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Download Service Manual Nissan Patrol Model 60 Series
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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 reverse and type TIM Gear ratio AnI 2 900 1 High 1 562 1 1 3rd 1 000 1 Reverse 3 015 1 speed 1st 2nd Oil Range Trans Low 2 264 1 capacity Transmission capacity Auxiliary transmission 2 1 0 52 U S Itr gal 3 4 Itr 0 90 U S Type Steel bar and steel tube Universal Spicer type Oil gal PROPELLER SHAFT joint REAR AIlE Semi floating 41T IOT Type Gear ratio 4 10 Drive Hypoid Oil 1 2 Itr system capaei ty bevel gear 0 32 U S STEERING SYST EM Gear mechanism Worm Gear ratio 23 6 1 and roller 280 Stearing angle inside 25032 outside FROIT AIlE Type Tracta Toe in 3 Camber 1030 1030 7030 Caster Knuckle flange inclination 3 joint type 4I0Il gal r BRAKE SYSTEM Type Foot internal expansion Hydraulic brake 2 hoes type Drum dia 11 Band brake Mechanical 5 external clamping type 5 Drum dia 9 in SPRING AID SHOCK ABSORBERS Front Parallel spri ngs semi elliptic leaf springs Dimension Rear and number of leaves x 70 I 6 1100 x 60 I 6 Omm l Parallel springs 3 5I0Il 1100 semi elliptic leaf eprings 1300 Dimeneions and number of leaves Shock 70 x 7 I 5 I0Il 5 absorbers double Telescopic Type front Torsion bar Stabilizer acting rear type front and rear FRAME Pressed steel bOI eection Type ladder all type parte welded WHEElS Steel di Type ec TIRES Type Front 6 50 16 6P Rear 6 50 16 6P MBI load distance long driving Air pressurl P TO device CAUTION in Front 22 Ibs sq Rear 30 Ibs sq in optional Power to front 24 Ibs sq in 36 Ibs in c enter sq or 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 Muim Muim Minmu Brake Muimwn at SlIr oal 0 8 rrh 1 W J a w z w o yo t i 0 0 J w Cl 0 I I l 11 Ny 0il6 I N6 I sz 11 II ill Il 0 0 I I I r 069 SO 20 ffi 4A I cl g 21 1 rO rll SL coS a 1 5 Q g lfz6 1 c Clo fJ Zr 22 COMPARISON LIST OF MAJOR CHASSIS BETWEEN MODEL 60 AND G60H PARTS PARTS NllMlIER PARTS NAME 60 G60H 44000 32700 44300 32700 44000 32701 44000 32701 44000 32703 44300 32703 lilT 1 Set Gear pinion speedometer speedometer 5 teeth Pinion drive epeedometer Gear l4T 44000 37320 44300 37320 SetPropeller shaft with joint rear 3730044000 44300 37300 4301044000 43010 44300 43068 32200 30100 43068 38212 1300 38212 95960 43081 32201 43081 30100 32201 43083 30100 43083 40227 32200 44000 38164 30100 43223 44300 38164 32000 43217 4321632200 44000 38175 30100 43217 4321630100 44300 38175 44000 43070 38440 25660 38441 25660 Ass y Prop Complete seal eeal rear Cage bearing Bolt serration Oil seal Rear Spacer 50000 40211 Taper aIle rear aIle aIle rear bearing R B grease catcher rear aIle rear 30100 43070 aIle rear shaft Grease catcher Shaft rear aIle aIle ehaft Packing rear Housing oil Spacer Oil shaft aIle bearing bearing rear tapar roller bearing rear 25660 38442 4021450000 Cup 44000 40207 43207 30100 Brake drum 44000 44010 4401044300 Brake disc ass y R H Brake disc ass y L H Wheel 44000 44100 1 44001 44100 41124 30100 30101 41124 31400 44135 44126 31400 44300 44100 axle shaft roller Cone 44300 44023 axle taper roller bearing rear cylinder ass y rear ase y rear 44301 44112 cylinder for tropiC Cup wheel cyl Cup wheel cyl 30100 44135 Boot 1 1 axle L H 40213 50000 44000 44023 rear 8 44301 44100 44300 44112 44126 30100 Wheel Spring boot 23 rear tropic cylinder rear wheel cyl wheel lock rear rear for r PARTS NllMBEB PARTS NAME 60 G60H 44000 38300 2 44000 38310 44000 38420 40000 38423 3 44300 38300 Ase y 30100 38310 Ass y Gear carrier 30100 38421 Case 3842330100 38424 85060 38424 30100 Gear carrier gear differencial Side diff bevel gear Thruet washar diff side gear or 44460 38424 4 40000 38425 30100 38425 45460 38426 30100 38426 Pinion mate Washer diff thrust pinion mate or 85060 38426 44000 38427 38427 None 30100 30100 38430 None 30100 38431 None 0100 3842 44000 38101 44300 38101 44000 38102 3810230100 Shaft pinion Block thrust mate Spacer thrust block Pin pinion mate ehaft Gear drive hypoid 41T lock 44000 38103 30100 38103 44000 38112 44300 38112 drive gear drive gear bolt Pinion drive hypoid lOT 30100 38120 Bearing 4021550000 Bolt Lock washer drive 42100 38129 lone pinion pinion adjusting Shim drive pinion adjusting Shim drive pinion adjueting Shim drive pinion adjusting Shim bearing adjusting pinion Shim pinion bearing adjusting Shim pinion bearing adjusting Shim pinion bearing adjusting Spacer drive pinion bearing oil seal Spacer pinion Oil seal drive pinion Flange companion Washer plain drive pinion not Nut drive pinion differencial case Side bearing Nut adjust diff caee nim adjueting diff side 42100 38130 None Shim 42100 38131 None Shim 42100 38132 None 30100 38153 45460 38127 60 3812 45460 38133 45460 38144 30100 38154 3815530100 30100 38156 45460 39127 45460 38154 45460 38155 45460 38128 45460 38155 None 45460 38133 45460 38134 44000 38163 30901 38163 44000 38191 38189 44000 30100 38191 44000 38210 38215 44000 44000 38216 42101 38440 None 3ll901 38189 38211 30901 3821530901 3821530901 40211 50000 30100 38316 Shim drive bearing adjueting diff side diff eide diff side bearing adjusting bearing Shim adjusting bearing 24 PARTS NUMlIER PARTS NAME 60 GlIOB None 5 30100 38319 Finger lock diU adju 44000 40513 None Cover 44000 40515 1I0ne Gasket cover 30100 38320 Gasket gear carrier 43027 4100 Drain 1I0ne 31112 9 41400 40535 38322 4321944000 44000 43220 44000 43221 43069 plug Ventilator plug Shim rear le case end Shim rear BJle case end Shim rear aIle case end Shim rear aIle case end 4308430100 Nut rear 30100 43069 Washer 44000 54010 44300 54010 Front 44000 54011 44300 54011 54012 44000 44300 54012 44000 54013 II one 44300 54013 44300 54014 None 44300 54015 55045 7200 44000 54026 55045 0900 None 44300 55010 Rear 44000 55011 44300 55011 Leaf 44000 55012 44300 55012 44000 55013 44300 55013 44000 55014 44300 55014 44300 55015 None 44300 55016 None 44300 55017 None 44300 55018 None 44300 55287 None 44300 55297 44000 55054 44300 55054 44000 55055 44300 55055 44000 55247 44300 55247 None 44300 55246 BJ aIle lock shaft rear 2 pce 44000 55240 1 bearing 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 clashing 1f c case f 1 f it 1 fMh t1CC i i H t i r there is in the former teet c z 6 Setting Adjusting Nut 43 no and the SERVICE NEWS REFERENCE NO DATE CONTENTS 44 OF SERVICE JOURNAL AND BULLETIN 4 20 8506 8506 X4 C 4 0 0 67512 151 5 3042 305 1 305 30540 3053 332 20 31842 1 248 278 46C 440 8 9 3 32014 I I 3 88 I 39 92 1248 27830 1 9 2 TIs 32 60 MODEL ASEMBLY 580 l C 12 86 CLUTCH 1 34 16 15418 4 Q 4 0 580 DRAWING INSTRUCO 4 0 151 7 1 314 0 530 55 t 1 145 1452 40 40 1 01 L r4 3052 305 2 99 2 32 03 32 01 32 04 44 53 4 0CXJ 524 0 91628 522 523 1541 1 34 3 4 3 21 9 J 63 438 1 I 24 23 9 9 9 33 40 1 5 I I 2 9 21732 Q25 01 1 205 I 5 9 1313 S S4 1 WTCI 8506 151 302 3 COVER Y ASS 3675 6 174 151 4 3 9 I 55 30 01 E ENGI TO TRANSMISSION 1 DESCRI PTI ON 1 AND DATA DESCRIPT ION ibe transmission is of the 3 speed type with synchronized s coLl The transmission and transfer caee as a unit gears is aesembled to the clutch housing ibe gearshift lever is in in corporated in the gearshift cover and high speed 1 2 DATA Type Gear ratio 1st 2nd 1 562 3rd 1 000 Rev 4 015 2nd and on meshed Synchro 3rd gear 2 900 I Gear tooth number Main drive gear Main shaft 2nd gear 21 Main shaft 1st gear Counter drive gear Counter 2nd gear 27 Counter 1st gear 18 Counter 13 Reverse 15 29 26 revers gear idler gear 15 Outer diameter of Reverse idler 18 979 shaft Back lash of varioue Pilot bearing Diameter Buehing x of main length gears shaft x number of main shaft 2nd o 075 0 125 Needle roller 30 x 28 31 975 1 2589 outer diamet 38 040 r 1 4976 Thiskness of thrust washer for 3 860 main shaft 2nd gear available 0 1520 3 910 0 1539 3 960 0 1559 play gear of main shaft 2nd I0Il 0 7480 in x 24 I0Il 0 03 bearing I0Il gear inner diameter End 19 000 0 7472 32 000 I0Il 1 2598 in 38 050 I0Il 1 4980 in 3 900 I0Il 0 1535 3 950 0 1555 4 000 0 003 45 in I0Il 0 1575 in speed o 067 in I0Il 0 133 I0Il 0 016 in 0 05 in Synchronizer spring Free 12 7 length 1 mm 2 in Outer diameter 6 7 mm 02638 in Wire diameter 0 8 I0Il 0 031 Tension 1 8 in 2 3 kg when 8 mm 0 315 in in length Locating ball of eynchronizer Outer diameter Bearings x 7144 outer dia x 0 2813 in width Main drive 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 the hub push the idle gear shaft into the hole and insert the set screw head and bend up the of the cap screw edge Alins the set caee with lock of the lock screw Bending up the lock plate of set 53 ecrew plate Tighten the plate against the hpx screw 4 2 liST ALL COUIfTER GEAR Lay toward 4 3 A the countershaft gear in the case with the the tront INSTALL MAIISHAFT ASSEMBLY SUBASSEMBLY SECOID GEAB 0 GCONO 6EAA BUSHINg Replacing o second gear bushing SECOND Replacing second gear 54 00 large gear SNAP Replacing RING o thrust wash3r Drive in the second gear bushing on the mainshaft with driver Insert the lock pin in the bushing hole suitable Slide the second speed gear onto the mainshaft with tapered end of the gear toward the front Slide in the thrust washer Three of thickness of washers are available for adjusting the end gear the main o 067 gear mm play shaft 0 0026 inch bushing to 0 locking rinj into the groove on gear must have an end play of from 133 mm 0 005 inch The eecond itself must have gear onto ward the front reverse 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 SERVICE NEWS REFERENCE NO DATE CONTENTS 85 OF SERVICE JOURNAL AND BULLETIN SERVICE NEWS REFERENCE NO DATE CONTENTS OF SERVICE JOURNAL AND 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 NEWS REFERENCE NO DATE CONTENTS 91 OF SERVICE JOURNAL AND BULLETI SERVICE DATE NEWS CONTENTS 92 REFERENCE OF SERVICE NO JOURNAL AND BULLETIN DIFERNTAL 397 r 60 REMAKS FOR FRONT REAR REAR REAR 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 SERVICE NEWS REFERENCE NO DATE CONTENTS 100 OF SERVICE 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 JI4 Ifj 4 Jl fBrNT fOB fiT ING Of 1 ETAIL I 4 QYJ rc lPlOW r KE9fl rS CI flJ1E L JfIY I J uv 46l160l 51a I ufI1J 63 4f I 64 46i AK HING J q l C oflA h 1 f4l6P215 fl45Z6 Wl 1145 tqf 9 fION FPI 1E a cl 1 r1r l t J 6l101 f 6l61 4fb1 il 4fJ fflUC INS 1 0 V l 1 1 46 5651 1 5116 146 f 91 46J u o cO Q S 1 Xl l a0 Jl ll G l JO 6 S Z od o ct it o em J C z 6 l L I J 0 J r 6 j 1 g i Xl 0 z 11 0 06 5 e i V @ O t 2 r I t o t t W G l z I 4 r wO RQIE m U 60 MODEL BRAKE 440iW n fJ j t1 04rJ I CENTR F UlJ1 S r f7 I I N9 l13 r I1I14 t Il PI 60 utfJ 6 N1J4 17465 J6IJ5 m 3 6 ANI JI pP J6 r INSTRUCO 1b11J1 fW 1 DRAWING r j liNI G TWE N Q03 1fl Q02B 07l1Rm RF EF 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 sively high section becau able to have e type of its construction and separable struction drawing of frame simple is of the all The rigidness Therefore construction 221 welded ladder of the frame is the typs excee body is Refer to the in SERVICE DATE NEWS CONTENTS REFERENCE NO OF SERVICE JOURNAL AND BULLETIN 222 0 44 05 963223 A 4 0 7287 A 72871 SECTIQN 60 E 41t 14 18 0 7286 0 4400 1 1 II 0 1 03 0 0 44 0 44 0 44 44 1 99 0 7281 0 7261 044 0 726 72613 72613 0 1 I i DRAWING I1I11III 0 44 0 I i I J 1II I1 I J I I WINDSHEL 0 1 1Q 4 I MODEL oQ 08 728 J 1 9 INSTRUCO 1 9 U 0 4400 4 AI AJ Ut I J Q J I i i 9 il o l CO I l J C o y o v l i
