DATSUNCAR CLUB

Engine Specs

Cooling System

Ignition System

Carb Adjustments

Clutch

Braking System

Suspension

Clutch Master Cylinder Removal / Installation

1. Disconnect the master cyclinder push rod for the pedal arm.
2. Disconnect the fluid line from the master cylinder and drain fluid into a container.
3. Remove the master cyclinder flange bolts and remove unit from engine compartment rear
   bulkhead.
4. Installation is the reverse of procedures above.



Clutch Master Cylinder Servicing

1. Unscrew and remove the reservoir cap and drain any fluid.
2. Peel back dust excluder and extract the circlip.
3. With draw the push rod and piston assembly.
4. Remove the valve assembly and return spring.
5. Wash all components in clean hydraulic fluid or mineral spirits and examine the 
   surface of the piston and the bore of the cylinder for scoring or wear areas. If 
   these are present recommend replacing master cylinder.
6. If in good condition after inspection, discard rubber seals and obtain a repair 
   kit. The end of the valve stem can be released from the "keyhole" in the spring seat 
   by first compressing the return spring and pulling the spring seat to one side.
7. Dip the new seals in clean hydraulic fluid and place them into position using 
   only your fingers. Check that their lips and chamfers face the correct way.
8. Reassembly is the reversal of the procedures above, use all new parts supplied in 
   the repair kit.
9. Check that the vent holes in the reservoir cap are clear by probing them with a wire.



Clutch Slave Cylinder Removal / Installation

1. Detach return spring at the slave cylinder.
2. Unscrew and remove the two bolts which secure the slave cylinder to the clutch 
   bellhousing. Withdraw the slave cylinder extracting the end of the pushrod from the 
   cutch, withdraw lever at the same time.
3. Without straining or twisting the hydraulic hose unscrew the slave cylinder from 
   the hose, and plug the end to prevent fluid loss.
4. Installation is reverse of removal instructions above.



Clutch Slave Cylinder Servicing

1. On slave cylinders with adjustable type pushrods, peel back the dust cover and 
   extract the circlip.
2. Withdraw the piston/seal assembly.
3. On cyclinders without adjustable pushrods, pull out the pushrod complete with dust 
   cover. Extract piston/seal assembly and spring.
4. Wash all parts in clean hydraulic fluid and examine the surfaces of the piston and 
   cyclinder bore for scored marks or wear spots, if found replace slave cylinder 
   with a new unit.
5. If inspection is good, discard seal and obtain a repair kit.
6. Place new seal into piston, ensuring that its lip faces in the correct way.
7. Reassembly is the reversal of dismantling, but take care not to nip the piston 
   seal as it enters the cylinder bore. Always dip parts in new clean hydraulic 
   fluid prior to assembly of new/old parts.



Clutch Removal

1. Remove or "drop" transmission from engine. 
2. Seperate trans from engine by removing the clutch bellhousing to crankcase bolts.
3. The pressure place need not be marked in relation to flywheel as it can only be 
   fitting in one direction due to dowel pins.
4. Unscrew the clutch assembly securing bolts a turn at a time in diametrically opposite 
   sequence until the tension of the diaphram spring is released. Remove the bolts the 
   rest of the way and lift the pressure plate assembly away.
5. By this point the drive plate or fiction disc will fall from its location between the 
   pressure plate and the flywheel.



Clutch Release Bearing - Renewal

1. The sealed, ball bearing type release bearing, although designed for long life, 
   is well worth the renewal if you are replacing the clutch or having service done on 
   trans.
2. If signs of grease leakage or the unit is noisy when spun with the fingers, 
   deterioration is present, and recommend replacement.
3. Remove rubber dust excluder which surrounds the withdrawal lever at the bellhousing
   aperture.
4. Disconnect and remove the spring from the release bearing hub.
5. Disconnect the withdraw lever from the release bearing hub.
6. Withdraw the release bearing/hub assembly from the front cover of the gearbox.
7. Remove the release bearing from the hub using 2 to 3 legged puller and a bridge 
  piece across the end face of the hub.
8. Press on the new bearing but apply pressure only to the center track.
9. Reassemble is the reversal of dismantaling but apply high temp grease to the 
   internal recess of the release bearing hub, also supply grease to the pivot points 
   of the clutch withdrawal lever.



Clutch Installation

1. Clean the face of the flywheel and the pressure plate.
2. Apply high temp grease to spigot bush in the center of flywheel. On later model Z's 
   this unit is self lubricating and need not be greased. Apply grease also to the 
   spines of the input shaft.
3. Locate the driven plate against the flywheel so that its larger projecting boss is to the rear.
4. Place drive plate against the flywheel so dowel pins engage, and the alignment marks align.
5. Position the pressure plate bolts finger tight and then centralise the driven plate. 
   This is accomplished by passing and old input shaft to stepped dowel rod through the splinded 
   hub of the driven plate and engaging it in the spigot bush. By moving the shaft or rod in 
   the correction directions, the position will be established where the centralising tool can 
   be withdrawn without any side pressure from the driven plate, proving that the driven plate 
   is centralised.
6. Without disturbing the settings of the driven plate, tighten the pressure plate 
   bolts, a turn at a time, in diametrically opposite sequence to a final torque spec reading 
   of 17 lb/ft.
7. Refit the gearbox to the engine when, if the driven plate has been correctly centralised, 
   the input shaft of the gearbox will pass easily through the splined hub of the driven plate 
   to engage with the spignot bush in the center of the flywheel. Do not allow the weight of 
   the gearbox to hang upon the input shaft while it is passing through the clutch mechanism or 
   damage to the clutch components may result.