NISSAN ALMERA N16 2003 Electronic Repair Manual

SFA090A
REMOVALNJAX00141. Remove wheel bearing lock nut.
Brake caliper need not be disconnected. Do not twist or
stretch brake hose when moving components.
SFA153B
2. Remove strut lower mount bolts.
3. Remove brake hose clip.
SFA499A
4. Separate drive shaft from knuckle by lightly tapping it. If it is
hard to remove, use a puller.
Cover boots with shop towel so as not to damage them
when removing drive shaft.
Refer to “Wheel Hub and Knuckle”, “FRONT AXLE”, AX-5.
5. Remove right drive shaft from transaxle.
SAX012
6. Remove left drive shaft from transaxle.
— For M/T models —
Pry off drive shaft from transaxle as shown at left.
GI
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FRONT AXLE
Drive Shaft (Cont’d)
AX-11

SFA730
— For A/T models —
Insert screwdriver into transaxle opening for right drive shaft
and strike with a hammer.
Be careful not to damage pinion mate shaft and side gear.
SFA482-D
INSTALLATIONNJAX0015Transaxle SideNJAX0015S011. Drive a new oil seal to transaxle. Refer to MT-20 or AT-409,
“Replacing Oil Seal” or “Differential Side Oil Seal
Replacement”, “ON-VEHICLE SERVICE”.
2. Set Tool along the inner circumference of oil seal.
SFA483-D
3. Insert drive shaft into transaxle. Be sure to properly align the
serrations and then withdraw Tool.
4. Push the drive shaft until the circular clip on the drive shaft fits
into the circular clip groove of the side gear.
5. After its insertion, try to pull the flange out of the slide joint by
hand. If it pulls out, the circular clip is not properly meshed with
the side gear.
Wheel SideNJAX0015S02Install drive shaft into knuckle.
Tighten upper knuckle nut and wheel bearing lock nut. Refer
to section Installation in “Wheel Hub and Knuckle”, “FRONT
AXLE”, AX-5.
FRONT AXLE
Drive Shaft (Cont’d)
AX-12

SFA476
DISASSEMBLYNJAX0017Transaxle Side (DS90 and DS83 types)NJAX0017S011. Remove boot bands.
2. Put matching marks on slide joint housing and inner race,
before separating joint assembly.
3. Remove stopper ring with a screwdriver, and pull out slide joint
housing.
SFA514A
4. Put matching marks on inner race and drive shaft.
5. Remove snap ring, then remove ball cage, inner race and balls
as a unit.
6. Draw out boot.
Cover drive shaft serrations with tape so as not to damage the
boot.
SFA963
Transaxle Side (TS70C, TS79C, TS83, GI2000I and
GI2300I types)
NJAX0017S041. Remove boot bands.
2. Put matching marks on slide joint housing and drive shaft
before separating joint assembly.
3. Put matching marks on spider assembly and drive shaft.
SFA612
4. Pry off snap ring, then remove spider assembly.
CAUTION:
Do not disassemble spider assembly.
5. Draw out boot.
Cover drive shaft serration with tape to prevent damage to the
boot.
SFA092A
Wheel SideNJAX0017S02CAUTION:
The joint on the wheel side cannot be disassembled.
ZF90F type joint assembly cannot be disassembled because
a plastic boot and special boot band are used. Do not use
other drive shaft boots. If the boot or joint is damaged, replace
the drive shaft assembly.
1. Before separating joint assembly, put matching marks on drive
shaft and joint assembly.
2. Separate joint assembly with a suitable tool.
Be careful not to damage threads on drive shaft.
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FRONT AXLE
Drive Shaft (Cont’d)
AX-13

3. Remove boot bands.
4. Draw out boot.
SFA442B
Support BearingNJAX0017S031. Remove dust shield.
SFA692
2. Remove snap ring.
SFA693
3. Press support bearing assembly off of drive shaft.
SFA617
4. Separate support bearing from retainer.
FRONT AXLE
Drive Shaft (Cont’d)
AX-14

INSPECTIONNJAX0018Thoroughly clean all parts in cleaning solvent, and dry with
compressed air. Check parts for evidence of deformation or
other damage.
Drive ShaftNJAX0018S01Replace drive shaft if it is twisted or cracked.
BootNJAX0018S02Check boot for fatigue, cracks or wear. Replace boot with new boot
bands.
Joint Assembly (Transaxle side)NJAX0018S03Check spider assembly for needle bearing and washer dam-
age. Replace if necessary. (Tripod type)
Check roller surfaces for scratches, wear or other damage.
Replace if necessary. (Tripod type)
Replace any parts of double offset joint which show signs of
scorching, rust, wear or excessive play. (Double offset type)
Check serration for deformation. Replace if necessary.
Check slide joint housing for any damage. Replace if neces-
sary.
SRA121A
When replacing only spider assembly, select a new spider
assembly from among those listed in table below. Ensure the
number stamped on sliding joint is the same as that stamped
on new part.
Housing alone cannot be replaced. It must be replaced
together with spider assembly.
TS70C
Stamped number Part No.
00 39720-51E00
01 39720-51E01
02 39720-51E02
03 39720-51E03
TS79C
Stamped number Part No.
01 39720-61E01
02 39720-61E02
03 39720-61E03
04 39720-61E04
05 39720-61E05
06 39720-61E06
07 39720-61E07
Joint Assembly (Wheel side)NJAX0018S04Replace joint assembly if it is deformed or damaged.
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FRONT AXLE
Drive Shaft (Cont’d)
AX-15

Support BearingNJAX0018S05Make sure wheel bearing rolls freely and is free from noise, cracks,
pitting or wear.
Support Bearing BracketNJAX0018S06Check support bearing bracket for cracks with a magnetic explora-
tion or dyeing test.
ASSEMBLYNJAX0019After drive shaft has been assembled, ensure that it
moves smoothly over its entire range without binding.
Use NISSAN GENUINE GREASE or equivalent after every
overhaul.
SFA800
Wheel SideNJAX0019S011. Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.
SFA942A
2. Set joint assembly onto drive shaft by lightly tapping it.
Install joint assembly securely, ensuring marks which were
made during disassembly are properly aligned.
SFA592B
3. Pack drive shaft with specified amount of grease.
Specified amount of grease:
AC2300I type 40 - 50 g (1.41 - 1.76 oz)
AC2000I type 118 g (4.16 oz)
ZF80 type 75 - 85 g (2.65 - 3.00 oz)
BF83 type 80 - 100 g (2.82 - 3.53 oz)
BF90 type 100 - 120 g (3.53 - 4.23 oz)
4. Make sure that boot is properly installed on the drive shaft
groove.
Set boot so that it does not swell and deform when its length
is “L
1”.
FRONT AXLE
Drive Shaft (Cont’d)
AX-16

Length “L1”:
AC2300I type 94 - 96 mm (3.70 - 3.78 in)
AC2000I type 90 mm (3.54 in)
ZF80 type 91.4 - 91.6 mm (3.598 - 3.606 in)
BF83 type 95 mm (3.74 in)
BF90 type 85.5 mm (3.366 in)
SFA443B
5. Lock new larger and smaller boot bands securely with a suit-
able tool.
SFA313B
Dynamic Damper (Where Fitted)NJAX0019S021. Use new damper bands when installing.
2. Install dynamic damper from stationary-joint side while holding
it securely.
Length:
Refer to AX-21, SDS.
SFA800
Transaxle Side (TS70C, TS79C, TS83, DS90, DS83,
GI2000I and GI2300I types)
NJAX0019S031. Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
during installation.
SFA514A
2. Install ball cage, inner race and balls or spider assembly as a
unit, making sure the marks which were made during disas-
sembly are properly aligned.
3. Install new snap ring.
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FRONT AXLE
Drive Shaft (Cont’d)
AX-17

SFA149A
4. Pack drive shaft with specified amount of grease.
Specified amount of grease:
GI2300I type 125.5 - 135.5 g (4.42 - 4.77 oz)
GI2000I type 90 g (3.17 oz)
TS79C type 155 - 165 g (5.47 - 5.82 oz)
TS70C type 110 - 120 g (3.88 - 4.23 oz)
TS83 type 125 - 145 g (4.41 - 5.11 oz)
DS83 type 115 - 135 g (4.06 - 4.76 oz)
DS90 type 145 - 165 g (5.11 - 5.82 oz)
5. Install slide joint housing, then install new snap ring.
6. Make sure that boot is properly installed on the drive shaft
groove.
Set boot so that it does not swell and deform when its length
is “L
2”.
Length “L2”:
TS70C type
96.4 - 96.6 mm (3.795 - 3.803 in)
TS79C type
101.5 - 103.5 mm (3.996 - 4.075 in)
TS83 type
99 mm (3.90 in)
DS83 type
98 mm (3.86 in)
DS90 type
98 mm (3.86 in)
GI2000I type
90 mm (3.54 in)
GI2300I type
98 - 100 mm (3.86 - 3.94 in)
SFA395
7. Lock new larger and smaller boot bands securely with a suit-
able tool.
SFA618
Support BearingNJAX0019S04Press bearing into retainer.
FRONT AXLE
Drive Shaft (Cont’d)
AX-18

SFA694
Press drive shaft into bearing.
SFA444B
Install snap ring.
Install new dust shield.
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FRONT AXLE
Drive Shaft (Cont’d)
AX-19

Service Data and Specifications (SDS)
DRIVE SHAFT=NJAX0020
Applied modelEngine QG YD22T
Transaxle A/T M/T M/T
Joint typeTransaxle side TS79C GI2300I DS90 + B
Wheel side ZF90 AC2300I BF90
Grease Quality Nissan genuine grease or equivalent*2
Capacity
g(oz)Transaxle side155 - 165
(5.47 - 5.82)125.5 - 135.5
(4.42 - 4.77)145 - 165
(5.11 - 5.82)
Wheel side —*340 - 50
(1.41 - 1.76)100 - 120
(3.53 - 4.23)
Boot length
mm (in)Transaxle side “L
2”101.5 - 103.5
(3.996 - 4.075)98 - 100
(3.86 - 3.94)*197 - 99
(3.82 - 3.90)
Wheel side “L
1”—*394 - 96
(3.70 - 3.78)*184.5 - 96.5
(3.327 - 3.799)
SFA961AA
SFA962A
*1: Fit boot to boot groove in bar shaft
*2: Use grease sachet 39209 BM510 in service for wheel side and 39709 BM500 for transaxle side. (Genuine GKN grease for 20001
joints)
*3: ZF90F type joint assembly cannot be disassembled because a plastic boot and special boot band are used. Do not use other drive
shaft boots. If the boot or joint is damaged, replace the drive shaft assembly.
FRONT AXLE
Service Data and Specifications (SDS)
AX-20