NISSAN PRIMERA 1999 Electronic Repair Manual

Clutch HousingNCMT0009S021. Remove transaxle case from clutch housing.
2. Remove magnet from housing.
3. Remove check plugs, check springs, check pins, and check
balls from housing.
4. Remove 3rd & 4th bracket retaining pin.
5. Remove 3rd & 4th shift fork stopper ring.
6. Remove 3rd & 4th fork rod.
7. Remove 3rd & 4th shift fork and bracket.
8. Remove interlock plunger and check ball.
9. Remove 5th & reverse bracket stopper ring.
10. Remove retaining pin from 5th & reverse shift fork and reverse
switch bracket.
11. Remove 5th & reverse fork rod.
12. Remove interlock pin from 5th & reverse fork rod.
13. Remove reverse switch bracket and 5th & reverse bracket.
SMT654D Clutch
housingCheck plug
SMT656D 3rd & 4th shift fork
3rd & 4th bracket
SMT655D Stopper ring
3rd & 4th
shift fork
3rd & 4th bracket
SMT658D Stopper ring
5th & reverse
bracket
Check ball
Interlock plunger
SMT657D 5th & reverse
shift fork
5th & reverse
bracket
DISASSEMBLYRS5F70A
Clutch Housing
MT-54

14. Remove check ball from housing.
15. Remove retaining pin for 1st & 2nd shift fork and bracket.
16. Remove 1st & 2nd fork rod.
17. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd
bracket.
18. Remove both input shaft and mainshaft assemblies from hous-
ing.
19. Remove final drive assembly from housing.
20. Remove oil pocket from housing.
21. Remove mainshaft bearing retainer from housing.
22. Cut off oil channel using a cutter as shown in the figure.
23. Remove mainshaft front bearing from housing.
SMT659D 1st & 2nd
shift fork
1st & 2nd bracket
Check balls
SMT660D Mainshaft assembly
Input shaft
assembly
SMT661D Oil pocketFinal drive
assembly
SMT662D Oil channel
Mainshaft bearing
retainerCut area
SMT663D Mainshaft front bearing
DISASSEMBLYRS5F70A
Clutch Housing (Cont'd)
MT-55

24. Using a magnet or other suitable tool, remove retaining pin
from selector shaft.
25. Remove selector shaft and plug, then remove selector.
26. Remove reamer bolt, then remove selector leaf spring, return
spring, steel ball, reverse gate, selector arm, bearing, and
bushing.
CAUTION:
Be careful not to lose the steel ball.
27. Remove retaining pin and plug from striking lever.
28. Remove striking rod, then striking lever from housing.
29. Using a flat-head screwdriver or other suitable tool, remove
dust seal, input shaft oil seal, and striking rod oil seal from
housing.
CAUTION:
When removing dust and oil seals, be careful not to damage
mounting surfaces of dust seal and oil seal.
SMT664D Selector
Selector pin
SMT665D Selector
shaft
Selector
SMT666D Selector leaf spring
Return spring
SMT667D Striking lever
SMT668D Flat-head
screwdriver
Dust sealFlat-head
screwdriver
Input shaft
oil seal
DISASSEMBLYRS5F70A
Clutch Housing (Cont'd)
MT-56

30. Remove differential oil seal from housing.
31. Remove differential side outer race from housing.
SMT669D Differential
oil seal
SMT670D Differential
side bearing
outer race
DISASSEMBLYRS5F70A
Clutch Housing (Cont'd)
MT-57

Input Shaft and Gears
DISASSEMBLYNCMT0010
1. Before disassembly, measure the end plays of 3rd and 4th
input gears.
Gear end play:
Refer to SDS, MT-90.
IIf end play is not within specification, disassemble and check
the parts.
2. Remove oil channel from input shaft rear bearing.
3. Press out input shaft rear bearing.
4. Remove C-ring holder.
5. Remove 5th gear rear C-ring.
6. Remove 5th input gear from input shaft.
7. Remove 5th gear front C-ring.
SMT759D Feeler gauge
Input shaft assembly
SMT671D Oil channel
Input shaft
SMT672D Input shaft
rear bearing
SMT673D C-ring holder
Flat-head screwdriver
5th gear rear C-ring
SMT674D 5th input gear
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears
MT-58

8. Remove 4th input gear, baulk ring, 4th gear needle bearing,
and 4th gear C-ring from input shaft.
9. Press out both 3rd & 4th synchronizer hub assembly and 3rd
input gear from input shaft.
10. Remove 3rd gear needle bearing.
11. Press out input shaft front bearing from input shaft.
INSPECTIONNCMT0011
Gear and ShaftNCMT0011S01
ICheck shaft for cracks, wear or bending.
ICheck gears for excessive wear, chips or cracks.
SynchronizersNCMT0011S02
ICheck spline area of coupling sleeves, hubs and gears for
wear or cracks.
ICheck baulk rings for cracks or deformation.
ICheck insert springs for wear or deformation.
IIf any crack, damage, or excessive wear is found on cam face
of baulk ring or working face of insert, replace it.
SMT675D 3rd & 4th
synchronizer
hub assembly
3rd input gear
SMT676D Input shaft
front bearing
SMT693D
SMT637A
SMT867D
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont'd)
MT-59

IMeasure the movement (play, dimension ªLº) of 3rd & 4th cou-
pling sleeve with their end fixed and the other end lifted as
shown in the figure. If the movement exceeds specification,
replace the sleeve.
Coupling sleeve Length ªLº
3rd & 4th0 - 0.95 mm (0 - 0.0374 in)
IMeasure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to SDS, MT-90.
BearingNCMT0011S03
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
ASSEMBLYNCMT0012
1. Press on input shaft front bearing.
2. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring
bearing to input shaft.
3. Install spread spring, shifting insert, and 3rd & 4th synchronizer
hub onto 3rd & 4th coupling sleeve.
IPay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting insert.
CAUTION:
Do not reuse 3rd & 4th synchronizer hub.
SMT841D Fixed
3rd & 4th coupling sleeve
Dimension ªLº
SMT140 Baulk ring to
gear clearance
SMT148A
SMT696D Input shaft
front bearing
Input shaft
SMT694D Shifting insert
(3rd & 4th) (5th & reverse)
Flat shape R-shape
Spread spring
Shifting insert
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont'd)
MT-60

IInstall synchronizer hub with its three grooves facing the front
side (3rd input gear side).
IInstall 3rd & 4th coupling sleeve with its chamfered surface
facing the 4th input gear side.
4. Position bearing replacer to the front side of input shaft front
bearing.
IAlign grooves of shifting insert and 3rd gear baulk ring. Then,
press it onto 3rd & 4th synchronizer hub assembly using a drift.
5. Install 4th gear C-ring onto input shaft.
6. Measure the end play of 3rd & 4th synchronizer hub, and
check if it is within allowable specification below.
End play specification:
0 - 0.06 mm (0 - 0.0024 in)
7. If not within specification, adjust the end play by changing
thickness of 4th gear C-ring.
Available C-ring:
Refer to SDS, MT-90.
8. Install 4th gear needle bearing, 4th gear baulk ring, and 5th
gear front C-ring.
9. Install 4th input gear.
SMT695D Front
SMT699D 4th input gear
3rd input gear
SMT698D 3rd & 4th
synchronizer
hub assembly
SMT700D Feeler gauge
3rd & 4th
synchronizer
hub assembly
4th gear C-ring
SMT701D 5th gear front C-ring
4th gear needle
bearing
4th gear baulk ring
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont'd)
MT-61

10. Position 5th input gear as shown in the figure, and install it on
input shaft.
11. Install 5th input gear.
CAUTION:
Do not reuse 5th input gear.
12. Install 5th gear rear C-ring onto input shaft.
13. Measure the end play of 5th input gear, and check if it is within
the allowable specification below.
End play specification:
0 - 0.06 mm (0 - 0.0024 in)
14. If not within specification, adjust the end play by changing
thickness of the 5th gear rear C-ring.
Available C-ring:
Refer to SDS, MT-90.
15. Install C-ring holder onto 5th gear rear C-ring.
CAUTION:
Do not reuse C-ring holder.
16. Install input shaft rear bearing.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the input gear side.
17. Install oil channel onto input shaft.
18. Measure gear end play as a final check. Refer to, MT-58.
SMT703D 5th input gear
4th input gear
SMT702D 5th input gear
4th input gear
SMT704D 5th input gear
5th rear C-ring
Feeler gauge
SMT705D Input shaft rear bearing
C-ring holder
SMT671D Oil channel
Input shaft
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont'd)
MT-62

Mainshaft and Gears
DISASSEMBLYNCMT0013
1. Before disassembly, measure gear end play.
Gear end play:
Refer to SDS, MT-90.
IIf end play is not within the specificed limit, disassemble and
check the parts.
2. Remove snap ring.
3. Remove C-ring holder and mainshaft C-ring.
4. Press out mainshaft rear bearing from mainshaft.
5. Remove mainshaft thrust washer.
6. Remove snap ring from mainshaft. Then, remove reverse main
gear assembly, reverse gear needle bearing, and reverse gear
baulk ring.
SMT760D Mainshaft assembly
Feeler
gauge
SMT677D Snap ring
SMT678D C-ring holder
Mainshaft C-ring
SMT679D Mainshaft rear
bearing
SMT680D Mainshaft
thrust washer
Reverse main
gear assembly
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears
MT-63