Datsun 521 Service manual

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INFORMATION

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NISSAN

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TOKYO JAPAN

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MODEL
IDENTIFICATION

GENERAL

GENERAL
FINAL

RECOMMENDED

JACKING

VARIATION

VIEWS
SPECIFICATIONS

TRANSMISSION

SPHDOMETER

PERIOD

ICAL

UP

AND

LUBRICANTS

NUMBER

AND

RATIO

AND

MAINTENANCE

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model

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Rear

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SPECIFICATIONS

113

ENG

lNE
52lU U52lU
L521

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capacity

model

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volt

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Final

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capacity

type

Model R4W63

Synchro

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radius

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ft 52

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single

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chanically

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disc

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500
300kg661 41b

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GENERAL

ENGINE

VN521U

UNL521

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345

1

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2

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830

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300

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INFORMATION

L16

ENGINE

PL521TU

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1

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400

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200787

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5

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0

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5

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2

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12

40

Dry

single

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112

disc

spring

60

F4W63

Warner Warner

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Re

circulating

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Duo

elliptic

600146PR
600146PR

ball

Servo

Servo

on

rear

wheels

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leaf

spring

LT
LT

0

301

R4W63

113

G521U

G521

125

Dry

Mechanically

ENGINE

78

LG521T

4

715

1

575620

1

545608

2

770

2

240882

1

430563

400
250

267
200787

1

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1

000

1

0

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5 6 18

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disc

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circulating

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elliptic

600146PR

6

00148PRLT

185

109

15 7
492
49

2

2

0

2

40

Diaphragm

R4W63

Servo

Servo

torsion

GN521
GNL52

6

1

9

226

204

289

4

ball

on

leaf

115

6

6

135

rear

spring

LT

U

I

115

bar

ENGINE

84

0

spring

F4W63

wheels

247

GNL52

4

IT

GI 9

r

jt

CHASSIS

Item

Final

gear

Type

Control

S

f

u

Speedometer

ratio

system

1st

2nd

3rd

4th

Reverse

gear

ratio

FINAL

L521T
LG521T

4

875

19

TRANSMISSION

SPEEDOMETER

PL521TU

PL52ITN

shift

5

5

NL521T

GNL521T

4

625

F4W63

Floor

3

657

2

177

1

419

1

000

3

638

18

4

375

17

AND

RATIO

N52lU

NL521

GN52lU
GNL521

4

625

UNL521
VN52lU

UNL521

4

375

R4W63 R4W63

Column

5

5

18

4

2

1

1

589

243

558

000

4

367

shift

17

5

52lU
L521

G521U
LG521

875

4

19

Column

5

000

3

014

1

685

1

000

5

146

5

U521

UL521
V52lU
VL521

4

625

shift

18

5

RECOMMENDED

RECOMMENDED

PERIODICAL

SAE

ENGINE

GEAR

Multi

01

OIL

Single

L

viscosity

5W

I

viscosity

VISCOSITY

oil

20

oil

lOW

L

IOW

LUBRICANTS

MAINTENANCE

NUMBER

30

10W

40

20W

40

20W

20

SAE

BO

SAE

AND

30

OQ

90

30 20 10

22

4

ature

range

10

50

20 30 40

6B

anticipated

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104

OF

0

14

32

Temper

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80

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MobilegreascMP

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30

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42

40

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36

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MAINTENANCE

42

39

3

1

PL521TN

POINTS

4

78

75

2

6
0

kilometers

of

thousand

of

Number

52

28

26

50

miles

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11

to

m

kg

ft

Ib

5

m

kg

ft

Ib

6

iLn

T

d

j

1

to

5

3

1

m

kg

10

8

to

152ft

Ib

J

Note

Arrow

at

this

marks

place

means

that

engine

Fig

ER

removal

9

Sectional

carries

for

the

out

view

PL521

ER

of

model

5

rear

engine

mounting

CHASSIS

1

t

lU

F

r

H

liR

l

ll

PH

RW

1

REF

REl

rF

DATE

JOURNAL

BULLETIN

or

No

PAGE

No

SUBJECT

ER

6

SECTION

CLUTCH

CL

CD

J

DATSUN

MODEL

CHASSIS

521

NISSAN

I

PICK

SERIES

BODY

I

UP

NISSAN

MOTOR

TOKYO

JAPAN

CO

LTD

CLUTCH
CLUTCH CONTROL

SERVICE

SPECIFICATIONS

TROUBLE DIAGNOSES

AND

AND

DATA

CORRECTIONS

CL

CL

CL10

CL

1
5

11

CLUTCH

CLUTCH

CONTENTS

L

I

DESCRIPTION

REMOVAL

DISASSEMBL
INSPECTION

assembly

Clutch

DESCRIPTION

The

clutch

The

type

plate

provided

springs

while

major

diaphragm

with

arranged

engaging

Y

AND

is

of

components

spring

riveted

in

the

ADJUSTMENT

a

single

and

plales

a

link

clutch

softening

The

wire

dry

are

on

coil

disc
clutch

rings

both

springs

and

diaphragm

cover

The

clutch

surfaces

absorb

smoothing

CL
CL

CL
CL
CL

spring

pressure

disc

and

shock

clutch

coil

1

2

2
2
3

Disc

assembly

Release

bearing

REASSEMBL

Release

mechanism

REINSTALLATION

and

sleeve

Y

CL

4

CL

4

CL

4

CL

4

CL

5

engagement

and

engagement

the

of

a

with

sleeve

clutch

trouble

a

new

Release

is

to

control

Each

Therefore
clutch

bearing

clutch

part

when

assembly

withdrawal

and

assembly

is

uncorrectable

assembly

disengagement

is

lever

secured

are

with

replace

used

rivets

the

o

1

732

o

M

441732

44

dia

e

Xl

9

45

240

g

255

dia

10

dia

04

e

Fig

CLot

Construction

CX1

clutch

of

Unit

mm

in

CL

1

CHASSIS

REMOVAL

The

clutch

same

manner

mounting

Transmission

the

ass

as

clutch
and

Fig

mbly

the

other

CL

is

dimlounted

engine

assembly

relative

2

Clutch

assembly

efer

sections

arsembly

primarily

Thus

to

the

when

Section

2

Removing

in

the

dis
TM

Remove

I

2

Remove

separate

3

Remove

front

cover

lever

ball

1

Withdrawal

2

Withdrawal

the

pin

release

dust

return

withdrawal

release

and

remove

lever

lever

mechanism

cover

ball

from

spring

lever

bearing

withdrawal

pin

from

3

4

clutch

from

and

Return

Release

housing
bearing

bearing

bearing

lever

spring

bearing

sleeve

from

sleeve

sleeve

withdrawal

and

from

DISASSEMBLY

When

separating

loosen

gradually

Note

and

Fig

When

pport

stallation

diaphragm

CL

separating

remove

clutch

J

Removing

bolts

spring

clutch

installation

clutch

cover

gradually

tension

assembly

bolts

clutch

assemly

sufficiendy

and

is

always

from

diagonally

assembly

from

and

carefully

applied

flywheel

flyWheel

loosen

because

and

in

CL

Fig

3

Withdraw

use

of

CD

Thoroughly

disc

assembly

wear

crack

4

a

bearing

Release

Fig

Removing

release

puller

bearing

CL

5

clean

and

and

other

release

bearing

bearing

Withdrawing

all

disassembled

release

bearing

defective

and

from

bearing

release

D

AfJ

parlo

and

conditions

withdrdwallever

sleevebyIhe

bearing

IU

except

check

I

them

for

the

for

CLUTCH

Clutch

1

etc for

occurs

2

1

on

clutch

assembly

Check

clutch

excessive

on

clutch

Measuring

Line

up

assembly

cover

wear

assembly

and

distance

diaphragm

adjusting

piece

base

plate

spring

crack

and

damage

replace

heightofdiaphragm

special

T2005S001

tool

tool

special

presswe

When

8T2oo58001

81

20051000

plate

noise

spring

3

Press

0

307

pressure
this

first

mounting

loosened

fully

0

307

pressure

cover

is

diaphragm

is

plate

the

pressure

360

kg

780

Stroke

7 8

facing

the

in

from

with

gauge

face

in

The

plate

mounted

spring

depressed

gauge

793

71b

307

to

0

307

thickness

master

clutch

clutch

to

pressure

Then

result

is

pressed

is indicated

by

replace

H

be

pressed

Clutch

the

is

attached

gauge

plate

cover

cover

installed

height

plate

subtract

indicates

against

is

That

that

distance

clutch

H

Tfil

down

mounting

H

contacting

the

value

the

flywheel

the

a

by

If

the

cover

gauge

with

on

flywheel

from

H

distance

initial

a

pressure

as

an

exactly

face

clutch

end

from

when

when

press

assembly

to

with

by

pressure

to

is

less

7 8

mm

measure

To

cover

cover

7 8

nun

which
clutch

pressure

which

than

do

of

Fig

2

Place

clutch

assembly

condition

3

surfaceofbase

1

to

Measure

Height

772

distance

of

in

BASE

CL

6

Base

clutch

on

piece

the

diaphragm

plate

diaphragm

at

diameter

43to45

PLATE

plate

assembly

base

is

with

vernier

spring

44

and

plate

placed

spring

mm

91

693

distance

on

distance

stationarity

beneath

caliper

end

733

I

to

height

depth

43to45

in

1

772

piece

piece

pressure

from

Unit

Under

the

gauge

mm

mm

and

1

plate

upper

lin

this

693

set

Fig

4

Adjust

diaphragm

ST20500000

CL

B

Measuring

height

spring

if

required

pressure

of

diaphragm

adjusting

of

diaphragm

spring

wrench

by

special

spring

the

use

of

tool

Fig

CL

7

Measuring

height

of

diaphragm

spirng

L

G

9

Adjusting

diaphragm

spring

height

Fig

CL

3

Disc

assembly

CHASSIS

Release

bearing

and

sleeve

If

I

kerosene

facing

2
deflection

the

following

Upper

facing

if

Check

is

and

dress

required

disc

at

the

value

of

limit

5

0

85

rom

soiled

for

rom

outer

the

with

facing

deflection

circumference

deflection

0

0197

3

346

in

gIease

with

in

radius

a wire

and

at

oil

Jf

clean

off

brush

repairorreplace

of

facing

with

Replace

if

the

exceeds

I

When

withdrawal

point

2

occurs

is

When

on

worn

in

grease

release

Fig

step

CL

REASSEMBLY

replace

leaks

bearing

12

lever

from

replace

Fitting

and

sleeve

release

rekase

hearing

release

bearing

bearing

bearing

sleeve

contact

or

noise

3
extent

mm

loose

Fig

Replace

that

0

0118

CL

10

Checking

disc

assemblyiffacing

the

facing

in

facing

height

is

worn

disc

above

deflection

fur

is

rivet

unevenly

worn

Release

1

sleeveasshown

completely

such

than

rivets

an

03

are

to

less

is

or

bearing

2

Tightly

operates

Apply

Bearing

mechanism

fit

release

in

Figure

turn

bearing

smoothly

multi

purpose

inside

sleeve

bearing

CL

with

grease

groove

12

a

Pack

to

When

finger

to

this

the

the

place

bearing

make

and

following

recess

on

is

bearing

installed

sure

places

that

Fig

CLot

1

Checking

clutch

facing

for

wear

Lubricated

CL

Fig

CL

4

13

position

on

the

bearing

sleeve

CLUTCH

Withdrawal
Withdrawal

contact

1

2

CL

Fig

3

When

withdrawal
clutch
install

Withdrawal
Withdrawal

14

grease

housing

dust

cover

surface

Position
grease

lever

lever

lever

lever

lever

is

is

release

connect

on

and

ball

on

applied

applied

clutch

bearing

ball

pin

the

bearing

them

housing

pin

withdrawal

the

to

with

sleeve

and

3

Return

4

Release

necessary

and

contact

withdrawal

5pring

bearing

levertowhich

places

bearing

return

spring

point

sleeve

lever

install

and

REINSTALLATION

Clean

clutch

pilot

bushing

purpose

2

by

on

Install

the

grease

disc

use

ST20630

00

assembly

of

a

and

clutch

andf1itwith

clutch

assemblyonflywheel

aligning

bar

special

multi

tool

Note

Apply

desulfide

DESCRIPTION
CLUTCH

PEDAL

Removal

Inspection

Reinstallation

Adjustment

CLUTCH

Removal
Disassembly

J

MASTER

nspection

DESCRIPTION

The

521

series

control

The

system

hydraulic

grease

to

type

lubricate

vehicles

compounded

main drive shaft

CYLI

NDER

adopt

clutch control

with

CLUTCH

hydraulic

system

molybdem

splines

type

consists

CONTENTS

CL

5

CL

6

CL

6

CL

6

CL

6

CL

6

CL7
CL

8

CL

8

CL

8

clutch

a

of

Fig

CONTROL

Reassembly

Reinstallation

OPERATING

Removal

Disassembly

Inspection

Reassembly

Reinstallation

ADJUSTING

BLEEDING

pendent

withdrawal

and
fulcrum

CLJ5

clutch

type

Installing

CYLINDER

WITHDRAWAL

CLUTCH

pedal

lever

SYSTEM

master

The

disc

and

LEVER

cylinder

withdrawal

clutch

assembly

operating

is

lever

of

CL
CL

CL
CL
CL
CL
CLog
CLog

CLog

CLog

cylinder

an

inner

8
8

8
8
8
8

Cl

5

CHASSIS

t

I

I

I

I

I

I

CLUTCH

Removal

1

Remove

2

Loosen

disconnect

3

Remove

remove

pedal

Inspection

Thoroughly

below

other

new

Reinstallation

abnormal

ones

Pedal

1
2

Return

3

Pedal

A

C

Reinstall

and

if

t

PEDAL

return

lock

rod

push

lock

lever

clean

carefully

conditions

required

head

rubber

spring

lever bush

clutch

spring

nut

end

nut

A

L

pedal

of

and

all

check

t

in

master

cylinder

washer

disassembled

them

for

Repair

reverse

of

pedal

parts

wear

or

replace

sequence

push

shaft

indicated

damage

them

of

Fig

rod

removal

CL

with

and

and

and

16

Clutch

control

Adjustment

Adjust

RH

selecting

Be

upper

Next

2

pad

height

secure

Note

drive

and

sure

and

the

a

to

it

required

Do
because

cylinder

pedal

without

applying

to

lower

153

adjust

is

position

150

Make
the

noL

not

use

MG

rom

mm

sure

saew

it

pedal

JLr

pad

shims

135

5

with

marked

may

height

stopper

shim

02

6

stopper

mm

lock

591in

that

W

in

it

clog

s

having

in

nut

chassis

portions

PI

more

to

The

having

same

for

properly

533in

for

U

than

the

138

5

adjustment

adequate

L

H

drive

forRH

H

drive

L

grease

two

I

3

return

mm

thickness

that

so

has

places

mm

port

545

is

drive

been

ll

0

in

made

thickness

for

the

applied

Grease

J

1181

of

master

for

by

both

pedal

and

j

inl

CL

6

CLUTCH

Fig

126

117

mm

grease

shim

Thickness

160

080

050

1

in

4

96

4

61

150

mm

0630

0315

0197

mm

2

5

33

13S

s

0591

in

in

Adjusting

Part

number

30611

30612

30613

27260

27260

27260

Item

Applied

model

H

drive

R

LHdrive

Multi

8

CL

17

Pedal

height

adjustment

purpose

CLUTCH

MASTER

CYLINDER

Fig

CL

18

Sectional

view

of

CL

7

clutch

master

cylinder

r

CHASSIS

Removal

1

Disconnect

2

Disconnect

drain

fluid

3

Remove

assembly

from

Disassembly

Remove

1

Pull back

2

pusluod

assembly

Inspection

inspection

1

damage

2

cylinder

wear

piston

can

be

Thoroughly

Check

cylinder

Replaceifrequired

Replace

is

disassembled

or

deformation

pum

clutch

securing

vehicle

riller

dust

assembly

removed

clean

piston

cap

cover

due

rod

bolts

and

all

and

cup

from

line

drain

and

parts

It

to

clutch

from

and

remove

primary

piston

primarily

must

fatigue

fluid

with

remove

also

or

pedal

master

snap

cup

brake

for

damage

cylinder

master

ring

and

return

uneven

whenever

be

replaced

fluid

is

cylinder

Stopper

spring

before

wear

master

when

found

and

Reinstallation

Reinstall

sequence

Adjust

2

Bleed

OPERATING

of

the

master

removal

heightbychanging

pedal

air

of

out

CYLINDER

and

the

cylinder

adjust

hydraulic

s

assembly

push

system

follo

rod

in

length

reverse

Removal

2 Di

3

4
to

clutch

Remove

Disconnect

Release

return

nect

two

housing

clutch

push

bolts

spring

line

rod

used

from

from

to

operating

withdrawaHever

mount

operating

cylinder

cylinder

Disassembly

Remove

or

2

Remove

assembled

dust

snsp

cover

ring

All

other

parts

can

be

dis

3

Check

dust

line

for

damage

found

replace

Reassembly

Reassemble

sequence

1

before

2
and

of

The

reassembly

r

Apply

assemble

disassembly

piston

brake

with

them

cover

deformation

or

the

cup

Install

fluid

oil

new

one

ma5ter

noting

should

sufficiently

reservoir

cylinder

piston

the

be

abnormal

If

following

soaked

cup

to

fIller

cap

assembly

in

carefully

cylinder

and

condition

in

matters

brake

so

and

reverse

that

piston

clutch

fluid

it

r

is

It

@t

CL

J

all

par

damaged

19

Operating

especially

cyUnderdisassembled

cup

and

replace

piston

if

Fig

is

iIlW

Check

or

worn

CL

8

Reassembly

Reassemble

disassem

ly

noting

operating

the

cylinder

following

in

matters

reverse

sequence

CLUTCH

of

1

Soak

piston

cup

2

Apply

and

assemble

Reinstallation

Reinstall

removal

I

Bleed

2

Adjust

0

to

30

2
the

following

piston
carefully

brake

them

the

air

out

push

mm

instructions

in

cup

fluid

operating

of

rod

0

0787

fluid

thatitis

so

sufficientlytocylinder

cylinder

the

hydraulic

so

that

0

1181

to

before

faced

in

system

withdrawal

in

reassembly

correctly

reverse

lever

in

accordance

and

sequence

end

Install

piston

play

wilh

of

is

Unit

mm

in

1
2

3

Lock

nut

Adjusting

Withdrawal

nut

4

Release

5

Diaphragm spring

bearing

AD

JUSTING

Correct

essential

slip

The

and

while

of

the

clearance

bearing

to

ment

diaphragm

drawallever

I

Loosen

clearance

bearing

2

Return

and

set

adjusting

When

lever

end

in

and

spring

fingers

adjustment

Insufficient

the

excessive

clutch

spring

end

lock

between

adjusting

adjusting

is

returned

clearance

is

WITHDRAWAL

of

free

diaphragm

free

between

fingers

as

follows

nut

tighten

the

top

nut

nut

stationarily

nut

is

to

2

between

to15

1

2

the

travel

spring

travel

the

can

withdrawal

of

I34

returned

0

to

release

mm

clutch

between

fingers

affects

release

be

adjusted

adjusting

turns

with

3

I

3

0

mm

bearing

0

0472

LEVER

withdrawal

causes

full

bearing

nut

lever

from

lock

nut

4

turns

0

0787

and

0

to

0591

the

the

disengage

and

the

at

and

eliminate

and

that

position

withdrawal

to

diaphragm

in

lever

release

clutch

with

release

0

1181

the

screw

withdrawal

dust

CL

20

Fig

is

BLEEDING

Remove

Adjusting

CLUTCH

bleed

lever

SYSTEM

cap

from

play

operating

cylinder

a

fluid

it

down

slowly

pedal

of

clean

the

a

2

Open

turn

container

3

Fill

fluid

4

Depress
retighten
Repeat

container

5

Screw

remove

Attach

this

bleed

bleed

which

master

bleed

is

free

up

screw

a

tube

contains

cylinder

clutch

screw

pumping

from

bleed

tube

approximately

immersing

pedal

and

action

air

bubbles

screw

and

replace

small

a

reservoir

quickly

allow
until

on

dust

the

a

open

amount

while

it

the

down

cap

three

with

to

fluid

quarters

end

into

of

brake

recommended

keeping

return

entering

stroke

of

CLog

CHASSIS

Clutch

Clu

Clutch

cover

tch

release

Withdrawal

Diaphragm

disc

Type
Facing

Outer

Total

Thickness

SERVICE

type

lever

lever

end

play

springtoflywheel height

size

dia

x

Inside

dia

friction

Free

Compressed

area

of

disc

assembly

Thickness

x

DATA

cm2

mm

mm in

mm

sq

mm

in

in

in

in

mm

in

AND

SPECIFICATIONS

All

521

series

0 0

dry

56

003386

8

002992

I

MF200K

0787

1

693

disc

Diaphragm

2 0to3

43to45

Single

200x130x3 5 7

362

6to9

8

7

6

to

to

to

U72

20OCBL

87

to

to

O

x

0

3543

03

1l81

5

12xO

ISO

1378

Numbe

Allowable

head

Allowable

Allowable

Clutch

Pedal

Free

Pressing

Master

Master

Capacity

Operating

Operating

from

pedal

height

travel

cylinder

cylinder

torsion

of

minimum

fscing
facing

free

of

strength

Clutch

cylinder

of

cylinder

when

pedal

clutch

spring

surface

run

play

not

at

diameter

reservoir

clutch

diameter

deplh

lOt

of

spline

depressed

head

stroke

full

6

of

rivet

mm

in

mm

in

mm

in

mm

in

mm

in

kg

lb

mm

in

cc

Imp

pts

US

pts

mm

in

03

O

05O

04001 57

135

5

15005

910

14

13

2

29Ifor

14131

15

87

25

44

19

050750

OI18

0I97

5

33

91

I

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lM

out

TM

front

and shaft

plug

not

11

retaining

l0

Removingcountergear

and

rear

snap

from

interlock

lD

lose

spring

pin

interlcck

used

RemoVing

and

rings

to

hole

fix

check

hok

fOlk

and

and

ball

pL

withdraw

take

g

and

rod

out

Main

main

shaft

shaft

assembly

assembly

G

Maindrive

Fig

gear

13

lM

0

Removing

ll

i

@

c

d1

I

lM

14

by

Fig

Main

shaft

disassembled

gear

TM

5

r

CHASSIS

13

and

@

14

viously

Remove

remove

See

Remove

Figure

and

remove

Fig

soap

3rd4th

TM

main

TM

ring

synchro

14

shaft

reverse

15

for

part

Removing

from

assembly

identification

lock

gear

nut

and

main

map

@

sleeve

shaft

@

loosened

ring

fron
and
numbe

3rd

t

side

gear

pre

TM

Fig

17

Removing

bushing

15

1st

of
and
washer
TM

When

gear

withdraw

IB

removing

to

bearing

bearing

simultaneously

@

Fig

TM

main

puller

retainer

16

shaft

special

@i

by

using

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gear

apply

tool

1st

gear

a

press

bearing

the

front

ST22130000

and

ill

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end

thrust

Figure

I

2

3

4

5
6

7

Fig

Snap

ring

3rd

4th

assembly

1st

2nd

assembly

1st

gear

Thrust

shaft

Main
Main shaft

TM

synchronizer

synchronizer

bearing bushing

washer

and

bearing

18

Cross

sectional

ball

8

9

Support

pecial

depress

and

together
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draw

iog

nizer

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tool

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1

st

totether

assembly

of

this

end

ST22I30000

main

draw

with

end

this

gear

with

main

with

shaff

bearing

I

st

bearing

synchrcr

and

shaft

forward

gear

and

2nd

with

bush

gear

gear

the

front

together

synchro

assembly

by

end

using

ppot

of

a

2nd

@

press

gear

2nd

gear

@

@

and

withdraw

and

bushing

1st

@

2nd

To

all

17

spread

TM

6

disassemble

springs

from

both

synchronizer

ends

assembly

remove

1

2

o

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TMJ9

Fig

cJ

9

sleeve

insert

Synchronizer

3

4

@

cr

Synchro
Spread

disassembled

hub

spring

TRANSMISSION

INSPECTION

and

conditions

Transmission

crack
conditions

joint

2

Thoroughly

check

them

Clean

them

which

may

When

bur

repairorreplace

Remove

adhesive

clean

with

pitting

for

case

cause

all

disassembled

wear

and

solvent

oil

and

from

damage

rear

thoroughly

leaking

or

other

installing

with

parts

and

other

extension

and

and

other

damage

surface

completely

solvent

defective

check

defective

exists

for

on

18

from

19

special

To

front

Remove

tool

disassemble

side

by

Fig

main

ST30030000

using

TM 20

drive

main

snap

Removing

gear

and

drive

ring

bearing

press

gear

pliers

snap

with

remove

ring

bearing

snap

ring

puller

3

Repair

ben

t

or

warped

4

Replace

unevenly

Bearing

I

Thoroughly

compressed

2

When

sliding

crack

rough

3

4

surfaces

or

surface

Replace

Replace

extension

clean

bearing

are

round

bearing

extension

dowel

bearing

inner

worn

of

bearing

ball

or

replace

rear

air

ball

out

of

replace

needle

rear

pin

bushing

dry

race

unevenly

is

excessive

with

if

worn

bushing

knock

and

and

a

or

if

remove

unsmooth

new

damaged

if

worn

pinifdamaged

interior

cen

one

due

is

worn

dust

with

ter

race

ball

due

to

wear

or

cracked

to

or

rig

ir

TM

21

Removing

main

drive

gear

bearing

TM

V

t

t

ii

t

22

TM

Fig

7

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baIl

bearing

CHASSIS

Gear

I

Check

and

shaft

gear

replaceasrequired

2

Check

Replace

3

Check

Replace

end

exceeds

if

required

Maximum

shaft

main

main

maximum

for

shaft

shaft

runout

for

wear

crack

for

straightness

with

l

t

0

15

damage

wear

a

new

mm

one

5

End

from

and

or

and

worn

if

run

out

0

0059

in

crack

and

spline

at

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range

the

soap

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end

ring

ring

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Replace

as

plays

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05

play

again

Fig

balk

required

of

is

TM

I

st

0 15

to

deviated

25

rings

2nd and

mm

from

Measuring

for

wear

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0

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this

ge

IT

pitting

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range

end

0059

pl4y

chip

should

select

and

be

in

in

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proper

or

bur

2

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ringinposition

to

ring

TM 23 C

Fig

4

Measure

excessively

driven

i

gears

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Wear

beyond

are

limit

backlash

replaced

all

all

cking

gears

g

of

limit

as

ars

m

1in

each

recommend

a

set

0

0

s

ft

gear

05to0

0

0020to0

20

mm

fOT

straightness

When

both

10

mm

0039

0 0079

gear

drive

in

in

is

worn

and

gear

clutch

tooth

1

6

mm

0

031

in

excessively

TM

Fig

and

front

0

047to0

replace

26

check

Balk

gap

face

063

balk

ring

This
in

ring

tcrcone

between

gap

When

with

on

cone

should

gap

installing

balk

a

new

of

ring

is

less

each

end

within

be

than

one

dimension

gear

It

face

08

is

1

worn

Push

and

2

mm

to

Fig

TM 24

Measuring

gear

backlash

TM

8

Shifting

Replace

damaged

insert

ifworn

excessivelyorunevenly

deformed

or

Oil

Replace

snap

seal

ring

if

is

dropped

TRANSMISSION

is

deformed

lip

off

worn

or

cracked

or

when

Rear

engine

Replace

if

REASSEMBLY

Reassemble

assembly

Main

When

shaft

mounting

weakened

transmission

reassembling

and

gear

insulator

deteriorated

ADJUSTMENT

in

reverse

note

the

or

cracked

sequence

following

of

matters

dis

1M

fitting

bearing

to

28

Driving

main shaft

adapter

inner

install thrust

race

bearing

ball

special

firmly

wash

bushing

bearing

tool

and

use

ST23800000

ball

a

hollow

Note

3

drift

to

Fig

When

transmission

depress

Be

sure

Note

1

2

3

1

blies

tion

2

use a

Snap

ring

3rd

4th

assembly

Ist

2nd

assembly

For

both

install

When

brass

a

If

deviated

applied

b

Do

synchronizer

synchronizer

TM 27

Fig

Ist

2nd

synchronizer

Ist

fitting

drift

endofcollar

Recommend

while

tapping

not

use

Main

gear

wooden

and

is

4

1st

5

Thrust

6

Main

7

Main

shaft

3rd4th

hubs

needle

damaged

a

piece

mallet

gear

bearing

washer

shaft

shaft

bearing

assembly

synchronize

toward

bearing

1st

gear

of mild

correct

collar

bushing

and

end

ball

to

metal

assem

lifec

shaft

play

1M

snap

29

3rd4th

ring

hub

synchronizer

end

Fig

4

For

proper

synchronizer

Part

number

32263 14600

32263

14601

is

be

32263

32263

32263

14602

14603

14604

main

Fitting

from

those

is

play

Thickness

1

40

to

1

45

to

1

50to1550

1

55

to

1

60to1

shaft

hub

minimum

1450

1

50 0

1600

65

bearing

snap

listed

0551to0

0571

0591

0610to0

0 0630

mm

below

to

to

to

ring

0

0

0

in

0571

0591

0610

0630

0650

so

select

that

TM

9

JfIl

CHASSIS

5

To

lock

sion

case

with

the

to

795ftlband

Lock

G

rated

washer

Fig

main

double

TM

shaft

intermesh

tightening

fIrmly

30

install

torque

bend

Lock

o

Tightening

main

gears

lock

8 0

lock

nut

shaft

tighten

to

washer

nut

in

transmis

lock

nut

11

m

kg

57 8

0

disassembly

shown

proper

05

0

to

in
thrust

the

0

For

following

washer

15

rear

side

tluust

washer

are

table

that

so

mm

counter

0

0020

to

available

gear

0

0059

five

end

in

types

Select

play

when

as

a

is

assembled

Note

Part

32225

32225

32225

32225

32225

Install

number

A0900

A090

A0902

A0903

A0904

thrust

washer

132225

A0900

Thickness

2

35

to240

I

2

40

2

45to2

2

50

2

55to2

to

to

0

0925

2450

0945to0

5000965to0

2

55

0

0984to0

60

0

I004to

front

in

mm

to

side

in

0

0945

0965

0984

1004

0

1024

6

Main drive

Reassemble

disassembly

those

listed

minimum

Part

number

32204

08000

32204

08001

32204

08002

32204 08003

32204 08004

32204 16500

32204

16501

gear

main

For
below

drive

gear

ring

snap

that

so

Thickness

1

49

to

1

56to1620

1

62

to

1

68

to

1

74

to

1

80

to

1

86

to

in

reverse

select

proper

drive

gear

mm

1550

0587to00610

0614

1

68

1

0638

1

74

0

0661to0

1

8000685to0

1

8600709

1920

0732

sequence

end

in

0

to

to

0

to

0

0

to

one

0638

0661

0685

0709

0732

0756

play

from

of

Reverse

is

Reverse

disassembly

following

Select

play

idler

idler

a

proper

is005

table

gear

gear

For

to

are

snap

0

is

reassembled

snap

available

15

ring

mm

ring

in

reverse

sequence

five

so

that

0

0020

types

reverse

as

shown

idler

to

0

0059

in

gear

in

when

of

the

end

assembled

Note

Part

32285

32285

Install

number

14600

14601

snap

32285 14600 in

ring

1

15

1

35

Thickness

1

25 0

to

1

45

to

o

front

mm

0453

0531to0

0

to

side

in

0 0492

0571

7

Counter

Counter

gear

gear

is

reassembled

I

32285

14603

22285

in

reverse

sequence

of

TM

10

14604

45to155 0

1

05to1

0571to0 0610

15 0

0413

0

0453

to

TRANSMISSION

Shift

fork

Rear

and

view

Operating

Reverse

operating

lever

check

ass

lever

y

3

41st

Reverse

2nd

shift

shift

fork

fork

3

shift

li

o

J

1

1

c

Forward

@

shift

rod

y

shift

rod

rod

5
6

3rd

4th

Operating

shift

fork

ver

ass

Install

Note 8

Note aInstall

2

check

using

b
and

Install

check

b
flush

c

Pay

ball

a

Be

shift

fork

In

When

locking

each

attention

sure

fork

each

check

rod

ball

standard

with

agent

fork

that

fork

ball

guide

fork

groove

upper

installing

rod

and

to

shift

there

rod

together

spring

special

rod in a

is

coincided

position

surface

plug

shift

is

of

Fig

fork

fork

no

gap

and

tool

position

upper

adapter

be

sure

TM

installing

between

check

with

interlock

ST23620000

where

with

ball

surface

to

31

apply

Layout

direction

fork

ball

plunger

fork

of

plug

thread

rod

plug

rod

by

up

cross

Fig

operating

and

pin

lever

TM 32

shaft

operating

with

tightening

Layout

into

lever

lock

case

lever

to

pin

torque

check

of

the

Assemble

in

case

See

ball

correct

and

Figure

03

2

0

thrust

to

to

direction

set

operating

TM3I

04

03inlb

washer

kg

cm

fork

and

3 Set
Insert

snap
lever

operating

ring
stationarily

of

shift

is

Lock

TM

11

I
f

I

f

0

CHASSiS

REINSTALLATION

Remount

mounting

transmission

in

reverse

sequence

ofdis

JwaSherl

Q

Fig

DESCRIPTION
REMOVAL
DISASSEMBLY

AND

DESCRIPTION

The

type

floor

shift

type

2JCross

TM 33

INSTALLATION

F4W63

vehicle

Installing

TYPE

transmission

Generally

slirlt

fLockPin

cross

shaft

is

used

however

F4

especially

the

W63

TM
TM
TM

construe

TRANSMISSI

CONTENTS

12
13
13

for

INSPECTION
ASSEMBLY

Shift

tion

is

Thus

in

control

fork

the

this

system

same

AND

REPAIR

as

that

chapter

and relative

ON

of

the

description

matters

type

R4W63

is

made

tran

only

for

TM
TM
TM

14
14
14

ssion

the

Fig

TM

t

34

T

yp

F4W63

TM

transmission

12

TRANSMISSION

REMOVAL

Primarily

the
mission
and

F4W63

installation

transmission

For

procedures

the

DISASSEMBLY

Drain

transmission

2

spring

clutch

3
front

4

bottom

Remove

Remove

cover

Remove

remove

housing

cover

dust

withdrawal

five

14
from

of

bottom

AND

F4W63

shift

front

lever

gear

cover

cover

transmission

INSTALLATION

for

removal

the

are

transmission

release

lever

cover

are

oil

securing

securing

same

required

withdrawal

and

case

release

and

as

however

bolts

bolts

installation

R4W63

lever

bearing

and

and

trans

removal

return

from

remove

remove

6

Remove

speedometer

drive

pinion

assembly

of

7

and
from

8

and

Remove

remove

fork

Unscrew

balls

rod

Fig

rear

eight

gates

TM

three

rear

extension

37

check

extension

housing

Removing

ball

housing

rear

plugs

securing

Disengage

extension

and

remove

s

iking

bolts

rod

springs

I

5
control

Remove

lever

Fig

TM

clevis

35

pin

Removing

used

to

bottom

secure

cover

striking

rod

Drive

9

rods

10

gear

shaft

11

together

to

12

remove

and

remove

Move

and

nul

Withdraw

with

Release

reverse

at

out

retaining

Ist

the

needle

reverse

idler

and

rods

2nd and

time

same

counter

roller

idler

gears

pins

forks

lock

shaft

bearings

gear

and

used

3rd4th

shaft

and

to

coupling

main

and

secu

secure

shaft

remove

ing

spacers

snap

forks

sleeves

Release

counter

ring

to

fork

into

main

gear

and

Fig

1M

36

Control

arm

13

TM

Fig

TM 38

Removing

reverse

idler

gear

CHASSIS

13

bearing

Fig

14

case

Shift

Remove

retainer

1M

Draw

fork

bolts

shaft

used

case

assembly

four

transmiSsion

to

39

RemovingmainslraftbNring

main

out

to

secure

from

main

retiD

transmission

shaft

TM

Fig

15

Draw

INSPECTION

detailed

For

to

the

section

Service

TM

18

out

covering

data

40

Drawing

main

procedure

and

out

drive

shaft

AND

the

REPAIR

for

type

inspection

specifications

main

R4W63

slraft

are

assembly

and

repair

transmission

shown

refer

in

page

ASSEMBLY

The

transmission

disassembly

in

the

section

Refer

covering

is

to

assembled

the

instructions

the

type

in

R4W63

reverse

and

transmission

notes

sequence

described

to

h

f

f

l

41

shift

Layout

fork

shift

rod

fork

14

and

operating

of

shift

TM

lever

21st

Fig

2nd

TM

t

1

TRANSMISSION

l

I

Install

and

sleeves

2

Place

3rd4th

fork

TRANSMISSION

REMOVAL
INSPECTION

INSTALLATION

shift

apply

interlock

rod

AND

forks

1st

1st

2nd

plunger

REPAIR

2nd and

fork

rod

fork

to

fork

rod

in

the

position

with

rod

Place

3rd

4th

on

coupling

in

the

position

and

fit

3

reverse

4

interlock

shift

fork

Secure each

plunger

and

fork

and

retaininjfpin

assemble

rp

r

GEAR

CONTROL

CONTROL

SYSTEM

COLUMN

SHIFT

CONTENTS

TM
TM
TM

17
17
17

TM
TM
TM

16
17
17

ADJUSTMENT

Shift

linkage

Select

linkage

31Tobe

lSE

1

Control

rod

Lower

2

3

Cross

bracket

shaft

and

knock

4

Shift

lever

5

Select

6

Select

lever
lever

boss

1

Select

8

Shift

lod

greased

rod

When

disassembled

Fig

TM 42

Control

system

TM

4

forward

15

speed

transmission

r

CHASSIS

REMOVAL

Remove

2

lighling

Remove

switch

Fig

steering

TM

4

steering

wheel

J

Removing

column

assembly

sleering

shell

cover

Snap

o

w

turn

I

signal

and

4

ring

Remove

Fig

0

C

Controllcver

TM

washel

46

Withdrawing

pivot

pin

hand

l

lever

C

washer

Fig

Fig

3

withdraw

Remove

TM

44

TM

45

hand

Removing

Removing

snap

ring

lever

sleering

turn

and

signa

control

column

and

lever

slrea

lighting

pivot

co

switc

pin

and

TM

5

6

7

8

lever

9

positioning

10

upper

control

16

I

Lock

2

Select

3

Lower

Separate

Separate

Remove

Withdraw

Loosen

pin

lever

bracket

Fig

Depress

support

rod

and

lock

lower

knock

and

and

shift

select

control

lock

select

turn

select

7M

47

lever

pin

pin

remove

lever

wire

rod

Separating

from

from

and

lever

bracket

can

rod

lower

select

be

bracket

it

toward

4

Shift

5

Select

shift

select

lever

boss

to

up

removed

downward

ever

rod

rod

select

such

to

driver

lever

lever

and

pivot

lever

remove

change

and

shift

boss

rod

bolt

and

extent

an

direction

s

compartment

rod

shift

that

it

from

of

TRANSMISSION

The

Note

rings

sequence

individual

Before

INSPECTION

all

and

Check

other

sliding

defective

INSTALLATION

Install

control

ADJUSTMENT

CD

and

removing

direction

AND

parts

system

joints

and

conditions

in

use

small

check

REPAIR

other

reverse

washers

them

for

components

Replace

sequence

and

reinstalling

for

as

required

of

removal

snap

wear

When

parts

I

2

3

4

control

5

24

mm

installing

Select

Select

Reverse

Insert

shaft

Cross

C

94

10

lever

lever

and

shaft

nli

check

n

J

apply

pivot

boss

unit

change

both

100

Control

center

bolt

select

frame

oc

chassis

bushing

lever

lever

Steering

line

grease

units

and

Figure

rod

unit

guide

in

transmission

J

A

center

to

upper

the

line

following

portion

sides

of

Shift

1

2

arrives

linkage

Set

Adjust

A

1

Shift

2

Select

3

Select

4

Control

transmission

trunion

position

CID

lever

lever

rod

nut

rod

outer

and

lever

to

tighten

Fig

neutral

it

5

6

7

8

TM 48

when

Reverse

Trunion

Shift

Outer

Transmission

position

change

rod

lever

check

ou

lever

77

mm

303in

E

f

M

l

nnl

select

lever

wheel

bracket

change

@

II

II

I

I

into

comes

lever

is

to

neutral

in

position

contact

B

posi

B

Figure

9

Outer

lever

t

shift

control

return

with

Note

2

linkage

spring

control

In

tion

Set

transmission

10

Control

11

Beneath

assembly

seat

rod

this

arrangement

ring

on

rod

steering

lower

outer

Select

1

linkage

Arrange

component

parts

where

no

3

Tighten

so

that

reverse

check

TM

able

force

17

trunion

is

applied

to

nut

select

at

a

position

rod

unreason

CH ASSIS

General

Specifications

General

Type

trol

Con

Synchromesh

ratio

Gear

SERVICE

specifications

specifications

system

type

1st

2nd

3rd

4th

DATA

F4W63

Floor

Warner

3

2

1

1

000

TM

TM 18

shift

657

177

419

AND

CONTENTS

18

SPECIFICATIONS

TIGHTENING

R4W63

Column

Warner

TORQUE

4

243

2

558

1

587

1

000

shift

R4W63

Column

Warner

TM

20

shift

5

000

3

014

1

685

1

000

Speedometer

Final

Extension

Oil

gear

capaci

ratio

ty

Note

Specifications

Item

Each

gear

Standard

gear

housing

a

b

backlash

Rev

ratio

See

I

7L3

2 0L4 2

For

backlash

19

4

TM2Extension

page

6

US

US

all

gears

875

pis

pts

3

638

5

18

4

short

I

7L

625

5

17

5

4

375

long

2

0L

4

367

18

5

4

625

short

I

7L

17

4

long

2

375

0L

5

long

2

5

146

19

5

4

875

short

1

71

0L

18

4

long

2

0L

5

625

housing

3

0

Imp

pts

5

3

Imp

pts

Model

mm

in

F4W63

0

0

0020

05to0

to

R4W63

10

0

0039

Replacement

standard

mm

0

in

TM

IS

20

0

0079

TRANSMISSION

Item

Each

Balk

3rd4th

gear

ring

adjusting

standard

For

cone

StMdard

aU

gears

clearance

clearance

end

Replacement

shim

play

standard

Model

mm

mm

mm

F4W63

0

in

05

0 0020

in

in

Part

number

32263

14600

32263 1460

32263

32263

32263

I

14602

14603

14604

12

0

0472

1

40

145

1

50

1

55

1

60

to

to

to
to00630

0

8

0

0315

Thickness

to

to

1

50

to

1

55

to

1600

1

to

R4W63

0

15

0

0059

6

1

1450

0

0

65

0 0630to0

mm in

0551

0571

0591

0610

0

0571

to

0591

to

0

0

0610

to

to

0

0630

0650

Main

Reverse

drive

idler

gear

gear

adjusting

adjusting

shim

shim

Part

number

32204

08000

32204 08001

32204

08002

32204

08003

08004

32204

32204 16500

32204

16501

Part

number

32285

14600

32285

14601

32285 14602

32285

14603

22285

14604

Thickness

1

49to1

55

74

80

86

1620

to

68 0

to

1800

to

86

1

to

1920 0732

1

56

162to1

168to174 0

I

1

1

Thickness

1

to

to

to

to

to

25 0

1450

1

35

1

55 0

1150

1

15

1

35

1

25

1

45

1

05

in

mm

0

0587

to

0614to0

0638

to

0661

to

0685

to

0

0709

to

to

mm

in

0453

to

0531to0

0

0492to0

0571to00610

0413to0

0

0

0

0

0

0

0

0610

0638

0661

0685

0709

0

0756

0492

0571

0531

0453

32

TM

19

1

i

CHASSIS

Item

Counter

Tightening

Transmission

gear

Engine

Front

thrust

torque

proper

transmission

cover

washer

transmission

installation

installation

bolt

bolt

Model

Part

32225

32225

32225

32225

32225

number

A0900

A090

A0902

A0903

A0904

I

F4W63

Thickness

235to240

240to245

245to

2

to

2 55

2

50

55to2

2

2

4to2

8to1

0

R4W63

mm in

0

0925

0945

0

5000965

0

0984

1004to0

60

0

m

kg

8

174

0

to

0

0945

to

0

0965

to

0

0984

to

0

1004

1024

ft

lb

20

2

to

5

7 2

8

to

extension

Rear

Main shaft

tightening

Companion

Rear

engine

Filler

plug

Drain

plug

Back

Bottom

lamp

up

cover

Speedometer

Interlock

Operating

Reverse

plug

lever

check

transmission

flange

mount

switch

installation

pinion

tightening

installation

installation

for

both

nut

installation

bolt

shift

nut

bolt

and

bolt

select

bolt

14to1

8

to

to

10

3

3to3

to

25

20to

2 0to3

0 8to1

03

to

17

to

to

03

2 0to3

8

II

14

8

35

18

3014

0

0

04

2

1

04

0

10

57

72

23

5

2 2

2

8

3

9

5

14

5

8

12

3

2

145t021

1to13 0

to

to

to

27

1

to

21

7

to

to

21

to

7 2

to

2 9

to

15 2

2

to

79

5

25

3

1Ol

2

5

7

9

7

Transmission

Trunion

nut

outer

for

both

lever

shift

and

select

0

1

5

8

8

to

0

2

0

to

2 8

14

TM

20

to

5to20

7 2

2

TRANSMISSION

Transmission

Difficult
intermesh

Select

Lower

Steering

Control

Condition

to

gears

lever

pivot

support

wheel

tightening

control

gear

lever

installation

TROUBLE

Causes

and

When

may

First

bolt

bracket

floor

for

transmission

the

alsobeunsmooth

make

nut

shift

bolt

DIAGNOSES

Probable

difficult

gear

sure

shift

that

gear

lever

the

cause

shifting

clutch

is

heavy

are

classified

and

operates

AND

it

is

correctly

CORRECTIONS

troubles

to

difficult

and

to

inspect

shift

0

0

7

1

Corrective

concerning

gears

the

5

0 8 3

to

6

to

10

0

to

2 2

9

to

action

the

clutch

transmission

to

6

43

to

75

50

6to54

7

to

13

control

system

disengagement

5

8

7 2

2

15

9

Gear
of

mesh

Worn

Insufficient

loose

or

Defective

I

ips

out

In

the

is

worn

this

In

shooting

It

should also

weakened

Worn

Worn

broken

Worn

gears

sliding

or

most

or

case

must

front

interlock

check

spring

fork

shaft

operating

part

damaged

case

weakened

the

be

be
and

plunger

ball

rod ball

and

synchronizer

this

trouble

or

trouble

carried

noted

rear

and

groove

or

stroke

when

out

engine

or

bearing

due

occurs

cannot

carefully

that

weakened

the

gear

mounts

to

worn

when

control
be

system

corrected

slips

or

the

out

Replace

Repair

Replace

interlock

is

defective

by

replacing

mesh

of

Replace

Replace

Replace

or

replace

plunger

due

gears

to

check

and

vibration

ball

therefore

generated

and

or

trouble

spring

A

by

Worn

Worn

damaged

or

damaged

bearing

gear

TM

Replace

Replace

21

fI

CHASSIS

Noise

Condition

noise

When

noise

occurs

Insufficient

Oil

leaking

gasket

Worn

bearing

high

speed

Damaged

occun

Worn

each

each

Worn

or

clogged

bearing

also

at

spline

bushing

Probable

occurs

while

improper

due

breather

High

a

to

low

under

shifting

defective

humming

Cyclic

speed

cause

engine

gearsitmay

lubricant

etc

knocking

oil

occurs

idling

seal

sound

and

at

and

be

a

stops

judged

Add

Clean

while

that

oil

or

Replace

Replace

Replace

Replace

Corrective

the

the

or

replace

replace

clutch

noise

action

is

disengaged

is

from

with

transmission

the

designated

or

when

oil

DATE

SERVICE

JOURNAL

BULLETIN

JOURNAL

or

No

PAGE

No

OR

BULLETIN

REFERENCE

SUBJECT

TM

22

SECTION

PD

DATSUN

MODEL

CHASSIS

521

PICK

SERIES

BODY

UP

PROPELLER

DIFFERENTIAL

CARRIER

SHAFT

CI

NISSAN

NISSAN

I

MOTOR

TOKYO

I

JAPAN

CO

LTD

PROPELLER

DIFFERENTIAL

SHAFT

UNIVERSAL

AND

JOINT

CARRIER

PD

PD

1

5

77

C

1

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

DESCRIPTION

REMOVAL

DISASSEMBL
INSPECTION

PROPELLER

Y

SHAFT

AND

CONTENTS

PO

PD

3

PD

3

PD

3

UNIVERSAL JOINT

ASSEMBL
SERVICE
TROUBLE

CORRECTIONS

Y

DATA

DIAGNOSES

AND

SPECIFICATIONS

AND

PO

PD

PD

4

4

5

DESCRIPTION

Three

N

G

series

These

struction

A

for

propeller

521

a

vehicles

correct

good

types

and52IT

propeller

riding

shafts

are

balance

in

of

used

shafts

comfort

service

Fig

propeller

Floor

of

propeller

parts

PO

shift

adopt

at

high

and

I

Propella

shafts

vehicles

solid

shaft

speed

ones

for

except

tubular

is

very

Therefore

assembled

shaft

UV N 52l

GN52IT

steel

important

for

@

@

521

UV

N

and

vehicle

gr

cm

care

The

con

tapped

bottoming

Check

36

the

in

the

000

9

000

except

are

0

2

propeller

with

kill

km6000

Floor

counter

in

lz

a

hammer

occurs

propeller

24

000

Shift

4

at

shaft

during

miles

vehicles

balanced

000

may

while

off

shaft

miles

for

within

the

at

rpm

be

unbalanced

servicingorflying

road

driving

and

joint

and

propeller

grease

an

factory

center

shaft

unbalance

with

if

erroneously

bearing

spline

the

rocks

of IS

best

or

every
every

PD

6

CHASSIS

f

rA

u

Fig

PD

2

Propeller

shaft

for

G

NJ521

series

vehicles

Fig

PD

3

Propeller

shafr

PD

for

2

Floor

shift

vehicles

REMOVAL

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

S21

UV

N

Remove

transmission

N

G

Remove

differential

brackets

S21

except

propeller

and

mounting

gear

DISASSEMBLY

Primarily

is

balanced

are

required

1

With

movement
disassemble

2

Put

propeller

can

be

do

as

however

journal

When

match marks

shaft

reassembled

an

side

Floor

not

assembly

installed

journal

and

to

Floor

shaft

and

spline

shift

bolts from

case

and

disassemble

the

following

on

on

other

parts

the

original

shifl

vehicles

carefully

rear

vehicles

remove

propeller

When

propeller

does

sleeve

as

condition

as

so

not

oil

seal

3

joint

transmission

both

bearing

shaft

disassembly

procedures

shaft

not

move

yoke

required

to

damage

mounting

because

and

apply

checkitfor

smoothly

flange

that

so

and

repair

yoke

they

it

S

Lightly

withdraw

Note

When

to

bearing

damage

Fig

tap

race

removing

jau

PD

base

mal

5

Removing

of

journal

yoke

from

bearing

with

yoke

a

hammer

careful

be

and

not

3

Remove

snap

ring

with

an

ordinary

screw

driver

CD

@

ClO

A

Fig

PD

4

Removing

snap

ring

INSPECTION

Check

When

replacing

When

2

replace

journal

each

Fig

part

journal

pin

PD

and

unit

6

exterior

Exploded

repair

replace

A

or

view

replace

as

is

an

assembly

pitted

if

defective

or

cruised

4

Remove

bearing

PD

When

3

3

yoke

hole

C

is

worn

or

damaged

replace

1

CHASSIS

4

When

snap

5

When

bearing

is

damaged

@

6

When

sleeve

or

When

When

worn

propeller

replace

center

damaged

7

cracked

8

ASSEMBLY

Assemble

assembly

Greaseissealed

Fill

joint

shaftisoverhauled

Snap

a

proper

0008

0

to

select

opposite

that

so

less

than

Tightening

Companion

G521

Bearing

G521

ring

snap

in

another

side

joint

10

and

and

propeller

with

functions

Moreover

moves

kg

torque

GN521

mounting

GN521

ring

or

wheel

ring

Install

cm

flange

CD

oil

worn

yoke

replace

bearing

in

joint

that

so

soap

and

under

56Ib

bracket

is

seal

replace

and

shaft

is

shaft

bearing

also

when

ring

in

center

damaged

ring

main

sleeve

tube

worn

in

that

so

grease

a shim

as

slackness

a

snap

having

assemble

bending

bearing

10

to

installation

24to2 7

or

and

@

shaft

and

yoke

surface

or

damaged

reverse

no

greasing

to

is0to

ring

the

components

friction

unit

15

kg

kg

m

deformed

or

splined

main

sequence

whenever

adjust

is

selected

same

installation

m

74toIII

bolt

18

needle

portions

is

replace

is

0

02

thickness

resistance

to

replace

shaft

dented

required
propeller

gap

mm

correctly

20

roIler

to

Select

be

ft

shaft

kg

Fig

over

installation

m

18

PD

size

Thickness

7

Propeller

2

5to3 0

are

or

dis

Snap

ring

0

to

sure

Part

number

for

nut

ft

Jb

37146

of

Ib

37147

37148

37149

37150

37151 14600

37152

14600

14600

14600

14600

14600

14600

2

2

2

2

2

2

2

bolt

5

to

22

Direction

I

Selection

mm

00

00788

02

0

0795

04

0

0803

0

0811

06

0800819

1000827

12

00834

ft

Jb

slackness

of

snap

ring

Color

in

identification

White

Yellow

Red

Green

Blue

Brown

No

paint

SERVICE

Distance

Spline

Permissible

between

model

DATA

joints

unbalance

AND

SPECIFICATIONS

in

mm

grcmrpm

U V

N521

1

233

x

68

9

Involute

154000

PD4

1

6

spline

Vehicle

52IT

Floor

shift

IT

GN52

Except

1st

615

24

6

spline

2

29

3

48

5

2nd 743

63

5x1

Involute

4

000

15

GN521

1st

615

2nd 983

63

5x1

Involute

15

4

000

24
38

6

spline

2
7

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

TROUBLE

Condition

Vibration
tion

propeller
during

or

high

the

vibration

transmitted

body

l

I

occurs

at

speed

DIAGNOSES

Vibra

on

haft

medium

and

i

to

Worn

bearing

Unbalance
shaft

Loose

Worn

transmission

AND

or

damaged

due

propeller

CORRECTIONS

Probable

to

shaft

universal

bent

installation

rear

cause

extension

or

dented

joint

propeller

bushing

needle

Replace

Repairorreplace

Retighten

Replace

Corrective

action

t

r

starting

on

haft

sound

or

during

pro

Knocking

during

noise

coasting
peller

Damaged

Worn

Worn

Loose

center

or

damaged

sleeve

propeller

yoke

bearing

universal

and

shaft

joint

main

shaft

installation

spline

Replace

Replace

Replace

Retighten

DESCRIPTION
REMOVAL

DI

ASSSEMBL

I

nspection

INSPECTION

ASSEMBL

Assembling
Adjusting

Y

pinion

Y

before

AND

differential

DESCRIPTION

The

differential

aluminum

contact

Shims

alloy

and

preload

AND

height

gear

and

washers

and

Loose

Damaged

disassembly

REPAIR

ADJUSTMENT

gear

carrier

uses

hypoid

are

used

backlash

installation

joint

center

bearing

DIFFERENTIAL

case

is

of

made

bevel

for

adjustments

the

gear

of

gear

light

and

PD
PD
PD
PD

PD
PD

PD

PD

strong

of

CONTENTS

5
6

7
7

8

8
8

9

tooth

CARRIER

Adjusting
Adjusting

I

nspecting

tooth

gear

INSTALLATION
SERVICE

TROUBLE

CORRECTIONS

Differential

km

600

miles

and

replaced

Adjust

Replace

drive
side

bearing

and

repairing

contact

DATA

DIAGNOSES

gear

checked

every

snap

pinion

AND

oil

36

should

000

ring

preload

shim

drive

SPECIFICATIONS

AND

be

replaced

3

every

km

000

24

000

km 2

miles

at

initialI000

000

PD
PD

PD
PD14

PD

PD

miles

lO
ll

13

14

15

PD

5

CHASSIS

ID

11

j

@

I

j

I

I

Companion

2

Front

3

Spacer

4

Pinion

5

Pinion
Pinion

6

7

Side

@

bearing

height

mate
mate

gear

thruit

nange

adjust

gear
gear

j

washer

shim

@

8

9

10
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13

14

Side

bearing

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Oil

Adjust

Drive

Rear

cap

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case

Qt

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Drive

IS

16

17

Adjust

18

Thrust

19 Side

20

Pinion

Lock

gear

gear

pin

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block

mate

shaft

REMOVAL

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companion

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removal

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3
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assembly

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PROPElLER

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DIFFERENTIAL

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before

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1

In

order

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pinion
pinion

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to

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backlash

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carrier

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remove

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drive

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out

pinion

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special

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value

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clearance

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side

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PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

number

Part

38424 25660

38424

32200

32201

38424

38424 32202

38424

32203

gear

thrust

Side

Thickness

0 76to0 81 0

0 81to0860

0

86

0 91

to

1

01to1

1

06

to

washer

mm

in

to

0299

0319

0

0339

06

0

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l

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0

0417

0

0319

to

0

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to

0

0358

to

0

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specified

measure

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install

oil

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16

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7

to

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height

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kg

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m

ST3321

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61 to

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3
and

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ferential
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lock

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4

8

to

Fit

side

case

10000

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side

drive

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5 5

15

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pin

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kg

bearing

by

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back

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tighten

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thickness

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bearing

3

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specified

obtained

4

Install

ferential

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pinion

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7to10

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ST31100000

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gauge

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6

install

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flange
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3

Measure

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shim

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torque

Turn

pinion

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check

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applied

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installed

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pinion

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bearing

with

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and

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spacer

select

and

When

and

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obtained

T
Where

Calculation

Thickness

by

N

Hx0 01

When

T

0

Part

38153
38154

38156

38157

Fig

the

T
N
H

example

N

is

5

number

10601

10601

10601

10601

PD

drive

of

following

Thickness

Value

Number

05

2x0

Pinion

18

Measuring

pinion height

equation

0

2

measured

on

H

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Thickness

clearance

adjust

thickness

by

pinion

28

shim

0

05000020

0

075

0

25000098

0

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shim

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gauge

head

1D19

Fig

mm

in

Part

0

0030

0197

0

number

n o

3816632202

3

38167

202

Measuring

Bearing

spacer

Length

6775

68

preload

2

00

2

mm

6673

6772

in

PD

lO

i

PROPELLER

SHAFT

Pinion

bearing

DIFFERENTIAL

washer

adjust

CARRIER

i

4

Remove

oil

seal

disassembled

5

Install

prescribed

inlb

Part

38127
38128

38129

38130

38131

38132
38133

38134

with

flange

tightening

number

09400
09400

09400

09400

09400

09400

09400

09400

flange

a

new

and

and

one

washer

torque

install

whenever

mm

Thickness

2

59

0

2

57

0

2

55

0

2

53

2510

2

49

0

2470

2450

oil

seal

Be

sure

differential

and

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to

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17

kg

cm

in

1020

0

1012

1004

0996

0988 38140

0980

0972

0965

to

replace

carrier

is

nut

with

129

104

to

Part

38135

38136

38137

38139

38140

38141

number

09400

09400
09400

09400

09400

09400

09400

E

F

Tolerance

width

0

7874

and

om

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of

against

in

mm

Thickness

2

43

2 41 0

2 39

2370

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2

31

left

or

standard

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0

0004

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right

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side

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of

0

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6

Turn

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shim

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approximately

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thickness

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om

0

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00

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measure

mm

0

175

mm

0

case

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again

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weight

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7874

mm

in

case

bearing

block

in

and

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mallet

Apply

cone

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selected

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install

20

Adjusting

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case

it

on

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assembly

carrier

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case

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with

and

a

fit

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side

PD

e

ll

1

I

Part

number

38453

38454 61200

38455
38456

38457

61200

61200

61200

61200

Side

bearing

shim

Thickness

0 05 0

0Q70

0120

0250

0500

mm in

0020

0028

0047

0098

0197

F

CHASSIS

8

9

backlash

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When

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than

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3

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6

Tighten

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7

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cap

edges

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00

dimension

198

marks

cap

PD

Fig

bolts

42to

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the

40

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in

use

198

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diagnal

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Installing

sequence

8

kg

m

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of

mm

cap

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31

left

cap

7

811

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cap

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right

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to

7

817

prescribed

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drive
between

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Measuring

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gears

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a

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PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

Inspecting

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drive

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CATIONS

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gear

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bearing

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nuts

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nuts

DIAGNOSES

drive

nut

bolts

cap

carrier

flange

bolts

to

axle

to

propeller

Shortage

Incorrect

and

drive

Damaged
improper

housing

shaft

AND

Probable

of

oil

tooth

contact

pinion

differential

adjustment

m

ft

kg

m

ft

kg

m ft

kg

m

ft

kg

m

ft

kg

CORRECTIONS

cause

between

side

drive

bearing

lb

Ib

Ib

Ib

Ib

Supply

gear

or

Adjust

Replaceoradjust

14to17

4 8

4 2to4 8304to34

55

34

to

1

6

24

to

116to

25to3018

C

aerective

oil

gear

tooth

contact

101

2

7to39

1to21

action

9

to

122

8

7

174

7

Noise

Noise

and

coast

Damaged

on

coast

Incorrect
drive

Incorrect

on

drive

Worn

Incorrect

Damaged

teeth

Seized

Pinion

Seized

Seized

gear

backlash

pinion

adjustment

or

damaged

tooth

side

surface

drive

bearing

damaged

damaged

gear

contact

gear

under

or

or

between

drive

drive

and

broken

broken

of

drive

pinion

pattern

gear

drive

pinion

inadequate

pinion

side

drive

pinion

bearings

drive

preload

bearing

bearing

gear

bearing

pinion

and

Replace

Adjust

Adjust

Rebuild

Adjust

Replace

Replace

Adjust

Replace

Replace

defective

backlash

correctly

differential

backlash

as

required

hypoid

preload

bearing

side

bearing

or

gear

parts

and

replace

set

replace

hypoid

as

gear

required

set

Swinging

defferential

case

PO

Replace

15

differential

case

J7

CHASSIS

Condition

Noise

Excessive

backlash

Breakage

differential

them

defective

backlash

worn

differential

adjusting

specified

abusing

Corrective

to

parts

preload

condition

of

Probable

Loosen

side

gear

rom

on

of

Side

gear

Pinion

Worn

and

pinion

Incorrect

drive

pinion

Worn

Shortage

Severe

Incorrect

gears

or

differential

selVice

clamp

bearing

jammed

too

damaged

thrust

backlash

of

oil

adjustment

bolts

due

or

etc

in

tigh

washer

gear

use

to

pinion

and

differential

their

t

on

side

gear

bwtween

case

or

of

improper

an

excessive

of

drive

nuts

cause

holding

case

shaft

thrust

drive

gear

washer

gear

oil

loading

and

drive

and

drive

Retighten

torque

Replace

Replaceasrequired

Replace

Adjust

Replace

Rebuild
After
and

engaging

and

apply

oil

Avoid

Excessive
side

gear

backlash

and

thrust

due

washer

to

defacement

of

the

parts

and

volume

the

action

designated

replaceasrequired

of

bearings

of

gears

of

genuine

car

tightening

backlash

fasten

parts

gear

DATE

SERV

JOURNAL

BULLETIN

Loosened

bolts

uLri

No

and

Oll

nl

PAGE

nuts

At

No

suchasdrive

Un

tilULLt

gear

t

E

SUBJECT

i

i

h

l

bolts

or

PD

16

SECTION

FA

DATSUN

MODEL

CHASSIS

521

PICK

SERIES

BODY

UP

FRONT

AXLE

FRONT

SUSPENSION

NISSAN

NISSAN

I

MOTOR

TOKYO JAPAN

I

CO LTD

FRONT
FRONT

SERVICE

TROUBLE DIAGNOSES

AXlE

SUSPENSION

DATA

SPECIFICATION

AND

CORRECTIONS

FA

1

fA

9

S

FA

FA

19

21

lit

r

FRONT

AXLE

FRONT

SUSPENSION

DESCRIPTION

FRONT

AXLE

Removal

DESCRIPTION

FRONT

CONTENTS

FA

FA

FA

AXLE

FA

Inspection

2

2

Reinstallation

Wheel

bearing

adjustment

3

FA

7

FA

8

The

support

placed

knuckle

through

between

spindle

the

the

knuckle

is

king

installed

pin

spindle

The

1

Knuckle

2

Inner

3

Outer

4

Oil

5

Wheel

6

Washer

7

Spindle

8

Bearing

9

Brake

10

Wheel

11

Knuckle

12

King

13

Thrust

14

Fulcrum

15

Fulcrum

16

Spindle

17

King

t8

Collar

19

Knuckle

20

King

FAlCross

Fig

the

on

knuckle

bushing

pin

king

and

king

pin

spindle

sliding

sectional

is

view

parts

knuckle

arm

is

of

and

set

ront

the

spindle

stationariIy

axle

thrust

and

bearing

knuckle

on

the

wheel

wheel

seal

hub

drum

nut

pin

pin

pin

is

spindle

knuckle

spindle

nut

cap

spindle

bearing

bolt

pin

shim

lock

arm

bushing

inserted

support

bearing

bearing

support

bolt

spindle

or

nut

between

The

knuckle

and

the

when

FA

l

CHASSIS

the

knuckle

The

the

round

wneel

knuckle

on

operated

on

secured
construction

spindle

axis

FRONT

Removal

I

Jack

up

2

Remove

3

Remove

Remove brake drum

4

5

Remove

Remove

6

spindle

arm

king

hub

the

wheels

AXLE

vehicle

hub

brake

hub

cotter

moves

pin

is

spindle

wheel

and

nuts

hose

cap

the

axis

supported

and

hub

lightly

support

and

wheeL

from

and

pin

knuckle

with

brake

with

rotate

it

wheel

spindle

spindleislightly

two

wheel

drum

and

hub

bolts

round

with

stands

cylinder

nut

from

the

bearings

wheel

With

knuckle

knuckle

are

this

11

other

hole

with

pulling

Remove

proper
65

mm

a

tap

boll

Fig

M8

FA

plug

mean

0

256

screwing

3

Removing

from

Plug

in

dia

the

a

may

bolt

on

top

lting

of

be

upper

into

lock

pin
king

removed

plug

threaded

pin

threading

nut

witharod

drilling

by

hole

and

or

a

hole

by

7

from

8

knuckle

9

Remove

knuckle

Remove

spindle

Remove

wheel

spindle

brake

knuckle

Fig

hub

F

disc

arm

A

wheel

assembly

from

2

Removing

bearings

knuckle

from

knuckk

oil

seal

the

spindle

ann

and

flange

collar

of

12

king

Apply

pin

drift

together

Fig

to

with

FA4

Removing

the

lower

top

of

plug

king

king

pin

pin

plug

and

drive

out

lock

10

Remove

king

pin

bolt

FA

2

Fig

FA

5

Removing

king

pin

13

and

not

Tap

detach

to

drop

spindle

it

thrust

from

lightly

knuckle

bearing

r

FRONT

with

a

copper

spindle

AXLE

or

support

lead

hammer

Be

careful

FRONT

Standard

SUSPENSION

Clearance

dimensions

King

19

pin

limit

outer

979

to

15

0

diameter

20 000

mm

0

0059

in

i

mm

0

7866

to

0

7874

in

14

by

race

ence

Lightly

applying

from

tap

a

wheel

evenly

Fig

outer

tap

brass

hub When

if

ldf

FA

6

Removing spindle

race

bar

and

tI

circumference

remove

tapping

outer

support

withahammer

wheel

race

bearing

circumfer

outer

2

1

replace

2

3

Remove

check

ness

be

checked

hub

indicated

Bushing

20

seal

Oil

When

When

Wheel

bearing

operating

Visual

as

inner

010

20

to

grease

leakage

worn

or

bearing

from

grease

for

condition

sound

with

bearing

serviceability

follows

diameter

035

cracked

wheel

and

when

0

mm

is

detected

replace

bearing

Checkitfor

appearance

outer

race

standard

7878

filled

for

to

0

during

with

rotating

Rolling

installed

wheel

in

7888

disassembly

solvent

smooth

surface

wheel

on

bearing

and

ca

are

Inspection

King

Replace

worn

and

diameter

Fig

and

pin

when

clearance

direction

FA

7

bushing

damaged

between

exceeds

Exploded

seized

king

limit

listed

view

pin

rusted

and

below

of

bushing

bushing

or

excessively

toward

Standard dimensions

Inner

diameter

Outer
diameter

FA

3

mm

mm

Outer

bearing

to

20
0

to

787412594

to

52

2

0472

to

000

000

19

990

in

0

7870

51

987

in

2

0467

Inner

bearing

31

to

32

to12598

to

65

to

2

000

000

5591

988

64

987

5585

2

f

l

Visual

Serviceability

Standard

for

Wheel

CHASSIS

Bearing

Judgement

INNER

x

INNER

RACE

COLLAR

RACE

SMALL

Unserviceable

used

be

May

should

Rust

SURFACE

SURFACE

OUTER

be

SUR

FITTED

COLLAR

ROLLER

when

removed

FACE

RACE

minor

with

0

emery

OUTER

SURFACE

OUTER

SURFACE

ROLLER

SURFACE

INNER

LARGE

SUPPORTER

paper

RACE

FITTED

RACE

ROLLING

RACE

COLLAR

Flaking

Crack

Race

atU

8

O

15o

x

x

and

roller

The

or

improper

Cause

fatigue

following

However

causes

installation

shockisreceived

this

are

symptom

considered

from

occurs

the

s

O

t

l

l

ii

x

l

l

Service
before

x

life

the

Abnormal

Improper

Excessive

is

Gap

due

service

load

handling

tightening

excessive

to

rolling

life

overload

andaconsiderable

outside

due

Rapid

Abnormal

Tapped

heat

with

generation

load

thrust

a

hammer

on

while

the

race

removing

to

creep

FA

4

FRONT

AXLE

FRONT

SUSPENSION

Seizure

Scratch

Recess

made

or

striking

Wear

or

by

wear

pressing

Race

and

roller

a

l

l

l

0

u

6 6

g

o

ro

l

00

0

x x x

6

6 6

6 6

I

i

1

Cause

0

0
0
l

In

the

most

cases

seizure

occurs

the

as

result

of

grown

discoloringorflaking

Shock

is

Bit

foreign

6

Careless

carelessly

given

matter

installation

during

removal

installation

or

other

handling

scar

due

to

striking

Recess

made

Poor

6

lubricant

Intrusion

Wear

duetoexcessive

bit

by

quality

of

dust

Fitted

foreign

deteriorated

or

surface

preliminary

matter

is

worn

pressure

lubricant

remarkably

Biting

Fretting

Rust

Discoloring

6 6 6

6

6

The

serviceable

ing

with

wheel

can

6

6

be

solvent

bearing

if

discolor
removed

or

polishing

Excessive

6

The

Fretting

on

6

Temperature

bearing
becoming

The

long

Intrusion

touched

fitted

metal

bearing

period

preliminary

is

part

corrosion

contact

increased

stops

fine

drips

has

time

of

moisture

of

bare

with

discolored

rust

surface

moisture

and

been

hand

pressure

placed

to

on

fitted

during

inside the

the

grease

in

chemicals

and

or

faulty

brown

part

operation

a

highly

no

lubrication

or

black

means

bearing

is

moistened

moistened

etc

rustproof

or

fine

lowers

action

is

the

relative

when

condensed

for

place

bearing

has

been

slip

the

a

is

taken

by

is

Slight

grease

In

discoloring

most

the

cases

may

this

become

Occurs

when

like

preliminary

oxidized

oil

stain

due

pressureistoo

to

high

l

FA

5