1977 DATSUN PICK-UP Service Manual

Automatic
Transmission

REMOVAL
AND
INSTALLATION

TRANSMISSION
ASSEMBLY

REMOVAL

INSTALLATION

TRANSMISSION

ASSEMBLY

When

dismounting
the
automatic

transmission
from

a
vehicle

pay
at

tention
to
the

following
points

1

Before

dismounting
the
trans

mission

rigidly
inspecl
it

by
aid
of
the

Troubleshooting
Chart
and
dis

mount
it

only
when
considered
to
be

necessary

2
Dismount
the
transmission
with

utmost

care
and

when

mounting

observe
the

tightening

torque
indi

cated
on
another
table
not
to
exert

excessive
force

REMOVAL

In

dismounting
automatic
transmis

sion
from
vehicle

proceed
as
follows

I

Disconnect

battery
ground
cable

from
terminal

2

Disengage
torsion
shaft
from
ac

celerator

linkage

3
Jack

up
vehicle
and

support
its

weight
on

safety
stands
Recommend
a

hydraulic
hoist
or

open
pit
be
utilized

if
available

Make
sure
that

safety
is
insured

4
Remove

propeller
shaft

Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from

flowing
out

5
Disconnect
front
exhaust
tube

6

Disconnect
selector

range
lever

from
manual
shaft

7

Disconnect
wire

connections
at

inhibitor
switch
CONTENTS

AT
33

AT
33

AT

33
TRANSMISSION
CONTROL
LINKAGE

REMOVAL
AND
INSTALLATION

ADJUSTMENT
AT
35

AT
35

AT
35

8
Disconnect
vacuum
tube

from

vacuum

diaphragm
and
wire

connee

lions

at
downshift
solenoid

9
Disconnect

speedometer
cable

from

rear
extension

10
Disconnect
oil

charging
pipe

II
Disconnect
oil
cooler
inlet
and

outlet
tubes
at
transmission

case

12

Support
engine
by
locating
a

jack
under

oil

pan
with
a
wooden

block
used
between

oil

pan
and

jack

Support
transmission

by
means
of
a

transmission

jack

13
Detach
converter

housing
dust

cover
Remove

bolts

securing
torque

converter
to
drive

plate
See

Figure

AT
4

AT261

Fig
AT
47

Removing
torque
conv
rter

attaching
bolts

Note
Before

removing
torque
con

verter
scribe
match
marks
on

two

parts
so
that

they
may
be

replaced
in
their

original
posi

tions
at

assembly

14
Remove
rear

engine
mount

securing
bolts
and
crossmember

mounting
bolts

15
Remove

starter
motor

16
Remove
bolts
securing
transmis

sion
to

engine
After
removing
these

AT
33
bolts

support
engine
and
transmission

with

jack
and
lower
the

jack
gradually

until
transmission
can
be
removed
and

take
out
transmission
under
the
car

Note

Plug

up
the

opening
such
as
oil

charging
pipe
oil
cooler
tubes

etc

INSTALLATION

Installation
of
automatic
transmis

sion
on
vehicle
is

reverse
order
of

removal
However
observe
the
follow

ing
installation
notes

Drive

plate
runout

Turn
crankshaft
one
full
turn
and

measure
drive

plate
mnou
t
with

indi

cating
finger
of
a
dial

gauge
rested

against
plate
See

Figure
AT
48

Replace
drive

plate
if

in
excess

of

0
5
mm
0

020
in

Maximum

allowable
mnout

0
3

mm
0
012
in

A
T262

Fig
AT
48
MeCJ
uring
drive

plate

runout

2
Installation
of
torque
converter

Line

up
notch
in

torque
converter

with
that
in
oil

pump
Be
extremely

careful
not
to
cause
undue
stresses
in

parts
in

installing

torq
e
converter

See

Figure
AT
49

Starter

should
be

brought
into

op

eration

only
when
selector

lever
is
in

P

and
N

positions
it

should
not

be
started

when
lever
is
in
D
2

I

and
R

positions

Back

up
lamp
should
also

light

when

selector
lever
is

placed
in

R

position

S
After

converter
is
installed

rotate

10

Check
level
of
oil
in
transmis

crankshaft
several
turns
and
check

to

be
sure
that
transmission

rotates

freely
sion

For
detailed

procedure
see

page

AT48

without

binding

6
Pour

recommended
automatic
II

Move
selector
lever

through
aU

positions
to
be

sure
that
transmission

transmission

fluid

up
to
correct
level

operates
correctly

through
oil

charge
pipe

verter
to
transmission
measure

dis

With
hand

brake

applied
rotate

tan
A

to
be
certain

that

they
are
7

Connect
manual
lever
to
shift

engine
at

idling
Without

disturbing

correctly
mbi
d

S
F
rod

Opeiationsliould
oecaTrie
f
bue

the
above

sclUng
ffiovTSelector
lever

AT

50
with

manual
and
selector
levers
in

through
N

to
D
to
2

to
I

Distance
A
N

and
to
R
A

slight
shock
should
be

More
than
21

5
mm
0
846
in
8
Connect

inhibitor
switch
wires

felt

by
hand

gripping
selector

each

time
transmission
is
shifted
Automatic
Transmission

4
Bolt
converter
to
drive

plate

Note

Align
chalk
marks

painted
a

cross
both

parts
during
disas

sembling

processes

AT116

Fig
AT
49

Torque
converter

aligning
cu
t

3
When

connecting

torque
can

A

ATl17
Notes

a
Refer
to

covering
topic

under

Checking
and

adjusting

inhibitor
switch
n

on

page

AT
49

b

Inspect
and

adjust
switch
as

above
whenever
it
has
to

be

removed
for
service

Fig
AT
50

Installing

torque
converter
9
Check
inhibitor
switch
for

op

eration

AT
34
Note

See

page
AT

49
for

checking

engine
idling

12

Check

to
be

sure
that
line

pres

sure
is

correct
To
do
this

refer
to

relative

topic
under

Testing
line

pres

sure
on

page
AT

52

13

Perform

stall

test
as

per
the

instructions

on

page
AT

50

Automatic
Transmission

TRANSMISSION
CONTROL
LINKAGE

4

120N

L
B

j

p

r

4

1
Control
lever
knob

2
Pusher

3
Control
lever

assembly

4
Selector
range
lever

5
Control
lever
bracket

6
Selector
rod

REMOVAL
AND

INSTALLATION

1
Disconnect
control
knob
from

control
lever

by
removing
two
2

screws

2
Remove
console
box

3
Remove

selector
rod
selector

range
lever
and
control
lever

assembly

with
bracket

To
install
reverse
the
order
of

removal

ADJUSTMENT

The

adjustment
of

linkage
is
as
Tightening
torque
1
of

nuts
and

screw

kg
m
ft
lb
G

A

T273

@
T
0
07

to
0
13

0
5
to

0
9

@
T
1
6
to
2
2

12
to

16

T

3
to
4
22

to
29

@
T

0
35

to
0
45
2
5
to
3

3

C8i
T

0
8
to

1
1
6
to
8

important
as

Inspection
of
oil
level

for
the
automatic
transmission

Therefore

great
care
should
be

exercised
because

faulty
adjustment

will
result
in
the
breakdown
of
the

transmission

1

Prior
to

installing
control
knob

set
the
dimension
A
to
II
to
12
mm

0
43

to
0
47
in

2
Install
control
knob
on
lever
At

the
same
time
check
the
dimension

B
and

adjust
it
to
0
1
to
1
1

mm

0
004
to
0
043
in

by
turning
pusher

@
See

Figure
AT
51

AT

35
Fig
AT
51

Controlli
f
kage
sy
tem

3
Loosen

adjust
nuts

@
Set

control
lever

@
and
selector
lever

@

at
N

position
moreover

J
set
the

clearance
C

to
I
mm
0
039
in

by

turning
in
or
out

adjusting
nuts
at

trunnion
with
connects
selector
rod

@

After

adjusting
make
sure
that

control
lever
can
be
set
in

any
position

correctly
and
that
selector
lever

oper

ates

properly
without

any
binding

If

levers
do
not

operate
satisfactori

ly

readjust
or

replace
parts
as
neces

sary

Automatic

Transmission

MAJOR

REPAIR

OPERATION

SERVICE
NOTICE
FOR

DISASSEMBLY

AND

ASSEMBLY

TORQUE
CONVERTER

INSPECTION

TRANSMISSION

DISASSEMBL
Y

INSPECTION

ASSEMBL
Y

SERVICE
NOTICE

FOR
DISASSEMBLY

AND
ASSEMBLY

I
It

is
advisable

that

repair
opera

tions
be

carried
out
in
a

dust

proof

room

2
Due

to
the
differences
of
the

engine
capacities
the

specifications
of

component

parts
for

each
model
s

transmission

may
be
different

They

do
however
have

common

adjust

ment

and

repair

procedures
as
well
as

cleaning
and

inspection

procedures

outlined
hereinafter

3

During
repair
operations
refer
to

Service
Data

and

Specifications
see

tion
for

the
correct

parts
for
each

model

4

Before

removing
any
of

subas

semblies

thoroughly
clean
the
outside

of
the

transmission
to

prevent
dirt

from

entering
the
mechanical

parts

5

Do
not
use
a
waste

rag
Use
a

nylon
or

paper
cloth

6
After

disassembling
wash
all
dis

assembled

parts
and
examine
them
to

see
if
there
are

any
worn

damaged
or

defective

parts
and
how

they
are

affected
Refer
to

Service
Data
for

the

extent
of

damage
that

justifies

replacement

7

As
a
rule

packings
seals
and

similar

parts
once
disassembled
should

be

replaced
with
new
ones

TORQUE

CONVERTER

The

torque
converter
is

a
welded

construction
and

can
not
be
disas

sembled
CONTENTS

AT

36

AT

36

AT

36

AT

36

AT

36

AT
38

AT

38
COMPONENT
PARTS

FRONT

CLUTCH

REAR

CLUTCH

LOW
REVERSE
BRAKE

SERVO

PISTON

GOVERNOR

OIL

PUMP

PLANETARY

CARRIER

CONTROL

VALVE
AT

40

AT
40

AT
41

AT
42

AT
42

AT
43

AT
43

AT
44

AT

44

INSPECTION
2

Remove
bolts

securing
converter

1

Check

torque
convertf

for

any
housing
to
transmission

case
Remove

sign
of

damage

bending
oil
leak

or
torque
converter

deformation

If

necessary
replace
3
Remove

speedometer
pinion

2

Remove
rust
from

pilots
and
sleeve

bolt
Withdraw

pinion

bosses

completely
4

Remove
downshift
solenoid
and

If

torque
converter
oil
is

fouled

or
vacuum

diaphragm
Do

not
leave
dia

contaminated
due
to
burnt
clutch

phragm
rod
at
this

stage
of
disas

flush
the

torque
converter
as
follows
sembly
Rod
is

assembled
in

top
of

vacuum

diaphragm
See

Figure

I
Drain
oil
in

torque
converter

AT

53

2
Pour

non
lead

gasoline
or

kero

sene
into

torque
converter

approxi

mately
0
5
liter

I
U
S

pt
U

Imp

pt

3

Blow
air

into

torque
converter

and

flush
and
drain

out

gasoline

4
Fill

torque
converter
with

torque
converter
oil

approximately

0
5
liter
I

V
S

pt
U

Imp
pt

5

Again
blow
air
into

torque
con

verter
and
drain

torque
converter
oil

TRANSMISSION

DISASSEMBLY

I

Drain
oil
from
the

end
of
rear

extension

Mount
transmission
on

Transmission
Case

Stand
ST07870000

or
ST07860000
Remove

oil

pan
See

Figure
AT
52

AT118

Fig
AT

52

Removing
oil

pan

AT

36
Fig
AT
53
Down

hilt
olenoid
and

vacuum

dilJphragm

5

Remove

bolts
which

hold
valve

body
to
transmission

case
See

Figure

AT
54

Fig
AT
54

Removing
valve

body

6
Loosen
lock
nut

@
on

piston

stem

D
as
shown
in

Figure
AT

55

Then

tighten

piston
stem
in

order
to

prevent
front
clutch

drum
from

falling

when
oil

pump
is
withdrawn

AT121

Fig
A
T
55
Loosenin
band
seruo

7
Pull
out

input
shaft

8
Withdraw
oil

pump
using
Sliding

Hammer
ST25850000
Do
not
allow

front
clutch
to
come
out
of

position

and

drop
onto
floor
See
Figure

AT
56

AT122

Fig
AT
56

Removing
oil

pump

9

Remove
band
strut
This
can
be

done

by
loosening
piston
stem
further

See

Figure
AT
57

Fig
AT

57
R

moving
band
strut

10
Remove
brake
band
front

clutch
and
rear
clutch
as
an
assembled

unit

11
Remove

connecting
shell

rear

clutch
hub
and
front

planetary
carrier

as
a
unit
See

Figure
AT
58
Automatic
Transmission

Ii

AT124

Fig
AT
58
R
mouin
connectin
shell

12
With

the
aid
of

Snap
Ring
Re

mover
HT69860000

pry
snap
ring
off

output
shaft

See

Figure
AT
59

Fig
AT
59
Remouing
sruzp
ring

13
Remove
connecting
drum
and

inner

gear
of

rear

planetary
carrier
as

an

assembly
See
Figure
AT
60

AT126

Fig
AT
60
Remouing
connecting

drum

14
Remove

snap
rings
and
then

remove
rear

planetary
carrier
internal

gear
connecting
drum
one

way
clutch

outer
race
and
one

way
clutch
in
that

oroer

15
Remove
rear
extension
by

loosening
securing
bolts
See

Figure

AT
61

AT
37
AT127

Fig
AT
61
Remouin
rear
extension

16
Pull
out

output
shaft
remove
oil

distributor

CV

together
with

governor

valve

CD
See

Figure
AT
62

Fig
AT

62

Remouinggouernorand

oil
distributor

17
Pry
off

snap
ring
using
a
pair
of

pliers
Remove

retaining
plate
drive

plate
driven

plate
and
dish

plate
in

that
order
See

Figure
AT
63

Fig
AT
63
Remouing
driue
and

driuen

plates

18
Reaching

through
back
side
of

transmission
case
remove
hex
head

slotted
bolts
as
shown
in

Figure

AT
64
To
do
this
use
Hex
head

Extension
ST25570001

ST25570000
One
way
clutch
inner

race
thrust
washer

piston
return

spring
and
thrUst

spring
ring
can
now

be
removed

I
i
0

t
V

iL

1

0

ST25570001

j

w
1
h

AT130

Fig
AT
64

Removing
hex
head
slotted

bolt

19
Blowout
low
and
reverse
brake

piston
by
directing
a

jet
of
air
into

holeJn
cylinder
See
F

igure
AT
65

Fig
AT
65

Removing
piston

20
Remove
band
servo

loosening

attaching
bolts

Note
If

difficulty
is
encountered
in

removing
retainer
direct
a

jet
of
air

toward
release
side

as
shown
in

Figure
AT
66

II

AP

fW
l

1

A
T132

Fig
AT
fiB

Removing
bond
servo

21

Pry
snap

rings
CD
from
both

ends
of

parking
brake
lever

@
and

remove
the
lever

Back
off
manual

shaft

lock
nut

ID
and
remove

manual

plale
@
and

parking
rod

CID
See

Figure
AT
67
Automatic
Transmission

Up

@
J1i

ll
J

t
i
p

lli
l
1

I
l
P
l

1
Ii

@

j
Y

L

l

rr
i

J

ry

j

AT133

Fig
AT
67

Removing
manual

plate

22
Remove
inhibitor
switch
and

manual
shaft

by

loosening
two
secur

ing
bolts

INSPECTION

Torque
c
onverter
housing

transmission
c
ase
and

rear
extension

I

Check
for

damage
or
cracking
if

necessary
replace

2

Check
for
dents
or
score
marks

on

mating
surfaces

Repair
as
nee

essary

3
If
rear
extension
bushing
is
worn

or
cracked
replace
it

as
an
assembly
of

bushing
and
rear
extension
housing

Gaskets
and
O

ring

1

Always
use
new

gaskets
when
the

units
are
to
be
disassembled

2
Check
O

rings
for
burrs
or
crack

ing
If

necessary
replace
with

new

rings

011
distributor

I
Check
for

signs
of
wear
on
seal

ring
and

ring
groove
replacing
with

new
ones
if
found
worn

beyond
use

Check
that
clearance
between
seal

ring
and

ring
groove
is
correct
If
out

of

specification
replace
whichever
is

worn

beyond
limits
Correct
clearance

is
from
0
04
to
0
16
mm
0
0016
to

0
0063
in
See

Figure
AT
68

AT
J8
j
Clearance

1

61
Seal

dng

0

j

J

I

I

AT134

ig
A
r
68
Me

q
sur

ingseal
r

ing
to

ring
groove
clearance

ASSEMBLY

Assembly
is
in

reverse
order
of

disassembly
However
observe
the
fol

lowing
assembly
notes

After

installing
piston
of
low
and

reverse
orake
assemble
thrust

spring

ring
return

spring
thrust
washer
and

one

way
clutch
inner
race

Torque

hex
head
slotted
bolt
to
L3to
1
8

kg
m

9
to
13
ft
ib

using
Hex
head
Ex

tension
ST2SS7000
ST2SS70000

Torque
Wrench
GG93010000
and

Socket
Extension
ST2S490000

ST2SS
12001
See
Figure
AT
69

ST2557000t

ST25490000

I

GG930JOOOO

A
T135

Fig
AT
69

Installing
ont

woy
clutch

inner
race

2
After
low
and
reverse
brake
has

been
assembled
measure
the
clearance

between

snap
ring
CD
and

retaining

plate
@
Select

proper
thickness
of

retaining
plate
to

give
correct

ring
to

plate
clearance
See

Figure
AT
70

Low

and
reverse
brake

clearance

0
80
to
1

05
rom

0
0315
to
0
0413
in

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

Adjustment
of
front
end

play

Sele
t
front
dutch
thrust
washer

by

calculating
the

following
formula

T

F
C
D

0
2
mm

where

T

F
Required
thickness
of
front

clutch
thrust
washer
mm
in

C
Measured
distance
C
mm
in

D
Measured
distance
D
mm
in

Available
front
clutch
thrust

washer

Thickness
mm
in

1
5
0
059

I
7
0
067

1
9
0
075

2
1
0
083

2
3
0
091

2
5
0
098

27
0
106

Specified
front
end

play

0
5
to
0

8
mm

0
020
to
0

031
in

Notes

a
Correct
thickness
of

bearing
race

and
thrust
washer
is
always
the
one

which
is
nearest
the
calculated
one

b
Installed
thickness
of
oil

pump
gas

ket
is
0
4

mm
0
016
in

10
Check
to
be
sure
that
brake

servo

piston
moves
freely
For
detailed

ptocedure
refer
to

page
AT
42
for

Servo
Piston
Use
care
to

prevent

piston
from

coming
out
of

place
dUI

ing
testing
since
servo
retainer
is
not

tightened
at
this

point
of

assembly

II
Make
sure
that
brake
band
strut

is

correctly
installcd

Torque
piston

stem
to
1
2
to
1
5

kg
m
9
to
11

f1
lb
Back
off
two
full
lurns
and

secure
with
lock
nut
Lock
nut

tight

ening
torque
is
1
5
to
4

0

kg
m

II
to

9

f1
lb
Automatic
Transmission

12
After
inhibitor
switch
is
in

stalled
check
to
be
sure
that
it

op

erates

properly
in

each
range
For

detailed

procedure
refer
to

page
AT

49
for
Checl
ing
and

Adjusting
Inhibi

tor
Switch

13
Check
the

length
L
between

case
end
to
rod
end
ofvacuum
throllle

valve
fully

pushed
in
Then
select

adequate
diaphragm
rod
of
corre

sponding
measured
length
See
Figure

AT
77

Available

diaphragm
rod

Distanl
e

measured
L
ITIm
in

Under25
55

l
OO59

25
65

to
26
05
1

0098
to
1
0256

26
15
to
26
55
1

0295
to
1

0453

26

65
to
27
05
1
0492
to
1

0650

Over
27
15
1
0689

COMPONENT
PARTS

The
transmission
cons
sts
of

many

small

parts
that
are

quite
alike
in

construction
yet
machined
to

very

close
tolerances
When
disassembling

parts
be
sure
to

place
them
in

order
in

part
rack
so

they
can

be
restored
in

the

unit
in
their

proper
positions
It
is

also

very
important
to

perform
func

tianal
test
whenever
it
is

designated

FRONT
CLUTCH

Disassembly

Front

clutch
drum

I

Pinon

lcz

t

AT146

1

Snap
ring

2

Retaining
plate

3
Drive

plate

4

Driven

plate

Fit
AT
78
S
Dished

plate

6

Snap

ring

7

Spring
retainer

8
Coil

spring

Sectional
view

of

front
clu
tch

AT
40
i

i
n
H

I
I

ni
c
A
i

iif

L

1

AT145

Fig
AT
77

Measuring
the
distance

L

Diaphragm
rod

length
mm
in

29
00
142
u

29

5
1161

30
0
1
81

30
5
1201

31
0
I
O

I

Pry
off

snap
ring
D
with

a

suitable
screwdriver
or

a

pair
of

pliers

Remove
a

retaining
plate
@
drive

plate
CID
driven

plate
@
and
dished

plate
@
in

the
order
listed
as
shown

in

Figure
AT
78

I

2

Compress
clutch

springs
using

Clutch

Spring
Compressor

ST25420001
or

51
25420000
Re

move

snap
ring
@
from

spring
re

tainer

using
Snap
Ring
Remover

ST2532000
I

See

Figure
AT
79

AT147

Fig
AT
79

Removing
snap
ring

Note
When
Clutch

Spring
Compres

sor
ST25420000
is
to
be
used
cut

the

toe

tips
of
three

legs
by
a

grinding
wheel
See

Figure
AT
80