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SERVICE MANUAL

NISSAN PATROL
MODEL

60 SERIES

INISSAN

NISSAN MOTOR CO
TOKYO

99999

20017

JAPAN

L TD

GROUP

SERVICE

INDEX

MANUAL
lritle

NISSAN

PATROL

GENERAL
MODEL 60 SERIES

INISSANI

EXPlAllATION OF DIFFERENCES BETWEEN


VARIOUS MODELS OF 60 SERIES

17

ENGINE

29

CLUTCH

35

TRANSMISSION

45

TRANSFER CASE

65

PROPELLER SHAFT AND


UNIVERSAL JOINTS

FRONT SUSPENSION

87
93

FRONT AXLE

101

REAR SUSPENSION

141

REAR AXLE MODEL GO ANDGGO 147


REAR AXLE

NISSAN

MOTOR

TOKYO

CO

L TD

MODEL GGOH

157

BRAKES

171

STEERING SYSTEM

189

WHEELS AND TIRES

201

ELECTRICAL SYSTEM

209

JAPAN

I
L

r
FOREWORD
The

information in this Service Manual

of construction

and

through

data

on

covers

operation

care

description
specifications

hrief

and overhanl of the NissM Patrol Model 60


This Manual

shoul be

kept

in

place handy

for

quick

reference

build
Properly
you will be able to better service Nissan Patrol
ing an enviable reputation for outstanding service in your locality
used

as

It is emphasised
replacements

that

only genuine

Nissan Spare Parts

shoul be used

memoranda space has been provided at the


end of each section
you may note any additional service in ormation
the
current
received during
period following publication of the Manual
A

Service News Reference


so

Certain
and

helpful

sercice information will be given

Service Journal

as

Service Bulettine

GENERAL
1

MAJOR

SPECI FI CATI ON

MODEL
Model

60

Year

1960

Jlind of vehi cle

4wheel

N8IIIe of vehicle

Nhsan Patrol

Maker

Nhean Motor go

Location

Yokoh8llla

drive

Ltd

Japan

CAR DIIlUSIOIS
Overall

length

approI

Overall width
Overall

height

Wheel base

3770

lOll

1693

lOll

approI

1980

apprOI

2200

lOll

Tread Front

1386

lOll

1404

rear

Road el earance

222

Rear Floor height at rear end


no load

726

Rear overhang lOll


Rear IlIle center to

730
rear

end of

boctY

CAR WEIGHT
Front

kg
kg

Rear

kg

of B chassis

Weight

Distribution

Weight

Pront
Rear

Height of
MBIimnm

826

kll

740

kg

640

center

angle

turn

470
470

de g
de g

Right
Left
MllIimnm pay load

496
1566

gravitational

over

814

kg

of vehicle

Distribution

1310

400

kg

kg

Seating capacity
2

with load

persons
without load
persons
Gross vehicle

with

weight

DistributionPront
Rear

108d

kg

2076
846

kll

1230

kg

PERFORIIAICE
117

speed kmhr
conwnmption km ltr

MBIimnm
loel

on

paved

9 0

rosd

ability sin 0
Minimum turning radius

06

Grade

Brake

stopping

distance

6 6

ui

14 0

at 50 km hr

r
RillE
Model

Cylinder number and arrangement


Cycle
Valve arrangement

Bore

86 7

stroke

6
1

lOll

Total

pieton displacement
Compression ratio
MaI
power rpa
i torque rpn
Ma
Length I width I

height

kg

without

3 956

cc

in line
head valve

114 3

3 8I41 2 ins

242

ins

cu

7 6
14hp

3800rpll

235ft Ibs 2000r p m


S A E rating

mm

without transmission

Weight

cylinder
cycle
type over

904

trlllUlmission

671

938

295
4
1 5
362

Firing order

181mOl SYSTEII
Igni tion

12V

timing

battery and
10deg B T D C

Ianition

coil

Ri tachi

ignition system

Distributor
Automatic

Ol
CIZ

Ri tachi
advance

Spark plugs
Spark plug

01
0017

Centrifugal

gap

coil

and

NGK B54E

or

06

I0Il

0 7

vacUtllll

B6E

14

tpe

lOll

FUEL SmEll
Carburetor

Ri tachi

Fuel tank

50 Itr

loel

capacity

42 4A
VC
13 U S

Glass bowl

strainer

Mechanical

loel pump
Air cleaner

gal
type
diapbrap type

Oil bath type

lUBRICATlDI SYSTEII
f

Pressure feed and

Lubrication method

splash

lubrication
Gear

Oil pump
Oil filter
Oil

type

Filter paper
by pass
1 8 U S gal
6 7 Itr

capacity

type

CODllIB SYST Ell


Cooling

Water cooling

method

forced circula

tion
Fin and

Radiator

Cooling

water

tube

17 5 Itr

capacity

pressurised

46 U S

Centrifugal type

Water pump
Thenllostat

Bellows type

BATTERY
25MC

Model

Voltage

12 V

Capacity

60 AB

lllinal
Te1

20 hr rate

posi1iive

grounded
2

type

gal

belt driven

GENERATOR
Model

Hi tachi G 115

Generating system

Shunt winding

Voltage
Capaei ty
Voltage current regulator

12V

11

200W
Hitachi

pile type

carbon

STARTER MOTOR
Model

Hitachi

Voltage and power

12 V

hp

CLUTCH
Dry single plate type

Type
Operating system
Facing Dimeneion

Me chani c al

275

I0Il

175

mm

TRANSMISSION
Three forward

Type

speeds and one


synchromesh on 2nd
water protect
gear
top

reverse

and

type

TIM

Gear ratio

AnI

2 900 1

High

1 562

3rd

1 000

Reverse

3 015

speed

1st
2nd

Oil

Range

Trans

Low
2 264

capacity Transmission
capacity Auxiliary transmission

0 52 U S

Itr

gal

3 4 Itr

0 90 U S

Type

Steel bar

and steel tube

Universal

Spicer type

Oil

gal

PROPELLER SHAFT
joint

REAR AIlE
Semi floating
41T IOT

Type
Gear ratio

4 10

Drive

Hypoid

Oil

1 2 Itr

system
capaei ty

bevel

gear
0 32 U S

STEERING SYST EM
Gear mechanism

Worm

Gear ratio

23 6 1

and roller

280

Stearing angle inside

25032

outside

FROIT AIlE
Type

Tracta

Toe in

Camber

1030
1030
7030

Caster
Knuckle

flange

inclination

joint type

4I0Il

gal

r
BRAKE SYSTEM
Type

Foot

internal expansion

Hydraulic

brake

2 hoes

type

Drum dia

11

Band brake

Mechanical

external

clamping

type
5

Drum dia

9 in

SPRING AID SHOCK ABSORBERS


Front

Parallel

spri ngs

semi

elliptic

leaf

springs
Dimension
Rear

and number of leaves

70

1100

60

6 Omm l

Parallel

springs

3
5I0Il

1100

semi

elliptic

leaf

eprings
1300

Dimeneions and number of leaves


Shock

70

5 I0Il

absorbers
double

Telescopic

Type

front

Torsion bar

Stabilizer

acting

rear

type

front and

rear

FRAME
Pressed steel bOI eection

Type

ladder

all

type

parte

welded

WHEElS
Steel di

Type

ec

TIRES
Type

Front

6 50 16 6P

Rear

6 50 16 6P
MBI

load

distance

long

driving
Air pressurl

P TO device

CAUTION

in

Front

22 Ibs sq

Rear

30 Ibs sq in

optional

Power to front

24 Ibs sq

in

36 Ibs

in

enter

sq

or

EXPLANATION
to the paragraph
lEiWEEN MOIEL 60 AND G60H

Refer

rear

OF DIPFEHENCES

IDENTIFICATION

chassis serial number is stamped on the right


end
and the engine serial number is

The manufacturers
frame eide member

stamped

on

at the front

the right side of the

Both of the above

engine

NUMBER

room

eide

of

cylinder

serial numbers

dash

panel

are

block

stamped

front lower
on

corner

plate

a name

at

under hood

Location of engine
number

Location of chassis serial number

serial

stamped

etamped

GENERAL

LUBRICATION

3 1 UNIT CAPACIT IES


6 7 Itr

Transmission

2 0 ltr

0 52 U S

Gal

Transfer

3 4

case

Front BIle
Rear ule

0 90 U S

Gal

12 ltr

0 31 U S

Gal

12 ltr

0 31 U S

Gal

Itr

of the proper lubricant and its correct application at


all mov
lar intervals does much to inrease the life and operation of
correct
that
the
Coneequently it is important
parts of the vehicle
be
used
as noted in the following descriptions
of oil or grease
The eelection

re

8 U S

Gal

Engine

ing
grade

r
3 2

ENGINE LUBRICATION

Proper selection of the oil


formance

reliability

to be used will add much to the per


long life of the engine

economy and

Oil PRESSURE GAUSE


When

starting

cold engine

it will be noted that the oil

gauge

the instrument

As the engine
panel registers a high oil pressure
warms
until
the
will
it
reaches
a
pressure
up
drop
point where changes
to higher speeds will raise the pressure very little
if at all
If the oil pressure registers abnormally high after the engine is
thoroughly warmed up an inspection should be made to aecertain if the
oil lines and passages are
plugged up
on

lUBRICATIOI
The

oil

should be

climatic

and

driving

eelected to

conditions

give

in the

the best

performance under the


territory in which the vehicle

is driven
When the crankcase is drained and refilled
selected

not

on

but

the change

the oil

the basis of the


on

the lowest

or

should be

at the time

existing temperature
highest temperature lIIlticipated

period during the oil is to be used


The grades best suited for use in an engine
peratures are ehown in the following table

of

for

the

Temperature

Grade

of oil

Under

lOoP

100F

120C

900F
320C

8AE

30

MS

MAIITAIIIIS Oil lEVEL


The oil

level gange is marked


MAX
and
should be maintained between these two lines
MAX

line

nor

under the

Check the oil

Always
D

Over

ME 2OW 20

MS

900F

tem

320C
120C

lOW

SAE

at the various

be

sure

level

KIN

MIN
neither

The oil

going

level

above

the

line

frequently

the crankcase ie full

and

add oil

before

when necessary

starting

on

long

drive

WHEI TO CHAISE EI611E Oil


Some

greatly improved driving conditions have


improvements in engines have greatly lengthened ths life

oils have been

changed and
However
to insure continuation
of best
of good lubricating oile
and long engine life it is necessary
low
maintenance
cost
performance
to change the engine oil whenever it becomes contaminated with harmful
Under normal driving conditions draining the
foreign materials

crankcase and

replacing

is recommended
the
oil

Under

with freeh oil


the adverse

every 3 000 Km 2 000 Miles


conditions described in

driving

following paragraphs
frequently

it may become
necessary to

more

change

the engine

Driving over dusty roads or through dust storms introduces ab


rasive material into the engine
Carburetor Air Cleanere decrease
the amount of dust that may enter the crankcase
The
of
frequency

changing depends
draining periods
Short

runs

upon severity of dust conditions


can be recommended
in cold weather

such as

and

city driving

definite

no

do not

thorough warming

permit

up of the engine and water may accumulate in the


crankcase from condensation of moisture
produced by the burning of
Water
in the crankcase
gasoline
may freeze and interfere with
It also promotes rusting and
proper oil circulation
may cause
clogging of oil sereens and paseages
Under normal driving condi
tione this water is removed in the form of
vapor by the crankcase
ventilator
But if water accumulates
due to short runs in cold
weather

it should be removed

frequently

as

may be

by

the

changing

the

engine

oil

as

required

It is

always advisable to drain the engine oil only after the


engine has become thoroughly warmed up or reached normal operating
The benefit of draining is
to large eItent
lost if
temperature
the crankcaee is drained when the engine ie cold as some of the
suspended foreign material will cling to the sides of the oil pan and
will not drain out readily with the cold
elower moving oil
E

CRANKCASE DILUTION
A

of all

of engine oil deterioration


is that of crankcase dilution

phase

probably

the most serious

By crankcase dilution we mean a thining of the oil due to cer


portions of the gasoline leaking past the pistons and rings and
mixing with the oil
tain

Leakage of gasoline
mostly occurs during the
thoroughly vaporized and

F AUTOIIATIC COIITROL DEVICES


The Nissan Model
which aid

greatly

in

Rapid warming

temperature

control

or

gasoline

warming up

vapors

into the oil

reservoir

period when the gasoline is not

burned

TO MINIMIZE CRANlCASE DILUTION

engine ie equipped with automatic devices


minimizing the danger of crankcase dilution
P

up of the engine is aided by the thermostatic water


which antomatically prevente circulation of the

r
water in the cooling

eystem

until it reaches

determinded
pre

tem

perature
the exhaust manifold which during
the warming np period
antomatically directs the hot exhaust gasee
the
center
of
the
intske manifold
greatly aids the proper
against
Thermostatic heat control

vaporization
The

of the

draft
down

minimizing the

danger

of

gasoline
aid to easy etarting
thereby
Sparing use of the choke reduces
gasoline entering the combustion

carburetor is
use

of the choke

or unvaporized
leaking into the oil

raw

chsmber and

on

an

pan

or

crankcase

efficient crankcaee ventilating eystem drives off gasoline


other vapors and aids in the evaporation of the raw gasoline and
water which may find its way into the oil pan or crankcase
An

and

Crankcase Ventilation

CONTROL BY OWNER UNDER NORMAL CONDITIONS

Ordinarily
or

eliminate

However

the above

there

abnormal

are

must aid in the control


Short

automatic control devices will minimize

the danger of crankcase dilution

runs

conditions of sercice when the

owner

of crankcase dilution

in cold weather

such

as

city driving

do not

permit

the thorough warming up of the engine nor the efficient operation of


automatic control devices
It is recommended that the oil be chang
ed

often when the

more

car

is

to this

of

type

operation

Poor
good mechanical condition
such as scored cylindere
engine
poor
ring fit
sloppy or looee pistons faulty valves poor ignition and
A good grade of gaso
incomplete combustion will increase dilution
The

car

mechanical

should be kept
of the

subject

line should be used

ignite
H

in

condition

and slow

Poor

to burn

gasoline

will increase

which

contain

portions

hard to

crankcase dilution

WATER IN CRANKCASE

Serious lubrication troubles may result in cold weather by an


This condition is
as a rule
accumulation of water in the oil pan
little understood
of water in the
the exhaust
collection

by

the

il pan
of the

pipe
of drops

car owner

To

hold

of cold metal

engine

of water

piece

demonstrate the chief

and note the

on

The

it

rapid

near

cause

the end of

condensation and

exhaust

with water vapor and the moment these gases strike


will condence
forming drops of water

gaees are charged


a cold surface

even
A slight amount of these gasee passes the pistons and ringe
under the most favorable conditione
and causes the formation of water

in a greater or less degree


until the engine becomes
pan
When the engine becomes thoroughly
warm
the crankcase and
oil pan will longer act as a condenser and all of these gases will
pass out through the crankcase ventilator system
in the oil
warm

Short

rune

vate this water

in cold weather

forming

euch

as

city driving

will aggra

condition

I CORROSION
gasolines contain a small amount of
Proctically all
day
preeent
but
eulphur which in the state in which it is found is harmless
of
certain
small
forms
a
this sulphur on burning
portion
gaees
which
is likely to leak past the pistons and rings and reacting
form very corrosive acids
with water
when present in the oil pan
the greater the danger from this
The more sulphur in the gaaoline

r
of corrosion

type

avoided

This is

condition which

but it may be reduced to

minimum

can

by

not

wholly
care

proper

be

of

the

engine
As long

the gases and the internal walls of the crankcase are


keep water vapor from condensing no harm will result

as

hot enough to
but when an engine is

run

moisture will collect

in low temperatures

and unite with the gases formed by combustion


formed and is likely to cause serious etching

thne

acid will

be

This

pitting
pitting or corrosion when using gasoline caontaining con
eiderable sulphur
manifests itself in eIceseively rapid wear on
camshaft
bearings and other moving parts of the engine
piston pins
owner to blame the car manufacturer or lub
oftentimes causing the
oil
when
in
ricating
reality the trouble may be traced back to the
or the condition of the engine
such as
character of gasoline used
eIceseive blowbys or improper carburetor adjustment
or

etching

WATER PUMP lUBBICATlOI

water pump grease to the


DIt remember that lubrication to this part should be
Otherwise
the drain hole
rather moderate than to other parts

Every
bearing

600 Km

400 miles

or

for the leaked cooling

requested keenly

water

supply

will be

That

clogged

to lubricate water pump

why

it is

periodicaly

off the excessive grease around the

Wipe

is

nipple

to avoid

slip

of the fan belt

I STARTIIG
Every

MOTOB AID GEIERAToR LUBBICITIOI


600 Km

generator by putting
oil

400 miles

or

few

drops

lubricate
of

ligPt

the starting motor and


in the
or engine oil

oil

cup

0 CLUTCH RELEASE BEIBIIS lUBBICATlol


The clutch release

bearing

and is lubricated at the time


no

further

is of the thrust ball

of manufacture

bearing type
requires

The bearing

lubrication

DISTRIBUTOR lUBBICAlIol
The

ignitiom

distributor is
lubricant

equipped

with

Fill
grease cup
soft
amooth grease

equivalent
cup with chassis
or 400 miles
and turn one or two turns down every 600 Km

thie

or

apply one or two


To lubricate the rotor and the cam surface
and also on
the rotor
machine
oil
the
felt
under
of
on
light
drops
the cam surface lubricate with cup grease which should not be over
saturated

10

FROIT AILE REAR AXlE AID TRANSMISSIOI lUBRICATION

3
A

lUSRICAITS FOR AllES AID TRAISIIISSIOI

BIles and transmission as delivered from the


lubricant
Yeararound
filled with SAE MPIlO as t
he
The

However

eItremely low temperatures are encountered


SAE MP80 grade may
time dnring winter months

when
of

long periods

are

factory

for
be

used
And

tremely

aleo

warm

conditions

eI
or when the weather is
the 8UD11Der monthe
the vehicle ie the subject to other severe working
such as SAE MP140
heavier grade of lubricant
may be

during

or
a

used in BIles and transmiesion


The following table shows the recommended

oil

grade

in different

temperature
Under

Teperature

lOOp
120C

SAE

Gear oil

10 l

9001

12 C

320C

SAE

80

MP

9001
320C

SAE

90

140
MP

MP

MP

Over

multi purpose

lUSRICAIf ADDlTIOIS
The lubricant level

checked

in the axle and transmission

case

should be

periodicaly
that any additions required to bring up the
be made using the same type lubricant as in the

It is recommended
lubricant

houeing

level

or

case

The level

just
C

temperature should
opening
plug

of the lubricant under normal

to the bottom

of the

filler

be

lUSRICAIT CHAISES

it is
seasonal changes of the lubricant are not required
with
the
refilled
recommended that the housing and case be drained and
While

recommended lubricant at least twice

year

or

every 10 000 KIll

or

6 000 miles
drain SIles and transmission
It may be neceesary and desirable to
re
service
more frequently than
in the vehicles in subject to severe
commended above

11

CAl1rION

Use

Do not

draining

3 4

water

stesm

flush out the honsinge when

kerosene

alcohol

gasoline

ETC

UNIVERSAL JDIIT LUBRICATION

The universal

joint of front
bearing type equipped with

needle

to

oil

light flushing

use

and

rear

shaft is of the

propeller

the lubrication fittings and should


be lubricated with chassis grease recommended in the table which is
shown at the end of thie information
The lubrication shoul be done

every 600 Km

or

FRONT WHEEL LUBRICATION

3 5

It is necessary to remove the wheels and drive


cate the ball bearings which ie used on front ade
The bearing assemblies
retainer

packed

should be cleaned

high melting point


following table

with

recommended in the

In mounting the front


perly adjust the bearings
skill

wheels
an

great

operation

bearing ball
bearing grease

mnst be taken to
mechanical

pr

requires

It ie

In

at least

requested to
bearings

remove

rear

BIle

shaft and hub to lubricate

wheel

mounting

the

treat the oil

bearing
The

required

REAR WHEEL LUBRICATION

rear

perly

Inbri

and the

care

that

to

which ie described in the Front AIle Section

3 G

with

flanges

front wheel

The lubrication to the front wheel bearing is


or 6 000 miles
twice a year
or every 10 000 Km

the

400 miles

BIle
The

great
lips

care

be taken to pro
seal should be coated

ehould

of oil

grease

bearing

10 000 Km

rear

seals

or

should be lubricated at least twice

6 000 miles

with

year

high melting point bearing

or

grease

recommended in the following table

3 7

SPRING SHACKLES
with lubrica

spring shackles on Hissan Patrol are equipped


fittings and should be lubricated with the chaesis
The

tion

recommended in following table

every 600 Km

eye of front and rear


not he lubricated or sprayed with oil
On the front

12

or

spring

grease
400 miles

rubber

bushings

mnst

3 8

STEERING GEAR LUBRICATION

The

gear ie filled at the factory with a all eeason


Seasonal change of this lubricant is unnecessary and
the
should not be drained
Whenever required
additions should

steering

lubricant

houeing

be maid using
will not

lubricant which

channel

satisfactory

or

hard

cause

lubrication under eItreme

It is recommended that the


on

RIles and transmission

according
3 9
The
oil

to the

conditione

grade of gear oil which is used


on steering gear

should be used

temperature

pedals

should be lubricated with

1 000 Km

or

few

drops

of

light

motor

600 milee

CHASSIS LUBRICAT JON

For the chassis


tion

e8me

summer

BRAKE AND CLUTCH PEDAl lUBRICATIOI

every

3 10

at low temperature
ie fluid lind
and which will provide
steering

That

lubrication

shows the

lubricant should be

points
supplied

consult the lubrication instruc

to be lubricated and how often the

The recommended lubricants

are

13

shown in the following tables

r
I
RECOMMENDED

Oil

ub
I

Nippon

Standard

Castrol

California

Gulf

Standard

Oil

Oil

Oil

cation

Elephant
Engine

Mobile Oil

Motor

oil

Oil

Mobile

lZrade

Spirax

Chassis

90

Grease

Bearing

Grease

Grease

No O

MP
Mobile

bear

Grease

Grease

No

RetinaI
A

or

Hypoy

Gearlube

Castro
lease
CI
Castro

Retjna
A

or

lease

90
Marfok
No O or I

Gulflex
A

Marl ok

Gulflex

No 0

RetiIlca

Castra
lease

Gllflex

No

Heavy

Under

10

900

Over

900

Under

12u

12

320

Over

320

SAE

lOW

SAE

oil

100

80

SAE

REMARKS

2OW 20

90

SAE
MP

MP

MS

Motor SerVice

MP

Multi

Purpose

14

30

SAE
MS

HS

MS

Gear oil

or

Marfak

Viscosity which is recommended for various temperature

Temperature

Engine

UBiversal

Gear
po
lube 90

No 2
Oil

Moltipar

Uniioint

Wheel
Grease

Castrol

90 E P

No 2
No O
Chas8 i 8 Mobile

Joint

HP

Snecial

Oil

Motor

Price HD

lIulti

Chassis Mobile
Grease
Grease

Universal

Castrolite

Mobilube
G

a p M

Gulf

100

MP90

Grease

She11x

or

Gear Oil

Wheel

She 11
Oil

Vacuum

Oil

Classifi

LUBRICANTS

SAE

140
MP

2 HD

ft

I NSTRUCTI ON

LUBRICATION

CHASSIS

Descrip t ion

Engine

il

Water

pump

Starter

Distr buter

LubricatioD

efiJI

Lubricant

6 7Itr

Generator feed 2 3

motor

Water pump

drops of

motor

i1

C
g

Clutch

elease

yoke shaft
drain

light

lubricate

pedal

Transmission

Propeller shaft lubricate joints

Knuckle

Tie roo

Front

efill

I
motor

ebassis

lubricate
Itr

0
0
0

iI

0
0

gruse

ur

0
0

chassis grease

bearing grease

aange bearing lubricate


lubricate
d

dill

od of

chassis

rod

xle differential
1

rain

sear

grease

Drag link lubricate joint

Spring

Steering gear box


Air cleaner

Radiator

Sattery

drain

0
0

iI

chassis

greue

shaclde

ch

21tr

check

level

gear

iI

efill

0
0
0
0

clean
check

CAUTION The

od top

cleaner

be drained and

distilled

up

sed
efi lied

nder

dusty

more

o
0
0
0

3 4 Itr
r

0
0
0

0
grease

lubricate shaft

od brake

motor

bearings lubricate slight

Clutch

00

Fluid

duin

ndition

ofter than

15

must

bovementioned

water

r
SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

OF

SERVICE

JOURNAL

AND

BULLETIN

16

EXPLANATION
DIFFERENCES

OF

BETWEEN

MODELS OF

60

VARIOUS

SERIES

EXPLANATION OF MODEL NUMBERS

This manual is described based upon the construction of model 60


However
there are many
which is the standard model of 60 series
and it ie essential to understand
variations in model 60 seriee
model
and the
that the
itself
the meaning of model numbere
differences between these varioue models
service to the vehicle
The

and to

table will

following

give

in order to give proper


the
give
proper order of spare parts
the
rough idia as to these quee
you

ti one

Description

Model No

Standard model
2 200

wheel base

60

I0Il

2 persons

carrying capacity

400

Kg

Four wheel drive

Long

wheel

baee

2 500

carrying capacity

000

Four wheel

Short wheel

base

Carrying capacity
Two wheel

500

2 200
2

on

750

Kg

400

Kg

I0Il

persons

drive

of the left hand drive


head
of the model number
the

If the vehicle is
must have

llIlll

2 persons

drive

Four wheel

N60

400 Kg

drive

Long wheel base 2


Carrying capacity

G60H

I0Il

2 persons

its model number


LH60
as 160

type
such

LOO0H and lli60


Auotber
V

and

the head of model numbers


D
indicate the type of body

letters
F

on

such 8 e
means

one
arrangement is different from the standard
the
van type
V
means
delivery
station wagon type
model
the
fire
F
means
engine
model
the hard top

17

the seat

means

the
meanS

MAJOR

DI FFERENCE BETWEEN

MODEL 60 000

2 1

AND G60H

DIFFERENCE BETWEEN 80 AND GGO

The

differences between model 60 and G60

already

are

you noticed

as

from the difference of the wheel base

come

The

long frame is ueed on model G60 and the wiring harness of


wiring the rear propeller shaft the body iteeU and the
relative mall parts are different from model 60
chassie

2 2

DIFFERENCE BETWm MODEL 80 AID G80H

Model G60

designed

is

chassis of model 000


are

as

heavy duty vehicle basing upon the

The differences betwen model

from the difference of wheel base

come

60 and G60H

and from the difference of

carrying capacity
In order to carry heavier load than model 60 doee
following
60
Ae to the different
for
model
are
specially
designed
systems
P
l
l ts of G60H that origined the
catalogues because these parts
with

on

of

exception

The different
gears and rslative
are

with model

called

the

The

rear

from model

same

as

model

parts
G60

Bl4O

axles

differential

Many of these parts

which is

3 4
1

tOnDer

conven

NISSAN JUllIOR

are

speedometer

aleo different from model 60

gear

eetting

cylindere

brake drums and wheel

Ac

is different

are

also different

60

The front and


G60H

refer to the

the

shaft

propeller

The wheels and tiree

cordingly

exactly

are

type of rear axle housing


parts are used on the G60H

interchangeable

tional truck

rear

wheel base

long

rear

springs

The relative front

and

specially designed

are

rear

suspension parts

for model
are

different

from model 60

parts numbers of
following comparison
The

the

these different parts


chassis
list of

major

are

illustrated in

parts

between 60 and

G60H
Please read
difference

carefully through

And remember each

described based upon model

60

this mannal

paragraphe
with

18

eome

thinking

of this manual

exception

of these
are

in in in in in in
0
5

O 0H

SPECIFATON

44

lb

lb lb

lb

3638 1929 1709 5 34 2061 3473

mm mm

Kg Kg Kg Kg Kg Kg

4070 1693 2015 250 1382 140 223 755

1650 875 775 2510 935 1575

in

Ibe Ibe Ibe Ibe Ibe lb

66 79 98

mm mm mm mm

m 54

55

mm

in in in in in
5

4 4

in

in

28

3516 1907 1609 4641 2028 2613

mm mm mm mm mm mm
mm mm

Kg Kg Kg Kg Kg Kg

4070 1693 1980 250 1382 140 213 720

1595 865 730 2105 920 1 85

in

Ibe Ibe Ibs Ibe Ibe Ibe

160

66 78 98 64 55

Kg

Ibe

29

160

000

in

in

lb

person

MPH

750

feet

75
or

one

KPH

per

120

20
m

625

Kg

person

400
or on

fe d

75

20

KPH

per
8

MPH

120

625

feet
6

47

145m

degre degre
47 47

fe tJ
9

45

140m

degre degre
47 47

JOR
MA

in in in in in

OF

5 0

60

LIST

148 66

in

in
3

78 86 54 55

8
8

28

3461 1819 1642 4586 1863 2723

mm mm mm mm mm mm mm
mm

Kg

37 0 1693 1980 2 0 1382 140 222 720

i570

COMPARISN

Kg Kg

Kg Kg Kg

825 745 2080 845

1235

end

rear
at

DIMENTlOS Overal Overal Overal

length width height bae front rear

CAR

Whe l Tread

height

Dweight istrbuon

front rear weight front rear

clearn flo r WEIGHT


Road Rear
Viehcl
CAR

vehicle

GrOBS
0
I

Distrbuon

Kg

person
7

400
or

perone

feet

75

18

KPH
120

625
0

m
6
5

fe tJ
9

46

d140m egre degre


47 47

right left
angle

CAPITY

Sin

CARGO

SEATING

MPH

PERFOMANC

abilty radius diatnce turn


epe d grade turni g stop ing KPH over
50

Muim Muim Minmu Brake Muimwn


at

SlIr

oal

0
8

rrh

a
w
z
w

yo

0
0
J
w

Cl
0

11
Ny

0il6

N6

sz

11
II
ill
Il

r 069

SO

20

ffi

4A
I

cl
g

21

rO
rll

SL

coS

a
1

5
Q
g

lfz6

Clo

fJ
Zr

22

COMPARISON

LIST OF MAJOR CHASSIS


BETWEEN MODEL 60
AND G60H

PARTS

PARTS NllMlIER

PARTS NAME
60

G60H

44000
32700

44300
32700

44000
32701

44000
32701

44000
32703

44300
32703

lilT
1

Set

Gear

pinion speedometer
speedometer 5 teeth
Pinion
drive
epeedometer
Gear

l4T

44000
37320

44300
37320

SetPropeller

shaft with

joint

rear

3730044000

44300
37300

4301044000

43010 44300

43068 32200

30100
43068

38212

1300

38212 95960

43081 32201

43081 30100

32201
43083

30100
43083

40227 32200
44000
38164

30100
43223
44300
38164

32000
43217
4321632200
44000
38175

30100
43217
4321630100
44300
38175

44000
43070
38440 25660
38441 25660

Ass y

Prop

Complete
seal

eeal

rear

Cage

bearing

Bolt

serration

Oil

seal

Rear

Spacer

50000
40211

Taper

aIle

rear

aIle

aIle

rear

bearing

R B

grease catcher
rear

aIle

rear

30100
43070

aIle

rear

shaft

Grease catcher
Shaft

rear

aIle

aIle ehaft

Packing

rear

Housing
oil

Spacer
Oil

shaft

aIle bearing
bearing rear
tapar roller bearing
rear

25660
38442

4021450000

Cup

44000
40207

43207

30100

Brake drum

44000
44010

4401044300

Brake disc

ass

R H

Brake

disc

ass

L H

Wheel

44000
44100
1
44001
44100

41124 30100
30101
41124
31400
44135
44126 31400

44300
44100

axle shaft

roller

Cone

44300
44023

axle

taper roller bearing

rear

cylinder

ass

rear

ase

rear

44301
44112

cylinder
for tropiC
Cup wheel cyl
Cup wheel cyl

30100
44135

Boot

1 1

axle

L H

40213 50000

44000
44023

rear

44301
44100

44300
44112

44126 30100

Wheel

Spring
boot

23

rear

tropic
cylinder
rear wheel
cyl

wheel

lock

rear
rear

for

PARTS NllMBEB
PARTS NAME
60

G60H

44000
38300

44000
38310
44000
38420
40000
38423
3

44300
38300

Ase y

30100
38310

Ass y Gear carrier

30100
38421

Case

3842330100

38424 85060

38424 30100

Gear

carrier

gear

differencial

Side

diff
bevel
gear
Thruet washar
diff
side gear

or

44460
38424
4

40000
38425

30100
38425

45460
38426

30100
38426

Pinion mate
Washer

diff

thrust

pinion

mate

or

85060
38426
44000
38427

38427

None

30100
30100
38430

None

30100
38431

None

0100

3842

44000
38101

44300
38101

44000
38102

3810230100

Shaft

pinion

Block

thrust

mate

Spacer thrust block


Pin
pinion mate ehaft
Gear drive
hypoid 41T

lock

44000
38103

30100
38103

44000
38112

44300
38112

drive gear
drive gear bolt
Pinion
drive
hypoid lOT

30100
38120

Bearing

4021550000

Bolt

Lock washer

drive

42100
38129

lone

pinion
pinion adjusting
Shim
drive pinion adjusting
Shim
drive pinion adjueting
Shim
drive pinion adjusting
Shim
bearing adjusting pinion
Shim
pinion bearing adjusting
Shim
pinion bearing adjusting
Shim
pinion bearing adjusting
Spacer drive pinion bearing
oil seal
Spacer
pinion
Oil seal
drive pinion
Flange companion
Washer
plain drive pinion not
Nut
drive pinion
differencial case
Side bearing
Nut
adjust diff caee
nim
adjueting diff side

42100
38130

None

Shim

42100
38131

None

Shim

42100
38132

None

30100
38153

45460
38127
60

3812
45460
38133
45460
38144

30100
38154
3815530100
30100
38156
45460
39127

45460
38154
45460
38155

45460
38128

45460
38155
None

45460
38133
45460
38134

44000
38163

30901
38163

44000
38191
38189
44000

30100
38191

44000
38210

38215
44000
44000
38216
42101
38440
None

3ll901
38189
38211

30901

3821530901
3821530901
40211

50000
30100
38316

Shim

drive

bearing

adjueting

diff

side

diff

eide

diff

side

bearing

adjusting
bearing
Shim
adjusting
bearing

24

PARTS NUMlIER
PARTS NAME
60

GlIOB

None
5

30100
38319

Finger

lock

diU

adju

44000
40513

None

Cover

44000
40515

1I0ne

Gasket

cover

30100
38320

Gasket

gear carrier

43027
4100

Drain

1I0ne
31112
9
41400
40535

38322

4321944000
44000
43220
44000
43221

43069

plug

Ventilator plug

Shim

rear

le

case

end

Shim

rear BJle

case

end

Shim

rear

aIle

case

end

Shim

rear

aIle

case

end

4308430100

Nut

rear

30100
43069

Washer

44000
54010

44300
54010

Front

44000
54011

44300
54011

54012 44000

44300
54012

44000
54013
II one

44300
54013
44300
54014

None

44300
54015

55045
7200
44000
54026

55045
0900
None

44300
55010

Rear

44000
55011

44300
55011

Leaf

44000
55012

44300
55012

44000
55013

44300
55013

44000
55014

44300
55014
44300
55015

None

44300
55016

None

44300
55017

None

44300
55018

None

44300
55287

None

44300
55297

44000
55054

44300
55054

44000
55055

44300
55055

44000
55247

44300
55247

None

44300
55246

BJ

aIle

lock

shaft
rear

2 pce

44000
55240
1

bearing

spring aesembly
rear spring 110 1
Leaf
rear spring 110 2
Leaf
rear spring lio 3
Leaf
rear spring No 4
Leaf
rear spring No 5
Leaf
rear spring No 6
Leaf
rear spring No 7
Leaf
rear spring lio 8
Plate
clip rear spring
Plate cclip
rear spring
Ass y
Ass y

Clip
Clip
Ase y

pc

25

R H
L H

seat

rear

spring

R B

seat

rear

spring

L B

rear
rear

spring
spring

R H
5524044000

bearing lock

axle

spring ass y
Leaf
front spring No 1
Leaf
front spring No 2
Leaf
front epring No 3
Leaf
front spring No 4
Leaf
front spring No 5
Rubber buehing
front spring
Spacer front spring center

44000
55010

55015 44000

carrier

30100
43219

30100
43222

32200

gear

30100
43220
43221 30100

43219 32200
4308432200

55100

t nut

carrier

gear

bumper

bound

inner side

PARTS NUMBER
PARTS NAME
660H

60
None

44300
55240

44000
56247

44300
56247

44000
56271

44300
56271

Aes y bumper bound R H


1 pc
Bo t connecting
rear stabilizer
Bracket
sDock ab
ade side R H

REMARKS
1

Parts number of the


G60H

is

propeller

44500
37320

Set

3730044500
Remember the prop
or GlI0H

Gear carrier
BIle

shaft for model

000

not for

followe

as

shaft

660 is not

rear

rear

same

as

model 60

of model 60 is welded

on

the

shaft of

assembly

shaft with joint

Propeller

Ass y prop

38300 44000

housing
Accordingly
provided for sale

and

rear

44000
38310

not

are

85060
38424

and

44460
38424

are

provided

for select

aseembly

45460
38426

and

44000
38426

are

provided

for

assembly

Gear carrier

cover

of model

OO0H is welded

select

on

the

rear

BIle

housing assembly
6

The correct

parts

the fact that the


of different model
For

name

that ie mentioned

name

211 50000

bearing
rrect

is

the

different from the

This difference

which is

designed

as

came

from

another

part

is ueed

is

of another type

name

However

sometimes

above

Bearing

side

bearing
originally designed as a

the differential

example

OO0H

part

are

case

of vehicle
front wheel

representative

name

of model
front wheel

Therefore

thats

co

outer

is used

in this

comparison

liet for the convienience

As to the difference of the tires


WHEEL AND TIllES

of this manual

26

refer to the section

SERVICE
DATE

NEWS

CONTENTS

27

REFERENCE
OF SERVICE
NO
JOURNAL AND
BULLETIN

SERVICE
DATE

NEWS

CONTENTS

28

REFERENCE
NO
OF SERVICE
JOURNAL AND
BULLETIN

ENGINE
1

I NSTRUC11 ON
The

engine used in Niesen Patrol Model 60 is a straight Bix


over head valve type
The model of the engine is
P

cylinder

The detail

operatione
Model

are

specification of this engine and service


in the service manual of
NiBBan Engine

which has been

However

top

of the

given

published independently

the necessary data of this engine

is

given

in

the

of this Manual

REMOVE
To

tioned

ENGI NE ASSEMBLY FROM CHASSI S

remove

the engine

from the chassis

follow the undermen

operations
2

Drain the radiator and cylinder block


Open the hood
ae wide aB
Place some rag between the hood and
pOBible
the windBhield
in order to prevent any damage on the

paint
2 2

Disconnect head lamp


and parking lamp at
the junction block

3
2

Dieconnect

the main

harnees which is fitt


ed

on

the left hand

hood ledge
nected

the

and

con

voltage

regulator and junction


block

29

4
2

Remove

the upper and lower radiator hose

2 5

Remove

the bolte and the nuts that

to the left and right fenders


radiator shell

and radiator

secure

Then

ae

cOlDlectione
the radiator

lift off the

assembly

an

t
t

i
I

t
l

z
I

jA

4
PO

r
I

L
r

L
r

OJ C7 O
1

Removing

2 6

Disconnect the

J
i

radiator shell

primary

and radiator

wire from the distributor and high

tension cord from the coil

2 7

DiscolDlect the gasoline line from the fuel pomp


connect the throttle and choke controls from

Dis

the carbure

tor

8
2

2 9

Disconnect the exhaust

pipe

from

the emanst manifold

the transmission cover from the board


the lever
off
the control lever of the transmission
Take
the high low control lever of the
of the side brake
c
transfer
ase
the front drive control lever of the

Remove

c
transfer
ase

and

cover

of these levers from the trans

mission and transfercaee


2 10

Disconnect the clutch


cross shaft

operating

30

linkage at the clutch

21

Hand Brake

Clutch Control

T F Case Lever

T F Case Lever

Change Speed

linkage

Cover

Linkage

Gear

T Mission
7

Remove

these parts from

Remove the bolte and nuts that


of the front and

joint

end of transfer
2 12

engine

with garage jack

supporting engine
2 11

Remove
Use

the

rear

secure

propeller

engine

Remove

2 14

Attach

hoist

raiee the

the universal
shaft at the

case

rear

suspension

the support underneath of the

2 13

Rear Engine Mount

the front

engine support

on

on

the both eide

engine
the both eide

chain

engine clear of
its mountings
then pull it for
ward
Again raise
the engine

ficiently

suf
to

clear

the frame front


cross

member

The

chassie may then


be rolled back to
clear the

engine

Raising engine

31

To

replace

the engine

in

the chassis the removal opera


tions are just revereed
Pnrther service operatione
engine should be refered

of the
the

Service Manual of the

Nisean Engine Model 1

Rolling chassis

back

32

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

OF

SERVICE

JOURNAL

AND

BULLETIN

33

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

OF

SERVICE
JOURNAL AND

BULLETIN

34

CLUTCH
CONSTRUCll ON

AND DATA

CONSTRUCTION
is of

The clutch of the Niesan Patrol

disc

aingle dry

type

and

It
illustrated in instruction drawing
parts
composed
bodies a machaniam which is known as centrifugal weight preesure
is

of

Thie mechanism

system

engine

of the
so

as

that clutch is

1 2

helps

increases
easier

increase

It makes
to

plate

as

the

pressure

speeds

possible

idling speeds

at

operate

pressure

spring

reduced

em

DATA
Single dry disc plate with
centrifugal governer weight

Type
essure
I
P

plate

Diameter

276

Thickness

15

10 875

I0Il

in

0 595 in

mm

Clutch disc
2

Facing number

Facing

Woven aebesto

material

Facing diameter
Facing thickness

275

Total thickness

10 6

10 827 in

I0Il

0 138 in

36I0Il

0 417 in

mm

free

thickness

Facing

353 5

area

eul

Preesure
Free

spring
length

61

81 Kg when the

Tension

Height

2 405 in

I0Il

of releaeB lever

length

is 39 7

in

0 008 in
Release bearing
Play of clntch pedal

Height of clutch

Oil

lees ball bearing

Ii
210
5

pedal

in

I0Il

from the toe board

8 22 in
Travel

Type

of

of clutch

180
4

pedal

pilot bearing

I0Il

t0
5
5
21
Measured up to flywheel surface
Difference between each levers
should not to exceed 0 2 I0Il
63

I0Il

Oili te

35

I0Il

bearing

2 ADJUSTMENT AND REPAI R

2 1

REMOVE THE CLUTCH ASSEMBLY

Remove
Remove

the trans
first

assembly

mission

the clutch housing


Remove

cover

clutch

wi thdrawal lever
and release
Remove

the

shaft

bearing

screws

that

aseembly
Clutch
flywheel
assembly and clutch disc
can be taken off through
the clutch

secure

to the

the bottom of the clutch


Care

houeing
taken

eo

screws

should be

that all

are

the

loosened

ly

instead of

one

after

even

removing

another

so

that the tension of


six pressure
be

gradually

relieved

the

springs may
and evenly
Otherwise

the

screws

may be

damaged by

the

springing

tension

2 2

ADJUSTIIEIIT OF CLUTCH PEDAL HIGHT AND PLAY


the higbt of the clutch
from the toe board 210 mm
To make this adjust
8 22 in

Keep

edal

Oil hol e

cover

ment

adjuet

the thicknese of the

shim fitted in the stopper of the

pedal
To
clutch

adjust

pedal

the

play

adjust

of the

the

of the intermediate rod


can be increased by

play

length
The
means

of

screwing out the adjust nut of the


intermediate rod
nut is screwed

If the

in

the

adjust

play

will

be decreased

Proper adjustment

ie

of 1

pedal play

before the clutch starts

36

It

in

to

engine

Wear of clutch

adjusted

to

in due

facing
time

will lessen the

clutch

elippage

pedal play

and if not

insufficient clutch

or

en

gagement will result


An excessive

2 3

will make clutch

play

disengagement

difficult

CLUTCH TROUBLES AID THEIR REMElDlES

A SLIPPAGE

OF CLUTCH

When clutch fails to

fully transmit the power of engine usually


A sliiht slippage is often unnoticed
but
slipping
if you find anyone or combination of the
following phenomena you
are warned against a
poor clutch
the clutch ie

Poor

pick up and speed


Larger fuel coneumption
Overheating of epgine
Truck epeed does not pick

i
Hi
iv

much

as

up

as

is

engine speed

accelerated
Poor performance

at the
In thoee

seme

in

climbing

check up to find

cases

hill

and

detestable

smell

time
out

if these conditions exist in

the clutch

No

Broken

or

iU

Uneven

wear or

iv

Worn

Worn

For

remedy

play

free movement of the

or

fatigued

clutch

pedal

springS

groove in clutch pressure plate


hardened
or greaey clutch facing
surface of the flywheel
or

of

follow the inetruction

ae

shown in the

caption

ID1USDtENr OF CWTCH PEDAL HEIGHT AND PLAY


If this
must be

step

lying

has

doee not give

adjustment
in either

to be taken

as

one

or

satisfactorr

combination of

instructed in the

ii

caption

result
to

the trouble

and proper
DISASSEMBLING AND
v

REPAIRING OF CIDTCH

POOR DISElGAGEMEIT OF CLUTCH

This will

when

happen

There is

Clutch release yoke end is excessively worn


Friction surface of the release bearing sleeve to the

iii

too much

lease yoke
iv

is

play

of clutch

pedal

worn

Clutch release lever is bent

37

or

damaged

re

Clutch disc

vi

Main drive
excessi ve

vii

assembly

gear
heat

Clutch disc

hub

shaft

is

out of

alignment
pilot bushing

is stuck to

is sticking to main drive

gear

due to

shaft

at the

spline
or

IEIGHT
cure

of

remedy

AND PLAya

the trouble

given
C

in

refer to item of

correct

adjustment

the trouble

tion of the items


are

for
ii

caption

to

vii

can

ADJUSDlENT OF CWTCH
If this

adjustment

be 10csted in either

Repair

one

PEDAL
does not

or

combina

instruction for these items

DISASSEMBLING AND REPAIRING OF CWTCH

TRUCI JEBIS WHEI mRTEO

If the truck jerks at the tUne men clutch is being


gradually en
the touble is usually caused by friction surfaces of the clutch

gaged

facing having
or

been hardened like mirror

oil

grease
release lever

or

having

been Geared with

Or else

it may be due to uneven height of the clutch


Refer to
lllLING
DlSASSD
AND REPAIRING OF CWTW
for

removal of the trouble

2 4
To

D1SASSEMBlIIG AID REPAIRIIG OF CLUTCH


remove

clutch

cover

from

the pressure plate


place the cover aseemhly
under

a press
and hold the
under pressure so that
the pressure eprings will
cover

not throw up the cover


Then remove tttree screws

and

relieve

gradually the pres


sure of the press
Now the
cover will come off

Prese the pressure

38

springs

Removement

A careful

of clutch

cover

inspection should be made on the component parte


remedy ehould be made on any defective one

of

the

clutch and necessary

BACK lASH BETWEEI MAil DRIVE GEAR AID CLUTCH DISC

If there is
gear shaft

more

and the

than 0 020

spline

inch backlash between the main drive


disc
replace them with new

of the clutch

parts
B

WoRI CLUTCH FACING AID lOOSE RIVETS

If the

facing

facing

is scarred

ie
or

worn

down flush to the brase

hardened

reline the

If the rivet holes are


enlarged and
it is also advisable to reline with

or

if the

facings

plate
facing is not securely
new facings
new

in

place

CLUTCH FACIIG SMEARED WITH lUBRICAIT

If the clutch
dicates

rivet

with

facing

is found smeared with

either the release

grease

or

oil

it in

bearing has been damaged or else trans


mission lubricant is leaking
Remove these troublee firet and then
take care of the facings
by cleaning the faces with gasoline or by
replacing with new facings if they are worn or hardened

39

r
I

WARPAGE OF CLUTCH DISC

Check the clutch diec for

war

page by means of a tester as il


lustrated in figure right hand
diec will

Wshbling

give

poor per

fL

formance
1

t
I

Check of clutch Disc warpage

Release Lever

Lock Not

Adjusting

Release Yoke Pin

Nut

Release Lever Yoke

Release Yoke Roller

Needle

Release Lever Pin

Bearing

Release Lever

If the
ference

wabbling

Check the
release

parte

wear

come

yoke pin
engagement

in poor
with new

pin

ones

the

pin

EIceesive

and needle
wear

are

of the clutch

be taken

so

and at

bearing

at these

points

Replace any of
the releaee
In making replacement
pressure plate by removing the cotter

Care ehould

missing they
F

the limit of 0 014 inch at the circum

at releaee lever

and roller

be removed from
lever

beyond

CHECK THE RELEASE lEVER mOLE BEARIIG

result

is

diec must be used

a n

the

will
worn

lever

can

and then the

that needle rollers will not be

nineteen in number

CHECK THE SURFACE OF FLYWHEEL AID PRESSURE PLATE

Check the friction surfacee of both


These surfacee must be flat and smooth

flywheel

and pressure
or

plate
uneven

groove
Auy
or if nece
must be treated with fine emery for mirror finish
of
treatments
never
In
either
case
must be worked on a leath
ssary
1
16
inch
remove the etock more than
deep

wear

40

ecar

If
is

more

stock has

to be shaved off

is

it

advisable

a new

part

replaced

By the way when the preuure plate eurface is shaved supplement


the reduced thickness with a washer of corresponding thickness insert
ed between release lever yoke and clutch cover
CHECK THE CLUTCH SPRIIG

The

bearing

clutch
the

on

spring tension has a direct


efficiency of the power

transmission

and a very careful check up


First
is necessary
check each one of
the nine eprings for absence of any crack
and

see

another

one

tester

spring

the

Next

put each epring

illustrated in

as

to

on

Such
a

inch

or

as

The

more

crack

or

than 1 8

pressure difference of more than


from other springs should be re

pounds
placed with

to

of

10

ject

will have

spring
length difference

free

7
i

fignre

height
in
If the reading of pressure gange is
less than 180 190 pounds
the spring is
and
a
new
fatigued
spring should be ueed

a new

one

and compress
of 39 7 I0Il
1 9 16

f
I
Ii
r

tr
r
0

i
t

f
r
Jit

ja

fl

@v

If i i t
yf

ir

that they have proper free length


of which difference most be within 1 8 inch

itl

flj J

@n

ri

1l

it
J

J
or

Bf
I

t
k
M

f
3
14 F
tqt

ffi i

If
l

i1i
sr2J

i
d

insulator washers

spring

wear

as

pressure of the
spring teneion

I CHECK THE

are

eub

Spring

they are constantly under


Worn or damaged washers
spring
Such waehers should be replaced

Tester

will effect the


with

new

ones

CLUTCH PILOT BUSHIIG

If the main drive


o 005 inch
A

new

gear ehaft is loose in the bushing more than


will
it
have bad effect on the clutch and transmission

bushing

should be ueed

0 CHECK THE HEIGHT

OF THE RELEASE lEVER

When the clutch ie


the

heignt

re

installed to the

of the release levers

41

flywheel

be

eure

to check

J
t

i
r

t
f
f
s t

Measurement of Release Lever

If all

the foregoing

and if the thickness

The
than 0 2

2t

in

bight

by

difference from

0 008

mm

repairs
plate is

are

properly

0 47 inch

made

the

height

gauge as illustrated in figure


above the face of the flywheel

of the release lever measured


should be

and

adjustment

of the clutch diec

Screw Height

Adjusting

other lever

should not to exceed

more

in

CHECI CLUTCH RELEASE BEARING AID SLEEVE

First

thoroughly

clean and

give

few

drops

of oil

to the

Auy noise
deshaped races or balls of
Use of such a bearing will produce noises in truck
the bearing
and
will result in premature wear of the head of clutch
operation
A new bearing should be inetslled
release lever adjueting ecrew
Also
the release bearing eleeve
for satisfactory truck operation
Wear on
ie apt to wear on the side it contacts the release yoke
so a new
thie part will result in poor disengagement of the clutch
should
be
inetalled
if
worn exceseively
part
bearing
or drag

To

and then check it for free


is

result of

corroded

or

assemble the clutch unit to the

plate assembly
sure

worn

and silent rotation

is

strictly

in

alignment

that the centers of both units

are

42

flywheel

be

sure

with the flywheel


on the e8me line

the pressure
making it

To

piloting
one

alignment

obtain the

If

device

from

it is

however

usually

euch

done

by

the

use

of

device is not at hand

make

main drive ge Bl shaft


cutting off the gear of the shaft
shaft to the clutch disc hub and insert the end of

Install thie
the shaft to the
Thus

pilot bushing in the center of the flywheel


flywheel and the clutch preeeure plate on the
proceed to fasten the latter unit to the flywheel
the

placing

center line

same

CHECK AGAII AFTER ASSEMBLlNS


i

First

with the

engine running

depress

the clutch

pedal

it goes
Try to shift the tran8D1ission gear
shift lever into various geare
The shifting will be made easily and quietly if the clutch

ii

as

far

is

properly

ae

8Beembled

Pull the emergency brake


and with the truck standing
speed up the engine
Depress the clutch pedal and throw
the ehift lever into
Then

gradually

the low gear poeition


the clutch
and eee if the engine

engage

stalls
If the clutch ie

satisfactorily repsired

noise of the gears


engine will stall in the latter

clashing

1f

case

f 1

it
1

fMh

t1CC

i
i

t i

there is

in the former teet

6
Setting Adjusting Nut

43

no

and the

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

44

OF

SERVICE

JOURNAL AND
BULLETIN

4 20 8506 8506 X4 C 4 0 0
67512 151 5 3042 305 1 305 30540 3053 332 20 31842 1 248 278
46C

440

32014

88

39

92

1248 27830
1

9 2

TIs

32

60

MODEL

ASEMBLY

580

l
C

12 86

CLUTCH

1 34 16 15418

4 Q 4 0 580

DRAWING

INSTRUCO

4 0 151 7

1 314

530 55

1 145 1452

40 40

1 01

r4

3052 305 2

99 2

32 03 32 01

32 04

44 53

4 0CXJ

524 0 91628

522 523 1541 1 34


3
4
3 21

63

438

24 23

9 9 9 33

40

21732

Q25

01
1
205

1313
S
S4

WTCI

8506 151

302 3

COVER

ASS

3675

174

151 4

55

30 01

ENGI
TO

TRANSMISSION
1

DESCRI PTI ON

AND

DATA

DESCRIPT ION

ibe transmission is of the 3

speed type with synchronized s coLl


The transmission and transfer caee as a unit
gears
is aesembled to the clutch housing
ibe gearshift lever is in in
corporated in the gearshift cover
and

high speed

1 2 DATA
Type
Gear ratio

1st
2nd

1 562

3rd

1 000

Rev

4 015

2nd and

on

meshed
Synchro
3rd gear
2 900

Gear tooth number


Main drive gear
Main shaft 2nd gear

21

Main

shaft 1st gear


Counter drive gear
Counter 2nd gear

27

Counter 1st gear

18

Counter

13

Reverse

15

29
26

revers

gear
idler gear

15

Outer diameter of Reverse idler

18 979

shaft
Back lash of varioue
Pilot

bearing

Diameter

Buehing

of main

length

gears
shaft
x

number

of main shaft 2nd

o 075

0 125

Needle roller
30

28

31 975
1 2589

outer diamet

38 040

1 4976

Thiskness of thrust washer for

3 860

main shaft 2nd gear available

0 1520
3 910
0 1539
3 960
0 1559

play

gear

of main shaft 2nd

I0Il

0 7480 in

24

I0Il

0 03

bearing

I0Il

gear

inner diameter

End

19 000

0 7472

32 000

I0Il

1 2598 in
38 050

I0Il

1 4980 in
3 900 I0Il
0 1535
3 950

0 1555
4 000

0 003

45

in

I0Il

0 1575 in

speed
o 067

in

I0Il

0 133

I0Il

0 016 in

0 05 in

Synchronizer spring
Free

12 7

length

mm

2 in

Outer diameter

6 7

mm

02638 in

Wire diameter

0 8

I0Il

0 031

Tension

1 8

in

2 3 kg when 8

mm

0 315 in

in length

Locating

ball

of

eynchronizer

Outer diameter

Bearings
x

7144

outer dia

0 2813

in

width
Main drive

gear bearing
Main drive shaft rear bearing
Counter shaft front
Counter abaft
Oil

I0Il

Inner dia

rear

bearing
bearing

80

4O

18

80

35

21

52

25

15

62

25

17

2 Itr

apaei ty

type
type

NU205
6305ZR

0 52 U S Gal

F
t

J0
1

illJ

Oc

IR

7
i

kf

Z
o

t
v

Y
o

ir

Constructive diagr8111 of Transmission

46

Gear train of transmission

Main drive gear

2nd and

MaIn

Main

Main drive

Reverse

idler

Counter

rever

Counter low gear


Counter 2nd gear

9
10

top eyochronizer

haft 2nd gear


haft low gear

Counter

haft
gear
e

gear

haft drive

47

gear

TRANSMI SSI ON
2

DI SASSEMBLY

1 REMOVE TRANSMISSION FROM TRANSFER CASE

Removing

rear cover

of transfer

case

Drain the oil from the transmission and transfer


Remove
the rear cover from the transfer case

Remove

castellated nut and flat washer that

the

the drive

gear on
the transmiesion mainshaft and remove the drive gear from the
use
suitable puller if necessary
transmission mainshaft
Remove
er

tht four

screws

and

one

to transmission

2 2

REMOVE GEARSHIFT COVER


the six

to the transmission

2 3

nut that

Slide transfer

case

Remove

secure

case

secure

case

the transf

ont rearward

p screws that secure the gearshift


Lift the cover from transmission

cover

REMOVE MAli DRIVE GEAR RETAIER

Remove
retainer

and lock washer from the bearing


Slide the bearing retainer and oil seal off the
the seven nuts

main d rive gear

48

UT

Removing bearing
2 4

REMOVE COUNTER SHAFT REAR BEARING

Bend the

lip

of the lock

the counter gear

enough

2 5

assembly

pul1y
bearing

so

out the

can

plate

with

and

unscrew

the nut

Drive

rearward 1 8 inch from front

be hooked

on

the

bearing

enap

just
Pull
ring

REMOVE MAINSHAFT REAR BEARIJIG

Drive out main shaft rearward

ing

retainer

puller
mainshaft partly

Remove
toward

the

rear

rear

just enough
bearing and

to hook the bear


slide out the

and then take out from the

case

Driving

out main

49

shaft rearward

top

of

2 G

REMOVE DRIVE GEAR

Remove

the

drive

gear

and drive the

snap ring
drive gear in with mullet
until free
from

out from

then

pullout
bearing

Drive

case

inside

Removing the

2 7
Tap

the countershaft from


from

race

2 9

and

remove

countershaft

top

the countershaft front

reverse

bearing by driving

in

the

with suitable driver

REMOVE REVERSE IDLER GEAR AND SHAFT

Bend the lock

take

front

REMOVE COUITERSHAFT FROIlT BEARING

Remove
outer

ring

REMOVE THE COUNTER SHAn

and washer

2 8

snap

idler shaft

out the idler

plate

and

Remove

the cap screw which locks the


idler
shaft with drift
and
the

remove

gear and thrust washer

50

aEANI NG

3 1

CLEANING

Wash all
trace of

old

parte thorougPly
to

prevent

3 2

INSPECTION AND REPAIR

TRANSMISSION CASE ASSEMBLY

Inspect

the

any kind

in cleaning solvent until all


Oil the bearings im

lubricant hae been removed

mediately after cleaning


polish surfaces

of

AND REPAI R

I NSPECTI ON

case

Cracked

and
or

gearshift

corrosion of the

cover

for

cracks

higPly

or

damaged

damaged units must be replaced

MAIN DRIVE GEAR

conditions are
Replace the main drive gear if the following
wear
Broken teeth or excessive
pitted or twisted
apparent
to
Small
surfaces
due
discolored bearing
overheating
shaft
with
fine
stone
a
nicks can be honed and the polish

MAINSHAFT

A mainshaft

bearing
D

surfaces

excessively

worn

due to overheating

or

with

pitted

must be

or

discolored

replaced

FIRST AND REVERSE GEAR

and reverse gear with excessively worn teeth or


be replaced
splines or with broken or chipped teeth must
backlash
between
If the
Slide the gears onto the mainshaft
0
005
inch
either
the
0 125 I0Il
gear end the shaft exceeds
with
A
or both muet be replaced
gear
gear or the shaft
small nicks can be honed and then polished with a fine stone
A first

SECOND 6EAR

or chipped
A eecond gear with exceesively worn broken
Measure
must
be
replaced
teeth
or scored bearing surface
I0Il
more
than
38
175
the
If
the inside diameter of
gear
be
re
shaft
must
or
or
main
the gear
1 503 inches
bushing
less
than
2nd
diameter
of
bushing
If the outer
gear
placed
must
it
in
or
wae
worned
38 00 I0Il
1 495
exceseively
from
If the pin which prevente the bushing
be replaced
and
together
loosen
bushing
pin
was
replace

turning

51

Small nicks

can

be honed and then

with

polished

fine

stone

SECORD GEAR BUSHIRG REPLACEMEIIT

gear buehing is press fitted on the mainshaft


first remove snap ring and thrust washer
take out the pin which prevents the
Slide eecond gear out
To
Drive out the bushing with drift
bushing from turning
ihe second

To

bushing

remove

install

new

bushing

uee

arbor prees with suitable

driver

COUIlTER GEAR

Replace excessively worn


chipped teeth or with pitted
to overheating

and geare with broken or


gears
or discolored bearing surface due

or roller

Bearings with loose or discolored balls


pitted or cracked races most be replaced

H REVERSE

or

with

IDLE GEAR

or with a
A gear with excessively worn or broken teeth
Small
nicks
can be
scored bearing surface most be replaced
Measure
the
inside
fine stone
honed and then
with

polished

If

diameter of the idle par bushing


0 7480 inch
the bushing most be

than 19 00

more

I0Il

replaced

I IDLE GEAR BUSHIRG REPLACEMEIl


Place the idler
driver

to press
from lY U4O

a new

gear

press the
mm

bushing
buabing in

in

an arbor press
out of the gear

gear
to 19073

Use

with
a

I0Il

U 7509

suitable

suitable

drive

buehing

Ream the

the idle

0 7496 inch

and

inch

IDLE GEAR SHAn

Ridged
On idle gear
be replaced

scored

or

excessively

worn

shaft measuring under 18 879

shafts most be
I0Il

7432

replaced

inch

most

ISYlCHRORIZER
Blocking ring
discarded
be

with

Hubs and

Week
replaced
replaced

worn

spline

broken
with

deflected

or

or

nicked teeth

exceseively
cracked

most be

52

worn

must be

splines most
spring

check ball

MAIl DRIVE GEAR ROLLERS

Needle bearing roll ere with flat spots


pitted or dis
colored surfaces must be
Measure
the diameter of
replaced
each roller
If leBB than 2 99 mm
0 117 inch
the roller
must be

ly

SHIFT LEVER

Replace the gear shift lever if the pivot ball is excessive


Replace the pivot ball pin it is loose or excessively
Replace the shift lever spring if it is cracked

worn

worn

replaced

ASSEMBLY
CAUTION

Dip or coat with transmission lubricant


shafts and thrust washere before
aseembly

all

gears

bearings

4 0 INSTALL IDLE GEAR


Hold the idle gear in place in the case with the cone end of
toward the front
with thruet washers at each sides
and

the hub

push the idle gear

shaft into the

hole and insert the set


screw

head

and bend up the


of the cap

screw

edge

Alins the set

caee

with lock

of the lock

screw

Bending up the lock plate of set

53

ecrew

plate
Tighten the
plate against the hpx

screw

4 2

liST ALL COUIfTER GEAR

Lay
toward

4 3
A

the countershaft

gear in the

case

with the

the tront

INSTALL MAIISHAFT ASSEMBLY


SUBASSEMBLY SECOID GEAB

GCONO 6EAA BUSHINg

Replacing

second

gear

bushing

SECOND

Replacing

second gear

54

00

large

gear

SNAP

Replacing

RING

thrust wash3r

Drive in the second gear bushing on the mainshaft with


driver
Insert the lock
pin in the bushing hole

suitable

Slide the second

speed gear onto the mainshaft with tapered end


of the gear toward the front
Slide in the thrust washer
Three of thickness of washers are available for
adjusting the
end

gear

the main
o 067
gear

mm

play
shaft

0 0026 inch

bushing

to 0

locking rinj

into the groove

on

gear must have an end play of from


133 mm
0 005 inch
The eecond

itself must have

gear onto
ward the front
reverse

Insert snap
The second

the shaft

no end play
Slide the first and
with the shifter fork chsonel to

SUBASSEMBLY SYNCHRONIZER

Special gnides

are

available to facilitate
the

reassembling

of the

three balls and

springs
eynchronizers
gnide ie slipped over
synchronizer hub the

into the
The
the

3 holes in gnide and the


3 holes of the hub must
coincide
ball

are

position

spring and
placed in
depreee the
A

then

balls and insert


lock

plates

the

in the three

grooves

Sliding gnide

55

onto

the hub

Replacing

the

epring

and ball

DePRESS

Depressing
The

gmide

is then

1 3

followed

the

plate

of gmid

pushed further along the synchronizer


As the coupl
by the conpling sleeve

splines
ing sleeve replaces the guide the balls find their correct
It ehould be noted
location in the coupling sleeve groove
that the synchronizer bob has a much greater depth of flange
on

one

side

wards the

and

rear

on

reassembly

of the

to mainshaft this

case

56

ehould be to

Push the guide downward

Replace

the eleeve

In addition the intarnal


to allow thebaulking
to

ring

on

the

eplines moet
through

pass

lide

be

correctly

located

the machined grooves

between the teeth


Place the

baulking rings in both sides of the hub the


pointed ends of the baulking ring lugs must face inwards to the
synchronizers

57

LONG

@
Slide the

HU

OF

Muet

eyochronizer

of the hob toward

END

corespond

to

onto the mainehsft with the long end

the front

IISTAllIIAllSHAn ASSEMBLY II CASE

Carefully
opening of the
and lock with

caee

Place

special plate
bearing

driver

off the front

deive gear

case

drummy bearing

drive in the

into the dummy


Take

through the top


in upper bearing hole
Insert the front end of mainshsft

ill8ert the mainshsft in the

rear

dummy bearing

bearing with suitable


end drive in

asey

Installing

mainshsft

58

assembly

the main

Holding mainshaft assembly

Driving

main drive

59

gear in

Installing

main drive gear

IISTAll COUlTER SHAFT

Raise countershaft

gear
with hand thru power
take off hole
Insert front

assembly
washer

end drive in roller

bearing
bearing

Place the
on

rear

ball

the countershaft

and drive in with suitable


driver
screw

nut

and

Install washer
n

the unt

securely

Tighten

and bend the

of the lock washer

over

the

ears

the unt

Inserting

60

front washer

Driving

Ben4ing

roller bearing in

the ears of the lock washer

61

ASSEMBLE FROIT BEARIIG RETAilER

Coat main drive


gear wi th oil where
oil eeal contacts
Assemble the main
drive

gear bearing
retainer and gasket
to the

and

case

tighten the
securely

nuts

Fitting

F lIST ALL GEAR


Install

the

front

bearing

retainer

SHIn COVER
cover

assembly

and gaeket to the tranwssion


case
er

meking

Bure

that the shift

forks enter the shifter fork

grooves in the gears

Transmission assembly
62

SERVICE

NEWS

REFERENCE

DATE

CONTENTS

63

OF

SERVICE
JOURNAL AND
BUllETIN

NO

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

OF

SERVICE

JOURNAL

AND

BULLETIN

64

4WOV 27IJ OJIB42


J
IM

J20

9
2

F
1

IfI

60

MODE

AS EMB

ON
SS

TRANSM

TRANSFER
1

DESCRI PTI ON
1

DATA

DESCRIPTION

The transfer
The

AND

CASE

transfer

case

case

is located at the

eesentially

ie

provides two gear ratios and a means


the transmission to the two BIlee

rear

speed
of

of the transmission

transmission

distributing

which

the power from

Main

gear
Counter shaft

Counter shaft

Front drive ehaft

Front

Hi gh 11 low

Front drive

sleeve

Front drive

ehift rod

Front

gear

bearing
ehift rod

bearing of

10

Hi gh

11

Low

12

Rear drive

rear

drive

speed gear
speed gear

Gear

shaft

train of transfer

65

caee

shaft

12

Main gear
Counter shaft

43

Counter shaft
Front drive

gear

shaft

Front bearing

67

High

Front drive

sleeve

Front

shift rod

Front

low

drive

shift rod

10

bearing of
High speed gear

11

Low

12

rear

drive shaft

speed gear
Rear drive shaft
Gear train of transfer

66

case

2
1

DATA

Gear ratio

high

000

low

264

Combined gear ratio with tranemission


T mission ratio
T fer case position
let

2 900

2nd

3rd

562

1 000

4 015

Rev

Combined gear ratio

low

6 564

high

900

low

3 535

high

1 562

low

264

high

1 000

low

9 089

high

4 015

Gear teeth number


Main ehaft gear
Counter gear front

21

Counter gear rear


hi gh epeed gear

30

low

31

speed

Thickness
for

46
21

gear

of thruet waeher
rear

drive

3 88

shaft

0 1528
for counter

3 43

gear

outer dia

92

mm

0 1543 in
3 47

0 1350

Bearings

mm

0 1366

in

Inner dia

Width

Rear drive shaft bearing front

90x40x23

Rear drive shaft bearing

90x40x23

type SJ2225
type 6308
type 630BNR

80x35x21

type 6307NR

25xl8x22

type

Pilot

Front

bearing

for main drive shaft

rear

drive shaft bearing

35x22x25

I0Il

Pilot bearing for front drive


ehaft
Oil

3 4 Itr

capaeity
Back lash

on

varioue

o 102

gears

18V2522

0 90 U S
0 152

I0Il

0 0040006 in
Front

drive shaft

pilot

order

end dia

17 989
0 7082

meter

31 734

Counter shaft outer diameter

1 2494

67

18 000

I0Il

0 7087 in
31 000
1

I0Il

2205 in

Gal

REMOVAL FROM VEHICLE


2 1

REMOVE PROPELLER SHAFT

Disconnect

he front

and

propeller

rear

shaft at the transfer

case

REMOVE HAND BRAKE ROD SHIFTER ROD AND SPEEDOMETER CABLE

Remove
brake

on

the clevis

the trnafer

shifter rods

2 3

secures

Remove

Disconnect

the

the hand brake rod

the clevis

pins

speedometer

cable

that

the

that

at the

eecure

REMOVE REAR COVER

Remove
transfer

that

pin

case

the six cap

screws

secure

rear cover

case

Drain gear

oil

Removing hand brake linkage

Removing
68

rear cover

to the

the

REMOVE MAINSHAFT GEAR

2 4

Through the opening

at the rear of the transfer case


remove the
the mainehaft gear to the transmission mainshaft
the flat washer and mainshaft gear

nut that
Remove

securee

Removing main ehaft

REMOVE TRANSFER CASE FROM TRANSMISSION

2 5

Place

that

screws

transfer

jack

under the transfer

secure

case

the transfer

etraight

of the transfer

gear

case

case

caee

Remove

the five cap


Move the

to the transmission

back until the transmission mainshaft is out


Remove

the tranefer

case

DI SASSEMBLY

REMOVE BRAKE BAND AND DRUM

3 1

Remove the five anchor


Remove

the brake band

secures

screws

from

Remove

joint flange

69

brackets

the castellated nut that

assembly
joint flange to the output shaft
is tight use puller to remove flange

the univerdal
if it

the brake band anchor

Pullout the

Removing

brake band

Removing brake drum

3 2

REMOVE TOP ctVERS


Remove

and

remove

the twelve cap

the two

screws

covers

70

that

secure

the

two

top

covers

3 3

REMOVE FRONT JOINT FLANGE AND BEARING RETAINER

Remove
Remove
to

remove

flunge

with mullet

secure

if

joint flange
tight use puller

the front

it is very

flange

five cap screws that


the bearing retainer

Remove
Remove

the castell ted nut that

the joint

the

secure

the front

Removing front joint flange

71

bearing retainer

i
0

st
I

1r

qf

LJ

IJ

r
0

II

g
J
J

j
I

o
Remove

drive flange

REMOVE FROIT DRIVE SHm BEARIIG RETAIlER


Remove

Remove

front

the five cap

retainer out from

screws

that

secure

retainer to

cover

cover

Removing bearing retainer

3 5

REMOVE CHECK BALLS AND SPRINGS

Remove
two

springe

the two spring plugs from the front


and the two check balls

72

cover

Remove the

Removing

3 6

check ball

spring

REMOVE THE SHIFTER ROD EYELET

Undo the two check nuts


from

and

and remove the two shifter rod

eyelet

the rods

7 REMOVE THE FRONT COVER

the eix cap screws and slide the front


Leave the one shifter rods in place
Remove

Removing front

73

cover

cover

out

carefully

38

REMOVE FROIT DRIVE SHIFT ROD WITH FORI

Remove
sleeve

the front drive

Remove

the front

shift rod with fork and the front drive


drive needle roller

bearing

Removing front drive shift rod

39

REMOVE HIGH AND LOW SHIFT ROD

Remove
and low
and

case

the set

speed

screw

that

shifter rod

Remove

fork from

secures

the shifter fork to the

high

Slide the shifter rod out of the fork


case

Removing high

and low shift rod

74

3 10

REMOVE COUNTER SHAFT AND GEAR

Remove
that

the cap screw


the lock plat

securee

Remove

the lock

plate

Drive the counter shaft


with suitable
move

drift

the counter

thruet washers

bearings

from

the transfer

out

Re

two
gear
and roller

the

top

of

caee

Removing counter

gear

11 REMOVE DRIVE SHAFT

Remove drive shaft rear bearing with a suitable


puller or prees
drive ehaft out toward front with an arbor
Remove the low
prese

speed gear from the top of the transfer case


out from csse with suitable driver
if drive
arbor press

Drive the
shaft

Removing drive shaft

75

was

rear

pressed

bearing
out by

3 12

DISASSEMBLE DRIVE SHAFT


snap ring from the drive shaft that secures the front
Remove the spacer washer and the ball bearing with suitable
Remove the thrust washer and the high speed gear from the

Remove

bearing
puller

drive shaft

4 CLEANI NG I NSPECTI ON

AND REPAIR

4 1 CLEANING
Clean the
Cleaning all parts thoroughly in cleaning solvent
while
immersed
in
solvent
until
bearings by rotating then
cleaning
all trace of lubricant has been removed
Oil the bearings im
mediately to prevent corrosion of the highly polished eerface

4 2
A

kind
tion

INSPECTION
TRAIlSFER CASE ASSEMBLY

Inspect the transfer case houeing


Inspect the top and rear cover
Replace all gaskets for covere

Transfer

76

for cracks
for bent

or

or

and retainers

case

damage of any

damaged

condi

FROIT DRIVE SHAfT BEARIIS COVER ASSEMBLY


i

Front

Replace
Shift rod oil

ii

shaft

the front
seal

cover

bearing cover
replaced

if it is cracked

or

damaged

drive shift rod and fork

front wheel
if it has

or worn

iii

bearing

must be

Front wheel

Replace the
Replace the fork
cracked

drive

or

drive shift rod

stripped

set

if bent

screw

threads

d81118ged

or

if it is

has bent forks

Front drive

shaft

and sleeve

Replace the front drive ehaft if the splinee or gear teeth are
Check the dia
chipped or orn if the gear has any teeth missing
meter of the pilot end of the drive shaft
If the diameter ie less
than 17 000 I0Il
0 6693 in
replace the drive shaft
Replace the
drive sleeve

if it is

worn

PILOT

or

Ball
cracked

Shaft

front drive

haft

bearing

bearings

races

any broken teeth

END

Removing
iv

has

with loose

must be

or

discolored balls

or

with

pitted

or

replaced

Speedometer

Replace

the

speedometer

drive gear

teeth

77

if it is

worn

or

has

damaged

are

COUlTER GEAR ASSEMBLY

Replace
d8lllAged

the counter gear if excessively worn


or if any teeth
If the
Check thickness of the thrust washers

thrust washers

are

less than 3 33

If the surface of thrust washer

0 1311

I0Il

inch

exceseively

was

replace them
replsce them

worn

If the diameter is
Check the diameter of the counter gear shaft
less than 31 73 mm
0 1249 inch
replace the counter gear shaft
if the rollers are scored or have flat
the roller bearing

Replace
sports

REAR DRIVE SHAFT BEARIIG BElAIIER ASSEMBlY

Replace the drive ehaft bearing retainer if cracked or damaged


Replace the brake
Replace the oil seal in the bearing retainer
drnm if it is cracked or 9Iceseively worn
Replace the universal
are
worn
if
the
splines
joint flange

E DRIVE SHAFT ASSEIIBLY


Replace
can

the drive shaft if the

be removed

Replace

and then

by honing

the front drive sleeve

splines
polishing

are

gear if it is

Small nicks

worn

with

worn

fine
or

stone

has any

if it is worn
gear
Replace
thrust washer
of
the
teeth
Measure
the
thickness
damaged
0 142 inch
the thrust washer thickness is less than 36 mm
the slow

teeth

speed sliding

Or if the surface of thrust washer is

it
it

Replace

the roller bearings if they

worn

are

excessively

scored

or

damaged

or

has
If

replace
replace

have flat

spots

HIGH AID lOW SPEED DRIVE SHIFTER FORI ASSEMBLY

Check the fork for

stripped

set

screw threads

or

bent

the shifter

DRIVE SHAFT BEARIIG RETAilER OIL SEAl REPUCEIIEIT

Drive the old oil

using a
seal out of the bearing retainer
seals out
working from the inside

suitable driver

Drive the oil

of the retainer

To

size

cracked

Replace

fork
Replace if in any of these conditions
rod if it is bent

of the oil

install

oil

new

seal and drive the

new

78

eeal

use

driver the

seal in the bearing retainer

ASSEMBLY
5 1 ASSEMBLE REAR DRIVE SHAFT
Push the

rear

eide toward

Insert the drive


transfer

on

the

speed

in the transfer case

sliding gear
channel

bearing

Set the low

drive shaft

rear

shaft

in

the

and through the gear


Insert dnmmt bearing at the front
case

side to center the drive shaft


Drive

in the

drive shaft

rear

bearing

assembly

retainer gaskat on case


Place rear bearing drive
on

shaft

spacer
toward bearing
oil

seal in the

and

Paste

rear

shaft

chamber side
Install
rear

the

bearing

Install

bearing cap on the


Tighten the five
cap screws evenly to prevent
cracking the drive shaft bearing
cap

transfer

caee

Press in bearing

Coat oil seal with grease


cap
Ineert the universal joint flange

Inetall the

on

rear

joint flange

universal

the drive

shaft

and tighten

securely

with nut

Insert

co

pin

Remove

the

tter

dummy bearing
front eide

of drive

Slide the

shaft
hi gh

from the

speed

the drive

gear onto
amall
ehaft

gear toward rear


Insert the thrust
washer

gooved
gear
front

Driving

rear

drive shaft in

face the
side toward

bearing with a
In
suitable driver
stall the

spacer on the drive shaft


the drive shaft

Insert

the snap ring in

79

the

Drive in the

bearing

the groove of

INSTALL COUNTER GEAR

5 2

Insert the

bearings

place

gear

roller

in the counter
the spacer
roller

between the two

Place the

bearings

rear

thrust washer in the


transfer

case

with the

side

having the oil goove


facing toward the count
er gear
Apply grease
to

the

thrust washer

hold it in

to
if

position

in shaft

drive
necessary
for enough to hold the
washer
counter gear washer

Replacing
Place

ring
the

rear

shaft

on

counter

transfer

into

Insert

the counter

gJide
gear

0
PI ace

gear

in the

large

case

gear toward the front


Insert the front thrust
washer

and drive the


Drive the

shaft in
shaft

out

to the

side far enough

place
shaft

ring

front
to

on

the

Drive the

shaft back is and in


stall
that

the lock
secures

plate

the

coun

gear ehaft to th
tranef er case
ter

into

FitUng

80

ring

the counter

gear

Locking counter ehaft

5 3

INSTALL SHIFTER RODS

Place the low drive

shifter

fork in the transfer

case

Ineert

the high and low shifter shaft in the tranefer case and shifter fork
Inetall the shifter fork eet screw that secures the fork to the shifter
shaft

Secure the

set

screw

with lock wire

Locking

with wire

81

Fittjng

front

drive

sleeve and

rod

Driving bearing in
Slide the front drive
stall

the set

Place

the front wheel

drive sleeve
er case

needle

screw

gear

place
roller

shifter fork

in the shift
drive

the front drive

bearings

the shifter shaft

secure

shifter fork in

Insert the

in

on

fork and

drive

with

position

on

In

lock wire
the front

shift rod into the bole in the transf


sleeve
ehaft

on

the drive

shaft

Insert

Replacing poppet

5 4

ball

and

spring

INSTALL FRONT COVER

Place

new

gasket in position on the transfer case


Install
case cJver
Tighten the six cap screws evenly

the front fransfer

prevent cracking tbe

bearing assembly
poppet ball

5 5

with

cover
a

suitable

poppet spring

and

new

gasket

on

drive

the front

in

the

fr

driver

nt

drive

Install
in

poppet plug

INSTALL FRONT BEARING RETAINER

Slide the speedometer


Place

Drive

the

to

sgaft and

the shifter rod


two

holes

ASSEMBLY

gear
cover

the

on

front drive

and install

the

shaft

retainer with

five cap screws


Coat the oil seal
lip with chassis grease NCSl
Install the front universal joint flange on the fron
drive shaft
install nut
Tighten the nut securely and insert cotter

and

pin

5 6

INSTALL TOP COVERS TO TRANSFER CASE

Install

new

gasket in position

the

covers

on

the transfer

case

the

covers

to

the transfer

case

on

the

Install

83

transfer
the cap

case

serews

Place
that

secure

57

IISTAll HAlO BRAIE BAlD ASSEMBLY TO CASE

Place the brake band


screwB

cap
Brake

that

assembly

band must be adjusted

to

the

INSTALLATlON

the

on

brake drum

Install the

the brake band

secure

anchor to the transfer case


installation to vehicle
Refer

after

BRAKE ADJUS7MENT

paragraph

1 RAISE TRANSFER CASE

Raise the

transfer

transmission
transfer

Place

case

forward

the transfer

secures

62

line up the transfer case with the


on the transmission
Slide

and

case
new

gasket

install the four cap


to transmission

screws

and

one

nut

that

case

INSTALL MAINSHAFT GEAR

Insert the epacer and mainshaft gear


small gear toward rear
Inetall the lock washer and nut that secure the
mainahaft gear on the transmiseion mainshaft
Tighten the nut
the main shaft

on

and

securely
and

the

bend the

rear

cover

Install the cap

6 3

lip

witb

of

that

screws

Install the clevis

the

secure

that

pin

epeedometer

cable to the

drive ehaft

cover

64

on

Place

a new

the transfer
to

cover

the

gasket

case

cass

the hand brake rod to the

eecuree

arms

transfer

to

shifter

case

rods

at the

top

Install the
of

the

front

INSTALL PROPELLER SHAFT

Connect the front


Fill the

transfer

and

rear

propeller

with specified
the hand brake band

Temperature

Oil

bearing

CDINECT HAND BRUE SHIFT ROD AND SPEEDOMETER CABLE

brake band md shifter lever

Adjust

the lock washer

roller

SAE

I
I

case

oil

Under

100

100

Under

12u

120

MP 80

shaft
to

900
320

MP 90

84

to the transfer

case

the proper level

Over 900
Over
MP

320
140

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

85

OF

SERVICE

JOURNAL AND
BULLETIN

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

OF

SERVICE

JOURNAL

AND

BULLETIN

86

t1F

9S

26

0
4

p05l1
tON
u

HtGt QW

CASE LC

LC
l1G
9001

GH

LC

tlGH

1
5

562

GE

1M

LO O

0
4

nd

lei

60

MO E

AS ENlB

L
E

3EGTION

CASE

TRANSFER
B

5EGTI

PROPELLER

SHAFT

UNIVERSAL
1

AND

DESCRIPTION

AND

JOINTS

DATA

1 DESCRIPTION

The power from the transfer case is carried


through two propell
shafts
One shaft runs from the front of the transfer case to the
front aIle
and a second propeller shaft runs from the rear of the
er

transfer

case

to

the

aIle

rear

joints

All four nniversal

The

front

and

the

bearings

snap

rear

Each is

joints

with two

equipped

of

are

the needle

universal

bearing type

yoke of each universal joint is machined to receive


bearings are preseed into the yokes and locked by

The

rings
Each journal

tion

trunnion

is drilled and fed by a central lubrica


the side opposite the

fitting
On
lubricating the bearings
lubrication fitting a relief valve is mounted
for

This valve is
at from 40 80 Ibs
pop
preseure
thereby preventing
over lubrication or damage to the
journal bearing seals

adjusted

to

A lubrication
the

splines

opening
center

to

is mounted

plug is staked into

the sleeve yoke to lubricate

on

the

forward end of

duet

The

to

packing

conta ned

in a retainer cap which screws on the

cover

splined slip joint

at one

end

of

each

variations in distance between the transfer


to

spring actions

2
1
Length

Type

splined

retain the lubricant

this

sealed by cork

due

the

A amsll hole is drilled in the


relieve
plug
trapped air
The rear end of the
is
sealed
dust
cover
end
of dust cover is
the
opening
by

of

splined
end of

fitting

Solid yoke type

shafte allowe for

case

and

the

of universal

aIle units

jointe

are

used

DATA
Out

dia

Inn

Dia

length ehowes
and joint

between joint

Front

566

45

38

mm

Rear

457

45

38

mm

of Joint

Cross

Outer diameter of journal

spider type

17 272
0 6800

17 285

mm

0 6805

in

Needle roller
Outer diameter

3 165
0 1246

Dynamic

balance of

with Joint

propeller
assembly

Tightening torque

of

fix

3 175

mm

0 1250 in

shaft
Not exceed 36 grcm
7
51 ft lbs
m 43
kg
6

bolt

87

REMOVAL
REAR PROPELlER ffiAFT

FRONT
the univp rsal
shaft

peller

Remove

the four nuts

that

secure

joints flange yoke to the flange at both ends of pro


Remove the propeller shaft which ever worked on

o
o
o
O

3 DISASSEMBLY
3 1

FRONT AND REAR PROPELLER SHAFT

A REMOVE

SlAP RIIGS FROM YOIE

Remove the snap rings the


propeller shaft in a vise
with a pair of pliers
in
the
bearings
flange
journal
yoke
If the snap ring does not snap out of the groove
tap the end of the
This will relieve the pressure against the snap
bearing lightly
ring
Place the

secure

the

REMOVE SPIDER FROM THE YOIE

Drive

lightly

bearing is pushed
thp visp

on

out

the end of the


of the

journal

yokp flange

bearing until thp oppositp


Turn thp

and drivp thp first spider bp aring back

88

out

mbly

assp

of

its

over

lug by

in

driving
flat

the exposed end of the spider


Use a brass drift with
1 3
inch smaller in diameter than the hole in the

on

about

face

yoke

otherwise there is danger of damaging the spider bearing


Repeat the
operation for the other two bearings
then lift out the journal
slid
ing to one side and tilting over the top of the yoke

REMOVE SLEEVE YOlE FROM SHAFT

Slide
cap and

3 2

or

placed

parts thoroughly with cleaning solvent


Inspect the
for cracks broken welds
scored journal bearing
sur
bent shafts
Parts with any of these faults must be re
Inspect the sleeve yoke for worn splines worn
bearing

bearings

and

lubricant

plugged

meter of the machined surface of the


less than 17 172
grease

0 676

mm

in

Check dia

fittings

journal

If the diameter is

the journal

replace

Replace

all

seals regardless of their condition

ASSEMBLY
4 1

SHAFT AND SLEEVE YOKE

Place

the

the cap and

yoke

on

is in the
er

the dust

all

surfacee and

ve

Remove

ehafts

faces

shaft

CLFANING INSPECOTlON AND REPAIR

Clean
drive

the sleeve yoke off the drive

seal

shaft in

the dust

the shaft
same

shaft

arigle

Coat oil

cap

splines
as

the

Screw the dust

NOTE

2
4

propeller

slide

seal

on

being

yoke
cap

bench vise

sure

at the

on

Place

the sleeve yoke


that the

opposite

the dust

cover

a new

seal in

Slide the slee

yoke

on

the shaft

end of the

propell

securely

with lubricant

REAR PROPELLER SHAFT

Insert the journal into the yoke


Spider in Yoke Flange
the journal bearing approximately 1 4 inch into the yoke
rift approximately 1 32 inch smaller than
using a brass
he
hole in the yoke
Tap the other bearing into the opposite end of the
yoke flange until the bearing is in line with the snap ring grooves
With a pair of pliers
install the snap rings on both ends of the yoke
Insert the flange assembly in the sleeve yoke
flange
Tap the
Place the other
bearing approximately 1 4 inch into the yoke
bearing into the opposite end of the yoke
and tap this bearing into
the yoke until the bearing is in line with the
snap ring groove
Install the snap rings on both ends of the yoke
Install

flange
flange

Tap

89

NOTE

Coat the ineide of the bearings with chassis


install to

journal

INSTALLATION
Be

sure

to

place

ard the transfer

flange
the

grease before

propeller

shaft with

shaft with the

propeller

splined

the four nute that

Install

case

at both ends of

propeller

the

shaft

specified

and

tight eecurely

lubricant

90

secure

end to
the

joint

Lubricate

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

91

OF

SERVICE
JOURNAL AND
BULLETI

SERVICE
DATE

NEWS

CONTENTS

92

REFERENCE
OF SERVICE
NO
JOURNAL AND
BULLETIN

DIFERNTAL

397
r
60

REMAKS

FOR

FRONT REAR REAR REAR

ASEMBLY

56 m 457m

OF

LINE

CENT R
BOTH
397

86161 861 0 86161 301 0 85460

PLANE

MUST SAME

BEARINGS

THE
ON

5
442

7219 72 0 3721 71 1 37
I

507
5mm

5mm
52

87
6

4 0 4 0 4 30 4 50

BE

321 212

h
6

SHAFT

PROEL

MODEL

SIDE

TO

65

MODEL

G60H G60

60

NO

PARTS 37 0 37 0 37 0
1

37

FRONT
1

SUSPENSION

CONSTRUCTION AND
1

DATA

DESCRIPTION

Ths front suspension of Hissen Patrol consists


of front springs
front shock absorbers
stabilizer
rebound stoppers
rubber
bumpers
and torque arrsster
8Dd is shown in the

drawing

1 2 DATA
SFIlING

FROIlT

Parallel

Type

with

Thickness x Width
I
Span Number

semi elliptic leaf spring


grooved section

for Hodel 60 6 000


6 6
6 6

x
x

70
60

3
100
100 1

for

Model GOOH
x
70 x 1 1006
Model 60 Ik 660
6 6

Spring constant

Model
Camber when
loaded

Model 60 Ik 660
Mode 1

rear

AlIS 0llIIEIIS

FRONT

spring

on

spring eyes
act

double

Torsion bar type


torsion bar
20

ing

outer diameter of
IIIDl

SPRINGS

The front
low

63

GOOD

Telescopic

STABlLIZEIl

kill
kill

47
Steel bushiDa used 08 front
hackles
Silentblock type rubb r bushing used

JUlhiog

I0CK
S

2 90
3 86

OOOD

rate

springs
type

on

the Hissen

Patro
l

are

of

low c8lllber

end

The

advantage of this type spring is that the


rsbound or throw is IllUch less giving a smooth rids
The second leaf
is wrappsd around the main eye for
A special stesl bushing
safety
with bolt type is used at the shackles of front
spring
The

rear

mounted in
ternal

end of the front

bond

rubber

steel

tube and
is molded end

bushing
quire no lubrication

springs on the Hi ssan Patrol


The bushing consist of
bushings

tubular outer retainer

securely
and

no

bonded

to which

These rubber

attention othsr than to

93

are
an

in

rubber

bushings re
keep the bolt

drawn up snugly
Before installation coat the bushing securing with
to protect it from freezing by corrosion
a very thin coat of grease
To

bushing
special

removs

and

replace

in the eye
a
arbor
or
press

press with

drift is

necessary

Special

Front

spring

94

front shackls

press

Front

The
of the

great

spring

cares

eyss

spring parts

should be paid for

tightening the
HBMely the springs

and shackles

nuts up
IllUSt be

loaded when
they are tightened up
initial deflection to the rubber

to prevent to give unnecessary


bushings of the springs

It is

recommended that the weight of the vehicle is on the


in order to give correct load to the springs
To be sure
whsther or not the corrsct load has been keeping
check the buffer
clearance
betwesn the rubber bumper and the axle
If that clear
vehicle

encs

is 46
The

tightening torque

the

springs

loaded with correct

are

of the

spring

eye nut is 6 2

spring

shackles

weight

6 9

Kgm

50 ft
lbs

45

The nuts
the

181 in

following

W
3

on

the front

should be ti ghtened up

method

nut up as tight as po sible


Back off the nut a quarter turn
If the slot in the nut end the cotter
pin hole line up
insert the
cotter pin
If not
back the nut off until
the slot and the hole are in line
and then insert the

Tighten

95

by

cotter

The
Ubolt

pin

tightsning torque
should bs 6 9

FRONT

of the nut that

8 3

SHOCK

m
kg

the

spring clip

ABSORBERS

The front shock absorbers

adjustable type

secure

60 ftlbsh

50

on

and the double

the Hissan Patrol


That

acting type

are

is

of the

why

no

none

fur

ther maintenance will bs needed

or

Replace the shock absorber if


dumping force is dscreased

the

of fluid is found

leakage

the

The

s8llle

shock absorbers

used

are

on

the

rear

suspension

of

this modsl

FRONT
Tbe

typs

STABILIZER

stabilizer used in the Hissan Patrol

with rubber

bushing

on

the

eny

rsplace
Replace

ths rubbsr

bushing

bar

mounting

Check the torsion bar for the


it

is of the torsion

crack

if it is

or

eny other fanlt

If

worn

Check every nuts that secure the stabilizer end connecting rods
to the axle end frame at least every 10 000 Km 6 000 miles

96

080

CONNECTING

100

ROD

Front stabilizer

FRONT REBOUND
The front rsbound

ween

rail
is

front

axle and

of the fr8llle

designsd

so

as

I
0

II

parts

STOPPER

stopper

of the Hissan Patrol

the bracket which is welded


This
with rubber bushings

to be strong

enough

bounding

Yl

to receive

on

are

mounted bet

the inner

rebound

big

side

stopper

tension in

bolt
re

Rebound

Rebound

stopper

stopper

R B

98

and

L B

torque

arrester

In order to avoid
as

well

length

any damage on the shock absorbers and springe


of the rebound stopper should be adjusted care

If the bottom end of the screwed parts of the stopper is


0 47 in
far from the bottom surface of the nut
the re

fuly
12

the

mm

bound stroke will be


is 85

mm

3 34 in

kept in
Adjust

Correct stroke

correct measurement
the

length

of the screwed

if necessary to maintain the rebound stroke


must not be less than 5mm 0 2 in
rod

Every
and rubber

10 000 Km

bushings

6 000 miles

Replace

The Hissen Patrc l is

right hand side rail


The front

get
ing

comfortable

the

running
propeller

the

rebound

bumper

if necessary

equipped

with

torque arrester

on

its

of the frame

spring of the Nissan Patrol


riding during the driving

is

so

soft in order to

that the

rear

axle hous

end up when the vehicle is braked during


ths universal joint of
If this movement is kept free

be turned its

rear

shaft will have

rotation of the
and the damage

of ths

ARRESTER

TORQUE

can

check the nuts

these rubbers

part

However it

propeller
of the

so

shaft

propeller

big engle
and

that disturbs ths

8IIIOOth

he uncomfrotable riding
well

causs

shaft

as

ent
Ths torque arrsster Of the Hissan Patrol prevents this muv
lllal
nOl
and kesp the housing of the rear axle in its
position
pre
viding the good riding sven when the car is going to be brsked or

running
Chsck the rubber
every 5 000 Km

lllation
defol

of ths

3 000 miles

99

torque

arrester

at lsaat

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

100

OF

SERVICE

JOURNAL AND
BULLETIN

r
o

1
I

J
1
o
o
z
o

iii
z
1
Q
II

II

tj
I

FRCNT

II
1

I
Z

o
a
b

CJ
Z

c
a

I
1

j
o
RANC

a
l

II
Z

of

r
T

62

E 9

44JI
J
f
f
m
55m

1rIA

50tt
c4S

FE

OUT SI
lE
RFAR
FRONT DE

Elf

n
J
Indl

ARFFI

IlUBI3EB

NOT TO

OA T

FRONT AXLE
1

DESCRI Pll ON

AND DATA

1 1 DESCRIPTION
The front axle
assembly is a front wheel driving unit with spe
cially designed spindle housings
and has a conventional type dif
ferential with hypoid drive
The differential parts are in
gears
interchangeable with those of the rear axle
The axle shafts are of
the full floating typs
The differential is mounted in the hous
ing similar to the rear axle except that the drive pinion shaft is
toward the rear instead of the front and to the
right of the center
of the axle
Tracta type universal joints have been used

2
1

DATA

Type

Full

Tracta

floating

joint

type
Front wheel

alignment

Tread

1382

Camber

1030

Swivel

54 4

mm

in

7030

pin angle

Toe in

Caster
Driving method

1030
Bypoid

Gear ratio

4 I

0 12

IIID
4

0 16 in

bevel gear

Number of teeth

Bing gear

41

Drive

10

gear

Differential

gear

type

straight

Humber of teeth

Side

bevel

Pinion mate
Standard
drive

position
pinion

Distance
gear

Preload

of

from

to

gear

16

gear

10

install

center of

drive

to

pinion head
drive pinion

70 36

mm

II

14 kgcm

7706

seal and ring

Tightening torque
Drive pinion nut

25

30 kg
180

Drive

gear fix bolts for diff

Differential
Side

bearing

case

case

bolt

cm

217 ft lbs
9 0 kg

65 ft lbs

55

9 0 kg m
65 ft lbs

10

II
72

101

gear

55
7 5

cap bolt

in

without oil

m
kg
80 ft lbs

Upper end
flenge

lower cap for nuckle


19

m
21kg
15 ft
lbs

14
Back lash

Ring

gear and drive

o 13

pinion

0 18

0 005
Diff

side gear

end

pinion

mate

0 006

mm

0 007

in

0 008 in

Bearings
Out

Inner wheel bearing

Inn

dia

dia

75 mm Type
20
11
85 45
roller JIS 30209
Outer wheel

bearing

1116 7
275

width

taper

73

41
025

Type

taper roller Timken

mm

18590 18520

52x20d6 25

Swivel lawer bsaring

Type taper
Standard Oil and

mm

roller

JIS 30304

cspaci ty
SAE MP90 I 2 Itr

Diffsrential housing

Gal

Front

8Ile

102

assembly

0 31 U S

Front

axle knuckle

flange

end

shaft parts

OQOO

e
I

00

1
Front

axle differential gear

103

parts

REMOVAL

2 1 PRELIMINARY WORK
Remove
gear oil

at the differential housing and drain the


Raise the vehicle until the weight is off the front
the drain

plug

springs
2 2

DISCONNECT SHOClABSORBERS DRAG LINKS STABILIZERS BRAKE


AID REBOUND STOPPEl

Rebound stopper
Remove
absorbers

th

nuts

Remove

washer

the

drag

end
link

grommet that secure both front shock


plug at the steering arm and remove

Remove four cap screws that secure the stabilizer bar


Disconnect the center brake hose
and remove the stabilizer bar
rubber bush
Remove washer
Remove nut that secure steering damper
the

drag

ing

and

2 3

link

steering damper

DISCONNECT FRONT PROPELLER SHAFT AND SPRIRG D BolTS

DiscoDDsct the front

propeller

shaft

at the front

axle

the eight nuts from the two studs end three U bolts that secure
Remove the spring seat plate and U bolts
seat

spring

plates

lM

Remove

tqs

Steering dumper
Drag link

Stabilizer

Pitman

arm

Tie rod
Disconnect those parts

2 4

REMOVE FRONT SHACKLE

Remove

front

shackle nuts and

the front

springs

and

Roll the front

the forward

drop
assembly

axle

from

end

remove

the shackle

of the

spring

from both

to the floor

the vehicle

3 DI SASSEMBLY

3 1 REMOVE WHEELS
Place the front axle
nuts that

3 2

on

two blocks

weels to the brake drum

Remove

Remove

the six

the wheels

REMOVE AXLE SHAFT ASSEMBLY

Using
Remove

secure

assembly

a screw

the anap

driver

flange

in

puller

ring

the drive
pry the hub cap off
Install the
axle shaft groove

105

on

drive

flange

end

Remove

the drive

lock washer off the


nut

lock washer

bearing
and bsaring adjustment

Remove

bearing

Remove
nut

hose

Remove the six nuts that

car

the

bearing

using

wheel

of the

lock

bearing

lock nut

Slide the brake drum


adjust nut wrench
ing the wheel bearings off the spindle
brake

Bend the

flange

lock nut

and hub

includ

assembly

Disconnect the

secure

hydraulic
plate to the
Slids
spindle

the brake

Remove the brake plate from the


spindle housing
the spindle off the llIle shaft
The lIIle shaft can now be removed
from the housing
Use the same procedure to disassemble the other
snd of the front axle

3 3

AIlE SHAFT D1SASSEIBl Y

Remove

portion

TKACTA JOIIlT

the outer

of the axle

shaft snd the outer

portion

of the univer

joint from the axle


Pull the
housing
inner portion of the
sal

ule shaft and the

SS

portion of ths
joint out
ths housing

inner

universal
of

Front axle shaft

106

34

REMOVE SPINDLE HOUSING

Remove the castellated nut that


two

spindle

arms

knuckls

and

the tie

remove

upper cap and

the tie

rod ends

to ths

Remove ths four nuts that


the knuckle

flenge upper
the four nuts that
bsaring
secure the lower bearing cap to the knllckle flenge and remove the
lower cap and pin assembly
Remove the eight cap screws that se
cure the knuckle flange oil
ssal retainer to the knuckle flange
Remove the knuckle flenge from the axle housing
Use the same
the
other
knuckle
for
disassembling
flange
procedure
securs

disc

spring

cap

3 5

flange

secures

rod

and

remove

Remove

cone

REMOVE DIFFERENTIAL

Remove

the twelve

diffsrsntial
rential

cover

and

cover

plain

end lock washers

nuts

to the diffsrential
Remove

gasket

ths two

cap

that secure
Remove

housing

screws

the

the diffe

from the

bearings cap at each end of the differential

gears end remove the


from
the housing using
assy

Remove the differential gear


caps
Reinstall the bearing caps in the hous
if necessary
pry bar
the
to
assure their being installed in thsir
marking
ing noting
correct

location

NOTE

st8lllp
no

bearing

caps end housing

if there

markings

REIOVE OIFFEREITIAL PlllOl GEARS AID SIDE GEARS

To

disassemble the dif

ferential
sure

on

DISASSEMBLE DIFFERENTIAL

3 8
A

marks

the

marked

check and make


case

halves

are

it may be re
assembled in the same posi

tion

So

four bolts

Remove

by removing

the cotters

castellated nuts
the

cass

the four

cover

pinion

and

Lift off

end

remove

mate and two

side gears with thrust


washers

Mark

107

on

the

case

are

BElOVE BIIB BUB FBOI CISE

Bend th

ears

of the lock

the cap screws that


the ring gear
Pull side

secure

bearings

the

plstes off the cap screws


ring gear to the case end

of diff

case

t with

suitable

Remove
remove

puller

3 7 REMOVE DRIVE PIIION


Remove

the nut and flat washer that secure the universal joint
Install puller to the joint flange and
pinion
drive the drive
a braes
drift and hammer

flange to the drive


remove

pinion

the flange
Using
out of the axle housing

the drive

pinion

noting

Remove the shims

the thickness of the shims

and spacer from


removed from ths

pinion

r
j

i
r

t4iiS

fir

G
i

Flange

fix

nut

R
4 CLEANI NG I NSPECTI ON AND REPAI

4 1

CLEANING

gasoline or cleaning solvent


until all
the bearings while immersed in the cleaning solvent
to
Oil the bearings
prevent
of lubricent has been removed
Clean all

rosion

of the

parts

in clean

highly polished

surface unless they

mediately

108

are

Rotate
trace
cor

to be used im

4 2

INSPECTION AND REPAIR

AILE HOUSIIS

Replace

or

repair

broken welds

or

cracks

the axle housing if it is bent or has any


Drive pinion bearing cups that are pitted

or discolored due to overheating must be replaced


flange bearing cups that are pitted or corroded must be re
placed
Replace the oil seals in axle housing regardless of their
conditions
Check differential cover for crack and damage
of
also check for missing or damage
threads 1n the filler plug hole

corroded
Knuckle

breather

end of the
1 350

Measure

valve

housing
replace

inch

the inside

diameter of the bushing at each


worn to more then 35 3 mm

If the bushing is
the

bushing

172

I
BE

SURE

ARE

IN

HOLES

106

40524

44000

LINE

J
cS
H

PRESS

BU

ING

d
C
o

Ul
D

IUl

lJ

Housing end bushing

109

IN

Rear exle

housing

DBIVE PIlIOI BEARIIS CUP REPLACE Ell

Remove the inner end outer bearing cups


using standard puller
noting the thickness of the shims when removing the inner bearing
To install Dew b aring cups
use brass drift and hammer
cup
Place the original thickness of shims behind the inner bearing cup
and tap the

bearing

until flush with 4he

cups

lightly

around the entire circumference

shoulder in the axle

Removing

housing

inner bearing cup

110

Installing

Removing
C

inner bearlng cup

outer

bearing

cup

KNUCKLE FLAISE BEARIIG CUP REPLACEMEIIT

Working through one of the bearing cups tap the opposite


bearing cup out of the axle housing using a brass drift and hammer

To
and

tap

install
the

bearing cups
cup lightly until it

place

new

the

bearing

seats in the axle

111

cup in

housing

position

ti

Installing knuckle
flange bearing cup

OIL lEAL REPLACEMENT

To

remove

the inner axle oil

to install the inner oil


oil

seal

seal

use

use

the oil

the oil
seal

seal

replacer

remover

and

and

the

tap

seal in the inner end of the axle housing

0j

i 7 Icr

lj J

1
f

J
V

i
X

Replacing

new

112

oil

f
i
seal

filijiO
M

AXLE HOUSII

DUSHII

REPLACEIEIf

the bushing from

Remove

the outer end of the axle bushing

To install a new bushing place ths


using a standard puller
bushing in position in the axle housing align the grease hole
and using a suitable driver
drive the bushing in ths housing until
it seats

F DRIVE

PIIIO

ASSEMBLY

Roller

bearings that are pitted corroded or discolored due to


overhestingmust be replaced
Replace the pinion if it has worn or
broken teeth
The differential ring gear and the drivs pinion
assembly are furnished only in matched sets and if either is found
Small nicks cen be removed from
d8lllaged both IllUst be replaced
the pinion gear with a fine stone
DIFFEREllTlAl ASSEMBlf
Replace any
Replace

teeth

mster is

worn

meter is

worn

mster of the hub


end

gear

that is

excessively
pinion

the differential

the differentinl

Replace
Replace
is

pinion

shaft if ths dia

axle shaft gears if the outside dia


Replace the differential pinion gear

the

worn

axle shaft

gear thrust washers


races that are pittsd

bsarings and
ovsrheating IllUst
disassembly must

has any broken


if the inside dia

worn or

gsars

be

replaced

be

replaced

H TRACTA UIIVERSAl JDIIlTS AID

if the thickness
corroded

All

or

shims that

worn

Roller

discolored due to

wers

damaged during

SHAFT

Replace the inner portion or the outer portion of the axle


if they are bent or havs worn splines
Replace the innsr
of
if they ars
or
the
outer
the
universal
joints
portion
portion
Small nicks or scratches can be re
cracked or excessively worn
shafts

moved

with

fine

stone

TIE ROD

Replace

the tie

snds if the sockets

rod if bsnt
are

or

damaged

Replace

the tie rod

loose

the tie rod ends loosen the lock nuts at both ends of
To install tie rod
the tie rod and screw out the tis rod ends
tie
rod
end
then
screw in the tie
the
lock
nut
on
the
ends
place
The amount screwed in must be same for
rod ends into the tie rod
To

remove

both ends

113

i
L

ft
@
o

o
o

o
o

m
J

Shock absorber

Stabilizer

Front

Tie rod

Drag link
Steering dumper

le

Knuckle

housing
flange

Torque arrester

UDellE rUIG BEABIIS CAP

the upper bearing pin


cone end cup if they are worn
the
lower
knuckls flange bearing cap
cllrroded
Replace
pitted
8Dd
if
are
worn
pin bsaring
cup
they
pitted or corroded or dis
colored due to overheating

Replace
or

flange cap in a press and with e suitable


use
a
To install a new pin
out
the
press
bearing pin
suitable drive and press the pin in until it seats
Place the knuckle

driver

I DOCIlE rLAm

AID BPlloLE

If the studs on
the knuckle flange if it is cracked
Re
broken or damaged
the knuckle flange are bent
replacs them
threads
or
sur
if it has damaged
the
grooved bearing

Replace

place

faces
must be

spindle

Roller

bearings

that

are

pitted

replaced

114

corroded

or

discolared

Indent

the end of the broken

stud

exactly

in the center with

center punch
Drill approximately two thirds
stud
using a small drill then follow up with

the broksn

size

of the drill

depending

The drill selected

pth

however

of the threads

Select

on

through
a larger

drill

ths

the size of the stud to be removed

must leave

wall thicker than the de

extractor of the proper size


In
sert it into the drilled hols and screw out ths remaining
part of the
broken stud
To install a new stud
use
a stendard stud
driver and
drive

all

If the

studs until

stud

is too

no

an

thrsads show

tight

or

at the bottom of the

too loose in the stud hole

stud

select

ano

thsr stud

5 ASSEMBLY

5 1 INSTALL INNER BEARING ON PINION


Press the inner
Make

sure

the

bearing

bearing

on

is seated

the

pinion using an
against the shoulder

arbor press
of the pinion

gear when installed


Press the

rear

inner

bearing cup in the housing


with proper thickness of
shims
front

Press in the

bearing

cup

il
it

5 2

ADJUST PINION IN HOUSING

If the original ring gear and pinion are being used in the ori
If a
ginal carrier use the original shim packs at each bearing
carrier is installed
note the markings
new pinion or differential

115

I
i

the end of the p1nlon gear and differential carrier to obtain


the correct thickness of shimming to be used for correct
setting of
Tbe marking figure signify thousandth of a inch
gears
on

Place

the pinion in the differential housing


Install the
gauge to check the setting from the back lace of th
pinion
the center line of the differential case bearing
The standard
setting is 70 36 mm 2 7706 in
U the
llIark on the

depth

setting

head is
0 002

inch

tance is
or

correct

If the

70 36

removing

o 002

th

mm

setting

setting

minns 0 002

llIark is
inch

distance is

pinion

70 36

mm

2 the correct

Adjustment

shims under inner bearing


cup
each case
in order to give

inch in

to

plus

setting dis
by adding

is made

And add another shim

preload

on

bearing

INSTAll OUTER BEARING ON PINION

5 3

After the correct pinion setting has been obtained


spacer and the original amount of shims on the pinion
outer bearing on the pinion

5 4

install
Install

the

PRE lOAO ADJUSTMENT OR DRIVE PINION BEARING

Place the universal


while

holding

load of 2S

the

joint companion flange on the p1n10n and


from turning
tighten the nut to a torque
180
21S ft lbs

flange

30 kgm

Check the

cord
Pull

pinion bearing pre load with a spring scale and heavy


wrapped
cOlllpanion flange oil seal contsct serf ace
on the spring scale
The torque required to rotate the pinion
around the

is II
from

14 kg

If not within these limits

cm

add

or

remove

behind the front

bearing

to

obtain

proper pre load


After the correct
ment is
remove

obtained

adjust
again

the universal

join

flangs

a new

oil

soaked

the

on

end install

seal

well

the

pinion

Reinstall the universal

joint flange

Install

nut and cotter


Check the

again

pin
pinion hight

to be

sure

Checking pinion

116

pre

load

ahims

Measuring pinion height

5 5

Pinion

alignment

gauge

INSTALL GEARS IN DIFFERENTIAL CASE

Place the ring gear side half of the differential case on bench
and assemble side gear with thrust washer in it
Do not forget to
lubricate gears and thrust washers before installation
Install
differential main shaft
spider with pinions and thrust washers in
differential case
Install the second side gear and thrust washer
on

top

of

pinion

Assemble the other half

of the

case

being

sure

to line up the marks on the case halves


Drive the four bolts from
the small side of the case
install nuts and tighten ths nuts to a

117

load of 6 9
9 kgm
50
65 ft
lbs
Check differential
side gear back lash
clearance must be within 0 003
0 010 inches
If it is out of these limit the
thrust wsshers Or gears must be
If it is correct secure the nuts with
changed
cotter

torque

pins

CASE
U

CUA

Te

ERIO
IOE

CileAR

Differential gear parts

Assembling

differential

118

gears

Be

8ure

to line up

he marks

FEELER

Checking

back lash

119

GAUGe

1
1
I

Securing

5 8

differential

case

bolts

INSTALL DIFFERENTIAL RING GEAR

Placs the differen


gear in
ths case

tial

ring

tion

on

stall ths lock


screws

In

plates

that

cap
ths ring gear

posi
and

secure

to the

tighten the cap


screws to a torqus load

case

of 4 4
32

Bend the
lock

5 8

m
kg

42 ft lbs
ears

plates

of the

on

the cap

screws

Installing ring

120

gear

Installing bearings

on

diff

case

5 7 INSTALL ROLLER BEARING ON CASE


If all

the

asssmbly

same

ths roller
If the

bearings
original parts

thickness

bearings

on

is not known
on

the

have been used in the differential

original parts

add the

case

thickness of shims
the
are

case

original used and press


subparagraph h below
shim
or if the original
as

then with

not being used


shims as table I

use

without

shims

and

or

proceed

install the roller

with

paragraph

below

Part Ho

Thickness

Pcs

HOTE

Humbsrs of pcs
showes for I unit

38129

42100

008

not

for

one

side of

housing
38130

42100

o 13

38131

42100

o 25

38132

42100

o 76

Table

58

IISTALL DIFFEREIT IAL ASSEMBLY II HOUSIIG

Place the

bearing

cups

on

the roller

121

bearing

Tilt the bearing

I
I

cups in

assembly in the housing


assembly is seated firmly in

until the

cups lightly
Install the two
face the

ing

differential

proceed

Tap the bearing

order to start the

with

bearing

s8llle

way

caps so
and match

the numbers

on

the

the housing
caps

and the hous

If the
in every way as shown in
used is not the original in the axle

assembly being
subparagraph 59

below

Instslling

diff

assembly

case

ADJUST DIFFERENTIAL ASSEMBLY

5 9

without any
bearing cups on the differential assembly
the
Slide
assembly to
shim and place the assembly in the housing
the
between
bearing
Check the clearance
one side of the housing
After this clear
with a feeler gauge
differential
and
housing
cup
Place the

ance

has been dsterminde

to the left bearing and 0 01

add 0 002

right bearing
for proper bsar
give the thickness of shims required
from
the housing
Remove the differential assembly
ing adjustment
Install
the emount
case
Remove the bearings from the differential
to the

This will

of shims determined

above in

equal

amounts

on

and install the bearings back on the case


and place the differential in the housing

lightly
stall

ing

until the

asssmbly

is

seated

the two bearing cups so


and match
the same way

face

cap bolts to a torque


wire lock on the bolts

firmly

the numbers

each side of the

In
in the housing
the caps and the hous

on

in every way
10 kgm
62
load of 8 6

122

case

Tilt the bearing cups


Tap the bearing cups

Tighten

the four

72 ftlbs

and

Measuring thickness of shims

5 10

CHECK BACKLASH

Install

dial indicator

the indicator contact is


as

Rotate the

shown

backlash
inch

If the backlash is

remove

ings

on

the differential

resting on the
ring gear back

from the differential

case

and forth

less thau 0 005

the differential from the

housing

surface of

housing

that

to determine the

inch
and

so

ring gear tooth

or

more

remove

than 0 007

the bear

If the backlash is Isss than 0 005

inch

the ring gear must be moved away from the pinion


This is ac
shims
to
srror
in
backlash
from ons
the
complished by moving
equal
side of the

case

bearings

the

the

on

and
case

adding

them to the other side

Install

differential

in

Install

houaing

the

and recheck

backlash

5 11

CHECK RING GEAR RUN OUT

Install

dial indicator

indicator contact is resting


Turn the
the

ring

run

out

gear
is more

ferential

ring
the

assembly

housing
ring

so

flange by

hand to

gear
determine the run out

them with
case

Check the surface of the differential


small

or

for

nicks

which

might

case

and the

have occured

during

fine

If any small nicks are found


re
also check the flange on the diffsren

stone

Reinstall the diffrential

being

sprung
the housing and recheck the

ring

gear

run

assembly

GEAR TOOTH CONTACT PATTERN

0238

Correct tooth contact


Short toe contact
Short heel

Move

contact

Contact too high and

Move

ring
ring

narrow

gear away from p1n10n


gear toward pinion

Pinion should be moved toward

center

of axle
5

in

out

47

on

ut should not exceed 0 0025 inch


If the
than 0 0025 inch
remove the
from
the
dif
ring gear

chips

tial

that the

of the differential

move

5 12

the differential

the flat side of ths

The

case

gear for

drive

pinion

on
on

Contact too low

and

narrow

Pinion

center of axle

124

should be moved

away from

Allowable variations in the carrier or drive


p1n10n may
to be too far in or out even when shimmed

the

pinion

Thus
or

the tooth contact must be tested and

the

cause

properly

gear may be

corrected

as

necessary

noisy

Paint the ring gear teeth with a light coating of red lead
or
or prussion blue
Revolve the gears and observe the
contact
referring to the illustrations shown in for this operation

white lead

5 13

INSTALL DIFFERENTIAL COVER

Place

a new

axle
the

housing
housing

5 14

the ten cap

screws

cover

that

in

place

secure

the

on

the

cover

to

INSTALL SPINDLE HOUSING


flenge lower taper roller bearing in grease
0
Press in the
ring on the lower cap
Install the oil seal
0
lower
Press
on
the
ring
cap
roller
to
in
lower
on
the
greased tapper
bearing
pin
cap

Dip

the knuckle

Install the oil


grease
in the

gasket and the differential


Install

seal

o
Q
1

O ring and

bearing

cup

Install standard thickness of shims according to table two


Place the knuckle flange on the axle houaing with the steering
to the front of vehicle

Install the lower

bearing

cap

arm

assembly

the cap
the upper
Insert spring disc and bearing cone
align grease hole of pin
cap
Install upper bearing cap assembly without shim to knuck
and cone
le flenge
on

the knuckle

flenge

to the knuckle flange

and install the four nuts that secure

Install the oil

125

seal

ring

on

Installing
lower

AsSembling

ap

upper cap

126

INQ

cap

Assembling

upper cap

Tighten equally the four nuts that


cone

secure the cap until the bdaring


does not turn when the knuckle flange is turned back and forth

Check the clearance between cap

Measuring
After this clearance

and knuckle

thickness

flange

with feeler gauge

of shims

has been determined

add 0 4

mm

0 016 inch

This will give the thickness of shims required for the upper bearing
2 I
adjustlllent
Tightening torque for the bearing cap nuts is I 9
The torque load for turning the knuckle
m
14
15 ftlbs

Ig
flange
Ibs

at the
Add

edge
or

arm is 9
10 kg 20
22
bearing cap until the correct

of the steering knuckle

remove

shims

to upper

tension is obtainsd

127

Checking knuckle flange tuming torque

TABLE
NG WIDTB

mm

16

16 1

16 1 16 2

16

2 16 3

16 3 16

16 416

SHDI PART NO
44000
40605

44000
40606

0 0711

127

mm

Total

Lower bearing cap Standard shim thickness


See the instruction drawing of

front

128

axle

lsembly
al

5 15

INSTALL SPINDLE HOUSING OIL SEAL

Place
screws

that

the oil
secure

seal

on

the oil

Installing

the knuckle
seal

oil

seal and its

Connect both ends

of oil

5 1G

oil

shaft

so

seal

spring

SCREW

guard

ASSEMBLE AXLE SHAFTS AND TRACTA JOINT

Lubricate with chassis

joints
portion

the 6 cap

spring

seal and

CAP

Installing

Install

flange

guard to the knuckle flange

grease all bearing surface of shafts and


portion of the axle shaft and the inner
universal joint into the axle housing
Turn the axle
line up the splines of the axle shaft with the axle

Slide the inner


of the
as

to

129

shaft

in the differential

gear

universal

joint

on

the outer

the slots of the two


in

place

on

Slide the outer portion of the

portion

universal

of

the axle shlut

joints and slide

the

outer

Line up
axle shaft

the axle

Installing inner axle shaft and joint

Installing

outer

joint

and shrlt

5 17 INSTALL SPINDLE AND BRAKE PLATE


Pack roller

bearing with specified bearing


Secure in place with locking ring
spindle
the spindle housing
Place the hrake plate on
oil

spindle

the

spindle

with the

grease catcher on the


line up the oil drain hole of grease cotcher and brake plate
the six lock washers and nuts

drain hole toward

Install

grease and place in


Place the spindle on

the bottom

Place the

130

Installiug front spindle

Fixing brake disc

5 18

and front

spindls

INSTALL HUB AND DRUM

Install

spindle

collar

coat

surface where

oil

seal

contact

KWH
Pack the wheel bearings with
with very thin layer of grease
the specified lubricant
Insert the hub and brake drum on the
with the inner wheel bearing and oil seal in the hub

spindle

spindle and
adjusting nut until
then
back
off
the
binds when turned
adjusting nut
correct
wheel
This will give the
bearing adjust

Insert outer wheel bearing and the thrust washer


install the bearing adjusting nut
Tighten the
the brake drum
one

eight

turn

on

the

ment
the

Install the lock washer and


ears

of the

be within 15

lock washers
45 kg cm

over

lock nut

the nut

on

Hub

Bend
spindle
turning torque must

the

3 ft Ibs

Installing wheel

ring nut
be

Ti ghtening bearing nut

132

Measuring turning torque

5 19

of hub

HUB AND SPINDLE ALIGNMENT

Place the straight edge or steel rule on


spindle and measure
the space between hub and straight edge with a feeler gage or shims
to determine the thickness of shims to be installed

Measuring

5 20

Insert inner snap


and three lock

tightening
25

and

spindle

DRIVE FLANGE INSTALLATION


ring

quired thickness of shims


nuts

between hub

space

the nuts

275ft

Ibs

plates
to

the

on

on

the axle

the

and

Bend the

torque

shaft groove
the drive

secure

ears

wrench

Insert outer anap

133

of lock

setting of
ring on axle

Place

the

re

flange with six


plates after
3 5
3 8 kg m
shaft groove

lIIS
S

G
f

Install

in

Ti

dri

ening
t

flange

dri

34
1

flanr

nut

SNAP

Inserting

outer snap

Installing flange

RING

ring

cap

5 21 INSTALL TIE RODS


Insert the ends of tie rods in the
Be sure the
spindle arms
seal and covers are on the tie rods
Install the castellated
nuts that secure the tie rods to the
arms
dust

spindle

135

Installing

tie

rod

6 INSTALLATION

8 1 PRELIMINARY WORK
Place

hydraulic jack

under the front

under the vehicle

axle

Raise the

assembly
assembly
springs can be raised and secured to the spring shackles
jack to allow the axle assembly to rest on the springs

82

Roll the

assembly

until the front


Lower the

INSTALL SPRING U BOLT S

Place the

spring U bolts
spring seat plates

in

position

on

the axle

housing

the U bolts at the both side of the


Install the nuts that secure the spring seat to the U bolts

Install the
axle

63

INSTALL SHOCK ABSORBERS AID TORSION BAR

Insert rubber
Install

special

torsion bar

INSTALL

Insert

bushing

washer

on

each side of each shock

castallated nut and cotter

insert rubber

castellated nut

64

on

bushing

special

Lock the nut with cotter

washer

pin

absorber

pin
and

plate

Install

tighten

with

from turning

STEERING OAMPERNER REBOUND STOPPER


rubber

bushing in the eyes of steering damper eys and

assemble to the drag link

136

steering dumper
Drag link

Tie rod

Ii

Stabilizer

Pitman

arm

Insert rubber bushing on the


stopper rods and assemble to

rebound

the bracket at both end of the axle


Tighten the nuts until the dist ncs
from end of rod to top of check nut
The rebound
15 32 in
ia 12 mm
3 11 32 in
not
be lesa than
Distance should
in
5 mm
13 64
stroke

85

is

STALL PROPELLER SHAFT DRAB LINK

Iatall the

propsller

85

mm

AID WHEElS

shaft to ths front aIle

137

Place the drag

link in the ball

on

the drag link

Install the cotter

the

steering

Install

arm

pin

the

in

the drag link


drag link plug

plug

on

In

stall the wheels

LUBRICATE

6 6

Fill the differential

to proper level with specified oil


and to all fittings

specified grease in each spindle housing


the hydraulic brake system

WHEEL ALIGNMENT

1 1

CASTER AND CAMBER

The

caster

and cannot

and

camber is established at the time of manufacture

be altered

by

eny

Af ter the front axle is


remove

adjustment

TOE IN ADJUSTMENT

2
7

assembled

axle

so

gauge

that the chains

registers
to a position
The

toe out

0 012
the

must be the

barely touching

are

zero

floor

lubricated

the blocks end lower the vehicle

straight forward at least three feet


the telescoping wheel aligning gauge

or

Apply
Bleed

th

floor

to

remove

between
same

and brakes

bleeded

Pull the vehicle

ground

on

the backlash and

place

the wheels in front of the

length

on

Set the scale

both ends of the


so

the

pointer

Pull the vehicle forward until the gauge is brought


back of the axle with both chains barely touching the

point will be the amount of toe in or


4 mm
adjuster until toe in of 3
Recheck the toe in after making
is obtained
Tighten the tie rod adjuster lock nut

reading
Adjust

0 016 in

adjustment

at this

the tie rod

l
1

lLt

Adjusting
138

toe

in

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

OF SERVICE
JOURNAL AND

BULLETIN

139

SER

CE

NEWS

REFERENCE
NO

DATE

CONTENTS

OF SERVICE
JOURNAL AND

BULLETIN

140

PI

Q
8

VA

t
il
Il

i
i
b

1
r

AND l SL Lu IS

iDRIl if EAL MLCBQWJL

lb

fI

NUT

0
I

OILS

OF

0
J

PINO WITH

TORQUE WITHOU B DRIVE


m

ka

UP

CLEAN

Wft

PARTS
EV RY

181
m

14

30KG
D
i
E
R
L
R
l
TURNIG Pili WHEN TIGHEN
I

ON

CAUTION

60

BE

25

RATING
G
N

EASMBLI

CSAE
90

MP

Oil

WASH BEFORE USE

2
I

MODEL

In
ft

797

GEAR
WITH

JQR 725

BE

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BEAR MUST UP
WHE L GREAS L ED

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FI

6 6

N5I

ASEMBLY

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0

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65ft

TORQ 155

GEAR

TIGHEN
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REAR
1

SUSPENSION
DATA

CONSTRUCTION AND

CONSTRUCTION

1
The

springs
frame

of the Nissan Patrol

rear

suspension

rear

shock absorbers

and torque arresters

on

consists

of

rear

rebound stopper on the


Rsfer to the instruc

stabilizer
the frame

tiondrawing

1 2 DATA
REAR SPRIliG
Parallel

Type

with
Thickoes8

Width

for Model

ben loaded

70

Model

300 7

60 Ik 660

3 42
6 18

Model 60 Ik 660
Model 660D

41

mm

48

mm

front

STABILIZER

on

rear

Telescopic

double

Torsion bar

type

torsion

on

eyes

Steel bushing
SBDCK ABSORBERS

l
k
klll

Model GBOB

Silentbloc type rubber bushing

Bushing

leaf spring

5 x 70 x 1 300 5
for Model G60D
300
1
8 x 70 x 1

ring constant

ClIlIlber

elliptic

section
60 Ik 660

Jilumber
Span

semi

grooved

bar

20

spring

shackles

acting
outer di

ter of

mm

REAR SPRI NG

of the Nissan Patrol are of a low camber and low


The
advantage of this spring is that the rebound
spring rate type
The torque arrester
less
or the throw is much
giving a smooth ride
rearwards
of
the
fixed
the
frame
spring eye is
which is
on
just
The

provide

rear

spring

to work

as

after the surface of

Hsmely
when vehicle is loaded
attached the bottom face of the
spring
mak
arrester acts as a kind of rubber spring
spring helper
the

torque arrester the


with rear spring higber tben the rate of
ing the combind spring rte
Thus
the rear spring of the Nissan Patrol will
rear spring alone
and give the enougb hardness
give smooth ride when it is not loaded
in order to carry the load

hen it is loaded

141

The

second leaf of the

for the safety


the shackles of
mounted in
ternal

ing

special
rear spring

spring is wrapped around the main eye


bushing with bolt type is used at
Tbe front end of the rear springe are

rear

steel

bond rubber bushings

Tbe bushing

steel tubs and tubular outer retainer

is molded and

securely

bonded

consist of

in

an

to which a rubber

Tbese rubber bushings

bush

require

no

lubrication and no
keep the bolt drawn up
Before
installation
the
coat
bushing securing with a very
snugly
attention other than to

thin coat

of

grease

to

protect

it from

freezing by corrosion

n n
o

Rear

00
00

suspension parts

for model

60

660

It must be remembered that the rear sprin s should be loaded when


the nuts of spring front eyes and shackles of the rear spring are
tightened as well as the front spring
To be

sure

between th
clearan

is

loaded

correctly

or

not

check the buffer

torque arrester and main leaf of the


13

mm

515

in

the

springs

are

clellrance

spring
loaded with

If that
a

correct

weight
The
6 2

tightening torque of the spring


50 ft lbs
6 9 kg m
45

142

eye

rubber

bushings

is

The nuts

following

on

the

Tighten nut up

Back

shackles

rear

should be tightened up

by

the

method

tight

as

off the nut

posible

as

quarter turn

If the slot in the nut and the cotter


insert the cotter

pin

slot and the hole

are

pin hole line up


back the nut off until the

If not

and

in line

then insert

the cotter

pin
Ths
U bolt

tightening torque
should be 6 9

of the nut that


8 3 kg

secure

50

the spring

clip

60 ft lbs

3 REAR SHOCK ABSORBERS


The
none

rear

shock absorbers used

adjustable type

and

the Nissan Patrol

on

the double

acting type

That

are

is

of the

why

no

further maintenance will be nesded

Replace
cognized
The

or

same

the shock absorber if the


the

dumping

shock

force is

absorbers

are

leakage

of the fluid is

re

decreased

used

on

the front

suspension

of this

vshicle

4 REAR STABI LI ZER


The

type

stabilizer used

with rubber

bushing

on

the Nissan Patrol is of the torsion bar

on

the

mounting

143

TORQUE ARRESTER

Rear

suspension

CONNECTING

1000

t
0

OISA SEMBLEO

Rear stabilizer

144

Replace
Replace

if the crack or any other fault


the torsion bar
the rubber bushing
if it is worned

Checking must

be

done at least every 10 000 Km

is found

000 miles

TORQUE ARRESTER

The
ers on

Nissan Patrol

its bottom face

is

equipped

with

of the side rail

pair

near

the

of the

spring

torque arrest
brackets

These torque arrester have the two purposes


Namely one is to
vehicle is go
prevent the movement of the rear axle housi ng when the
kind
of
rubber spring
Another purpose is to act as a
ing to start
can
be
when the springs are over loaded
Thus
designed as
springs
a

low

spring

vehicle
ers

and

providing go d ride with less weight on the


providing enough carrying capacity with torque arrest
rate

one

with much weight

on

it

the
The buffer clearance between the torque arrester and
0 515 in
when it is loaded
should
13
mm
be
springe

of the
normal

surface
with

load

Check the deformation of the torque arrester at least every


3 000 miles
Replace it if it is deformed eIcesively

5 000 Km

145

I
I
I

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

146

OF

SERVICE

JOURNAL AND
BULLETIN

r
o
CO

3T

I
L

J
IaJ

C
o
zl

in
z
IaJ
D

4
70

o
CHASS I

eto
fO

92

ff

f
J

II

501114

c
IaJ
a

o
or

REAR SPRI N

c
a

c
z

i
o
J
a

f
z

4
I

QlJ
U
Q 4 X2Q

5635u

1 qc 1
1

222

009

00
1044
4 44QJQ
1235
TH

BEASE

REAR EYE

LJ

REAR
1

AXLE MODEL

DESCRI PTI ON

60 AND

G60

AND DATA

DESCRIPTION

The

rear

axle of the Nissan Patrol

mo

el

60 and 660

is of the

semi floating type with conventional type differential and hypoid


dri ve gears
The differential parts are interchengeable with those
of the front

axle

The differential

similar to the front axle


front instead of the
For the model
axle is

The

heavy duty type model


rear

axle

the

housing

differential

the

pinion

housing
is

toward

the

the sp cial rear


axle shaft
the

rear

and relative

gear carrier assembly


ferent from model 60 and 660

1 2

drive

rear

660H

designed

is mounted in

except that th

parts

arS

quite

dif

DATA

Type

Semi

Tread

I 400

floating
55 15

mm

Dri ving method

Hypoid

Gear ratio

in

bevel gear
I

Number of teeth

Ring gear

41

Drive

10

pinion

Rear axle

shaft bearing

Type
Out

roller

Taper
Dia

Inn

dia

80

Width
End

play of rear axIs shaft


Torque wrench setting
Axle shaft bearing

40

o 05

mm

0 002

0 006 in

157 ft lbs

1 52 0

cage bolt

20

0 15

12 K

lock nut

Bearing

JIS 30208

m
Kg

21

28 ft lbs

Rear axle shaft adjust


shims available

Recommended

As

oil

and

capacity

to the differential

gears

o 076

mm

0 003

o 127

mm

0 005 in

0 254

mm

0 010

in

o 762

mm

0 030

in

SAE

in

MP 90 1 2 Itr

refer to the

147

0 31 U S

paragraph

Gal

FRONT

AXLE

REMOVAL

2 1 PRELIMINARY WORK
llemove the drain
at

plug

the differen

tial housing and drain


the gear oil
Raise
the vehicle until the

weight is off the rear


axle supporting the
frame

Disconnect these

2 2

olSColneT SHOCK ABSORBERS STABILIZER AID BRAIE HOSE


the

ReMove
absorbers

nuts

Remove

brake hose from

d grommet

washers

the

secure

rear

shock

the connector

on

and

the

rear

axle

olSCoINECT REAR PROPEllER SHAFT AND SPRING U BOlTS


rear

propeller

shaft at the

Remove

plates

the

rear

bolts that

spring clip
spring seat plate

eight nuts from the four

seat

that

grommets that secure the sta


the shock absorbers and stabilizer
Remove the

Disconnect the
th

washer

Remove Nuts

bilizer

2 3

part

axle

Remove

and U bolts

the

spring
spring clip

secure

bolts I

2 4

REMOVE REAR SPRING SHACKLES

Remove
from both
floor

spring shackle nuts and remove the shackles


springs
Drop the rearward end of tbe springs to
the rear axle assembly from the vehicle

the

rear

rear

Roll

148

ths

D1SASSMBLY

1 REMOVE WHEELS
Remove

move

six nuts that

wheels to the brake drum

secure

Re

the wheels

REMOVE AXLE SHAFT ASSEMBLY

3 2

Remove
Remove

the

screws

secu
e the

rear

axle housing

the axle

secure

the axl

the brake drum to the

rear

axle

Back the four nuts off

shaft

axle shaft bearing cage and brake disc to the


the rear axle shaft with brake disc from

Remove

housing

Remove

special

that

drum from

the brake

that
rear

th

the lock

teewrench

and back the bearing lock nut off with


Remove the wheel bearing end spacer from the

plate

the brake disc with the

ule

shaft

Remove

from

the

axle shaft

rear

rear

ule bearing cage

Press out the four serrated bolts that hold the brake disc and
the bearing cage
and remove the bearing cage from the brake disc
Remove the outer lace of the bearing and the outer oil seal from
the bearing cage
Remove

the

suitable

the inner oil

with suitable

3 3

using

puller

seal from the end of the

rear

ule

housing

puller

REMOVE DIFFERENTIAL

As to the removal
inspection repair and re
AXLE
The parts and these
FRONT

paragraph
actly the same

front axle differential

as

4 CLEANING

INSPECTION

assembly

operations

refer to
are

ex

parts

AND REPAIR

4 1 CLEANING
until
in the cleauing solvent
Oil
the
bearings to pre
all trace of lubricant has been removed
vent corrosion of the highly polished surface
Clean the all

parts

f11y
throu

149

2
4

AXLE HOUSING

Replace

4 3

repair the axle housing if it is bent

or

broken welds

or

rear

the

axle shaft if it is bent


If the

spline

parts

th 3

replace

4 4

axle and

bearing is fitted
bearing together

twisted
rear

or

axl e

has any
on

has any coloured

sur

WHEEl BEARING

bearings that are pitted


heating must be replaced

corrded

The

4 5

or

of the

which the inner lace of the

or

discolored due

to

over

OIL SEAL

Replace
they

has any

REAR AXLE SHAFT

Replace the
damaged tooth of
face

or

cracked

the oil

seals which

do not look like they


Never

use

the old oil

are

seal

are

fitted

originally

even

though

damaged
in

reassembling operation again

5 ASSEMBLY

5 1 BEARING CAGE ASSEMBLY


Press the

new

oil

seal into the bearing


cage with suitable
drift end press
Press the bear

ing
ing

cup into

the bear

cage

Press oil

150

seal and bearin

cup in

ASSEMBLE BRAKE DISC AND CAGE

5 2

Place
brake

di

the

bearing
the

on

Press the four

and

cage

suitable

press
serrated bolts in

through both brake

di sc

and cage

ASSEMBLE BEARING CAGE AND


SHAFT

5 3

Put

the

rear

the brake di3c

axle shaft through


Place

assembly

the bearing spacer

into the

bearing

cage
Fit the wheel
axle shaft

in using the

to

bearing

and drive

special

the

the bearing
hamm

Press serrated bolt in

Place

bearing

Place the

spacer

151

bearing

Place the bearing lock nut and


plate thsn tighten the

its

lock

nut up
12 K

The
157

tightening torque
ftlbs

plate so that
locked securely
lock

is

Crock the

sPec

the lock nut is

H
wRENC

Tightening

5 4

lock nut

ASSEMBLE AILE ASSEMBLY TO THE HOUSING


Place the

adjust
0 059

rear

axle

shims I 495 mm
in total
in

thickness on the bearing


axIs
cage of one rear

assembly
the
to

rear

the

axle

rear

Replacs
assembly

axle housing

Secure the four nuts


that hold the cage to

tighten
ing torque is I 52 0
the housing

m
Kg

Replace

152

28 ft lba
21

rear

axle shaft

Placs enother
axle

rear

without

assembly
adjust shims

and tighten

the two bearing cage nut


Measure the
temporarily
clearance between the

bearing

and the end

cage

of the axle housing

using
Say this

feeler gauge
value as A

Measure thickness

of

adjust

shims

Remove

tightened

tem

porarily

Remove

the

rear

axle shaft

from

the

the

rear

O I
A

total

thickness

rear

shims

Place
measure
rear

If not

ness

adjust

play

so

this time

Because

than I 0

adjust

mm

the former
the end

rear

axle

play

th

and

four nuts up

axle

the

rear

0 15

and

axle shaft flange


The

axle shaft

play

of the

thickness

more

than 10

of the

the

adjusting

0 002

mm

end

of the

play

0 006 in

the thickness of the adjusting shims on the later


Record
is in the standard value
that the end

changed

is

differ

rear

shaft must be in 0 05

axle shaft
the total

of

disl indicator onto

the end

axle

play

onto

axle bearing

axle with

tighten
end

in

mm

Replace

cage
rear

assembly

housing Place
axle adjust

shims
the

Measure

the nuts

was

that

and

mm

thick
each time when the
thickness of both axle must not

adjusting shims
the total

If th

0 04 in

the thickness
And then

adjusting

of the

repeat

the total

the

difference exceeds

shims which is fitted


same

operations

in

on

checking

thickness of later axle

153

more

6 I NSTALLAnON

6 1 PRELIMINARY WORK
Fill the lubricant into the differential housing
under the
be raised
allow the

62

under th

Place

Roll the assembly


assembly
Raise the assembly until the rear springs can
vehicle
Lower the jack to
and secured to the spring shackles
axle assembly to rest on the springs

hydraulic jack

INSTALL SPRING

rear

axle

BOLTS

Place the spring U bolts in position on the axle housing


of
the spring seat plates on the U bolts at the both side
to
the
Install the nuts that secure the spring seat
the axle
Install

U bolts

63

INSTALL SHOCK ABSORBERS

Insert the rubber bushings on each side of each shock absorber


castellated nut and cotter pin
Install the special washer
plate
bber
insert
Install the torsion bar
bushing special washer and

tighten
turning
6 4

with castellated nut

Lock the nut with cotter

pin

from

INSTALL PROPELLER SHAFT AND CONNECT BRAIE HOSE

Install

the

propeller

shaft

to

the

rear

Connect the brake hose to the connector


Bleed the air which is in the brake

154

axle

on

the

hydraulic system

rear

axle

the

SERVICE

NEWS

REFERENCE
Of SERVICE
JOURNAL AND
BULLETIN

NO

DATE

CONTENTS

155

SERVICE
DATE

NEWS

CONTENTS

REFERENCE
OF SERVICE
NO
JOURNAL AND

BULLETIN

156

Jl

CNC
AX

PlN
FO

LINE

RT1C

JBaAlSiLE

fRAhl

FRON

TY9E
NOVrl
lit
l
Ulll

Al
IA

50

60

ASEMBLY
AXLE
REAR

CS

MODEL
i

RtiA
y

Bf
J

tflHU

OOS 0 06
f
lIl

JilW

SEAT

TREAO J4o spRING 1010

05

Lti
1

TO

u
i

REAR AXLE
1

MODEL

G60H

DESCRIPTION AND DATA


1

DESCRIPTION

The
is

rear

of the semi

hypoid

axle of the Nissen Patrol model 660H


heavy duty type
floating type with conventional differential gears and

gears

In

comparison with the rear


following parts are different
The
form

of

axl e housing

is made out of the

and for it

banjo

60 and

axle of model

steel

pressed

witb its

light weigat

660

the

plate

rear cover

in the

being

welded
The

carrier is made out of

gear

the differential

is

strong malleable
constructed

assembly
dismounting and the adjustment of each gear
separable from the rear axle housing instead
carrier of model

The

rear

therefore
does

co

gear

60 and

iron and

the welded gear

special

steel of

highly strength

than model 60 and 660


carry heavier weight
with ita pressed banjo type axle housing and strong

660H

operating

differential

The
of

cast

to maka easy
gear carrier is

as

660

axle is made of

model

so

can

gears

the dri V8 p1n10n drives the bevel gear which


Inside the housing
The each two
is closely connected with the differential gear case
side gears are fixed in this case and locked each
other
The pinion mate wi th the pinion shaft which is supported by
which is support ed as to func
while the side gear
the gear case
is
connected with the spline at
tion freely inside the gear case

pinion

the

mates

top

and

end of

rear

axle shaft

in the construction of differential gears


The thrust
is the existence of the thrust block
of model 660H
the
of
the
differential
in
center
block and its spacer are located
The block is designed so that
case by supporting pinion mate shaft
sbafts
is supported by this
rear
axle
the thrust force on the both
themselves
support the thrust force
whila the both rear axle shafts
case of model
660
differential
and
The
in the case of model 60
the
of model 60 has
block
while
case
mono
660H is constructed as a
construction to two pieces
the
The

particular point

separable

157

1 2

DATA

Type
Driving

Semi
method

floating type
bevel gear

Hypoid

Gear ratio

100

Number of teeth

Ring

gear

41

Drive

pinion
Pinion nut tightening
torque
Pre load for pinion bearings
Pinion gear adj
shim thick

10
120 180

ft Ibs

12 15 kgcm

10 413 in

lbs

o 003 in

nes

o 005 in
o 010 in
Pre load

adj

ahim thickness

o 030

in

o 003

in

o 005

in

o 010

in

o 030 in
Standard
drive

position
pinion

to install

Distance from center of


drive

gear to

Tightening
gear
Drive
Side
Side

cap

pinion

torque for

head

82 55

3 25 ins

mm

drive
55 65 ft lbs

screws

gear backside

out
run

gear number of teeth


gear thrust washer

thickness

Not to exceed

1 55

Pinion mate number of teeth

0 076

mm

0 003

in

16

mm

0 063

in

mm

0 063

in

Q 008
006

in

10

Pinion mate thrust washer


thicknsss

I 55

Pinion mate and


back lash
gear and

Ring

side gesr
o

pinion

gear back lash


Preload of side

bearings

Tight adjusting

Q 008 in
006
nut until

bearing

cap stopper distan e is


262
262
9
85 mm
10 348

Torque

wrench

Pinion nut
Side

bearing

Standard oil
Wheel

10 350

120 180 ft lbs


cap bolts

capacity

bearings

Dimensions

80

90 ft lbs

Hypoid gear oil 2 5 Itr


Taper roller bearing
100

55

26 75

mm

0 66 US

3 937

1053 in
End

play

of

ins

setting

rear

axle shaft

0 050 10 mm

158

Q 004 in
002

gal

2 165

of

Thickness

adjusting

shims

0 030

in

o 010 in
o 005
o

in

003 in

DI SASSEMBLY

As

to

the

removal of the

rear

axle

aud the removal of the

rear

axle sbaft

principle exactly the


only differential gear
graph

same

as

from the cha

operations

the

60 and

660

are

Therefore

carrier removal is described

is

in

the

in tbis para

REMOVE REAR AILE SHAFT AND PROPELLER SHAFT

2 1

Drain the oil


both axle from
at

shaft

model

assembly

the

axle

of the gear

carrier

carrier

REMOVE GEAR CARRIER ASSEMBLY


the twlve nuts

Remove
axle

housing
Place
housing
2 3

the gear

rear

least 4 inches

companion flange

2 2

Pull out the


assembly
or pullout the
completely
assembly
Then
remove the propeller shaft from the

from

that

secure

the

the garage jack

assembly to
assembly fro the

carrier

Dismount fOThard the carrier

the

axle

if necessary

REMOVE DIFFERENTIAL CASE ASSEMBLY

out the
Take off tbe si1e bearing caps of the carrier and lever
Such
as dismount the differen
case
and
gear
bearing
the side bearing puller is adopted and pull out
tial side bearing
should be handled with care in catching
Tbe
the

differential

bearing

puller

to hook
Both bear
race which is hard
the edge of bearing inne
should
be
and
the
left
arranged
separately
ings of the right

2 4

REMOVE RING GEAR

Slacken the differential


lock washer and
set

screws

in a

case

set

pullout

the ring gear

diagonal

line

screws

considering

bending

159

after

bent back the

in this time loosen the


to

keep the gear from

REMOVE PINION MATES AND SIDE GEARS

2 5

The pinion mate


mate

pinion
from

left

pulling
as

well

2 6

out

by striking out the


locking pin which is fixed on the differential case
to the right
befo e
from the ring gear fixed side

side

pulled

side gear ani the thrust wash r


thrust wasbers should be arranged separately

front

right

should be

shaft

out the
as

shaft

Tbe

pinion

and

ae

gears

left

and

rear

REMOVE DRIVE PINION

Remove

the

nut using drive

BT4449

flengB wrench

Pull

and box wrench


out th

e
flen

pinion

companion flange
puller

wi th suitable

Remove

drive

th

pinion from the gelU


carrier by striking out
lightly

to the backwards

the frunt end

at the

companion
pinion

side of

the

flange

of drive

with the drift of soft


metal

pinion
out

the
Remove

nut

flange

togethpr with the

inner

ing

Thus

would be taken

race

of

rear

bearing

and ruller

distance

and the

piece

adjust

shims
The oil
outer
end

race

rear

seal

of front

bearing
shims

pinion adjusting
are

remained

Pull out

carri er
rear

the

inner

drive

special
drive

The

AT 4712
rear

bear

raplacer
adopter
employed in
race

4454
BT

case

easy to

and it

is

handle wi th

the vice fixin gone


Remove

rear

bearing

end of

160

the

from

pinion

pinion

should be
this

race

tool

ing inner
end

into the

replacer

o
Drive

pinion

inner

race

Pullout front

bearing
replacer
rear

Remove

rear

outer

bearing

race

outer race and oil seal of


plnlon gear
seal should be replaced with new one
and
removed the rear and front bearing outer race
by uaing service tool
4450
BT
which is drive pinion front and rear bearing outer race

by

drift

and

bearing

the oil

replacer

3 I NSPECTl ON
CHECK NG

AND

1 BEARINGS

Inspect

all

bearing

and rollers
cups
for scoring
chipping or
races

excessive

large
wear

wear

This

most evident
roller

Inspect

end of rollers for


is where
on

is

taper

bearing

Drive plnlon front


bearing outer race

rear

replacer

161

3 2

OIL SEAL

Inspect

oil

seals

it is recommended to

pinion

3 3

for evidence

replace

of

them with

wear
new

or
one

any

damage

whenever

is disassembled

DRIVE PINION AND RING GEAR

Inspect pinion splines and flan e for evidence of


Inspect ring gear and pinion teeth for scoring
Chipping
Inspect the gear tQotb contact bearings

wear

3 4

Check fit of

differential

3 5

case

cracking

or

for cracks or scores on side gear and


Check fit of differential side gears in
side gears and axle shaft splines
Inspect

pinion

rlt
sh

case

for

scoring

or

evidence

of excessive

wear

GEAR CARRIER

Inspect differential carrier


ferential bearing cups and bosses
3 6

excessive

DIFFEREIITIAL CASE AND GEARS

Inspect differential
pinion mate thrust faces
case

However

the drive

for

cracks

or

cross

threads

on

dif

ALIGNMENT Of RIIG GEAR TO OIH CASE

At the stage when the ring gear is assembled witb differential


assembly the alignment of the ring gear should be tested

onto
case with side bearings and ring gear
its
the
carrier
Rest
on
the gear
place by strik
complete assembly
of
the
dial indica
hammer
Place
the
soft
metal
leg
ing li tly by
and
rotate
the
onto
surface
of
the
ring
gear
tor
the
ring gear

Place

the differential

If the fluctuation of dial gauge reading is


0 003 in
the ring gear and differential
or

more

than 0 016

case

should be

mm

repaired

replaced together

3 7 GEAR TOOTH CONTACT PATTERN


carrier
It is very important that tooth contact be tested before
Allowable variations in the carrier or rear
assembly is installed
out even when shimmed
pinion may cause pinion to be too far in or
Thus
tooth contact must be tested and corrected as

correctly

This test may be performed


necessary or the gears may be noisy
mounted
in the
the
carrier
holding fixture
follows
with
assembly
as
and paint
clean the ring gear and drive p1n10n teetb
with red lead and oil of suitable con istency
gear teeth lightly
contact
a
pattern

Thoroughly
ring
to

produce

162

small

end

above the

The

large

the

toe

pitch

line is

pitch

teeth is

called the

referred to

As to the

paragraph

end of the teeth is called the


heel
and the
Also
the top of the tootb
which is the part
line
is called the
face
while the part below the

tooth

8S

flank

The

between the meshed

space

back 1 ash

contact

pattern and its

remedies

refer to

the

FRONT AXLE

ASSEMBLE OJ FFERENTI AL GEAR


AND CARRI ER ASSEMBLY
4

1 ASSEMBLE DiffERENTIAL GEAR


Place

the pinion mat s and side gea s in the differential


gear
Every parts should be cleaned and oiled with new gear oil

case

then

the pinion mates

assembled
mates

by

the

shaft into

and

thrust washers

should be

and selection before

pushing

mates

should be made

Inspection

the

pinion

in the clearance of back lash

again

Strike the

pinion

shaft

that

locking pin into the differential case


opposite side of drive gear and
fixed by setting well
and by striking around the hole of it
the pin should not be loosen or come out

4 2

ASSEMBLE RING GEAR

from the rigbt side of


must be
so

side gears

inspection
the pinion

the

case

Fix the

ring gear with


the drive pinion

the differential

case
The ring gear
inspected or they must
he replaced as a set whenever the replacement is required
Other
wise
the proper tooth contact pattern would not be given after
assembling is completed
as

well

In
case

as

mounting in the
be thorougbly

must

washers

case

the fitting

surface of the gear


set screws and

cleaned and fixed with

and

lock

Bend the lock washers

should be set

and

not to

it and

fit

sbould be well

damage
correctly

supported by

it
In tigbtening up the screws
vice or a y other setting tools so as

screw up in a
with the head of thp

diagonal

line with

screw

The

to

at this time
que is 55 ftlbs to 65 ft lbs
ligbtly be striken by a quarter pound hammer

163

wrench which

standard
the

screw

screwing
head should

ASSEMBLE BEARINGS

4 3

Mount the

both side of

side

bearing

he bearings by

on

tbe differential

using

the drift

Press in the

case

by usipg suitable

or

press

4 4
drive

ASSEMBLE PINION TO CARRIER

Fit the bearing outer race to the gear carrier by


pinion front and rear outer race replacer

Refi t the
not

available

and 0 003

head

select

the shim from 0 030 in

repl

the

Fit the
and

machine
Fit

bearing outer

race

to

inner

race

rear

of th

fit the inner

race

the drive pinion to

oil

gradually
load

the

gear

carrier by

using

bearing to the pInIon shaft by


race replacer or suitable
the front bearing

of

the gear

carrier

to
at

seal
a

ani

pinion bearing
companion flange

and

sbim

ens

re

that

the gear carrier

tbe flange nut


180 ftlbs
checking

Tighten

torque wrench reading of 120

intervals to

to

it is

15

Kgcm

10

ADJUST DRIVE PINION HEIGHT

To

adjust

the

tion of the drive


service

tool

posi
pinion
4447
BT

drive pInIon alignment


is to be applied
gauge
The stanfard beigbt of
the drive
3

mm

pinion
in

is 82 55

from the

center of the carrier bear


Set both sides of

ing
the
to

13 0

If tbe pre load is too great


more shims must be added
small th
thickness of the shim must be decrease

4 6

the

or

0 005 in

rear

bearing iDn

Assemble the drive

if too

0 010 in

ADJUST PINION PRE lOAD

fit the

pre
in
lbs

shim is damaged

original

acer

using drive pinion

4 5

shim

the

in

Fit the front

the

if

pinion

using

alignment gauge closely


position of the

the

Drive

164

pinion alignment

gauge

and in ert the

bearing

feeler gauge between


extreme

bar

end of the

and the

pinion

The hi gilt of the

the

gauge
head

gauge

has been made 10 1 000


than the

inch less

gular
fore
the

provided
pinion head

re

There

dimention

that

mark

reads 0 and the gap


10 1 000 inch

measured

pinion can be
regarded as fixed at
the correct position
the

When it is necessary to
adjust the pinion height

pull

ut

and also

the drive

pinion

Measure

pinion height

pinion

rear

bearing outer

race

from
it

carrier and

the

by adding

apply

uk

Pinion

4 7

10

000

gauge with
that
12

inch

hight

ADJUST SlOE BEARING PRE LOAD AND BACK LASH

Place

ths differencial

case

side bearing cap


th
the
bearing
cap bolts with
up

Replace

12

example

shown

the feeler

thickness
is

For

shims

adjust

when the

adjust

reducing ths

or

assembly

gear carrier
the carrier
Tighten

onto the

of the carrier

on

tightening torque

165

80

90 ft lbs

Measureing

side bearing cap

distance

The differential
case

moved

assembly can be
by tightening or

backing off the side


bearing adjusting nut
At first

adju3t

the

back lash of drive


an 1 ring gear by
of moving
differential case to

pinion
meens

ward rignt

or

left bani

The back
necessary
lash should be in
as

0 008
006

inch

After correct

back

Adjusting

lash has been settled

nut

wrench

in another words the


correct

position

of

differential

side bearings should be

case

the pre load of


got
the side bearing caps in

has been

given by tightening

the pre load of the bearings


When the bearing adjust nut is turn in
the measuring surface of
distance
between
be
increased
and
the
will
the caps and
increased
Because
will
be
both
the
bearing cap
carri r will be deformed by the stress which is given by tightening

torque of the adjusting nut

166

Adjusting
The value of the pre
of the both

bearing

load

side

bearing

thus

can

nut

be measured

by

the

distance

caps

To give the correct pre load to the bearings


turn the both
bearings in evenly
The distance of the both cap
should be
262

85 262

90

mm

10

10 350 in
348

in diameter

5 ASSEMBLE REAR AXLE SHAFT AND


MOUNT TO CHASSI S
As to these
60 AND 660

operation

refer to

becuase the construction

with those models

167

the

paragraph BEAR
and operations are

AXLE MOreL
identical

30100
39320

151 6 1 140
11

II

tl

6
c

fjloDEl
E

Q
I

ly
S

66100
39322

lIEl

44300
43020

3010 3010
43216 4321

G80H

MODEL
AXLE
REAR

30100
38316

a
I

4 30 4383102
3810

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

OF

SERVICE
JOURNAL AND

BULLETIN

170

BRAKES
1

DESCRIPTION

AND

DATA

DESCRIPTION

The brakes

all

four wheels are hydraulically operated by foot


pedal application directly coupled to a master cylinder in which the
hydraulic pressure of the brake operating fluid is origined
A supply tank cast
integrally with the master cylinder provides a re
servoir by which the fluid is replenished
and a pipe line consisting
on

of tube

flexible hose

and connectors

cylinder

and

cylinders

the wheel

interconnect the master

The pressure generated in the master


cylinder by application
with the foot pedal ia transmitted with equal and undiminisbed force
to all

wheel

wards

which in turn

This moves the pistons out


cylinders simultaneously
expand the brake shoes thus producing automatic
equalisation and efficiency in dirct proportion to the effort sup
plied at the pedal
When the
sboes Which

fluid back into


An
or

the

mechanical

independent
the brake

external

in

springs return the


cylinder pistons a nd therefore
and master cylinder

shoes which

linkage

located

at

actuated

the

drum mounted at the

are

ensure

by

the

hand brake lever

center of the floor board

rear

end of

the transfer case

bend

contracting

The front brakes

ing

lines

pipe

parking brake lever

operates

by

is released the brake sboe

pedal

then return the wheel

of the two

leading

shoe

type

with slid

automatic centtralisation of the brake shoe

operation
The

cylinder

rear

and

brakes

sliding

are

of the leading

trailing type

with

sliding

sboes

Refer to the instruction drawing


of the brake piping
and of the pedal

171

of

the front

arrangement

and

rear

axle

1 2

DATA

Type

Hydraulic two leading shoe


leading trailing for rear

Pedal free movement

Drum di 8IIIeter

292

front

Lining

inner
and

3 4 in

lIt

mm

in

rear

material

Special

width

55 mm

length

302

mm

II 9 in

thickness

6 8

mm

0 268 in

Total friction

020

area

inside

cylinder

Master

for front

25 4

woven

16 in

I in

mm

diameter
Wheel

cylinder

inside

diameter

model 60 and 660

model

660 H

front

25 4

mm

I in

25 4

rear

25 4

mm

I in

28 57

I in

mm
mm

lj8in

Hand brake
external contracted brake

mechanical

type

band at the end of the tranafer


150

drum diameter

case

5 9 in

mm

lining
materi al

woven

length

220

width

45

thickness

6 3

friction

brake

I 77

in

2 47 in

cm2
0 8

o 7

drum and

8 69 in

mm

mm

198 5

area

Clearance between

5
mm

mm

0 028

0 032 in

lining

REPAIRING OF THE

BRAKES

2 1 MASTER CYLINDER
The master
with

polished

of the Nissan Patrol consists of


and reservoir with a cap
finished bore

cylinder

body
The inner

rod
piston stopper stopper lock
assembly is made up of the push
retainer and
ring
piston secondary cup
piston piston primary cup
of
the
cylinder
The open end
valve
and valve seat
of piston cup

172

001

CD

tI

ct
10

Q
g

iiii

w
j

11

ct

ct
W
CO
CO

ct

ct

CD

173

is protected

by

rubber dust

cover

REMOVE THE MASTER CYUlm


To

the master

cylinder from dash board take off the


penetrate the clevis pin at the end of pusb rod
Remove the clevis pin that connects the push rod and pedal
Back
the nut off that secure the master cylinder to the dash board
cotter

remove

pin

that

Care should be taken to check the thickness

of the shim which is

fitted between master

hoard

connect

cylinder

and the dash

the

piping from the master cylinder


cylinder assembly can be withdrawn from tbe
Remove
rubber dust

the

Dis

panel

Then tbe master


vehicle

filler cap and drain tbe fluid out


and remove the stopper lock with

cover

Pull back the


a

of

pair

long

removed
piston stopper
When
rod has been removed the piston with the secondary
tberefore remove the piston assemhly com
piston cup will be exposed
The
can
be
separated by lifting the secondary cup
plete
assembly
shouldered
of the piston
over
the
end
ring
nosed

The push rod and

pliers
the push

Give the shock


pressure tube

was

primary piston
will be

come

cup

out

sligbtly

connected
its

the

at the front

can

end of

the

body

using the wooden mullet

retainer

return

spring

be

valve

where the

Then the
and valve seat

gradually

Examine every parts carefully


especially the cups
and replace with new parts where necessary

for

wear

or

distortion

ASSEMBUIS THE BRAlE MASTER CYlIIDER

Replace th
Replace the valve seat at the bottom of tbe body
assembly so that the large end is correctly seated on tbe valve
Put the new primary piston cup on the piston return spring
seat
assureing the projection of the cup is centered in tbe hole of the
Replace the piston return spring and primary
piston return spring
Replace the primary cup retainer on the pri
cup into the cylinder

valve

mary

cup

Replace the secondary piston cup on the piston rear end with new
Put the
part
Replace the piston assembly into the cylinder
Re
tbe
and
the
into
cylinder
press
piston
stopper on tbe piston
the
the
and
fix
piston assembly
place the stopper lock pressing
coat the
If rubber grease of good quality is available
stopper
in order
it
with
before
assembling
primary and secondary piston cup
wall
the
and
cilinder
to get smooth sliding between
cups
Replace
of two nuts

the
on

push

rod

and dust

cover

Secure the unit

the flange and refit the pressure

cylinder

174

pipe

by

means

into the

Within the

ing hole
Put

car

in the

brake

line up the push rod fork with its corespond


pedal arm and push through tbe clevis pin

the cotter pin

hight

through the clevis pin hole


Adjust the pedal
free movement
pedal play by means of the follow

and

pedal
ing paragraph
If

further maintenance

no

must be remenbered to bleed

2 2
A

the brake system is neccesary

it

FRONT BRAKES
COIST RUCTlON
front

The
ed

to

the system

brakes

are

diametrically opposit
by means of

and connected

operated by

each
two

other

on

two wheel

situat

cylinders

the inside of the brake

pressure tube and connector

on

disc

the out

side
Each wheel
consists

of

cylinder
light al

loy body containing


piston
piston cup
spring

and

Each shoe
the

dust

cover

is located

slot of

one

in

wheel

cylinder and expanded by


the piston of the other
wi th the leading edges of
both shoes making initial
contact with the drum
The shoes
ed to

slide

and

are

allow

centrali

during the actual


braking operation which
distributes the braking
se

force

equally

lining

over

the

Front brake

lining

area

assembly

ensuring high efficiency and

even

wear

Adjustment for lin

by

wear

two

knurled snail

adjusters

means

each

TO cUP

operat

to

turn clock wise

pand

00
00
Front wheel

of

cam

peg at the
end
of each
actuating
Both adjusters
shoes

ing against

PISTO

PIS

is

ing

The brake
rest

cylinder
175

ex

the shoe s

on

inside

shoes

the seat

fixed

of the brake

disc

and

in

held

are

tbe

which pass from

position by

two

return

for

springs

the web to the bolt located

hole

eacb

shoe

the brake

on

disc

FIlTIIS REPLACEMENT BRAKE SHOES


Always

fit

Genuine

Nissan

the correct type of lining and


ensures a fast and easy bed in
Wben fitting

These have

replacement
accurstely ground to
a

size which

the drums
fit

shoes

replacement

as

Shoes
are

set

new

of shoe return

spri ngs
The following
should

present
i

ii

no

one

abutment
wheel

car

shoe

either

owner

and

remove

the

to

sequence

road wheels and brake

one

the

piston
it

slot of the other

simple

in

then re

cylinder

will be found

out

mechanic

or

out of the

slot of

lease from

carried

carefully

to

difficulty

Jack up the
drums
Lift

if

instructions

quite
the

remove

shoe return

springs
prevent the wheel
cylinder piston from
expanding it is advis
able to place a rubber
band round each cylinder
Repeat with the second
To

shoe

iii

Clean down the brake


disc

check wheel

cylinders

for

leaks and

freedom of motion

iv

adjusters for easy


working and turn back
Check

anti

clockwise

off

position

to

Remove

full

Smear the

tips

ends of the

Keep

all

new

and

drum

Lubri

cate where necessary with rubber


if available

the road wheel

of the rest the


shoes with

176

operating

rubber

grease off the linings

of

grease

on

grease
new

good quality

and abutment
of

good quality

replacement

shoes

and do not handle

CAUTION

more

Never

use

than necessary
tbe

ordinary

chassis

grease for the

brakes
vi

Fit the

new

springs

to

shoes

return
the

new

Place the

short hooked end


the

sprin g

the hole
and

wev

of

throu gh

in the shoe
the

long

to

the

on

the brake disc

end

bolt located

Each sboe

can

be re

placed independently
but it
to

is advisable
the upper

replace

shoe first
vii

Make

sure

the drums

clean and

are

from

grease

free
etc

then re fi t

viii

Adjust

the brakes

descirbed
ix

later

as

on

Re fit the road wheels


and lower the

car

to

Replacing

the return

the

ground
C

EXAMINATION OF THE WHEEL CYLINDER

The front wbeel

cylinder
by means
that

can

secure

tbe wheel

to

the brake

cylinder
disc
to

Do

remove

tube

be removed

of three nuts

from

cylinder

not forget
the pressure
the wheel

before

remove

the three nuts

Examine

all

parts

especially the cup of the


piston for wear or dis
tortion and
new

parts

replace

with

if necessary

Removeing

177

the pressure

tube

spring

To

be

the

sure

of the

spacer

cylinder is in correct posi


tion
then replace the wheel
cylinder

wheel

Do not confuse
wheel

the left

hand

and right hand

cylinder

one

Replacing

snail

the

separate
provided for
car

each

cam

until the wheel

lease both the hex


on

the out

adjuster

shoe

ed clear of the ground


bolts

to

Jack up
be

adjust

tben fully
head

re

adjuster

side of the di

turning anti clock wise with


ended

cylinder

AOJUmNG THE LINING CLEARANCE

is

the wheel

an

by

open

spanner
Turn

of the

one

adjuster

bolt

clockwise until the brake shoe con


cerned touches the brake drum then
release the
is

just

adjuster

free

the whole

until the shoe

of the drum

procedure

for

Repeat

the second

front wheel

It is
rear

brakes

advisable to
in

the

described latter

same

adjust
time

the
as

on

Adjusting

the brake lining


clearance

178

2 3

REAR BRAKES

DESCRIPTION

The
not

are

lowed

rear

shoes
al

are

slide and centra

to

lise with the


as

brake

fixed but

effect

same

in the front brakes

They are hydraulically


operated by a single
At the
wheel cylinder
cylinder end the leading
shoe

located in

is

in the

trailing

shoe

rests

slot formed in

body
end they

At

er

slot

while the

position

the
the

rest in

in

cylind
adjuster

slots

in

the adjuster links


Both

shoes

by dimples

are

brake disc and

position by

Rear brake

supported

assembly

formed in the
are

two

held in

springs

from

shoe to

shoe

of a light alloy die casting into


piston with cup in a hignly finished bore
Into the other end of the housing is machined a slot to carry the
The cylinder is attached to the brake disc by a
trailing shoe
spring clip allowing it to slide laterally

Tbe wheel

cylinder

the end of which

Adjustment

moves

consists

for lining

wear

is made

by

the brake

shoe

adjuster

Thi s has

steel

housing which is spi


goted and bolted firm
to

ly

the inside

brake disc

ing

two

carries

steel

of the

Tbe hous

links

opposed

the outer

end slotted to

carry
and the in

the shoes

clined inner faces

besring

inclined

on

faces of the hardened


steel

wedge

wedge has
threaded
Rear brake

shoe

adjuster

square

spanner to be used

for

179

The

finely
spindle with
end
enabling
a

asjustment

pur

I
j

which project on the outside


poses
the wedge in a clockwise direction
the

tbe brake

fulcrum of

When the brake

hydraulic

to

the

By rotating

brake disc

tbe links

are

forced apart

and

shoes expanded
the

applied

piston under the influence of the


body reacts by sliding on the

and the

shoe

moves

pressure

brake disc

is

of

the trailing sboe

operate

REFITTING REPLACEMEIIT BRAKE SHOES

Jack up the
drums

ii

Lift

one

car

remove

the

road wheels and brake

shoe out of the alots in the

of the

link and wheel

iii

and

adjuster

cylinder piston

Clean down the brake


disc

check wheel

cylinder

for

leaks

and freedom of motion

iv

Check

adjuster

for

easy working and turn


off
back until
Lubri

position
cate

where

sary

with rubber

of

ase
gre

good

qua

if available

lity
v

neces

tips of
dimples the
operating and abut

Smear

the

the

ment ends
new

of the

shoes with rubber

grease of

ty

good quali

Keep

all

grease

off

the linings

on

new

replacement

shoes

end do not handle

Removing

rear

brake

shoes

more

than necessary
vi

Fit the two


shoe to

from

Locate

one

piston

slots

its

vii

new

shoe return

shoe

and between

to the

new

shoes

shoe web and brake disc

adjuster link and wheel cylinder


then prise over the oposite shoe into the
position

shoe in

relative

springs

Make

sure the drums

then

re fit

the

are

180

clean and free from grease

etc

Fitting

two

return

viii

Adjust

ix

Re fi t the

the

springs

hrakes

as

Replacing
described later

road wheels anI lower the

the

shoes

on

car

to

tbe

ground

EXAMINATION OF THE WHEEl CYLINDER


The

rear

wheel

cylinder is
a spring

attached to the disc by

clip allowing it to slide lateral


After taking brake shoes off
ly
disconnect the pressure tube from
the wbeel cylinder
Take off the
of the wheel

spring clip

lide the shims


ed between wheel
out

Then

cylinder

off whicb

cylinder

are

fitt

and tbe

side of the brake disc


it

can

Examine

especially

he removed

all

the

parts carefully
cup for
and replace

piston

wear

and

distortion

with

new

parts

where necessary

When the wheel

cylinder

is

Taking off the spring clip


181

check the

replaced
brake

disc

fitting

face

of

so

that it

small quantity

of

if
cylinder
cylinder keep free

the wbeel

movement of wbeel

cylinder

Apply

slide

can

smoothly

on

the

necessary

to

grease

the

on

brake disc
be

sure

and

the

REMDVlIG OF ADJUSTER

attacbed by means of two nuts to the


adjuster take the clip off which secure
Remove the dust cover
the rubber dust cover of the adjuster
Back the nuts off that secure the adjuster to the brake disc
The

rear

brake adjuster is
To

brake disc

remove

the

Check every parts carefully


especially two
the
If
inclined faces of links
wedge for wear
thrnn with

replace

end

square

new

Replace wedge

parts

f the threaded spindle

steel links
and wed

with new

and the

are

part

if

worn

the

worn

ADJUSTMENT THE L1IIIG CLEARAICE


One

common

ment of both

adjuster is provided for

rear

wbeels is

both

shoes

and

the adjust

identical

Jack up the car until the wheel to be adjusted clear of the


ground then turn the square end of the adjuster on the out side of
each rear brake disc in clockwise direction until a resistance felt
Slacken two

clicks wben the drum should rotate

freely

Immediately after fitting


replacement aboes it is advis
able

to

slacken

one

click to allow for

further

possible

lining expansion reverting to


normal adjustment afterwards

Adjusting
182

the

rear

lining clearance

2 4

GENERAL MAINTENANCE

REPlENISHMENT OF HYDRAULIC FLUID

Inspect
about

the

supply

tank at

regular

intervals and maintain at


of brake fluid of good

three quarters full by the addition

quality
Great
vent dirt

care
or

should be exercised wheu

foreign

adding

brake

fluid

to pre

matter entering the system

BLEEDING THE HYDRAULIC SYSTEM

Bleeding is necessary any time a portion of the hydraulic


system has been disconnected or if the level of the brake fluid has
been allowed to fall so low that air has entered the master cylinder
With

topped
bleed

all

the

nipple

connections

hydraulic

secure

and

the

supply

ing the free end

of

remove

in

the tube

clean jar containing

little

brake fluid

Unscrew the bleed

about

nipple

three quarters of
operate the brake

pedal

full stroke until

the

fluid enter

completely

free of air

ing jar

is

bubbles
stroke
the

Then
of

screw

ball

turn and

during

dust

Under

slow

down

tighten
seat

bleed tube and

nipple

then

with

pedal
sufficiently to

CAUTION
must

he brake

remove

the bleed

the

replace

cap

no

circumstances

excessive force be used when

tightening

the blepd

screws

This process must now be re


peated for each bleed screw at
each of the three remaining brake
discs

finishing

at

nearest the master

the wheel

cylinder

Always keep a careful I check on


the supply tank during bleeding
since it is most important that
a

full level

tank

the rubber cap from the L H


rear
and fit the bleed tube over the bleed nipple
immers

up with the fluid

Bleeding

is maintained

183

the

system

Should air reach the master


whole

of the

bleeding operation

cylinder from tbe supply


be repeated

After bleeding

approximately
Never
for

use

top up the supply


three quarters full
the fluid that

bas

up the supply tank


tent aerated
Such fluid must

topping

twenty
in

Great
the

to

cleanliness

hydraulic system
Dirty fluid
It is advisable

as

off

is

and

its

just been bled

correct

from

level

brake

be allowed to

stand for

at

of

system
some

ex

least

This will allow the air

again

essential when dealing with any part of


especially so where the brake fluid is con

must

to

never

turn

before

position

the

disperse

cerned

full

tank to

this brake fluid may be to

as

four hours before it is used

the fluid time

tank

must

all

be added to the system


the brake

sboe

After

bleeding

adjusters

to

bleeding adjust

their
brakes

described

HElEBAL ADVICE
i

Always exercise extreme cleanliness


part of the hydraulic system

ii

Always
face

iii

take

of

Always

care

cylinder

scratch the
or

highly polished

no

should

account

contact

these

any

sur

pistons

cleaning internal parts

On

allowed to

iv

to

bores

clean brake fluid of excelent

use

alcohol for

system

not

when dealing with

quality or
hydraulic

of the

petrol

or

p raffin be

parts

Always examine all rubber cups carefully when overhaul


ing hydraulic system and replace with Genuine Nissan
Spares eny which show the least sign of wear or damage
Always use the rubber grease of excelent quality for
packing rubber boots and dust covers and lubricating
Never
parts likely to contact any rubber components
use
ordinal chassis grease nor bearing grease for these
purpose

vi

If it is

suspected

All Rubber Cups

cylinders

paraffin

changed after the components


thoroughly flushed and cleaned

must be

lines have been


alcohol

that incorrect fluid have been used


cylinder and wheel

in the master

or

clean brake

fluid

for this purpose

184

Never

use

and

pipe

out

with

petrol

or

If incorrect fluid has been in the system for


any
to replace the high pressure hoses

length

of

time

it is advisable

2 5

ADJUSTMENT OF CENTER BRAKE


center brake

The

of

emergency brake
ing band type
or

or

sometimes called

the Nissan Patrol

hand brake

is of the

parking

brake

ternal contract

The clearance bet


drum end

lining
adjusted by
means of anchor adjust
ing screw
adjusting nut
ween

should be

and bracket bolt


brake
o

7
o 032

lining
0 8

evenly

0 027

mm

in

The

IllUst have

clearance

on

drum

The upper half of


lining is adjusted by
the

nut

adjusting

lower half

and

of the lin

ing is adjusted by the


bracket

screw

Lock anchor

ing

screw

screw

by

by

adjust

the lock wire

means

and lock the

adjusting

nut and bracket

of lock nut
After

adjusting

brake lining cl earance

adjust

the

of

length

the lever rod

so

that

the bottom of the


can

be seated

bracket

DJUSTIN8

NUT

BRACKET

185

SOL

on

correctly

csm

the

Replace
ing

if

the lin

it is

cessively

or

worn

ex

hardened

Center brake

linkage

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

187

OF

SERVICE
JOURNAL AND
BULLETIN

SERVICE

NEWS

REFERENCE
NO

DATE

CONTENTS

OF

SERVICE
AND

JOURNAL

BULLETIN

188

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STEERING
DESCRIPTION

SYSTEM

AND DATA

1 1 DESCRIPTION
l

The

of the Nissan Patrol


sists

assembly

arm

gear

pitman

tie rod

tie

sacket and

steering dumper assembly

providing
steering
hi gh

both easy

on

trans

arm

drag link

verse

road

con

of the steering

gear

rod

steering system

the

iit

11

ttt 7
r

1ft

r
i

ift

rough

and

stability at
speeds driving

OR

rJ

fj

i lf

Tie rod

JJ

ift

t1

ROD

l
I

f
I

drag link and steering dumper

DATA

1 2
Type

teeth semi

wo

external mesh

hindlley

worm

Gear

23 6 to 1

ratio

Steering angle
inner

280

outer

25032

Cen ter di stance


Worm

gear

65

mm

559 in

bearing adj ust

shims
Thickness available

Roller shaft

adjust

o 762

in

one
one

for

o 254

mm

0 010 in

o 127

mm

0 005 in

one

0050

mm

0 002 in

three

1 6

torque

0 063 in

mm

0 25

shaft tulning

0 030

standard

snims

Thickness available

Worm

mm

mm

two

for

0 0099 in

one

o 125

mm

0 005 in

two

o 075

mm

0 003 in

four

o 15

0 25

kg

steering wheel
shaft

189

0 33

standard

0 55 lbs

rim without roller

at

0 8 Kg
0 66
1 76 lbs
at
assem
led
steering wheel rim after

o 3

completely
Back lash

worm

ani roller

0 1

with roller shaft

mm

pitman

arm

0 004

and at mid

in

end

at

of

position

wheel turns
Back lash must not to exceed 4
0 158 in

at

any

position

of

mm

wheel

turns
The difference of back lash between

right end and left end of the wheel


must not to
turns
006 in

exceed 1

5 mm

Torque wrench setting for


Pi tman

arm

15

nut

Flange bl lts
Housing cover bolts
Roller

shaft

cover

Housing bracket bolts

ft Ibs

18 ft
lbs

Kgm

2 5

bolte

110

m
Kg
5

m
Kg

18 ft Ibs
18 ftlbs

Kgm

9 Kgm

66 ft
lbs

Di smeter of ste ering wheel

410

16 Ii in

wbricant

o 5 1 tr

capasi ty

mm

0 132 U S

Gal

Steering dumper dumping


75 Kg at 0 3

force

m sec

GEAR ASSEMBLY

STEER NG

2 1 DESCRIPTION
steering gear used in the Nissan Patrol is of the two teeth

The

semi external mesh


two

row

of

needle

The sector

housing side and


lubrication

hindley

worm

type

shaft
one

The sector
The

roller bearings

roller rotates
ratio
is 23 6 to 1
gear

on

one in the
long bushings
having oil groove for adequate
taper roller bearing is mounted in the

rotates in two
in the

cover

The upper worm


assuring accurate

The worm shaft is align


aligllIl1ent
Shims are placed in bet
bushing
top by
for corect setting of
ween the steering column jacket and housing
Shims are also placed in between the lower cover
steering worm
and steering housing for worm bearing adjus1ment
gear

housing

ed at the

vinyls rubber

attachment

of

steering gear roller shaft is serrated for


of the
the steering wheel is serrated for attachment
the pitman arm
in
410
16
14
mm
The steering wheel is
worm and shaft
assemhly
The

190

in diameter

2 2

DISASSEMBLY

REMOVE PITMAI ARM

Remove

the nut

roller sector
shaft

assembly

aud lock washer that hold the

shaft

Pull the

asso

mbly

with

pitman

pitman

arm

arm

on

itable puller

REMOVE ROLLER SHAFT ASSEMBLY

Remove the four cap screws th t secure the roller shaft


the housing and remove the roller shaft cover and rubber
0
Slide the roller shaft assembly from the housing

Remove the four cap


to the housing
0

ring

screws

off the

that

the front

secure

Slide the front


and

worm

shaft

housing

housing

cover

shims

cover

assembly

top end of the worm and shaft assembly with mullet until
Remove the front bearing
bearing cup out of the housing

Remove the four cap


cup off the housjng
steering column jacket to the housing and
the

ring

the

Tap

and

puller

2 3

ring off
housing

the

housing

Slide

the

that

screws

slide
war

secure

the j cket

and shaft

the
shims

assembly

Remove the upper and lower bearing with suitable

if necessary

INSPECTIDN

Clean all

parts
ly in cleaning solvent
Replace a
thoroug
that
or
roller
shaft
cover
is
cracked
or damaged
housing assembly
worn
the
inner
and
outer
in
the
if
housing
Replace
bushings
larger
than 32 30

mm

Replace

272

in

inside diameter

roller shaft

assembly

that has flat

spots

on

the

has chipped roller


Replace roller shaft
end
roller
is
excessive
if
the
of
play
Replace the
assembly
1 255 in
roller shaft if the shaft measures less than 31 875 mm
roller surface

or

that

at the bearing surface


the

worm

a worn

Replace

to

REIOVE ST ERIIG GEAR WORM BEARIIG

the front

off

cover

REMOVE fROIT COVER

and shims
and

the

off the roller

is

excessively

pitted
a

broken

or
or

jacket that is bent

Replace the
ridged

worn

cracked

worm

horn

damaged
or damaged

wo

and

scored

upper and lower


wire
Replace

Replace

191

assembly if
Replace
chipped
bearing cup

shaft

or

the whole

steering column

assembly

if it

Replace upper and lower bearing if it is damaged or


domaged
worn
Replace a steering column jacket bushing that
eIcessively
is excessively worn or with domsged horn wire
is

ASSEMBLY

2 4

Al BEPUCE

IEW OIL SEAl

Ilrive the
into the

lip

of

new

housing

the oil

oil

seal

Coat the

seal with

grease

Oil seal fitting


b

PLACE UPPER

BEARING CUP

Drive the upper bearing cup in


to the housing with suitable driver

Fitting upper bearing cup

192

ASSEIIBLE COLDIII JAIIET TO THE HOUSIIS


Place the column jacket on the
0
to
ring
ring seat

housing wi th
and adjusting
thickness
of the
the

shims

of standard

As to the thickness

adjusting

shims

refer to

DATA

and paragraph
MENT OF WORM BEARING PRE
Care
of

should be taken in
0

the

paragraph

ring

secure

selecting

Refer to the

SELECTING

Tighten
that

ADJUST
LOAD

RING

the four cap screws


jacket to the

the

housing

Assembling
D

column jacket

ASSEMBLE BEARIISS TO THE WORM SHm


Press the upper and lower
bearings into the steering
column with

Pressing bearing in

193

press

E liSTAU WOHl
Slide the
shaft

AlII SHAfT ASSEMBLY II

worm

HOUSIIG

and

assembly
Drive the low
housing
er bearing
cup into the
Place the
0
housing
into the

ring

ring seat

adjusting

worm

shims of

stwndard thickness and


front housing
the housing
the four csp
secure

th9

cover

screws

cover

the housing

SHIMS

to

Tighten

is 2 5

18 ft
lbs

that

of these

ing torque
screws

on

Tighten

m
Kg

Driving

the front bearing cup

ADJUSTMEIT OF WORM BEARIIG PRE LOAD

To check the upper and lower


turn

bearing preload measure the


ing torque of the worm shaft

rifo

This

torqu

0 25

Kg

should

0 33

be in 0 15

0 55 Ibs

steering wheel rim


steering wheel three

at

Turn the
fonr times

or

before

measureing the torque


If not
adjuat the thickn sa of
the worm adjust shims so that the
turning torque is in above mention
ed value

decreasing

increasing

or

the numbers of the shims

During
ness of

this

operation

the thick

both upper and lower ahims


should be nearly the same as other
side

Measuring

of the turning torque

194

G IISTALL ROLLER

SHAn ASSEI BLJ

Install the roller


abaft

assembly into
housing with thrust

the

washer and roller shaft

adjust

of standard

shims

thickness
Install the roller
sbaft

cover

assembly

the housing wi th

Tighten
screws
cover

onto

ring

the four cap


that secure the

to

the housing

Torque wrench setting


is 2 5 Kgm
18 ft Ibs
Roller sbaft

Installing
H

roller shaft

CORRECTIOI WORM SHAn SETTlIG

worm

adjust

shims

cover

tE
u

Check the back lash of


the

and

Bad

III

and roller at ths

end of the

pitman

The

arm

back lash should be minimum


mid

posi

at the center

or

tion of wheel

turning

illustrated in the fi
with solid line and
have the

same

as
re

should

value in both
Left

195

Right

of

right and left end

turns

If the back lash has the two minimum


in figure with broken line
and

roller in axial

it

means

direction of

points

as

the relative

is not

shaft

worm

illustrated
of

position
correct

worm

In

gear by means of transfer


to
lower cover
or reversely
ing worm adjust shim from upper flange
Never change the total
until the correct alignment ca be got
this

adjust

case

thickness of the whole

I SELECTlIG
Care

of th

position

the

worm

shims

RIIG
in

should be used

of
upper and lower flange
oil leakage

selecting the 0 ring for the both


in order to prevent
steering housing

the

of worm gear is corrected


total thickness of the
the
paragraph
one by one
and seat of both side of the housing

After the
H

setting

measure

the suitable

ring accordIng

to gether at
Less than 1
1

2 7

one

ring

to

described in

worm

adjusting

Then

select

table

be used

Part number

44000
48035

0 106 in

0 106

mm

J ADJUST BACI

following
0

seat

side

0 075

the

0 075 in

mm

mm

than 2

More

shim and

thickness of

Total

to

as

44001
48035

in

standard

44002
48035

LASH

Turn the roller shaft

adjust

screw

clockwise

in

until the inside


screw

is

flange

screw

Then
off

LoOK

just

enough the roller shaft


can

RM

attached the end

of roller shaft
back the

PITMAN

of

be ratated

NUT

rSCREW
AO

smoothly

Check the back lash at the


end

of the

pitman

arm

The back lash should be in


0
0 004 in
o
0 1 mm
at mid

position

of the wheel
back lash
0 158 in

or

center

turns

more

than 4

No
mm

should be

allowed at any

position

of

Adjusting

196

the back lash

shims

wheel

turns

end

and

06 in

Also

1 eft end

Check the

of

the difference of the back lash between right


turns
should not to exceed 1 5 mm

the wheel

turning torque

of the

th
stage
torque should be in 0 3
the steering wheel rim

ll INSTALL PlTMAI
Install
the nut

th lt

assembly

shaft

0 8 Kg

to

th

arm

secure

the pitman

arm

to

operation

can

be worked

This
re

In this

again

0 66

76 lbs

at

ARM

pitman

110 ft lbs
is

worm

installed

roller shaft

Tightening torque

the roll

of

shaft is 15 Kg m
after the steering gear
er

chassis

on

l REPlElISH GEAR OIL


Replenish
ing

the

is 0 5 ltr

STEERI NG

U S

recommended

The

capacity

of

gear hous

Gal

DUMPER

The steering

steering dumper

oil

gear

0 132

system

between

of

drag

the Nissan Patrol


link and

is

the front

equipped

with

cross member of the

frame
du per is of the none adjustable
e should be necessary

The

type

therefore

no

further

maintenaJ1l

If the oil
founded

dumping force of the dumper is


m
sec
replace it to assure the
to keep comfortable feeling on steer

is founded

less than 75 Kg at 0 3
in high speeds drive

stability
ing wheel
wheel

leakage

or

to relieve the kick back from

and to

prevent

the

happening

of

197

rough road

shimmy

to

the

steering

4 RE1l GHTEN

STEERI NG

LI NKAGE

BOLTS AND NUTS

It is
on

the

strorrgly recommended to retighten every


steering system after the vehicle have done

OOO miles

with suggested torque wrench settings

198

bolt

and nut

first 3 000 Km

SERVICE

NEWS

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DATE

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199

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NEWS

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6510

60
0
0

27

MODEL

4854

ASEMBLY

CD

GEAR

STERING
16120
9

3080 4 0 0

48405 4839

WHEELS
I NFLATI ON

AND

TIRES

PRESSURES

Maintaining the correct inflation pressures is one of the most


important elements of tire care
The inflation pressure recommend
ed for the Nissan Patrol is carefully worked out as the hest
pressure
to give an efficient balance of the following factors of good car
performance comfortable ride stability steering ease even tread
wear
tire cord life and immunity from blowouts
It is recommended that tires in ordinary use he checked for
pro
This will result in added tire life as
per pressure once each week
2 pounds pressure will normally be lost in a week of
ordinary driving
Cars

at

operated

high speeds

TESTING
The

plained

in

or

should have the tire checked

than

more

at more

relatively simple

The

are
car

causing

the noise

should be driven

speeds and note taken of the effect of part throttle

ous

celeration

and deceleration

haust noises

on

the noise condition

as

at

constant

of

speeds

Tire noise

approximately twenty

The tire noise may be further checked


pavements or dirt roads not gravel

pressure
again
heen inflated to fifty

over

test is being made

is

the

ssme

pounds

caused

stretch

is

sudden

ac

axle and

ex

however

thirty

by driving

of road when

while
most

miles per hour

the

with the tires

smooth

and

or

com

at vari

show definite variations under these conditions

tire noise wilt remain

pronounced

service

severe

intervals

FOR TIRE NOISE

determination of whether tires


of is

ordinary

frequent

car over

at

normal

the tires have

If the noise for which the


pressure
it
tires
will
by
noticeably decrease

when the tire pressure is increased


whereas
rear axle noise should
show no change in volume 8S a result of changes in tire pressure
If
be

on

creating

inspection
most

should be checked
pressure

as

incorrect

CORRECTI ON

Since
tain

places

irregular
on

the tires

of the noise

on

the

the front wheels

alignment

are

of the front

found to
wheels

excessive tire noise result from low tire

alignment

or

from

uneven

tire

wear

OF IRREGULAR TI RE WEAR

tire

tire to

wear

wear

due

more

to

some

action which

than others

201

the

causes

remedy

is

cer

However
after
naturally to correct the condition causing wear
adjusting have been made it is wise to interchange the tires to
equalize the future normal wear which will occur

the

Tires may be alternated several ways to even up irregular wear


the following method is the simplest and
in most cases
the

However
most

satisfactory
Wheels
to

front

spare

the left

should be

rear

changed without dismounting the tires right


to right rear
and
right rear to left front

spare
to

front

right

TI RE BALANCE
Original equipment tires and tubes are marked at
light portion of the casing is counterbalanced by

the

source

the

that

so

heavy

por

tion of tube

irregularities in tread wear caused by sudden brake app


low inflation pressure
or tube a d casing
misalignment
repairs a casing and tube assembly can lose its original balance
If a disturbance is felt in the steering wheel due to the action of
Due to

lications

the front wheels

the first items to check

halance of

Wheel balance is
wheel

and tire

are

pressures and the

and wheel

the tire

assembly
equal distribution

the

around the

assembly

axis

ways in which every wheel must be balanced

of the

of the weight

There

of rotation

statically

are

two

and

dynamically

4 1 STATIC BALANCE
static
of

axis

is the equal
balance
and tire assembly about the
that the assembly has no ten

sometimes called

balance

distribution of the weight


rotation in such

of

still

the wheel

manner

itself until the

bottom

For examp
position
always rotate by
Any wheel with a heavy

side

balcne

Static unbalance of

dency

to

le

A wheel with

ratate

by

itself
a

heavy side at the


staticaly out of
hopping or pounding

like this is

wheel

causes

quently

leads to wheel

4 2

balance

the wheel IllUst be in

speeds

flutter and

on

of its

the rim will

which fre
up and down
often to wheel
tramp

action

quite

DYNAMIC BALANCE

Dynamic

tire

regardless

chunk of dirt

on

an

and is

axis

sometimes called running balance


static balance and

which

runs

perpendicular

through

the

also

run

smoothly

at

that
all

center line of the wheel

to the axis of rotation

202

means

To

explain

and
the

principle of dynamic balance let us first consider what happens


we swing a weight attached to a string
If we start to swing
this weight slowly it is apparent that the weight swings in a sharp

when

angle with reference to the axis of rotation the hand


speed is increases the weight climbs until the weight

right angles
principle to

to
a

the axis

spinning

of rotation

Now

let

us

If the
mass

is

this

apply

wheel

By referring to the
figure shown right hand
it
a

can

be

wheel

seen

that when

and tire

assembly
the

is in static balance
sum

of the

of

weight

equal

sections A and B is
the

to

of the weight

sum

of sections

C and D

in other words

weight

is

or

the

equally

die

stributed about the axis


of rotation

figure
a

is

This

drawing

of

CID
I

wheel that is in sta

tic

balance bec811se the

shaded

heavy point B is
by the shaded
heavy point C
balanced

However
tion A is

it

can

be

lighter

seen

Wheel in etatic balance


that with reference

than section

to the center line

and that section D is

sec

than

lighter

section C
When

start to

we

spin this wheel


the figure left

as

in

the

center line of the

weight
angles

just
the

on

tried to

angles

at

right

to the axis of

rotation

weight

B and C

masses

tries to get

the

string
right

at

get

axis of

to its

rotation

as

the hand

tendency to get at
right angles exerts a
This

force

on

the wheel

shown

by

the

This ferce
tends to
er

Wheel in Static and

Dynamic

Balance

203

as

arrows

in

move

turn
the cent

line of the wheel

and

in

so

distorts the axis of rotation

doing

turned

When the wheel has


sections B and C

move

the forces

exerted

the center line of


the wheel

In other words

by

the

the wheel

heavy
in the

tries to rock first

then in the other

direction

one

tend to

direction

opposite
in

now

1800

The result of the movement of these unbalanceed forces causes


and the condition becomes more violent
or ahilllDlY

the wheel to wobble


with increased

speeds

sections A and D
we must add weight to
Notice
sections
B
end
C
to
the
of
weight
equal
they
that this addition of weight now distributes the total weight evenly
about both the axis of rotation and the center of the wheel as seen
correct this consition

To

will be

so

in

figure

wheel

is

both

now

Bteering
notlceabIe
Tbe wlieeh
be balanced
we

must De
To

will

use

Before the wheel

aBsembly

placed

or

3
4

straightened

OYIAMIC BALAICE 01 THE

The wheel

and

of

over

being

dynamic

the wheel

is balanced

The tires

forign matter

before

balanced

demonstrate the balancing of

a nmout

this

Therefore

at

combination static

be clean and free from all


Bent wheela that have

C and D

dynamically balanced to give


BpeedS where unbalance becomeB
jjtati cal ly balanced before they can

Btabili ty

dynamically

and

statically

and

ease

dynamically

and

statically

Wheel must be both


miximnm

assembly

parte

with shaded four

3 16

abould

wheel

wheel

balancer

and tire must

should be tube
either be

re

balanced

ISSAI PATROL

of the Nissan Patrol is balanced at the fac


wheel
wear of the tire or run out of the

assembly

due to the

However
it may be cansed to lose the wheel balance

tory

It is recollllllended

to check the balance

naturallY
both static and

dynamic

periodically
wheel
which is used in order to balance the
20
0
35
oz
gr
must be in various Bize such as 10 gr
In uaing thsse various kind of counter
and so on
will be balanced better
wheel

The counter

aSBsmbly
0 70

oz

weights

weight

88sembly

5 TIRES AVAILABLE

ON

THE

NISSAN

JL
PA1H

5 1 SIZE OF WHEEL
The wheel diBc of the NiBsan Patrol

204

is of the

pressed

steel disc

The

type

thickness of the steel

rim is 4 50E

available

an

5 2

16

optional

is 4 5

plate

The wheel to

The

mm

which the wheel cap

be fixed

is

part

TIRE SIZE AND INFLATED PRESSURE

For the Iiissan Patrol

Model

Tire

the

following

tires

are

available

Air pressure

Size

front

60

aize of the

can

Front

660

6 50 16 6PR

660H

60 660

G60H

Front

6 50 16 6PRLT

Rear

6 50

Front 7

Xg cm2
in2
Ibs

2 1

22

Xgcm2

4 2

1 1

Rear

8PRLT
16

00 16 6PRLT

rear

in2

t24

lbs

1 2

Kg cm2

Rear

18 Ibs

Xg cm2

30 Ibs

Kg

60 lba
1 5

in2

in2

in2

Xgcm2

22 Ibs

in2

REMARKS
1

In the

case

of

Xg cm2

save

It is

and for the

should be I 7

pressure
2

36 Ibs

the fuel

But

The
base

the

use

in2

the tire

for Front
wear

660H

the tire 7 00 166FRLT for

and

440 lbs

is model 60

means

the

one

sandy

of the vehicle is limit

carrying capacity

standard model
one

24 Ibs

60 and 660

drive

for Rear to minimize tire

ed not to exceed 200 Kg


3

long

Xgcm2

in2

distance

comsumption

recommended to

area

the Iiissan Patrol Model

using

with full load

maximum
660

means

the

for the heavy

long
duty

wheel
with

long

wheel base

5 3

TIRE PATTERNS

It is very important to select the correct tire patterns for the


in which the vehicle is used
If the grip tire for mud

conditions
and

snow

type

is used for the

air pressure
it may
excessive tire noise

cause

driving

the irre

On the contract

way and with low


of the tire tread and

high

if the tire with passenger


road such as on the mnd and

type

pattern

snow

road

it is obvious that the traction force in

on

the

the

wear

tread

saficient

is used

on

lar

rough

enough

205

the mud is not

Therefore
various

type

strongly

the Nissan Patrol has been provided to be used with

of the tire shown in

recommended to

tire which is

fitted

on

driving condition or
following table gives

the

following

table

It is

tire pattern
if the pattern of the
the vehicle is not auitable for the local

chsnge

if the local

condition is

various

patterns

tire

The

chsnged

available

on

tbe Niessn

Patrol

TYPE OF

TIBE SIZE

FOR

TREAD PATTERN

The vehicle used

on

6 50

6PR
16

the rough

road
Snow

Mud

PARTS NO

42100
43300
tire

grip

and

Standard for
60 GIlO 1
60
and LGIlO

43301
40310

type
6 50 166PR

lug

tire

Standard for
model

GIlOB

and LG60B
front

Standard for
6 50 16

Ie
C

BDIAlIKS

8PRLT

lug

OOOB

42200
43300

model

tire

and LOOOB
rear

On and off

type

For the vehicle


used

rough

on

Optional
6 liO

6PR
16

44002
40310

the

road

and

parts

for

model

60 GIlO

and LOOO

60
1

hi gh way

Ie

The vehicle used 6 liO 16 6PR


on

the hi

aJl

44000
40310

way

Opti onal
parts for
model

6 50 166PR

44300
40310

light

truck tire

60 000

and L660

60
1

Optional
parts

for

model

660B

and LOOOB
front
6 50 16
8PRLT

it
I

44300
43310

light
truck tire

Optional
parts

for

model

G60B

and LOOOB

rear

7 00 16
6PRLT

44200
40310

liaM
truck tire

Optional
parts
used

206

for

all model
in

ssn

such

dy

area

sa

desert

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208

BODY
1

AND

FRAME

BODY

TARPAULIN BOW ASSEMBLY

The

body of the Nissan Patrol is usualy delivered from factory


packsd tarpaulin and tarpaulin bow
Following steps should be
taken to assemble tarpaulin and its bow to the
body

wi th

PLACE WIIDSHIELD GLASS FRAME ASSEMBLY

Mount front windshield onto the

cowl

Fix windshield
assembly
to
the
cowl
with three
assembly
spring washers and cap screws
Rubber shim should be inserted
between

hinge plate

and

of

panel

cowl
In

case

of above mentioned

should be ueed
to check that the bottom surface
of the windshield frame is cor

operation

rectly

care

seated

on

the rubber

strip

shown in the fi gun


Both
part A and B should contact to
as

the rubber

strip firmly to pre


coming into the
inside
This fitting position
can be adjusted by means of adjust
ing the relative position of wind
vent the water

shield frame and


shown in figure

its

hinges

as

It is also

posible to adjust the relative


position of the hinges and cowl
aS8embly according to the same method

Replacing

windshield

II
209

Before
connect th

fixing

the inside hooks

wire of the

the hole

wiper

motor

the cowl

and

check the sag of the wire


fix the wind shield by means

Then

through

on

of the

inaids hook

Adjusting
B

Place

Be

position

of windshield

PLACIIB 8W BOW AID REAR GUARD BARS


rear

bow and

bars to the channel

body

the

and

rear

rear

of the

guard

rear

end of the wheel

sure every junction


ahim in its position

QUARD

BAR

house

has rubber
REAR

Replacing
and

210

rear

rear

BOW

bow

guard bar

PLACE CENTER PILLAR SEAT BRACKET AID SEAT BACK SUPPORT

Place the center

pillar by

of five cap screws and


nut which secure the center

me8D3

pillar to
rear body

the top channel

Fit the
to

rear

of

eight cap

Install

of the

seat back support

and wheel house

the channel

means

one

by

screws

the seat bracket

on

the wheel house

FRo n BOW

iZ
CANTf

IL

center

Replacing
i
C

fO

ir
rl

etc

PLACE CAITRAIL AID FROIIT BOW

fl

ll
n

IJ

Ii

II

Paste two
the cantrail

Ri ght

screws

by

on

the

means

the

pillar

ani

pillar

bow

secure

four bolts and nuts

of two

and Ieft si de

Place the front


center

er

Replacing

seat

front end of the cantrail to

rubber
then fix

windshield frame

pillar

to

on

the

with

the cent

secureing the

rear

end of the rail together

cantrail and front bow

PLACE FRDIIT CEllTER BOW AID THREE CEIlTER BOWS

Place front center bow between windshield frame and the center
Place three center bows between front bow and
of the front bow
Another two bows should be placed when the side curtain
rear bow
is

installed

curtain

on

stopper

the vehicle

bscause

they

acting the center bow

211

as

are

well

designed

as

the upper

ENTER
BOW

REAR

BOW

CANTRA IL
RONT
BOW

Tarpaulin

The rubber

bows

shims

mDst be inserted bet


ween

front
each

center bow and


or

rear

junction

illustrated in

bow at
as

figure

Junction

212

of bows

CURT
IN
STOPpeR

uppeR
FRONT

LOWER

CURTAIN

Side

view

aFlACKE

B A

GuARD

STOPPER

of

BRACKET

bows

tarpaulin

REMARK
The front

1 2

guard bar is available

as

FITTIIG TARPAULII

FlTTIIS SIDE CURTAil

Insert the center bow into the upper


as a upper stopper of the cu tain

part of the curtain


during operation l

ie left

Secure both end of the bow to front and

plain

washere

spring

washers

Insert the lower curtain


tain

nuts

stopper

washers

bow

with bolts

nuts

shims

into the bottom of the


to

which

front

stopper
spring washers

and

rear

cur

bow with

and rubber shims

FlTTlIS TARPAIU

Fit the
the

plain

rear

and rubber

Fix the lower curtain

bolts

optional parts

top

top

end of curtain

of the windehield

the groove which is welded


hand

Fix the curtain with


the snape

and

frame
on

into

the groove which is welded on


Fit the side of the curtain into

the cantrail

side curtain

cl8l1lps

213

and

Right

rear

hand and left

curtain

by

means

of

1 3
I

FRDIT DOOR

FROIT DOOR FmllG

The front door


onto door
cap

of Nissan Patrol

hinge pillar

screws

8S

Each

illustrated in

hinge
figure

is

installed with two

is

secured

by

means

i
I

l
1

fi

rI

v
r
u

i
I

r
I

I l

Front door

left hand

214

11

hinges

of four

FBOIT OOOB REIOVIIG


The front door

of the

Nissan Patrol is of the


detachable

body

as

an

type from
assembly

also the door

sash

the
and
or

can
upper part of door
be divided from door

asssmbly
In order to

remove

door

assembly from the


body following eteps
should be taken

of front door
i

Remove the door


check link from door

ii

Back the

door

screws

off which

secure

hinges

the

to door

illustrated in

as

fill11re
Then

door

can

be

removed
To

remove

the door

sash

assembly from door


following steps should
be taken

Back the two cap screws


B
off that
to the front end of the door

ii

Back two
door

iii

iv

off that

secure

the door

the door

sash

sash to the

panel

Back two
the

screws

secure

rear

D
off that
cap screws
end of the door panel

Rai3e the door

sash up

as

215

an

secure

assembly

the door

sash to

ADJUrflEIT OF THE OOOB ClEABUCE

Whenever the door


the

adjustment

is installed

of the door clearance

is necessary

Adjust
at

the front

the door

frBDl8

rear

and

assembly

Insert

ween

evenly
top part of

the clearance

adjust shim bet


body IIIOUDting bracket and
some

if necessary

Door clearance

216

1 4

HOOD ADJUSTMEIl

The two

quired
adjust

on

adjustments

the hood

the relative

hood lock dovetail

are

One

position
and its

re

is to
of

female

in order to close hood

properly
adjustment is doue by means
loosing the screws that secure

This
of

the hood lock dovetail and


female

to the hood

radiator shell
dovetail

end its

its
and

panel
moving

end of

the

female

adjustment is to
evenly between
the hood panel and cowl assembly
and fender
This operation can
be worked by changing thl relative
position of hood panel and its
hinges and aho by changing the
relative position of hood hinges
and cowl assembly
Another

make the clearance

Hood support and hood lock


dovetail

Hood

hinge

217

FENDER AND RAD TOR SHEll

1 5

Those

such

parts

as

rigbt and left fendere


hood ledges
and radiator
ehell

are

bolted

firmly

each other and to the


Therefore
cowl assembly
it is very easy to remove
radiator shell or fender
if necessary

Followiag pictures
show the bolts and
screws

parts

that secure

cap
thoee

esch other

218

q
Q

t
h
I

Ir

III

it
r

E or

1i

COWL

ASSE

IJL

l
f

Underneath the felider

1 8

INSTRUMENT PANEL

The instrument

panel

or

cluster lid

of the Nissan Patrol is

provided with removing


easily as il

very

lustrated in the follow

ing picture cluster


and glove bOI are in
stalled by means of
the set
cromed

screws

lid

which is

beautifully

Cluster lid and

219

glove

bOI

It

Inside of the instrument

panel

1 7 BODY MOUIfTIS
The

body assembly

Niss8D Patrol

of the

is mounted with five

point of each side of the body


Every mounting bracket is provided
wi th the duck bel t and the eteel
if necessary
Following pictures show the mount
ing brackets undeneath the tloor

adjusting

shims

MOUNTlN9

BRACKETS

Underneath the front

220

part

of the

body

Underneath

the

rear

part

of

the

body

2 FRAME
The frame of the Nissan Patrol
and of the box

sively high

section

becau

able to have

type

of its

construction

and separable
struction drawing of frame

simple

is of the all

The rigidness

Therefore

construction

221

welded ladder

of the frame is
the

typs

excee

body

is

Refer to the in

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222

0
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