Datsun F10 200SX B210 1976 77 Brake Repair Manual

DESCRIPTION

Brake system is hydraulically operated, utilizing a tandem master cylinder and a Master-Vac power brake unit. Front disc brakes consist of rotors attached to wheel hubs, and single cylinder, dual-piston, floating-calipers attached to steering knuckles. Rear brakes are leading-trailing shoe/drum type, using a single piston sliding wheel cylinder. Parking brake is cable actuated; operating wheel cylinders of rear brake assemblies.

ADJUSTMENT

PEDAL HEIGHT & FREE PLAY

F10 - Adjust pedal height to 6.8-7.0" (172-178 mm) by turning nut on master cylinder push rod. Adjust stop light switch so pedal just touches end of stop light switch; tighten lock nut. NOTE - Brake pedal should be checked for travel and smooth operation. Travel should be 5-5.25" (127-133 mm).

200SX - Adjust pedal height to about 6.9" (175.5 mm) using stop light switch. Lock switch in place with retaining nut. After pedal height is adjusted, loosen push rod lock nut and adjust pedal free play to .039-.118" (1-3 mm).

B210 - Adjust pedal height to specifications by moving stop lamp switch. Pedal height should be 6.14" (156 mm) on vehicles equipped with manual transmission and 6.22" (158 mm) on vehicles with automatic transmission. After pedal height is adjusted, loosen push rod lock nut and adjust pedal free play to .039-.197" (1-5 mm).

FRONT DISC BRAKE PADS

Front disc brakes are self-adjusting, therefore, no adjustment in service is required.

REAR BRAKE SHOES

F10 - Raise and support vehicle. Pump brake pedal several times to center brake shoes. Using a screwdriver, turn adjuster star until considerable drag is evident. Back off adjuster five or six notches and make sure drum rotates freely.

200SX - No adjustment required.

B210 - Raise and support vehicle. Using a suitable brake adjusting tool, tighten adjuster eccentric clockwise until brake shoe contacts drum. Return adjuster eccentric until shoe is slightly separated from drum. Check operation by turning drum and applying brakes; if shoe interferes with drum rotation, readjust.

PARKING BRAKE

With rear brakes properly adjusted, adjust parking brake cable turnbuckle until rear brakes are locked when parking brake lever is pulled to sixth or seventh ratchet stop. Release parking brake lever and ensure rear wheels turn freely and that all parts are returned to their original position.

COMBINATION VALVE

Function Test, All Models - Accelerate engine to 30 mph and rapidly apply brakes. If rear wheels lock before front wheels, malfunction of combination valve assembly (200SX & B210), or of separate proportioning valve (F10) is indicated.

Warning Light Operation & Reset, Except 200SX - 1) Instrument panel light will come on when a pressure difference of between 71-224 psi is evident between front and rear hydraulic systems. Combination valve  shuffle moves to side of low pressure and grounds electrical circuit, causing warning light to come on.

2) When hydraulic problem has been corrected and brakes have been bled, system should have 427 psi. Shuttle will then return to position and light will go out.

HYDRAULIC SYSTEM BLEEDING

Attach a bleed tube to bleeder screw and immerse opposite end of tube in a container partially filled with brake fluid. Pump brake pedal two or three times, keep pedal fully depressed, open bleeder screw and exhaust air, close bleeder screw, and return brake pedal. Repeat operation until air bubbles are no longer seen in discharged fluid. Repeat procedure on remaining brake lines. Bleed rear wheels first, then front wheels.

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS

Removal - Raise front of vehicle and support in place, then remove front wheels. Remove clips from retaining pins and pull out pins, coil springs and pad springs. Remove  pads from caliper assembly using a suitable pair of pliers.

Inspection - With friction pads removed, measure their thickness. Replace any pad that is worn to less than .063" (1.6 mm) in thickness (not including metal backing plate). It is recommended that friction pads be replaced as a set to prevent any possibility of uneven braking

NOTE - Replace all pads at same time.

Installation - Clean and apply P.B.C. grease (or equivalent) on yoke groove of cylinder body, sliding contact portions of yoke and end surface of piston. Loosen bleeder screw and push outer piston in cylinder until end surface of piston coincides with end surface of retaining ring on boot. Install inner brake pad. Push inner piston in cylinder by pulling on yoke, then install outer brake pad. After installing pads, depress brake pedal several times to seat pads.

FRONT DISC BRAKE CALIPER

Removal - Raise vehicle and suitable support on safety stands; remove tire and wheel. Remove brake friction pads as previously described. Disconnect brake line from wheel cylinder. To ease removal of caliper, remove strut assembly and knuckle arm mounting bolt. Withdraw caliper mounting bolt and separate it from strut assembly.

Installation - To install brake caliper assembly, reverse removal procedures, noting the following: Bleed hydraulic system.

FRONT DISC BRAKE ROTOR

Fig. 1 Exploded View of Datsun 200SX Rear
Brake Assembly

Removal - With caliper removed, remove hub dust cap, cotter pin and nut. Remove hub and rotor assembly with wheel bearing and washer in place. Remove bolts attaching rotor to wheel hub, and separate rotor from hub.

Installation - Reverse removal procedure, tighten rotor-to-hub bolts securely, and adjust wheel bearings. Use a dial indicator to measure rotor runout. Resurface rotor if runout exceeds .0047" (.12 mm) for 200SX & B210 or .006" (.15 mm) for F10.

REAR BRAKE ASSEMBLY

Removal (Rear) - Raise vehicle and suitable support on safety stands; remove tire and wheel. Loosen parking brake linkage at clevis pin and place out of way. Remove brake drum. Remove shoe retainer and return spring, then lift off shoe assembly. Disconnect brake line from wheel cylinder. If necessary, wheel cylinder can now be removed by taking out mounting bolt.

Inspecting - Inspect all brake components for damage or excessive wear and replace those found defective. Replace brake lining if it is oil soaked or lining is less than .059" (1.5 mm) thick.

Fig. 2 Exploded View of F10 and B210  Rear
Brake Assembly - 200SX Similar

Installation - To install rear brake lining, reverse removal procedures, noting the following:  Readjust shoe-to-drum clearance and, if necessary, bleed hydraulic system.

MASTER CYLINDER

Removal - Disconnect any electrical leads attached to cylinder reservoir. Disconnect front and rear brake lines from master cylinder outlet ports. On models equipped without power brakes, separate master cylinder push rod from pedal. Remove cylinder mounting nuts and slide unit off stud. Make sure brake fluid does not drop on point

NOTE - On F10 models, fluid reservoir can be removed attached to cylinder.

Installation - To install master cylinder, reverse removal procedures, noting the following: Bleed hydraulic system and check pedal height.

POWER BRAKE UNIT

Removal - Disconnect power unit push rod from brake pedal by removing clevis pin. Disconnect hydraulic lines from master cylinder and vacuum line from power unit, remove master cylinder attaching nuts, and remove master cylinder. Remove nuts attaching power unit to firewall, and remove power unit from engine compartment.

Installation - Reverse removal procedure, adjust brake pedal height, and bleed hydraulic system.

Check Valve Removal - Check valve is located in vacuum line between intake manifold and power unit on firewall. To remove, disconnect retaining clip from firewall, remove hose clamps, separate hoses from valve, and remove check valve. To install, reverse removal procedure.

OVERHAUL

Fig. 3 Exploded View of Front Disc Brake Caliper

FRONT DISC BRAKE CALIPER

Disassembly - With caliper removed, drain brake fluid and remove bleeder screw. Push both pistons into cylinder bore, then place yoke in a vise and tap the top of yoke lightly with a hammer to separate cylinder from yoke. Remove bias ring from outer piston, then remove retaining rings and boots. Push both pistons out in one direction. Remove piston seals from cylinder and yoke spring from yoke.

Inspecting - Thoroughly clean all internal parts and check each component fro excessive wear or damage. If caliper bore is damaged or excessively rusted, it must be replaced. If however, slight imperfections are evident, honing will eliminate them. It is recommended to replace all seals when overhauling.

Reassembly - Before assembling components, lightly coat with suitable brake grease. Insert bias ring into piston so round portion of ring fits to bottom of piston. Insert piston into cylinder. Do not fully seat piston. Install dust boot and retaining ring. Install yoke bias ring so it coincides with yoke groove of cylinder. Fit bias spring to yoke so bias spring faces bleeder side of cylinder. With yoke spring inserted in cylinder groove, properly align position of bias spring so groove of spring aligns with yoke. Assemble body-to-yoke, tapping lightly if necessary.

Fig. 4 Exploded View of Datsun Wheel Cylinder
Used on F10, 200SX and B210 Models

MASTER CYLINDER

NOTE - On F10 models, separate reservoir tank assembly.

Disassembly - Remove master cylinder reservoir caps and filters and drain brake fluid. Using a screwdriver, pry off stopper ring. Remove stopper screw and pull out primary piston assembly, spring and secondary piston assembly. Remove plugs and pull out front and rear check valves.

NOTE - On all except F10 models, do not remove reservoir tanks. If tanks are removed for any reason, discard and install new ones.

Inspecting - Thoroughly clean all components in approved grade brake fluid. Inspect all components for excessive wear or damage and replace parts as necessary.

Reassembly - Reverse disassembly procedure and note the following: Coat all parts with brake fluid (rubber parts with brake grease) when assembling.

Fig. 5 Exploded View of Datsun 200SX and B210
Master Cylinder - F10 Models Have Different
Reservoir Arrangement

POWER BRAKE UNIT

Disassembly - 1) Place power unit in a soft jaw vise with operating rod pointing up. Scribe an alignment mark on front and rear shell to assure reassembly in original position, then remove lock nut, clevis and dust boot from rear shell.

2) Place suitable wrench (ST08080000) over rear shell mounting studs. Press down on wrench while

rotating counterclockwise and remove rear shell, then lift out diaphragm plate assembly, diaphragm spring and push rod assembly. Pry off retainer and remove bearing and valve body seal assembly.

3) Remove diaphragm from diaphragm plate assembly, then pry off air silencer retainer and remove silencer and filter. Rotate diaphragm plate assembly until valve plunger key slot is down, then press in on plunger and shake out stop key. Remove reaction disc from plate assembly. Detach flange from front shell and remove front seal assembly.

Cleaning & Inspection - Clean all parts in denatured alcohol and blow dry with compressed air. Inspect front and rear shells for wear or damage. If slight rust is found on inside surface of shells, polish clean with fine emery cloth. Inspect all parts for cracks, nicks, distortion or other damage and replace as necessary.

Reassembly - Reverse disassembly procedure and note the following: Apply a thin coat of silicone grease to parts before installation. When assembling front shell to rear shell, ensure marks made during disassembly are aligned. After reassembly, measure distance from master cylinder mounting surface of power unit to end of power unit push rod; distance should be .38-.39" (9.8-10.0 mm). If distance is not to specifications, correct by adjusting end of push rod.

Fig. 6 Sectional View of Datsun Master Vac

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Arrow 1976 77 Drive Axles Repair Manual

Models Covered:

• Arrow 
• Colt

DESCRIPTION

Rear axle is of the banjo type, utilizing the removable carrier style differential. Light weight construction joins split tubular housing for each side with center covers welded to axle housing. Final drive is of the hypoid style. Axle shafts are semi-floating type supported with bearings at their respective ends in axle housing. Bearings are fitted to axles with pressure type bearing retainers. Pinion bearing preload, side bearing preload, and pinion depth adjustments are made with shims while differential side gears are adjusted with spacers.

REMOVAL AND INSTALLATION

Axle Shaft and Bearings

Removal - 1) Raise and suitable support rear axle housing so rear wheels clear ground. Remove rear wheel and brake back plate nuts, then disconnect wheel cylinder brake line. Fix suitable puller set (CT-1003 and C-637) to lug studs and work slide hammer until axle shaft is free to be withdrawn. Set brake back plate with parking brake attached out-of-way. Using suitable tool (C-637 with hook) remove axle shaft oil seal.

FIG. 1 MEASURING AXLE SHAFT
DEFLECTION

2) To remove axle bearing proceed as follows: Grind down bearing retainer at one point until retainer thickness is .04 - .06" (1.0 - 1.5 mm) then chisel ground portion and remove retainer. Using suitable bearing puller or press (CT-1120) remove bearing from axle.

3) Using a dial indicator, inspect axle shaft deflection in three spots (see illustration). Replace axle shaft if specifications are exceeded.

                                 Axle Shaft Deflection Table

Application                        Std. Value                           Service Limit

Point "A".............................  0-.004".................................   .004"

                                               (0-.10 mm)............................. (.10 mm)

Point "B"............................... 0-.002".................................   .002"

                                               (0-.05 mm)..............................(.05 mm)

Point "C"............................... 0-.08".....................................  .08"

FIG. 2 EXPLODED VIEW OF AXLE
SHAFT ASSEMBLY

                                               (0-2.0 mm)..............................(2.0 mm)

4) Rear axle bearing should be replaced when bearing noise is detected, when bearing axial play exceeds .014-.016" (.36-.41 mm) or if bearing axial free play exceeds .001-.002" (.03-.04 mm) at approximately 11 lbs. (5.0 kg) measuring force.

5) Inspect wheel hub bolts for tightness and bearing outer retainer for deformation, replace parts as necessary.

Installation - 1) Fit outer bearing retainer for sie against shaft splined end, then install bearing and inner bearing retainer. Seat bearing retainer with smaller chamfered side directed to the bearing. NOTE - Ensure bearing is completely seated.

2) Lightly coat lips at oil seal and using suitable oil seal installer (DT-10078 and CT-1008) fit axle shaftt oil seal in rear axle housing.

3) Using packing and shim in proper sequence, set clearance between bearing and outer bearing retainer to .00-.01" (.0-25 mm).

4) Carefully insert axle shaft assembly into axle housing using care not to damage seal. Slightly turn axle shaft until splines line up with differential side gears. Align packing oil holes with outer bearing retainer and tighten bearing retainer to axle housing flange. Connect brake line to wheel cylinder and bleed air from system.

DIFFERENTIAL CARRIER

FIG. 3 REMOVING DIFFERENTIAL
GEAR HOUSING

Removal - Drain oil from rear axle differential housing, then disconnect propeller shaft. Pull out both rear axle shafts approximately 2 1/2". Remove differential gear housing mounting nuts and withdraw the differential gear carrier. It may be necessary to top outside of housing to break gear carrier loose.

Installation - Lightly coat each bearing and gear with oil. Apply sealing compound on packing and axle housing seat, then assemble gear carrier to axle housing with nuts and tighten. Fill differential gear housing with .96 quart of suitable multi-purpose gear oil (API GL-5).

OVERHAUL

FIG. 5 REMOVING DRIVE PINION BEARING

Disassembly

Differential Gear Assembly - 1) Remove bearing carrier and lever gear case assembly form housing. Using suitable puller tool (C-293-P & C-293-39) pull differential side bearing. Keep right and left bearings and shim in sequence for reassembly.

2) Remove ring gear lock plate tabs and loosen bolts in diagonal sequence, then remove ring gear. Drive out pinion shaft lock pin from ring gear back side using a punch, pull out pinion shaft and pinion. Pinion side gears and spacers are now accessible. Note placement of pinion side gear and spacers and ensure they are reassembled in same position.

FIG. 6 REMOVING DRIVE PINION FRONT
BEARING OUTER RACE

Drive Pinion Assembly - 1) Hold end yoke with suitable tool (C-3281) and remove lock nut, then remove end yoke. Using a wheel puller, force out drive pinion with adjusting shim, rear inner bearing rce, spacer and preload adjusting shim.

2) With suitable bearing puller (C-293-P & C-293-39) remove rear bearing inner race and at the same time, pull off drive pinion adjusting shim. Using suitable drift, remove front drive pinion bearing outer race and oil seal. Repeat same procedure to remove bearing outer race.

INSPECTION

Check differential gears for correct tooth contact and replace gears if wear is excessive. Inspect bearing faces for roughness or score marks and replace, if necessary, bearing assembly. Ensure splines of side gears and rear axle shafts fit correctly. Check clearance between pinion gears and pinion shaft, if wear is excessive, replace components.

NOTE - To check gear tooth contact using pain impression method, refer to beginning of this section.

FIG. 7 EXPLODED VIEW OF COLT SEPARATE HOUSING REAR AXLE ASSEMBLY

FIG. 8 CHECKING DIFFERENTIAL PINION
AND SIDE GEAR BACKLASH

REASSEMBLY AND ADJUSTMENT

Case Assembly - 1) Install thrust washers (spacers) behind side gears in their original position and assemble pinion and side gears in differential. Insert both pinion gears, with pinion washers attached, so they mesh with side gears. It may be necessary to slightly rotate pinions to achieve desired meshing. Insert drive pinion shaft.

2) Check pinion and side gear backlash as shown in illustration, if backlash is beyond 0-.003" (0-.08 mm) adjust by selecting a side gear thrust washer (spacer) of correct size. If backlash is to be adjusted, ensure right and left sides are equally shimmed.

3) Thoroughly clean all dirt from ring gear mounting surface of differential case. Install bolts and lock washers. Tighten bolts alternately in a diagonal sequence and bend over lock tabs. Ensure lock washers are in contact with case rib after final torque has been performed.

Drive Pinion - Using a suitable drift and hammer or a press, seat front and rear bearing outer races into gear carrier ensuring that outer races do not cock. Ensure bearing races are completely seated before proceeding. Install shim between drive pinion and rear bearing. Using suitable bearing installer (CT-1075) press bearing onto drive pinion shaft. If drive pinion and bearings are scheduled to be reused, shims should be replaced with new ones of same thickness. In instances where the gear set is to be replaced, install new shims that are the same thickness as the used shims on drive pinion. NOTE - When determining the desired thickness of shim pack, amount of compression (sinkage) of shim pack and wear of the bearing (where old bearing is reused) must be taken into consideration.

Drive Pinion Depth - Install drive pinion spacer, front bearing, washer, end yoke and washer in order of removal. fit pinion shaft retaining nut and slowly tighten nut, continously checking, until pinion bearing preload is 6-9 INCH lbs. (7-10 cmkg) with oil seal not installed. Place suitable cylinder gauge on inside bearing pedestals of gear carrier housing. Place a block gauge on top end of drive pinion and slip a feeler gauge between the two gauges to obtain the correct clearance. The clearance between gauges should be .0118" (.300 mm). This is the standard height and any deviation from this height will be marked on the head of the pinion shaft and side of ring gear. To calculate the correct pinion height,  add or subtract the variation value from the standard height.

NOTE - Stamped values are in hundredth millimeters. Add or subtract the correct amount of shims as necessary.

Pinion Bearing Preload - This adjustment must be performed after the setting of the drive pinion depth. Remove end yoke and insert the bearing preload adjusting shim between pinion spacer and bearing, then tighten end yoke to 9-11 INCH lbs. (10-13 cmkg). In addition to the preload adjusting shims there are spacers available to provide proper adjustment. After finishing adjustment of drive pinion bearing preload remove the end yoke and apply a thin coat of grease to outer surface of oil seal, then drive seal into position in gear carrier. After greasing oil seal lip, insert end yoke and tighten nut.

FIG. 9 MEASURING CLEARANCE
BETWEEN SIDE BEARING AND GEAR CARRIER

Side Bearing Preload - Fit each side bearing into differential case leaving shims out; use suitable tool (CT-1102) for this procedure. Ensure side bearings are completely seated before proceeding. Install differential case assembly on gear carrier, then calculate the clearance bwetween side bearing outer race and gear carrier as shown in illustration. After obtaining clearance add .002" (.05 mm) preload figure to each side. Insert shims equally on both sides. Align gear carrier and bearing cap index marks, then tighten cap retaining bolts.

Ring Gear Deflection - Attach a dial indicator to back side of ring gear and measure deflection. If ring gear has excessive deflection, correct position of assembly in relation to differential case and again perform measurement. Replace ring gear or differential case as necessary.

Drive Pinion Backlash - Measure backlash of drive pinion in at least four different spots on ring gear with drive pinion securely fixed in final position. Set up a dial indicator on ring gear teeth edges. If measured backlash is greater than .005-.007" (.13-.18 mm), shift shims from ring gear side to back of the ring gear to obtain proper backlash. If the measure value is less than standard value, reverse the moving of shims as stated above. Side bearing shims are available in various thicknesses.

NOTE - Check gear tooth contact using point impression method described at beginning of this section.

Final Inspection and Assembly - Lightly coat each gear and bearing before and during reassembly with gear oil. After installing each component, ensure all rotating parts are free to move smoothly. Install differential gear assembly to axle housing after applying sealing agent and tighten gear carrier mounting nuts in diagonal sequence.

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