torque NISSAN ALMERA 2001 Service Manual

SMT649D
11. Install transaxle case onto clutch housing, and tighten mount-
ing bolts with specified torque.
Tightening torque:
Refer to MT-54.
SMT648D
12. Apply Three Bond TB1215, Loctite Part No. 51813 or equiva-
lent to threads of reverse switch, PNP switch, and drain plug,
and install them. (Fill the case with oil before installation of filler
plug.)
13. Install speedometer pinion assembly.
CAUTION:
Do not reuse O-ring.
SMT749D
14. Install check springs and check balls. Apply sealant to the
thread on the check plug, and install it.
SMT746D
15. Calculate thickness of adjusting shim using the following pro-
cedure to satisfy specification of end play for mainshaft rear
bearing.
End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension ªPº = (P1 ± P2) + End play
P: Thickness of adjusting shim
P1: Distance between transaxle case end face and
mainshaft rear bearing
P2: Distance between adjusting shim end face of
rear cover and transaxle mounting face
Mainshaft rear bearing adjusting shims:
Refer to SDS, MT-128.
ASSEMBLYRS5F70A
Transaxle Case (Cont'd)
MT-89

SMT644D
21. Install selected snap ring.
CAUTION:
Do not reuse snap ring.
22. Apply gear oil to rear cover O-ring, and install rear cover, side
cover gasket, and side cover. Then tighten mounting bolts with
specified torque.
Tightening torque:
Refer to MT-54.
CAUTION:
Do not reuse mounting bolts for rear cover and side cover.
ASSEMBLYRS5F70A
Transaxle Case (Cont'd)
MT-91

NJMT0022
Input Shaft End Play and Differential Side
Bearing Preload
NJMT0022S01If any of the following parts are replaced, adjust input shaft end
play.
+Input shaft
+Input shaft bearing
+Clutch housing
+Transmission case
If any of the following parts are replaced, adjust differential side
bearing preload.
+Differential case
+Differential side bearing
+Clutch housing
+Transmission case
SMT132AA
1. Remove differential side bearing outer race (transmission case
side) and shim(s).
SMT845B
2. Reinstall differential side bearing outer race without shim(s).
3. Install input shaft and final drive assembly on clutch housing.
4. Install transmission case without input shaft bearing shim(s).
Then tighten it to the specified torque.
Refer to ªCase Componentsº, MT-92.
SMT074A
5. Using the following procedures, measure clearance between
bearings and transmission case.
DIFFERENTIAL SIDENJMT0022S01011. Attach dial indicator. If clamp diameter of dial indicator is too
small or too large, attach dial indicator using a magnetic stand.
ADJUSTMENTRS5F50A
Input Shaft End Play and Differential Side Bearing Preload
MT-111

SMT075AA
2. Insert Tool all the way into differential side gear. Move Tool up
and down and measure dial indicator deflection.
SMT076A
INPUT SHAFT SIDENJMT0022S01021. Set dial indicator on end of input shaft.
2. Move input shaft up and down and measure dial indicator
deflection.
3. Select shims with proper thickness with SDS table as a guide.
Refer to SDS, MT-136.
4. Install selected differential side bearing adjusting shim and dif-
ferential side bearing outer race.
SMT475C
5. Check differential side bearing turning torque.
a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
+Tighten transmission case fixing bolts to the specified
torque. Refer to ªCase Componentsº, MT-92.
Mainshaft Bearing PreloadNJMT0022S02If any of the following parts are replaced, adjust mainshaft bearing
preload.
+Mainshaft
+Mainshaft bearings
+Clutch housing
+Transmission case
SMT077AA
1. Remove mainshaft rear bearing outer race and shim(s).
ADJUSTMENTRS5F50A
Input Shaft End Play and Differential Side Bearing Preload (Cont'd)
MT-112

SMT644AA
2. Reinstall mainshaft rear bearing outer race without shims.
3. Clean mating surfaces of clutch housing and transmission
case with solvent.
4. Install mainshaft and mainshaft front bearing outer race into
transmission case. Turn mainshaft while holding bearing outer
race so that bearings are properly seated.
SMT078A
SMT079A
5. Put straightedge [width must be more than 50 mm (1.97 in)] on
transmission case, and measure the distance from upper sur-
face of straightedge to surface of the bearing outer race using
a depth micrometer.
+Measure at three places on bearing outer race, and take
the average.
6. Determine dimension A to be used by the following equation.
Dimension A = Width of straightedge þ measured dis-
tance
7. Measure the distance from mating surface of clutch housing to
portion with which mainshaft front bearing outer race is to be
mated.
+Measure at three places on the portion, and take the aver-
age.
Dimension B = Measured distance
8. Determine dimension C to be used by the following equation.
Dimension ªCº=BþA
9. Determine total thickness of shims with SDS table as a guide.
Mainshaft bearing adjusting shim:
Refer to SDS, MT-134.
10. Install selected mainshaft bearing adjusting shim and main-
shaft bearing outer race.
11. Check total turning torque after assembly Ð Refer to
ªASSEMBLYº, MT-114.
ADJUSTMENTRS5F50A
Mainshaft Bearing Preload (Cont'd)
MT-113

SMT070A
17. Place magnet on clutch housing.
SMT446C
18. If bearing preload of mainshaft was adjusted, install selected
shim(s) into transmission case.
+To aid in installation of transmission case, place shift
selector in the 1st and 2nd shift bracket or between 1st
and 2nd bracket and 3rd and 4th bracket.
19. Apply sealant to mating surface of transmission case and
install it. Refer to ªCase Componentsº, MT-92.
20. Install PNP switch.
SMT626D
21. Apply sealant to threads of check plugs. Install balls, springs
and plugs. Refer to ªShift Control Componentsº, MT-94.
22. After assembly, check that you can shift into each gear
smoothly.
SAT478EA
23. Measure total turning torque.
Total turning torque (New bearing):
8.8 - 21.6 N´m (90 - 220 kg-cm, 78 - 191 in-lb)
+When old bearing is used again, preload will be slightly
less than the above. Make sure torque is close to the
specified range.
ASSEMBLYRS5F50A
MT-117

Gear End PlayNJMT0069Unit: mm (in)
Gear End play
1st main gear0.18 - 0.31 (0.0071 - 0.0122)
2nd main gear0.20 - 0.30 (0.0079 - 0.0118)
3rd main gear0.20 - 0.30 (0.0079 - 0.0118)
4th main gear0.20 - 0.30 (0.0079 - 0.0118)
5th input gear0.18 - 0.31 (0.0071 - 0.0122)
Clearance Between Baulk Ring and GearNJMT00701ST, 2ND, 3RD, 4TH & 5TH BAULK RINGNJMT0070S02Unit: mm (in)
Standard Wear limit
1.0 - 1.35 (0.0394 - 0.0531) 0.7 (0.028)
1ST AND 2ND DOUBLE BAULK RING (WHERE FITTED)NJMT0070S04Unit: mm (in)
SMT906D
Dimension Standard Wear limit
A 0.7 - 0.9 (0.028 - 0.035)
0.2 (0.008)
B 0.7 - 1.0 (0.028 - 0.039)
Available Check PlugsNJMT0071REVERSE CHECK PLUGSNJMT0071S01
Reverse check turning torque (At striking rod) N´m (kg-cm, in-lb) 4.9 - 7.4 (50 - 75, 43 - 65)
Thickness mm (in) Part number*2
8.3 (0.327) 32188-M8001*1
7.1 (0.280) 32188-M8002
7.7 (0.303) 32188-M8003
8.9 (0.350) 32188-M8004
*1: Standard size check plug
*2: Always check with the Parts Department for the latest parts information.
SERVICE DATA AND SPECIFICATIONS (SDS)RS5F30A
Gear End Play
MT-119

Available WashersNJMT0072DIFFERENTIAL SIDE GEAR THRUST WASHERNJMT0072S01
Allowable clearance between side gear and differential case with washer 0.1 - 0.2 mm (0.004 - 0.008 in)
Thickness mm (in) Part number*
0.76 - 0.81 (0.0299 - 0.0319) 38424-01M10
0.81 - 0.86 (0.0319 - 0.0339) 38424-01M11
0.86 - 0.91 (0.0339 - 0.0358) 38424-01M12
0.91 - 0.96 (0.0358 - 0.0378) 38424-01M13
*: Always check with the Parts Department for the latest parts information.
Available Shims Ð Mainshaft and Differential
Side Bearing Preload and Adjusting Shim
NJMT0073BEARING PRELOAD (REUSED BEARING)NJMT0073S01Unit: mm (in)
Mainshaft bearing Differential side bearing
0.20 - 0.25 (0.0079 - 0.0098) 0.24 - 0.32 (0.0094 - 0.0126)
TURNING TORQUE (NEW BEARING)NJMT0073S02Unit: N´m (kg-cm, in-lb)
Final drive only Total (Final drive + Mainshaft)
2.0 - 7.8 (20 - 80, 17 - 69) 3.9 - 12.3 (40 - 125, 35 - 109)
MAINSHAFT REAR BEARING ADJUSTING SHIMSNJMT0073S03
Thickness mm (in) Part number*
0.10 (0.0039) 32137-M8000
0.15 (0.0059) 32137-M8001
0.20 (0.0079) 32137-M8002
0.25 (0.0098) 32137-M8003
0.30 (0.0118) 32137-M8004
0.35 (0.0138) 32137-M8005
0.40 (0.0157) 32137-M8006
0.45 (0.0177) 32137-M8007
0.50 (0.0197) 32137-M8008
0.55 (0.0217) 32137-M8009
0.60 (0.0236) 32137-M8010
0.65 (0.0256) 32137-M8011
0.70 (0.0276) 32137-M8012
0.75 (0.0295) 32137-M8013
0.80 (0.0315) 32137-M8014
0.85 (0.0335) 32137-M8015
0.90 (0.0354) 32137-M8016
0.95 (0.0374) 32137-M8017
1.00 (0.0394) 32137-M8018
*: Always check with the Parts Department for the latest parts information.
SERVICE DATA AND SPECIFICATIONS (SDS)RS5F30A
Available Washers
MT-121

Available Shims=NJMT0029Ð INPUT SHAFT END PLAY AND MAINSHAFT AND DIFFERENTIAL SIDE BEARING PRELOAD AND
ADJUSTING SHIM
BEARING PRELOAD AND END PLAYNJMT0029S01Unit: mm (in)
Mainshaft bearing preload 0.06 - 0.11 (0.0024 - 0.0043)
Input shaft end play0 - 0.05 (0 - 0.0020)
Differential side bearing preload 0.40 - 0.45 (0.0157 - 0.0177)
TOTAL TURNING TORQUE (NEW BEARING)NJMT0029S02Unit: N´m (kg-cm, in-lb)
Total turning torque (new bearing) 8.8 - 21.6 (90 - 220, 78 - 191)
MAINSHAFT BEARING ADJUSTING SHIMNJMT0029S03
Thickness mm (in) Part number*
0.40 (0.0157)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
1.20 (0.0472)32139-03E11
32139-03E00
32139-03E01
32139-03E12
32139-03E02
32139-03E03
32139-03E04
32139-03E05
32139-03E06
32139-03E07
32139-03E08
32139-03E13
*: Always check with the Parts Department for the latest parts information.
TABLE FOR SELECTING MAINSHAFT BEARING ADJUSTING SHIM(S)NJMT0029S04Unit: mm (in)
Dimension ªCº Suitable shim(s)
0.30 - 0.34 (0.0118 - 0.0134)
0.34 - 0.38 (0.0134 - 0.0150)
0.38 - 0.42 (0.0150 - 0.0165)
0.42 - 0.46 (0.0165 - 0.0181)
0.46 - 0.50 (0.0181 - 0.0197)
0.50 - 0.54 (0.0197 - 0.0213)
0.54 - 0.58 (0.0213 - 0.0228)
0.58 - 0.62 (0.0228 - 0.0244)
0.62 - 0.66 (0.0244 - 0.0260)
0.66 - 0.70 (0.0260 - 0.0276)
0.70 - 0.74 (0.0276 - 0.0291)
0.74 - 0.78 (0.0291 - 0.0307)
0.78 - 0.82 (0.0307 - 0.0323)
0.82 - 0.86 (0.0323 - 0.0339)
0.86 - 0.90 (0.0339 - 0.0354)
0.90 - 0.94 (0.0354 - 0.0370)
0.94 - 0.98 (0.0370 - 0.0386)
0.98 - 1.02 (0.0386 - 0.0402)
1.02 - 1.06 (0.0402 - 0.0417)
1.06 - 1.10 (0.0417 - 0.0433)
1.10 - 1.14 (0.0433 - 0.0449)
1.14 - 1.18 (0.0449 - 0.0465)
1.18 - 1.22 (0.0465 - 0.0480)
1.22 - 1.26 (0.0480 - 0.0496)
1.26 - 1.30 (0.0496 - 0.0512)
1.30 - 1.34 (0.0512 - 0.0528)
1.34 - 1.38 (0.0528 - 0.0543)
1.38 - 1.42 (0.0543 - 0.0559)
1.42 - 1.46 (0.0559 - 0.0575)
1.46 - 1.50 (0.0575 - 0.0591)0.40 (0.0157)
0.44 (0.0173)
0.48 (0.0189)
0.52 (0.0205)
0.56 (0.0220)
0.60 (0.0236)
0.64 (0.0252)
0.68 (0.0268)
0.72 (0.0283)
0.76 (0.0299)
0.80 (0.0315)
0.40 + 0.44 (0.0157 + 0.0173)
0.44 + 0.44 (0.0173 + 0.0173)
0.44 + 0.48 (0.0173 + 0.0189)
0.48 + 0.48 (0.0189 + 0.0189)
0.48 + 0.52 (0.0189 + 0.0205)
0.52 + 0.52 (0.0205 + 0.0205)
0.52 + 0.56 (0.0205 + 0.0220)
0.56 + 0.56 (0.0220 + 0.0220)
0.56 + 0.60 (0.0220 + 0.0236)
0.60 + 0.60 (0.0236 + 0.0236)
0.60 + 0.64 (0.0236 + 0.0252)
0.64 + 0.64 (0.0252 + 0.0252)
0.64 + 0.68 (0.0252 + 0.0268)
0.68 + 0.68 (0.0268 + 0.0268)
0.68 + 0.72 (0.0268 + 0.0283)
0.72 + 0.72 (0.0283 + 0.0283)
0.72 + 0.76 (0.0283 + 0.0299)
0.76 + 0.76 (0.0299 + 0.0299)
0.76 + 0.80 (0.0299 + 0.0315)
SERVICE DATA AND SPECIFICATIONS (SDS)RS5F50A
Available Shims
MT-134

Trouble DiagnosesNJSC0011Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suit-
able test probes are necessary for the test. The alternator can be checked easily by referring to the Inspec-
tion Table.
+Before starting, inspect the fusible link.
+Use fully charged battery.
WITH IC REGULATORNJSC0011S01
SEL338V
NOTE:
+If the inspection result is OK even though the charging system is malfunctioning, check the B terminal
connection. (Check the tightening torque.)
+When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary, replace faulty
parts with new ones.
MALFUNCTION INDICATORNJSC0011S02The IC regulator warning function activates to illuminate ªCHARGEº warning lamp, if any of the following
symptoms occur while alternator is operating:
+Excessive voltage is produced.
+No voltage is produced.
CHARGING SYSTEM
Trouble Diagnoses
SC-30