J
DAT5U N PICK UP 4
MODEL 521 SERIES r
CHASSIS AND B ODY
i r I
NISSAN I f
J
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NISSAN MOT TOKYO r ev
JJN
20023 99999
R CO JAPAN
LTD
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IV
1
r FOREWORD
This seroice manual has been prepared for the purpose of aJsisti g seroice personnels
of our
distributors and dealers in
DA TSUN PICK PU model 521 Since
proper
maintenance
providing effective
se1 0e
and maintenance
of
series
and
seroice
are
absolutely
essential
satisfying
our
The following matters should be noted
customers this manual should be read carefully
for effective utilization of this manuaL 1
G N 521 U right Explanations in this manual are mainly concerning the model hand drive but will easily be referred also to the left hand drive models
2
PleaJe
refer to both thi
and 13
15 ENGINE SERVICE MANUAL
or LI3
for PL52 1 series for complete details information concerning the chaJsis and
L16 and L20 ENGINE SERVICE MANUAL
of
the
car
because this manual describes
body only 3 All part
names
in this manual conform to the DATSUN 521 PARTS CATALOG
only the genuine seroice parts listed in this PAR TS CA lA LOG must be used for replacements and
4 All information on
illustrations and
atispeci onsfi
contained in this manual are based
the latest product information available at the time ofpublication approval
5 It should be emphasized that those who use this manual are responsible for revising the contents according to
the SER VICE JOURNAL and SER VICE DAT4 AND
SPEClflCA 1IONS issued by the faclory which carry the Intest
servicing 6
approved factor
methods
Rights for alteration of specifications and methods at any time are reserved i
NISSAN
MOTOR
CO
JAPAN TOKYO
LTD
v
SECTI ON GI
GENERAL INFORMATION
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
I NISSAN I
MODEL VARIATION
GI
3
IDENTIFICATION NUMBER
GI
3
GENERAL VIEWS
GI
4
GENERAL SPECIFICATIONS
GI
a
FINAL
TRANSMISSION AND SPHDOMETER RATIO
GI l0
RECOMMENDED LUBRICANTS AND PERIOD ICAL MAINTENANCE
GI l0
I
JACKING UP AND TOWING THE CAR
GI la
t
NISSAN MOTOR CO TOKYO
LTD
JAPAN J
r
l
ll
GENERAL INFORMATION
I t O
Fig
Gl l
Short body pick up
ft
Fig
1
GI 2
Long body pick up
GI 1
r
CHASSIS
I I
f
Fig Gl 3 Double pick up
Fig
GI 4
GI 2
Van
GENERAL INFORMATION MODEL VARIATION Engine
Vehicle model
model
Pick up
R H drive
L H drive
521U
LS2I
V n 0
4 R4W63
Pick up
US2JU
ULS21
VS21U
VLS21
N521U
NU21
2
I
2 204 6
5
400
2
3 102 5000 300 6614
OtXl
4 F4W63 JI3
5
881
8
4 R4W63
4 R4W63
4 R4W63 2
000 2 1
204 6
NU2lT
5
Rem ITkl
L
LS21T
Double Plck up
TIM speed
Seating 3Plcity payload kg lb
F4W63
4
R4W63
4
R4W63
4
Double UNLS21
JlS
5
400
8 881
2
SOO
1
5
300
6614
Pick up VN521U
V
102 3
NU21
for US A
PL521TU ick J
L16
up
454 2
1
000
4 F4W63 for CANADA
PL52ITN LG521
GS21U 0
GNS21U
GNLS21
S
body
number
engine capacity
113
2
000 2 204 6 1
JIS
2
000 2 204 6 1
4 F4W63
LGS11T
Pick up
The
4 R4W63
4 R4W63 4 F4W63
GNLS21T
plate identifies
the
maximum hose power
SAE
type uf
car
wheel base
engine number and car number The body number plate is attached to the center of cowl top panel
GI 6
Body number plate
Fig GI
Engine number
Fig
Fig GI 5 Chassis number plate
Upper face of left side frame
near
front suspension
member
GI 3
Ill J
IU U I U I en
G 1 Z 1a o
in
mm
MDe
models
71
40 01
5012
81 I
1 I
1850172
IT
Jb 6PR
14
0Q
1035
1
6
61 II
II II II t
gM
j
PL521TN PL521TU Indicates
J
253019 4290168 4325170
f
if
91 3
Unit
13
T
Mark
up
pick
body
Short
Ii
B
0
710 28 iio
In In
Gl
Fill
jj r
Q m Z ma
M ci
r
Z oa
oz
or
0M
0
1
o
in
o II
71 I
mm
Unit
185146
2
88
2 40
II
IIII
N
up
0M
pick
i I I
1
I
body
Long
ii
9
GI
Fig
Cl U
r
CHASSIS
Ir
T 1
c
E E
1
c
o
J
0 o
I
I
1
S
o
9lE I M
L
1
B B
ii ai
C
M
r 0 M
O Z9 OZE l
N
1 I
OJ oi 0
IB lS OVEl I
I
o
11
Q
m
o o
IT
q
iaio I
00
t o
O
00 r
iXlOr O N
ON NN
J
1 11 ll
GI 6
m Zm a
r
ZT1 o a
oz
r in N o
mm
Unit
o
co
0
J1
N
1r e1
I
Oo tN
f I
ON C
bN OL N 00
e
tC 1
rf
1111
Van l1
GI
Fig
in
oN
N
Gl L
CHASSIS GENERAL SPECIFICATIONS 113
ENG lNE
52lU L521
Item
L521T
U52lU
V52lU
UL521
VL521
345 4
Ovralllenglh
mrn
in
4 325
Overall widlh
mm
in
1 575
62 0
1 570
Overall height
mrn
in
1 545
60 8
1 530 60 2
Wheel base
mrn
in
2 530 99 6
2 530 99 6
mrn
in
1 850 72 8
3 170
1 171
618
1
c
c
g
E
5
Length
830
32 7
1 040
65 0
40 9
is 0 0
Width
c
mrn
1430
in
1
3 56
320
52 0
1
2
1 245
1 240
49 0
48 8
u
16 5
900 35 4
Height
mrn
in
400
15 7
0
Front
mrn
in
I 250
49 2
1 250
49 2
o f
Rear
mrn
in
1
267 49 9
1 267
49 9
187
36 7
Minimum road clearance Vehicle weight
Pay load
u
420
Maximum speed
in
200
7 87
kg Ib
960
2
mrn
2
1 650
1 055
1 035
4 116
22818
kg Ib
1 000
2 204 6
km h MPH
125
1 78
400
2325 9 soo 1 102 J
881 8
125
300
4 661
78 1 1
E
Maximum grade ability
sin
8
308 0
0 221
362 0
Minimum turning radius
m
380 0
5 2 17 I
52 17 1
ft
2
382 0
g
1
2
Seating capacity Engine model V
AH
12
Clutch type
5
J13 12
40
Dry single disc Diaphragm spring
Model
2
2
JI3
Battery volt capacity
0
5
R4W63
40
Dry single disc Diaphragm spring
F4W63
R4W63
c
El Synchro type
Hypoid
Hypoid
Re circulating ball
Re circulating ball
Final gear type
Steering gear type oS
Warner
Warner
Front
Uni
Servo
Uni
Servo
Rear
Duo
Servo
Duo
Servo
Service
u
I
Parking ii Front
Independent torsion bar
Rear
elliptic leaf spring
Suspension
I
Mchanically operated on rear wheels
Rear
Semi
I
mmR rK
GI B
Mechanically operated on rear wheels Independent torsion bar Semi
LT
elliptic leaf spring
5
LI
1
3lb 102
1
loaded 500 kg
2
loaded 300 kg 661 41b
GENERAL INFORMATION
115
ENGINE
L16 ENGINE
N521U
VN521U
NL521
NL521T
UNL521
3 170
4 325
4 345
1 575 62 0 545
60 8
2 530
99 6
1
VNL52 I
1 570 1
1
320
G521
GNL52 I
LG521T
168 9
4 715 185 6
62 8
1
575
1 525 60 0
1 545 60 8
1
545 60 8
2 530 99 6
2 770
1 850 72 8
2 240 88 2
1 430
3 56
1 430
3 56
400
15 7
400
15 7
32 7
52 0
62 0
109 1
1 650
1 040
65 0
40 9 2
1 245
1 240
49 0
48 8
400
157
1 250
492
1 250
49 2
1250 49 2
I
250 492
1 267
49 9
1 267
49 9
1267 49 9
I
267 49 9
200 7 87
187
36 7
200 7 87
960
1
420
2
4 116
000 2 204 6
1
035
1 055
2 281 8
2 325 9
400 8818
4 84
135
0 296
17 2
00
2
1
2 366 0
2 lI5
115
40
12
12
Dry single disc Diaphragm spring R4W63
52
1
5
2
301 0
010
2 226 6
1 000
2 204 6
78 1
40
0 215
0 289
5 6
2
12
0 247
4 18
2 113
112
40
60
Dry single disc Diaphragm spring
R4W63
F4W63
Warner
Warner
115 12
40
Dry single disc Diaphragm spring R4W63
F4W63
R4W63
Hypoid
Hypoid
Hypoid
Hypoid
Re circulating ball
Re circulating ball
Re circulating ball
Uni
Servo
Uni
Servo
Uni
Servo
Uni
Servo
Duo
Servo
Duo
Servo
Duo
Servo
Duo
Servo
Mechanically
Mechanically
Mechanically
operated on rear wheels
operated on rear wheels
operated on rear wheels
Independent torsion bar
Independent torsion bar
Independent torsion bar
Semi
Semi
Semi
Independent torsion bar elliptic leaf spring 6 00
6 PR LT 14
6 00 14 8 PR LT
elliptic leaf spring
5 50
50 5
elliptic leaf spring
Mechanically operated on rear wheels
elliptic leaf spring
6 PR LT 14
6 00 14 6 PR LT
6 00 14 6 PR LT
14 6 PR LT
6 00 14 6 PR LT
6 00 14 8 PR LT
GI 9
F4W63
Warner
Re ciecula ting ball
Semi
84 4
135
17 1
L16
Diaphragm spging
Warner
7 87
5
Dry single disc
F4W63
125
351 0
1 17
200 1
5 87
140
368 0 52
2 1274
454 1 000
5 87
348 0
1
965
300 MIA
1 1023
140
253 0
5
900 354
5 16
GNL52 IT
2
1
3 56
PL521lN
1 595
1
I 430
G521U PL521TU
ENGINE
GN521 U
4 290
1 171
530 60 2
830
115
618
2 530 99 6
1 850 728
113 ENGINE
jt
r
CHASSIS FINAL
TRANSMISSION AND
SPEEDOMETER RATIO
L521T
NL521T
PL521TU
LG521T
GNL521T
PL52ITN
N52lU
52lU
NL521
UNL521
L521
UL521
GN52lU
VN52lU
G521U
V52lU
GNL521
UNL521
LG521
VL521
4 625
375 4
4 875
4 625
Item
4 875
Final gear ratio
4 625
Control system
f
R4W63
F4W63
Type
S
375 4
R4W63 Column shift
Column shift
Floor shift
U521
1st
3 657
4 243
5 000
2nd
2 177
2 558
3 014
3rd
1 419
589 1
1 685
4th
1 000
1000
1000
Reverse
3 638
367 4
5 146
u
Speedometer gear ratio
19 5
18 5
17 5
18 5
19 5
17 5
RECOMMENDED LUBRICANTS AND PERIODICAL MAINTENANCE
RECOMMENDED SAE VISCOSITY NUMBER ENGINE
OIL Multi viscosity oil
5W 20 I
IOW 30
40 10W
20W 40
Single viscosity oil 20W
L
20 30
lOW
GEAR
OQ
01 L SAE BO
SAE 90
30
20
10
0
10
20
30
40
IOe
22
4
14
32
50
6B
B6
104
OF
Temperature range anticipated
GI 10
18 5
CmZm a rJ1 1oo s s 1 ZC1 C rc CD rJ o
3D
SHEL
SheUXIO Special
MOBILE
ShelXIOQ Supc
Enco
ES O
40 IOW
BPSuperVl5Coda
I
BP
Eocol E
lOW 20W 30 40 SO
MotrOiJ
ex
HD
Lube 80 80 90 140
Lube
Mobile
Mobile
Er
lOW 20W 30 40 SO
Enco
80
90
u
ES O Oil
E
80
90 140
RetinlA
1X Don
Shel
Shel IlD
80
90
140
MobilegrascP
140
GP
E
Mobile Bukcl
5W lOW
l Hydr
Mulu 80
90
140
ex
HD40
H
Enco greas
Enco FlUid
Esso purpo
Essu Buke
c
oIHD
AtluJPcrmaGd
20W
BPEne
lOW lOW 30 40 SO
IJPGcuOil
HypogcarOil
1I0Er 90EI 140EP
IlrakeFIl lkl
I OEP 90EP 140EP
UP
BP
Ill
GTX20W
IOW
20
SW
ulw D lOW 20W
Canroli1 Cutrol Cunol
30 40 SO
CntrolHyp
Hypoy Cntrol
90
HI
Brake
B
40 XL2QW
frost Anu
Energ a
SO
CASTROL
Mobile
L2 20 3D SO
3Q
Frc
l lull
l ic
Gear Enco so
v
Super
Oil
Gear
20
Eoca
lOW
shclpuD
Oil
Mol r 3D 20W 40
or
80Er 90EP HOEP
SheUSpu
20
MobilO u
Slo
lOW lOW 30 40 SO
40 IOW
Extra
5
shclzon
Il
MobiJe Mobile 20
oz
z uI
20W
Oil lOW Oil
tNeO Uni o
z oa
O
lOW
3D
r
CadwlGirg
LM 90
Castwl
FlUid
fCareezt 5troIAnti v
lteh Cll
Crl n
C purpo
MolrOi
FivcSI u
CALTEX
30
Cunom MotalOn
40 20W
10W
20
lOW 20W 30 40
Star Five
UmveualThbn
80
MultproeThban
90
80
140
E
AIPurpow
Coflirmecl
FludHD
Mufaklti Marflk Brake
Anti
marked
u
CHEVRON
RPMSupromctI
30
MOlor
40 20W
IOW
RPMSpcla
Oil
Oil
20
VICl
Gc
Lubn
RPMMulli ScI
lOW 20W 30 40
Umvers al
80
90
140
RPM
Geu
Oil
ITXACO Mot r lOW
20W
O
140
Mol r lOW 20W
Havolin
30 40
UmvcnalGer
Lubn EPI O EP90
Multi
Extu
purosc Purposc
u
Ge
HD
RPM Grease
Lubm
20
Havoline
90
Jnt
Oil 3D
Lubneat
80
motive
80 90
Multi EP
140
AtluPcIl laGl lard
HUldoiO
and
Atlas BTake
Anti
oils
fren to
superHD
ColanFtre z
MurakUi MarfkAl BukeFlJ
Anti
Colan
permisble it
avilabe not
oils
MANUFCTRE
gradc 21048
l1048 MS
L
L
MulL MIL APIMS
Recu1ar MIL API
L210S APIGL
210SB GLS
MIL
MIL API
10924
L
Q
6
Z3z
a
l G
Clutch
G MIL
puroseG
Mul i
lkc BT
2108
Q
70R3
COLANT EFijZE
G MIL
ANTI
brand above the
case In
l
I s
1
Zt1 1Z
INTERVAL
I
II I
ct
36
72
24
48
X
R
33
69
22 46
X
X
X
X
30
66
20
44
X
X
X
X
27
63
18
42
X
X
X
X
24
60
16
40
X
X
X
X
21
57
14
38
X
X
X
X
18
54
gO
12
36
60
X
X
15
51
87
10
34
58
X
X
X
X
12
48
84
8
32
56
X
X
X
X
9
45
81
6
30 54
X
X
X
X
6
42
78
4
28 52
X
X
X
X
39
75
50
X
X
X
X
X
X
X
MAINTEC
26 2
3
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6
X
1
0
Replacmnt
R R
kilometrs
of
PL521TN PL521TU except els
Allm
top
miles
level
of
oil
POINTS thousand thousand
LUBRICATNG
of
of
Number
Number
jOints
necsary
gear
ball
except
if
diferntal oil e
eng
up
transmio
eck
bushings
heel earn
top
parts
linkage linkage pedal linkage box ball control supenio grease joint spline res voir water suthaofrt operatd gear linkage is ion pIes bearing shaft shaft elrato brake luid lIer lIer level joints oil
of
y
9
t
g
9
I
f
nec s brak cae dist Change Change up Refil Change Grease or
if
Cl
han ste ste
tra
all
wt
pro pro
Lubricate Lubricate Grease Check Grease Grease Grease Repack Grease Grease
z o0
mz
F X
r
R
24 48
36 72
X r
33 69
X
20 44
30 66 63
27
46
22
18
42
16
40
14
38
24 60 21
57
18
54 90
15
51
12
36 60
10
34 58
JAI R E
X R
87
IN
32 56
8
12 48 134
NANnECE
45 81
9
42 78
I IAI
llace Re
28 52
4 6
ent
30 54
6
26 SO
39 75
R
X X X
2 3 6
0 1
leak lor
eteilors
l etc
iles
I
nuts
oi
oi
con ection
d
TS N
l I Jsand too
PO oi
CE J SER
ber
Nu
lOusand t oi
Wpe
ber
oos
Nu
er
NE
ENG
eJtcept odels I
p
cleane
llace re
air llace Re
igniton tension idling Ioses
distrbutor cartidge ldge Iinder clearnce adiust belt
larl s
or
replace IiIoilter cartr or
Checl coed
llace Re
a
g
and
Wpe Mad
ele
iW
ater
ling li
ti
luel
Jgs l1
leak
io9
and
breal Wpe tralner Olt
li
ent
PL5
ani1o
pointS
c
Replace Reti9hen
line luel
oil
lor
lecillc s
bat e
engine e n g i n e and CMck Checl Ch e c l A d j u s t CMc l Adju Checl
e
al t
ian
J
v
MAINTEC
X
24
48
33
69
22
46
X
30 66
20
44
X
63
18
42
24 60
16
40
X
21
57
14
38
X
18
54
90
12
36 60
15
51
87
10
34 58
X
12
48
84
8
32 56
X
g
45
81
6
30
54
6
42
78
4
28
52
X
26
50
X
27
INTERVAL
X
36 72
39 75
X
X
X
2
3
JJ Vi
X
X
X
X
X
X
X
X
X
X
X
PL521TN PL521TU except els
Al m
X
0
POINTS kilometrs
miles
of
of
thousand
thousand
SERVICE
of
X
X
X
X
X
BODY Number
AS IS C
Number
X
cylinders defcts
or
brake brake for 11
clu clu
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
bolts
positon angle fjloaninget
nd
wear
o p e r a t i o n pedal sy tem leaks liners as embly absor e Iree
X
linkage
hoses play
X
X
X
pi ngs
of
X
X
6 1
X
X
X
X
X
etc
for
whe l turni g
parts box load
rotae universal d a m g e and s u p e n i o s t e r i n g shaft brake and b e a r i n g a l i g n m e t aiming mountigs cracks s h o c k c y l i n d e r hand lin gs ulic atighsn etighten whe l discs bal nce whe l ropel r light ody ake and
gear pre
for
for e
I
t
100 bra
hy an
an
Ir
I
wt
wt
fre
he
Ir
tes
Check Check coneti Check Check Overhaul Check Check Check Adjust Check Check Check Retigher Check Relighte Check Road
I
m ZmQ
60 30
INTERVAL
MAINTEC
R
X
X
X
X
R
X
X
X
X
X
52
24
48
X
X
21
45
X
X
18
42
X
X
15
39
X
X
12
36
X
X
g
33
X
X
6
X
X
3
X
X
X
R
54
Z r1 o Q
X
27
57
r
oz
X
X
X
X
X
X
X
r
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Replacmnt
X
X
6 0
necsary
whicevr
jf
top
miles
level
POINTS thousand
of
oil
For
LUBRICATNG Number
diferntal bdrraukme
months
of
necsary
gear
or
PL521TN PL521TU
A
first
if
up
C
L L
comes oil
transmio resvoir water water fluid
engine check brake co ling co ling or
heel eam
linkage shaft
distrbuo acelrto
bushings pedal
top
level
linkage
oil
box
operatd brake gear foot
hand
joints
parts
grease joint s u p e n i o shaft linkage ball
of
bearing
ste ring ste ring nip les whe l pro el r all
Change Change Refil Change Change Grease Lubricate Lubricate Grease Check Grease Grease Repack Grease U1
r
60 30 27
51
57 X
24 48
INTERVAL
MAINTEC
R
R
X
X
X
X
X
X
X
X
X
X
R
R
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
21
45
18
42
15
39
X
X
12
36
R
R
g
33
X
X
6
X
X
X
3
X
X
X
54
I C I IC C
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Replacmnt
X
X
X
6
X
0
X
X
X
X
X
X
whicevr
POINTS
sy tem I
leaks
of
for
thousand
nuts
SERVIC months
PL521TN ENGIE Number comes
first
P
A
conetis leaks
air
hoses
igntion cables tension idling spark distrbuo buret r lace lace filter ridge Inder clearn djust tension elt
0
c
or
or
c
val
an
hig fan
e
up ine
en
tu
fue
oil
for e
en
tion
lo se
of es
oper 5wit
for
for
pi ngs andwater gravity tension
type head
emison
S I
elment break r strainer mandanifold cleaner plugs fuel bolts timing
I
For
C
etc
points
or
521TU
control
V
miles
of
R
conelis operation vcoanlvterosl elctrial
of
specif belmpt pi ng mp peratio for
ion
ry
ba
air
ho air
em
fa
Replace Check Check Replace Replace Retigh n Adjust Check Check Check AdjuSl Engine Check Check Check Check Check Check Check Check
5z
Z n o0
r
Cm Z m 10
I
27
48
21
45
X
X
X
X
X
X
X
X
X
X
X
24
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
57
51
X
X
X
X
X
X
30
X
X
X
X
60
X
X
X
X
X
X
X
INTERVAL
MAINTE C
18
42
15
39
12
36
9
33
X X
X
X
54
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6
X
X
X
X
X
X
X
3
X
X
6
X
X
X
0
etc
whicevr
coneti s
POINTS miles
SERVICE thousand
or
PL521TN PL521TU
8
For
BODY months first Number comes of
CHAS I
bolts
pi ngs
of
wear
hoses
positon
linkage
a s e m b l y drums
for
parts
angle flange
whe l tuandrni g
and load boX pre
joint
cylinders operation caliper rotate universal liners sbore supenio ste ring bearing damge alignmet shaft aimng pedal sy tem brake m o u n t i g s s h o c k c y l i n d e r s brake brake hand lin gs retighen retighen whe l discs balnce whe l propel r body light
play iree
and
for
and
def cts
brake
brake
hydraulic
and and
front whe l whe l front
head
test
clutch clutch leaks Check Road R e t i g h n R e t i g h n C h e c k C h e c k C h e c k A d j u s t C h e c k C h e c k C h e c k O v e r h a u l Check Check for Check Check or
foot
e
ooJ
CHASSIS LUBRICANTS CAPACITY sA U Liter
41
Fuel tank l
Imp
measure
measure
gallon
gallon
10 8
9 0
Without heater
6 0
58 1
32 1
With heater
6 6
74 1
45 1
4 6
1 69
141
I 5 ai
MOO c
Ul
Coolant Without heater
c
60 c
lUl
With heater
6 8
1 80
50 1
113
115 Engine
3 0
0 79
0 66
Ll6 Engine
4 0
1 06
0 88
113
0 63
0 17
0 14
0 7
0 19
0 15
Transmission case
20
53 0
0 44
Steering gear box
33 0
0 087
0 073
Differential case
0 83
0 22
0 18
Oil pan
115 Engine
Oil filter Ll6 Engine
JACKING UP AND TOWING THE CAR
JACK UP Screw
jack
When jacking up Ihe front side
apply screw jack 10 the
front jacking point beneath lower link When jacking up the rear side rear
apply screw jack to the
jacking point beneath rear spring
In
no
event should
screw
jack be applied
to
other
points
Fig CI 12 FTont jacking point
GI 18
GENERAL INFORMATION Supportable point The front supportable points
are
two
places in frame
side member The
rear
supportable points are in front of the leaf
spring of frame side member
Fig
CI 13 Rear jacking point
Garage jack Note
When carrying out operations with the car jacked up be sure to support the car with stands
When jacking up the front side front
cross
member
or
apply garage jack to
center
portion of suspension
side
apply the jack to rear
member When jacking up the
rear
axle housing
Fig
Fig
CI t6 Front supporl4bk point
Fig
CI t7 Rear supportable
GI t4 Front jacking point
point
TOWING When towing forward
apply
a
rope
to
tension
rod
bracket When towing rearward
apply a rope
to leaf
spring
shackle
Fig
CI H
Rear jacking point
Note
GI 19
When towing be careful
not to
apply load rapidly
or
CHASSIS
Fig GI I8
Front towing point
Fig
GI I9
towing point
4T R
SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL
or
BULLETIN
No
DATE
t
PAGE No
SUBJECT
GI 20
SEen ON ER
GI
ENGINE REMOVAL INSTAllATION
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
I NISSAN I
NISSAN MOTOR CO TOKYO
JAPAN
LTD
ENGINE REMOVAL AND INSTALLATION
ER
1
lGIl El
lE
EtlG1tlE
REMOi
ll
lSl Il
l g
tlOtl
LLA ItlSfA At10
IlEfAOL II
ER 3
CON1EN15 ENGINE REAR ENGINE RON
RemoVal nstaHattOn
l 110l
ER
2
HI
3
ING MOUN ING MOUN
ER
H it
I
I
J
6
fig EJI
2
Engin
tment comp EA 1
or
th
L16
ngin
4
CHASSIS Removal
12
Disconnect speedometer cable
Disconnect flat attaching plug connector from Scribe alignment marks
on
hood around hinges and
reverse
lamp switch
remove hood from hinges 2
drain coolant
Completely
engine
and transmission 13
lubricant
Disconnect
remove
3
Remove blow by hose
from
cross
shift rod and
select
rod
shaft assembly by removing
and
then
cross
shaft
bracket from side member
rocker cover and air
cleaner 14 4
Remove radiator grille
5
Disconnect battery cable and remove battery offthe
Disconnect
front
exhaust
tube
from
exhaust
manifold
car
15 6
Take off both upper and lower radiator hoses
loosen
fIxing
bolts
of
radiator
and
take
it
by disconnecting it from
companion flange of gear carrier
Then
out
Disconnect propeller shaft
in
sequence
16 7
Disconnect fuel tube from fuel pump
8
If equipped with heater
Jack up transmission a little and then
remove
rear
engine mounting cross member by removing fixing bolts of engine mounting insulator mounting cross member and
remove
its hoses at engine
hand brake cable clamp
attachment
9
Disconnect
accelerator control
linkage and choke 17
wire at the carburetor side
Remove
bolts securing front engine mounting in
sulators to cross member 10 coil
Disconnect
wirings
for starter
alternator
ignition
oil pressure switch and thermal transmitter 18
II
Remove
clutch operating cylinder
and its
Hook with cable or chain to stringers
the other at the rear
spring
Fig Fig
hooks
ER J
which
are installed on engine cylinder head one at the front and
relurn
Removing clutch operating cylinder
ER 2
4 ER
Lifting engine for the J 1 J and J15 engine
ENGINE
REMOVAL
INSTAllATION
At this lifting lower jack placed under the transmission
gradually
draw offjack at adequate stage
check
hoist up engine
disconnecting parts
for
before
positions
actually disconnecting
observing the tension of wire and adjusting the position of chain block so that engine tilts in order to make it cleared off body At this stage take care that accessories installed on
the body side do not touch engine and transmission
Installation Reverse the removal procedure but do not connect any to
parts
the
engine
steadily
until
engine
mounting
insulators have been replaced since the power unit weight Note
8
Use fender
protecting cover
to
protect
body
is supported by them
from damaging b
When hoisting
or
operation carefully
jacking up engine
carry out
that component parts are
so
FRONT ENGINE MOUNTING
not damaged
The c
It should be noted that long body series vehicles
adopt flange
to
join propeller shaft and
When
disconnecting
remote
dismounting control
1 1
to
1 6
kg m
linkages
IT I I
8 0 116
1I lb
or
1 1 to
1 6
I
1 1 to 1 6 kg 0 11 6 It Ib Crank
2 S g m to 20 2 It Ib
center
m
line
I
116 6
to
20 2 I
Fig ER 5 Sectional view offront engine mounting for theJ13 andJlS engines
ER 3
kg m
S O 11 6 II Ib
I 8
however
remounting engine
J
j T
noted
used for both left and right that bracket and
support
and
member installation bolts are removed or reinstalled
I T
be
are
support for left side differ from those for right side When
mission and others adopt spline d
insulators
It should
sides
trans
same
cross
CHASSIS
T
T
2 6 to 3 2 kg
2 5 to 3 Okg m 181 to 21 7 ft Ib
m
1
O
I
jj l l
Fig ER 6 Sectional view offront engine mounting
for the L t6 engine
REAR ENGINE MOUNTING One type of rear engine mounting is used for engine with
long
extension
T
two types of rear
For engines with short extension
engine mounting for the J series engines
and L series engines
are
33 to 3 8 kg m 123 9 to 27 5 ft Ib
r
T
lIto 1 6 kg m 8 0 10 11 6 ft Ib
Fig ER 7 Sectional view of rear engine mounting
for the GN52t model 4 ER
used
v
ENGINE REMOVAL
INSTALLATION
i
to 4 3 to 5 0
T
kg m
31 1 to 36 2 ft Ib
I
I
i
T
1
5 to 2 1
10 8
to
kg m
15 2 ft Ibl
Fig ER 8 Sectional view of rear engine mounting
for the U V N521 models
I T
3 3 to 3 8
lu
iLn
kg m
23 9 to 27 5 ft Ib
d
T
j1
5 to 3 1
kg m
10 8 to 15 2 ft Ib
T
1
1
to 3 6
J
kg m
8 0 to 11 6 ft Ib
Fig
ER 9 Sectional view of rear engine mounting
for the PL521 model
Note
Arrow marks means that engine removal carries out at this place
ER 5
CHASSIS t1
DATE
lU rF
JOURNAL
or
BULLETIN
No
H
ll l liR
PAGE
PH RW
No
1
REF
SUBJECT
ER 6
rF REl
SECTION CL
CLUTCH
CD J
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
I NISSAN I
NISSAN MOTOR CO TOKYO
JAPAN
LTD
CLUTCH
CL
1
CLUTCH CONTROL
CL
5
SERVICE DATA AND SPECIFICATIONS
CL10
TROUBLE DIAGNOSES AND CORRECTIONS
CL 11
CLUTCH
L CLUTCH I CONTENTS
DESCRIPTION
CL 1
Disc assembly
CL 4
REMOVAL
CL 2
Release bearing and sleeve
CL 4
DISASSEMBLY
CL 2
INSPECTION AND ADJUSTMENT
CL 2
REASSEMBL Y
4 CL
REINSTALLATION
CL 3
Clutch assembly
CL 4
Release mechanism
CL 5
DESCRIPTION The clutch is of
type
a
single dry disc diaphragm spring
The major components are clutch
cover
engagement and withdrawal lever are used
Release bearing sleeve
pressure
plate diaphragm spring and wire rings The clutch disc is
to
control clutch engagement and disengagement
Each part of the clutch assembly is secured with rivets
provided with riveted plales on both surfaces and coil
Therefore
springs arranged in a link The coil springs absorb shock while engaging the clutch softening and smoothing clutch
when
a
trouble is uncorrectable
clutch assembly with
a
new
replace
assembly
o
44
732 44 1
732 1
dia
o M
e Xl
240 9 45 dia
g
255
10 04
dia
e CX1
Fig CLot Construction of clutch
CL 1
Unit
mm
in
the
CHASSIS REMOVAL The clutch same
ass
manner as
mounting
mbly is dimlounted primarily the engine assembly
the clutch
Thus
in the
2
Removing release mechanism
I
Remove dust cover from clutch housing
2
Remove
when dis
the Section TM
assembly efer to
return
spring
from
bearing
sleeve
and
separate the withdrawal lever from bearing sleeve
Transmission and other relative sections
3
Remove release
bearing and bearing sleeve from
front cover and remove withdrawal lever from withdrawal lever ball pin
Fig
CL 2 Clutch arsembly
DISASSEMBLY When loosen
remove
Withdrawal lever ball pin
3
Return spring
2
Withdrawal lever
4
Release
Fig
separating clutch assembly from flywheel
and
1
installation
bolts diagonally
and
3
CL 4
bearing
Removing release bearing and withdrdwallever
Withdraw release bearing from bearing sleeve by Ihe
use
of a bearing puller
gradually
CD Fig
Note
When
CL J
Removing clutch assembly
Fig CL 5
pport clutch cover bolts
sufficiendy
gradually
and
and loosen in
carefully
diaphragm spring tension is always applied
because
Withdrawing release bearing
D IU AfJ
separating clutch assemly from flyWheel
stallation
Release bearing
I
Thoroughly clean all disassembled parlo except for the disc assembly and release bearing wear
and check them for
crack and other defective conditions
CLUTCH Clutch
3
assembly
Press the master gauge plate down exactly 7 8 mm 307 0
1 etc
Check clutch cover
diaphragm spring presswe plate
for excessive
crack and damage When noise
occurs on clutch
2
wear
assembly replace
in
this
first
on
clutch assembly base plate
gauge
fully loosened 307 0
the height
H
from
clutch
cover
special tool 8T2oo58001
plate
special tool
is
cover
20051000 81
Then subtract the value
H
from 7 8 nun
The result indicates the distance by which
in
pressure
Line up distance piece
measure
mounting face to pressure plate contacting end with cover
Measuring and adjusting height of diaphragm spring
1
from clutch cover mounting face to
pressure with clutch cover installed on flywheel To do
is
pressed against flywheel when
mounted
is
That
the
clutch
initial pressure
of
diaphragm spring is indicated by a gauge when pressure plate is depressed by that distance with a press to which the pressure gauge is attached
T2005S001
360 kg 793 71b
If the pressure is less than
replace clutch cover as an assembly H
7 8
0 307
H
Stroke to be pressed 7 8
0 307
Clutch
facing thickness
Fig
2
Tfil
CL 6 Base plate and distance piece
Place clutch assembly
clutch assembly
on
on
distance piece
base plate stationarity
and set
Under this
condition distance piece is placed beneath pressure plate 3
Fig CL B Measuring pressure of diaphragm spring
Measure the diaphragm spring height from the upper
surface ofbase plate with vernier caliper depth gauge
Height of diaphragm spring end
43 to 45 mm
4
Adjust height of diaphragm spring by the use of diaphragm spring adjusting wrench special tool
1 693
to 1 772 in at diameter 44 mm I 733 in
ST20500000
if required
43 to 45 91693 to 1 772
BASE
PLATE Unit
mm
lin
Fig CL 7 Measuring height of diaphragm spirng
Fig G L9 Adjusting diaphragm spring height CL 3
CHASSIS Disc
assembly Jf oil
If facing is soiled with gIease
I
kerosene and dress
facing with a
clean off with
wire brush
bearing and sleeve
I
withdrawal lever and hearing sleeve contact
When
point is worn in step replace sleeve
Replace
facing if required
2
When
grease
occurs on release
Check disc for deflection and repair or replace if the
2
Release
leaks from release
bearing
or
noise
bearing replace release bearing
deflection at the outer circumference of facing exceeds the following value
Upper limit of the deflection 0 5 rom 0 0197 in at 85 rom
346 3
in radius
Fig CL 12 Fitting rekase bearing
REASSEMBLY Release mechanism 1
Fig
CL10
Checking disc fur deflection
Tightly
mm
0 0118 in
facing height above rivet is less than facing
is worn
unevenly
or
to the
place
on
bearing
turn
bearing with a finger and make sure that
bearing operates smoothly
Replace disc assembly if facing is worn to such an
extent that the
bearing
sleeve as shown in Figure CL 12 When bearing is installed
completely 3
fit release
3 0 2
rivets are
Apply multi purpose grease
loose
to the
following places
Bearing sleeve inside groove
Pack this recess
Fig CLot 1 Checking clutch facing for wear
Fig
CL 4
CL 13 Lubricated position on the bearing sleeve
CLUTCH REINSTALLATION
Withdrawal lever and bearing sleeve contact point lever
Withdrawal
ball
pin and withdrawal lever Clean clutch pilot bushing
contact surface
and
f1 it with multi
purpose grease
2
Install disc assembly and clutch assembly on flywheel
by
the
of
use
a
clutch
aligning bar
special
tool
00 ST20630
1
Withdrawal lever ball pin
3
Return 5pring
2
Withdrawal lever
4
Release bearing
Fig CL 14 Position on the withdrawal lever to which grease is applied 3
When grease is
withdrawal lever clutch housing
applied to the necessary places install
release bearing connect
and bearing sleeve
them with return spring
on
and
install dust cover on clutch housing Note
Apply
grease
compounded
with
molybdem
Fig
desulfide to lubricate main drive shaft splines
CL J 5
Installing disc and clutch assembly
CLUTCH CONTROL CONTENTS DESCRIPTION
CL 5
Reassembly
CL 8
CLUTCH PEDAL
CL 6
Reinstallation
CL 8 CL 8
Removal
CL 6
Inspection
CL 6
Removal
CL 8
Reinstallation
CL 6
Disassembly
CL 8
Adjustment
CL 6
Inspection
CL 8
CL7
Reassembly
CLog
CLUTCH MASTER CYLI NDER
OPERATING CYLINDER
Removal
CL 8
Disassembly
CL 8
ADJUSTING
Reinstallation
CLog
J nspection
CL 8
BLEEDING CLUTCH SYSTEM
WITHDRAWAL LEVER
CLog
CLog
DESCRIPTION The 521
series vehicles adopt hydraulic type clutch
control system The hydraulic type clutch control system consists of a
master
and withdrawal lever
The withdrawal lever is of an inner
fulcrum type
Cl 5
cylinder operating cylinder
pendent clutch pedal
CHASSIS
t I
I
I
I
I
I
Fig
CL 16 Clutch control
CLUTCH PEDAL Removal 1
Adjustment
Remove return spring
Adjust pedal pad height to RH drive
Loosen lock
2
nut of master
cylinder push rod and
selecting and
disconnect push rod end
138 5 mm
545 in
adjustment is made
without stopper The
for
by
applying shim s having adequate thickness
Be sure to use shims
having same thickness for both
upper and lower 3
Remove lock nut
remove
and washer of pedal shaft and
153 rom
2
Inspection Thoroughly below
all
disassembled
parts indicated
secure
Repair or replace
5 135
33 5
mm
in
for R H drive
and
150 mm
5 91 in
for L H drive
them with
if required Note
Pedal head rubber
Return spring
C t
A
L
a
Make sure that chassis grease has been applied
to
the
MG
marked
portions
two
places
Grease
it required
3 Pedal lever bush A
adjust pedal stopper properly so that the pedal
the position with lock nut
and carefully check them for wear damage and
new ones
2
Next
pad height is clean
other abnormal conditions
1
6 02 in for L H drive
pedal lever
t
noL JLr
W PI U
I
ll J
Do not saew in it more than 3 mm
Reinstallation
because
Reinstall clutch pedal in reverse sequence of removal
cylinder
CL 6
it
may
clog
the
return
j
0 1181 inl
port of master
CLUTCH
Adjusting shim Part number
30611
Thickness
27260
16
0 0630
30612 27260
0 8
0 0315
30613 27260
0 5
0 0197
Item
model R H
drive
L H drive
8 Fig
CL 17 Pedal height adjustment
CL18 Sectional view of clutch master cylinder
CL 7
mm
in
126 4 96 117
4 61
Multi purpose grease
CLUTCH MASTER CYLINDER
Fig
2
1
Applied
in
mm
mm
in
33 s 5 13S 150 0
5 91
r CHASSIS Removal
Reinstallation Reinstall
1
Disconnect pum rod from clutch pedal
2
Disconnect clutch line from master cylinder
the
master
cylinder assembly
sequence of removal and adjust s
reverse
follo
and
Adjust pedal height by changing push rod length
drain fluid
3
in
Remove securing bolts and
2 remove
Bleed air out of the hydraulic system
cylinder
master
assembly from vehicle
OPERATING CYLINDER Removal
Disassembly
Remove return spring
1
Remove riller cap and drain fluid
2
Pull back dust cover and remove snap
pusluod piston assembly primary
2
Di
3
Disconnect push rod from withdrawaHever
4
Release two bolts used to mount operating cylinder
nect clutch line from operating cylinder
ring Stopper
and return spring cup
assembly can be removed
to clutch housing
Inspection parts with brake fluid before
Thoroughly clean all
Disassembly
inspection Remove dust cover 1
Check
cylinder and piston for
uneven
wear
or
2
damage Replace if required
Remove
snsp
ring
All other parts
can
be
dis
assembled 2
Replace
cylinder
piston
primarily
cup
is disassembled
master
It must also be replaced when
wear or deformation due to
3
whenever
fatigue or damage is found
r
Check dust cover oil reservoir fIller cap and clutch
line for damage or deformation If abnormal condition is found replace with new one
It Reassembly Reassemble
the
ma5ter
sequence of disassembly
1
cylinder assembly
@t
in reverse
noting the following matters
The piston cup should be soaked in brake fluid
Fig
CL 19
Operating cyUnderdisassembled
before reassembly Install piston cup carefully so that it is
r 2
iIlW
Apply brake fluid sufficiently to cylinder and piston
J
Check all par
and assemble them
worn or
CL 8
damaged
especially piston cup
and replace if
CLUTCH Reassembly Reassemble operating cylinder in reverse sequence of disassem ly noting the following matters
Soak piston cup in fluid before reassembly
1
piston cup carefully
so that it
Install
is faced correctly
Apply brake fluid sufficiently to cylinder and piston
2
and assemble them
Reinstallation Reinstall the operating cylinder in reverse sequence of removal
I
Bleed air out of the hydraulic system
2
Adjust push rod so that withdrawal lever end play is
2 0 to 3 0 mm
0 0787 to
1181 0
in
in accordance wilh
the following instructions
Unit
mm
1
Lock nut
4
Release bearing
2
Adjusting nut
5
Diaphragm spring
3
Withdrawal
Fig
in
CL 20 Adjusting withdrawal lever play
WITHDRAWAL LEVER
JUSTING AD
Correct adjustment of the clutch withdrawal lever is essential
Insufficient free
travel
between
the
BLEEDING CLUTCH SYSTEM
release
bearing and the diaphragm spring fingers causes the clutch to
slip
ment
Remove
while excessive free travel affects full disengage
screw
dust
cap
from
operating
cylinder
of the clutch
The
clearance between the
diaphragm spring fingers
can
release bearing and the be
adjusted
at
2
the with
turn
drawallever end as follows
I
bleed
Loosen lock nut
Open bleed
screw
approximately three quarters of a
Attach a tube immersing the open end into a clean
container which contains a small amount of brake fluid
tighten adjusting nut and eliminate
3
clearance between the top of withdrawal lever and release
Fill
master
cylinder reservoir
with recommended
fluid
bearing Depress clutch pedal quickly while keeping it down retighten bleed screw and allow it to return slowly 4
2
Return
adjusting
nut I 3 4 turns from that position
and set adjusting nut stationarily with lock nut
Repeat this pumping action until the fluid entering the
When adjusting nut is returned I 3 4 turns withdrawal lever end is returned to 2 0 to 3 0 mm in
container is free from air bubbles
0 0787 to 0 1181
and clearance between release bearing and diaphragm
spring fingers is 1 2 to 1 5 mm
5
Screw up bleed
screw
on
a
down stroke of pedal
remove bleed tube and replace dust cap
0 0472 to 0 0591 in
CLog
CHASSIS SERVICE DATA AND SPECIFICATIONS
All 521 series
Clutch cover type
Diaphragm MF200K
Clu tch release lever Withdrawal lever end play
mm
in
2 0 to 3 0 0 0787 to O 1l81
Diaphragm spring to flywheel height
mm
in
43 to 45
1 693 to U72
Clutch disc
Single dry disc 20OCBL
Type Facing size Outer dia
x
Inside dia
x
Thickness
mm
cm2
Total friction area
200 x 130 x 3 5
in
sq in
362
7 87 x 5 12 x O 1378
56 I
Thickness of disc assembly Free
in
mm
Compressed
6 to 9 0
8
in mm
3386 0
to
7 6 to 8 0 0 2992 to
Numbe of torsion spring
3543 0
3 ISO 0
6
Allowable minimum deplh of rivet head from fscing surface
mm
in
3 0
O OI18
Allowable facing run
mm
in
0 5
O 0I97
mm
in
4 0
0 01 57
lOt
Allowable free play of spline
at
mdius 85
Clutch pedal Pedal height when not depressed
in mm
Free travel of pedal head
Pressing strength at full stroke Master cylinder
33 5
for RH drive
5 91
for LH drive
5 135 150 0
in mm
910 14
kg lb
3543 0
to 0 5512
13 2
29 I for RH drive
14 1
31 I
15 87
5 8
for LH drive
Clutch
Master cylinder diameter
mm
in
Capacity of clutch reservoir cc Imp pts US pts Operating cylinder
25
44 O 52 8
clutch
Operating cylinder diameter
mm
in
19 05 0 750
Tightening torque Clutch assembly securing bolt
kg m ft lb
1 5 to 2 2 10 8 to 15 9
CL 10
346 3
CLUTCH TROUBLE DIAGNOSES AND CORRECTIONS
Corrective action
Probable cause
Condition
Noises audible on
Excessively worn damaged or poorly lubri
Replace
pedal depression
cated release bearing
cannot
Seized release bearing and diaphragm spring
Replace the release bearing Clean diaphragm
fingers
spring fingers out
which
bearing
cased
being
be greased inside
bearing
with metal brush and smooth
contact
faces with felt polishers
Readjust pedal free travel correctly
Insufficient pedal free travel unhooked or broken clutch pedal
Weakened
the
Set
in
springs
position or replace
them
if
return and control springs
weakened or snapped
Weakened broken or unhooked clutch with
Replace the spring or hook it up as required
drawal lever return spring Excessive
play between clutch disc hub and
drive shaft spline
Replace
the
clearance
between hub of
new
clutch and
shaft is within 0 50
rom
0 0197 in
drive
endwise
clutch
disc and
ensure
and 0 20 rom 0 0079 in
that
crosswise
When clearances exceed above limits
replace
the drive shaft also
Noises audible on
Misalignment
pedal release
causes
slight
of
clutch disc to
movement
of disc
Set
hub
place
in
idling
or at
Broken
or
on
drive
shaft
audible with engine
it
set
rotation and check for no
respect of facing This noise is especially
level of clutch disc with clutch disc in
flywheel
under
run
ut
slight
using a
scriber
low speed weakened clutch
disc cushion
Replace the clu Ich disc
springs Insufficient pedal free travel
Set pedal free travel correctly
Weakened unhooked or broken clutch con
Check the springs for correct position and
trol and pedal return springs
replace them if necessary
Weakened broken or unhooked clutch with
Replace the spring or hook it up as required
drawallever return spring
Replace the
Distorted or worn drive shaft
drive shaft and clutch disc if
necessary
Excessive
play of release bearing
on
sleeve
CL 11
slip
Replace the worn parts
CHASSIS
Condition
C lu1ch drags
Corrective action
Probable cause
Insufficient push rod length
Adjust the push rod length correctly
Excessive pedal free travel
Adjust free travel correctly
Warped clutch disc
Set level of clutch disc if possible 0 mm 0 0197 in 5
Maximum plate run out
Roughened linings
Repolish
linings
with
a
metal
brush
or
should
be
replace them if necessary Improperly filled loose or broken lining
Replace
linings
clenched
with
Lining no
rivets
protrusion
to
avoid
damaging pressure plate and flywheel Incorrect release bearing
diaphragm to
spring
Adjust correctly
finger clearance Clutch disc hub forcing on drive shaft
Locate
cause
of trouble and
remove
it
if
possible otherwise replace the clutch disc Damaged drive shaft splines prevent the
Replace the drive shaft also the clutch disc
clutch disc from sliding
if required
Oil or grease on linings
cLcate the cause of oil or grea se leakage and
mrrect it
as
required
Clean or replace linings
Warped or damaged pressure plate or clutch
Replace defective parts
cover
Air
pockets
in the
hydraulic system
not
Bleed out completely
bled correctly Dirt or
foreign
matter
on
sealing faces of
Clean
replace piston
cup
if damaged
master cylinder piston cup
bleed the system
Air
Replace piston cup and bleed the system
pockets in master cylinder due to loose
and
piston Fluid leakage from cylinder
Replace piston
cup
if damaged
bleed the
system Low fluid level in reseIVoir
Top
up
with brake
fluid and bleed the
system if necessary
Clogged vent hole in reservoir cap promotes infiltrate past the seal
CL 12
Clean reservoir cap unclog the vent hole and
CLUTCH Condition
Abnormal lining
Probable cause
Corrective action
Insufficient pedal free travel
Adjust clutch pedal free travel correctly
wear
Driver
steps unnecessarily
causes
lining
wear
on
and damage
pedal to
this
release
Advise driver to discontinue wrong practice and step
clutch pedal only when
on
ne
bearing
cessary
Weakened or snapped pressure springs
Check pressure springs for tension as speci fied
and replace springs
if they
are
un
serviceable
Replace linings with new
Incorrectly installed linings
them correctly
ones
and install
Check clutch disc for center
alignment
Clutch drags
Oil or grease on flywheel pressure plate and
Remove cause of leakage clean flywheel and
linings
pressure
plate
and
thoroughly
replace
linings Loose disc linings due to poor rivet tightness
If
linings
rivets
are
not
Otherwise
worn
replace defective
replace linings and clutch
rivets securely
Clutch
disc hub does
not
slide
freely on
drive shaft spline
Remove any from
shaft
foreign matter or dirt deposits When
splines
trouble is still
present replace damaged parts
Warped or cracked pressure plate
Replace pressure plate
Misalignment
Locate
the defective
adjust alignment
or
point and if possible
replace distorted parts
J
Check
Stiffened hydraulic control mechanism
spring
tension
If necessary
take
down pedal and lubricate components Worn out lining
Install new
linings and
cIu tch disc
pressure
not
Clutch slips
Insufficient clutch pedal return travel to
due
the control and pedal return springs being
weak
or
make sure that the
plate and flywheel are
damaged
Locate cause of failure and replace defective
springs
misadjusted
Weakened or broken diaphragm spring
Overhaul clu tch and replace springs
Oil or grease on linings
Remove cause of leakage and replace linings ifcleaning is ineffective
CL 13
CHASSIS
a
Corrective action
Probable cause
Condition
Replace linings
Worn or burned disc linings
ij
Overloaded
master
cylinder
d
to a
re
Overhaul
the master
cylinder replace the
piston cup if swollen or damaged and clean
stricted transfer port
the transfer port bleed the system
SERVICE JOURNAL OR
BULLETIN REFERENCE
I JOURNAL
or
BULLETIN
No
PAGE No
DATE
iO
SUBJECT
1
I
J
f
I i
1
I l I
1 CL 14
I SECTION TM t
TRANSMISSION
em l
DATSUN PICK UP MODEL 521 SERIES
CHASSIS
I
BODY
NlsSAN I
NISSAN MOTOR CO TOKYO JAPAN
LTD
1
TRANSMISSION
TM
TYPE F4W63 TRANSMISSION
TM 12
TRANSMISSION GEAR CONTROL COLUMN SHIFT CONTROL SYSTEM
TM 15
SERVICE DATA AND SPE CIFICATlONS
TM 18
TROUBLE DIAGNOSES AND CORRECTIO N S
TM 21
lr r
TRANSMISSION TRANSMISSION
CONTENTS DESCRIPTION
TM
l
Gear and shaft
TM
8
SPECIFICATIONS
TM
l
Balk ring
TM
8
REMOVAL
TM
3
Shifting
TM
8
DISASSEMBl Y
TM
4
Oil seal
TM
9
INSPECTION
TM
7
Rear engine mounting insulator
TM
9 9
insert
Transmission case and rear extension
TM
7
REASSEMBLY AND ADJUSTMENT
TM
Bearing
TM
7
REINSTAllATION
TM 12
DESCRIPTION 521
Datsun
series
vehicles
adopt type
column
shift
forward
I reverse
F4W63
4 forward I reverse
Both
the
type
R4W63
consist of transmission gear assembly
housing
are
R4W63
transmission
4
housing and transmission case are combined unit
and
The
transmission
floor shift
transmission
cover
and type F4W63
transmission
made easily
rear extension
case
housing
and
case
With this construction
is
single provided with a bottom to
a
can be
maintenance service
This chapter mainly describes about the type R4W63
The transmission case and rear extension
transmission
made of aluminum alloy metal The clutch
SPECIFICATIONS
L521T
NL52 IT
PL521TU
N521U
GN521U
LG521 T
GNL52 IT
PL52ITN
NL521
GNL52 I
Final gear ratio
G521U
UL521
L521
LG521
V521U
4 875
4 625
375 4
4 625
375 4
VL521 4 875
4 625
Type
F4W63
R4W63
R4W63
Control system
Floor shift
Column shift
Column shift
1st
3 657
4 243
5 000
2nd
2 177
2 558
3 014
3rd
1 419
1589
1685
4th
1 000
1 000
1 000
Reverse
3 638
367 4
5 146
s
6 s os
E
Speedometer gear ratio
19 5
a
b
18 5
18 5
17 5
17 L
Oil capacity Note
VN521U
U521U 521U
VNL52 I
Item
os
UNL521
2 0
See Figure TM l 17 L 3 6 US pts 3 0 Imp pts 2 0 L 4 2 US pts
5 Imp pts 3
TM 1
17 5 17 L
2 0L
19 5 2 0L
18 5 17 L
2
t 0
CHASSIS
l J 1
2
J
3
Applied model
Extension housing type
short
GN521U GN521 G521U LG521 N521U NL521 UNL52l VN521U VNL521
2 long
3 short
521U L521
52IU VL521 L521T
Fig
TM j
LG521T NL521T GNL521T PL521TU PL52lTN
R4lV56 and F4lV56 transmissions
TM 2
U521U UL521
TRANSMISSION REMOVAL For transmission dismounting
applies Refer to Section
ER
the following procedure
Engine Removal
of this
Manual
I
Disconnect battery cable from terminal
2
Remove
starting
motor
and bolts used
to
attach
du tch housing to engine
Jack up vehicle and support it with four stands
3
Fig
Recommend a hydraulic hoist or open pit be utilized if available
4
6
Disconnect front
1M 3
Disconnect
Detaching propeller shaft
speedometer
drive
cable and back up
lamp switch cable from transmission extension housing
exhaust tube from exhaust mani
fold
7
Remove cotter
shift levers
pin
Remove
and disconnect shift rods from
cross
shaft assembly from transmis
sion case
8
Remove clutch
operating cylinder from clutch hous
ing 9
Apply a jack beneath oil pan and support engine
careful not to apply jack to oil pan drain plug
Be
When
applying jack apply a wooden block between oil pan and jack to protect oil pan from damaging 10
Remove
rear
engine mount from transmission and
cross member
rw o
hT 0
I
V
r@
co
Q
S I
Cross shaft
4
Exhaust manifold
2
Back up lamp switch cable
5
Propeller shaft
J
Speedometer drive cable
Fig 5
I 11
Pull
TM 4 out
TM 2 Bottom view of vehicle
Rear engine
mounting bolts
Removing rear engine mount
transmission
portion of extension
on
to
rear
cross member
once
place
rear
and pull it down
toward fron t
propeller shaft Seal the end of rear Note
extensi9n housing to prevent oil leakage except equipped with
I
mounting bolts
Fig
Remove four bolts from companion flange of gear
carrier and detach
Rear extension
When dismounting transmission be careful
damage clutch diaphragm spring hub spline
flr r shift vehicle TM 3
not to
CHASSIS 4
Remove 14 bottom cover
securing bolts and remove
bottom cover from transmission
5
Remove
speedometer pinion
and remove rear exten
sion
Note When
rear
extension cannot
lightly tap it with
a
be
removed easily
plastic or wooden mallet
Fig TM 5 Dismounting transmission DISASSEMBLY For transmission disassembly
the following procedure
applies The casings are made of aluminum alloy metal Be careful not to damage it 1
Drain gear oil from transmission
2
Remove dust cover
release withdrawal
lever return
spring and remove withdrawal lever and release bearing from clutch housing
Fig
6
TM 8
Removing TNr eXtension
CD used to fix crosS shaft and rings @ and thrust washers and
Remove lock pins
select link withdraw
snap
cross
withdrawing
shaft together
cross shaft
with outer
lever When
be careful not to damage oil seal
lip with groove for snap ring
Removing release bearing and withdrawal lever
Fig
TM 6
3
Remove five front cover securing bolts and remove
front cover
Fig
7
TM
Removing cross sluft
Double intermesh counter gear and reverse idler gear
and loosen main shaft lock nut
Fig
TM 7
Note
Remo11ing front co
4 TM
Loosen interlock plug previously
I
I I
i
I
I
I
I I
I
I
I
I I I I
I
I
I
J
I
I
I I I
p with a drift
using a fork rod pin punch special
ST23510 0 tool
Removing fork pull out rod
ear
I
I
I
I I
fnt
I
I
I
I
I
i
r
I
I TRANSMISSION
I
I I
II
i
I I
I
J
I
I
I
I
I
I
I
Fig
I
I
12
I
TM 12
Driving out retaining pin
Remove main shaft assembly from
rear
side and
main drive gear from front side Note
I
When main cannot
I
shaft assembly and or main drive gear
be removed easily
lightly tap transmission
case with asticor wood mallet
I
Fig 9
TM l0
Remove front
reverse idler gear and
10
Remove
Remol1ingcountergear
and
rear
snap
rings
and
withdraw
shaft
plug from interlock hole
and take out
spring and ball
GM
Note Be careful not 10 lose spring and check ball
ain drive gear
Fig
TM 13
0
Main shaft assembly
Removing main shaft assembly
lvl i l l
@ O
c V
ili
V
Fig TM l1 RemoVing interlock hok plug II
Drive out retaining pin used to fIx fork and rod by
Fig
TM 5
TM 14 Main shaft gear disassembled
CHASSIS 13
Remove snap ring @ from main shaft front side
synchro assembly @ and 3rd gear
4th 3rd
and
remove
@
See Figure TM 14 for part identification numbers
14
Remove main shaft lock nut
viously
@
loosened pre
and remove reverse gear and sleeve
Fig
Fig
IS
TM 15
apply the front end
bearing puller special tool ST22130000
and withdraw bearing retainer washer
Removing bushing
Removing map ring
When removing main shaft gear
of 1st gear to
TM 17
j 1st gear j and thrust
@ simultaneously by using
a
press
See
Figure
TM IS
f@
@
1
Snap ring
2
4th 3rd
3
8
synchronizer
special toot ST22130000
asscmbly
depress main shaft forward
ht 2nd synchronizer
and with draw bearing
assembly
j
rIng Mu
TM 16
together with ht gear
4
1st gear bearing bushing
5
Thrust washer and ball
6
Main shaft
iog
7
Main shaft bearing
nizcr assembly and 2nd gear
Fig Fig
Support this end with
TM 18
9
Support this cnd
and with
draw 1st gear bearing
Cross sectional view
bush
totethcr with synchro
of main shaft gear
Removing bearing
Ir
pm
the front end
f 2nd gear
synchroassembly
@
@
and withdraw 1st 2nd
2nd gear
@ and bushing @ all
17
To
disassemble
synchronizer
spread springs from both ends
together by using a press
TM 6
assembly
remove
TRANSMISSION a drift Push out counter shaft from rear to front with
8
or other proper tool
using
a
fork rod pin punch
jJ special tool ST235IOOOO
Removing fork pull out rod
and take out counter gear
Fig 12
1M 12
Dril1ingoutretainingpin
Remove main shaft
assembly from
rear
side
and
main drive gear from front side Note
When main shaft assembly and or main drive gear cannot
be removed easily
lightly tap transmission
case with asticor wood mallet
Fig 9
Remove
TM l0
front
Removingcountergear
and
rear
snap
rings
and
withdraw
e idler gear and shaft rever
10
Remove
plug
from
interlock hole
and take out
spring and ball NOlE
G
Be careful notlD lose spring and check ball
Main drive gear
0
Main shaft assembly
Fig lM 13 Removing main shaft assembly
i
l c @
d1 I
Fig lM 11 RemoVing II
interlcck hok pL g
and rod by Drive out retaining pin used to fix fOlk
Fig
TM 5
lM 14 Main
shaft gear disassembled
r
CHASSIS 13
and
from main shaft fron t side
Remove soap ring
synchroassembly
4th 3rd
remove
@ and 3rd gear
@ See Figure TM 14 for part identification numbe 14
Remove
viously
main
shaft lock nut
@
loosened pre
and remove reverse gear and sleeve
Fig
Fig
15
TM 15
Removing map ring
When removing main shaft gear
of 1st gear to
TM 17 Removing bushing
apply the front end
bearing puller special tool ST22130000 @i 1st gear ill and thrust
and withdraw bearing retainer washer
@ simultaneously by using a press See Figure
TM IB
I
Snap ring
2
4th 3rd
3
8
synchronizer
Support this end with pecial tool ST22 I 30000
assembly
depress main shaff forward
1st 2nd synchronizer
and with draw bearing
assembly
together with I st gear
4
1st gear bearing bushing
5
Thrust washer and
6
Main shaft
iog totether with synchrcr
7
Main shaft bearing
nizer assembly and 2nd gear
Fig
TM 18
9
ball
Support this end
and with
draw 1 st gear bearing bush
Cross sectional view of main
shaft gear
Fig TM 16 Removing bearing
ppot the
front
end of 2nd gear
assembly synchro
@
@
and withdraw 1st 2nd
2nd gear
@ and bushing @ all
17
To
disassemble
synchronizer
spread springs from both ends
together by using a press TM 6
assembly
remove
TRANSMISSION INSPECTION Thoroughly clean all disassembled parts with solvent
cJ
and check
them for
and other defective
damage
wear
conditions
@ Transmission
o
Coupling sleeve
3
Synchro hub
2
Shifting insert
4
Spread spring
TM J 9
rear
extension
Clean them with solvent thoroughly crack which may
When bur
cause oil
leaking
and check for
and other defective
remove
other
pitting and or
damage exists
on
joint repair or replace
Synchronizer disassembled
To disassemble main drive gear
and
conditions
1
Fig
18
9
cr
case
snap
2
Remove adhesive from
3
Repair or replace dowel pin
installing surface completely knock pin
if damaged
ben t or warped
ring
from front side by using snap ring pliers 4
Replace
rear
extension
bushing
if interior is worn
unevenly
Bearing I
Thoroughly clean bearing dry
and remove dust with
compressed air 2
When ball bearing inner race and
sliding surfaces crack
or
are
worn
unevenly
out of round of ball is
cen ter
race
ball
unsmooth due to
excessive due to wear or
rough surface replace bearing with a new one Fig TM 20 Removing snap ring 19
Remove main drive gear bearing with bearing puller
special tool ST30030000 and press
3
Replace needle bearing if worn or damaged
4
Replace rear extension bushing
if worn or cracked
V t t
ii t
ir
rig TM 21
Removing main drive gear bearing
Fig
TM 7
TM 22
Inspecting baIl bearing
CHASSIS Gear and shaft
End
5
plays
of I st 2nd
and 3rd gears should be in
range from 005 to 0 15 mm 0 0020 to 0 0059 in I
Check gear
for
damage and or crack
wear
and
the end play is deviated from this range
replace as required 2
Check
shaft
When
select proper
soap ring again for
crack
wear
and
worn
spline
if
out run
at rear
Replace if required
3
Check main shaft for straightness
Replace
main shaft with a
end exceeds maximum l
Maximum
out run
new
one
t
0 15 mm 0 0059 in
Fig Balk
TM 25 Measuring ge IT end pl4y
ring
Check balk rings for wear pitting chip and
or
bur
Replace as required
Fig 4
TM 23 C
s
1in cking m
ft fOT straightness
limit
recommend
both drive
0 05 to 0 10 mm
Wear limit all g ars
0 20 mm 0 0079 in
ring
gear and check gap between balk ring end face and This gap should be within 1 2 to
16 mm 0 047 to 0 063 in
0 031 in
and
When gap is less than 0 8 mm
replace balk ring with a new one
It is worn
excessively
driven gears are replaced as a set Standard all gears
Place balk ring in position on cone of each gear Push to
clutch tooth front face
Measure backlash of each gear When gear is worn
excessively beyond
2
0 0020 to 0 0039 in
Fig
TM 26 Balk ring tcrcone installing dimension
i
Shifting insert Replace if worn excessively or unevenly deformed or Fig
TM 24 Measuring gear backlash
damaged
8 TM
TRANSMISSION Oil seal if lip is deformed
Replace
worn or cracked
or when
snap ring is dropped off
Rear
engine mounting insulator
Replace
if weakened deteriorated
or cracked
REASSEMBLY ADJUSTMENT Reassemble
transmission
in reverse sequence
of dis
assembly
1M 28
Fig
When reassembling note the following matters
3
Main shaft and gear
When
drift
Driving bearing bushing
fitting main shaft ball bearing
transmission adapter
use
a
hollow
special tool ST23800000
to depress bearing inner race firmly Note
1
Snap ring
4
1st gear bearing bushing
2
4th 3rd
5
Thrust washer and ball
assembly
6
Main shaft
Ist 2nd synchronizer
7
Main shaft
3
synchronizer
Be sure to install thrust
and ball wash
bearing
assembly
Fig
TM 27 Main shaft assembly
Fig 4 1
For both I st 2nd and
blies
4th 3rd
synchronize
assem
For
proper
install synchronizer hubs toward correct lifec
1M 29
4th 3rd snap
Fitting main shaft bearing
synchronizer hub ring from
snap
select
ring
those listed below
so
synchronizer hub end play is minimum
tion
2
use a brass
Note
Part number
When fitting I st gear needle bearing collar to shaft
a
mm
in
drift
If end of collar is damaged
deviated
Recommend
a
piece
1st gear end play is
32263 14600
40 1
to
32263 14601
45 1
to 1 50
45 1
32263 14602
1 50 to 1 55
32263 14603
55 1
32263 14604
1 60 to 1 65
0 0551 to 0 0571
0 0571 to 0 0591 0 0591 to 0 0610
of mild metal be
applied while tapping b
Thickness
Do not use wooden mallet
TM 9
to
1 60 0 0610 to 0 0630
0 0630 to 0 0650
that
JfIl
CHASSIS 5
disassembly
To lock main shaft install main shaft in transmis
sion
double
case
intermesh gears
with the rated tightening torque 8 0 to 11 0 kg m to 79 5
lb ft
For rear side tluust washer five types as
nut
shown in the
following table
57 8
proper thrust
washer so that counter gear end
tighten lock
0 05
and fIrmly bend lock washer
to
0 15
mm
available
are
0 0020
0 0059
to
Select a
in
play is when
assembled
Note
Install thrust washer 132225 A0900
Part number
G
o
Lock washer
TM 30
Fig
Thickness
in front side
mm
in
32225 A0900
35 2
to
40 2
0 0925 to 0 0945
32225 A090 I
40 2
to
45 2
0 0945 to 0 0965
32225 A0902
45 2
to 2
50
0 0965 to 0 0984
55 2
0 0984 to 0 1004
32225 A0903
2 50 to
32225 A0904
2 55 to 2 60 0 I004to 0 1024
Lock nut
Tightening lock nut
6 Main drive gear of
Reassemble
main
drive
gear
in
disassembly
For
snap
ring
select proper
those
below
that
drive gear end play is
listed
so
reverse
sequence one
Reverse idler gear
from
Reverse idler gear is reassembled in reverse sequence of
disassembly
minimum
For snap ring five types as shown in the
following table are available Select a proper snap ring so that
play is 0 05 Part number
Thickness
mm
149 to 1 55
0 0587 to 0 0610
32204 08001
156 to 1 62
0 0614 to 0 0638
32204 08002
1 62 to 1 68
1 0638 to 0 0661
32204 08003
1 68 to 1 74
0 0661 to 0 0685
32204 08004
74 1
0 0685 to 0 0709
32204 16500
1 80 to 1 86 0 0709 to 0 0732
32204 16501
1 86 to 1 92
to 1 80
idler gear end
0 0020 to 0 0059 in
to 0 15 mm
when
assembled
in
32204 08000
reverse
Note
Install snap ring
32285 14600
Part number
0 0732 to 0 0756
Thickness
in front side
mm
in
32285 14600
1 15 to 1 25
0 0453 to 0 0492
32285 14601
35 1
45 1
0 0531 to 0 0571
32285 14603
I 45to 1 55
0 0571 to 0 0610
22285 14604
1 05 to 1 15
0 0413 to 0 0453
to o
7
Counter gear
Counter gear
is reassembled
in reverse sequence of
TM 10
TRANSMISSION Shift fork and operating lever i l
Rear view
o
3
J
Forward
1 c
1
@
Reverse shift fork
shift rod
5
3rd
4th shift fork
Operating lever ass y
3
Reverse check
41st
2nd shift fork
TM 31
Layout ofshift fork and operating lever
Fig
shift rod
6
Operating
ver ass
shift rod
y
Install each fork rod and shift fork
Note
shift fork
8
Pay attention
b
Be sure that there is
to
no
installing direction
gap between fork rod
and shift fork
2
Install each fork rod together with check ball plug
check ball check ball spring and interlock plunger by
using a fork rod guide special tool ST23620000 Fig
Note
a
I nstall
fork rod in
a
position where fork
In standard
3
When
position upper surface of plug is
installing plug
be
sure to
Set
Insert
up
operating
cross
lever
shaft into
to
case
lever stationarily with lock pin
apply
the
correct direction
Assemble thrust washer
snap ring and operating lever in case and set operating
flush with upper surface of adapter c
Layout of check ball
rod
check ball groove is coincided with ball b
TM 32
thread
See Figure TM 3 I
Lock pin tightening torque
locking agent
TM 11
0 to 3
4 0
0 2 to
3 in lb 0
cm kg
I f I f 0
CHASSiS REINSTALLATION Remount
transmission
in
reverse
sequence
ofdis
mounting
Q JwaSherl 2JCross slirlt Fig
fLockPin
TM 33 Installing cross shaft
TYPE F4W63 TRANSMISSI ON CONTENTS DESCRIPTION
TM 12
INSPECTION
REMOVAL
TM 13
ASSEMBLY
TM 14
TM 13
Shift fork
TM 14
AND INSTALLATION
DISASSEMBLY
DESCRIPTION The
AND
REPAIR
TM 14
tion is the same as that of the type R4W63 tran
type F4W63 transmission is used especially for
Thus
floor shift type vehicle Generally however the construe
in this
t
Fig
TM 34
yp T
chapter
description
control system and relative matters
F4W63 transmission TM 12
is made
ssion
only for the
TRANSMISSION REMOVAL AND INSTALLATION Primarily
Remove speedometer drive pinion assembly
7
Remove eight rear extension housing securing bolts
procedures for removal and installation of
the F4W63 transmission mission
6
are
the same as R4W63 trans
For the F4W63 transmission however removal
and remove rear extension housing Disengage s iking rod from fork rod gates
and installation of shift lever are required
DISASSEMBLY Drain transmission gear oil
release withdrawal lever
Remove dust cover
2
spring
remove withdrawal
lever
return
and release bearing from
clutch housing Remove five front
3 front
4
cover
securing bolts and remove
cover
Remove 14 bottom cover securing bolts and remove TM 37
Fig
bottom cover from transmission case 8
Removing rear extension
Unscrew three check ball plugs and remove springs
and balls
9
Drive out
retaining pins used to secure forks to fork
rods and remove rods and forks
10
Move
gear
and at the same time lock main shaft Release main
Ist 2nd
and
4th 3rd
coupling
sleeves into
shaft nul
11
Withdraw counter shaft and
remove
counter gear
together with needle roller bearings and spacers Fig
TM 35 Removing bottom cover 12
5
Remove
clevis
pin
used
to
secure
striking
Release
remove reverse
control lever
Fig
reverse
rod to
1M 36 Control arm
Fig
TM 13
idler gear
secu
ing snap ring and
idler gears and shaft
TM 38
Removing reverse idler gear
I
CH ASSIS 13
Remove
four
bolts
used
to
secure
main
shaft
bearing retainer to transmiSsion case
Fig
TM 40
Drawing out main slraft assembly
Draw out main drive shaft
15
INSPECTION AND REPAIR Fig
1M 39
RemovingmainslraftbNring retiD
For detailed procedure for inspection and repair refer to the
section covering the type R4W63 transmission
Service
data
and
specifications
are
shown in page
TM 18 14
Draw out main
shaft assembly from transmission
ASSEMBLY
case
The transmission is assembled in reverse sequence to
disassembly
Refer to the instructions and notes described
in the section covering the type R4W63 transmission
Shift fork
h f
t
1
f
l
21st
Fig
2nd shift fork
TM 41
shift rod
Layout ofshift fork and operating lever
TM 14
l
TRANSMISSION I
Install shift forks
1st 2nd and
4th 3rd
on
reverse shift fork and
sleeves and apply 1st 2nd fork rod
2
Place 4th 3rd
interlock
plunger
in
Place interlock plunger in the position
3
coupling
the
position
and
fit
and assemble
fork rod
Secure each fork to fork rod with retaininjfpin rp
4
fork rod
r
TRANSMISSION GEAR CONTROL COLUMN SHIFT CONTROL SYSTEM
CONTENTS
REMOVAL
TM 16
ADJUSTMENT
TM 17
INSPECTION AND REPAIR
TM 17
Shift linkage
TM 17
INSTALLATION
TM 17
Select linkage
TM 17
31 To be greased
lSE
1
Control rod
4
Shift lever
1
Select rod
2
Lower bracket and knock
5
Select lever boss
8
Shift lod
3
Cross shaft
6
Select lever
Fig
TM 42 Control system
4 forward
TM 15
speed transmission
When disassembled
r
CHASSIS REMOVAL Remove steering wheel assembly
o Snap ring 0 Fig Fig 2
4J TM
Removing sleering w
Remove steering column shell cover
I
turn
l
Controllcver pivot pin
TM 46
C washer
Withdrawing hand lever
Remove C washel
4
signal and
lighling switch
Fig
44 TM
I
Lock pin and lock wire
4
Shift lever and shift rod
2
Select lever and select rod
5
Select lever boss
3
Lower bracket
Removing sleering column slrea co
Fig
47 7M
Separating
ever
and rod
5
Separate shift lever from shift rod
6
Separate select lever from select rod
7
Remove lock pin and select lever pivot bolt
8
Withdraw select lever
boss
select lever
and shift
lever
9
Loosen
lower
bracket up to such
an
extent
that
positioning knock pin can be removed Fig 3
45 TM
Removing turn signa and lighting switc
Remove snap
ring and control lever pivot pin
10 and
Depress control
control rod
TM 16
remove
it
from
turn lower
bracket to change direction of
and remove it
toward driver s compartment
upper support
withdraw hand lever
rod downward
TRANSMISSION The individual
Note
joints use small washers and snap
When
rings Before removing check them for reinstalling
parts
apply chassis
installing
grease
to
the
following
sequence and direction I
Select lever pivot bolt bushing
2
Select lever boss select lever guide unit
3
Reverse check unit
4
Insert and change lever units in upper portion of
INSPECTION AND REPAIR Check all sliding parts and other components for wear and
defective
other
conditions
Replace
as
required
control shaft
INSTALLATION Install control system in reverse sequence of removal
Cross shaft both frame and transmission sides
5
ADJUSTMENT J Figure A
CD
100
C 24 mm 10 94
nli
n J
Steering center line
oc Control rod center line
77
CID
mm
3 03 in
M nnl l @
Ef
II
Figure B
II
1
Shift lever
5
Reverse check
9
Outer lever select
2
Select lever
6
Trunion out
10
Control rod
3
Select rod
7
Shift rod
11
Beneath
4
Control rod
8
Outer lever shift
Fig
Shift
steering wheel
TM 48 Transmission control linkage assembly
return spring
linkage
seat
on
lower bracket comes into contact
with control rod ring 1
Set transmission outer lever to
neutral
position Note
2
Select 1
A
change lever is in
B
posi
tion
Adjust trunion nut and tighten it when change lever
arrives
In this arrangement
position
linkage
Arrange
component
parts
so
that
reverse
2
Set transmission outer lever to
3
Tighten trunion nut at a position where no unreason
able force is applied to select rod
check
TM 17
neutral
position
CH ASSIS SERVICE DATA AND SPECIFICATIONS
CONTENTS General specifications
TM 18
Specifications
TM 18
General
TIGHTENING
TORQUE
TM 20
specifications F4W63
R4W63
R4W63
Floor shift
Column shift
Column shift
Warner
Warner
Warner
1st
3 657
4 243
5 000
2nd
2 177
558 2
3 014
3rd
1419
1 587
1 685
4th
000 1
1 000
1 000
Rev
3 638
367 4
5 146
Type Con trol system
Synchromesh type Gear ratio
Speedometer gear ratio
19 5
18 5
17 5
18 5
17 5
19 5
18 5
Final gear ratio
4 875
4 625
375 4
4 625
4 375
4 875
4 625
Extension housing Oil capaci ty
Note
a
b
See page TM 2
short
long
short
long
long
short
long
7L I
2 0L
7L I
2 0L
2 0L
71 1
2 0L
Extension housing
I 7 L
3 6 US pis 3 0 Imp pts
2 0 L
4 2 US
pts
3 5 Imp pts
Specifications Model F4W63
R4W63
Item
Each gear backlash
For all gears
Standard backlash
0 05 to 0 10
in mm
0 0020 to 0 0039
Replacement standard
mm
0 20
in
0 0079
TM IS
TRANSMISSION
Model
F4W63
R4W63
Item
Each gear standard end play For aU gears
mm
0 05 to 0 15
in
0 0020 to 0 0059
Balk ring cone clearance StMdard clearance
mm
2 to 1 6 1
in
0 0472 to 0 0630
Replacement standard
4th 3rd
0 8 mm
in
0 0315
adjusting shim
Part number
Thickness
Reverse idler gear adjusting shim
40 1
45 1
0 0551 to 0 0571
32263 1460 I
1 45 to 1 50
0 0571 to 0 0591
32263 14602
1 50 to 1 55
0 0591 to 0 0610
32263 14603
55 1
0 0610 to 0 0630
32263 14604
1 60 to 165 0 0630 to 0 0650
to
to 1 60
Thickness
mm
in
32204 08000
1 49 to 1 55
0 0587 to 0 0610
32204 08001
56 1
to 1 62
0 0614 to 0 0638
32204 08002
1 62 to 1 68
0 0638 to 0 0661
32204 08003
1 68 to 1 74
0 0661 to 0 0685
32204 08004
I74 to 1 80 0 0685 to 00709
32204 16500
1 80 to 186
0 0709 to 0 0 32
32204 16501
1 86 to 1 92
0 0732 to 0 0756
Part number
TM 19
in
32263 14600
Part number
Main drive gear adjusting shim
mm
Thickness
mm
in
32285 14600
1 15 to 1 25
0 0453 to 0 0492
32285 14601
35 to 1
45 1
0 0531 to 0 0571
32285 14602
25 1
to
35 1
0 0492 to 0 0531
32285 14603
45 1
to
1 55
0 0571 to 0 0610
22285 14604
1 05 to 1 15
0 0413 to 00453
1
i
CHASSIS Model R4W63
F4W63 Item
Counter gear thrust washer
Thickness
Part number
mm
in
32225 A0900
2 35 to
40 2
0 0925 to 0 0945
32225 A090 I
2 40 to
45 2
0 0945 to 0 0965
32225 A0902
45 2
to 2 50
0 0965 to 0 0984
32225 A0903
50 2
to 2
55
0 0984 to 0 1004
2 55 to 2 60
0 1004 to 0 1024
32225 A0904
Tightening torque kg m
Transmission proper
Engine transmission installation bolt
2 4 to 2 8
Front cover transmission installation bolt
0 8 to 1 0 4 to 1 8 1
Rear extension transmission installation bolt
ft lb
174 to 20 2 5 8 to
7 2
10 1 to 13 0
Main shaft tightening nut
8
to II
57 8 to
5 79
Companion flange tightening nut
10
to
14
723 to
2 1Ol
Rear engine mount installation bolt
3 3 to 3 8
23 9 to 27 5
5 3
18 1 to
3 25
Drain plug
2 0 to 3 0
14 5 to
7 21
Back up lamp switch
2 0 to 3 0
Bottom cover installation bolt
0 8 to 1 0
5 to 2
Filler plug
Speedometer pinion installation bolt
3 to 0
Interlock plug
7 to 2 1 1
Operating lever
3 to 0
for both shift and select
4 0
4 0
14 to 21 7 5 5 8 to
7 2
2 2 to
2 9
12 to 15 2 3 2 2 to
2 9
Reverse check
2 0 to 3 0
5 t021 7 14
Transmission outer lever
0 8 to 1 0
5 8 to
Trunion nut for both shift and select
2 0 to 2 8
TM
20
7 2
14 5 to 20 2
TRANSMISSION Select lever pivot bolt
0 5 to 0 8
3 6 to
5 8
Lower support bracket
0 6 to 1 0
3 to 4
7 2
Steering wheel tightening nut
7 0 to
Transmission gear control
5 7
50 6 to 54 2
1 9 to 2 2
13 7 to 15 9
floor shift
Control lever installation bolt
TROUBLE DIAGNOSES AND CORRECTIONS Condition
Probable cause
Corrective action
Difficult to
Causes for difficult gear shifting are classified to troubles concerning the control system
intermesh gears
and transmission
When the gear shift lever is heavy and it is difficult to shift gears
clutch disengagement
may also be unsmooth
First make sure that the clutch operates correctly and inspect the transmission
Worn gears shaft and or bearing
Replace
Insufficient operating stroke due to worn
Repair or replace
or loose sliding part
Defective or damaged synchronizer
Gear
I ips out
of mesh
Replace
In the most case this trouble occurs when the interlock plunger check ball and or spring is worn or weakened or when the control system is defective
In this case
the trouble cannot be corrected by replacing gears
and therefore trouble
shooting must be carried out carefully It should also be
A
noted that gear slips out of mesh due to vibration
weakened front and rear engine mounts
Worn interlock plunger
Worn
check
ball and or
Replace weakened
or
Replace
broken spring
Worn fork rod ball groove
Replace
Worn damaged bearing
Replace
Worn or damaged gear
Replace
TM 21
generated by
fI
CHASSIS
Noise
Corrective action
Probable cause
Condition
When noise occurs under engine idling and stops while the clutch is disengaged noise occurs while shifting gears
Insufficient or improper lubricant
Add oil or replace with designated oil
Oil leaking due to defective oil seal and
Clean or replace
gasket clogged breather etc Worn bearing High humming occurs at a
Replace
high speed Damaged bearing Cyclic knocking sound occun also at a low
Replace
speed
Worn each spline
Replace
Worn each bushing
Replace
SERVICE JOURNAL OR
DATE
or when
it may be judged that the noise is from the transmission
JOURNAL
or
BULLETIN
No
BULLETIN REFERENCE
PAGE No
SUBJECT
TM 22
SECTION PD
PROPELLER SHAFT
DIFFERENTIAL CARRIER
CI
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
I NISSAN I
NISSAN MOTOR CO TOKYO
JAPAN
LTD
PROPELLER SHAFT AND UNIVERSAL JOINT
PD
1
DIFFERENTIAL CARRIER
PD
5
7
1
C
PROPELLER SHAFT
DIFFERENTIAL CARRIER
PROPELLER SHAFT AND UNIVERSAL JOINT
CONTENTS
DESCRIPTION
PO
ASSEMBL Y
REMOVAL
PD 3
SERVICE
PO 4
DATA
DISASSEMBL Y
PD 3
TROUBLE
INSPECTION
PD 3
CORRECTIONS
AND SPECIFICATIONS
DIAGNOSES
PD 4
AND PD 5
@ @
Fig PO I Propella shaft for UV N 521 and except Floor Shift vehicles
DESCRIPTION Three
GN 521
types
and 52 IT
series vehicles These
of
vehicle are counter balanced within UV N 52l
cm gr
Floor shift vehicles except GN52IT
care
propeller
shafts
for
The
are used
lz in
at 4 000 rpm at the
an
unbalance of IS
factory with the best
propeller shaft may be unbalanced if erroneously
tapped with a hammer while servicing or flying rocks or
propeller shafts adopt solid tubular steel con
bottoming occurs during off road driving
struction A correct balance of propeller shaft is very
for a good riding comfort at high speed
0 2
Check propeller
important
36 000 kill
Therefore the
9 000 km
propeller shafts in service parts and ones assembled in the
PD
shaft
joint and center bearing every
24 000 miles and propeller shaft spline every
6 000 miles for grease
CHASSIS
f rA
6
u
series Fig PD 2 Propeller shaft for G NJ521
Fig
PD3
vehicles
Propeller shafr for Floor shift vehicles PD 2
PROPELLER SHAFT
DIFFERENTIAL CARRIER
REMOVAL
N S21 except UV Remove
Floor shifl vehicles
propeller shaft carefully so as not to damage
transmission side spline and rear oil seal
G N S21 and Floor shift vehicles Remove
3 joint
mounting bolts from both
transmission and
and remove
bearing mounting
differential gear
case
brackets
DISASSEMBLY Primarily is balanced are
required
do not disassemble propeller shaft because it as
an
however
Fig PD5 Removing bearing
When disassembly and repair
assembly
the following procedures apply S
1
With journal installed
movement
on
When journal
propeller shaft
does
not
move
Lightly
base
tap
of yoke
with
a
hammer
and
withdraw bearing race
check it for
smoothly Note
disassemble
When removing journal from yoke be careful not to damage jau mal
2
Put
match
propeller shaft can
3
marks
on
sleeve
and other parts
as
yoke
flange yoke
required so that they
be reassembled to the original condition
Remove snap ring with an ordinary screw driver
CD
@
ClO A
Fig
PD 6
Exploded view
INSPECTION Check each part and repair or replace if defective When replacing journal unit
Fig
PD4
replace as an assembly
Removing snap ring 2
When journal
pin exterior
A
is
pitted or cruised
replace 4
Remove bearing
3
PD 3
When yoke hole
C
is worn or damaged
replace
1
CHASSIS 4
When snap ring CD is damaged or deformed replace
5
When bearing oil seal ring
Propeller shaft installation bolt 2 5 to 3 0 kg m
@ is damaged or
18 5 to 22
replace
worn
I
When sleeve yoke and main shaft splined portions are
6
damaged or worn replace sleeve yoke and main shaft When
7
propeller shaft tube surface
is
dented
Direction slackness
or
replace
cracked
When center bearing is worn or damaged
8
Jb ft
@ and or needle roIler
replace
ASSEMBLY Assemble propeller shaft in
reverse
sequence
to dis
assembly Fig
Selection of snap ring
PD 7
Grease is sealed in joint so that no greasing is required Fill joint
with wheel
bearing grease
whenever
propeller
shaft is overhauled
Snap ring over size
Snap ring functions also as a shim to adjust gap Select a
proper snap ring so that slackness is 0 to 0 02 mm 0 to
0 0008 in
to select another soap
opposite side so
that
Color
Moreover when a snap ring is selected be sure
Thickness mm in
Part number
identification
ring having the same thickness for
Install and assemble components correctly
joint moves under bending friction resistance of
37146
14600
2 00 0 0788
White
37147
14600
2 02 0 0795
Yellow
37148
14600
2 04 0 0803
Red
37149
14600
2 06
0 0811
Green
37150
14600
2 08
0 0819
Blue
37151
14600
2 10
0 0827
Brown
37152
14600
2 12
0 0834
No paint
less than 10 kg cm 56Ib in
Tightening torque Companion flange
center bearing unit installation nut
G521 and GN521
10 to 15 kg m 74 to III ft Ib
Bearing mounting bracket installation bolt G521 and GN521
4 to 2 7 kg 2 m18 to 20
Jb ft
SERVICE DATA AND SPECIFICATIONS Vehicle 52IT Floor shift
U V N521
GN521
Except GN52 IT Distance between joints
mm
in
1 233
5 48
Permissible unbalance
gr cm rpm
615
24 2
1st
615 24 2
743
3 29
2nd
983 38 7
5 x 16 63
5 x 16 63
Involute spline
Involute spline
Involute spline
15 4 000
15 4 000
15 4 000
68 9 x 1 6
Spline model
1st
2nd
PD4
PROPELLER SHAFT
DIFFERENTIAL CARRIER
TROUBLE DIAGNOSES AND CORRECTIONS Condition
Vibration tion
Vibra
occurs
on
Worn
or
Corrective action
needle
damaged universal joint
Replace
bearing
haft
propeller during
Probable cause
at medium
or
high speed and
the
vibration
transmitted
Unbalance due to bent or dented propeller
Repair or replace
shaft
i to
Loose propeller shaft installation
Retighten
Worn transmission rear extension bushing
Replace
Damaged center bearing
Replace
l body
I
t
r Knocking
sound
Worn or damaged universal
joint
Replace
during starting or noise
during
coasting
on
Worn sleeve yoke and main shaft spline
Replace
Loose propeller shaft installation
Retighten
Loose joint installation
Adjust snap ring
Damaged center bearing
Replace
pro
peller haft
DIFFERENTIAL CARRIER
CONTENTS DESCRIPTION
PD
5
Adjusting drive pinion preload
PD lO
REMOVAL
PD
6
Adjusting side bearing shim
PD ll
DI ASSSEMBL Y
PD
7
I nspecting and repairing drive
I nspection before disassembly
PD
7
INSPECTION AND REPAIR
PD
8
gear tooth contact
ASSEMBL Y AND ADJUSTMENT
PD
8
SERVICE DATA
Assembling differential gear case
PD
8
TROUBLE
Adjusting pinion height
PD
9
CORRECTIONS
PD 13
INSTALLATION
PD14
AND SPECIFICATIONS
PD 14
DIAGNOSES AND PD 15
DESCRIPTION The differential gear carrier is made of light and strong
Differential gear oil should be replaced at initial I 000
aluminum alloy and uses hypoid bevel gear
km
Shims and washers are used for adjustments of tooth contact
600 miles
checked every 3 000 km
and replaced every 36 000 km
preload and backlash of the gear
PD 5
24 000 miles
2 000 miles
CHASSIS
ID @
1
j
I
j
I
@
j
@ Qt @
8
Side bearing
IS
Drive gear
Front bearing
9
Bearing
16
Lock pin
3
Spacer
10
Differential
17
Adjust shim
4
Pinion height
1
Oil
18
Thrust block
19
Side gear
20
Pinion mate shaft
I
Companion nange
2
adjust shim
cap case
81
5
Pinion mate gear
12
6
Pinion mate gear
13
Drive pinion
7
Side gear thruit washer
14
Rear
Fig P
Adjust
washer
bearing
8 Cross secaonal view of differential carrier
REMOVAL When removing gear carrier assembly
pinion companion flange remove
two rear axle
to
disconnect drive
flange yoke connection
shafts Refer to
REAR AXLE
and
for
removal of rear axle
1
Jack up rear axle support it with a stand
and drain
gear oil
2
Remove rear axle shaft
3
Remove companion
stallation bolts
flange and propeller
shan in
CD and housing installation nuts @
remove differential
and
gear carrier assembly
Fig
PD 6
PD9
Removing differenti4 gear carrier
PROPElLER SHAFT
DIFFERENTIAL CARRIER
DISASSEMBLY
Note
Be
sure
to
segregate left
lright side bearings anc
together with shims Inspectio before 1
disassembly
In order to obtain the cause of trouble correctly
assembly for
oil
leakage
and measure
tooth
pinion
When tooth contact and backlash are incorrect
measure drive
backlash
and
torque
Unbend
lock
washer
loosen installation
bolts in
and separate drive gear
diagonal sequence
drive gear and
pinion
contact
4
check
of drive S
Pull out lock pin and turn and
shaft pinion mate gear side gear
gear hack tiIting also
remove
lst thl
pinion mate
block and thrust
washer 1
Secure differential gear carrier assembly
special
tool
ST07320000
and
remove
on
side
a
stand
bearing
Note
Segregate left and right gean and thrust washers
tightening nut and side bearing cap t
2
6
Remove differential case assembly and segregate eft
Hold companion
tool SB1530000
and right side bearing outer races
j
flange with a flange wrench special
remove
pinion
nut
withdraw flange
and remove drive pinion
Note
J
Be careful not to lose preload adjusting shim
I I
I
j i 1
Fig 3
Withdraw
PDl0
side
Removing differentidl case
bearing
with
puller
special
tool
Fig P
12
rear
bearing
Removing pinion nut
SB3010000 7
Remove
represser
inner
race
by
the use
special tool SB0030000
t I
I
I Fig PDl1
R
moving side bearing
Fig
PD 7
PD 13
Removing bearing inner race
of a
f
CHASSIS drags during rotation
Remove oil seal from differential gear carrier
8
Be sure to replace it with
Note
new
one
when rein
seized damaged
are
s
Apply an adapter to race side surface and withdraw
9
When side gear and
4
stalling
O
P
occurs
replace
pinion mate gear thrust washers
or worn
excessively replace
seal
When
bearing outer race Put removed pinion height adjust shims in order
or noise
oil
seal
is
weakened
or
damaged
replace
marily replace oil seal whenever disassembled
6
Gear carrier When sliding part is worn or cracked replace
7
Differential case When sliding part is worn or cracked replace
8
Flange When oil seal lip contact surface is damaged replace
ASSEMBLY AND
JUSTMENT AD
Assemble differential carrier in
reverse
sequence
to
disassembly by noting the following matters Fig
PD 14
rrace outl
Removing
Put shims and washers in order and install them on
1
INSPECTION
the correct positions
AND REPAIR
Thoroughly clean all disassembled parts replace if worn damaged
or
and repair or
Drive gear and drive pinion
1
3
When installing bearing
When installing oil seal
4
multi purpose grease When wear is excessive
or
tooth
put gear oil
When fitting
however clean off oil from filling part
check them for
and adjust correctly at the time of reassembly
cause
Clean shim washer and bearing contact surfaces
bearing
When tooth contact is incorrect
I
2
defective
contact cannot
be
carefully so
as
fIll space between lips with
C 21 08 or G I 0924 MIL
and install
not to damage oil seal lip
adjusted correctly replace gears as a set 2
When
seized
2
tooth
surface is
cracked
or
damaged
or
replace gears as a set
Assembling differential gear
Side gear and pinion mate gear When tooth surface is cracked or damaged
1
on
When
2
thrust washer
surface is
worn
or
Install pinion mate gear
1
replace seized
thrust
differential case Coincide pinion
case
block and side gear mate
shaft with lock
pin hole on case and install it
replace Repair with an oil stone when wear or seizure is UHUU
U
When 3
Bearing When bearing is seized
thrust
exfoliated
worn
rusted
value
or
8 PD
adjustment is required select a proper side gear
washer
so
that clearance
is within
the standard
PROPELLER SHAFT
DIFFERENTIAL CARRIER
Side gear thrust washer
Thickness
Part number
mm
in
ST3321 0000
38424 25660
0 76 to 0 81
0 0299 to 0 0319
38424 32200
0 81 to 0 86 0 0319 to 0 0339
38424 32201
0 86 to 0 91
38424 32202
101 to 1 06 0 0398 to 0 0417
38424 32203
1 06 to l ll
0 0339 to 0 0358
0 0417 to 0 0437
Fig PD 16 Installing side bearing
Adjusting pinion height Install pinion on differentia1 carrier temporarily
specified preload measure
When
7 to 10
m
kg
1 to 8 9 in lb 6
apply and
pinion heigh t installing pinion
on
differential carrier do not
install oil seal
Note
Do not
tighten
pmlon
nut
excessively
because
spacer and shim are oot installed
When
applied
PD15 Measuring sjd gear back clearance
Fig
adjustment is required adjust thickness of shim
to back of rear
bearing cup
Fit rear bearing cone to drive pinion
1ltool Speci
ST30030000
Standard side gear back clearance 002 to 0 08 mm 0 0008 to 0 0031 in
3
Fit lock pin
caulk circumference of lock
pin hole
and lock it
4
Install drive gear
head with
a
hammer
on
differential
case
Tapping bolt
tighten bolts in diagonal sequence
bend lock washer to lock bolts
Tightening torque 4 8 to 5 5 kg m
5
35 6 to 40 7 ft Ib
Fit side bearing together with
ferential
case
by
ihe
use
of
a
adjust shim to dif drift
special
tool
ST332 10000
r
Fig
PD 9
PD 17 Installing pinion bearing
CHASSIS 2
drive
Apply
pinion
carrier
to
and
install front
Remove drive
6
install shim
bearing cone
on
pinion
the
from
differential carrier and
back of rear bearing cup
When
adjusting preload check pinion height again 3
and tighten
companion flange
Install
specified preload 7 to 10 kgem
nut
so
6 2 to 8 9 in Ib
that
can
be
obtained
4
Adjusting drive pinion preload
Install
gauge
tool
special
ST31100000
on
dif
applied between front and
I
Spacer and washer
ferential carrier and measure clearance between gauge end
rear
bearing cones are used for adjustment of preload
and drive pinion end surface with a thickness gauge
When adjusting oil seal is not installed
2
ST31100000
Install spacer
to be
adjust washer front bearing cone and
flange on pinion and tighten pinion nut with prescribed tightening torque
Note
Turn
pinion by hand so that nut is not tightened
excessively
and
in
thickness of spacer and
washer when pinion does not rotate
3
Measure
preload of drive pinion
and select proper
spacer and washer to obtain the prescribed preload
Special tool ST3120OO00
Fig PD 18 Measuring clearance 5
Thickness of drive pinion height adjust shim can be
obtained by the following equation T
N
Where
H x 0 01
0 2
T
Thickness of shim
N
Value measured by thickness gauge
H
Number on drive pinion head
Calculation example When N is T
0 5
5 and H is 0 2 x 0 01
2
0 2
0 28
Fig 1D 19 Measuring preload
Pinion heigh t adjust shim
Part number
Thickness
mm
in
Bearing spacer 38153
10601
0 050
0 0020
38154
10601
0 075
0 0030
Length
Part number
n
38156
10601
38157
10601
0 250 0 0098 500 0
0 0197
mm
o
2 6673
38166 3 2202
6775
38167 3
68 00 2 6772
202
PD lO i
in
PROPELLER SHAFT
DIFFERENTIAL CARRIER i
Pinion bearing adjust washer
Part number
Thickness
38135 09400
2 43
00957
38136 09400
2 41
0 0949
0 1004
38137 09400
2 39
0 0941
53 2
0 0996
38139 09400
37 2
0 0933
51 2
0 0988
38140 09400
35 2
0 0925
2 49 0 0980
38140 09400
2 33
0 0917
38141 09400
31 2
0 0909
Part number
Thickness
38127 09400
59 2
38128 09400
57 2
38129 09400
55 2
38130 09400 09400
38131
38132 09400
1012 0
47 2
0 0972
38134 09400
45 2
0 0965
oil seal with
a
new
in
0 1020
38133 09400
Remove flange and install oil seal
4
mm
E F
Be sure to replace
against
0 7874 in
disassembled
in
Tolerance of left or right side assembled width
whenever differential carrier is
one
mm
standard
size
20 rriIi1
is expressed in unit of 0 01
and om mm 0 0004 in is expressed as Install flange and washer and tighten pinion nut with
5
prescribed tightening
cm torque 14 to 17 kg
one
104 to 129
lb in
6
Turn
flange to
let
pinion bearing breaking in and
make sure that preload of pinion is correct again
side bearing shim
Adjusting I
Use the same shim again unless differential case side
bearing and or carrier is replaced or preload of bearing is abnormal
2
When
replacing side bearing
approximately 2 5 kg 5 5 Ib before installing new bearing
use
weight block of
and measure bearing width
20 00 mm 0 7874 in
Standard width
Fig PD 20 Adjusting side bearing shim
Left side shim thickness Tl
A
C
D
F x om
0 175
mm
Right side shim thickness 3 T2
Where
B
D
F
x
0 01
0 150
mm
Apply selected shim to differential case and fit side
bearing cone
A B
Mark on gear carrier
4
C D
Mark on differential case
mallet and install it on gear carrier
PD ll e
Tap differential case assembly lightly with a rubber
F
O
3
T
1 I
CHASSIS Side bearing shim Part number
Thickness
38453 61200
0 05
mm
in
8
When the width is insufficient
add shim
9
Measure drive gear and drive pinion backlash When
backlash is less than standard value
it from left to
move
0 0020
right Move from right to left when excessive Q7 0 0028 0
38454 61200
38455 61200
0 12
0 0047
38456 61200
0 25
0 0098
38457 61200
50 0
0 0197
Standard backlash
0 13 to 0 18 mm 0 0051 to 0 0071 in
5
Coincide marks on bearing cap and bearing housing
and install bearing cap on bearing housing
Fig
Fig PD21 Installing bearing cap
10
PD23 M
When fluctuation
h bacU
ring
of backlash is excessive
measure
drive gear back deflection A foreign material may be bit 6
Tighten bolts in diagnal sequence with prescribed tightening torque 4 2 to 4 8 kg m 31 to 35 ft Ib
between drive gear and differential case
Deflection limit 7
Measure dimension between left and right bearing
cap
edges by
the
use
of
a
cap
gauge
special
0 05 mm 0 002 in
tool
00 ST32110
Standard dimension 198 40 to 198 55 mm 7 811 to 7 817 in
II
Fig
PD22 Measuring width
When
dirve
gear
deflection
backlash fluctuation is excessive
PD 12
is
satisfactory but
replace gears 3S a set
DIFFERENTIAL CARRIER
PROPELLER SHAFT Inspecting and repairing drive
TOE
tooth contact
gear l I
Put
red lead
Minium
evenly
three to four teeth of drive gear
on
both surfaces of
turn drive gear to both
directions several times by hand and check drive gear for tooth contact
2
When tooth contact is incorrect shim
adjust
HEEL SIDE
readjust thickness of
DRIVE
Be sure to wipe off red lead completely upon
Fig
completion of adjustment a
c
Heel contact When
surface is insufficient
contact
heel
may
PD 27 Flank contact
Flank contact When backlash is too tight flank contact occurs Noise
be
damaged Adjust by reducing thickness of shim in right side
HEEL COAST SIDE
of side bearing and increase thickness of shim in
increases
and
Replace
drive
one so
left side
d
tooth
edge
is
pinion adjusting
easily
in step
worn
washer with
a
thinner
that drive pinion is moved away from drive gear
Face contact
TOE In the most case excessive
Noise
damaged
In
replace
this trouble occurs when backlasH is increases
and
tooth
edge
is
easily
order to obtain correct tooth contact
drive
pinion adjusting
washer with
a
thicker
one so that drive pinion is moved to drive gear
HEEL DRIVE SIDE
Fig
b
HEEL COAST
SIDE
TOE
PD 25 Heel contact
Toe contact When
contact
surface is in sufficient
toe
may
be
HEEL SIDE
HEEL DRIVE SIDE
damaged Adjust by reducing thickness of shim in left
COAST
side of side bearing and increase thickness of shim in
right side Fig PD 28 Face contact
TOE
HEEL SIDE
DRIVE
Fig
PD 26
TOE
HEEL COAST SIDE
HEEL DRIVE SIDE
Fig
Toe contact
HEEL COAST SIDE
PD29 Correct contact
r
PD 13
r
CHASSIS e
Correct contact
shim is accompanied by change in backlash Check
When proper tooth contact is obtained lead from ilear face
it when installing gear
wipe off red
A correct contact pattern means
INSTALLATION
that it lies in the range of 2 3 to 3 4 from tip of tooth when no load is applied
Install
differential
in
carrier
reverse
sequence
to
removal Lubricate gears with gear oil upon completion of Note
Change
in the
thickness of
adjusting washer
installation
or
SERVICE DATA AND SPECIFI CATIONS
Final gear type
Hypoid
Final gear ratio number of teeth
521
G521
7 36
5 143
V52 I
37 8
4 625
N521 GN512
39 8
4 875
VN521 UN521
35 8
375 4
PL521
35 8
375 4
50 6 to
3 72
Drive pinion Preload when using new bearings without oil seal
kg m
ft Ib
7 to 10
Standard distance between drive gear center and top face of drive pinion
mm
in
mm
in
61
2 402
Thickness of drive pinion adjusting washers
31 2
to 2 59
Spacing Length of drive pinion bearing spacer
0 0909 to 0 1020
02 0 0079 0
mm
in
67 56 to 68 00 2 6598 to 2 6772
Backlash between drive gear and pinion
mm
in
0 13 to 0 18 0 0051 to 0 0071
Runout of rear side of drive gear
mm
in
Less than 0 05 0 0020
mm
in
0 76 to 1 11
mm
in
0 02 to 0 08 0 0008 to 0 0031
mm
in
20 00 0 7874
Drive gear
Side gear and pinion mate Thickness of side gear thrust washers
0 0299 to 0 0437
Clearance between side gear and thrust washer Side bearing Standard width
0 12 0 0047 0 50 0 0197
PD 14
0 25
0 0098
PROPELLER SHAFT
DIFFERENTIAL CARRIER
Tightening torque 2 to 122 9 101
Drive pinion nut
kg m ft lb
14 to 17
Drive gear bolts
kg m ft Ib
4 8 to
5
34 7 to 39 8
Side bearing cap bolts
kg m ft Ib
4 2 to 4 8
4 to 34 7 30
Differential carrier to axle housing fIx nuts
kg m
ft Ib
16 to
4 2
11 6 to 174
Companion flange to propeller shaft
kg m ft Ib
ftx nuts
mOUBLE
7 21
DIAGNOSES AND CORRECTIONS
Condition
Noise on drive
5 to 3 0 18 1 to 2
Probable cause
C aerective action
Shortage of oil
Supply gear oil
Incorrect tooth contact between drive gear
Adjust tooth contact
and drive pinion
Damaged
differential
side
bearing
or
Replace or adjust
improper adjustment
Noise on coast
Damaged gear
Replace defective parts
Incorrect backlash between drive gear and
Adjust backlash
drive pinion
Noise on drive
Incorrect adjustment of drive pinion bearing
Adjust correctly
Worn or damaged drive pinion bearings
Rebuild differential and
Incorrect tooth contact pattern
Adjust backlash or replace hypoid gear set
Damaged side gear drive gear drive pinion
Replace as required
replace as required
and coast
teeth surface
Seized drive gear and drive pinion
Replace hypoid gear set
Pinion bearing under inadequate preload
Adjust preload
Seized damaged or broken pinion bearing
Replace bearing
Seized damaged or broken side bearing
Replace side bearing
Swinging defferential case
Replace differential case
PO 15
7 J
CHASSIS
Noise on rom
Corrective action
Probable cause
Condition
Loosen clamp bolts and nuts holding drive
Retighten them to the designated tightening
gear side bearing
torque
etc
Side gear jammed in differential case
Replace defective parts
Pinion gears too tigh t on their shaft
Replace as required
Worn
or
damaged side gear thrust washer
Replace
and pinion thrust washer
backlash bwtween drive gear and
Excessive
Incorrect
backlash
drive pinion
Breakage of differential
Adjust backlash
Worn differential gear or case
Replace worn parts
Shortage of oil or use of improper oil Severe selVice due to an excessive loading
Rebuild differential and replace as required After adjusting preload of bearings backlash and engaging condition of gears fasten parts
Incorrect
adjustment of drive gear and drive
and
apply specified volume of genuine gear
oil
pinion
Avoid abusing of the car Excessive
backlash
due to defacement of
side gear and thrust washer
Loosened bolts and nuts such as drive gear bolts
SERV
DATE
uLri
JOURNAL
or
BULLETIN
No
OllAt Un tilULLt
nl
PAGE
No
tE
i h i l
SUBJECT
PD 16
SECTION FA
FRONT AXLE FRONT SUSPENSION
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
I NISSAN I
NISSAN MOTOR CO TOKYO
JAPAN
LTD
FRONT AXlE
FA
FRONT SUSPENSION
fA 9
SERVICE DATA SPECIFICATION S
FA 19
TROUBLE DIAGNOSES AND CORRECTIONS
FA 21
1
r
lit
FRONT AXLE
FRONT SUSPENSION
FRONT AXLE
CONTENTS
Inspection
FA 3
FA 2
Reinstallation
FA 7
FA 2
Wheel bearing adjustment
DESCRIPTION
FA
FRONT AXLE Removal
8 FA
DESCRIPTION
Fig
FA l Cross sectional view of
The knuckle spindle is installed on the knuckle spindle
parts
1
Knuckle spindle
2
Inner wheel bearing
3
Outer wheel bearing
4
Oil
5
Wheel hub
6
Washer
7
Spindle nut
8
Bearing cap
seal
9
Brake drum
10
Wheel nut
11
Knuckle spindle support
12
King pin
13
Thrust bearing
14
Fulcrum bolt
15
Fulcrum pin
16
Spindle shim
17
King pin lock bolt or nu t
t8
Collar
19
Knuckle arm
20
King pin bushing
ront axle
and the
thrust bearing is inserted between the
support through the king pin The king pin bushing is
knuckle spindle and knuckle spindle support The knuckle
placed between the knuckle spindle and king pin sliding
arm
FA l
is set
stationariIy on the knuckle spindle and when
CHASSIS the
knuckle
arm moves
the knuckle
spindle is lightly
operated round king pin axis The wneel hub is supported with two wheel bearings on
the knuckle
secured
on
spindle and brake drum and wheel are
the wheel hub with hub bolts
construction
With this
wheels lightly rotate round the knuckle
spindle axis FRONT AXLE Removal
I
Jack up vehicle and support it with stands
2
Remove hub nuts and wheeL
Fig 11
FA 3
Remove plug from the top of king pin with a rod or
other proper mean hole
Remove brake hose from wheel cylinder
3
5 mm 6
with a tap 4
Remove brake drum
5
Remove hub cap
6
Remove cotter
Removing lting pin lock nut
M8
Plug may be removed by drilling a
0 256 in dia
on upper
plug threading hole
screwing a bolt into threaded hole and by
pulling boll
pin and spindle
nut from knuckle
spindle 7
Remove wheel hub wheel bearings oil seal and collar
from knuckle spindle
8
Remove
brake disc assembly from
the
flange of
knuckle spindle 9
Remove knuckle arm from knuckle spindle
Fig FA 4 Removing king pin plug 12
Apply drift to the top of king pin
and drive out
king pin together with lower plug
Fig
10
FA 2
Removing knuckk ann
Fig FA 5 Removing king pin
Remove king pin lock bolt
FA 2
FRONT AXLE
FRONT SUSPENSION Clearance limit 0 15 mm 0 0059 in
Tap spindle lightly with a copper or lead hammer
13
and detach it from knuckle spindle support Be careful
i Standard dimensions
not to drop thrust bearing
King pin outer diameter
r
19 979 to 20 000 mm
Bushing inner diameter
0 7866 to 0 7874 in
when filled
20 010 to 20 035 mm
0 7878 to 0 7888 in
if
ldf tI
Fig
FA 6
2
Oil seal
1
When grease leakage is detected during disassembly
replace
Removing spindle support
When worn or cracked
2
replace
Lightly tap outer race circumference with a hammer
14
by applying a brass bar
and
remove
wheel bearing outer
race
from wheel hub When tapping outer race circumfer
ence
tap evenly
3
Wheel bearing Remove grease from wheel bearing with solvent
check bearing for condition ness
and
Check it for rotating smooth
operating sound and appearance Rolling surface ca
be checked with bearing hub
Visual
outer
race
serviceability standard for
installed
on
wheel
wheel bearing are
indicated as follows
Standard dimensions
Fig
FA 7
Exploded view of bushing
Inspection
Replace
damaged
worn and clearance
Inner bearing
Inner
19 990 to 20 000
31988 to 32 000
diameter mm in
0 7870 to 0 7874
2594 1
Outer
51987 to 52 000
64 987 to 65 000
diameter mm in
2 0467 to 2 04 72
2 5585 to 2 5591
to 1 2598
f
King pin and bushing when
Outer bearing
l
seized
rusted or excessively
between king pin and bushing toward
diameter direction exceeds limit listed below
FA 3
CHASSIS Visual Serviceability Standard for Wheel Bearing
INNER
RACE SUR FACE
OUTER RACE FITTED SURFACE
COLLAR SURFACE OUTER RACE SURFACE INNER RACE FITTED SURFACE
ROLLER ROLLING SURFACE
INNER RACE
SMALL COLLAR
LARGE COLLAR ROLLER SUPPORTER OUTER RACE
Unserviceable
x
May be used when minor
Judgement
Rust should be removed with
0 emery paper
Race and roller
Cause
s
t O O
atU 8
Flaking
l
l
15o
l
l
ii Service life due to rolling fatigue
x
However this symptom occurs
before the service life The following causes are considered Abnormal load overload
Improper handling or improper installation Crack
x
x
x
Excessive tightening
Gap is excessive and a considerable
shock is received from the
outside
Rapid heat generation on the race
due to creep
Abnormal thrust load
Tapped with a hammer while removing
FA 4
FRONT AXLE
FRONT SUSPENSION I
Race and roller
i 1
l
g o
Cause
l
a
0 0 0
0
0 Seizure
l l ro 00
l
u
x
x
In
x
the
most
seizure
cases
occurs
the
as
of
grown
scar
due to
result
discoloring or flaking
Scratch
6
6
6
Shock is given carelessly during installation Bit foreign matter
Recess or wear
6
6
6
made by pressing or
removal
or
other handling
striking
striking
Wear
Careless installation
Recess made by bit foreign matter
6
6
6
Poor lubricant quality or deteriorated lubricant
Intrusion of dust Fitted surface is worn remarkably Wear due to excessive preliminary pressure
Biting
6
6
6
Excessive preliminary pressure or faulty lubrication
Fretting
6
6
6
The fitted part is discolored to brown or black
Fretting corrosion on
Rust
6
6
6
rust on fitted part
means
fine relative slip
metal contact surface
increased
Temperature
bearing
stops
moisture
during operation inside
the
lowers
bearing
is
when
the
condensed
becoming fine drips and the grease is moistened The bearing has been placed in a highly moistened place for a
long period of time Intrusion
of moisture
chemicals
touched with bare hand and
no
etc
or
the
bearing
is
rustproof action has been
taken
Discoloring
The
wheel
bearing is
Slight discoloring may become like oxidized oil stain due to
serviceable if discolor grease
ing with
can
be
solvent
removed
by
or
In the most
high
polishing
l
FA 5
cases
this Occurs when preliminary pressure is too
17
CHASSIS
Inner race
RoUer flaking
Cracked roller
Cracked inner race
Recess on inner race made by
Recess on auter race made by
bit foreign matter
bit foreign matter
III Recess on roller made by bit foreign matter
4
Spindle Check
5
spindle for
exploration
or
crack
by
means
of
a
spindle with a new one
When thread is damaged
Check front hub for crack by
magnetic
dyeing test and replace if cracked
When bearing inner race slips against spindle
Fr nt hub
exploration or dyeing test
means
of a magnetic
and replace if cracked
replace repair or Standard dimensions
replace
Outer bearing
Inner bearing
Wheel hub bore
51 955 to 51 974
64 955 to 64 974
mm in
2 0455 to 2 0462
2 5573 to
Standard dimensions
Outer bearing
Inner bearing
5580 2
A
Spindle
19 9721019 985
31967 to 31983
diameter mm in
0 7863 to 0 7868
2585 1
to
6
2592 1
Thrust bearing Check thrust bearmg
FA 6
and replace If damaged rusted
FRONT AXLE or it does not rotate
smootWy or noise occurs
FRONT SUSPENSION
U
bushings 7
Spindle nut
both
and
upper
When reaming upper side
lower
utilize lower
side
as
side
utilize upper side as reaming guide to align the
reaming guide
when reaming lower
and
center line correctly
when thread is damaged
Repair or replace
from
Perform reaming
when fitted
Bushing inner diameter 20 010 to 20 035
mm
0 7878 to 0 7888 in
Reinstallation 2
install thrust bearing to face covered side upward
Reinstall front axle in reverse sequence to removal by
noting the following
matters
Moreover
when installing 3
front axle lightly apply multi purpose grease MIL G2108 or
10924 to sliding parts
Jack
bottom
up the clearance by means of a
When replacing king pin and bushing
I
Install bushing carefully by the use of a special tool so
Selecting spindle shim
I
I
ST35380000
When installing spindle on spindle support be sure to
of spindle slightly
filler gauge
measure
and select proper
spindle shims to obtain the correct clearance Standard clearance
0 04 mm
0 0016 in or less
that grease groove toward circumferen
tial direction is in upper side
and bushing joint is faced
rearward
Spindle shim
Grease groove
Upper side
Part number
Thickness
40032 25660
0 075
0 0030
40033 25660
0 25
0 0098
40034 25660
0 75
0 0295
in mm
Lower side
2
Fig FA 8 King pin bushing
When
smoothly
king pin
is
filled
make
sure
to
operate
When turning resistance exceeds standard value
readjust shim
and check bushing and king pin if neces
sary 2
Remove
grease
bushing through diameter
nipple
and
threaded grease
drill grease hole
nipple hole
Approximately 3 mm 0 1181 in
on
King pin turning resistance
Drilling
5 1
cm kg
3 in Ib 1
When grease
hole is drilled thoroughly remove metal particles and bur
4
Install plug after applying seal
n its
circumference
and caulk three positions around spindle by punch 3
Ream the inside of bushing to standard value by the
use
of
king
pin
bushing
reamer
special
tool
HT56802000
5
FA
Install bearing outer race
CHASSIS 6
Fill wheel hub and hub cap with
MIL
G2108
10924
or
up
to
1lurpose multi
grease
J
Wheel
bearing adjustment
the described level See I
Figure F A 9
Tighten spindle
nut
to
the
specified tightening
torque
Tightening torque
2 to 3 4 kg m 3 1 to 24 6 ft b 23
Fig FA 9 Filling space between 7
heel bearing
Fill space between wheel bearing rolle
and grease
Fig FA 11 Tightening
seal lip pocket with multi purpose grease MIL G2108 or
heel bearing lock nut
10924 completely 2
Turn wheel hub
a
few turns toward both clockwise
and counterclockwise to settle down bearing
and
re
tighten spindle nut to the same tightening torque 3
Return spindle nut in range from 400 to 700 and
cnincide it with cotter pin hole on spindle
4
Turn wheel hub
a
few turns toward both clockwise
and counterclockwise again to allow bearing breakingin
and measure bearing rotation starting torque If measured
starting torque is deviated from readjust
Fig
FA 10
FiHing space between
the specified value
heel bearing
rollers with grease
8 shaft
Apply
grease mentioned to spindle
1lurpose multi
threaded portion
wheel bearing washer and wheel
bearing lock nut exterior lightly Note In order to
bearing
piiivide bearing with a proper pressure
grease seal
washer
collar and lock nut
carefullV 5 that no dust and foreign material stick on
Fig FA 12 Measuring
grease applied to them
heel bearing rotation
starting torque
FA 8
FRONT SUSPENSION
FRONT AXLE
Note
Wheel bearing rotation starting torque New bearing and seal
15
Used bearing and seal
7
8
Correctly measure starting force toward tangen
tiar direction against hub bolt
13 0 in Ib orless
em kg
b
1 in Ib or less 6
em kg
No slackness should
exist toward
axial direc
tion
Spring balance indication at hub bolt New bearing and seal
2 1 kg 4 6 Ib
Used bearing and seal
1 0 kg
or
less 5
2 2Ib or less
Apply
cotter
pin to
secure
spindle
nut
and install
hub cap
FRONT SUSPENSION
CONTENTS
9
Reinstallation
FA 14
FA lO
ADJUSTMENT
FA 17
FA
DESCRIPTION FRONT SUSPENSION Removal
FA 10
Vehicle posture
FA 17
Inspection
FA 12
Wheel alignment
FA 17
DESCRIPTION
@ ijI
Ql
@
@
1
Upper link
2
Lower link
3
Tension rod
4
Knuckle spindle support
5
Upper link spindle
6
Lower link spindle
7
Fulcrum pin
8
Fulcrum bolt
9
Cotter pin
10
Shock absorber
t1
Frame
12
Adjusting shim
13
Lower bumper rubber
14
Upper bump
15
Bracket
r
rubber
f
Fig
FA J 3 Cross sectional view
FA 9
offront suspension
1
CHASSIS The
front suspension is
double wishbone type in
a
dependent suspension which uses torsion bar spring Both the upper and lower links bracket secured on the frame upper and lower links
by
are
installed on the
means
of welding The
swing through
screw
bushing and
rubber bushing respectively
Top and bottom of the knuckle spindle support installed respectively
rubber
through
bushing
on
are
upper
link and screw bushing on lower link The tension rod is installed tension rod receives a force
on
the lower link The
applied to the front and rear
directions The front end of the torsion bar spring is installed on the torque arm by means of serration and the torque arm is installed on the lower link The rear end is connected to the
spring
anchor
by
means
of serration
and is
Spring anchor
set
3
Anchor bolt
Torsion bar spring
stationarily on the anchor arm member The shock absorber is of a hydraulic
Fig FA 14 Removing anchor bolt
double acting
type The shock absorber installed between the lower link and the bracket to absorb vertical vibration In addition two
bamper rubbers are installed on the frame through
6
Spring anchor
torsion bar spring and stabilizer
I
Jack down slowly
the bracket limiting link operating ranges In relation to the above
described standard parts
a
and remove spring anchor and
torsion bar spring toward rear
stabilizer is also available as an optional part
2
When stabilizer is used
remove bolt
securing stabi
lizer bracket to frame Then remove stabilizer from lower link
7
FRONT SUSPENSION
Detach shock absorber by removing upper and lower
nuts
Removal
I
Jack up vehicle and support it with stands
2
Remove hub nuts and wheel
3
Remove front axle See Section FA Front Axle
5
Remove anchor bolt after
nuts
using jack under spring anchor
loosening lock and adjust
a
Fig FA 15 Shock absorber
FA 10
FRONT AXLE 8
RemOve nuts
tension rod
D
from the front and
rear
FRONT SUSPENSION ends of
Remove bracket bolts @ from the front end
of tension rod and then detach tension rod together with bracket
Fig
Fig
FA 16 Tension rod
12
FA 18
Removingcotterpin
Drive out fulcrum
pin with
a
drift
and detach
knuckle spindle support from lower link Remove dust cover
Remove fulcrum bolt after
9
loosening
its
nut
and
detach knuckle spindle support from upper link
Fig FA 19 Removing fulcrum pin
J
Fulcrum bolt
Fig
2
Screw bushing
FA 17 Fulcrum bolt 13
Remove
upper link bushing from knuckle spindle
support 10
Remove screw
bushings from both sides offulcrum
pin 14 I
Remove tightening nut from
lower
rear
side of
knuckle spindle support and drive out cotter pin
Remove upper link
detach upper link spindle camber adjusting shim
FA 11
spindle installation bolt
and
from mounting bracket with
CHASSIS 17
Remove lower link
arm bolt
and separate
CD
torque arm @
torque arm from lower
and torque link
f
I
Fig FA 20 Upper link spindk 15
Twist and
spindle
separate
upper link
and remove dust cover
separated upper link
on a vise
from upper link
and dust seal
Secure
Fig FA 23 Lower link and torque ann
and remove screw bushings
r
18 t
Using a special tool ST36070000
bushing
tap it with
a
hammer
and drive
to lower link out lower
link
bushing from bracket
r
J t I
I
Fig 16
Removing screw bushing
Loosen lower link spindle nut
link spindle on
FA 21
and remove lower
Remove lower link with torque arm installed
lower link from lower link mounting bracket
Fig FA 24 Removing lower link bushing
Inspection I
Shock absorber
or noise ocems
replace shock absorber with a new one
Check upper and lower rubber bushings for condition and replace if necessary
Fig FA 22 Removing lower link
FA 12
FRONT SUSPENSION
FRONT AXLE
replace if necessary
Specifications for Shock Absorber
Check dust seal for wear and damage Max
315 mm 12 4 in
length
Min length
205 mm
8 1 in
Stroke
110 mm
3 in 4
Rebound
110 kg
5 Ib 242
Compression
55 kg
and replace as
required Check threaded part of upper link spindle fulcrum pin and screw bushing and repair or replace if necessary
Damping force 3
3lb I21
Lower link bushing
upper link bushing I
O 3m sec
Check rubber
0 98 ft sec
bushing for condition
and replace
as
necessary 2
Upper link spindle
fulcrum pin and screw bushing 4
Apply screw bushing to upper link spindle and fulcrum
Check torsion bar for distortion and weakness Whim
pin and measure end play toward axial direction When end play exceeds 0 35 mm upper link
spindle
or
0 0138 in
fulcrum pin together
posture of vehicle is adjusted and specified vehicle height
replace
cannot be obtained
wIth screw
See
bushing Check
Torsion bar
dust
cover
for
weakness
and
damage
replace torsion bar with a new one
Adjustment of vehicle posture
and
Specifications for Torsion Bar Spring Torsional regidity
Diameter x length
Part number L R
Short
54009 10
15200
Long
54009 10
14900
Van
54009 10 15200
Double cabin
54009 10 15200
10 54009
Option
5
mm
or
20 7 x 830
2 99 216
219 x 830
3 74
0 862 x 32 7
27 0
20 7 x 830
2 99
0 815 x 32 7
21 6
20 7 x 830
2 99
32 7
21 6
219 x 830
3 74
0 862 x 32 7
27 0
x
14900
6
ft lb
0 815 x 32 7
0 815
Tension rod When tension rod is distorted and
kg m deg
in
deg
Bumper rubber Replace when weakened or damaged
threaded part is
damaged repair or replace When cushion rubber is weakened or damaged
7
replace
Upper link and lower link When distorted
cracked or damaged
damaged repair or replace
FA 13
or when
thread is
1
CHASSIS
1
I
Lower link bushing
Upper link
3
When collar interior of lower link mounting bracket
along which lower link bushing is inserted and bushing
5 kg m 615 to 68 7Ib ft 9
5 to 8
Tightening torque
Reinstallation
Tighten screw bushing on upper link Install grease
I
seal and dust cover
exterior are rusted remove rust with emery paper
24 to 25 kg m
Tightening torque 2
Apply
disassembly hammer
tool
special
a
to lower link
and
fit
lower
ST36070000
bushing link
tap
bushing
it
used for
5 to 180 8Ib ft 173
evenly with a lower
to
2
MIL G2108
0 r
r
10924
Apply
grease to
thread
on
ently 6
Ie I
or
bushing interior and thread on upper link spindle suffici
r
u
in Fig
fitted to upper link with multipurpose grease
FA 27
mounting braclwt
indicated by asterisk
Fill screw bushing
link
r
i t r v
62 5 2 4611
I j
I
l Fig FA 25 Fitting IoweT link bushing 2
Lower link
I
Install torque arm on lower link
44 6
Fig
T I ghterung torque
2
3
Arm head
2 5 to 3 1
Serration boss
0 8 to 12 kg m 5 8 to 8 7Ib ft
kg
1 to 22 4 Ib ft 18
m
FA 2
Unit
U561
Upper link and up
mm
inl
Unk spindle
Screw front and rear links against upper link spindle
in the same length so that opening width 1 756
in
standard
dimension
A
is 44 6 mm
When
screwing
recommend fIller plug be removed
InStall lower link on lower link mounting bracket
and tighten lower link spindle nut at the position oflower
4
link shown in Fig FA 26
spindle smoothly
Upon installation make sure to operate upper link
Operating resistance 5
Remove filler plug
Less than
5 kg m 3 6 0
lb ft
install grease nipple and inject
grease until grease comes out from dust cover
Reinstall
filler plug 6
Install upper link spindle on upper link mounting
bracket Be sure to use the same camber shims which were used before
I
di
Apply
pin imd thread
Fig
FA 26
Installing
10
link
embly
iurpose grease multi on screw
bushing
Grease screw bushing sufficiently
FA 14
to thread on fulcrum interior
sufficiently
FRONT SUSPENSION
FRONT AXLE 2
Install dust seal on knuckle spindle support
3
Coincide
5
Remove f1ller
grease until
of notch
direction
for cotter
pin
on
plug
install grease nipple
and inject
grease comes out from dust cover Reinstall
f1l1er plug
fulcrum pin with direction of pin hole of knuckle spindle and drive
support
fulcrum
pin
into knuckle
spindle
6
support with a copper or lead hammer Insert cotter pin into hole
Upon
installation
sure
that
fulcrum pin
Less than 0 5
kg m
3 6 ft Ib
bushing
the
make
operates smoothly
tighten lock nut
Operating resistance
0 4 to 0 6 kg m
Tightening torque
2 9 to 43 ft Ib 7
Install
upper link
on
upper end of
knuckle spindle support
Install the upper end of knuckle spindle support on
8
upper link
arrange
them to condition shown in Figure
FA 30 and tighten fulcrum bolt
Tightening torque
4 7 to 5 2 kg m 34 0 to 37 6 ft Ib
4r t
Fig
FA Z8
Note
Be sure to install fulcrum bolt from
rear
side of
vehicle a
Installing fulcrum pin
l
Screw bushings in both sides manually and tempora
4
rily
that knuckle spindle support is in the center of
so
lower link and retighten them to the specified tightening Make
torque
angle
is
sure
76 50
that knuckle
Make
sure
and lower link
spindle
again that knuckle spindle
support is in the center of lower link TIlls operation can
@ j 4
be performed easily by removing f1ller plug
Tightening torque 24 to 25 kg
I73 m
5 to 180 8 ft Ib 54 5 mm 2 146 in
Fig
FA 30 Assembled posture of knuckle spindle
and upper link
Unit 9 05 to 11 05 0 3563 to 0 4350
Fig
FA Z9
5 1 437
36
mm
inl
5
Tension rod
I
Tighten nut on the rear end of tension rod to obtain
an
extent that rubber
mm
9 05 to 1105 4350 0 3563 to 0
3IS 1
in
bushings are compressed into
as shown
n
Figure FA
1 3
and tighten lock
f nut 2
Installing screw bushing
fA 15
4 33
Install tension rod bracket on frame bracket
r
or
r
CHASSIS 3
Make the distance of rubber bushings to be 36 6 1441 in
mm
by tightening nut on the front eod of
tension rod
When
rubber
bushings are compressed unequally adjust the position of adjusting nut I
Lock nut tightening torque
5 to 2 1 kg m 1 10 8 to 15 2 ft Ib
Bracket bolt tightening torque
1 5 to 2 1 kg m
E
E
10 8 to 15 2 ft Ib
Fig FA 32 Stabilizer instJJUation Bracket bolt tightening 1 5 to 2 1 kg m 4 mm 33
torque
10 8 to 15 2 ft Ib
1315 in
8
Torsion bar spring
I
Grease serrations
sufficiently Note
Be
on
both ends
of torsion
bar
torsion
bar
and install it on torque arm
careful
to
select
left
and
right
springs correctly They can be identified with Right and
36 6mm
2
1441 in
L
Left
R
marked on the end surface
Position lower link so that
no clearance
is between
lower link and bumper rubber and install spring anchor
Fig 6
FA 31
Tension rod installation
on
torsion
bar
to
obtain
A
dimension shown
Figure FA 33
Shock absorber Turn nut fully against the threaded upper end ofshock
absorber and tighten lock nut with specified
tightening
torque
Note
Be sure to position suspension as shown in F
Figure
30 A
Upper lock nut tightening torque
1 5 to 2 1 kg m
10 8 to 15 2 Lower bolt tightening torque
3 6 to 26 0 to
7
lb ft
3 kg m 4 1 31
lb ft
Stabilizer
Tighten nut to arrange the height between lower link and stabilizer as shown in Figure FA 32
Fig FA 33 Anchor ann instal1Jtion
FA 16
in
FRONT AXLE
FRONT SUSPENSIO
t 3
Jack up
applied
spring anchor
which anchor bolt is
that
dimension shown in
tighten
nut
so
Figure FA 33 meets the standard dimension
Jack up vehi
e
and support it with stands
and secure
lock nut A
68 5 mm 2 697 in
dimension
A
dimension
Short body
98 3 86
Long body
92 3 62
Van
75
2 95
Double cabin
75
2 95
Option
90 3 54
mm
in
P
@1 t@
fii
Fig FA 34 Dimmension for standard vehicl posture
Lock nut tightening torque 4to 5 kg m
28 9 to 36 2 ft Ib 2
4
Check vehicle for posture and adjust if necessary
See
Adjustment
of Vehicle Posture
as
outlined below 3
ADJUSTMENT
dimension with anchor bolt adjust nut
dimension changes approximately
5 3
mm
vertically when adjust nut is turned one complete
spring or other defective condition
mm
in
Without load
4
When
H
dimension is in the
following range
posture of vehicle is correct
ShortfLong
Van Double cabin
Option
79 to 84
73 to 77
76 t081
3 11 to 3 31
2 87 to 3 03
2 99 to 3 19
54 5
5 54
54 5
2 15
2 15
2 15
With standard load
Standard load indicates the following condition
body
3 passengers and 1 000 kg
Van
3 passengers and 300 kg
Double cabin
2 passengers in front
2 204 6Ib
661 4Ib
I passenger in rear
and 250 kg
551 2 Ib
Wheel alignment 1
turn
due to weakened
The following ins true
tions apply when adjustment is required
lShorongt
3 in 25
See Figure FA 34
Vehicle posture may be incorrect
dimension
H
Adjust H
Vehicle posture
H
Jack up a part near anchor bolt of spring anchor so as
to release nuts from spring force
Carry out whee alignment on a flat surface with tire
FA 17
air pressure adjusted to the normal pressure
CHASSIS Thoroughly check all
2
componenV parts of steering
parts before starting wheel alignment
and repair OT replace defective
and suspension systems
v
Short Long
2 t03
2 t03
2t03
0 0787 to 0 1181
0 0787 to 0 1181
0 0787 to 0 1181
CambeT
1015
lOIS
1020
Caster
1050
2015
1055
King pin inclination
6015
6015
6010
Inner wheel
360
360
360
Outer wheel
310
310
310
Toein
1
r
D Cabin
Van
mm
in
Steering angle
Toe in
I
f
Measure
2 in toe
and adjust
as
F OT adjust
necessary
Loosen stopper bolt lock nut
ment the following instructions apply
ISc
Steering angle adjust stopper bolt to
obtain the standard steering angle
0
U
c Ji
r
i 1 I
r I
1
IIl
l
t
l
r
0 r
t
L
3
r
7
I
e wr
so
7
1
t
Jj
1 Fig
FA J5
1IIIIIIII
Adjusting toein Fig
Change the length of CTOSS rod CD Loosen lock nuts @ hand thread
to
adjust toein
left hand thread and ID
right
in is reduced Toe
When cross rod is
turned to opposite side toe in is increased
m
Adjusting steering ang
and turn cross rod to forward direction
arrow direction
I
FA J6
CambeT and CasteT
Measure camber and caster and adjust if necessary in
iQ I
centers of left and
3
lLmrL right ball joints
Standard cross rod length
Tightening torque
is indicated below
516 mm
9 to 12 kg m
UIU
lLlflLIn
ot
Both camber and caster are adjusted
by increasing or decreasing thickness of adjust shim inserted between
3 in 20
upper link spindle and upper link mounting bracket
65 186 8 ft lb
FA 18
FRONT AXLE Adj osting shim
FRONT SUSPENSION
1
J
I Thi kness
Part number
5454204101
1
I li
11 mm
in
I
IAJ t
i
rr
1
o
1
r rro I
J
0 0394 t
V 5454304101
2
0 0787
J
Standard thickness
J
1
54544 04101
4
0 1575
r t
r
t
j 1
1
J
II
To
adjust caster
make a
t
difference between thickness
of front shim and that of rear shim When front shim thickne
increases
approximately
33
caster per
I
reduces
mm
Caster changes
0 0394
in
of shim
Fig FA 37 Adjusting camber and caster
thickness Note
a
Caster
adjusted To
valve
reduces
When thickness of shim increases
not
change although camber
b
camber
Camber changes approximately 13 per I mm
Do not adjust caster with difference between
front
0 0394 in of shim thickness
and
rear
shim
thicknesses
beyond 2
mm
0 0787 in
SERVICE DATA AND SPECIFICATIONS
King pin Oearance limit between the king pin and bushing
in mm
Bushing inner diameter
in mm
when fitted
15
0
0 0059
20 010 to 20 035 0 7878 to 0 7888
Oearance between the knuckle spindle support and spindle mm in
0 04
0 0016
King pin turning resistance
15
3 1
kg CJJi in lb
Wheel bearing
Tightening torque
kg m
ft lb
3 2 to
4 23 1 to 24 6 3
40 to 700
Spindle nut returning angle
r
Wheel bearing rotation starting torque When both
bearing and seal are new
is
however that camber
changes when caster is adjusted
adjust camber change front and rear shims in the
same
does
It should be noted
kg cm in lb
FA 19
less than
13 15
0
r
CHASSIS
When readjusted at
in Ib
cm kg
r
less than
7
6 1
the hub bolt
When both bearing and seal are new
1b kg
less than 2 1
4 6
When readjusted
Ib kg
less than 10
2 2
Upper link sliding resistance
kg m
ft lb
less than
5 0
3 6
Lower link sliding resistance
kg m
ft Ib
less than
5 0
3 6
Tightening torque 7 to 2 0
3 to 14 5 12
Brake hose connecting nut
kg m ft Ib
Wheel bearing lock nut
kg m ft Ib
3 2 to 3 4 23 1 to 24 6
Brake disc fixing bolt
kg m ft Ib
4 0 to 5 4 28 9 to 39 0
Knuckle arm fixing bolt
kg m
ft Ib
King pin lock bolt
kg m
ft lb
1 2 to 13 2 2 1 to
8
0 to 95 4
5 15 2 to 2
1 18
Torque arm
w Arm end
kg m ft Ib
2 5 to 3 1
18 1 to
4 22
Serration boss
kg m ft Ib
2 5 7 to 8 7 0 8 to 1
Lower link spindle nu t
kg m
ft Ib
8 5 to 9 5
5 to 68 7 61
Upper link screw bushing
kg m ft lb
24 to 25
173 5 to 180 8
Upper link spindle bolt fixing to bracket
kg m ft lb
Cotler pin lock nut
kg m ft lb
0 4 to 0 6
Lower link screw bushing
kg m ft Ib
24 to 25
173 5 to 180 8
Falcrum bolt
kg m ft Ib
4 7 to 5 2
34 0 to 37 6
5 to 6 2 39 8 to 44 8 2 9 to
3 4
Tension rod Lock nut
kg m ft Ib
5 to 2 1 10 8 to 15 2
Bracket bolt
kg m ft Ib
5 to 2 1 10 8 to 15 2
Shock absorber 10 8 to 15 2
kg m ft Ib
1 5 to 2 1
kg m ft Ib
3 6 to
ft Ib
5 to
Lock nut of the anchor bolt
kg m ft Ib
4 to 5
28 9 to 36 2
Bumper rubber bolt
kg m ft Ib
1 to
6 8 0
Lock nut of the upper end Lower end
3 4
1 31
26 0 to
Stabilizer Bracket bolt
kg m
FA 20
1 10 8 to 15 2 2
tol 6
I
r
FRONT AXLE
FRONT SUSPENSION
1 I
TROUBLE
DIAGNOSES AND CORRECTIONS
V v
Condition
Probable cause
Corrective action
shock and shimmying of steer
Vibration
ing wheel Vibration
Too much backlash of steer
ing gear abrasion of each part of linkage and
vibration
many cases
of front
wheels
wheel This is very much noticeable when
travelling
Unbalance
ar
d
Adjust
deformation of
road
in
are
transmitted to the steering
over
Improper air pressure of tire
bad roads and at higher
Correct the unbalance
wheel
or
Unevenly worn tire or insufficient tight
Replace or tighten
replace
ening
speeds Improperly adjusted or worn front wheel
Adjust or replace
bearing Faulty wheel alignment When the front wheels are travel
Shock
ling over bumpy roads steering
is
linkage
the
play of the
transmitted
to
Worn
or
loose
Adjust
suspension
link
screw
Replace
bushing
the
Demaged idler arm
steering wheel This is especially notice able when travelling rough road
Insufficiently
Replace steering
tightened
gear
Tighten
housing Shimmying front
Abnormal vibrations of the
suspension group
and the
which
steering linkage
occur
whole
when
Replace ball joint
Worn steering linkage
a
specific speed is attained
Improper steering
gear
adjustment
in
Adjust
sufficient backlash Defective shock absorber or loose installa
Replace or tighten
tion
Unbalanced vehicle posture
Adjust
When driving with hands off the steering
Improper air pressure of tire or insuffici
Adjust or tighten
wheel
ent tightening ofwheel nuts
Vehicle pulls to right or left
on
swerves
Note
a
flat road
the vehicle gently
to right or left
A defective
rear
Difference in height of right and left tire
suspension may
Replace tires
treads
also be the cause of this trouble and therefore see also the with the rear
chapter dealing
spension
Incorrect adjustment
or
abrasion of front
Adjust or replace
wheel bearing
su
Weakened front torsion spring or devia tion from standard specification
FA 21
Replace
I
v
CHASSIS
9frective action
Probable cause
Condition
L
Worn
loose
or
link
screw
Replace
linkage
and
Replace
suspension
bushing of
Deforrned
steering
suspension link
Instability of vehicle
Unbalanced vehicle level
Correct the unbalance
Improper air pressure of tire
Adjust
Worn
loose
or
suspension link
screw
Replace
bushing Adjust
Incorrect wheel alignment Worn
or
deforrned steering linkage and
Replace
suspension link Incorrect adjustment of steering gear
Adjust
Deforrned unbalanced wheel
Correct or replace
Improper air pressure of tire
Adjust
Stiff s1llering wheel
checking up procedure Jack up front wheels detach the steering wheel and gear and operate the steering
If it is light check steering linkage and
suspension groups If it
is
heavy check steering gear and
steering coluOUl groups
lubricants
Insufficient in
impurities
steering
or
mixing
linkage
or
Replenish
grease
or
place the part
excessively worn steering linkage Insufficient
in
lubricant
gear
box or
or
replace
gear
oil
contaminated lubricant Unsmooth king pin
Add
damaged part
or
Replace
insufficient lubrication Worn
or
incorrectly
adjusted
wheel
Replace or adjust
bearing Worn damaged steering gear and bearing
Replace
Incorrectly adjusted steering gear
Adjust
Deformed steering linkage
Replace
Incorrect wheel alignment
Adjust
Interference of steering column with turn
Adjust
r
signal switch
FA 22
I
FRONT AXLE
Cfdi e o
FRONT SUSPENSION
tIOn
Excessive steering wheel play
Probable cause
Corrective action
I
7
v
Incorrectly adjusted steering gear housing
Adjust
Worn steering linkage idler arm
Replace
Improperly fitted of gear box
Retighten
Incorrectly adjusted wheel bearing
Adjust
Worn
or
loose
suspension
link
screw
I
Replace
bushing Noise
Improper air pressure of tire
Adjust
Insufficient lubricating oil and grease for
Replenish lubricating
suspension ball joint and steering linkage
oil
or their
breakage
replace
Loose
steering
gear
bolts
linkage and
and
Retigh ten
suspension groups Defective shock absorber
Replace
Defective wheel bearing
Replace
Worn steering linkage and steering gear
Replace
Worn
Replace
of loose
suspension link
screw
bushing Grating tire noise
Improper air pressure of tire
Adjust
Incorrect wheel alignment
Adjust
Deformed knuckle spindle and suspension
Replace
linkage Jumping of disc wheel
Improper air pressure of tire
Adjust
Unbalanced wheels
Adjust
Defective shock absorber
Replace
Defective tire
Replace
Deformed wheel rim
Replace
r
FA 23
grease
or
1
CHASSIS
Corrective action
Probable cause
Condition
Excessively or partially worn tire
Improper air pressure of tire
Adjust
Incorrect wheel alignment
Adjust
Defective wheel bearing
Replace
Incorrect brake adjustment
Adjust
Improper tire shifting
Adjust
rotation
Rough and improper driving manner
Drive more gently
SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL
or
BULLETIN
No
DATE
PAGE
No
SUBJECT
FA 24
SECTION RA 1
REAR AXLE
REAR
SUSPENSION
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
I NISSAN I
NI55AN MOTOR CO TOKYO
JAPAN
LTD
REAR AXLE
RA
1
REAR SUSPENSION
RA
4
REAR
AXLE
J
V
1
J
REAR AXLE
t CONTENTS
DESCRIPTION
RA l
INSPECTION
R 2
REMOVAL
RA l
INSTALLATION
RA 3
J
@ 1
12
Axle shaft
3
Wheel bearing
4
Plain washer
5
Lock washer
6
Lock nut
7
Oil sea1
8
Bearing cage
9 10
Fig
rear
housing is
a
axle is
3
of a semi floating type
pressed steel
in weight and is
Banjo
Shim Grease seal
11
Bnkedrum
12
Wheel nut
RA l Cross sectionallliew of rear ax
DESCRIPTION The
Ax1ccase
2
Remove brake shoe and disconnect hand brake wire
The axle
type housing It is light
sufficiently strong to withstand against
any torsional and bending loads
The
rear
wheel
bearings
are
tapered roller bearings
With those bearings the rear axle supports heavy load and withstands against severe use The rear axle receives thrust force through thrust block in the differential housing
REMOVAL 1
Jack up vehicle and support it with stands
2
Remove road wheel and brake drum
Fig RA 2 Removing bralee
RA l
CHASSIS 4
Remove four nuts used to install brake end to axle
and disconnect brake line
Fig
RA J
RemoPing rNr
8
p
A
Remove
lQck
RARemoPing loci nut
Withdraw axle shaft 9
Note Be careful notto damage oil seal in axle case side
6
tool
special
1e
Fig 5
wrench
by
nut
ST38020000
Use axle stand
special tool ST07630000
Withdraw axle bearing together with brake disc and
bearing cage by using a puRer special tool
0 ST371400
and secure
axle on vise
Fig
RA 7
Remove oil Seal
required
Do not use removed oil
seal again because lip is damaged When removing bearing
Fig RA 4 Secwring axle in
cup from 7
as
Remcwing bearing
Unbend lock washer with a screw driver Do not use
bearing cage remove seal apply
rass bar
and
tap it evenly with a hammer
unbent lock washer again
INSPECTION I
replace Repair or replace when
When axle is cracked
bent
Bending limit
10
mm
0 039 in
on
reading
of
indicator placed in center when axle is
supported
at
both
end center
holes 2
Repair or replace when seal surface and or thrust
block side end surface is roughened
Fig RA 5 Unbending loci wruher
3
RA 2
Replace when bearing
is defective
Rough rolling
REAR AXLE t i
surface rust on roUer
or other defective
4
condition
Coincide washer
tightening Be sure to replace removed oil seal and lock washer
4
lip with nut groove correctly by
nutand bend washer carefully
lip is not
so that
maged
with new ones When no plain washer is used beneath lock washer
Note
replace lock washer by adding plain washer as a set
INSTALLATION Fit bearing cup and grease seal
1
with
a
evenly while fitting
brass hammer
grease MIL G2108
or
rubber
to cage Fill
Tap
5
lip with
Fit oil seal to tube end evenly
bar When fitted apply grease to lip
G 10924 after fitting seal
by applying a brass
Multi purpose grease
MIL G2108 or GI0924
I 2
Install brake disc and bearing cage
on
axle
and fit
Be careful not to deform seal or damage lip
Note
bearing cone with a special tool ST38220000 Fill bearing with grease
6 Note Cone may be fitted by using a brass bar
G2108
or GI0924
MIL greas
Multi purpose
completely
Install left or right shaft and adjust clearance toward
7
direction by applying shim
axial
i
cated
by arrow
mark
Clearance toward axial direction
3 to 0 9 mm 0 012 to 0 035 in 0
Standard shim thickness 5 mm 0 059 in I
Fi
3
RA 8
nstaUing bearing
Tighten lock nut with a special tool ST38020000
Be careful to
place the faced side of nut to washer side so
that washer is not damaged
Tightening torque
15 to 20 kg m 108 to 145 ft Ib
Fig 8
RA tO
Adjust shim
Install shaft in opposite side
and adjust clearance
toward axial direction by applying shim
Clearance toward axial direction F
6 02 to 0 15
mm
0 0008 to 00059 in
Tightel torque ing Fig
RA 9
3 6 to 4 7 kg m 26 0 to 34 0 ft Ib
Tightening lock nut RA 3
CHASSIS Install other parts in reverse sequence to removal
1
Fig
RA ll
MClJSUring clearance toward tDCW direction
I
REAR SUSPENSION CONTENTS
DESCRIPTION
RA 5
SUSPENSION ASSEMBLY
RA 5
Removal SPRING Removal
AXLE
CASE
RA 5
Removal
RA 5
RA 5
INSPECTION
RA 5
ASSEMBL Y
RA 6
RA 5
SPEC I FICA TIONS
RA 6
AND REPAIR
RA 6
U
YO
i
c
@
Ofr
ff l
4
1 2
3 4
5
Spring helper rubber Qiprcar spring Pin rear spring front Pad rear spring lower R H L U Assy shackle rear spring outer
6
7 8 9
Leaf rear spring Kit shock absorber rcar Padrear spring upper Shackle rear spring inner
Fig
RA 12
Rear suspension
4 RA
10 11 12
13
Assy bush rear spring rear Assy bumper Reinforcement rear axle Bush robber shock absorber mounting
REAR AXLE DESCRIPTION The
rear
Banjo
suspension is a
which uses a parallel
type rigid suspension leaf spring Both front
elliptic semi
and rear ends of the spring are secured on the frame with rubber bushings and the shock absorber is installed on the cross
member from the spring lower pad The suspension
type is an under slung type
SUSPENSION
ASSEMBLY
Removal Fig I
RA H
Removing suspension assembly
Jack up vehicle and support it with stands Remove
road wheel
SPRING 2
Disconnect hand brake
wire
a
equalizer
unit
Removal
separate bracket CD
3
Remove brake tube
propeller shaft
@
4
axle
Support
remove
Note
shock absorber
V
@
Jack up vehicle
and
not
case
with
a
jack at
the
center
and
necessary
to
remove
spring
seat
2
Support axle case with jack or stand
3
Remove V bolts and separate
spring from axle case
from
shock absorber unless otherwise required
Note
It is
not
necessary
shock absorber
5
support it with stands and remove
road wheel
spring pin ID and shackle assembly @
It is
r
and
to
remove
nless otherwise
spring
seat
from
uired
Lower jack slowly and remove suspension assembly 4
Remove
manner
spring pin
and shackle
assembly in
the
identical with removal of suspension assembly
and remove leaf spring
AXLE CASE Removal 1
Jack up vehicle
support it with stands and remove
road wheel
2
Remove hand brake wire brake tube shock absorber
and propeller shaft
Remove U bolts and separate axle case from spring r
3
Pass axle case through space above spring and take it
out to the side
Fig RA lJ Removing re4r suspension RA 5
1 I
CHASSIS rubber and bushings
4
replace
Shock absorber If leaking noise or reduced
damping force is detected
repl ce
ASSEMBLY Rear suspension assembling is carried sequence to disassembly
I
out
in reverse
by noting the following items
When installing rubber bushings
coat soap water on
them slightly
Pig RA 15 Removing
Ie case 2
conditions after jacked down
INSPECTioN AND REPAIR I
Tighten the following rubber bushing under no load
Spring When
is
spring
cracked
broken
or
weakened
Shackle pin
I 1 5 to 13 kg m 83 2 to 94 0 ft Ib
Spring pin
5 to 13 kg m 83 2 to 94 0 ft Ib 11
ex
cessively replace
Tightening torque Note When
spring in one side is replaced
sprinilJn 2
recommend
U bolt securing nut
5 to 10 0 8
the other side be also replaced
5 to 61
m kg lb ft
3 72
Shock absorber installing nut
V bolt
Vpper When V bolt is bent
bruised cracked
or
broken
3 6 to
Lower
or
3 4
m 26 0 to 31 1 kg
4 to 1 6 kg m 1
10 1 to 11 6
lb ft lb ft
when threaded part is damaged replace
Propeller shaft 3
Rubber and bushings When
crac
wear
damage or deterioration exists in
Securing bolt
5 to 3 0 kg m 2
18 1 to 21 7 ft Ib
Securing bolt
2 3 to 2 8 kg m
16 6 to 20 2 ft Ib
SPECIFICATIONS
N 521 PL521 Rearspril18 UrlJth x width No of leaves
55020 20400
55020 20500 72
thickness 1 200 nun
G521 N
60
On
62 12 1
12 2
0 2756 2 47 2
2 36
02362 2
47 2x 2 36
0 4724 1
l
f
61
6 RA
U N 521 Option
55020 20801
55020 20800 7 2
1 200 x 60
U 52t N
V N 521
63 1 200
60x
51
63
200 1
x
60
12 1
0 27562
0 2362 3
0 2362 1
47 2 x 2 36 x 0 1969 1
0 47242
0 4724 1
5 1 12 2 0 2362 3
47 2
2 36
0 1969 1 0 4724 2
REAR AXLE
N 521 PL52
3 04
Spririg constant kg
mm
bfin
lb kg
170
0 to 20
1
N 521 G
5 2
0 to 44 J
292
257
144
20
0 to
195 0 to 430 1
95 to
9 9 544
than 5 8 1142
U N 521
112 95
2 209 to 430 1
4 5 252
than mo
mo
U 521 N Option
V N 52t
277 6
I
more
112 0 100 to 200 220 to 441 J
5 3 297
than 500
1102
th mo
1
500
1102
Camber
Free
mm
in
127
5 00
143
5 63
170
6 69
in
35
38 1
11
43 0
33
30
650
1433
698 5
500
102
70 6 69
Loaded with specified load mm
lb kg
540
5 27
108
500
1102
Spring eye diameter Front
in mm
41
161
4
16
4
161
41
161
11
in mm
33
30 1
33
30 1
3
22 1
31
1 22
Shock absorber
GN52
Stroke x max length
mm
in
t90
PL521
475
U V N 521
7 48 x 18 7
195 x 485 7 68 x t9
U V N 521 Option
1
195 x 485
7 68
19
r
I
11
Damping force at 0 3 mls Rebound
lb k8
97
213
72
158
72
158
90
198
Compression
lb kg
29
63 9
21
46 3
21
46 3
28
617 r
SERVICE JOURNAL OR BULLETIN REFERENCE
DATE
JOURNAL
or
BULLETIN
No
PAGE
No
SUBJECT
T
RA 7
CHASSIS
t
DATE
E JOURNAL UR RViJ
JOURNAL
or
BULLETIN
No
PAGE
6UL ETli l
No
SUBJECT
f
fi 1
lRECFEEHEi
B RA
SECTION BR
BRAKE
j i
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
r
I NIS
J
NI
l
ArJf NISSAN MOTOR CO TOKYO
LTD
BR
BRAKE
JAPAN
w
1
1
VA tf
BRAKE
BRAKE
CONTENTS DESCRIPTION
BR
Inspection
BR
6
BRAKE
BR
Reassembly and reinstallation
BR
8
PEDAL
t
Removal
BR
REAR BRAKE
BR
8
Inspection
BR
Removal and
BR
9
Reinstallation
BR
1
Inspection
BR
9
BR
2
Reassembly and reinstallation
BR l1
MASTER
CYLINDER
Removal
BR
2
Disassembly
BR
3
I nspecti on
BR
3
Inspection
Reassembly
BR
3
Installation
Reinstallation
BR
3
ADJUSTMENT
BRAKE
HAND BRAKE
BR 12 BR 13
iBR 1
pedal leight
4
Bra k
BR
4
Brake shoe clearance
Inspection
BR
4
Hand brake
Reinstallati m
BR
4
BR
5
SERVICE
DATA
BR
6
TROUBLE
DIAGNOS AND CORR
Removal and disassembly
3 l BR 13
BR
BRAKE
BR 12
1
Removal
Removal
FRONT
LINES
disassembly
BR 13
i I
i
BR 14 BR 14
Bleeding hydraulic system
BR 15 7
AND SPECIFICATIONS
BR 15
CTIO
BR 17
r
DESCRIPTION
Removal
The Datsun 521 series vehicles adopt a hydraulic brake The front brake is of a a duoservo
servo uni
type
I
Unhook return spring CD
2
Remove spring pin and clevis pin
and rear brake is of
type The master cylinder is of a single type
The hand brake is of a mechanical type
which operates
@ arid separate
push rod from pedal arm
the rear wheels 3
Remove fulcrum pin
@ and remove brake pedal
arm
BRAKE PEDAL F
Inspection Check
sliding parts for wear and return pring for
weakness
2
Check brake pedal for bending warping and crack
3
Check other parts for condition
Reinstallation Reinstall brake pedal in
2
Slightly and evenly coat multi purpose
G2108
Fig BR l Bra1ee pedal right hand
or
of removal
grease
MIL
GI0924 to sliding parts of fulcrum pin and
clevis pin and hook
P9rtion of return spring 1
BR l
reverse sequence
ii
CHASSIS 3
Tightening torque steering wheels
Fulcrum pin For vehicles
with
both
left
3 5 to 4 0 kg m
and right hand
MASTER CYLINDER
1
Valve cap
8
Packing
15
2
Valve cap gasket
9
Stopper bolt
16
Secondary piston cup
3
Check valve
10
Piston return
17
Stopper ring
4
Check valve spring
tt
Spring scat
18
Snap ring
5
Oil reservoir cap
12
Spring
19
Rubber boot
20
Push rod
6
Reservoir
13
Valve
7
Reservoir band
14
Piston
Fig
spring
Primary piston cup
BR 2 Master cylinder
Removal I
2
nect brake pedal return spring Disc
Remove clevis pin
and separate brake pedal from
master cylinder push rod
3
Disconnect brake tube CD from master cylinder
4
Remove
assembly
to
@
two
bolts
front
dash panel
retaining and
master
remove
cylinder
shims and
master cylinder assembly
Fig HR 3 Master cylinder
4r
BR 2
3 to 28 9 ft lb 25
BRAKE Disassembly
In
principle replace piston cup gasket and valves with
new ones
I
Drain brake fluid
2
Remove stopper bolt
5
3
Remove rubber boot
remove
4
whenever master cylinder is disasSembled
Check piston return springs for damage
snap ring and stopper ring and
6
Replace
others
if deformed
out
piston
and
damaged oLdefective
push rod
Take
wear
other defective conditions and replace as necessary
and
other related
from
parts
cylinder 5
Remove valve cap
and then remove gasket
check
Reassembly
valve and check valve spring
I Note
Disassemble master cylinder carefully so that the
Assemble
cylinder in
master
reverse
sequence to
disassembly
sliding surfaces of piston and piston cup are not damaged
Do
absolutely
necessary
not remove
fluid
Moreover
reservoir
unle
2
do not remove
Apply rubber grease to piston cup and other rubber
parts slightly Apply brake fluid to other component partS j
piston cup unless piston is replaced
and carry out the operations carefully
parts are
damaged
not
or
no
o that
dust and
component
oiher foreign
materials enter cylinder and brake fluid reseivoir
3
Tightening torque Valve cap
6 to 9 kg m 43 4 to
1 ft Ib 65
Inspection I
Thoroughly wash all disassembled parts in brake fluid
J
0
or alcohoL
Note
Do not wash rubber parts with mineral oil
they
are
When
Reinstallation
since
deteriorated
alcohol
is
used
however
Reinstall
do not immerse
Check cylinder and piston for damage and
wear
on
conditions
3
the
2
Fill reservoir with brake fluid
and
wheel
cylinder
uneven
Replace
sliding surface and for other defective
Note
3
if the cylinder and piston clearance is more
Master cylinder inner diameter
sequence
to
cylinder which
is
Bleed master cylinder
located nearest
master
Make sure that no brake fluid leaks
Do not use brake fluid other than specified
For pedal height adjustment
refer to the paragraph
covering pedal adjustment 19 05 mm
in 4
Tightening torque Master cylinder
Replace piston cup packing and valves if damaged
worn
reverse
Replace as required
than 0 15 mm 0 0059 in
4
in
dry them with compressed
air
2
cylinder
removal
rubber parts in alcohol longer than 30 seconds
After parts are cleaned
master
2 1
to
5 kg m 2
15 2 to 18 1 ft b
weakened or expanded
BR 3
CHASSIS BRAKE LINES
I
Brake hose
2
Brake tube
3
Brake
4
Front 4 way
tube
connector 5
Brake tube
6
Brake tube
7
Brake hose
8
Connector
9
Brake tube
10
Vinyl cover
11
Brake tube
12
Brake hose
13
Rear 3 way connector
Fig
BR4 BTaJe
14
Brake tube
15
Brake tube
lines
Removal 1
Disconnect brake tube
by turning flare nuts on the
both ends and remove clips used to secure brake tube on the panel
Fig
BR 6 Rear J WdY ConnectoT
Inspection Thoroughly clean brake tube and brake hose Fig
2
Disconnect
BR 5
FTont 4
them for collapsing
connector
crack scar and rust
for weakness expansion ear
Replace
brake hose from brake tube at 3 way
scar
Check
brake tube
and
and crack brake hose
if defective
connector by loosening flare nut
Reinstallation 3
Disconnect front brake hose
by turning flare nuts on 1
the both erids
1l
4 BR
Provide
a
sufficient space between brake lines and
BRAKE other parts so that brake lines do not interfere with other
4 way connector to 1 7 to 2
brake tube
parts due to vibration during driving
Connector to brake tube 2
Apply brake
fluid to threaded part of brake tube
12 0
3 to 14 5
17 to 2 0
12 to 3
5 14
17 to 2 0
12 to 14 5 3
Wheel cylinder to
flare nut correctly engage threads and tighten flare nul
brake hose Wheel cylinder to
3
Install brake
hose
Install front brake hose is not
being
sure
not
to twist
hose
hose
be
sure
Brake hose to brake tube
When brake hose is disconnected from 3 way
copper packing with
5 14
17 to 2 0
io
5 14
3 to 12
5 14
that hose is not twisted when 6
nector on rear axle
3 to 12
17 to 2 0 12
brake tube
wheels are completely unloaded
4
3 to 14 5 2
3 way connector to
suspension components do not interfere with brake In addition
17 to 2 0
brake hose
Turn
steering wheel from lock to lock and make sure that tires and
1
3way connector to
twisted when vehicle is in posture with standard
load and wheel is set to straight driving position
7 to 2 0 1
brake tube
particularly carefully so that hose
housing
once
be
sure
to
Fill master cylinder reservoir with brake fluid and
perform air bleeding completely
con
replace
7
brake
make
air bleeding
Upon completion of
a new one
sure
that
I
operates correctly and no brake fluid leaks from
brake tube and hose connectors 5
Tightening torque
Fully depress brake pedal kg m
ft Ib
pedal
4 way connector
10 to 1 5
7 2 to 10 9
3 way connector
10 to 1 5
7 2 to 10 9
17 to 2 0
3 to 12
continue to
If fluid leaks from connector
leakage
depress brake
and check brake line for fluid
for several seconds
tigh
connector
or replace if necessaiy
Master cylinder to brake tube
5 14
Note
Do not use brake fluid
1l1an specified otlll
FRONT BRAKE 1
Brake di
2
Front brake shoe Fore
assembly 3
Front
brake shoe
assembly After 4
Upper return spring
5
After shoe return spring
6
Wheel cylinder assembly
7
Adjuster assembly
8
Adjuster housing
9
Adjuster wheel
10
Adjuster screw
11
Adjuste
12
Shim
lower return spring
@@
Fig
HR 7 Front brake
BR 5
head
13
Lock spring
14
Spring plate
15
Lock plate
16
Shim
17
Rubber boot
CHASSIS r
Removal and disassembly
lf round Out
Jack up vehicle and support it with stands
I
254 mm
Inner diameter
10 00 in
Less than 0 02 mm 0 0008 in
2
Remove wheel and brake druOL When brake drum
Umit ofrebored drum JD
255 mm 10 04 in
cannot be removed easily return brake adjuster
3
In order to
ease
operation
remove
hub assembly
2
Brake shoe lining
from front spindle When
seated 4
Unhook upper lower and after shoe return springs
linings
are
cracked
incompletely
unevenly worn and or deteriorated due to exces
sive heating or soiled with grease
and then remove brake shoe assemblies
repair or replace
When
thickness of brake shoe lining is less than 1 0 mm 0 0394 in
5
brake shoe
replace
Disconnect brake hose from wheel cylinder Note
6
Loosen securing nut and remove wheel cylinder
7
Remove rubber boot
a
If oil
or
grease is found on brake shoe
grind brake
b When brake shoe lining is installed
spring plate
linings
clean thoroughly with solvent
lock plate and
lining face to diameter equal to that of brake
shoe
shim and then remove adjuster assembly from brake disc
drum
Lining dimension Width x Thickness x Length 45 x
Inspection I
5 x 244 mm 4
Total friction area
Brake drum
18 x 0 2 x 9 6 in
440 cm2
68 2 sq in
Thoroughly clean and inspect brake drum Replace if cracked or excessively damaged or
is
When brake drum in teri
excessively worn or scratched
excessive
correct
by
means
or
of rebating
of out
3
Check adjuster for smooth operation
round is
When minor
4
polish with fine emery cloth
Return springs Ifthey are considerably weakened
them
tce re
Return spring dimension
Upper return spring Wire diameter mm in x
free length mm in
20 x 136 5
37
0 079 x 5 37
37
Lower return spring
3 x 134 5 2
35
0 091 x 5 30 35
After shoe return spring
I 4 x 83 2
27 5
0 055 x 3 28
27 5
turns
Load kg Ib x
length mm in
15 x 159 5
22 x
0 591 x 6 28
0 866 x 6 28
6 BR
5 159
4 5
x
99
0 177 x 3 90
i
BRAKE
1 1
11 4
12 810 5039 die
4488 dla
11
1111
II
IU
ENGTH
FR
136 515
r r
371 F
Unit
mm
H
134 515
301
Unit
in
Fig BR 8 Upper return spring
mm
in
BR 9 Lower return spring
Fig 5
Check brake disc for distortion
6
Wheel cylinder
f
fl @
@
1
Wheel cylinder housing
2
Piston
3
Piston cup
4
Dust cover
5
Snap ring
6
Connector
7
Packing
8
Connector bolt
9
Bleeder screw
10
Bleeder cap
Fig BR I0 Front wheel cylinder I
1
Wheel
cylinder
can
be disassembled simply by the
Chec the
corrosion
following procedure described below
wash all disassembled parts in brake fluid
or alcohol
rubber parts in alcohol After parIS are cleaned
JA r
O Qo Wheel
t
Sup
damage X replaced if deformedrecommended that
cr ck
i tde Cy must
r
pla c ithem
if1il
diameter
20 mm 13 16 in 64 due
c6rroSign and
or
aging
min1 oil since
to
It is
piston eiJp be replaced even if they
are
apparently in
satisfactory condition
they are dotsriorated When alcohol is used
Qf wheel cylinder for scratches and
i
mm
of piston and piston cup
Do not wash rubber parIS with
it
beiew n cylinder and piston exceeds 0 15 Ifclelirimc
from wheel cylinder Be careful not to damage sliding part
Note
J
t
Remove snap ring and dust cover and take out piston
Thoroughly
ore
however
do not immerse
Assemble wheel cylinder in reverse sequence to disas
longer
than 30 seconds
sembly Carry out operations carefully so that component
dry tham with comprassed
parts are
air
not
damaged
materials enter cylinder
BR 7
or
no
dust and other foreign
CHASSIS Apply rubber
grease to
piston cup and other rubber
parts slightly and brake lIuid to piston and cylinder bore
Reassembly Reassemble sequence to
and reinstallation and
reinstall
front
disassembly and removal
brake
in
reverse
Note the following
matters
I
When
grease
to
assembling adjuster adjuster housing
assembly
bore
adjuster
apply
brake
wheel and
adjuster screw When installing adjuster assembly to brake disc brake grease to disc
adjuster
and spring
Fig
apply 3
Tightening torque
sliding resistance Adjust by shim
Whee
when sIding resistance is incorrect
cylinder bolt
Connector
I 10 to 26 5Ib
Before
installing brake shoe assemblies apply brake
grease to wheel cylinder and adjuster brake shoe installing grooves and brake disc and brake shoe assembly contact
4
faces
Upon completion
two places
Be careful not to allow brake grease to
stick on brake shoe surface
17 to 2 0
12 3 to 4 0 to
Brake disc 2
4 2 to 5 2
rn kg
30 4 to 37 6 ft Ib
Adjuster sliding resistance 5 to 12 kg
Greasing points on ront brake
plate sliding
surfaces to slide adjuster smoothly Measure adjuster
BR l1
rn kg
5 4 4 5
lb ft
rn kg
28 9 to 39 0
lb ft
Adjust brake shoe clearance and bleed brake system of the above
adjustments make
that brake operates correctly and no brake fluid leaks
REAR BRAKE
1f1
1
Brake disc
11
Adjuster head
2
Rear brake shoe
12
Shim
assemblies
13
Lock spring
Fore
After
14
Spring plate
Upper return
15
Lock plate
spring
t6
Shim
Lower return
17
Rubber boot
spring
18
AntiI1lttle pin
After shoe
19
Spring seat
return
20
Anti rattle
3
4
5
6
Fig
BR 12 Rear brake
8 BR
spring
spring
Wheel cylindet
assembly
21
Retainer
7
Adjuster assemblY
22
Extension link
8
Adjuster housing
23
Toggle lever
9
Adjuster wheel
24
Retumspring
10
Adjuster screw
sure
k
BRAKE
if
8
Remov al and disassembly
Disconnect brake tube at wheel cylinder by loosening
flare nut J
Jack up vehicle and support with stands
2
Remove wheel and brake drum
9
Remove wheel cylinder from brake disc by loosening
installation nuts
10
Remove rubber boot
spring plate lock plate and
shim and remove adjuster assembly from brake disc
1
Inspection For the rear brake inspection
refer to the instructions
for front brake
I
Fig
BR tJ Rear b ake
Brake drum
Refer to the paragraph covering brake drum of front brake
3
4
Remove anti rattle pin
Open brake shoe assemblies outward against return
Out of round
0 02 mm 0
0008 in 255 mm 10 04 in
Remove return springs 2
6
254 mm 10 00 in
Limit of rebored drum LD
spring and remove extension link 5
Inner diameter
Remove brake shoe assemblies
Note that after brake
Refer
When shoe assembly must be separated from toggle lever
7
Lining to
paragraph covering front
the
brake shoe
lining
separating after brake shoe assembly from toggle lever I
withdraw clevis pin
7
Disconnect toggle lever from hand brake rear cable
lining dimension Width x Thickness x Length 45 x 4 5
x
244 mm
Total friction area
Tpgg e lever
rJ
BR 14 Removing toggk leve
68 2 sq in
r
4 r
Fig
440 em
Check adjuster for smooth operation
3
I
18 x 0 2 x 9 6 in
Return
springs
Ifthey are considerably weakened replace them
r
9 BA
CHASSIS
1
J
Upper return spring
Wire diameter mm in x
2 0 x 175
free length mm in
2 3 x 158
32 5
0 079 x 6 89
spring
Lower return
0 091
32 5
x
After shoe return spring
14 x 83 2
5 27
0 055 x 3 28
27 5
30
6 22
30
turns
x
19 x 176
5 x 99 4
0 748 x 6 93
0 188 x 3 90
12 x 184
Load kg lb
473 0
length mm in
FREE LENGTH
x
7 24
FREE
L
1U
ll 1
1010 3941dia
Unit
Fig
BR 15
LENGTH
17516 69
mm
56
I 111 12 610 504
Unit
in
Upper return spring
Fig
mm
in
BR 16 Lower return spring
5
Check brake disc for distortion
6
Wheel cylinder
1
@ @J
@ CD
@
I
Wheel cylinder housing
2
Piston
3
Piston cup
4
Piston head
5
Dust caver
6
Connector
7
Connector bolt
6
Packing
9 10
r
Fig BR 17 Rear wheel cylinder
BR l0
Bleeder screw Bleeder cap
i
1
c
v
d
3
Wheel cylinder ifUler diameter
1 cover
For
piston assembly
Before installing brake shoe assemblies
apply brake
grease to the following places
64 mm 13116 in 20
Remove dust
t
BRAKE
and pull
out
piston head and
Brake shoe installing grooves of adjuster and wheel
cylinder
inspection and reassembly refer to
Wheel cylinder offront brake
2
Extension link installing grooves
3
Lower surface of spring seat
4
Contact surfaces between brake disc and brake shoe
assembly Six places
Reassembly
At this time
and reinstallation
be
sure
not to coat brake grease to the
surface of brake shoe Reassemble and reinstall rear brake in reverse sequence of disassembly and removal
1
noting the following mailers
Refer to the notes for front brake
1
Rear adjuster assembly is the same as front Refer to
ng front adjuster assembly covel
the paragraph
Adjuster sliding resistance 5 to 12 kg
n o to 26 5Ib
assembly
assembling toggle lever and after brake shoe adjust clearance between toggle lever and after
brake shoe
assembly to 0 to
2
a
When
3 mm 0 to 0
Ql18 0
in with
properly selected toggle pin washer
Fig
Part No
Thickness
44034 32200
2 0
0 079
44034
14800
3 2
0 091
44034
14801
2 6
0 102
44034 14802
2 9
0 114
44034 14803
3 2
0 126
mm
in
4
BR 18
Greasing points on rear brake
Tightening torque 1 5 to 18 kg m
IO 8to 13 0 ft Ib
Connector bolt
17 to 2 0 kg
12 m
Brake disc
4 0 to
28 9 to 39 0 ft Ib
Wheel cylinder
5
4 kg m 5
3to 14 5 ft Ib
Adjust brake shoe clearance and bleed brake system
Upon completion of the above adjustments
make
that brake operates correctly and no brake fluid
Itaks
r
BR ll
l
sure
r I
CHASSIS HAND BRAKE
@
I
Control bracket
6
Set spring
11
Inner lever
15
Equalizer
2
Control lever
7
Front lever
12
Arm spring
16
Rear cable
Lock plate Cable spring
3
Control stem
8
Front cable
13
Center link rod
17
4
Control guide
9
Outer lever
14
Equalizer link
18
5
Control yoke
10
Center cable
Fig BR 19 Hand brake construction
Front cable center cable
Removal
Completely loosen hand brake
Control stem 2 1
Completely loosen hand brake
2
Remove
clevis
pins
D
and
@
and
Remove clevis pin and separate cable from lever
separate
control steOL
Fig BR 20 Control stem
Fig
BR 12
BR 21 Cable and lever
1
BRAKE Rear cable
2
Replace if ratchet pawl and teeth are worn excessive
ly or unusually or damaged
I
Completely loosen hand brake
2
Remove clevis pin and disconnect equalizer from
3
Check springs for weakness
and replace if required
equalizer link
Installation 3
Remove lock plate CD and cable spring @ Reinstall hand brake in reverse sequence of removal
Grease
sliding parts with multi purpose grease
MIL
G2108 or GI0924
JUSTMENT AD
Brake pedal
height
Loosen stopper up to such an extent that stopper is
separated from pedal arm
Fig
HR 22 Lock
p
Fig HR 23 4
Rear cable
Unit
Remove both side rear brake drums and disconnect
rear cable from
5
and cable spring
mm
On
toggle lever @
Fig BR 24 Brake pedal adjustment
Separate cable connecting flange @ from brake
disc 2
Check cable for
master
cylinder push
rod
fully pulled
out
adjust thickness of adjusting shim so that height of brake
Inspection I
With
damage
ices ive e
elongation
pedal head is 138 5 mm
45 5
Standard shim thickness
1 6 mm
in from dash panel
and
other defective conditions and replace if required
BR 13
0 0630 in
r
CHASSIS
i
Rear drum brake Part No
Thickness
3061 I 27260
16
00630
30612 27260
0 8
0 0315
30613 27260
5 0
0 0197
mm
in
With hand brake fully released For
clearance
Note
When
having the m
be
adjusting
sure
to
for thickn
same
procedure
refer
to
Front drum
brake
adjusting
shim
upper and
lower
use
the
adjust rear brake shoe
cylinder installation bolts
Screw in stopper so that height of brake pedal head is
3
5 mm 135
5 33 in
and tighten lock
from dash panel
nut
Brake shoe clearance
Front drum brake
Fig BR 26 Adjusting rear brake
Jack up vehicle to lift up wheel
Hand brake
2
Remove rubber boot from brake disc
3
tightly tap adjuster housing and rrtove it forward
adjuster wheel with a screwdriver and spread brake shoes Stop turning adjuster wheel when a Turn
For both left and right brakes when adjuster wheel i
4
rear
adjust screw
cable stretched A portion
so
adjust equalizer link with that
L
dimension
shown
in Figure BR 27 is standard dimension Lock adjust screw
with lock nut
considerable drag is felt on brake drum Note
With
brake shoes
Equalizer link
spread
L dimension 161 5 mm 1 29
turned downward
in
Return adjuster wheel 12 ratches to obtain correct
clearance between brake drum and brake shoes Turn brake drum and make sure that brake drum turns without dragging brake drum 5
when
brake
shoes
interfere with
readjust clearance
Install rubber boot
e
f I
Fig BR 27 Hand brake adjustment F
Adjust front cable adjust Fig
BR 25
Adjusting front Inake
screw
B
control stem stroke is 80 to 100 mm
BR 14
portion
so
that
3 15 to 3 94 in
BRAKE when control
stem is pulled with a force of 20 to 30 kg
44 1 to 66 llb
Lock adjust screw with lock nut
other end of hose in a container containing some brake fluid
Normal stroke 3
80 to 100 mm 3 15 to 3 94 in Limited stroke Less than 144 mm 5 67 in Note
H nd
4
brake must operate smoothly
pulled and released noise
Depress brake pedal
two
or
three times
and keep
pedal fully depressed
while being
With brake pedal
screw
fully depressed
open the bleeder
to exhaust air
Make sure that no abnorm 1
dragging twisting or
5
othf ulty condition
Close bleed
screw
quickly as brake pedal is on down
stroke
occurs
Readiust when stroke exceed
limit 6
Allow brake pedal
to
return
slowly with bleeder
screw closed
7
Bleeding hydraulic system
Repeat these operations until no air bubbles emerge
in hose
Bleeding hydraulic system deserves much attention as it is an essential factor for regular service brake operation As
matter
a
of fact
during the brake service
8
air is
Conduct air bleeding on remaining wheel cylinders in
the same manner
creep into the circuit with the result that the
likely to
Note
fluid action is altered and brake pedal becomes spongy at
Check l 1lS8IVoir
operation
the travel end
b
1
Fluid
drained
and top up reseIVoir with the recommended
c
brake fluid
Thoroughly clean
screw
so
materials
the
bleeding
option
Ordinarily
ir
bleeding
i
performed
in the
following sequence Rear left
2
during
should not be used again for refilling
Clean any dirt around master cylinder reseIVoir and
reservoir cap
for fluid level during bleeding
that
the
any mud
or
dust from bleeder
d
outlet ho1e
is
free
pl ced
then attach
a
vinyl
from
hose to bleeder
foreign Dip
the
When
Rear right master
conduct
Front left
cylinder i air
bleeding
Front right
diSassembled
which i located most near to master cylinder
SERVICE DATA AND SPECIFICATIONS Specifications Brake type Front
servo Uni
Rear
servo Duo
Mechanical operating on rear wheels
Hand brake Brake drum Front Rear
mm
in
254
10 00
in mm
254
10 00
BR 15
or re
on wheel cylinder
CHASSIS Brake lining Dimension
front
rear rom
in
45 x 4 5
em
sq in
440 68 2
Front
rom
in
20 64
13 16
Rear
rom
in
20 64
13 16
rom
in
19 05 3 4
rom
in
138 5
545
rom
in
5 135
33 5
width x thickness
x
length
Total friction area
x
244
18 x 0 2 x 9 6
Wheel cylinder
Master cylinder diameter
Service data
Master Cylinder push rod At brake pedal height
Brake pedal Brake pedal height Wheel cylinder Allowable maximum clearance between
cylinder and piston
rom
0 15
0 0059
in
0 15
0 0059
in
0 02 0 0008
in
Master cylinder
Allowable maximum clearance between
cylinder and piston
rom
Brake drum Allowable maximum
fround out rom
Allowable maximum inner diameter of rom
in
255
10 04
rom
in
10
0 0394
rom
in
29 5
161 1
Normal stroke
rom
in
80 to 100 3 15 to 3 94
Allowable maximum stroke
rom
in
144
rebored drum
Brake lining
Allowable minimum thickness Hand brake
Equalizer link
L dimension
BA 16
5 67
BRAKE Tightening torque Fulcrum pin
kg m
lb ft
5 to 4 0 3
3 to 28 9 25
Master cylinder
kg m
lb ft
2 1 to 2 5
15 2 to 18 1
m kg
lb ft
6t09
Master cylinder valve cap
4 to 65 1 43
4 way connector
kg m ftIb
10 to 15
7 23 to 10 85
3way connector
kg m ft lb
10 to 15
7 23 to 10 85
30 4 to 37 6
Front brake Wheel cylinder
kg m
lb ft
4 2 to 5 2
Connector bolt
kg m
lb ft
1 7 to 2 0
Brake disc
kgm
lb ft
4 0 to 5 4
28 9 to 39 0
Wheel cylinder
kg m
lb ft
5 to 18 1
10 8 to 13 0
Connector bolt
kg m ft Ib
1 7 to 2 0
123 to
Brake disc
kg
4 0 to
28 9 to 39 0
3 to 12
5 14
Rear brake
m
ftIb
4 5
5 14
Brake lines Master cylinder to brake tubO
kg m ft Ib
4way connector to brake tube
kg m
Connector to brake tube
kg m ft lb
17 to 2 0
3 to 14 5 12
Wheel cylinder to brake hose
kg m ft Ib
7 to 2 0 1
12 3 to 14 5
Wheel cylinder tolbrake tube
kgm ft Ib
1 7 to 2 0
12 3 to 14 5
3way connector to brake hose
kg m ft Ib
17 to 2 0
3 to 14 5 12
Brake hose to brake tube
kg m
17 to 2 0
3 to 14 5 12
3 way connector to brake tube
kg m ft Ib
Ito 2 0 7
3 to 14 5 12
lb ft
lb ft
7 to 2 0 I
3 to 12
5 14
Ito 2 0 7
12 3 to
5 14
TROUBLE DIAGNOSES AND CORRECTIONS Condition
Probable cause
Corrective action
Lack of braking power Excessive pedal
Grease
mud or water on brake shoe linings
pressure required
Remove drums Clean and
dry brake shoe linings or replace
poor brakes
Full area of linings does not contact
Replace brake shoes
Scored brake drums
Reface drums and install
linings
BA 17
new
brake shoe
CHASSIS
Condition
Spongy pedal
Probable cause
Corrective action
Deteriorated brake shoe lining face
Replace
Worn brake shoe lining
Replace
Oogged brake line
Inspect and clean
Air in brake lines
Bleed thoroughly
Swollen hose due
to
deterioration or use of
Replace hose and bleed system
poor quality brake fluid
Use prescribed brake fluid
Use of a brake fluid boiling poin t of which is
Change
too low
bleed system
Oogged reservoir filler cap vent hole This promotes
a
vacuum in
with
prescribed
brake
fluid
and
Clean reservoir filler cap and bleed system
master cylinder
that sucks in air through rear seal
Pedal yields under
Deteriorated check valve
Fit a new check valve and bleed system
External leaks
Check master cylinder
slight pressure piping and wheel
cylinder for leaks and make necessary repair Leakage from master cylinder through pri
Overhaul master cylinder
mary cap
Unbalanced brakes
Insufficient brake fluid level
Check and add
Tires improperly inflated
Inflate tires to correct pressure
Improper brake adjustment
Readjust
Water or oil on brake shoe linings
Oean or replace
Mud or sand on brake drum
Clean
Deteriorated brake shoe lining face
Repair by means of polishing or replace
Improper brake shoe lining contact
Repair by means of polishing
Improper brake shoe lining angle
Rearrange or replace
Worn brake shoe linings
Replace
Deformed brake shoe
Replace
BA IB
BRAKE
Condition
Corrective action
Probable cause
Worn or
damaged
rust
other than
brake
Repair or replace
drum
Brake drags
Defective wheel cylinder operation
Repair or replace
Faulty brake shoe sliding
Adjust and apply brake grease
Faulty adjuster sliding
Apply brake grease
Loose back plate installation bolt
Retighten or replace
Deformed back plate
Replace
Improperly adjusted wheel bearing
Readjust or replace
Improper wheel alignment
Readjust
Clogged brake lines
Inspect and clean
Loose leaf spring U oolt
Retighten or replace
Insufficient brake shoe drum clearance
Adjust
Clogged master cylinder return port
Clean and adjust brake pedal height
No play on brake pedal
Squeak
Faulty brake shoe sliding
Adjust and apply brake grease
Faulty adjuster sliding
Adjust and apply brake grease
Defective wheel cylinder operation
Repair or replace
Expanded piston cap
Replace
Weakened or broken return spring
Replace
Defective hand brake return
Inspect and correct
Oogged brake lines
Inspect and clean
Improper wheel bearing adjustment
Readjust or replace
Dragging
See
Worn brake shoe lining
Replace
Bfl 19
Brake drags
above
CHASSIS Condition
Squeal
Probable cause
Corrective action
Deteriorated brake shoe lining face
Correct by means of polishing or replace
Deteriorated brake shoe lining face
Correct by means of polishing or replace
Worn brake shoe lining
Replace
Improper brake shoe and lining contact
Replace
Excessive friction between brake shoe and
Oean and apply brake grease
brake disc
Foreign
matter
on
brake drum sliding sur
Oean
face
Damaged or deflection of drum sliding sur
Rebore or replace
face
Chatter
Deformed or improperly installed brake shoe
Correct or replace
Loose back plate installation bolt
Retighten
Worn anchor contact part
Replace
Improper brake shoe lining contact
Correct or replace
Roughened brake drum sliding surface
Rebore or replace
Excessively distorted or deviated drum out
Rebore or replace
of round
Excessive pedal
Roughened brake shoe lining surface
Correct by means of polishing or replace
Improperly adjusted brake
Readjust
Air intrusion into hydraulic system
Bleed system
Brake fluid leakage from hydraulic system or
Check repair or add brake fluid
travel
insufficient lluid level
Worn brake shoe lining
Replace
Tilted brake shoe or faulty return
Correct
RR
O
BRAKE SERVICE JOURNAL OR BULLETIN REFERENCE
DATE
JOURNAL
or
BULLETIN
No
PAGE
No
SUBJECT
BA 21
CHASSIS E JOURI l SERVi
DATE
JOURNAL
or
BULLETIN
No
PAGE
L
OR
No
ET j I EFEI1E Il E k3UU SUBJECT
BA 22
SECTION WT
WHEEL AND TIRE
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
I NISSAN I
1
Jc
NI SSANMOTOR CO TOKYO
JAPAN
LTD
WHEEL AND TIRE
WIl
TROUBLE DIAGNOSES AND CORRECTIONS
WT 5
WHEEl AND TIRE WHEEL AND TIRE
CONTENTS DESCRIPTION
INSPECTION
WT2
I nflation of tires
WT 2
Tire rotation
WT2
WT 2
Wheel
WT 2
CHECKING WHEELS AND JACKING
UP
WT3
TIRE SIZE in
Front
6 00
Rear
6 00 146PR LT
Front
6 00 146PR L T
Rear
6 00 14 8PR
6PR 14
LT
PL52l
G N 521 Series LT
6 00 146PR LT L521 TU Only
U
V 521 N
TIRE INFLATION PRESSURE
Front
50 5
Rear
50 5
t
146PR LT
6PR 14
LT
To be measured when tires are cold Unit
Under 100 km h 60 MPH
Over 100 km h
kg
lb cm2
in
60 MPH Tire size
Front
Rear
Front
Rear
2 05 29
21
75 1
25
1 8 26
15
21
3 0
42
18
26
G N 52I
15
21
2 75
39
18
26
Series
15
21
4 25
60
18
26
15
21
15
PL52 I
N 52I V
Series
46
3 05 43 55 4
64
1 75 25
1 8 26
5 21 1
3 0
42
18
26
3
46
15
21
1 75
25
18
26
2 05
29
15
21
3 25
46
18
26
3 55 50
L52lTU
U
3
Front 6 00 Rear 6 00
6PR 14
8PR 14
LT LT
2 05 29
The upper column indicates moderate load and the lower column indicates heavy load
WTl
for both Front and Rear 6 0014 6PR LT
Rear 6 00 146PR LT
for both Front and Rear 5 50146PR LT
CflASSIS Tighten wheel nuts to
DESCRIPTION
a
torque of
5 to 10 0 kg m 8
61 5 to 72 3 ft Ib
Inflation of tires Tire rotation Tires with proper pressure
improve riding comfort and
steering stability reduce driving sound and extend the
To equalize the wear tires should be rotated as shown
service life
in the diagram
The tires should be
checked for proper pressure
on
monthly bassis or more frequently depending on driving tire conditions while the tires are cold Ordinarily pressure rises
5 0
kg cm
7 Ib
in2
PL521
of that when tire is
10 000 km 6 000 miles
5 500 miles
G
N 52I
9 000km
U
N V
9 000 km 5 500 miles
52I
cold during continuous driving under a constant speed due to the tire temperature rise When measuring tire pressure
accurately
first find out whether the tire is hot or cold
When tire valve caps are removed
be sure to
r
AIGHT FAONT
install
AIGHT
AEAA
them on the valves with out fail The valve caps assist in
keeping air in the tire in case of a valve leak
and
keep
When
inflation pressure
is
too
high
tit
tl
dust and water out of the valves the following
SPAAE
troubles will result Hard ride
2
Bruised tire
LEFT FAONT
or
LEFT AEAA
damaged carcass iromeadiately inside
the tread
Fig 3
Poor traction at rear wheel resulting in uneven wear
4
Rapid tread wear at center of tire in flation
When
pressure
is
too
low
WT
Tire rotation
AIGHT FAONT
the following
G N 521
AIGHT
v N 521 U
AEAA
troubles will result
I Ti
2
s
squeal on turns
SPAAE
Q
Hard steering
J
l
3
Rapid and uneven wear on tire tread edges LEFT
4
Bruised tire rim and various type of rupture
5
Tie cord fatigue or breakage
6
Tramp and shimmy troubles
FAONT
Fig
LEFT AEAA
WT 2 Tire rotation
PL521U
INSPECTION 7
Unusual tire temperature rise
8
Car roll while turning a
Wheel corner or
making
a
sharp
swerve in traffic
I
WT 2
When
wheel
deflections toward
vertical
and hor
WHEEL AND TIRE izontal
axes
the
at
points indicated by
the
asterisk in
Figure WT 3 are 15 mm 0 06 in or more replace wheel
Fig
2
Fig
WT 3
WT 4
Removing spare tire
Jacking up Place jack under lower link
Wheel rim run out check points
Front
Place jack under rear spring seat Rear Before car is jacked up apply parking brakes and as an added
precaution against moving place
block under the front
2
Check the
damage condition
tear
flange of
of
rim
welded
deformed
and
for deformation
unit
and
damaged
other
rim will
a
large stone or
lrear of one wheel an
crack
defective cause
air
leakage
3
Thoroughly
remove rust
rubber particles mud sand
and other foreign matters from the
flange of rim
if any
with a wire brush emery paper and for cloth
4
Remove small pieces of gravel
glass nail and other
foreign matters from tire tread
5
Fig
WT 5 Jacking up front side
Fig
WT 6
When the tire side wall is cracked noticeably or tread
wear indicator is
exposed replace the tire with a new one
CHECKING WHEELS AND JACKING UP Remove the sp re tire Insert
jack
rod
to
guide
and
then
turn
it
counterclockwise When installing
tighten a little strong after lifting up
and lock
WT3
Jacking up
rear
side
CHASSIS 3
5
Remove wheel cap
Change
tire
and tighten
wheel
nuts
temporarily
when tighling be sure to follow the order shown in figure
Fig
4
WT 7
Removing wheel cap 6
Loosen wheel nuts When loosening
turn nuts counterclockwise by wheel
Loos ing wheel
WT 9
Remove
jack
ing Tighl
order of wheel nul
and tightening wheel
following the above mentioned order
nut wrench
Fig WT B
Fig
a
4 WT
nut
properly
WHEEL AND TIRE TROUBLE DIAGNOSES AND CORRECTIONS Possible causes
Condition
Wheel wobbles
Corrective actions
Improper tire pressure
Measure and adjust correctly
Damaged tire or distorted wheel rim
Repair or replace
Unbalanced wheel
Balance correctly
Loosen wheel n ills
Retighten
or damaged wheel bearing cessive play of wheel bearing
Worn
or
ex
Correct play or replace
Improper front wheel alignment
Adjust
Worn or
Replace
damaged steering ball joint and
link bushing
Excessive steering linkage
play or worn
Adjust or replace
steering linkage Loosen steering linkage connection
Retighten nuts with the rated tightening torque or replace worn parts if any
Broken suspension spring
Replace
Defective shock absorber
Replace
Improper tire rotation
Conduct tire rotation periodically in stan
i
Unevenly exces sively worn tire
dard every 10 000 km 6 000 miles
Unbalanced wheel
Balance or replace
Improperly adjusted brake
Readjust correctly
Improper wheel alignment
Realign
Excessively distorted
or
improperly
in
Repair correctly or replace if necessary or
stalled suspension link
reinstall correctly
High speed on curves
Reduce speed
Sudden start and improper speeding due
Follow
rapid acceleration or improper brake
manner
to
application
WT 5
J
correct
and
proper
driving
I CHASSIS
Condition
Tire squeals
C
DATE
Corrective actions
Possible causes
Improper tire pressure
Measure and adjust correctly
Improper front wheel alignment
Realign correctly
Distorted knuckle or suspension link
Repair or replace if nesessary
pnV CE JOURN AL yn y
JOURNAL
or
BULLETIN
No
PAGE
01 UU 1
J
No
lE
P
J
n i n
t
RI lr t
SUBJECT
WT 6
SECTION ST
STEERING
DATSUN PICK UP MODEL 521 SERIES
CHASSIS
BODY
I NISSAN I
NISSAN MOTOR CO TOKYO
JAPAN
I
LTD
STEERING
ST
STEERING LINKAGE
ST
6
SERVICE DATA AND SPECIfiCATION
ST
8
TROUBLE DIAGNOSES AND CORRECTIONS
ST
9
I
STEERING STEERING
CONTENTS
DESCAIPTION
ST 1
INSPECTION AND REPAI A
REMOVAL
ST 2
ASSEMBLY AND ADJUSTMENT
DISASSEMBL Y
ST 3
INSTALLATION
4 ST 4 ST ST 6
fr
DESCRIPTION
1 J
Steering column
7
Cross rod
Steering column jacket
8
Cross rod socket
3
Steering wheel
9
Idler arm assembly
4
Column clamp
10
Side rod
5
Post grommet
11
Steering gear assembly
6
Steering
1 2
gear ann
P g ST l
Structural view of steering r1Jechanism
CT 1
v
CHASSIS The steering gear is of a recirculating ball type gear ratio is 19 8
IThe
rod
tie rods
one
on
link
as
the
front
steering linkage
each side of the cross rod is
suspension
of
an
and
has two side
and idler arm
if
the
left
moves
motion
wheel
gear
The gear
same
side At the
through
rotation
in proportion arm
to
is
vertically
and
remove
steering post
control
is attached
to
steering
colunan jacket
even
gear
I
Detach gear lever
2
Disconnect shift lever from shift rod and select lever
and
arm
from select rod at the steering column base
the gear ratio by the steering
motion
operates the side rod on the
same time
the cross rod
converted to
When transmission
8
independently steering can be safely maintained Steering
bolts
gear arm
With this construction
right wheel
and or
fixing
grommet
wishbone type These side rods are connected through ball
pitman arm
Unscrew
drag
independent
joints to both the knuckle arms steering arms
7
the idler
arm
is moved
and the opposite side rod is also
moved
REMOVAL I
Remove
horn
ring by depressing
and turning it
counterclockwise
2
Remove steering wheel nut
3
Remove steering wheel
4
Remove steering column shell
5
Remove turn signal and dimmer combination switch
Fig ST J Transmission control 9
assembly
Remove nut
used to secure gear arm to sector shaft
and withdraw gear
arm
by the use of a gear
arm
puller
special tool ST2714oo00 6
Unscrew two fIxing bolts and remove column clamp Note
Fig
ST 2 Column cLunp
Marl gear arm installing position before removal
Fig ST4 Removing gear arm ST 2
if STEERING 12
Remove steering gear housing installation bolts
10
Detach transmission
control
parts from
steering
column jacket 11
Remove steering gear
assembly toward engine com
partment
DISASSEMBLY
JID @ I
@
6
D
1
3 1
Sector shaft
6
Sector shaft
11
Column jacket
2
Filler plug
7
Oil seal
12
3
Sector shaft cover
8
Gear housing bushing
13
Steering column Column jacket bushing
4
Sector shaft adjusting screw shim
9
Worm assembly
14
0 ring
5
Gear housing
10
Worm bearing
15
Worm bearing
adjusting screw
ball nut assembly adjusting shim
Fig ST 5 Cross sectional view of steering gear b
I
Drain steering gear oil
2
Loosen lock nut and turn sector shaft adjusting screw
a
Jew turns counterclockwise Remove sector shaft Cover
fIXing bolts
I
it Fi
ST3
ST 6 Sector
raft s
cOlleT
CHASSIS 3
Pull sector shaft
together
housing Disassemble
from gear screw and
cover
with sector shaft
sector shaft
Remove column jacket bushing
7
adjusting
INSPECTION AND REPAIR
shims from the cover
Wash
all
parts
in
solvent
clean
and
dry
them
thoroughly I
Sector shaft
Check sector shaft tooth surface for pitting exfoliation or
c
other damage and replace as necessary
Yhen gear housing bushing contact surface is damaged replace
Check
sector shaft and or bushing as necessary
sector shaft and sector shaft bushing for bushing and shaft
fitting Replace them together when excessively worn Steering worm assembly
2 It
is not necessary
rotates
Fig 4
ST 7
Pulling outsector shaft
Remove fixing bolts used to secure column jacket to
gear housing
and pull out column jacket
disassemble ball
to
nut
when it
smoothly on column worm Raise steering worm
assembly vertically and observe ball nut When ball nut rotates and comes down by its own weight condition is satisfactory
if ball nut is turned until it
In this test
ball guide may be
the end of worm thread
reaches
damaged
Do not allow ball nut to turn down to the end
of worm thread
When steering worm assembly is defec
live
be sure to replace as an assembly
3
Worm bearing
1
Check worm bearing for pitting
wear or other
damage
and replace as necessary
r
ASSEMBLY AND ADJUSTMENT 3
Worm bearing
4
Worm bearing adjusting shim
gear oil
MP 90
to
all disassembled
parts
SY 8 Removing column jacket
Fig
Apply genuine
Fit column jacket bushing to column jacket
5
Remove steering worm assembly from gear housing
Note
and detach wonn bearings wonn bearing adjusting shims
When
fitting apply adhesive
to
bushing exterior
and grease to interior
and Oring 2 Note
Be careful not to allow ball nut to rundown to the worm
end
worm end
If
ball
nut rotates
suddenly
to
Fill space between sector shaft oil
seal lips with
grease and fit it to gear housing
the
ends of ball guides may be damaged
3
Place steering worm assembly in the position in gear
housing together with worm bearings and install column 6
Pry
discard it
out sector
shaft oil seal from gear housing and
jacket on gear housing together with worm bearing shims and Oring
STEERING Install sector haft adjusitng screw and selected shim
1 6 to 18 kg m
5
116 to 13 0 ft Ib
in the slot of sector shaft
Tightening torque
Standard worm bearing shim thickness
lj
Measure end clearance 1 5 mm 0 0591 in
and select a proper sector shaft
adjusting screw shim so that end clearance is 0 01 to 0 03 mm
0 0004 to 0 0012 in
Worm bearing adjusting shim
Part No
4
Thickness
mm
48029 71200
0 762
0 0300
48030 71200
0 254
0 0100
48031 71200
0 127
0 0050
48032 71200
0 050 0 0020
in
lecting worm
Adjust preload of worm t aring by
bearing shims to obtain steering colUJ nn initial turning torque of 4 0 to 6 0 kg m 28 9 to 434 ft lb
Fig
ST J 0
Measuring end deamce
Initial turning torque of steering column New worm bearing 4 0 to 6 0 kg
m
Sector shaft adjusting screw shim 3 5 to 5 2 in Ib
Used worm bearing 4 kg
4 to 2
m
Thickness
Part No 2 1 to 3 8
lb in
At steering wheel
48213 BOIOO
1 575
0 0620
48214 BOIOO
1 550
0 0610
48215 BOlOO
525 1
0 0600
0 4 to O 7lb
New
0 2 to
Used
0 12 to 0 22 kg
3 kg 0
nrn in
3 to 0
5 lb 0
48216 BOIOO
1 500 0 0591
48217 BOIOO
1475
48218 80100
1450 0 0571
a
0 0580
6
Install sector shaft in gear housing
I
Turn steering column by hand until ball nut is in its
travel center
so
that sector shaft center tooth enters baU
nut center looth space
2
Install
sector
shaft
cover
and
turn
sector
shaft
adjusting screw to raise sector shaft to sector shaft cover side so that 2 t03 mm 0 0787 toO 1181 in lash is made
1 r
between sector shaft teeth and ball nut
II
ball nut
Fig
ST 9
Measuring initidl turning torque
sure
that
is
not
and sector shaft intermeshing position
deviated from center
ST 5
Make
CHASSIS Operate gear arm several times retighten sector shaft adjusting screw 1 8 to 1 6 of one full turn and tighten 9
Sector shaft cover tightening torque m 116 to 13 0 kg
1 6 to 1 8
lb ft
lock nut finally Note Be
sure to
use
preventing agent surface of
new
gasket and apply oil
on the sector shaft
steering
gear
housing
cover
and
leak
Lock nut tightening torque
231 t026 8ft lb
the upper
surface of gasket 3
nut
when
temporarily
sector
shaft
comes
Volume of oil
into
contact with ball nut
7
Connect gear
33 0
arm to
sector shaft
move
Set gear
arm
to neutral
liter 0 70 US pts 0 58 UK pts
Installation may be accomplished in reverse sequence
measure backlash
at the end of gear
arm
When backlash is deviated from
0 1
mm
0 to 0 004 in
range of 0 to
Approximately
INSTALLATION
position and with ball nut
and sector shaft intermeshed at center
sector shaft
assembly upto level
sector shaft
several times to ensure it turns smoothly 8
into gear
of nner plug hole and install filler plug
slowly to lower
screw
MP 90
and tighten sector shaft adjusting screw with
sector shaft lock
Pour gear oil
10
Turn sector shaft adjusting
3 2 to 3 7 kg m
installing
of removal Pay attention to the following matters
Tightening torque
further tighten
adjusting screw and adjust backlash to the Steering gear housing
prescribed value
3 2 to 3 7 kg m 1 to 26 8 ft lb 23
Gear arm
14 kg m
Steering wheel
2
With
make
sure
7 to
front wheels to
2 ft lb 101
5 kg m 50 6 to 54 2 7
lb ft
directed
forward
punch mark
on
correctly
to
the top end of steering
column
When installing steering wheel
3
apply grease to sliding
part lightly Check steering wheel for smooth operation
4
Fig
ST 11
Metuuring backl4sh
STEERING LINKAGE
CONTENTS
AEMOVAl
AND DISASSEMBLY
INSPECTION AND AEPAIA
ASSEMBLY AND INSTAllATION
ST 7
Idler arm
ST 7
ST 6
assembly l
ST 7
8 ST
STEERING REMOVAL AND DISASSEMBLY
7
Remove cotter pins and nuts from ball studs in both
ends of cross rod
I
Jack up the front
of vehicle and support it with
and separate
cross rod
from gear arm
and idler arm
stands 2
pins and nuts
Remove cotter
and detach side rod
INSPECTION
AND REPAIR
ball studs from knuckle arms in both sides I
Side rod ball joint and cross rod sock t When
ball
stud is wo n and
direction is excesSive replace
clea
r
cross
ce
toward axi
rod socket or side rod
with a new one When dust cover is damaged replace Clearance toward ball joint axial direction 0 1 to 0 5 mm 0 004 to 0 020 in
Fig ST tZ Side rod and gear arm
3
Remove
used
nut
to
secure
and
puller
special tool ST27140000
4
gear arm
arm
by the use of a
shaft
remove
gear
on
sector
gear
arm
Remove idler arm assembly from frame i
Fig
ST 14 Cross sectional view afball joint
1 2
Idler arm assernbly Remove
old
grease and
dirt
and check idler
arm
assembly for wear deformation and damage
3
Cross rod side rod and gear arm Check
them
for
bending
damage
and crack
and
replace if necessary Fig
ASSEMBLY AND INSTALLATION
ST 13 Idler arm
Assemble S
Remove side rod
cross r od
idl
r
arm
m
ly an
steering linkage
in
reverse
of
sequence
disassembly by noting the following matters
gear arm as an assembly I
6
Tightening torque
Remove cotter pin and nut from side rod ball stud
and separate side rod from gear arm or idler arm
Cross rod ball stud
ST 7
6 to 7 kg m
4 to 50 6 43
lb ft
CHASSIS Side rod ball stud 6 to 7 kg m
Knuckle arm side
4 to 50 6 43
lb ft
6 to 7 kg m
Gear arm or idler arm side
o
434 to 50 6 ft Ib
@ Idler arm assembly
I
3 2 to 3 7 kg m 1 to 26 8 ft b 23
A Cross rod lock nut
9 to 12 kg m 1 to 86 8 ft lb 65
Fig When cross rod socket
2
an
cross ro
are
ST 15 Cross sectional view of idler arm a ssembly
parated se
adjust cross rod length correctly
I
Apply multi purpose grease MIL G210S or 10924
to threaded
Standard cross rod length
516 mm 20 3 in
seal inside
bushing interior plain bushing interior
dust
and threaded part and bushing sliding surface
of idler arm 3
Adjust toe in and steering angle 2
The procedure of toe in and steering angle adjustments are
outlined in
section
3 2 to 3 ffim
Steering 3 lgle
arm
Install
torque is
12
When idler arm assembly is installed install grease
Inner wheel
360
Outer wheel
310
grease MIL G2108 or 10924 until grease comes out from
lower end dust seal lip Remove grease nipple and reinstall filler plug When idler arm assembly is installed make sure that
the standard dimension
A
Standard dimension
A
is adjusted correctly
assembly
idler
arm
kg m
nipple on grease filler plug hole and inject multi purpose
0 0787 to 0 1181 in
4
Idler
bushing tightening
FRONT AXLE AND SUS
PENSION Toe in
Threaded
86 8 ft Ib
assembly
in
reverse
sequence
of
removal by noting the following matters
137 8 to 139 8 mm 5 425 to
1
SERVICE DATA AND SPECIFICATIONS SPECIFICATIONS Gear type
Recirculating ball type
Gear ratio
19 8
I
400
157
Steering wheel diameter
mm
in
8 ST
504 5
in
STEERING SERVICE DATA Standard thickness of Worm
bearing adjusting shims
in
mm
15
0 059 t
Initial turning torque of steering column New worm bearing
kgm
Used worm bearing
kgm in Ib
in Ib
4 0 to 6 0
3 5 to 5 2
2 4 to
2 1 to 3 8
4
End clearance of sector shaft
adjusting screw
mm
in
0 01 to 0 03
Backlash
mm
in
o to 0 1
at
the gear arm top end
Oil capacity
L US pts UK pis
Ball joint axial end play Idler ann A
33 0
0 0004 to 0 0012
0 to 0 004
0 70 0 58
mm
in
mm
in
mm
in
516
in mm
2 to 3 mm 0 0787 to 0 1181 in
0 1 to
5 0
0 004 to 0 020
dimension
Refer to page
8 ST
Standard cross rod length Toe in
8 to 139 8 5 425 to
137
504 5
3 20
Steering angle Inner wheel
360
Outer wheel
310
Tightening torque Steering column jacket to gear housing
kg m
ft Ib
16 to 1 8
116 to 13 0
Sector shaft cover
kg m
ft Ib
1 6 to 1 8
11 6
Sector shaft lock nut
kg m ft Ib
3 2 to 3 7
23 I to 26 8
Gear housing
kg m ft Ib
3 2 to 3 7
23 1 to 26 8
Gear arm
kg m ft Ib
14
Steering wheel
kg m ft lb
7 to 7 5
50 6 to 54 2
Ball studs of cross rod
kg m ft Ib
6 to 7
4 to 50 6 43
Knuckle arm side
kg m ft Ib
6 to 7 43 4 to 50 6
Gear or idler arm side
kg
0
to 3 0 l
1012
Ball stud of side rod
m
ft Ib
6 to 7
4 to 50 6 43
f
TROUBLE DIAGNOSES AND CORRECTIONS
In regard of this matter refer to the same subject described in the section
ST 9
FRONT AXLE AND SUSPENSION
CHASSIS SERViCE JOURNAL OR BUllETIN REFERENCE
DATE
JOURNAL
or
BULLETIN
No
PAGE
No
SUBJECT
r
J
ST 10
SECTION FE
ENGINE CONTROL FUEL EXHAUST SYSTEM
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
I NISSAN I
GI t
i
t
NISSAN MOTOR CO TOKYO
JAPAN
LTD
ENGINE CONTROL SYSTEM
FE
1
FUEL AND EXHAUST PIPINGS
FE
5
EN GINE CONTROL
FUEL
EXHAUST SYSTEM
ENGINE CONTROL SYSTEM 1 CONTENTS
DESCRIPTION
FE 3
Play of accelerator wire
ADJUSTMENT
FE 3
Pedal stopper height
FE 3 4 FE
f
L1
I Open Angle Operating
I
Close
Hitach 81 Nikki
82
C
A
Nut
B
Adjust nut
C
Lock nut
B
A
Unit
Fig
FE 1 Accelerator contTol syst
fE
for RH drive
mm in
CHASSIS
GP
l
Clearance 0 to 1 0 to 0 0394
Fig
FE 2 Accelerator control system for LH drive
Unit
rnm
in
Unit
mm
in
except model PL521
it E3
Fig
FE 3 Accelerator control system for LH drive PL521 model
FE 2
ENGINE CONTROL
half turns so that accelerator wire play is I to 2 mm 0 04
DESCRIPTION The accelerator is
system
so
linkage is light The accelerator control
constructed
and the
smootWy
EXHAUST SYSTEM
FUEL
the
that is
system
not
linkage
to 0 08 in
Tighten nut
in part
of carburetor side outer case
A
C
B
to lock nut
Nut
B
is
operates
affected by engine
Throttle Valve Operating Angle
vibration
0 AD
USTMENT
I
RH drive
I
Assemble accelerator control system
Figure
FE I Fully screw nut
A
as
B
can
RH
830 Nikki
LH
790 Hitachi
PL521
be turned
sure
freely and lock nut
I Close
that
C
is
With
adjust nut
wire
provided with sufficient slackness
B
clockwise
and
extent that throttle lever is about to move
I
I
turn
it up to such
tighten
Operating angle
ABC
loose 2
except PL52I
shown in
against accelerator wire
bracket and unscrew one complete turn Make
adjust nut
Nikki
830
Play of accelerator wire
MODEL
Open
2
an
play is zero at
Hitachi 81 Nikki 83
T
5
3 0 1181
this time A
3
Unscrew adjust nut
Play will be I to 2 mm tighten nuts
A
and
B
one to
two complete turns
0 04 to 0 08 in e
Now
bracket
completely
8
to secure nut
Accelerator wire securing
B
Nut
C
Lock nut
Fig
FE 5
Unit
in
Adjusting play of accele ato wire fo
3
mm
LH drive
PL521U vehicles mounted with L16 engine
Adjusting method is the exactly same as for LH drive Note
that
throttle
valve
completely closed position
differs C
8
A
A
Nut
B
Adjust nut
C
Lock nut
200
Fig
FE 4
Adjusting play of accele ato wire fo
RH drive 18
2
709 0
LH drive Install accelerator wire as shown in Figure FE 2
Set
Unit
mm
throttle valve to completely closed position and with wire
sufficiently slackened tighten nut
8
in part
A
such an extent that throttle lever is about to move is zero at this time
Unscrew nut
8
Fig FE 6 Adjusting play of accele ato
up to
fo
Play
one to IDe and a
L 6 engine
FE 3
wi e
PL521 vehicles mounted with
in
CHASSIS Pedal
stopper height
RH drive
Upon completion of accelerator wire play
depress
accelerator pedal and adjust stopper plate so that clear ance
between
pedal
I mm
proximately
arm
and
0 04 in
is
ap
when throttle valve is
fully
stopper
plate
opened Secure stopper plate with a lock screw
Unit Fig
18St
FE 8
mm
in
Adjusting ped41 stopper hight for LH drive
83
PL521U
3
Adjusting method is the same as for lR drive ever
Unit
How
pedal stroke differs
mm in
Fig FE 7 Adjusting ped J stopper height
for RH drive
Unit
2
LH drive
Depress
Fig
accelerator
pedal
height so that clearance bolt head is 0 to I mm is fully opened
T
and
adjust
stopper bolt
between pedal and stopper
pad
Secure stopper bolt with a lock nut
in
Pedal stroke
rom
in
Pedal depressing force when fully open
kg Qb
should be less than
center of stopper bolt
RH drive
mm
Adjusting ped41 stopper sheight for PL521U
Note Deviation in center alignment of accelerator pedal
0 to 004 in when throttle valve
Pedal free play
FE 9
mm in
LH drive
2 mm
0 08 in
against
LH drive only
PL521
10 to 2 0
1 0 to 2 0
10 to 2 0
0 0394 to 0 0787
0 0394 to 0 0787
0 0394 to 0 0787
46 1 811
50
3 7 8 2
1969
3 7 82
4 FE
48 1 890
3 7
8 2
ENGINE CONTROL
FUEl
EXHAUST SYSTEM
FUEL AND EXHAUST PIPINGS
CONTENTS
EXHAUST PIPE AND MUFFLEA
FE
5
FUEL TANK
Description
FE
7
Difference of part by model
FE
7
Precautions for removal and installation
FE
9
AND PIPINGS
FE
9
Description
FE
9
Removal
FE 11
I nspection and repair
FE 11
EXHAUST PIPE AND MUFFER
N521 Model Series
l
GN521 Model Series
t
Note
Front and are
Fig
FE tO Exhaust construction
rear
tubes of the GN521
model series
longer than those of the N521 model series
for N52t andGN52t models
FE 5 1 i
u
I I
CHASSIS
VN521 Model Series
UN521 Model Series
Note
Aear tube of the UN521 model series diffen from that of the VN521 model
Fig
ies
FE l1 Exhaust constructi01l for VN521 and UN521 models
G521 Model Series
521 Model Series
Note
L
Rear tube of the V521 model series diffen from
that of the 521 model b
ies
of the G521 model Muffl
that of the 521 model series
Fig FE 12 Exhaust construction for 521 a11d V521 models FE 6
ies is
than long
ENGINE CONTROL
FUEL
EXHAUST SYSTEM
e
i
1 i l11l I
Fig FE 13 Exhaust constTUction fOT PL521 model
Description
tube
Exhaust piping consists of front tube muffler and rear
Difference of part
These components
are
clamped
clips
by model
Front tube
Muffler
52tU
20010 14800
20100 00100
2040t
N52tU
20010 83000
20100 B2000
20401 B2000
521 1
20010 20600
20100 00 100
2040t 00301
52 IT 1
20010 t 4800
20100 BOIOO
20401
NL521
20010 B3600
20100 B2000
20401 B2000
52IT N1
20010 B3000
20tOO B2000
20401 82000
20010 B2OO9
20100 B2000
2040 I B2000
200 10 B2000
20100 B200D
20401 B2000
G521U
20010 14800
20100 B0200
2040 t
GN521U
20010 B3200
20100 B200D
2040 t B3200
LG52t
20010 20600
20100 00200
20401
t4800
LG52tT
20010
t4800
20100 B0200
20401
t4800
521 GN1
20010 B3700
20100 B2000
20401 83200
GNL52IT
20010 B3200
20tOO B2000
20401 B3200
V521U
200 10
t4800
20100 BOtOO
20401
t5200
VN521
20010 14800
20 t 00 B3000
20401
t5200
VL521
20010 20600
20tOO BOtOO
20401
15200
521 VN1
20010 20600
20100 B3llOO
20401
15200
U52tU
20010 t4800
20tOo
2040 t 28300
UL521
20010 20600
20too BOtOO
2040t
20010
20100 B3llOO
20401 28300
PL52ITU 52ITN P1
with U bolts or
Rear tube 14800
14800
c
521 UN1
20600
A
FE
BOtOO
f
V
14800
28300
CH ASSIS PL521
N521 521 SERISE
EXHAUST PIPINGS
1887 74 3 N521 serise
CD
1193147 01
A
2127183 71
0
@
b
GN521 serise
N L521
serise
@
A A
A
5
@
b
GNL521 serise
A
B 3
1638 5 164 51
206147
3
JiS 3P c
@
511
521
serise
G521 serise
@
37tI54 0 1653165 11
@ c
A
A
@
15e21
1
L521 serise
59 9
1
GL521 serise
1973 3 77 71 PL521 serise
D
Unit
FE S
mm
in
FUEL
ENGINE CONTROL
EXHAUST SYSTEM
Precaution for removal and installation I
Muffler side of front tube and rear tube side of muffler are embossed
Remove mount bolts A B and C See FigUres FE1O
through FEB 2
Remove clamps B and D
3
Remove installation
tube
on
manifold
bolts used
to
secure
and disconnect exhaust
L E J J
exhaust
tube from
EMBOSSMENT
manifold
Fig
b
FE 15
Clearance
Muffler and tube connection between
side
should be 55 mm 2 165 in
FE 14
Fig NOlll
a
When
and
muffler
See Figure FE 16
Removing mount A
connecting muffler to front tube or rear
tube to muffler
be sure to apply it complelllly to
of
See
cenlllr
frame
embossed portion
Front Unit
Figure FE 15
Fig
Description
FE 17 Fuel system
for the J13 and J15 Engine models fE 9
in
FE 16 Clearance between side rame and muffler
FUEL TANK AND PIPINGS
Fig
mm
C
CHASSIS Three types of fuel tank fuel tank for the 521 G521 N521 and GN521 UN521
fuel tank for the V521
Tank capacity is 41 liters
VN521 and
all fuel tanks
and fuel tank for the PL521 U are available
e
Fig
FE 18
F
l tank
Fig FE 19 Fuel tank
for VN521
r
V521 and UN521
for 521 G521 G521 and GN521 FE 19
10 8 US gal 9 0 Imp gal
for
ENGINE CONTROL
FUEL
EXHAUST SYSTEM
rY To CAANK CASE
V A
i
Fig
FE 20 F
1 tank rfoT PL521 U
FE ll
CFlASSIS Removal I
521 and GN521 models
I
Remove drain plug and drain fuel completely
2
Loosen hand brake
3
Remove
inspection
hole
cover
from
rear
body
Through inspection hole disconnect unit gauge wiring and disconnect outlet tube and breather tube clips 4
Loosen filler hose clip
5
Remove front and rear tank support bracket bolts
and then remove fuel tank
2
UVN521model Procedures for the 521
However
and GN521
Fig
models
apply that breather tube position and support
note
FE 22
er Vapor liquid separator COI
bracket differ 3
PL521 model Fuel
tank
is
installed along
with the
liquid vapor
Inspection
and
repair
separator A cover has been
damages Repair or replace as required Check rubber hose
wheel to protect vapor liquid separator against damage
Photograph below shows an exploded view
Inspect fuel tank and piping for leakage and other
I
provided just in front of left rear
and fuel line joint particularly carefully for crack and
lofiqvaporuid
leakage
separator
Note
a
When
soldering
make sure that
no
gasoline is
remained b
When
cleaning inside of tank
use
gasoline
Do
not use water
2
Unit gauge
adopts bayonet system for installation
and therefore it can be removed and installed simply with
Fig
21 FE
a screw driver
Vapor liquid separator
FE 12
ENGINE CONTROL
FUEL
EXHAUST SYSTEM
SERVICE JOURNAL OR BUllETIN REFERENCE
DATE
JOURNAL
or
BULLETIN
No
PAGE
No
SUBJECT
y
11
3
CHASSIS
SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL
or
BULLETIN
No
DATE
PAGE No
SUBJECT
CJ
FE 14
SECTION BF
BODY
DATSUN PICK UP MODEL 521
SEPIES
CHASSIS
BODY
I NISSAN I
NISSAN MOTOR CO TOKYO
JAPAN
LTD
FRAME
BF
1
BODY
BF
3
HOOD
BF
1
FRONT END AND FRONT FENDER
BF
8
DOOR
BF 13
DOUBLE PICK UP AND VAN
BF 18
WINDSHIELD AND REAR WINDOW
BF 21
INSTRUMENT PANEL
BF 23
SEAT
BF 25
ROOM TRIM
BF 26
a
BODY fRAME DESCRIPTioN The ladder
the frame as long as the vehicle is used under the standard
shape frame consists of left and right side
members and six
cross
members
This frame with in
When the vehicle comes into a hard collision or
condition
creased bending stress and torsional strength sufficiently
is driven with an excessive load on a
withstands against heavy load and severe use
high speed
The engine
springs
cab body
rear
body
rough road under a
the frame may be bent
however
cracked
broken and or twisted
shock absorbers and
When the vehicle is driven hard
are mounted on this frame
thoroughly inspect the
frame for damage and damaged parts Remove the frame
REPAIR
partially
or
entirely depending
on
the
condition
of
damage and repair
The frame is rigid and normally no trouble occurs on
5 n tll lI
tJ
OI IDI
hila 10
I
I
E E
U ClI
1011
I
i l
i 5
B
O
i
ii
J C llI aOl
9
2
oS
1 0
5
II
aj i cu
l Cl
1
n
ta
iS II
d
fi
0
i 1
IJC llne
01 tU
1II d
BF l r
a
p
BODY
5 ts stlOIOI 6
h
E E
lOS IlII os
I
n Uh
c
I
iJ c
J
m
Q
r
I
Q
Tg Ig
COVlill l EO It all
o
j
Il
II
m
t o
uml
r
u
E llOtoS
rtl I c
3
u
21 10 iE9
Q
o
I
E
ij r
E l
I
s
20 IO
ill
E tLlSl
IE l1
2 Q it
u
l
b ijo f 1M
t
alii
BF 2
a
BODY BODY CONTENTS
MAIN CAB
CAOSS SECTIONS BODY
AEAA
OF CAB
BODY
MOUNTING
BODY MOUNTING
BF 3
DETACHING
BFA
DETACHING
CAB BODY AEAA
BODY
BF 5 BF 6
BFA
MAIN CROSS SECTIONS OF CAB BODY
Fig BF J Crosssecticm of cab body
1
li
Fig
4 Cross secticm BF
BF 3
of cab body
2
I 10
BODY CAB
BODY MOUNTING
Jute
0
LA
S O
C
c
lif
S C
0
Body mounting jute
Body mounting bracket
Aubber washe
Body mountmg b 0 I t 3rd b Plain washer
y
mountmg rubber
r J
A bber
washu
et
o
Body mounting bolt Washe
Plain washer
is
1st body
mounting rubber
Special
I
washer
Body mounting bottom rubber ock nut Plain washer
Mounting bolt
Unless otherwi specially notBd the details are the same as those in aosa MCtion
Crosssection A A
Cross section B B
8J B
Cross section CC
Fig BF 5 Cab body mounting
REAR BODY MOUNTING
I I
Center of body
E
r
c
0 0
F
I L
E 0 lit
LO
S1 Co
a
l
F
E
3l I nstallation bolt
Plain washer Installation bolt
Shim Shim Plain washe
lock nut Cross
section O D
Cross section E E
Fig
BF 6 Rear
body mounting 4 BF
Shim Plain W3lher lock nut Cross section F F
BODY DETACHING CAB BODY
I
Disconnect battery terminal from battery
2
Disconnect speedometer cable
3
Remove steering mechanism
steering wheel steering
post assembly and remote control system
Fig BF 9 Disconnect brake tube
rear
5
Disconnect hand brake at front lever and cable joint
6
Disconnect
accelerator
partment
engine controls
linkage
harness
etc
such
heater hose
choke wire
as
engine
com
instrument harness and others between
body and engine or chassis
7
Fig BF 7 Removing steering post clamp bolts
4
Remove six cab body mounting bolts
Disconnect front brake tube at hose and brake tube
joint and rear brake tube at 4 way connector
Fig
8
BF 10 Cab body mounting
Apply rope wire or hanger to cab body
lift up cab
body by the use of a hoist or chain block and dismount Fig BF 8 Disconnect brake tube front
cab body
RJ
BODY
Fig BF 12 Rear body mounting 4
body rear
Fig
BF ll
Taking up cab body
wire or hanger to rear
Apply rope
body lift up rear
by the use of a hqist or chain block
and dismount
body
Lifting Note
Carefully baiance rear body while lifting
and be
scratch cab body
Slightly
careful
not to scar or
pull rear body rearward while lifting Aear
kg
9
Be
body
to detach
sure
since
radiator
body weight long body
Approximately 140
309lb
radiator grille before lifting cab
core
support
or
portion
near
is
suspended
Note
Carefully
balance
cab
body
while
lifting
and
dismount carefully so that cab body is not scarred or
scratched
Cab body weight 200 kg
standanl model
Approximately
441Ib
Fig
DETACHING REAR BODY
Note
a
BF 13
Rear
Lifting rear body Taking up
body mountings No
1
through
5
use
shims Be careful to select conect shim Disconnect battery terminal from battery b 2
15
Disconnect rear combination lamp wiring
Clearance between rear body and cab to
30
mm
toward the left
3
0 591 or
to
RF fl
in
body is
Deviation
right should be within 5
0 1969 in at the center line
Remove rear body mounting bolts
1 181
n1m
BODY HOOD
CONTENTS
Adjusting hood tightness
SF 7
ADJUSTMENT Centering hood lock
AEMOVAl AND
SF 7
Adjusting hood lock control lever operating force
SF S
SF S
INSTAllATION
SF S
Removal
SF S
Installation
SF S
ADJUSTMENT
CD 2
90
r
I
t @
0
1
f I
1
Fig
@
in 5
Dove tail bolt
4
Safety catch lever
2
Dove tail bolt retaining nut
5
Female lever
3
Spring
6
Spring
Fig
hood locks
The female hood lock is provided with a 3 mm 0 118
4
I
BF 15 Adjusting mal
adjusting stroke toward the front
or rear
side of the
vehicle
BF 14 Male and female hood locks
Centering hood lock The male hood lock is provided with a 3 mm 0 118 in
adjusting stroke toward
the left
or
right side of
the
vehicle
Fig
BF 7
BP 16
Adjusting female hood locks
I i
BODY Loosen installation bolts and align the center correctly
Adjusting hood lock control operating force
Disconnect windshield washer hose at nozzle
3
Cover
lever to
When the hood Jock control lever cannot be operated
lightly
2
cowl area with cloth or other proper material
protect them from dama
ng
loosen dove tail bolt retaining nut increase dove
tail bolt installation length and reduce securing force of
spring
Adjusting hood tightness When the hood is closed and is slack reduce installation
tightly
cannot be closed
length of the dove tail bolt
and increase securing force of the spring Note
When inspecting the hood lock note the following matters a
Safety catdllever
Check caulked portion of the safety catch lever for wear
and the
spring for weakness and breakdown
If the spring is broken
Fig 4
b
aid of a helper
Female lever the
operation down
female
lever for
smooth
upward
and correct
and the spring for weakness and break
Installation
If the female lever does not move smoothly
Position hood
engaging stroke with the dove tail bolt will be reduced
to
hood
hinges and install attaching
screws
and it may disengage
REMOVAL AND INSTALLATION Removal I
Coveringcowlarea
Remove hinge bolts and detach it from hinges with
and rapidly open during driving
Check
BF 17
the hood may be unlocked
2
Adjust hood position and tighten attaching screws
3
Install hood latch striker
on
hood and adjust hood
latch
Open hood and prop it in the open position
FRONT END AND FRONT FENDER
Q
CONTENTS BF
BUMPER Removal
BF
Installation
BF 10
RADIATDA GRILLE AND HEADLAMP Removal
FRONT APRON
9
Removal
9
FRONT
GRILLE SURROUNDINGS
RIM
BF 10 BF 10
Ri A
FENDEAS
BF 11 BF 11 BF 11
Removal
BF 11
Installation
BF 12
BODY BUMPER
@
1
Front bumper
2
Bumper day
3
Front member
Fig SF 18 Front bumper
Removal I
2
Remove installation bolts from both ends of bumper
Front bumper
bumper stays
at
engine compartment side
Bumper stays are installed on frame with four bolts
both ends of front apron
G
Detach
G
Front
apron
Fig BF 19 Removing bumper bolt
Fig
BF 9
BF 20
Removing bumper bolt
BODY 3
Pull
forward
and
remove
bumper together
Installation
with
bumper stays 4
Remove four installation bolts
and separate bumper
Install front
bumper in reverse sequence of removal
When installing
align position carefully and correctly so
that stays from bumper
RADIATOR
bumper height and clearance between bumper and
front apron are uniform
GRItE GRILLE SURROUNDINGS L
AND HEADLAMP RIM
1
@
Fig
BF 2J
Upper radiator grille surrounding
2
Radiator grille
3
Headlamp rim
4
Side radiator grille mrroundings
5
Lower radiator grille surrounding
Radiator grille grille surroundings and headlamp im
Removal I
Unscrew upper
screws
four
and front
two
2
installation
and remove radiator grille toward front
First
detach lower radiator grille surroundings and
remove both side radiator
next
Note
grille surroundings
Both ends of lower surroundings are overlapped on side
surroundings
and
the above de
therefore
scribed removing sequence must be regarded
Out
of five lower surrounding installation screws
two
screw s
in both ends are used to secure both side
surrounding bottoms also
In other words out of
three side left or rightl radiator grille surrounding installation screws secure
either
left
one or
in the bottom is used
right
end
of
lower
to sur
roundings also
3
Unscrew three self tapping screws
one in front
Fig BF 22 Removing radiator griu
BF 10
and detach head lamp rim
two on top and
BODY FRONT APRON
1
3
Fig
Bumper stay
2
Front bumper
3
Front apron
BF 23 Front apron
Removal
Removal
Detach front bumper See Figure BF 18
I
Remove apron to fender attaching bolts and remove
removing dirt from them
Clean fender attaching
screws
bolts and nuts
by
apron downward 2
Disconnect
side marker
FRONT FENDERS
3
wirings for headlamp and side flasher
lamp at their connecting terminals
Remove radiator grille
grille surroundings and head
lamp assemblies from the vehicle
III
Fig
BF 24 Front fender
Fig
BF l1
BF 25 Headlamp
assembly t
ODY 8 front side attaching bolts from headlamp
Remove
4
Remove front fender rear side attaching bolts
7
installing parL 4
Pig BF26 5
lt 7 Pr
j
ft
Jchf rg boJts att
Pig BP 29 Fender rear side attaching bolts
Remove apron to fender attaching bolts from both
sides
8
Remove
attaching bolt from
rear bottom
of front
fender
9
Pull left
or
right
front fender toward front left
or
right direction and detach it
Pig BF 27 Apron to fender attaching 6
bolt
Remove front fender top attaching bolts
Fig
BP 30 Detaching
front fender
Installation Install front fender in reverse sequence of removal
Note
Aeplace
lender rubber
used in rear side of fender
with a new one when reinstalling fender
Fig BF 28 Pender top attaching bolts BF 12
BODY DOOR
CONTENTS ADJUSTMENT
SF 13
DOOR
LOCK MECHANISM
Door lock striker
SF 13
Removal
Door hinge
SF 14
Installation
REMOVAL
SF 14
Fig
DOOR
SF 15 SF 15
SF 16
GLASS AND AEGULATOA
1
Door panel assembly
2
Door window ventilator
3
Door window glass
4
Glass run
5
Door window weather strip
6
Door ou tside handle
7
Door lock key cylinder Door lock and remote control Ass y
9
Door window
10
I nside handle
11
Regulator handle
12
Door finish
13
Scaling screen
14
Sealing screen
15
Sealing screen
16
Support cushion
regulator
BF 31 Door construction
Door lock striker
can
be
adjusted freely toward any
direction as required
Fig BF 32 Adjusting door striker
BF 13
assembly
8
ADJUSTMENT
Door lock striker
SF 16
I BODY 2
Align door position correctly before adjusting door
Fully
open
door
and apply
a
jack
or
rigid rack
beneath door to support it
striker It should be noted however that door sag cannot be corrected by adjusting door striker
Note 2
Loosen
attaching
striker
screws
and close
When applying a jack or rigid rack cloth between door and
door
gently to align striker against latch mechanism
jaek
apply piece of
or rack
to
protect
door from scratching
Open door and tighten striker attaching screws
3
Door hinge Door hinges are
adjusted toward
top bottom front
rear
right and or left to place door in the position
l
Visually inspect door from outside and make
I
sure
that accent stripe is positioned straight with front fender and door exterior is flush with body exte ior
When door is not placed in the position correctly
2
detach dash side trim
When adjusting door position toward top
3
front
or rear
adjust body side hinge
door position toward
eft or right
bottom
Fig
BF 34
Supporting door
and when adjusting
adjust door side hinge 3
4
When door position is adjusted at hinge side
sure
that door can be closed and opened
Remove upper and lower hinges at the body side
and
separate door from body
make
smoothly and
that door lock operates correctly
REMOVAL I
Remove package tray and remove dash side trim
Fig BF 35 Separating door from body
Note
When reinstalling door clearance
position it correctly so that
between door and body is even Adjust
door position with hinge installation bolts side
Adjust door lock engagement at door
striker side
Fig BF 3J Removing d4sh trim
BF 14
body lock
BODY DOOR
LOCK MECHANISM
Door lock is
provided with a lock knob
and is of an
door is open
unlock type in which lock knob does not lower while
6
D @
o l
@ @
1
Lock knob
2
Lock installation bolt
3
Bell crank installation bolt
4
Door lock remote control
5
Door lock
6
Outside handle lever
7
Inside lock knob installation bolt
assembly
assembly
Fig BF 36 Door lock mechanism
Removal I
2
Detach inside handle and regulator handle
damaged remove
door finish installation clips with an ordinary screw driver
Be careful
not to scar
or scratch
sealing
remove
screen
carefully
so
that
it
is
crank installation bolts and inside lock knob installation
panel and sealing
screen
w I
Lock installation bolts
4
Knob lock
2
Inside lock knob installation
5
Glass run
instaiIation bolts
bolts 3
CD
Door f1nish
13
Bell crank installation bolts
Fig
Cloth
Fig BF 37 Detaching door finish
3
BF 15
not
lock installation bolts lock knob bell
bolts and remove lock knob
and separate door fmish from door
Note
Detach
BF J 8
Removing lock assembly
Separate key cylipder and lock joint
BODY 4
Remove
door
lock
with remote control
together
DOOR
GLASS AND REGULATOR
assembly through work opening Detach door lock assembly
door finish
and
sealing
screen
I 2
Remove installation bults
and remove door window
support cushion
I a
1
I
I
Do
i I
r
b
Fig BF J9 Removing door lock
1
c
Installa tion 1
Install door lock mechanism in
reverse
Fig
sequence of
BF 41
Sealing screen and bolts
removal
2
3
Upon completion of installation make sure that play
A
between outside handle lever and lock side
lever end
is I to 3 mm
roller
Remove
on
end of regulator
locking
Recommend
that glass be suspended with a piece
of string beforehand
L
so
that glass can be taken out
easily
I
1
11
Q
t
I
3
J
I I
71 c
40 BF
Fig When play
A
from glass
0 0394 to 0 1181 in
Note
I
arm
channel and lower window glass to the bottom
Adjusting door lock is insufficient
adjust outside handle
installing position When door panel is deformed
e
g
hollow
etc
repair
panel
Fig
BF 16
42 BF
Take out glass
BODY 4
Remove four installation screws from upper portion
of door sash
Fig
BF 45 Removing door ventilator
8
Pull door glass upward and remove it
9
Remove four door window regulator assembly in
stallation screws
Fig
5
BF 43 Removing fouT installation SCTewS
Detach side window weather
screw
strip with an ordinary
driver carefully so as not to damage it
Fig
BF 46 Door window regulator instaLtion screws
10
Remove
door window regulator assembly through
service opening
Fig BF 44 Del4ch weatherstrip
6
Remove two door window ventilator center side sash
instaJlation screws
7
Pull
door
window ventilator
toward
upper
rear
direction and separate it from door
Fig
BF 17
47 BF
Removing window egulatoT flSsembly
BODY DOUBLE PICK UP AND VAN
CONTENTS BF18
TAIL GATE AND
Double pick up
BF 18
Double pick up
Van
BF 18
Van
SIDE WINDOW
SIDE
BF 19
LIFT GATE
BF 19 BF 20
WINDOW
Double pick up
CROSS SECTION A A
Fig
When installing
BF 48 Side window
double pick up
be sure to apply sealing agent between
body panel and weather strip
Van
Fig
BF lB
BF 49 Side window
van
BODY Remove
set
weather strip
screws
toward
remove side window
from
side
window sash
detach
luggage compartment side
and
assembly toward outside
When installing be sure to apply sealing agen t between weather strip and panel
G
Roof
Side window sash
Fig
BF 50
Removing side window
TAIL GATE AND LIFT GATE Double pick up Tail gate lock
r
ll
1
Side lock T G RH assembly
4
Clip
2
Side lock T G LH assembly
5
Thrust screw
3
Remote control assembly
Fig
BF 51
cross
Tailgate lock
Remove tail gate inside cover and remove tail gate side
headed
2
gate
lock
assembly
through
Striker
correctly
Remove tail gate remote control installation bolts tail
Spring washer
7
doubk pick up
lock installation screws from both sides
Remove
6
When strokes of claws in both sides are unbalanced
adjust
service
at remote control
adjuster so
locks are balanced
opening Upon completion of reinstallation I
Make
sure
3
that both left and right locks operate
Bf 19
Apply grease to slinding parts
that both
side
I
I J B Van Tail gate lock
@
II
1
Tail gate lock body assembly
2
Shaft
3
Lock lever spring
4
8
j
Fig
BF 52 Tail gate lock
Detach tail gate inside cover and remove both left and
r Strike
assembly
5
Lift gate side lock assembly
7
Push lever
8
Lock lever
9
Stopper A
10
Pull lever
11
Keylcrer
12
Tail gate
13
Lift gate lock
ide lock assembly
14
Striker assembly
15
Clip
16
Key cylinder
17
Outside
18
Pull handle lever
handle
van
Disconnect key cylinder and lock joint
right tail gate side lock installation screws CD through
key cylinder
jl rod
@
1
Sld c I k iri t
tion
screws
2
Lift gakdock
3
jen Ob inst btion screw
4
Lock body installation
Fig
installation screws
Fig
BF 53
BF 54
Removing key cylind
rod
screws
Remove
Removing tailgate installation bolts
lock installation
screws
assembly from service opening
RF 7n
and
remove
lock
BODY 3
When lock does not operate lightly and smoothly
check
lever sliding parts for lubrication
and apply
grease as required
Uft gate Remove lift gate support installation screws
Fig BF 55 Removing lock Upon completion of reinstallation I Make sure that both side locks and two locks on tail
gate top operate correctly 2
When both side claw strokes are unbalanced
at remote control
adjust
adjuster so that both claws engage
evenly Fig
Apply
a
BF 57
Lift gate
piece of cloth between roof and lift gate to
protect body from scratching Remove
hinge installation bolts and separate lift gate
from body Lift gate is installed in reverse sequence of removal When installing lift gate
position ocrrectly so that both
sides 3re aligned evenly
l
Fig
BF 56
Adjusting lock stroke
Upon completion of installation
make sure that lock
operates correctly and smoothly
When adjustment is
required
move striker side
WINDSHIELD AND REAR WINDOW
CONTENTS AEMOVAl
BF 22
INSTAllATION
BF 22
BF 21
WATEAlEAK COARECTION
BF 23
BODY windshield
REMOVAL Place
protective
a
cover over
hood
front fenders
The
glass
method which
below
procedure
may be used
to
check
ou
the
tlines
the windshield
opening
instrument panel and front seat I
Check
2
Remove rear view mirror support
ularities
3
Remove windshield wiper arm assembly
2
t
On inside of body loosen the lip of rubber channel
channel
rubber
windshield
for
anyirreg
Cle n off old sealer around windshield opening and
check entire b dy opening flange for any irregularities
from
spot welded flange
windshield
opening
pressure to glass near
putty knif
or
5
3
palm of the hand apply
With
the
edge
At the same time
other
rubber channel over
along the top and sides of
l1entgl31
ith ail of helper
ca
helper Carefully position replace
a
nAshi I t openip g
on
assist
spot welded flange
Note
Care should be exercised to make certain glass does not
After windshield rubber channel is free from spotI
welded flange
the aid of
a blunt
and carefully tQol
s itable
With
strike body
metal
during installation
Edge
chips can lead to future breaks
fully lift windshield
assembly from body opening and place it on a protected bench
6
glass and or Clean
either is to be
weatherstrip of all old sealer
if
used re
With
4
ndshield
glass supported
and
centered in
body opening check relationship of glass to body opening around entire peririleier of glass
I
Inside
surface of glass should completely
contact
spot welded flange 2
Curvature
of glass should be uniform
that of
to
body opening
Mark any sections of body to be reformed
5
Remove
glass and reform opening as required Fig
Note
BF 58
The windshield
Removing windshield
chrome
moldings
are
6
Install windshield
I
installed in
Clean
out
old
sealer in
glass cavity of windshield
rubber channel and around base of rubber channel
the rubber channel and shoo Id be removed prior to
removing rubber channel from the glass
INSTALLATION It is
2
Install rubber channel to glass
3
Insert
a
strong cord in the groove of rubber channel
where spot welded flange fits Tie ends of cord and tape to inside surface of glass at
important that the body windshield opening be
checked thoroughly before installation of the replacement
upper center of g
at
ss
BCJDY
r
t
CD 4
2
Weather strip
With
Glass
Fig
BF 59 Draw cord installed
the
aid of
a
helper
center windshield assembly in body
Note
Fig
carefully position
and
7
opening
Reinstall all previously removed parts and
remove
protective coverings
Do notposition glass by tapping or hammering at any time
BF 60 Sectional view of rubber channel
t
l
f
H11
WATERLEAK CORRECTION
iH
t l
In
many
instances
minor
waterleaks
around
the
windshield may be corrected by performing the following
operations 5
When glass and channel
are
properly positioned in
of windshield
to
seat
lip
of rubber channel
over
Using a pressure applicator
spot
tip
welded flange Cord should be pulled first across top of
wIndshield
then
Using
outer lips
weatherstrip
adhesive
lt 9J
a na
fSojw
black
j e qf gla
Use
a
pressure
J
applicator with a
from outside of bbdy
indicated in Figure BF 60 Seal
body
cli i i iel and j
completely around rubber channel
apply
a
i b narrow
q
tip Working
sealer under outer iip of
rubber channel around entire perimeter of body opening
INSTRUMENT PAN EL
CONTENTS REMOVAL
wit
ng gun
weatherstrip adhesive
approved
Leak between rubber
2
er
as
cor
completely around perimeter of glass
ana pressure type applicator sJ r irt of rubber channel to glass with ri appio ed a
apply
an
between glass and rubber chann l ofjthe
upj e ch side and finally across wind
shield bottom 6
Leak between rubber channel and glass
1
opening slowly pull ends of cord starting at upper center
BF24
RF
3
BODY
Fig
BF 61
Removing instrument panel
REMOVAL I
Disconnect battery terminal
2
Disconnect
heater control
strun1mtharnessfengine
wirings for 3
jwishienld
4 wire
from
lever
panel and two from both sides
in
compartment harness connector
wP
Remove four set screws from the top of instrument
5
instrument PulJ
panel rearward
and separate it from
body toward left
rietc
Remove steering pOst clamp insiallation bolts
Fig
BF 62
Fig BF 63 Remolling instrurTlent panel
Removing steerifJg post clamp bolts
RF
4
BODY SEAT
Seat uses steel pipe frame and Sshape and
square shape
Rear seat
van
for seat springs and urethane and vinyl leather are used cover
REMOVAL Front seat and
pick up
double
pick up
van
J@
a
Fig
Fig Remove four
BF 64 Front seat
installation
nuts
screwed
Remove
against
front side hinge installation
screws
separate
seat back from brackets in both side wheel housing units
double pick up SEAT BELT
Q
an
and remove rear seat as an assembly
riser Seat can be separated
Rear seat
seat
BF 66 Rear seat
Seat cushion
G
OPTION
Seat back
Fig
Fig BF 65 Rear seat double pick up BF 25
8F 67 Seat belt
Jling inst
positions
BODY
ROOM TRIM OVERHEAD LINING Removal o
Insert
a
spatula between roof panel and roof rail
and withdraw one end of overhead lining o
Peel off overhead lining from roof panel from the
t
withdrawn end to the other end
eAi
e j
Installa tion o
Thoroughly remove old adhesive pieces of overhead lining remained on roof panel dust and other foreign matter
o
and apply adhesive to roof panel
Adhere overhead lining from front side to rear side OVERHEAD LINING
carefully so that it is completely stretched o
Providing circumference with a sufficient space so folded into roof rail cut off unnecessary
that it i extra
space with
a
knife or other proper tool and
Fig BF 68 overhedd lining
fold circumference in o roof rail
SERVICE JOURNAL DATE
or
Al OR BUllETIN JpURi
PAGE
No
REFERENCE
SUBJECT
BULLETIN No
I
Bf 26
SECTION BE
BODY ELECTRICAL
DATSUN PICK UP MODEL 521
SERIES
CHASSIS
BODY
INI
NI
NISSAN MOTOR CO TOKYO
JAPAN
LTD
WIRING
BE
1
FUSE
BE
7
LIGHTING SYSTEM
BE
8
HORN
BE 15
METER AND GAUGES
BE l B
WINDSHIELD WIPER AND WASHER
BE 26
IGNITION SWITCH AND STEERING LOCK
BE 3D
RADIO
BE 32
CLOCK
BE 35
HEATER
BE 36
a
BODY ELECTRICAL WIRING CONTENTS
WIRING
HAANESS
BE 1
Body harness
Engine compartment harness
BE 1
WIRING
DIAGRAM
Instrument harness
BE 2
INSPECTION
BE 2 BE 4 BE 7
WIRING HARNESS
Engine compartment harness
t
Fig
BE 1
E
gi
compartment harness
BE 1
BODY Instrument harness
Body
harness
Fig BE 2 Instrument hamess
Fig BE 3 B09Y ham
BE 2
s
521
600
BodY
l
EtECJR C
t n
J
4
t
I
1
JN
harness C
bt j
S DC
C f
L
t 1 j
i
r
1
4 BE
fi
codY
lO
rness
V521 h f
f
t
lt l
rne55 0521 Fg
BE 5
Bod
BE 3
BODY WIRING DIAGRAM w
g r
c
s c
a
ta m
CI
i cm
o
0
a
J
OCO
t
lI
I
i I 8
i
cO
03
g
i eT
if
f n
J r r
I
I
01 4
o
o
o
g
0
o
g
a i c
IIl
8
8 l
I
l I
l
J 3
3
1 r
eve
Fig
I
6 Wiring dillgram BE
BE 4
common countms
3i
J C1
BODY
ELECTRICAL w c
8 o o0 U l ct OE a
o
6m J
lQOII J
t3S
lJi i
0
i
j
io a
H
i
II
u
lRi Jj Q
LJ
w
G O
0j
I 1
Ji
J
i f
l1
a 5d
a j
d
diagram Fig BE 7 Wiring BE 5
U S A
Canada
lP
Q3 a
a
cJ l
BOPY w
9 a
r
CD
c
og I CD
iL
M
i
5
V
Ii
t
C I
1
CD
U
J
n
i c J
Ii 1
i
i
t J
Q
J i
6 i
Ifi
I
i
i
ii
Iil
I
1
j
I
I
I
8
11 1 1
E t
1t ii l
l
2
gf
t I f
tit
Fig
8 Wiring diagram Van BE
6 BE
Double cabin
Q
12
tl
CI
Ca
a
o
I
i
lP
0 IJ
CC
J O
BOOYELE TRICAL INSPECTION
Cables should be clamped so that they do not come
6
into contact with
Referring to wiring diagram check wiring harness for connection with electrical connection
and
equipment and connector f i
installation
When
checking
wiring
harness note the following matters
Connected
unit should
not
be
loose
rusted
or
or
length
bolts should be
pletely
that
so
should
at
be
Note
When
8
in contact with body com
through
which current
when
or
due
occurs
to
IToneous
1
or
at
sections
engine operation and
inspecting
or
performing
it
is
other main
pply from battery
anticipated that
part
a
may
be
disconnect battery I I terminal
b
In
no
event
should
an
unloaded
directly connected with ground No
fan
flows
should not come into contact with othermetal parts 5
as
optumim extra
an
on body
tenance service without power s
continuity is provided jn between body
of unit
positions
others
circuited short
Terminals
in
rotating parts such
irily station
and bolts
4
securely clamped
from
sections
where vibration
insulating material should not be deteriorated
tion bolts
part temperature of
or
Cables should be provided with
8
For those parts which are grounded through installa
3
corner
pulley fan belt etc
Cable insulator cover should not be damaged crack
ed
Cables
sufficiently spearated
contaminated
2
wplFh 7
sharp
rises highly
connection should be present
test
Be
circuit be to use a
sure
lamp or circuit tester r
c
1
FUSE
j
DESCRiPtiON l ov When
to
a
rcurrent exceeding the rated amperage flows
circuit the
interrupted
INSPECTION
fuse is heated and melted
and tus s bles and
protected from damage due
to
In
the circuit is
or
most
cases
fuse
can
be
checked visually
when it is difficult to check visually
However
electric tequipment are
burning
the
a circuit
l
tester may be used
u
damage is
limited to the minimtim
Note
a
When fuse is blown off be sUre to correct the
cause before o
i
installing new fuse
I
Be
b
sure
to
use
fuse
having
the
specified
C
capaeity e
7 Q
ie
r
Do not use fuse having larger
i
j
c
When the contact surface is dirty or rusts or the
eontact is loose
voltage drops resulting in heated
fuses
and
ment
Remove dust or polish with a fine emery
abnormally operated
paper to improve the contact
Fig BE 9
capacity
20A 30A etc
Fuse box
BE
electrical
equip
I
BODY LIGHTING SYSTEM CONTENTS
SIGNAL
AND DIMMEA
BE
8
TUAN
Sealed beam unit replacement
BE
8
COMBINATION SWITCH
Headlamp adjustment
BE
8
HEADLAMP
FAONT
PAAKING AND TUAN
SIGNAL
LAMP
AEAA SIDE
COMBINATION LAMPS FLASHEA
LICENSE
PLATE
MAAKEA
BE 11
Removal
LAMPS
9
BE 11
SWITCH
LIGHTING BE
BE 11
Removal
DIAGNOSES AND
BE 10
TROUBLE
BE 10
COAAECTIONS
BE 12
Headlamp
BE 12
ILLUMINATION
LAMP
BE 10
BULB SPECIFICATIONS
BE 10
BE 13
Turn signal lamps
Tail lamp stop lamp
license lamp BE 15
backup lamp
HEADLAMP Sealed beam unit replacement I Remove wiring socket from the back of sealed beam unit
2
Remove head lamp fmisher
3
Remove retaining ring by unscrewing three screws
Note
Do not disturb two aiming adjusting screws
10
Fig
4
Remove sealed beam unit
5
Reinstafl sealed beam unit in
reverse
Remooing head Lmtp finUher
sequence to
removal
Headlamp adjustment For correct aiming adjustment
place vehicle to level
floor correct pressures of all tires
and remove all loads
such
except for standard
as
luggages
equipment
and passengers
spare lire and tools
Adjust vertical and horizontaI directions of head lamp
respectively with adjusting screws located
at
BE 11
the upper
and side portions of headlight mounting ring
Fig
BE B
BE II
Removing head Lmtp
BODY ELECTRICAL When adjusting low beam adjust aiming of low beam head lamps at the outside When adjusting high beam cover low beam head lamps at the outside with cover and then adjust aiming of high
beam head lamps at the inside
1
Vertical adjusting screw
1
Horizontal adjusting screw
Fig
BE 12 Aiming head lamp
Low beam
High beam
t
f I
r
r
c
i
J
1
t 10m 32 lIftl
i
J r
I
M
132 llftl
I
Gfll
f
in Hmm
f
h mm in
h mm
741
29 2
50
145
571
1040
291
G521 GN521
738
1 29
50
145
5 71
1040
291 115
U521 UN521
715
28 1
10
175 6 89
1050
320
12 6
V521
720
3 28
1010
204 8 03
20
349
13 7
521
N521
VN521
Fig BE 13 Head lamp aiming adjustment data
FRONT PARKING AND TURN SIGNAL LAMP I
When removing bulb
with lens removed
push bulb
toward socket turn bulb counterclockwise and withdraw bulb
When removing lamp housing
2
I
in
Remove mud cover
used to
cover
lamp from the
inside of wheel house
Fig
BE 9
BE 14 Mud coveT
11 5
BODY 2
Remove connector from wire harness
3
Remove
REAR COMBINATION LAMP
lamp housing installation nuts and remove
When removing bulb
toward socket
lamp assembly
turn bulb
with lens removed
push bulb
counterclockwise and withdraw
bulb
When removing lamp housing
2 I
Remove connector from wire harness
2
Loosen
lamp installation
nuts
and remove lamp
assembly 1
SIDE FLASHER MARKER i
Remove
if 1
i
Dking and tvm signal lamp Fig BE 15 Front p
side flasher lamp installation nut from the
inside of fender
and
and lamp housing
can
Of
LAMP
rem ve lens
packing and bulb Lens
be separated from body
LICENSE PLATE ILLUMINATION LAMP When
removing bulb
remove
lens and then
remove
bulb
BULB SPECIFICATIONS
All countries except
For U S A and Canada
for U S A and Canada Item
Wattage
SAE
Wattage
SAE
Candela
trade
Candela
trade
power
number
power
number
High beam unit
5 37
4001
5 37
4001
Lowbeam unit
37 5 50
4002
5 50 37
4002
Head lamp
Front parking
23
32 cp
1073
8
4 cp
67
6
5 cp 4
turn signal lamp
Side flasher lamp
1034
7 5
License plate illumination lamp
6 cp
Stop Rear combination
lamp
tail
89
7 5
6cp
23 8
23 8
r
32 33 cp
8 4 cp
Side maker lamp
j rr
23 8
1034
6 67 89
1034
32 33 cp
32 33 cp
Turn signal
23
32 cp
1073
23
32 cp
1073
Back up
23 32 cp
1073
23 32 cp
1073
Passenger compartment
6
4 5 cp
Engine compartment lamp
6
5 cp 4
BE lO
6
4 5 cp
6 4 5 cp
BODY ELECTRICAL 2
Remove horn ring and steering wheel
3
Remove shell cover
4
Unscrew two screws used to secure switch on steering
TURN SIGNAL AND DIMMER COMBINATION SWITCH Removal Disconnect combination switch from wire harness at
column jucket and remOve switch from locating hole on
connector plug
steering column jacket
Now
remove switch
completely
LIGHTING SWITCH Removal
Fig
BE 16
Removing
turn
I
Remove connector from the back of lighting switch
2
Remove screw and knob
3
Remove nut
4
Remove lighting switch
plain washer and spacer
sigMl and diameter
combination switch
A
CLOCKIL
M SW
8 TO FUSE
FLA 3l tER
Fig
F
UNIT
BE 17 Circuit diagram
BE ll
forlighting system
v
BODY
T
LIGHT TCH
CUXK
IL
iz
It
I
TO
USf
r
TO rUSE
H
Fig
BE iS
Circuit diagram for lighting system
CtUUJdU S A
TROUBLE DIAGNOSES AND CORRECTIONS
Headlamp Condition
The headlamp does not
light
Corrective action
Probable cause
Blown off fuse or faulty contact
for both
Check fuse for fusing and faulty contact When fused
detect and repair cause
then
replace fuse
upper and lower beams
Faulty lighting switch or light relay
Check continuity test and if the switch or
relay is defective replace Upper beam cannot
Conduct
Defective dimmer switch
beam or vice versa
continuity
switch is defective
be switched to lower
test
and if dimmer
replace
Check the operation if dimmer switch is
Defective light relay
defective replace
ne
BODY ELECTRICAL
Condition
Headlamps dim
Probable cause
Corrective action
Defective light circuit
Check the headlight circuit for cable being about
to
break
and
faulty
contact
or
check fuse for faulty contact
Repair or replace if required
Headlamps dim
Partly discharged battery
Measure specific gravity of electrolyte
when the engine is
Charge battery if required
stopped or operated under idling speed
Defective battery
Replace battery
Headlamps still dim
Faulty sealed beam unit
Voltage between headlamp red white cable
with engine run
or
above idling speed
12 8V or higher
black red
and black cable terminals is
Replace sealed beam units Faulty charging system
Voltage is less than 12 8V through above test
Check generator regulator and light circuit
Headlamp ip only one
Faulty headlamp terminal contact
Repair as required
Defective lamp
Replace lamp
side lights
Turn
signal lamps Condition
All turn signal
Probable cause
Corrective action
Blown offfuse or faulty contact
Check fuse for fusing and faulty contact
When fuse is fused
lamps do not ligh t
cause
Faulty flasher
unit
terminal
contact
defective flasher unit
or
detect and repair the
and replace fuse
When two lead wires of flasher unit
are
connected with turn signal switch turned on
and individual turn signal lamps light her unit is defective
fla
Repair connector terminal if necessary Replace flasher unit Defective turn signal switch
Conduct continuity test If the
replace
tF BE 13
turn
signal
switch is
defective
BODY
Condition
Corrective actions
Probable causes
Defective flasher unit
All turn signal
Replace the flasher unit
lainps do not go out
Flashing cycle is
A
to low
specified wattage is used
Turn signal lamp
lamp having wattage
more
than
the
Replace with the specified one
Defective flasher unit
Replace flasher unit
Faulty contact in circuit
Repair as necessary
A
Replace with the specified one
flashing cycle is too high
lamp having wattage less than the spe
cified wattage is used
Flashing cycle ofteft or
Defective flasher unit
Replace flasher unit
There is a lamp which does not flash
Replace
Burnt out lamp bulb fIlament
Check all lamps for operation Check lamp which does not light for burnt
right side turn signal
lamp differs from that of right
or
out fIlament and defective socket
left side turn
Replace if necessary
signal lamp Only left or right side turn
Check both side lamps for difference in
Faulty connector contact
brightness
signal operates
Repair as necessary
When windshield wiper
A lamp other than specified is used
Replace with the specified one
Partly discharged battery
Measure specific gravity of electrolyte
which uses ignition for power supply
Charge battery if necessary
is operated
flashing cycle and brigh tness change
Faulty contact of power supply circuit
BE 14
Improper contact of power supply circuit
ELECTRICAL
BODY Tail lamp
license
stop lamp back up lamp
lamp
Condition
Both left and right
Probable cause
Corrective action
Blown offfuse or faulty contact
Check fuse for fusing and faulty contact
lamps do not light
When fuse is blown off detect and correct cause
Defective stop lamp switch or backup lamp switch
or
faulty contact
When two lead wires of switch are
neeted
Stop lamps and backup lamp only
and replace fuse
and the
lamp lights
con
lamp and
circuit are normal
Replace switch or repair connector termi nal
Only one side lamp
Faulty grounding
Repair grounding cable contact
Burnt out lamp bulb filament
Replace lamp with a new one
Faulty contact of connector terminal and
Repair
lights
or
socket
Brigh tness of one side
Faulty contact of connector terminal and
lamp differs from the
or socket
Repair if required
other
tI
HORN CONTENTS
AEPLACEMENT
BE 15
TROUBLE
DIAGNOSES AND
ADJUSTMENT
BE 16
CORAECTIONS
BElT
REPLACEMENT 1
Disconnect wire from horn
2
Remove bolts retaining horn to bracket
3
Install horn in reverse sequence to removal Test horn
operation when installed
Low and high tone horns are
located in upper and lower sides respectively
BE 15
BODY JUSTMENT AD
Note
When adjust screw is turned Clockwise
I
Secure horn in a vise and connect horn cables to
power supply
2
Current decreases
Counterclockwise
Current increases
See Figure BE 19
Set power
supply switch to
and make sure
ON
4
that voltmeter indicates 12 to 12 5V
Upon completion of above adjustment
make
sure
that horn sounds correctly with 14 to 15V generated by alternator
AMMETER
110
to
15Al HORN
Sound
VOLTAGE METER 115 to 20VI
Fig BE 19 Circuitfor hum adjustment
3
Consumed current adjusting value
High
5
440
Low
5
350
A
Figure encircled in parenthesis are basic frequencies Hz
Listen horn sound for level volume and tone Adjust
sound
as
ammeter
required
to
obtain
sepecified
When adjustment is required
amperage by
loosen lock nut 5
and turn adjust screw adequately
Secure lock nut of adjust screw
HOR N BUTTON IHI
III
Fig
BE 20
Adjusting hum
Fig
BE 16
HE ll Circuit diagram
for horn system
BODY ELECTRICAL TROUBLE DIAGNOSES AND CORRECTIONS
Probable cause
Condition
Horn does not
Excessively discharged battery
operate
Corrective action
Measure specific gravity of electrolyte
Charge if required Blown off fuse
Check fuse for fusing and improper contact
Replace or repair if required Improper horn button contact
In this case the horn sounds though horn
relay terminal S
is grounded
Check and repair horn button Defective horn relay
Horn
sounds though the horn relay termi
nals B and H
are
circuited short
Replace horn relay Defective horn
Horn
does not sound though horn relay
terminals
B
and
still does
horn
and H
are
not
circuited short
sound
though
terminal is connected to horn
battery
terminal directly
Replace horn Horn sound
Defective horn relay
Horn does not stop though horn relay
continuously
S
terminal is disconnected
Replace horn relay Short ircuited horn button and horn relay
When
terminal S
nection
horn
stops through above discon
check horn
button unit particu
larly carefully
Repair horn relay terminal S Replace horn button Reduced volume and or
Improper fuse wire contact
Correct
Broken cable
Repair or replace if required
Improper horn button contact
Repair
tone quality
BE 17
I
BODY METERS AND GAUGES CONTENTS
COMBINATION
BE lB
OIL PAESSUAE WAANING
Description
BE 1B
IGNHlON WARNING LAMP
BE 21
Replacement
BE 19
BULB SPECIFICATION
BE 21
SPEEDOMETEA
BE 19
TAOUBLE
Replacement
BE 19
COAAECTIONS
BE 22
FUEL
METEA
METEA AND THERMOMETEA
LAMP
BE 21
DIAGNOSES AND
BE 19
Speedometer
BE 22
Description
BE 19
Thermometer and fuel meter
BE 23
Replacement
BE 20
Oil pressure and ignition warning lamps
BE 25
COMBINATION METER
Description The
combination fuel
speedometer indicator
lamps
meter
meter oil
consists
and
of three meters
thermometer
and
five
indicator
lamp ignition warning lamp head lamp high beam pilot lamp and turn pressure
signal pilot lamps left and right
For illumination of the
combination meter four lamps are used The combination meter
uses
a
printed
circuit board located
behind the
meter for wiring With this construction the combination meter can be simply connected to power supply the 12 pole connector See
1
Speedometer
2
Meter illumination
through
Figure BE22
6
Oil pressure warning
lamp
lamp
7
Ignition warning lamp
3
Fuel meter
8
Head lamp upper beam
4
Thermometer
5
Tum signal
lamp
pilot
pilot tamp 9
Regulator
to
12 pole connector
Fig
BE lB
BE 22 Combination
met
1
BODY ELECTRICAL The illumination lamp sockets are secured on the back
board with clips
they can be removed and reinstallation
4
Loosen
speedometer cable
union nut and remove
speedometer cable from speedometer head
easily The fuel meter and thermometer The
regulator
use
meter
regulator
minimize indication error due to
voltage
Install combination meter in reverse sequence to
s
removal
fluctuation and therefore the meters are very reliable
SPEEDOMETER
Replacement I
Replacement
Disconnect negative battery cable
I
With combination meter removed
screws
2
Unscrew two set
screws
from lower part of combi
2
Loosen two screws
combination
nation meter
loosen attaching
and separate combination meter from meter cover
meter
used to secure
housing
speedometer on
and detach speedometer
from combination meter
3
Install speedometer in reverse sequence to removal
Fig
Fig
BE 23 Removing combination meter
BE 24
Removing speedometer
FUEL METER AND THERMOMETER
Description The fuel meter consists of a tank unit located in the fuel tank and fuel meter The tank unit detects fuel level with its float converts fuel level variation to a resistance 3
Pull out 12 pole connector from the back of combi
of slide resistor installed
nation meter
on
the float
controls current flowing to the fuel meter
BE 19
base
and thus
J
BODY The
consists
thermometer
thermaltransmitter
of
in
located
a
the
thermometer and
engine
meter
block The
resistance
thermaltransmitler
the
and thus
ON
set to
The
a
controls
thus
the
are
provided
current flows to the heat coil
with
the
to
interrupted
and the heat
tolerance may
occur
on
part of the regulator
consists
of
a
bimetal
ann
As the bimetal cools
current to the coil is
the contact closes The
repetition of this operation produces
a
pulsating voltage
of8Y which is applied to the temperature and fuel gauges
is
If both
operated The characteristics ofboth meters are same A
operating
opening the contact Consequently
the bimetal ann is bent and
pointer connected
voltage
bimetal arm and a heater coil When the ignition switch is
When the ignition switch is
coil is heated With this heat
The
turned on the bimetal arm is heated and bent by the coil
fuel meter and thermometer
bimetal arm and healer coil
voltage fluctuation
thermometer and fuel meter operate correctly
current flowing to the thermometer The
source
regulator is used to supply a constant voltage so that the
thermaltransmitter is equipped with a thermistor element which converts cooling water temperature variation to
due to
defective
the thermometer of fuel
at
the
thermometer
the same time
and
fuel
meter
become
this may be attributable to
trouble in the voltage regulator
r AEGULATOA
FUSE
M
TEMPE AATUAE
IGNITION
GAUGE
SWITCH GAUGE TANK UNIT T
I
FUEL TANK
THEAMAL TAANSMITTEA
Fig BE 25 Circuit di4gram for fuel meter temperature meter and voltage regulator
Replacement 1
With
screws
combination meter removed
used to
secure
combination meter
fuel meter
housing
remove
two set
thermometer
on
and remove fuel meter
or
or
2
Install fuel meter or thermometer in reverse sequence
to removal
thermometer from combination meter
BE 20
BODY ElECTRICAL When the ignition switch is set to circuit is closed
warning
ON
the ignition
and current flows from the
ignition switch to the warning lamp bulb and ground through the regulator When the engine is started and the generator current
opposes in
lamp
comes
into
effect it
the generator output
operation
flowing from the warning
the current breaks
the
warning circuit ground
connection and the lamp goes out
Ignition switch
r
Fig
8
BE 26 Removing thermometer
c 0
5 co
Pilot
OIL PRESSURE WARNING LAMP The engine
lubricating system incorporates
an
relay oil
1
I a
L
pressure waming lamp which glows whenever engine oil
Alternator
Regulator
5 7 to 8 5
pressure falls below OA kg em to 0 6 kg em when the
is
Ib sq in
Under normal operation
stationary
the light glows with the ignition switch turned
on
a 3
Ql
te lD J 2
engine
Fig BE 28 Circuit of ignition warning system
When the engine is running and oil pressure reaches
the above range the circuit opens and the light goes out
u
I
i c o
Warning light
BULB SPECIFICATIONS
Fuse
0
Wattage
Switch
en
Item
J
power
J without
with
pressure
pressure
Meter illumination lamp
Turn signal indicator
lamp Fig
trade number
T
I
34 2cp
158
7 1 cp 1
161
17
lcp
161
17
lcp
161
I 7
I cp
161
BE 27 Circuit of oil pressure warning system
High beam indicator lamp
Ignition warning lamp
IGNITION WARNING LAMP Ignition warning lamp glows when the ignition switch is set to
SAE
Candela
ON
and the engine is not operated
Oil pressure warning
or when the
lamp
generator fails to charge with the engine operated
BE 21
rr
BODY mOUBLE DIAGNOSES AND CORRECTIONS
Speedometer
Condition
Probable cause
Speedometer pointer and
Improperly tightened speedometer cable
odometer do not operate
union nut
Corrective action
Retighten union nut correctly
Broken speedometer cable
Replace
Damaged speedometer drive pinion gear
Replace drive pinion gear
Defective speedometer
Replace
Rapidly bent speedometer cable
Correct or replace
Damaged speedometer drive pinion gear
Replace pinion gear
Defective speedometer
Replace
Unstable speedometer
Improperly tightened speedometer cable
Retighten union nut correctly
pointer
union nut
Speedometer pointer deflects widely
Defective speedometer cable
Replace cable
Defective speedometer
Replace
Unusual sound occurs
Excessively
Replace meter cable or lubricate
in response to increase
cable inner wire or lack of lubrication
bent
or
twisted speedometer
of driving speed Defective speedometer
Replace
Defective speedometer
Replace
Inaccurate odometer
Improperly meshed second and third gear
Replace speedometer
operation
worm gears
Inaccurate speedometer indication
Faulty feeding due to deformed odometer and pinion carrier
BE 22
Replace speedometer
BODY ElECTRICAL Thermometer and fuel meter
Both thermometer and
Corrective action
Probable cause
Condition
Blown off fuse
or
improper connection
Check fuse for fusing and improper contact
fuel meter do not
Replace after correcting cause if fused
operate
Correct contact
Defective fused
or
voltage
regulator
Damaged
Replace
open contact
Both thentlometer and
Defective voltage
fuel meter indicate
wire
inaccurately
grounding
seized
regulator
contact
Broken heat
and or
improper
In this case meter operates excessively
Replace
In this case meter operates slightly
Improper cable contact
improper contact
for
Check cable
and
repair if required
ThennometeJ Thermometer does
Defective thermal transmitter
thermal transmitter
Replace
if
pointer
deflects when thermaltransmitter yellow
not operate
white cable is grounded
Defective thermometer
Replace
thermometer if pointer does not
deflect
when
thermaltransmitter yellow
white cable is grounded
Pointer indicates
Defective thermal transmitter
Pointer moves to low limit when ignition switch is turned off
maximum temperature
In this case
Pointer
Defective thermometer
indicates
even after
seIViceable
when
applied
to
thermal
yellow wihite cable
cable is
40 n resistance
not operate accurately
transmitter
grounded
temperature
replace thermometer
Thermometer
Defective thermometer
maximum
ignition switch is turned off
In this case
Thermometer does
replace thermaltransmitter
is is
a
and thermometer indicates ap
proximately 800C I760F Defective thermal transmitter
If thermometer
is
normal
above inspection
Replace thermaltransmitter
BE 23
through the
v
BODY
Condition
Probable cause
Corrective action
Improper cable contact
If thermometer indicates
a
temperature
slightly lower than the actual temperature check cable from thermometer to thermal transmitter for cable poor contact
and
being about to break
faulty grounding
and
repair if necessary Fud meter
Fuel meter does not
Defective tank unit
Replace tank unit if pointer deflects when tank unit yellow cable is grounded
operate
Defective fuel meter
Replace fuel
meter
with a new
one
if
pointer does not deflect through the above inspection Pointer indicates F
Defective tank unit
Replace tank unit if pointer lowers below empty limit when ignition switch is turned
position
off
Defective fuel meter
Replace fuel meter if pointer still indicates F
Fuel meter functions
Defective tank unit
position through the above inspection
Replace tank unit if pointer indicates a half level when a 35 n resistance is applied to
improperly
tank unit yellow
cable and then cable is
grounded Defective fuel meter
Replace fuel indicate
a
meter if
pointer does
half level through the
not
above
inspection Improper cable contact
If fuel meter indicates a level slightly lower than actual level
check cable from
fuel
meter to tank unit for cable being about to
break
poor contact and faulty grounding
and repair as necessary
BE 24
BODY ElECTRICAL Oil pressure and
ignition warning lamps
Condition
Probable cause
Corrective action
Oil pressure warning
lamp Lamp does not light
Blown offfuse or faulty contact
Check fuse for fusing and faulty contact
when ignition switch
Replace after correcting cause or repair as
is set to
necessary
ON
Broken lamp bulb filament or faulty cable
If oil pressure switch yellow black cable is
contact
grounded and warning lamp does not light check bulb for burnt out fIlament and
replace as necessary Defective oil pressure switch
If warning lamp ligh Is through the above
inspection replace oil pressure switch Lamp does not go out
Lack of engine oil
Check oil level and add oil as required
Oil pressure is too low
Inspect engine oil pressure system
Defective oil pressure switch
Continuity
while engine is being
operated
exists
on
oil pressure switch
men engine is being operated
Replace oil pressure swi tch Ignition warning lamp Lamp does not light
Blown off fuse or faulty contact
when ignition switch is set to
Check fuse for fusing and faulty contact
Repair or replace if necessary
ON Bumt
out
lamp bulb ftlament or faulty
cable contact
Pilot lamp does not light when voltage
regulator connector is disconnected
white
red cable is grounded and ignition switch is set to
NO
Check bulb for burnt out fIlament and
replace if necessary Lamp does not go
Faulty charging system
Inspect charging system
out when engine is
started
BE 25
rl
BODY WINDSHIELD WIPER AND WASHER
CONTENTS
BE 26
Wiper switch
BE 27
BE 27
Washer nozzle adjustment
BE 28
Wiper motor linkage
BE 27
Caution for windshield washer operation
BE 28
Wiper motor
BE 27
Specifications
BE 28
DESCRIPTION AEMOVAl AND INSTAllATION
DESCRIPTION The windshield
mechanism wiper
wiper consists of wiper arms
motor
and blades The wiper motor unit
consists of a motor and auto stop mechanism motor is of a
2
engine
used to connect those components
The wiper
The
ed type
The wiper motor unit is located on the cowl the
electrically operated windshield washer consists of washing fluid tank pump washer nozzles and vinyl tube The
link
compartment
and the
link
windshield washer switch is combined with the
windshield wiper switch to a single unit When operating
dash in
the washer twist the switch knob
mechanism is
located behind the instrument panel
BATTERY
IGNITION SWITCH
WASHER MOTOR LR
IBL
FUSE W
L
WIPER SWITCH
1
llAI
OFF
IVI
lVl
ILl
ILl
IBI
IBI
lLWI
ILW
j JSher Fig BE 29 Circuit diagram for windshield wiper UJ
BE 26
2
lWlST
X
lBll
system
1
Z
I
BODY ELECTRICAL REMOVAL AND INSTALLATION
Wiper motor linkage Removing wiper arm from pivot shaft
I
Raise wiper blade from windshield glass
raise the base
of wiper ann and remove wiper ann from pivot shaft 2
Separate wiper
motor
drive shaft
arm
from
con
25mm 0 984 in
necting rod
Fig BE J 1 Wiper arm installation
Wiper motor Disconnect connector from wire harness
2
Separate wiper
motor
drive shaft
arm
from
con
necting rod
Fig BE 30 Wiper motor linkage
Fig 3
Loosen set screws
BE 32 Wiper motor
used to secure both pivot shafts
and remove pivot shaft connecting rod assembly
4
Reinstall windshield wiper motor linkage in reverse
sequence of removal
3
Loosen three bolts and remove motor
4
Reinstall wiper motor in reverse sequence of removal
noting the following matter
Wiper switch Note
I
Disconnect connector from the back of wiper switch
2
Loosen switch knob set
Install windshield wiper arm in correct installation
angle to obtain correct sweeping angle See Figure 31 BE
for correct installing dimensions
knob
BE 27
screw
and remove switch
J
BODY 3
Remove installation nut
4
Remove wiper switch from the back of instrument
Caution for windshield washer
plain washer and spacer
operation panel Do not operate windshield washer continuously more
Washer nozzle
than 30 seconds
adjustment
often
causes
When washer nozzle is installed or when washer fluid is not
without
improper
windshield
Norrnally
sprayed properly adjust nozzle direction so that fluid
or
applying washer fluid This
windshield
washer
washer should
be
operation
operated
10
seconds or less at one time
is sprayed in proper range See Figure BE33
Specifications Type
Interlocked parallel type
Angle
87 to 930 Driver side 96 to 1020 Assistant side
100mm 3 94 in
Operating speed
High
59 to 73 rpm
Low
41 to 51 rpm
Fig BE 33 Washer nozzle adjustment
TROUBLE DIAGNOSES AND CORRECTIONS
Condition
Windshield wiper does not operate
Corrective action
Probable cause
Motor
No current flows to motor due to
Broken armature
Replace motor or armature
Worn motor brush
Replace motor brush
Motor
is
overheated
when
4
to
5
minutes are elapsed due to
Replace motor
Seized motor shaft
Windshield wiper circuit fuse
15A
is
easily fused due to circuit Short
rare
circuit short
burning of motor inside component
BE 2B
or
Replace motor or repair part
circuited short
BODY ElECTRICAL
Probable cause
Condition
Corrective action
Power supply
Blown off fuse due to trouble of other
Check
and cable
part in windshield wiper circuit
correct trouble
Loose open or broken wiring
Check wiring near motor and terminal
for
other part
operation and
for connection
connector
I
Correct if necessary Erroneous wiring
Check each
connecting cord for cord
color and correct as
Switch
Improper grounding
Correct
Improper switch contact
Connect
L Blue
B Black
and see if motor operates If
motor operates
Link
uy necess
Wire harness of other part is hooked on
LW Blue white
or
to
replace switch
Correct
link
Windshield wiper
Motor
Disconnected link rod
Correct
Seized or rusted arm shaft
Lubricate
With
arm
raised
or
replace arm shaft
still excessive current
flows 3 to 5A due to
operating speed is too slow
Rare
of motor armature
circuit short
Replace motor armature
Windshield wiper stops only by lightly
holding with hand due to Worn motor brush With
arm
raised
Replace brush
still excessive current
flows 3 to 5A due to Seized motor shaft
Replace motor or lubricate I earing
with
engine oil Power sup
Dropped source voltage
Measure voltage check other electrical
ply and
parts for operation
cable
action for power supply if necessary
Link
Hununing
occurs on
and take corrective
motor in arm op
erating cycle due to
Switch
Seized a9 shaft
Lubricate grease
Improper switch contact
Conduct continuity test and replace if necessary
BE 29
or
replace
5 r
BODY
Condition
Corrective action
Probable causes
Windshield
Windshield wiper blade sticks on wind
Raise arm and operate windshield wiper
wiper blade
shield glass
without applying load Oean windshield glass and or replace
wiper blade Windshield wiper
Motor
Low high
speed
considerably
ratio
speed cannot be
differs from I
changed correctly
Windshield wiper is operated under the same
or
14
speed at both low and high speeds
windshield wiper does not operate at
either low or high speed due to Motor brush for either low or high
Replace brush
speed is worn Motor
Contaminated
stop auto
improper
contact
or
relay due
contact
Remove
foreign
clean
to
device
stop to
carefully
so
cover as
not
and to
deform relay plate
matter
0
au
contact
Cable and
Improper connection between
switch
2nd switch steps
1st and
Remove switch and make sure that 1st
and 2nd steps are not connected at OFF
0
position
i
If connected replace switch
i 0
ii
0 0
Motor E
Contaminated autostop relay contact
0
or
0
matter
0
Incomplete
Cl
improper
con tact
due to
foreign
Remove
clean
autostop
contact
device
carefully
so
cover as
not
and to
deform relay plate
operation
stop auto
Contact is not interrupted
Remove
au to stop
device
correct relay plate bending
cover
and J
IGNITION SWITCH AND STEERING LOCK
CONTENTS
BE 31
IGNITION SWITCH WITH STEEAING
Description
BE 31
LOCK
Removal
BE 31
IGNITION
SWITCH
BE 30
BE 31
Description
BE 31
Steering lock replacement
BE 31
BODY ELECTRICAL Removal
IGNITION SWITCH
Remove ring nut from ignition switch
I
Description
and remove
plain washer and spacer The ignition switch controls the engine ignition system and most of electrical The terminal 2
Terminal
equipment
Remove ignition switch from the back of instrument
panel and disconnect connector
is for power supply from the battery
I
is connected upto the fuse block
the ignition switch is set
to
ON
When
supply
power
is
IGNITION SWITCH WITH
prepared for electrical equipment and ignition circuit The terminal
2
is connected to
3
S
terminal of the
STEERING LOCK
magnetic switch on the stater motor When the ignition switch is set to switch
START
current flows to the
magnetic
and the magnetic switch operates to start the
starter motor
The terminal
4
is for radio only 5
is
lS used for vehicle equipped with
ignition coil with resistor In order to increase ignition while
The steering lock is built in the ignition switch When the key is set to
The terminal
voltage
Description
cranking engine
by pass line so that
this
terminal forms
current does not flow
a
through the
Lock
and removed the steering system
locked automatically
The
locking mechanism is in
stalled on the steering column jacket tube When the key is set to
and removed the steering lock spindle is
Lock
inserted in a notch in the collar which is stationarily set on the
resistor of ignition coil
The
steering column to lock the steering wheel ignition switch is installed on the
back of key
cylinder with a attaching screw and interchangeable Key position Lock Terminal
Ace
Garage
On
Start
B On
Off
Start
II
IG S
1
2
A
R
3
IGNITION SWITCH
I
on
Ace
Off
On
Steering lock replacement
Start
Terminal
For the purpose of tamper proof the self shear type t screws
2 3 4
I
r
are
installed
so
used that
removed easily
are
sheared off when
the steering lock system cannot
Replace
the
be
steerfug lock proper in
accordance with the followiitg instructions when required
0
5
I
Loosen two attaching
two self shear
IGNITION SWITCH
and their heads
II
tool
BE 31
type
screws
screws
and break remaining
with a drill or other proper
r
BODY 2
Now
remove
steering lock
proper
from
sleering
jackel tube
When installing a new steering lock proper
3
tighten lwo new self
ear
be sure to
type screws 10 shear off their
heads
I
Ignition switch put
5
Lock spindle
2
Key cylinder part
6
S leering
3
Steering jactet tube
7
Self shear type screw
4
Lock collar
8
Attaching SCJeW
rb
haft
Fig BE 34 Steering lock
RADIO CONTENTS INSTAllATION
BE 32
ADJUSTING
BE 33
ANTENNA TRIMMER
Noise prevention chart
INSTALLATION
Fig BE 35 Instolling ado
BE 32
BE 34
l
BODY ELECTRICAL L
InslaII anlenna
7
InslaII mounting brackel on radio proper
and lead anlenna cable to Ihe back of
instrument panel 2
Remove mask for radio from instrument panel
3
Fit radio inlo inslrument panel by applying il from
8
the back of inslrumenl panel
4
Tighten plain washer
Connect anlenna cable and speaker cable 10 lead
cables from radio Connecl radio power source cable 10 blue cable of inslrumenl harness
spring washer and
nul
on
adjusl shaft
Note
Blue cable of instrument harness is used not only
for radio but also for clock 5
Tighlen
screw
securing brackel
of radio
10
in
strumenl panel
JUSTING AD
ANTENNA TRIMMER
When
radio is installed newly
replaced
anlenna trimmer
adjusl
or
when
adjusI
antenna is
screw on
the
bottom of radio in accordance with the following inslruc tion
1400 kc
EI
C
Fig BE 36 Ins tolling radio
6
InslaII speaker See Figure BE37
Fig
BE 38 Adjusting antenna timmer
L
Exlend antenna complelely
2
Sel frequency 10 I 400 KC
Noise may be generaled
bul disregard it t
3
Fig
Turn anlenna trimmer 10 left and righl slowly and
sel il al a position where receiving sensitivily is highest
BE 37 Installing speaker
BE 33
f BODY Noise
prevention
chart
Run engine raise antenna set volume to maximum and sel
dial al
a
medium point withoul catching
Condition
casting wave
broad
Probable cause
Corrective action
Ignition system Noise occurs when engine
High tension code
High
is operaled
tension
code
may
be disregarded
because noise suppressor is used coil Ignitio
Apart choke wire from ignilion coil as far as
possible
Install a
5 fJ F capacilor in primary side 0
lerminal of ignition coil Note
Be careful not to install capacitor in
secondary or primary breaker side otherwise engine becomes improper Connecl wire belween engine and ignition coil locating area of body with adhesive Secure ground of ignition coil
Secure contact of carbon electric poIe and
Dislributor
rotor
Elirninale excessive tip on rolor pole or cap
pole by scrubbing with a screwdriver Check slagger belween rotor and slator
Charging system Sound of allemating
AIlemalor
Inslall
current presents
a
5fJ O
F
capacitor
on
charging
lerminal A Note
Do not use capacitor excessively
If capacity is used
excessively
altema
tor coil will be broken
When acceleralor pedal is
depressed
Regulator
Inslall a 0 5 fJ F capacitor on
or released
A
lerminal
ofvoItage regulalor
noise preseo ts
Supplement equipmenl When engine slarts
Operative
noise presents
gauge
noise
of thermomeler and fuel
and ground wire
Noise still presents even after
inslaII 0 1 fJ F capacitor between lerminal
Note
stopping
If
a
capacitor
capacity is used
engine
be deviated
BE 34
having
excessive
indication of meter will
BODY ElECTRICAL
Condition
Probable cause
Noise presenls when
Corrective action
Horn
Inslall a 0
horn is blown
lF capacilor 5
on
horn relay
terminal or horn switch
Noise presents when turn
Flasher unit
5 p F capacitor 0
InslaII a
signallarnps are
operated
Note
a
Be sure to locate
capacitor most near position
completely
of noise source and connect in parallel b
Cut lead wire as short as possible
c
Ground
wire should
be
placed
on
the
body
d
Make installation and connection securely
e
Carefully
IN
identify
or
OUT
marks
CLOCK
Installation I
I
Apply rubber seal and sland 10 inslalIation screw of
clock and instaII them inlo located hole al the center of inslrumenl panel
v
Tighten insta1Ialion screw with nut
3
Connect lead cables of clock 10 inslrumenl harness
K cable
is
for
illumination lamp
j 9
i@
p
grounding
red blue
cable
is
for
it
and blue cable is for clock power
supply Note
Fil
o
J
i
i
po
Blue cable of instrument harness is used not only
for clock but also for radio
Fig
BE 35
BE 39
Instolling clock
I I
II
2
Black
1 JLIJllttlll
41
111lIl
rr BODY HEATER
@
CD
J @
Fig
I
Inlet hose
2
Outlet hose
3
Air duct
4
Defroster hose
5
Hose connector
6
Defroster nozzle
7
Heater control lever
8
Air control lever
9
Clamp
10
Room healer unit
11
Heater control cable
BE 40 Heatl T unit
Installation
I
Remove instrumenl panel
2
Install heater unil proper
on
dash panel Connecl
to blue cable
wire harness of
blue cable
from molor
healer unil
Secure black cable on heater unil with screw
10 ground
Fil heater hoses 10 hol waler inlet and outIel of
3
healer unil and secure them with clamps Connect the other ends of healer hose
10 engine side
Yfhen connecting use connector as required t
Inlet hose
3
Connector
2
Outlet hose
4
Connector
Fig
BE J6
41 BE
Installing heater hose
BODY ELECTRICAL 4
Install air intake duct on dash panei and heater unit
G
Air intake duct
Fig 5
42 BE
G
Heater unit
1
Defroster nozzle
2
Heater control lever
Fig
on
Air control lever
BE 43 Defroster nozzle and heater
and air control levers
Installing heater unit
InslaII defroster nozzle
3
9
the back of inslrumenl
Connecl healer conlrol cable 10 healer conlrollever
panel 10
6
InslaII healer switch on inslrumenl panel
7
Install heater conlrol lever and air control lever on
Install rod of air conlroI lever
on
air intake ducl
adjusl lever II
Connecl defroster hoses
12
Connecl heater swilch to instrument harness
inslrumenl panel
8
and
heater unit to instrument harness
ReinslaII inslrumenl panel
Motor speed
L
B
L
ill
High
Resistor YR
YB
DMediUmw II
Low
11 J
i21
YG
Body earth
t
Fig
BE 44
Circuit diagram
BE 37
for heater
JI BODY
TROUBLE DIAGNOSES AND CORRECTIONS Condition
Probable cause
Corrective actiQp
Hol air does nol come out
Molor does nol
Open or shorl circuil of feed harness
Check and repair wiring harness
Defective swilch
Conducl continuity tesl and replace switch
operate if necessary
Fan cannol be rotaled
Defective motor
Replace motor
Molor journal is out oflubricant or stick
Lubricatejoumal
smoothly by hand
Hot air does Dol come
Replace motor
Slow rolation offan
Replace molor
Loose fan installation
Repair
Defective water pump
Repair waler pump
Benl or clogged of connecting hose
Repair or clean piping
Defective hol waler cock
Repair
Air is left in hose
Purge air oul of hose
Defective thermoslal
Replace thermostat
Defective water hose
Replace waler hose
Loose clipping of waler hose
Retighten clip
Improper soldering of healer core
Solder leaking position
Disconnecled defroster hose
Correct connection
Benl or broken defroster hose
Correct or replace
Loose heater supporl
Tighlen completely
Loose fixing screw
Retighlen
JIll nevertheless fan is rotating
Air temperature is low
Hol waler does nol circulate
Water temperature is 100 low
Water leakage from
heater
Defective defrosler
Vibrating noise
BE 38
SECTION SE
SERVICE EQUIPMENT
DATSUN PICK UP MODEL 521 SERIES
BODY
CHASSIS
INI
NI
NISSAN MOTOR CO TOKYO
JAPAN
LTD
SPECIAL SERVICE TOOL
SE
18
SERVICE EQUIPMENT SPECIAL SERVICE TOOL
Tool number
M reference S
Figure
Tool name
mm
Description
in
Applied model
page
See Fig No
Clutch tool
For centering lhe c1ulch disc
ST20630000
521
Fig CIA 5
130 PA30
Clulch aligning bar
G
l
J
S30
j
ST20051000
Clutch assembly
@
base plale
For measuring the diaphragm
521
spring height
130
Use with the distance piece
C30
Sf20058001
S30
Fig CL6
510 41
C24 C80
ST20058001 q
For measuring the diaphragm
521
spring height
130
Clutch assembly
Use with the base pIale
C30
distance piece
S20051000
S30
Fig CL6
510
Q
BHO
ST2050000
For adjusting the diaphragm
521
Page
spring height
130
CL3
Diaphragm adjusI
C30
wrench
S30 510 BHO
SE 1
r CHASSfS M reference S
Applied
Figure
Tool number
Description Toolnarne
mm
in
model
page See Fig No
Transmission tool For supporting the inter lock
ST23620000
ball when inslalling Ihe fork
All
rod
Fork rod guide
ST23510000
page TM II
For removing Ibe fork rod
521
Page
relaining pins
CIO
TM 5
510
Fork rod pin punch
C30
n
I
ST22 I 30000
For removing the main shaft
521
bearing
780
For removing the drive shaft
521
bearing
C30
Fig TM 16
Bearing replacer
0 ST30030000
Bearing puller
II
S30
@ SE 2
Fig TM 21
2 E EQUIPMENL SERVI
jl 1 j
L j
Tool number tl r
Applied
Tl
r9 Lnarrie
ST23g00000
mm
I
Description
l
See Fig No
n
For inslalling the main shaft
521
bearing
130
q
1
ijL
adapter
If
Fig iM 29 1
Transmission
J
page
model
in
l
Ie
S M reference
1
Figure
1
0
r1
d
Uifferen tial
carrier tool
3tl
1
t l
Setting Iool of Ihe gear carrier
ST07320000
521
Fig PD IO
I
s 4L
130
J
Differential carrier stand
e
J
nj 1r
dl Cl lfl
jn in
lJtbs rlgf Hi tt li1
ST33010000
JUJJ I
t
For removing the differenlial
nIt
AIl
lbearing r
k r
Lm @
bearing puller
1
I
side Differential side
2
vn t
n
Fig PD n
1
i
r
1
I
L
t 1I
I
ST3fs30000
I
i
q 1HIU
J f
i1nwn
J 1
t
r
l
t
l1q ll
Drive pinion flange
V VV
For removing Ihe drive pinion
521
nul
130 1 11 111 i
3
A30
2U
t
ll
wrench
C30
1
7
S30
lo
CIO 510 i
I i
SE 3
Ir
Fig PD 12 l ll
CHASSIS
S M reference Tool number
Figure
Descriplion mm
Tool name
in
For removing the drive pinion
ST3003000ll
rear
bearing inner race
Applied model
page See Fig No
521
Fig PD 16
S30
PO I7
C30
Drive pinion rear
CIO
II
bearing inner race
replacer
510
@ ST33210000
For assembling the side
521
bearing
CIO V510
Differential side bearing drift
ST31IOOOO
Fig PD 16
V For heighl adjustmenl of the
521
drive pinion
130
Fig PO 18
V510
Drive pinion
arrangemenl gauge
For measuring the drive pinion
ST3 I 200000
preload Drive pinion preload gauge
SE 4
All
Fig PD 19
SERVICE EQUIPMENT
Tool number Tool name
S M reference
Figure
Description mm
in
For measuring the distance belween side bearing caps
521
Fig PD 22
130 V510
DifferenliaI side
Front axle and
page
model
See Fig No
ST321 10000
bearing cap gauge
Applied
n suspension tool
ST35380000
For removing the king pin
New
Page
bush
521
FA 7
King pin bush drift
r
For correcling the king pin
HT56802000
521
Page FA 7
bush
King pin bush reamer
ST36070000
Lower link bush drift
SE 5
For removing Ihe lower link
New
bush
521
Fig FA 24
f e
CHASSIS
Tool number
M referenc S
Figure
Tool name
mm
Description
in
Applied model
page See Fig No
Rear axle and suspension tool
ST38020000
For loosening and tighlening
521
Fig
6 RA
the rear axle bearing lock nul Rear axle bearing lock nul wrench
ST07630000
Fig RA4
For removing the rear axle sbafl
Rear axle stand
Use with sliding hammer ST36230000 C
r
II
ST3623WQO
Use as hammer by sliding the weighl
All
Fig
4 RA
Sliding hammer I f
ST37 I 40000
Rear axle shaft
bearing puller
SE 6
For removing the rear axle
521
shaft bearing
130
Fig
RA 7
SERVICr EtlJJPMENT
S M reference
Figure
Tool number
Descriplion
mm in
Tool name
Appjied IfV
10 1
I
page
model v
See Fig
1
i J
l
Il
I
I
No I
I
ST38220000
Jl ear axle
axle for inslalling the rear i
521
raft bearing and collar
130
Fig
RA 8
L Fig
T4
I
shaft
bearing collar insert l
f
1
I
1
to
I
I
tool Steering I t
ST27140000
521
For removing the sleering r gear arm
Steering gear arm
130 510
I
l
p
i i
BIIO
1 J
k
o
L f
I r
r I
J I
q
i r I
SERVICEJOURNALOR BULLETlN REEERENCE
I
1
I
JOURNAL DATE
r
or
BUltETIWNo
I
PAGE
No
1
SUBJECT
1 I
I
I
I
1 i
r
r
r
o
t
1 i
t
1
r J
i
i
I I
T
0
1
r I 4
7 SE
r V CHASSIS SERVICE JOURNAL OR BULLETIN REFERENCE JOURNAL DATE
or
BULLETIN No
SUBJECT
PAGE No
E R
INISSANl
Issuro Date
25th August 1970
U105501
Publication No
10E s
0521GO