NISSAN ALMERA N16 2003 Electronic Repair Manual

ASSEMBLY
AT-505
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
1. Measure dimensions “K” and “L” and then calculate dimension
“J”.
a. Measure dimension “K”.
b. Measure dimension “L”.
c. Calculate dimension “J”.
2. Measure dimension “M”.
a. Place bearing race and needle bearing on oil pump assembly.
b. Measure dimension “M”.
SAT375D
SAT376D
“J”: Distance between oil pump fitting surface of
transmission case and needle bearing mating surface
of high clutch drum.
J = K – L
SAT377D
SAT378D
“M”: Distance between transmission case fitting surface
of oil pump cover and needle bearing on oil pump cover.
“M
1 ”: Indication of gauge.
SAT379D

AT-506
[ALL]
ASSEMBLY
c. Measure thickness of straightedge “t”.
3. Adjust total end play “T
3 ”.
●Select proper thickness of bearing race so that total end play is within specifications.
REVERSE CLUTCH END PLAY
●Measure clearance between oil pump cover and thrust washer
for reverse clutch drum.
●Select proper thickness of thrust washer so that end play is
within specification.
1. Measure dimensions “O” and “P” and then calculate dimension
“N”.
a. Place thrust washer on reverse clutch drum.
b. Measure dimension “O”.M = M
1 – t
SAT443D
T3 = J – M
Total end play “T
3 ”:
0.25 - 0.55 mm (0.0098 - 0.0217 in)
Bearing races: Refer to AT- 5 1 5 , "
SERVICE DATA AND SPECIFICATIONS (SDS)"
.
SAT380D
SAT381D
SAT382D

ASSEMBLY
AT-507
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
c. Measure dimension “P”.
d. Calculate dimension “N”.
2. Measure dimensions “R” and “S” and then calculate dimension
“Q”.
a. Measure dimension “R”.
b. Measure dimension “S”.
c. Calculate dimension “Q”.
3. Adjust reverse clutch end play “T
4 ”.
●Select proper thickness of thrust washer so that reverse clutch end play is within specifications. “N”: Distance between oil pump fitting surface of trans-
mission case and thrust washer on reverse clutch
drum.
N = O – P
SAT383D
SAT384D
SAT385D
“Q”: Distance between transmission case fitting sur-
face and thrust washer mating surface.
Q = R – S
SAT386D
T4 = N – Q
Reverse clutch end play:
0.65 - 1.00 mm (0.0256 - 0.0394 in)
Thrust washer: Refer to AT-515, "
SERVICE DATA AND SPECIFICATIONS (SDS)" .

AT-508
[ALL]
ASSEMBLY
Assembly (3)
ECS007TR
1. Remove reverse clutch assembly and install needle bearing on
high clutch assembly.
●Pay attention to direction of needle bearing.
2. Install reverse clutch assembly
3. Install anchor end pin and lock nut on transmission case.
4. Place brake band on outside of reverse clutch drum. Tighten
anchor end pin just enough so that brake band is evenly fitted on
reverse clutch drum.
5. Place bearing race selected in total end play adjustment step on
oil pump cover.
●Apply petroleum jelly to bearing race.
6. Place thrust washer selected in reverse clutch end play step on
reverse clutch drum.
●Apply petroleum jelly to thrust washer.
SAT387D
SAT038D
SAT389D
SAT390D

ASSEMBLY
AT-509
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
7. Install oil pump assembly on transmission case.
8. Tighten oil pump fixing bolts to the specified torque.
9. Install O-ring to input shaft.
●Apply ATF to O-ring.
10. Adjust brake band.
a. Tighten anchor end pin to the specified torque.
b. Back off anchor end pin two and a half turns.
SAT391D
SAT392D
SAT034D
Anchor end pin:
Refer to AT-515, "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
SAT394D
SAT395D

AT-510
[ALL]
ASSEMBLY
c. While holding anchor end pin, tighten lock nut.
11. Apply compressed air to oil holes of transmission case and
check operation of brake band.
12. Install final drive assembly on transmission case.
13. Install differential lubricant tube on converter housing. Tighten
differential lubricant tube bolts to the specified torque. Refer to
AT-413, "
OVERHAUL" .
14. Install O-ring on differential oil port of transmission case.
15. Install converter housing on transmission case.
●Apply locking sealant to mating surface of converter
housing.
SAT396D
SAT397D
SAT030D
SAT063K
Bolt Length mm (in)
A 32.8 (1.291)
B 40 (1.57)
SAT405D

ASSEMBLY
AT-511
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
16. Install accumulator piston.
a. Check contact surface of accumulator piston for damage.
b. Install O-rings on accumulator piston.
●Apply ATF to O-rings.
c. Install accumulator pistons and return springs on transmission
case.
●Apply ATF to inner surface of transmission case.
17. Install lip seals for band servo oil holes on transmission case.
●Apply petroleum jelly to lip seals.
SAT406DA
Accumulator piston O-rings:
Refer to AT-515, "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
SAT407DA
Return springs:
Refer to AT- 5 1 5 , "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
SAT878J
SAT021D
SAT022D

AT-512
[ALL]
ASSEMBLY
18. Install control valve assembly.
a. Insert manual valve into control valve assembly.
●Apply ATF to manual valve.
b. Pass solenoid harness through transmission case and install
terminal body on transmission case by pushing it.
c. Install stopper ring to terminal body.
d. Tighten bolts A , B and C .
Bolt length, number and location:
SAT017D
AAT261A
: 7 - 9N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
BoltABC
Bolt length “ ”40 mm
(1.57 in)33 mm
(1.30 in)43.5 mm
(1.713 in)
Number of bolts 5 6 2
AAT260A

ASSEMBLY
AT-513
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
19. Install oil pan.
a. Attach a magnet to oil pan.
b. Install new oil pan gasket on transmission case.
c. Install oil pan on transmission case.
●Always replace oil pan bolts as they are self-sealing
bolts.
●Tighten four bolts in a criss-cross pattern to prevent dis-
location of gasket.
d. Tighten drain plug to specified torque.
20. Install park/neutral position (PNP) switch.
a. Set manual shaft in P position.
b. Temporarily install park/neutral position (PNP) switch on manual
shaft.
c. Move selector lever to N position.
d. Use a 4 mm (0.16 in) pin for this adjustment.
i. Insert the pin straight into the manual shaft adjustment hole.
ii. Rotate park/neutral position (PNP) switch until the pin can also
be inserted straight into hole in park/neutral position (PNP)
switch.
e. Tighten park/neutral position (PNP) switch fixing bolts. Refer to
AT- 4 1 3 , "
OVERHAUL" .
f. Remove pin from adjustment hole after adjusting park/neutral
position (PNP) switch.
SAT418D
SAT128E
SAT023JB
SAT426DB

AT-514
[ALL]
ASSEMBLY
21. Install A/T fluid charging pipe and fluid cooler tube to transmis-
sion case. Tighten A/T fluid charging pipe and fluid cooler tube
bolts to the specified torque. Refer to AT- 4 1 3 , "
OVERHAUL" .
22. Install torque converter.
a. Pour ATF into torque converter.
●Approximately 1 liter (1-3/4 Imp pt) of fluid is required for
a new torque converter.
●When reusing old torque converter, add the same amount
of fluid as was drained.
b. Install torque converter while aligning notches of torque con-
verter with notches of oil pump.
c. Measure distance “A” to check that torque converter is in proper
position.
MCIB9012E
SAT428DA
SAT429D
Distance A:
Refer to AT- 5 1 5 , "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
SAT430D