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this case is summary about NISSAN’S REVIVED DATSUN—THE MODEL T FOR THE TWENTY-FIRST CENTURY?”Full description
SERVICE MANUAL NISSAN PATROL MODEL
60 SERIES
INISSAN
NISSAN MOTOR CO TOKYO
P
N
99999
20017
JAPAN
L TD
GROUP
SERVICE
INDEX
MANUAL lritle
NISSAN
f
e
PATROL
1
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
s
care
description specifications
hrief
and overhanl of the NissM Patrol Model 60 This Manual
shoul be
kept
in
a
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
0
r
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
6
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
m
at 50 km hr
1
I
r RillE Model
P
Cylinder number and arrangement Cycle Valve arrangement
4
Bore
86 7
I
stroke
6 1
lOll
Total
pieton displacement Compression ratio MaI power rpa i torque rpn Ma Length I width I
height
kg
without
I
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
I
I
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
k
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
1
4
hp
CLUTCH Dry single plate type
Type Operating system Facing Dimeneion
Me chani c al
275
I0Il
175
x
3
5
mm
TRANSMISSION Three forward
Type
speeds and one synchromesh on 2nd water protect gear top
EXPLANATION to the paragraph lEiWEEN MOIEL 60 AND G60H
Refer
4
rear
OF DIPFEHENCES
2
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
3
GENERAL
LUBRICATION
3 1 UNIT CAPACIT IES 6 7 Itr
1
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
5
r 3 2
ENGINE LUBRICATION
Proper selection of the oil formance
A
reliability
to be used will add much to the per long life of the engine
economy and
Oil PRESSURE GAUSE When
starting
a
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
B
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
C
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
a
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
6
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
7
r water in the cooling
eystem
until it reaches
a
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
8
8
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
a
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
9
r of corrosion
type
avoided
This is
condition which
a
but it may be reduced to
a
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
J
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
a
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
M
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
a
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
8
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
a
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
a
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
a
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
a
a
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
a
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
a
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
t
lease
90 Marfok No O or I
Gulflex A
Marl ok
Gulflex
No 0
A
RetiIlca
5
Castra lease
H
Gllflex
No
Heavy
F
Under
10
900
Over
900
C
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
A
Viscosity which is recommended for various temperature
Temperature
Engine
UBiversal
Gear po lube 90
C
No 2 Oil
Moltipar
Uniioint
Wheel Grease
Castrol
90 E P
No 2 No O Chas8 i 8 Mobile
Joint
HP
Snecial
x
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
I
ft
I NSTRUCTI ON
LUBRICATION
CHASSIS
I
I
I
Descrip t ion
A
Engine
il
B
Water
pump
C
Starter
D
Distr buter
LubricatioD
efiJI
d
Lubricant
6 7Itr
Generator feed 2 3
motor
Water pump
drops of
motor
i1
C g
Clutch
elease
yoke shaft drain
light
lubricate
pedal
I
E
Transmission
F
T
G
Propeller shaft lubricate joints
H
Knuckle
I
Tie roo
J
Front
d
2
efill
I motor
ebassis
lubricate Itr
E
0 0 0
iI
0 0
gruse
I
ur
0 0
chassis grease
bearing grease
aange bearing lubricate lubricate d
dill
od of
chassis
rod
xle differential 1
rain
sear
grease
K
Drag link lubricate joint
L
Spring
M
Steering gear box Air cleaner
2
Radiator
3
Sattery
drain
0 0
0
iI
chassis
greue
shaclde
I
0
ch
21tr
check
d
level
gear
iI
efill
0 0 0 0
I
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
i
0 0 0
0 grease
lubricate shaft
od brake
g
I
motor
bearings lubricate slight
Clutch
00
Fluid
duin
E
ndition
ofter than
15
must
bovementioned
water
0
r SERVICE
NEWS
REFERENCE NO
DATE
CONTENTS
OF
SERVICE
JOURNAL
AND
BULLETIN
16
EXPLANATION DIFFERENCES
OF
BETWEEN
MODELS OF
60
VARIOUS
SERIES
I
EXPLANATION OF MODEL NUMBERS
1
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
I
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
L
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
K
and
the head of model numbers D indicate the type of body
letters F
on
such 8 e means
W
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
D
W
the seat
means
K
the meanS
r
MAJOR
2
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
a
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
j
in in in in in in 0 5
O 0H
SPECIFATON
3
44
1
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
8
mm
in in in in in 5
0
4 4
1
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
3
4
66 78 98 64 55
8
Kg
Ibe
29
160
7
8
0
000
in
in
lb
person
9
MPH
750
feet
75 or
one
KPH
per
120
2
8
20 m
625
2
o
6
Kg
person
9
400 or on
fe d
75
20
KPH
per 8
MPH
120
2
m
625
2
o
6
feet 6
47
145m
degre degre 47 47
fe tJ 9
45
140m
degre degre 47 47
JOR MA
in in in in in
5
OF
5 0
60
LIST
148 66
6
4
1
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
I
GrOBS 0 I
Distrbuon
Kg
person 7
6
400 or
perone
feet
75
18
KPH 120
2
625 0
m 6 5
fe tJ 9
46
d140m egre degre 47 47
right left angle
Q
CAPITY
Sin
CARGO
SEATING
MPH
PERFOMANC
abilty radius diatnce turn epe d grade turni g stop ing KPH over 50
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
I
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
f
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
2
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
3
85060 38424
and
44460 38424
are
provided
for select
aseembly
4
45460 38426
and
44000 38426
are
provided
for
assembly
5
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
a
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
7
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
r
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
P
are
2
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
1
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
I
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
1
A
secure
Then
ae
cOlDlectione the radiator
lift off the
assembly
an
c
c
c
t t
u
i I
t l
1
I
L
z I
t
m
l
J
jA
r
r
4 PO
i
f
J
r I
1
r
i
L r
v
L r
L
b
J
OJ C7 O 1
c
Removing
2 6
Disconnect the
l
t
I
J i
C
radiator shell
primary
t
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
3
Clutch Control
4
T F Case Lever
5
T F Case Lever
6
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
a
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
1
1
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
I
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
x
2
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
1
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
a
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
v
at the In thoee
seme
in
climbing
check up to find
cases
hill
and
a
detestable
smell
time out
if these conditions exist in
the clutch
i
No
H
Broken
or
iU
Uneven
wear or
iv
Worn
v
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
i
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
B
POOR DISElGAGEMEIT OF CLUTCH
This will
when
happen
i
There is
H
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
v
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
i
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
A
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
C
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
D
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
j
t I
4
Check of clutch Disc warpage
6
1
Release Lever
2
Lock Not
3
Adjusting
4
Release Yoke Pin
Nut
5
Release Lever Yoke
6
Release Yoke Roller
7
Needle
8
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
E
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
G
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
5
a
as
The
more
crack
or
than 1 8
pressure difference of more than from other springs should be re
pounds placed with
to
of
a
a
10
ject
will have
spring length difference
free
7 i
a
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
t
i
and compress of 39 7 I0Il 1 9 16
a
f I Ii r
tr r 0
i t
f r Jit
4
ja
W
fl
0
t
@v
l
k
h
If i i t yf
y
ir
that they have proper free length of which difference most be within 1 8 inch
itl
l
flj J
r
l
@n
1
q
7
i
r
t
r
r
ri
J
1l
p
it J
J or
Bf I
1
t k M
6
f 3 14 F tqt
r
ffi i
J
If l
i1i sr2J
0
1
U
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
4
J t
h
P
r
t
i r
c
t f f s t
Measurement of Release Lever
If all
the foregoing
and if the thickness
The than 0 2
J
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
a
other lever
should not to exceed
more
in
CHECI CLUTCH RELEASE BEARING AID SLEEVE
First
thoroughly
clean and
give
a
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
a
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
a
it is
however
usually
euch
a
done
by
the
use
of
device is not at hand
a
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
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
I
Gear tooth number Main drive gear Main shaft 2nd gear
gear bearing Main drive shaft rear bearing Counter shaft front Counter abaft Oil
I0Il
Inner dia
c
rear
bearing bearing
80
X
4O
x
18
80
x
35
x
21
52
x
25
x
15
62
x
25
x
17
2 Itr
apaei ty
type type
NU205 6305ZR
0 52 U S Gal
5
F t
j
1
l
t
b
0
J0 1
q
c
illJ
r
1
J
Oc
N
J
G
j
j
IR
y
O
7 i
kf
Z o
i
0
t v
c
Y o
r
i
ir
t
i
i
Constructive diagr8111 of Transmission
46
3
Gear train of transmission
1
Main drive gear
2
2nd and
3
MaIn
4
Main
5
Main drive
6
Reverse
idler
7
Counter
rever
8
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
4
2
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
c
p
screws
and
one
to transmission
2 2
REMOVE GEARSHIFT COVER the six
to the transmission
2 3
c
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
a
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
3
aEANI NG
3 1
CLEANING
Wash all trace of
old
parte thorougPly to
prevent
3 2
INSPECTION AND REPAIR
A
TRANSMISSION CASE ASSEMBLY
Inspect
the
any kind
B
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
C
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
E
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
a
fine
stone
SECORD GEAR BUSHIRG REPLACEMEIIT
F
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
G
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
J
gear
press the mm
bushing buabing in
in
an arbor press out of the gear
gear to 19073
Use
with a
I0Il
U 7509
a
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
u
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
0
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
M
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
4
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
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
B
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
C
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
0
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
E
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
J
J20
9 2
F 1
1
IfI
60
MODE
AS EMB
Y
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
a
2
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
I
1
Main
2
gear Counter shaft
3
Counter shaft
4
Front drive ehaft
5
Front
6
Hi gh 11 low
7
Front drive
sleeve
8
Front drive
ehift rod
9
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
5
Front bearing
67
High
Front drive
sleeve
8
Front
shift rod
9
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
1
000
low
2
264
Combined gear ratio with tranemission T mission ratio T fer case position let
2 900
2nd
1
3rd
562
1 000
4 015
Rev
Combined gear ratio
low
6 564
1
high
2
900
3
low
3 535
2
high
1 562
5
low
2
264
4
high
1 000
6
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
3
0 1528 for counter
3 43
gear
x
outer dia
x
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
2
REMOVAL FROM VEHICLE 2 1
REMOVE PROPELLER SHAFT
Disconnect
he front
and
propeller
rear
shaft at the transfer
case
2
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
a
that
screws
transfer
jack
under the transfer
secure
case
the transfer
etraight
of the transfer
3
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
i 0
1
6
st I
l
J
1r
R
r
i
j
qf
i
j
l
LJ
1
1
h
IJ
1
1
1
I
r 0
II
J
p
g J J
j I
o Remove
H
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
3
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
3
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
B
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
v
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
C
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
D
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
a
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
F
HIGH AID lOW SPEED DRIVE SHIFTER FORI ASSEMBLY
Check the fork for
stripped
set
screw threads
G
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
a
oil
new
seal and drive the
new
78
eeal
use
a
driver the
seal in the bearing retainer
5
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
0
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
0
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
a
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
a
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
a
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
a
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
6
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
6
Raise the
transfer
transmission transfer
Place
case
forward
the transfer
secures
62
a
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
F
Under
100
100
C
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
I
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BULLETIN
86
Z
t1F
9S
26
0 4
2
H
p05l1 tON u
r
HtGt QW
CASE LC
H
LC l1G 9001
0
GH
LC
l
G
tlGH
I
I
t
1 5
562
R
GE
1M
O
2
1
LO O
0 4
A
nd
lei
2
3
60
MO E
AS ENlB
L E
V
G
3EGTION
CASE
TRANSFER B
t
5EGTI
PROPELLER
SHAFT
UNIVERSAL 1
AND
DESCRIPTION
AND
JOINTS
DATA
1 DESCRIPTION
1
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
A
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
x
45
x
38
mm
Rear
457
x
45
x
38
mm
x
x
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
I
2
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
B
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
a
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
c
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
4
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
a
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
5
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
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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
I
ASEMBLY
6
56 m 457m
K
OF
LINE
CENT R BOTH 397
86161 861 0 86161 301 0 85460
PLANE
MUST SAME
BEARINGS
THE ON
5 442
5
7219 72 0 3721 71 1 37 I
I
507 5mm
5mm 52
87 6
7
4 0 4 0 4 30 4 50
7
BE
h
321 212
L
K
h 6
L
SHAFT
PROEL
MODEL
SIDE
TO
65
MODEL
G60H G60
60
NO
0
PARTS 37 0 37 0 37 0 1
2
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
x
1
x
1
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
I
63
GOOD
Telescopic
STABlLIZEIl
2
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
a
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
a
end of the front
bond
rubber
steel
tube and is molded end
bushing quire no lubrication
a
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
a
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
a
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
3
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
4
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
I
f
CONNECTING
100
ROD
Front stabilizer
5
FRONT REBOUND The front rsbound
ween
rail is
front
axle and
of the fr8llle
designsd
so
as
V
I 0
l
II
0
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
6
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
a
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
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REFERENCE NO
DATE
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100
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JOURNAL AND BULLETIN
r o
1 I
0
J 1 o o z o
iii z 1 Q II
w
0
0
t
B
II
I
tj I
I
FRCNT
II 1
n
I Z
o a b
CJ Z
j
c a
o
I 1
z
o
j o RANC
a l
II Z
of
r T
l
62
1
E 9
44JI J f f m 55m
1
1rIA
I
50tt c4S
I
FE
OUT SI lE RFAR FRONT DE
Elf
n J Indl
ARFFI
IlUBI3EB
NOT TO
i
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
3
Caster Driving method
1030 Bypoid
Gear ratio
4 I
0 12
IIID 4
0 16 in
bevel gear
I
I
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
2
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
7
5
cm
217 ft lbs 9 0 kg
m
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
e
flange
g
V
g
I
@
end
shaft parts
OQOO
L
e I
I
00
0
1 Front
axle differential gear
103
parts
REMOVAL
2
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
m
Steering dumper Drag link
4
Stabilizer
5
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
i
ule shaft and the
SS
portion of ths joint out ths housing
inner
universal of
Front axle shaft
106
i
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
a
BElOVE BIIB BUB FBOI CISE
8
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
o
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
4
I
i r
t4iiS
i
l
d
fir
I
I
r
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
A
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
i
106
r
40524
44000
LINE
I
I
J cS H
PRESS
BU
ING
d C o
b
i
Ul D
J
IUl
lJ
Housing end bushing
109
IN
Rear exle
B
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
0
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
1
J
J
I
0j
I
i 7 Icr
t
lj J
1
i
r
J
7
I
t
l
s
J
i
V
I
1
1 f
b
J V
i X
Replacing
new
112
oil
f i seal
filijiO M
J
l
j
AXLE HOUSII
E
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
0
a
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
L
ft @ o
o
o o
o
o o
I
m J
Shock absorber
5
Stabilizer
Front
6
Tie rod
7
Drag link Steering dumper
le
Knuckle
housing flange
8
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
a
ths
the size of the stud to be removed
must leave
a
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
l
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
2
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
O
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
i
below
Part Ho
Thickness
Pcs
HOTE
Humbsrs of pcs showes for I unit
38129
42100
008
6
not
for
one
side of
housing 38130
42100
o 13
8
38131
42100
o 25
4
38132
42100
o 76
2
Table
58
I
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
a
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
a
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
m
r
5 11
CHECK RING GEAR RUN OUT
Install
a
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
a
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
2
on
ut should not exceed 0 0025 inch If the than 0 0025 inch remove the from the dif ring gear
chips
tial
I
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
f
t
t
o
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
0
ring
on
r
I
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
8
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
2
mm
16
0
16 1
16 1 16 2
16
2 16 3
16 3 16
4
16 416
SHDI PART NO 44000 40605
0
44000 40606
0 0711
I
1
2
1
1
2
2
1
2
3
4
127
mm
Total
Lower bearing cap Standard shim thickness See the instruction drawing of
front
128
axle
lsembly al
5
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
w
on
the
ment the
Install the lock washer and ears
of the
be within 15
lock washers 45 kg cm
I
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
e
flange
dri
34 1
e
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
a
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
a
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
2
steering dumper Drag link
3
Tie rod
Ii
4
Stabilizer
5
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
7
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
L
r
L
I
c
I
l
l 1
lLt
Adjusting 138
toe
in
l
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
I
fI
NUT
0 I
OILS
OF
8
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
I
CAUTION
I
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
NG
m
I
BEAR MUST UP WHE L GREAS L ED
rolNL
k I
J
Iv
FI
6 6
N5I
n
ASEMBLY
Q
0
9
CARIE
OOlr
S
K
44J 4 tfJ 44 lJO 4 tW 460 4 tm
ii 3
ff
4ttm IlJJ tJ tJ 5t 15
YRIO J JJI4O w JIM Y21 JJ425 3tIl3 JJ1Z4
GOOI
THI GET
O
H
THE
ADJUST
HIM
tl
0 51 IBmm 0
H
441 il11J f4tW JtJ 31 IZ 45
l3 O
M
1
5 1
J
Ib
65ft
TORQ 155
GEAR
m
TIGHEN 44WI 5
405
lJ 4l1
ltrJ
90 5
4lltrJ 4 ZIJZ5 11M OJI 4l6IJ 71 m 24 JIJIJ
JJJI
5JIj4 aJIJ 4546f 4J5414flJ J1jJ
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
x
Width
for Model
7
ben loaded
5
70
x
Model
x
1
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
2
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
7
Jilumber Span
x
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
a
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
a
A
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
r
it from
freezing by corrosion
n n o
Rear
00 00
0
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
e
is
loaded
correctly
or
not
check the buffer
torque arrester and main leaf of the 13
mm
0
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
I
Tighten nut up
2
Back
3
shackles
rear
should be tightened up
by
the
method
tight
as
off the nut
a
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
m
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
0
I
CONNECTING
1000
0
8
0
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
5
be
done at least every 10 000 Km
6
is found
000 miles
TORQUE ARRESTER
The ers on
Nissan Patrol
its bottom face
is
equipped
with
of the side rail
a
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
z
o
in z IaJ D
1
8
4 70
I
o CHASS I
t
f
w
o
q
I
eto fO
92
o
0
ff
f J
f
II
a
501114
4
c IaJ a
I
l
o or
z
REAR SPRI N
L
c a
j
c z
o
i o J a
f z
4 I
I
QlJ U Q 4 X2Q
5635u
1 qc 1 1
222
009
00 1044 4 44QJQ 1235 TH
BEASE
REAR EYE
I
LJ
REAR 1
AXLE MODEL
DESCRI PTI ON
1
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
4
I
in
bevel gear I
Number of teeth
Ring gear
41
Drive
10
pinion
Rear axle
shaft bearing
Type Out
roller
Taper Dia
x
Inn
dia
80
Width End
play of rear axIs shaft Torque wrench setting Axle shaft bearing
x
40
o 05
x
I
mm
0 002
0 006 in
157 ft lbs
1 52 0
cage bolt
20
0 15
12 K
lock nut
Bearing
JIS 30208
x
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
2
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
a
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
3
D1SASSMBLY
3
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
c
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
r
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
L
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
a
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
a
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
L
fRAhl
FRON
TY9E NOVrl lit l Ulll
R
Al IA
50
60
F
ASEMBLY AXLE REAR
CS
I
MODEL i
L
RtiA y
I
1
l
Bf J
tflHU
OOS 0 06 f lIl
JilW
t
SEAT
TREAO J4o spRING 1010
05
Lti 1
TO
1
F
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
I
1 2
DATA
Type Driving
Semi method
floating type bevel gear
Hypoid
Gear ratio
4
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
o
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
a
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
x
55
x
26 75
mm
0 66 US
3 937
x
1053 in End
play
of
ins
setting
rear
axle shaft
0 050 10 mm
158
0
Q 004 in 002
gal
2 165
x
of
Thickness
adjusting
shims
0 030
in
o 010 in o 005 o
2
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
3
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
4
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
a
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
r
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
1
15
Kgcm
10
4
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
5
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
m
uk
Pinion
4 7
1
10
000
2
2
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
o
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
1
30100 39320
151 6 1 140 11
II
t
tl
6 c
fjloDEl E
Q I
ly S
66100 39322
R
lIEl
44300 43020
3010 3010 43216 4321
G80H
MODEL AXLE REAR
I
30100 38316
a I
4 30 4383102 3810
SERVICE
NEWS
REFERENCE NO
DATE
CONTENTS
OF
SERVICE JOURNAL AND
BULLETIN
170
BRAKES 1
DESCRIPTION
1
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
a
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
I
1 2
DATA
Type
Hydraulic two leading shoe leading trailing for rear
Pedal free movement
t
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
2
c
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
1
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
2
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
a
polished
of the Nissan Patrol consists of and reservoir with a cap finished bore
cylinder
a
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
J
j
001
b
z
o
o
CD
0
tI
ct 10
Q g
j
Z
iiii
w j
11
ct
G
ct W CO CO
Q
r
ct
F
Z
4
ct
8
CD
173
is protected
A
by
rubber dust
a
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
B
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
a
loy body containing piston piston cup spring
and
Each shoe the
dust
a
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
o
by
wear
two
knurled snail
adjusters
means
each
TO cUP
operat
a
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
0
The brake rest
0
cylinder 175
ex
the shoe s
on
inside
shoes
the seat
fixed
of the brake
I
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
B
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
a
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
v
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
A
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
n
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
0
is
the wheel
an
by
c
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
A
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
a
slot
while the
position
the the
rest in
in
a
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
a
for lining
wear
is made
by
the brake
shoe
adjuster
Thi s has
a
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
a
square
a
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
B
is
of
the trailing sboe
operate
REFITTING REPLACEMEIIT BRAKE SHOES
i
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
C
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
I
check the
replaced brake
disc
fitting
face
of
so
that it
small quantity
of
if cylinder cylinder keep free
the wbeel
movement of wbeel
D
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
E
o
new
Replace wedge
parts
f the threaded spindle
steel links and wed
with new
and the
e
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
A
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
B
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
a
clean jar containing
a
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
a
dust
Under
a
slow
down
tighten seat
bleed tube and
nipple
then
with
pedal sufficiently to
CAUTION must
a
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
a
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
C
HElEBAL ADVICE i
Always exercise extreme cleanliness part of the hydraulic system
ii
Always face
iii
take
of
Always
care
cylinder
v
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
e
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
T
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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MUST
CLEARN DRUM
STEERING DESCRIPTION
1
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
l
trans
arm
drag link
verse
road
E
con
of the steering
gear
rod
r
steering system
the
6
h
K
f
iit
11
ttt 7 r
J
C
u
1ft
r i
1
l
I
i
ift
rough
and
stability at speeds driving
OR
i
rJ
l
fj
r
J
i lf
j
Tie rod
JJ
l
ift
t1
ROD
l I
r
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
2
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
I
0 8 Kg 0 66 1 76 lbs at assem led steering wheel rim after
o 3
completely Back lash
worm
ani roller
o
0 1
with roller shaft
mm
pitman
arm
0
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
2
2
Housing bracket bolts
5
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
2
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
A
REMOVE PITMAI ARM
Remove
the nut
roller sector shaft
assembly
B
aud lock washer that hold the
shaft
Pull the
asso
mbly
with
a
pitman
pitman
arm
arm
on
itable puller
s
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
C
Remove the four cap to the housing 0
0
ring
screws
off the
that
0
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
1
mm
Replace
a
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
a
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
C
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
0
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
a
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
0
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
F
that
of these
ing torque screws
on
Tighten
m Kg
Driving
the front bearing cup
ADJUSTMEIT OF WORM BEARIIG PRE LOAD
t
To check the upper and lower turn
i
bearing preload measure the ing torque of the worm shaft
4
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
0
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
0
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
0
to gether at Less than 1 1
2 7
9
9
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
7
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
0
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
1
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
3
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
a
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
REFERENCE OF SERVICE JOURNAL AND BULLETIN
NO
DATE
CONTENTS
199
SERVICE
NEWS
REFERENCE NO
DATE
CONTENTS
OF
SERVICE
JOURNAL
AND
BULLETIN
200
0
6510
60 0 0
27
MODEL
4854
ASEMBLY
CD
GEAR
STERING 16120 9
3080 4 0 0
48405 4839
I
I
WHEELS I NFLATI ON
1
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
2
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
3
as
incorrect
CORRECTI ON
Since tain
places
irregular on
a
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
I
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
4
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
a
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
a
leads to wheel
4 2
balance
the wheel IllUst be in
speeds
flutter and
on
of its
the rim will
a
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
I
die
I
stributed about the axis of rotation
figure a
is
a
I
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
B
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
a
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
B
and
statically
and
ease
A
dynamically
and
statically
Wheel must be both miximnm
assembly
parte
with shaded four
3 16
abould
wheel
a
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
x
available
an
5 2
a
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
2
60 660
3
G60H
Front
6 50 16 6PRLT
Rear
6 50
Front 7
Xg cm2 in2 Ibs
2 1
22
7
Xgcm2
4 2
1 1
Rear
5
1
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
5
Xg cm2
save
It is
2
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
C
on
6 50
6PR 16
the rough
road Snow
C
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
C
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
I
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
I
Optional parts
for
model
G60B
and LOOOB
7
rear
7 00 16 6PRLT
44200 40310
liaM truck tire
Optional parts used
206
for
all model in
ssn
such
dy
area
sa
desert
SERVICE
NEWS
REFERENCE NO
DATE
CONTENTS
207
OF
SERVICE
JOURNAL AND BULLETIN
SERVICE
NEWS
REFERENCE NO
DATE
CONTENTS
OF SERVICE
JOURNAL AND
BULLETIN
208
BODY 1
AND
FRAME
BODY
1
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
A
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
C
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
p
FRo n BOW
iZ CANTf
IL
center
Replacing i C
fO
ir rl
D
etc
PLACE CAITRAIL AID FROIIT BOW
t
fl
ll n
IJ
Ii
g
II
Paste two the cantrail
I
I
D
l
Ri ght
screws
by
on
the
means
the
pillar
ani
pillar
bow
secure
four bolts and nuts
j
of two
and Ieft si de
Place the front center
er
Replacing
seat
front end of the cantrail to
l
S
rubber then fix
windshield frame
1
1
E
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
I
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
a
FITTIIG TARPAULII
A
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
8
nuts
stopper
washers
bow
with bolts
l
E
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
I
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
l
i I
e
l 1
fi
I
L
1
rI
v r u
I
i I
r I
l
I
I l
J
Front door
left hand
214
11
hinges
of four
B
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
A
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
i
Back the two cap screws B off that to the front end of the door
ii
Back two door
iii
iv
C
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
C
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
I
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
Y
t h I
Ir
III
it r
0
V
E or
1i
i
COWL
ASSE
IJL
l
l f
1
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
