NISSAN TERRANO 2004 Service Repair Manual

Clutch Master Cylinder
INSPECTION
ICheck cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
I Check piston and piston cup for wear or damage. Replace if
necessary.
I Check return spring for wear or damage. Replace if necessary.
I Check reservoir for deformation or damage. Replace if neces-
sary.
I Check dust cover for cracks, deformation or damage. Replace
if necessary.
Clutch Operating Cylinder
INSPECTION
ICheck rubbing surface of cylinder for wear, rust or damage.
Replace if necessary.
I Check piston and piston cup for wear or damage. Replace if
necessary.
I Check piston spring for wear or damage. Replace if necessary.
I Check dust cover for cracks, deformation or damage. Replace
if necessary.
SCL420-A
HYDRAULIC CLUTCH CONTROL
CL-8
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REMOVAL AND INSTALLATION
IInstall retainer spring and holder spring.
I Remove release bearing.
I Install release bearing with suitable drift.
NCL017
SCL217
CL145
SCL222
CLUTCH RELEASE MECHANISM
CL-9
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INSPECTION
ICheck release bearing to see that it rolls freely and is free from
noise, cracks, pitting or wear. Replace if necessary.
I Check release sleeve and withdrawal lever rubbing surface for
wear, rust or damage. Replace if necessary.
LUBRICATION
IApply recommended grease to contact surface and rubbing
surface.
Too much lubricant might cause clutch disc facing damage.
DUST COVER SEALING
I Apply recommended sealant to contact surface of dust cover to
transmission case and withdrawal lever and then install dust
cover clip.
NCL026
ECL006
CLUTCH RELEASE MECHANISM
CL-10
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Clutch Disc
INSPECTION
ICheck clutch disc for wear of facing.
Wear limit of facing surface to rivet head: 0.3 mm (0.012 in)
I Check clutch disc for spline backlash and facing runout.
Maximum spline backlash (at outer edge of disc): 1.0 mm (0.039 in)
Runout limit: 1.0 mm (0.039 in)
Distance of runout check point (from hub center): 120 mm (4.72 in)
I Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
INSTALLATION
IApply ªmolykote BR2 plusº grease to contact surface of splines
to clutch disc hub.
Too much lubricant might damage clutch disc facing.
YCL023
YCL024
YCL025
CLUTCH DISC AND CLUTCH COVER
CL-11
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Clutch Cover and Flywheel
INSPECTION AND ADJUSTMENT
ISet Tools and check height and unevenness of diaphragm
spring.
Diaphragm spring height ªAº: 36.5 - 38.5 mm (1.437 - 1.516 in)
I Check thrust rings for wear or damage by shaking cover
assembly and listening for chattering noise, or lightly hammer-
ing on rivets for a slight cracking noise. Replace clutch cover
assembly if necessary.
I Check pressure plate and clutch disc contact surface for slight
burns or discoloration. Repair pressure plate with emery paper.
I Check pressure plate and clutch disc contact surface for defor-
mation or damage. Replace if necessary.
I Adjust unevenness of diaphragm spring with Tool.
Uneven limit: 0.7 mm (0.028 in)
FLYWHEEL INSPECTION
ICheck contact surface of flywheel for slight burns or discolora-
tion. Repair flywheel with emery paper.
I Check flywheel runout.
Runout (Total indicator reading): Refer to EM section. (Inspection Ð CYLINDER
BLOCK)
SCL503
SCL504
SCL468
CLUTCH DISC AND CLUTCH COVER
CL-12
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INSTALLATION
IInsert Tool into clutch disc hub when installing clutch cover and
disc.
I Tighten bolts in numerical order.
I Be careful not to allow grease to contaminate clutch fac-
ing.
YCL026
CLUTCH DISC AND CLUTCH COVER
Clutch Cover and Flywheel (Cont'd)
CL-13
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General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch controlHydraulic
CLUTCH MASTER CYLINDER
Inner diametermm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in)
LHD 17.46 (11/16)
RHD 19.05 (3/4)
CLUTCH DISC
Unit: mm (in)
EngineTD27Ti ZD30DDTi
Model 250 260
Facing size
(Outer dia. x inner dia. x
thickness) 250 x 160 x 3.7
(9.84 x 6.30 x 0.1457)
Thickness of disc assembly
under load 7.0 - 7.4 (0.276 - 0.291)
Under a load of 5,884 N (600 kg, 1,323 lb)
CLUTCH COVER
Engine TD27TiZD30DDTi
Model 250 260
Full load N (kg, lb) 5,884 (600, 1,323) 6,760 (689, 1,520)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Handle LHDRHD
Pedal height* 227 - 237
(8.94 - 9.33) 210 - 220
(8.27 - 8.66)
Pedal stroke 155 - 160 (6.10 - 6.30)
Pedal free play
(Backlash at clevis) 1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of melt sheet to surface of pedal
pad
CLUTCH DISC
Unit: mm (in)
Engine TD27TiZD30DDTi
Disc model 250 260
Rear limit of facing
surface to rivet head 0.3 (0.012)
Runout limit of facing 1 (0.04)
Distance of runout
check point (from the
hub center) 120 (4.72)
Maximum of spline
backlash of spline (at
outer edge of disc) 1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Engine
TD27TiZD30DDTi
Cover model 250 260
Diaphragm spring height 36.5 - 38.5 (1.437 - 1.516)
Uneven limit of dia-
phragm spring toe height
ªAº 0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14
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MANUAL TRANSMISSIONSECTION
MT
CONTENTS
PREPARATION ................................................................2
Special Service Tools ..................................................2
Commercial Service Tools ...........................................4
TRANSMISSION FS5R30A .............................................5
Replacing the Rear Oil Seal ........................................5
FS5R30A
ON-VEHICLE SERVICE ..................................................6
Check of Position Switches .........................................6
REMOVAL AND INSTALLATION ....................................7
Removal .......................................................................7
Installation ....................................................................8
MAJOR OVERHAUL .....................................................10
Case Components .....................................................10
Gear Components ..................................................... 11 Shift Control Components .........................................13
DISASSEMBLY ..............................................................14
Case Components .....................................................14
Shift Control Components .........................................15
Gear Components .....................................................16
INSPECTION..................................................................21 Shift Control Components .........................................21
Gear Components .....................................................21
ASSEMBLY ....................................................................23
Gear Components .....................................................23
Shift Control Components .........................................31
Case Components .....................................................32
SERVICE DATA AND SPECIFICATIONS (SDS) ..........34
General Specifications ...............................................34
Inspection and Adjustment ........................................35
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Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST23540000*
Pin punch
Removing and installing retaining pin
ST30031000*
Puller
Removing 1st & 2nd synchronizer assembly
Removing counter gear rear thrust bearing
Removing main drive bearing
ST33290001*
Puller
Removing rear oil seal
ST33230000*
Drift
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
Removing mainshaft and counter gear
ST22350000*
Drift
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
Removing counter gear front bearing
(Use with KV38100300)
KV38100300*
Drift
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.
Removing counter gear front bearing
(Use with ST22350000)
Installing counter gear rear bearing
ST30720000*
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
Removing mainshaft front bearing
Installing mainshaft front bearing
PREPARATION
MT-2
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*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST33210000*
Drift
a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
Installing counter gear front bearing
Installing front cover oil seal
ST33220000*
Drift
a: 37 mm (1.46 in) dia.
b: 22 mm (0.87 in) dia.
Removing and installing counter gear rear end
bearing
ST30613000*
Drift
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
Installing main drive gear bearing
ST37750000*
Drift
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
Removing counter gear rear bearing
Installing OD gear bushing
Installing reverse cone
Installing reverse counter gear
Installing counter gear rear end bearing
ST22452000*
Drift
a: 40 mm (1.57 in) dia.
b: 36 mm (1.42 in) dia.
Installing reverse hub
Installing mainshaft rear bearing
ST33400001*
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
Installing rear oil seal
ST36730000*
Drift
a: 50 mm (1.97 in) dia.
b: 39 mm (1.54 in) dia.
Installing sub-gear on reverse
idler gear
PREPARATION
Special Service Tools (Cont'd)
MT-3
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