NISSAN ALMERA N16 2003 Electronic Repair Manual

ASSEMBLY
AT-495
[ALL]
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5. Attach dial indicator on differential case at transmission case
side.
6. Insert Tool into differential side gear from converter housing.
7. Move Tool up and down and measure dial indicator deflection.
8. Select proper thickness of differential side bearing adjusting
shim(s) using SDS table as a guide.
9. Remove converter housing from transmission case.
10. Remove final drive assembly from transmission case.
11. Remove differential side bearing outer race from transmission
case.
12. Reinstall differential side bearing outer race and shim(s)
selected from SDS table on transmission case.
13. Reinstall converter housing on transmission case and tighten
transmission case fixing bolts to the specified torque. Refer to
AT- 4 1 3 , "
OVERHAUL" .
14. Insert Tool into differential case and measure turning torque of
final drive assembly.
●Turn final drive assembly in both directions several times
to seat bearing rollers correctly.
●When old bearing is used again, turning torque will be
slightly less than the above.
●Make sure torque is close to the specified range.
REDUCTION PINION GEAR BEARING PRELOAD
●Be sure to remove final drive assembly before doing this proce-
dure.
●Using caliper and straightedge, calculate a dimension “T”
(adjuster shim thickness) in the right figure by the following for-
mula and adjust the inspection standard for pre load (rotating
slide torque) as shown below.Differential side bearing preload “T”:
0.04 - 0.09 mm (0.0016 - 0.0035 in)
Differential side bearing adjusting shim:
Refer to AT- 5 1 5 , "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
AAT947
AAT477
Turning torque of final drive assembly (New bearing):
0.49 - 1.08 N-m (5.0 - 11.0 kg-cm, 4.3 - 9.5 in-lb)
AAT466
T = A − E
Inspection standard for preload:
0.1 - 0.69 N-m (1.1 - 7.0 kg-cm, 0.95 - 6.08 in-lb)
SAT876J

AT-496
[ALL]
ASSEMBLY
1. Remove transmission case and final drive assembly from converter housing.
2. Select proper thickness of reduction pinion gear bearing adjusting shim using the following procedures.
a. Place reduction pinion gear on transmission case as shown.
b. Place idler gear bearing on transmission case.
c. Measure dimensions “B” “C” and “D” and calculate dimension
“A”.
●Measure dimension “B” between the end of reduction pinion
gear and the surface of transmission case.
●Measure dimension “B” in at least two places.
●Measure dimension “C” between the surface of idler gear
bearing inner race and the surface of transmission case.
●Measure dimension “C” in at least two places.
●Measure dimension “D” between the end of reduction pinion
gear and the adjusting shim mating surface of reduction pin-
ion gear.
●Measure dimension “D” in at least two places.
●Calculate dimension “A”.A = D − (B + C)
“A”: Distance between the surface of idler gear bear-
ing inner race and the adjusting shim mating
surface of reduction pinion gear.
SAT333DA
SAT334DA
SAT335D
A = D − (B + C)
SAT336DA

ASSEMBLY
AT-497
[ALL]
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d. Measure dimension “E” between the end of idler gear and the
idler gear bearing inner race mating surface of idler gear.
●Measure dimension “E” in at least two places.
e. Select proper thickness of reduction pinion gear bearing adjust-
ing shim.
3. Install reduction gear and reduction pinion gear bearing adjust-
ing shim selected in step 2-e on transmission case.
4. Press idler gear bearing inner race on idler gear.
5. Press idler gear on reduction gear.
●Press idler gear so-that idler gear can be locked by park-
ing pawl.
6. Tighten idler gear lock nut to the specified torque.
●Lock idler gear with parking pawl when tightening lock
nut.
7. Measure turning torque of reduction pinion gear.
●When measuring turning torque, turn reduction pinion
gear in both directions several times to seat bearing roll-
ers correctly.Proper shim thickness = A − E − 0.05 mm (0.0020 in)*
(*... Bearing preload)
Reduction pinion gear bearing adjusting shim:
Refer to AT- 5 1 5 , "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .SAT337D
AAT696
SAT339D
Turning torque of reduction pinion gear:
0.1 - 0.69 N-m (1.1 - 7.0 kg-cm, 0.95 - 6.08 in-lb)
SAT340DC

AT-498
[ALL]
ASSEMBLY
OUTPUT SHAFT END PLAY
●Measure clearance between side cover and the end of the out-
put shaft bearing.
●Select proper thickness of adjusting shim so that clearance is
within specifications.
1. Install bearing retainer for output shaft.
2. Install output shaft thrust needle bearing on bearing retainer.
3. Install output shaft on transmission case.
SAT341D
SAT347D
SAT438D
SAT439D

ASSEMBLY
AT-499
[ALL]
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4. Measure dimensions “1 ” and “2 ” at side cover and then cal-
culate dimension “A”.
●Measure dimension “1 ” and “2 ” in at least two
places.
5. Measure dimensions “
2 ” and “3 ” and then calculate dimen-
sion “B”.
●Measure “2 ” and “3 ” in at least two places.
6. Select proper thickness of adjusting shim so that output shaft
end play (clearance between side cover and output shaft bear-
ing) is within specifications.
7. Install adjusting shim on output shaft bearing.
8. Apply locking sealant to transmission case as shown in illustra-
tion.
9. Install side cover on transmission case.
●Apply locking sealant to the mating surface of transmis-
sion case.“A”: Distance between transmission case fitting
surface and adjusting shim mating surface.
A =
1−2
2
:Height of gauge
SAT874DA
“B”: Distance between the end of output shaft bear-
ing outer race and the side cover fitting sur-
face of transmission case.
B =
2−3
2
:Height of gauge
SAT875DA
Output shaft end play (A − B):
0 - 0.5 mm (0 - 0.020 in)
Output shaft end play adjusting shims:
Refer to AT- 5 1 5 , "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
SAT440D
SAT441D
SAT442D

AT-500
[ALL]
ASSEMBLY
10. Tighten side cover fixing bolts to specified torque.
●Do not mix bolts A and B.
●Always replace bolts A as they are self-sealing bolts.
Assembly (2)ECS007TP
1. Remove paper rolled around bearing retainer.
2. Install thrust washer on bearing retainer.
●Apply petroleum jelly to thrust washer.
3. Install forward clutch assembly.
●Align teeth of low & reverse brake drive plates before
installing.
●Make sure that bearing retainer seal rings are not spread.
4. Install thrust needle bearing on bearing retainer.
●Apply petroleum jelly to thrust bearing.
●Pay attention to direction of thrust needle bearing.
SAT124E
SAT354D
SAT355D
SAT356D

ASSEMBLY
AT-501
[ALL]
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5. Install thrust needle bearing on rear internal gear.
●Apply petroleum jelly to thrust needle bearing.
●Pay attention to direction of thrust needle bearing.
6. Hold forward clutch hub and turn overrun clutch hub.
Check overrun clutch hub for directions of lock and unlock.
●If not as shown in illustration, check installed direction of for-
ward one-way clutch.
7. Install rear internal gear assembly.
●Align teeth of forward clutch and overrun clutch drive
plate.
8. Install needle bearing on rear planetary carrier.
●Apply petroleum jelly to needle bearing.
●Pay attention to direction of needle bearing.
9. Install rear sun gear on rear planetary carrier.
●Pay attention to direction of rear sun gear.
SAT357D
SAT358D
SAT359D
SAT360D
SAT052D

AT-502
[ALL]
ASSEMBLY
10. Install rear planetary carrier on transmission case.
11. Install thrust needle bearing on front planetary carrier.
●Apply petroleum jelly to thrust needle bearing.
●Pay attention to direction of thrust needle bearing.
12. Install low one-way clutch to front planetary carrier by turning it
in the direction of the arrow as shown.
13. While holding front planetary carrier, turn low one-way clutch.
Check low one-way clutch for correct directions of lock and
unlock.
14. Install front planetary carrier assembly on transmission case.
15. Install snap ring with screwdriver.
●Forward clutch and bearings must be correctly installed
for snap ring to fit groove of transmission case.
SAT362D
SAT363D
SAT048D
SAT047D
SAT046D

ASSEMBLY
AT-503
[ALL]
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16. Install needle bearing on front sun gear.
●Apply petroleum jelly to needle bearing.
●Pay attention to direction of needle bearing.
17. Install front sun gear on front planetary carrier.
18. Install needle bearing on front sun gear.
●Apply petroleum jelly to needle bearing.
●Pay attention to direction of needle bearing.
19. Install high clutch hub on front sun gear.
20. Install needle bearing on high clutch hub.
●Apply petroleum jelly to needle bearing.
●Pay attention to direction of needle bearing.
SAT367D
SAT368D
SAT369D
SAT370D
SAT371D

AT-504
[ALL]
ASSEMBLY
21. Remove paper rolled around input shaft.
22. Install reverse clutch assembly.
●Align teeth of high clutch drive plates before installing.
23. Install reverse clutch assembly.
●Align teeth of high clutch drive plates before installing.
Adjustment (2)ECS007TQ
When any parts listed below are replaced, adjust total end play and reverse clutch end play.
TOTAL END PLAY
●Measure clearance between reverse clutch drum and needle
bearing for oil pump cover.
●Select proper thickness of bearing race so that end play is within
specifications.
SAT372D
SAT373D
Part name Total end playReverse clutch end
play
Transmission case●●
Overrun clutch hub●●
Rear internal gear●●
Rear planetary carrier●●
Rear sun gear●●
Front planetary carrier●●
Front sun gear●●
High clutch hub●●
High clutch drum●●
Oil pump cover●●
Reverse clutch drum —●
SAT374D