1979 DATSUN 210 height

Condition

Clutch

slips

Clutch

drags
Clutch

TROUBLE

DIAGNOSES
AND

CORRECTIONS

Probable

cause
and

testing
Corrective
action

Slipping
of
clutch

may
be
noticeable

when

any
of
the

following
symptoms
is

encountered

during
operation

I
Car
will
not

respond
to

erigine
speed
during
acceleration

2
Insufficient

car

speed

3
Lack
of

power

during
uphill

driving

Some
of
the

above
conditions

may
also
be
attributable
to

engine
problem
First
determine

whether

engine
or
clutch
is

causing
the

problem

If

slipping
clutch
is

left
unheeded
wear

and
or

overheating
will
occur
on
clutch

facing
to
such

an
extent
that
it
is

no

longer
serviceable

TO

TEST
FOR
SLIPPING
CLurCH

proceed
as
follows

During
upgrade
havelling
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
t
the
same
time

rev

up
engine
If
clutch

is

slipping
car
willnot

readily
respond
to

depression
of
accelerator

pedal

Clutch

facing
warn

excessively

Oil
or

grease
on
clutch

facing

Warped
clutch

cover
or

pressure
plate
Replace

Replace

Repair
or

replace

Dragging
clu

tch
is

particularly
noticeable

when

shifting

gears
especially
into

low

gear

TO
TEST
FOR

DRAGGING
CLurCH

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

gears
from
Neutral
into

Reverse

2

Stop
engine
and
shift

gears
Conduct
this
test
at
each

gear
position

3
In

step
2

gears
are
shifted

smoothly

except
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
ide

depress
pedal
to
check
for
free

travel
of

pedal

a
If

pedal
can
be

depressed
further
check
clutch
for

condition

b
If

pedal
cannot
be

depressed
further

proceed
to

step
5

below

5
Check

clutch
control

pedal
height
pedal
free

play
free

travel
withdrawal
lever

play
etc

If

any
abnormal

condition
does
not
exist
and
if

pedal
cannot
be

depressed
further
check

clutch
for

condition

Clutch
disc

runout
or

warped

Wear
or
rust

on
hub

splines
in

clutch

disc

Diaphragm
spring
toe

height
out
of

adjustment
or
toe

tip
worn

Worn

or

improperly
installed

parts
Replace

Clean
and
lubricate

with

grease
or

replace

Adjust
or
replace

Repair
or

replace

CL12

Condition

Clutch
chatters

Noisy
clutch

Clutch

grabs
Clutch

Probable
cause
and

testing
Corr
ctive
action

Clutch

chattering
is

usually
noticeable
when
car
is

just
rolled
off
with
clutch

parlially

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

in

stalled

correctly
Replace

Replace

Replace

Replace

Repair
or

replace

Adjust
or

replace

Retighten
or

replace

I
Replace

Apply
grease

Adjust

A
noise
is
heard
when
car

is

suddenly
rolled
off
with

clutch

partially
engaged

Damaged
pilot
bushing

I
Replace

When

grabbing
of
clutch
occurs
car
will
not
roll
off

smoothly
from
a

standing
start
or
clutch

will

be

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
clutch
disc

Warped
flywheel
or

pressure
plate

Loose

mountings
for

engine
or

power

train

units

CL13
Replace

Replace

Clean
or

replace

Repair
or

replace

Retighten

TM798

Fig
MT

45
In

talling
Snap
Ring

Main
drive

Bear

I
Press
main

drive

gear
bearing
onto

shaft
of
main
drive

gear
using
Trans

mission

Drift
ST23800000

Make
sure

that

snap
ring
groove
00

shaft

clears

bearing

L
i

ST23800000

TM714

Fig
MT
46

Imtalling
Main
Drive

Bearing

2
Place
main
drive

bearing

spacer

on

main
drive

bearing
and
secure
main

drive

bearing
with

a
new
thicker

soap

ring
that
will
eliminate
end

play

Note
Mlike
sure

soap
ring
fits
in

groove

1
Main

d
ive

gear

2

Snap
ring

3

Spacer

4
Main
drive

bearing

TM715

Fig
MT
47

Irutalling

Snap
Ring
Manual

Transmission

Available

nap
rings

No

Thickness
mm
in

No
Thickness

mm
in

2
20
to
2
25

1
34
to
1
40
0
0866
to
0
0886

0
0528

to
0

0551
2
25
to
2
30

2

0
0886
to
0
0906

140rol46

2

0

0551
to
0

0575

2
30
to
2
35

3

146
to

1
52
0

0906
to
0

0925

3

0

0575
to
0

0598

2
35
to
2
40

4

1
52
to
1
58
0
0925
to
0
0945

4

0
0598
to
0

0622

2
40
to

2
45

5

1
58

to
1
64
0
0945
to
0
0965

5

0
0622

to
0
0646

2
45
to
2
50

6

0
0965
to
0
0984

1
64
to
1

70

6

0

0646
to

0
0669

2
50
to
2
55

7

1
70
to
I
76
0

0984
to
0

1004

7

0
0669

to
0

0693

2

55
to
2

60

8

0
1004100
1024

Counter

Beer
Note
Be
sure
to

measure
at
two
or

more

positions
on
the

end
urface

of
outer
race

1

Press
counter

gear
rear

bearing

onto

counter

gear
usingCountershaft

Bearing
Press
Stand
KV32
100200

KV32100100

r
I

J

I

1

T

II

I
TM117

Fig
MT
49

Mecuuring
Counter
Gear

End

Phly

TM716

Fig
MT
48

Installing
Counter

Gear

Rear

Bearing
3
Remove
counter

gear
assembly

from
the
transmission
case

4

Press
counter

reverse

gear
onto

counter

gear
assembly
using
Counter

shaft

Bearing
Press
Stand

KV32
100200

2

Install
a
counter

gear
thrust
wash

er
and

unter

gear
with
counter

rear

bearing
into
transmission

case
and

select
counter

gear
thrust
washer
of

proper
thickness

using
Counter
Gear

Height
Gauge
KV32
100
100

Select
washer

from
those
shown
in

the

following
table
so
that
end

play
of

counter

gear
is

specified
value
KV32100200

Standard
end

play

0

10
to
0
20
mm

0
0039
to
0
0079
in
TM719

Fig
MT
50

Installing
Counter

Revene

Gear

MT12

Manual
Transmission

SPECIAL
SERVICE
TOOLS

Tool
number
tool
name

KV32
I

00300

Adapter
setting
plate

ST23540000
Fork
rod

pin
punch

ST22730000

Bearing
puller

STJ0031000

Bearing
puller

STJ5300000
Oil
seal
drift
I
Kent
Moore
No

Reference

page
or

Fig
No

Unit

application
Tool
number

tool
name

J

25693
ST23800000

Fig
MT
12

Fig
MT
40

Fig
MT
77

Fig
MT
104

J
25689

Fig
MT
13

Fig
MT

78

J
2568
1

Fig
MT
24

Fig
MT
27

Fig
MT
28

Fig
MT
92

J
25733
1

Fig
MT
22

Fig
MT
90

Page
MT
IO

Page
MT
24
Transmission

drift

ST22350000

Mainshaft

bearing
drift
I
Kent
Moore
No

I
Reference

page
or

Fig
No

Unit

application

J

25691

Page
MT
IO

Fig
MT
46

Page
MT
24

Fig
MT
I
II

J

25678

Fig
MT
44

Fig
MT
55

Fig
MT

I08

Fig
MT
I
25

Fig
MT
48

Fig
MT
50

F4W60L

KV32
100100

Counter

gear

height
gauge
J

26070

Fig
MT
49

F4W60L

J

26071

Fig
MT
52

Fig
MT
115

Applicable
to
all
B310
series

models
F4W60L
and
FS5W60L

MT35
KV32
100200

Countershaft

bearing

press
stand

KV32
100400
Mainshaft

puller

Fe
rnuffiUQ

cP

DATSUN

2JO
Model
83
J

0
Series

SECTIONPD

PROPELLER
SHAFT

DIFFERENTIAL
CARRIER

CONTENTS

PROPELLER
SHAFT

INSPECTION

GENERAL
INSPECTION

PROPEllER
SHAFT
VIBRATION

REMOVAL
AND
INSTAllATION

REMOVAL

INSTAllATION

DIFFERENTIAL
CARRIER

REMOVAL

PRE
DISASSEMBl
Y
INSPECTION

DISASSEMBLY

FINAL
DRIVE
ASSEMBLY

DIFFERENTIAL
CASE

INSPECTION

ASSEMBl
Y
AND

ADJUSTMENT

PRECAUTIONS
IN
REASSEMBLY

ASSEMBLY
OF
DIFFERENTIAL
CASE

ADJUSTMENT
OF
DRIVE
PINION

HEIGHT

ADJUSTMENT
OF
DRIVE
PINION

PRELOAD
PD
2

PD
2

PD
2

PD
2

PD
2

PD
2

PD
2

PD
3

PD
3

PD
3

PD
4

PD
4

PD
4

PD
4

PD
5

PD
5

PD
5

PD
6

PD
6
AQJUSTMENT
OF
SIDE
BEARING

SHIMS

INSTAllATION

REPLACEMENT

OF
FRONT
Oil
SEAL

SERVICE
DATA
AND

SPECIFICATIONS

PROPEllER

SHAFT

GENERAL
SPECIFICATIONS

SERVICE
DATA

TIGHTENING
TORQUE

DIFFERENTIAL
CARRIER

GENERAL

SPECIFICATIONS

SERVICE

DATA

TIGHTENING
TORQUE

TROUBLE

DIAGNOSES
AND

CORRECTIONS

PROPEllER
SHAFT

DIFFERENTIAL
CARRIER

SPECIAL
SERVICE
TOOLS
PD

7

PD
9

PD
9

PD
lO

PD
lO

PD
lO

PD
lO

PD
lO

PD
l0

PD
lO

PD
ll

PD
ll

PD
12

PD
12

PD
13

PD
15

Propeller
Shaft
Differential
Carrier

DIFFERENTIAL
CARRIER

fQ

@

1

11
Thrust
washer

12

Ring
gear

13
Differential
case

14
Lock
strap

15
Drive

pinion

16
Pinion
height
adjusting
washer

17
Pinion
rear

bearing

18

Collapsible
spacer

19
Side

bearing
cap

20
Gear
carrier
1

Companion
flange

2
Oil
seal

3
Pinion
front

bearing

4
Sidebearing

5
Side

bearing
adjusting
shim

6
Thrust
walher

1
Side

gear

8

Lock

pin

9
Pinion
mate
shaft

10
Pinion
mate
Tightening
torque
kg
rn

ft
lb

@
14
to
30

101
to

211

@
6
0101
0
43
to
51

@
5
0
to
5
0
36
to
43

@
1

6
to
2
4

12
to
11

PD446

Fig
PD

3
Differential
Carrier

2

Visuany
inspect
parts
for
wear

of

damage

3

Rotate

gears
to
see
that
there
is

any

roughness
which

would
indicate

damaged

bearings
or

chipped
gears

Check
the

gear
teeth
for

scoring
or

signs
of
abnonnal

wear
Measure

pre

load
of
drive

pinion

4

Set

up
a
dial
indicator
and
check

the
backlash
at
several

points
around

ring

gear
Backlash
should
be

specified

value

Ring
gear
to
drive

pinion
backlash

0
10

to
0
15

mm

0

0039
to
0

0059
inl
spected
before

any

parts
are
removed

from
it

These

inspections
are

helpful
in

fmding
the
cause
of
a

problem
and
in

detennining
the

corrections
needed

Mount
carrier
on
Differential

Carrier
Attachment
ST06320000
REMOVAL

I

Jack

up
rear
of

car
and

sup

port
it

by

placing
a

safety
stand
under

rear
axle

case
Drain

gear
oil

2
Remove

propener
shaft
and
rear

axle
shafts

These
works
can
be
done

by

referring
to
Rear

Axle
and
Rear

Suspensionu

3
Loosen
off
bolts

securing
differ

ell
tial
carrier

to
rear
axle
ca
se
and

take
out
differential

gear
carrier

as

sembly

PRE

DISASSEMBI
Y

INSPE
CTION

Differential
carrier
should
be
in
5

Check
the

gear
tooth
contact

with
a
mixture

of
recommended

Fig
PD
4

Holding
Differential
Carrier

PD

3

ADJUSTMENT
OF
DRIVE

PINION
HEIGHT

Adjust
the

pinion
height
with

wash

er

provided
between
rear

bearing
inner

race

and
the
back
of

piliion

gear

J

Press
fit

front
and
rear

bearing

outer
races
into

gear
carrier

using

Drive

Pinion
Outer
Race
Drift

STJ070
I
000

and
Bar
ST30611000

2

Fit
rear

bearing
on

gear
carrier

and
install

Dwnmy
Shaft
on
rear
bear

ing
and

place

Height
Gauge
on

gear

carrier

STJII21000

Height
gauge

KV38

103500

Height
gauge
spacer

ST3
II

22000

Dummy
shaft

KV3gl03600

Dummy
shaft

spacer

ST3112tOOO

PD461

Fig
PD
14

AqjUlting
Pinion

Height

3
Measure
the

clearance
N
be

tween
the

tip
end
of

height
gauge
and

the
end
surface
of

dummy
shaft

using

a
thickness

gauge

P0322

Fig
PD
15
Meo

uring
Clearance

4

The

proper
thickness
of

pinion

height

adjusting
washers
can

be
obtain

ed
from
the

following
formula
Propeller
Shaft

Differential
Carrier

T
W
N

HxO
01
OJ8

Where

T

Required
thickness
of

pinion

heightedjusting
w

shers

W

Thickness
of

temporarily
insert

ed
washer
mm

Be
sure
to
use
washer
of
2
74

0

1079
or
2
77
0

1091
or

2
80
0
1102
mm
in

thick

ness

N

Measured
clearance
between

height
gauge
and

dummy
shaft

face
mm

H

Figure
marked
on
the
drive

pinion
head

Note

e

Figure
H
is

e
dimensional
variation

in

units
of
1
100

mm

egainst
stand

ard
measurement

b
If
value

signifying
H
is

not

given

regard
it
as
zero
and

compute

Head

number

Hl

P0186
Set
number

Fig
PD
16
Variation
Number
on

Drive
Pinion

Examples
of

calculation

EX
I

W
2

74mmN
0
30mmH
1

T
W
N
H
x

0
01
0
18

2
74

0
30
I

x
0
01
OJ8

3

04
0

19

2
85

The
correct
washer
thickness
is

2

86

mm

EX
2

W
2
77

mm
N

0
21

mm
H
0

T
W
N
HxO
01
OJ8

2
77
0
21

OxO
0I

OJ8

2
98
0
18

2
80

The
correct
washer
thickness
is

2
g0
mm

PD
6
EX
3

W
2

80
mm

N
0
48
mm

H
2

T
W

N
HxO
OI
OJg

2
80
OA8
2
x
0

01
OJ8

3
28
0
20

3
08

The
correct
washer
thickness
is

3
07
mm

Pinion

height
adjusting
washer

Thickness
mm
in

2
74
OJ
079
3
01
0

1185

2
77
OJ09I

3
04
0
1197

2

80
OJ
102
3
07
0
1209

2

83
0
1114

3
10

0
1220

2
86
OJ
126
3J3
0
1232

2
89
0
1138

3
16
0
1244

2
92
OJ
150
3

19
0
1256

2
95
0
1161

3
22
OJ
268

2
98

0
1173
3
25
O
l2g0

5
Fit
detennined

pinion
height
ad

justing
washer
in

drive

pinion
and

press
fit
rear

bearing
inner

race
in
it

using
Drive
Pinion

Bearing
Drift

Bar
STJ0600000

Note
After

assembly
check
to

see

thet
tooth
contact
is
correct
If
Dot

readjust

ADJUSTMENT
OF

DRIVE

PINION

PRELOAD

Adjust
the

preload
of

drive

pinion

with

collapsible
spacer

This

procedure
has

nothing
to
do

with
thickness

of

pinion

height
ad

justing
washer

Note

Collapsible

spacer
oil

seal
and

pinion
nut

cannot
be

reused

I
After

adjusting
pinion

height

lubricate
front

bearing
with

gear
oil

and

place
it
in

gear
carrier

2

Install
a
new
oil
seal
in

gear

carrier

using
Oil
Seal

Fitting
Tool

ST33400001

Lubricate

cavity
between
seal

lips

with
recommended

multi

purpose

grease
when

installing

3
Place
a

new

collapsible
spacer
on

Propeller
Shaft
Differential
Carrier

SERVICE
DATA

Drive

pinion

Preload

with
oil
seal

Thickness
of

pinion
height

adjusting

washer

Side

gear
and

pinion
mate

Thickness

of
side

gear
thrust
washer

Pinion
mate
to
side

gear
backlash

clearance
between
side

gear
and

thrust
washer

Ring
gear

Ring
gear
to
drive

pinion
backlash

Thickness
of
side

bearing

adjusting

shint

Side

bearing
standard
width

L

dimension

Oil

capacity

TIGHTENING

TORQUE

Drive

pinion
nut

Ring

gear
bolt

Side

bearing
cap
bolt

Companion
flange
to

propener

shaft

fixing
bolt

Gear
carrier

to
rear
axle
case

fixing
bolt

Oil
drain
and
ftller

plugs
kg
cm
in

lb
6
0

to
8
0
5

2
to
6
9

mm
em
2
74

0
1079

2
77
0

1091

2
80
0
1102

2
g3
0
1114

2
86
0
1126

2

89
0

1138

2
92
0
1150

2

95
0
1161

2
98
0

1173

3
01
0

1185

3
04

0
1197

3

07
0
1209

3
10
0
1220

3
13
0
1232

3
16
0
1244

3
19
0
1256

3
22
0
1268

3
25
0

1280

mm
in

0
785
0

0309

0
835
0

0329

0
885
0

0348

0
10

to
0
20

0
0039

to
0

0079
mmOn

mm
in

0
10
to
0
15

0
0039

to
0
0059

mm
in

0
05

0
0020

0
Q7
0
0028

0
10

0
0039

0
20

0
0079

0

50
0
0197

17
5
0
689

153
40
to
153
45
6
0394
to
6
0413
mm
in

mm
in

liter

US
pt
Imp
pt
approximately

0
9

I
U
I

kg
m

ft
Ib

kg
m
ft
Ib

kg
m
ft
lb
14to30
IOI
t0217

6
0
to
7
0
43
to
51

5
0
to
6
0
36
to
43

kg
m
ft
Ib

kg
m
ft
b

kg
m
ft

lb
2
4
to
3
3
17
to
24

1
7
to
2
4

12
to
17

6
to
10
43
to
72

PD
ll