m
IO
to

123
ft
lb

S
Measure

preload
again

Preload
with
oil
seal

I
1

0
to
14

0

kg
cm

9
S

to
12
in
lb

At

companion
flange
bolt
hole

3
1
to
4
0

kg

6
8
to
8
81b

ADJUSTMENT
OF
SIDE

BEARING
SHIMS

I
If

hypoid
gear
set
carrier
dif

ferential
case
or
side

bearing
has
been

replaced
with
new
one

adjust
the
side

bearing
preload
with

adjusting
shim

The

required
thickness
of

adjusting

shim
can
be
calculated

by
the
follow

ing
formulas
T
A

C
D
H

xO
OI

O
l7S
E

T2
B
D
H
xO
OI

O
ISO
F

Where

T

1
Required
thickness
of
left
side

bearing
adjusting
shim
mm

T

2
Required
thickness
of

right
side

bearing

adjusting
shim
mm

A

Figure
marked

on
the

left
side

bearing
housing
of

gear
carrier

B

Figure
marked
on
the

right
side

bearing
of

gear
carrier

C
0

Figure
marked
on
the
differ

entia
case

E
F
These

are
differences
in
width

of
left
or

right
side

bearing
against

the
standard
width
20
00
mOl

mOl

If

bearing
width
is
19
89
the

differ

ence
will
be
as
follows

20
00
19
89
0
11

H

Figure
marked
on
the

ring

gear

See

Figures
PD

20
and
PD
2
I

Figures
for
A

B
C
0
and
H

are

dimensional
varia
tions
in
a
unit

of

1

100
mm

against
each
standard

meas

urement

f
@
a

rj

71

Markj
Mark
B

Mark
C
0

P0214

Fig
PD
20
Thickn
of
shim
on
l

ft

and

righ
t
sides

Fig
PD
21
Variation
number
on

ring
gear

PD
ll
Examples
of
calculation

Ex
I

A
I

B
2
C
2
0

3

E
0
11
mm
F

O
IS
mm

H
2

Left
side

T
A

C
0
H
x

0
01

O
liS

E

1
2
3

1
x

0
01

0
17S
0
11

1
2
3

2
x

O
O

O
l7S
0
11

4

x
0
01
0
175
0
11

0
04
0
1
7S

0
11

0
32S
mOl

The
correct
shims
are
as
follows

Thickness

0
07

0
20
Quantity

x
2
0

14

x
I
0

20

Total
thickness
0
34
mOl

Right
side

T2
B

0
H
x

0
01

O
lSO
F

2
3
2
x

0
01

O
ISO
0
15

2

3
2
x
0

01

O
ISO
0
15

3
x
O
OI
O
ISO
O
IS

0

03
O
lSO
O
lS

0
27
mm

The
correct
shims
are
0
07

plus

0
20
mm
thick

PROPELLER

SHAFf
DIFFERENTIAL

CARR
IER

Ex

2

A

0
B
3

C
I

0

0

E
0

20
mOl
F

0
17
mOl

H
2

Left
side

T

I
A
C

D
H
x
om

0

17S
E

0
I

0
2
x
0
01

0
I7S

0
20

0
I
0
2

x
0

01

0
17S
0
20

3

Om
0
17S

0
20

0
03
0
17S
0
20

O

34S
mrn

The
correct

shinjs

are
O

OS

plus

0
10

plus
0
20
mrn
thick

Right
side

T2
B
D
H

xO
0l

O
ISO
F

3
0
2
x

om

O
ISO

0
17

3

0

2
x

om

0
150
0
17

S
x
0
01

0
ISO
0
I7

O
OS

0
1S0
0
17

0
37

mrn

The

correct
shims
are
0
07

plus

0
1
0

plus
0

20
mm
thick

Note
If

w1ues

signifying
A

B
C
0

and

H
are
not

given
regard
them

as

zero
and

compute

Aft
assembly
check
to

see
that

preload
and
backlash

are
correct
If

not

readjust

Side

bearing

adjusting
shim

Thickness
mm
in

O
OS
0
0020

0
07
0
0028

0
1

0
0
0039

0
20
0
0079

0
50
0
0197
2

Fit
determined

side

bearing

adjusting
shim
on
differential
case
and

press
fit
left

and

right
side

bearing

inner

races
on
it

using
Side

Bearing

Drift
ST33230000
and

Adapter

ST33061000

3

Install
differential

case

assembly

into

gear
carrie

tapping
with
a
rubber

mallet

4

Align
mark

on

bearing
cap
with

that
on

gear
carrier

and
install

bearing

cap
on
carrier
And

tight
n
bolts
to

specified
torque

Tightening

torque

4
0
to
S
O

kg
m

29
to
36
fHb

S

Measure

ring

gear
to
drive

pinion

backlash

If
backlash
is
too

small
remove

shims
from
left
side
and

add
them
to

right
side
To
reduce

backlash
remove

shims
from

right
side
and

add
them
to

left

side

Backlash

O
1S
to
0
20

mrn

0
00S9
to
0
0079
in

Fig
PD

22

Mccuuring
back1aah

6
At

the
same
time

check

side

bearing
preload

Bearing
preload

should

read
12

0
to
20
0

kg
cm
10
to

17

in
lb
of

rotating
torque
3
S

to

S
8

kg
7
7

to
12
8

Ib
at

ring

gear
bolt

hole

PD
12
If

preload
does

not
accord
with

this

specification
adjust
it

with
side
bear

ing
shims

7

Check
and

adjust
the
tooth

con

tact

pattern
of

ring
gear
and

drive

pinion

I

Thoroughly
clean

ring
and
drive

pinion

gear
teeth

2
Paint

ring
gear
teeth

lightly
and

evenly
with
a

mixture
of
ferric

oxide

and

gear
oil

to

produce
a
contact

pattern

3
Rotate

pinion
through
several

revolutions
in

the
forward

and
reverse

directions
until

a
defmite
contact

pat

tern
is

developed
on

ring

gear

4
When

contact

pattern
is

incor

rect

readjust
thickness
of

adjusting

washer

S

Incorrect
contact

pattern
of

teeth
can
be

adjusted
in
the

following

manner

a
Heel
contact

To
correct
increase
thickness
of

pinion
height

adjusting
washer

in
order

to

bring
drive

pinio
close
to

ring

gear

P0193

Fig
PD
23
Hul

contact

b
Toe
contact

To

correct
reduce
thickness
of

pinion
height

adjusting
washer
in
order

to
make

drive

pinion

go
away
from

ring

gear

P0194
1

Fig
PD
24
To
contact

P
ROPELLER
SHAFT
DIFFERENTIAL
CARRIER

c
Flank
oontact

Adjust
in

the
same
manner
as
in

b

cV

t

PD195

Fig
PD
25
Flank
contact

d
Face
contact

Adjust
in
the

same
manner
as
in

a

P0196
t

Fig
PD
26
Face

contact

e
Correct
tooth
contact

Fig
PD
27
Correct

contact

Note

Change
in
thickness
of

adjWll

ing
washer
is

accompanied
by

change
in
backlash
Oled
it
when

instaIIi
gear
INSTALLATION

Installing
can
be

done
in
the
reverse

order
of
removal

Tightening
torque

Gear
carrier
to
rear
axle
case

1
7

to
2
5

kg
m

12
to
18
ft
lb

Drain
and
filler

plug

6
0
to
10
0

kg
m

43
to
72
ft
lb

Gear
oil

capacity
1
0
liter

2
US

pt
I
Y

Imp
pt

REPLACEMENT
OF

FRONT
OIL
SEAL

Replacement
of
front
oil

seal
with

d
ifferential
carrier

assembly
installed

on
the
vehicle

When

replacing
front
oil
seal

do
as

follows

1
Drain

gear
oil

2
Raise

the
rear
end
of

vehicle

and

support
it
with

safety
stands

3
Detach

propeller
shaft
from
com

panion

flange
of
carrier

4

R
1
ove
drive

pinion
n
t

holding

companion
flange
with
Drive
Pinion

Flange
Wrench

ST31S30000
P0238

Fig
PD

29
Removing
companion

flange

6
Remove
oil
seal

7
Set

new
oil
seal
in

position
using

Oil
Seal

Fitting
Tool

KV38102SS0

Apply
grease
in
between
seal

lips

8
Fit

companion
flange
and
flat

w

sher
on
drive

pinion
and
secure

them
in

position
by
tightening
nut
to

the

given

torque
confirming
specified

preload
using
Drive
Pinion

Flange

WrencliST31530000

Tightening
torque

14
0

to
17
0

kg

101
to
123
ft
Ib

Pinion

bearing
preload

with
oil
seal

11
0
to
14
0

kg
cm

9
5
to
12
in
lb

At

companion
flange
bolt
hole

3
1
to
4

o
g

6
8
8
8Ib

Notes

a
Preioad
of
old

bearing
is
the
same

value
as
that
of

a
new
bearing

b
If
the
desired
nut

tightening
torque

P0237
can
ot
be
obtained
renew
nut
and

readjust

Fig
PD
28
R

moving
drive

pinion

nut

S
Extract

companion
flange

using
a

standard

puller

PD
13
8
Reinstall

propeller
shaft
and
fill

up
differential
carrier

with

gear
oil

PROPELLER

SHAFT

DIFFERENTIAl

CARRIER

TROUBLE
DIAGNOSES

AND

CORRECTIONS

When
a
differential
carrier
is

sus

pected
of

being

noisy
it
is

advisable
to

make
a

thorough
lest

to
determine

whether
the

noise

originates
in
the

Condition

Noise

on
drive

coast

and
float

Noise
on
turn

Knocking
sound

during

starting
or

gear

shifting
tires

road
surface

exhaust
universal

joint
propeller
shaft
wheel

bearings

engine
transmission

or
differential

carrier

Noise
which

originates
in

other

Probable
cause

Shortage
of
oil

Incorrect
tooth
contact

between

ring
gear

and
drive

pinion

Incorrect
backlash
between

ring
gear
and

drive

pinion

Seized

up
or

damaged
ring

gear
and
drive

pinion

Seized

up
damaged
or

broken
drive

pinion

bearing

Seized

up
damaged
or
broken
side

bearing

Loose
bolts
or
nuts

fIXing
ring
gear
bearing

cap
etc

Seized

up
damaged
or
broken
side
and

pinion
mate

Seized

up
damaged
or
broken

side

gear
and

pinion
thrust
washer

Pinion

mates
too

tight
on

their
shaft

Excessive
backlash

Incorrect

backlash

ring
ar

to
drive

pinion
or
side

gear
to

pinionmate

Worn

gears
or
case

Worn
rear

axle
shaft
and

side

gear
spline

Drjve
pinion

bearing
under

p
reload

Loose
drive

pinion
nut

Loose
bolts

or
nuts

ftxing
ring
gear

bearing

cap
etc

PD

14
places
cannot
be
corrected

by

adjust

ment
or

replacement
of

parts
in
dif

ferential
carrier

Corrective
action

Supply
gear
oil
Rebuild

gear
carrier
if

necessary

Adjust
tooth
contact

or

replace
the

hypoid

gear
set

Adjust
backlash
or

replace
the

hypoid
gear

set

if

necessary

Replace
the

hypoid

gear
set

Replace
the

pinion

bearing
and

faulty

parts

Replace
the

side

bearing
and

faulty
parts

Clamp
them

to

specified

torque
and

replace

faulty
parts

Replace

faulty
parts

Replace

faulty
parts

Replace
faulty
parts

Adjust
backlash

Replace
worn

parts

Replace
worn

parts

Adjust
preload

Repair
or

replace

Clamp
them
or

replace
if

necessary

PROPELLER
SHAFT

DIFFERENTIAL
CARRIER

SERVICE
DATA
AND

SPECIFICATIONS

Type

Ge
ar
carrier

material

Gear
ratio
number
of
teeth

Drive

pinion
preload

adjusted
by
HI90

Malleable
cast
iron

4
375

3S
8

Spacer
and
washer

Drive

pinion

Preload

kg
cm
in
Ib

without
oil
seal

with
oil
seal

At

companion
flange
olt
hole

kg
Ib

without
oil
seal

with
oil
seal

Thickness
of
drive

pinion
adjusting

washer
nun
in
10
0
to
13
0
8
7
to
II

11
0
to
14

0
9
5
to
12

2
9

to
3
7
6
4

to
8
2

3
1
to
4
0
6
8
to
8
8

2
S8
0
1016

2
61
0
1028

2
64
0
1039

2
67
0
IOSI

2
70
0
1063

2
73
O
I07S

2
76
0
1087

2
79
0
1098

2
82
0
1110

2
8S
0
1122

2
88
0
1134

2
91
0
1146

2
94
0
1158

2
97
0
1169

3
00
0
1181

3
03
0
1193

3
06
0
120S

3
09
0
1217

3
12
0

1228

3
IS
0
1240

3
18
0
12S2

Length
of
drive

pinion
bearing

adjusting
spacer
nun
in
S4
50
2
14S7

54
80
2
IS7S

SS
IO
2
1693

SS
40
2
1811

SS
70
2
1929

S6

00
2
2047

PD

16

PROPELlER
SHAFT
DIFfERENTIALCARRI
ER

Thickness
of
drive

pinion
bearing

adjusting
washer
mm
in

over
3
80
to
3
82

0
1496
to
O

IS04

over
3
82
to

3
8

HO
IS04
to

OcISI2

over
3
84
to

3
86
0

ISI2
to
0
IS20

over
3

86
to
3
88

0
1520
to

0
IS28

over
3
88
to
3

90
0

IS28
to
0
IS3S

over
3

90
to
3
92
0
IS3S
to
0
1S43

over
3
92
to
3
94
0
1543

to
O
ISSI

over
3
94
to
3
96

0
I5si

to
0

ISS9

over
3
96
to
3

98
0
I5S9
to
0
IS67

over
3

98
to
4

00
0
1567
to
0

IS7S

over
4

00
to
4

02
0
157S
to
0
IS83

over
4

02
to
4
04
0

IS83
to
0

IS91

over
4

04
to
4
06
0
IS91

to
0

IS98

over
4

06
to
4

08
0
1598
to
0

1606

over
4

08

to
4

10
0
1606
to
0
1614

Side

gear
and

pinion
mate

Thickness
of
side

gear
thrust
washer
mOl
in

over
0
7S
to
0
80
0
029S
to
0

03IS

over
0
80
to
0
8S
0
03IS
to

0
033S

over
0
8S

to
0
90
0
0335

to
0
03S4

over
0

90
to
0

9S
0
03S4
to
0
0374

Pinion
mate
to
side

gear
backlash
or

clearance
between

side

gear
and
thrust

washer
mOl
in
0
02
to
0
08
0
0008
to
0

0031

Ring

gear

Ring
gear
to
drive

pinion
backlash
mm
in

Thickness
of
side

bearing
adjusting

shim
mOl

in
O
1S
to
0
20
0
00S9
to
0
0079

Side

bearing
standard
width
mm

in
O
OS

0
0020

0
07
0

0028

0
10
0
0039

0
20
0
0079

0
50
0
0197

20
00
0
7874

TIghtening
torque

Drive

pinion
nut

Ring
gear
bolt

Side

bearing

cap
bolt

Differential
carrier
to
axle
case

Companion
flange
of
front
shaft
and

flange
yoke
connecting
nut

Center

bearing
bracket
ut

Companion

flange
to

propeller
shaft

Oil
drain
and
filler

plug
kg
m
ft

Ib

14
0
to
17
0
101
to
123

7
0
to
8
0
SI
toS8

4
0

to
S

O
29

to
36

17

to
2
S

12
to
18

2
4
to
3

3

17
to
24

1

6
to
2
2
12

to
16

2
4
to
3
3
17
to
24

6
0
to
10
0
43

to
72

PD
l1

PROPELLER
SHAFT

DIFFERENTIAL
CARRIER

Oil

capacity
about
liter

US

pt
Imp
pt
1

0
2Ji
I

Y

Adjusting
methods

Variable
numbers

expressed
by

Dummy
shaft

Drive

pinion

adjusting
fonnula

Side

bearing
adjusting
fonnula
1
100
mOl

Use

T
N

H
0
S
x
0

01
2
18

TI
A
C
D

H
xO
OI

0
17S
E

T2
B
0
H

x
0
01
0
150
F

PD

18

PROPELLER
SHAFT
8i
DIFFERENTIALCARRIER

SPECIAL
SERVICE
TOOlS

No
Tool
number

tool
name

I
ST063
10000

Diff

attachment

2
ST3I
94S000

Drive

pinion

setting
gauge

assembly

H190

ST31942000

Dummy

shaft

ST31941000

Height

gauge

3
ST31970000

Collar

4
KV311
00300

Solid

punch
Description

Unit
mOl

in

This
tool
is
used
for
attaching
gear
carrier
to

ease
disassembly
or

assembly

SE023

These
tools
are

used
to

adjust
the

pinion
height

@

SE209

SE210

This

tool
is
used
for

Type
H
190

to

adjust
the

pinion
height

This
tool
is

used
with
ST3I
94S000

35
1
38
di

30
1
18

dia

1

27
1
06

l

For

driving
out
oflock

pin
of

pinion
shaft

4
5

0
177
di

Y
95
3
74

65
2

56

PD
19
For

use

on

620

610

620

610

620

610

620

610

710

S30
Reference

page
or

Figure
No

Fig
PD
7

Fig
PD
16

Fig
PD

17

Fig
PD
16

Fig

PI
13