NISSAN ALMERA 2001 Service Manual

SMT938D
9. Install input shaft rear bearing.
10. Select and install snap ring that gives the proper clearance of
input shaft groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of input shaft rear bearing:
Refer to SDS, MT-120.
SMT605
Mainshaft and Gears
DISASSEMBLYNJMT00451. Before disassembly, check 1st, 2nd, 3rd and 4th main gear end
plays.
Gear end play:
Refer to SDS, MT-119.
+If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Then check clearance of C-ring
groove. Refer to ªASSEMBLYº, MT-42.
SMT641-A
2. Press out mainshaft front bearing.
SMT638-A
3. Press out mainshaft rear bearing.
SMT592-A
4. Remove C-ring holder, mainshaft C-rings and thrust washer.
REPAIR FOR COMPONENT PARTSRS5F30A
Input Shaft and Gears (Cont'd)
MT-39

SMT593-A
5. Press out 5th main gear.
SMT687C
6. Remove 4th main gear, 4th bushing and steel ball.
+Be careful not to lose steel ball.
SMT780AA
7. Remove 3rd & 4th synchronizer, 3rd main gear, 2nd & 3rd
bushing, steel ball and 2nd main gear.
+Be careful not to lose steel ball.
SMT594
8. Remove 1st & 2nd synchronizer and 1st main gear, then
remove 1st gear needle bearing.
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont'd)
MT-40

SMT604A
INSPECTIONNJMT0046Mainshaft and GearsNJMT0046S01+Check shaft for cracks, wear or bending.
+Check gears for excessive wear, chips or cracks.
SMT387A
SynchronizerNJMT0046S02+Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
+Check baulk rings for cracks or deformation.
+Check shifting inserts for wear or deformation.
SMT140
+Measure clearance between baulk ring and 1st-4th main
gears.
Clearance between baulk rings and 1st-4th main gears:
Standard
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)
SMT714CD
+Measure wear of 1st and 2nd baulk ring. (For double-cone
synchronizer only)
a) Place baulk rings in position on synchronizer cone.
b) While holding baulk ring against synchronizer cone as far as it
will go, measure dimensions ªAº and ªBº.
Standard:
A 0.7 - 0.9 mm (0.028 - 0.035 in)
B 0.7 - 1.0 mm (0.028 - 0.039 in)
Wear limit:
0.2 mm (0.008 in)
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont'd)
MT-41

+If dimension ªAº or ªBº is smaller than the wear limit,
replace outer baulk ring, inner baulk ring and synchro-
nizer cone as a set.
SPD715
BearingNJMT0046S03+Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
+When replacing tapered roller bearing, replace outer and
inner race as a set.
SMT603A
ASSEMBLYNJMT00471. Assemble 1st & 2nd and 3rd & 4th synchronizers.
SMT761B
+Be careful not to hook front and rear ends of spread
spring to the same insert.
SMT605AA
2. Install 1st gear needle bearing and 1st main gear.
3. Press on 1st & 2nd synchronizer.
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont'd)
MT-42

SMT085CA
4. Install steel ball, 2nd main gear, 2nd & 3rd bushing, 3rd main
gear and 3rd & 4th synchronizer.
+Apply multi-purpose grease to steel ball before installing
it.
+2nd & 3rd bushing has a groove in which steel ball fits.
SMT687C
5. Install steel ball, 4th bushing and 4th main gear.
+Apply multi-purpose grease to steel ball before installing
it.
+4th bushing has a groove in which steel ball fits.
SMT606AA
6. Press on 5th main gear.
SMT592-A
7. Install thrust washer.
8. Select and install mainshaft C-ring that gives proper clearance
of groove in mainshaft.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Mainshaft C-ring:
Refer to SDS, MT-120.
9. Install C-ring holder.
SMT607AA
10. Press on mainshaft rear bearing.
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont'd)
MT-43

SMT639
11. Press on mainshaft front bearing.
12. Measure gear end play as the final check Ð Refer to
ªDISASSEMBLYº, MT-39.
SMT647-A
Final Drive
DISASSEMBLYNJMT00481. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
+Be careful not to mix up the right and left bearings.
SMT147AA
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
SMT083A
INSPECTIONNJMT0049Gear, Washer, Shaft and CaseNJMT0049S01+Check mating surfaces of differential case, side gears and
pinion mate gears.
+Check washers for wear.
SPD715
BearingsNJMT0049S03+Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
+When replacing tapered roller bearing, replace outer and
inner race as a set.
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont'd)
MT-44

SMT839
ASSEMBLYNJMT00501. Attach side gear thrust washers to side gears and install in
differential case.
2. Install pinion mate thrust washers and pinion mate gears.
SMT087A
3. Insert pinion mate shaft.
+When inserting, be careful not to damage pinion mate
thrust washers.
SMT610AB
4. Measure clearance between side gear and differential case
with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
SMT611A
b. Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.
Clearance between side gear and differential case with
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
c. If not within specification, adjust clearance by changing thick-
ness of side gear thrust washers.
Differential side gear thrust washer:
Refer to SDS, MT-121.
SMT147AA
5. Install retaining pin.
+Make sure that retaining pin is flush with case.
REPAIR FOR COMPONENT PARTSRS5F30A
Final Drive (Cont'd)
MT-45

SMT609A
6. Install final gear.
+Apply locking sealant to final gear fixing bolts before
installing them.
7. Install speedometer drive gear and stopper.
SMT648
8. Press on differential side bearings.
SMT086C
Shift Control Components
INSPECTIONNJMT0051+Check contact surface and sliding surface for wear, scratches,
projections or other damage.
SMT660A
Case Components
DISASSEMBLY AND ASSEMBLYNJMT0052Input Shaft Oil SealNJMT0052S011. Drive out input shaft oil seal.
SMT751BA
2. Install input shaft oil seal.
+Apply multi-purpose grease to seal lip of oil seal before
installing.
REPAIR FOR COMPONENT PARTSRS5F30A
Final Drive (Cont'd)
MT-46

SMT688C
Input Shaft Rear BearingNJMT0052S021. Remove welch plug from transmission case.
SMT633
2. Remove input shaft rear bearing by tapping it from welch plug
hole.
SMT634
3. Install welch plug.
+Apply recommended sealant to mating surface of trans-
mission case.
SMT635-A
4. Install input shaft rear bearing.
SMT636-A
Mainshaft Front Bearing Outer Race and Oil ChannelNJMT0052S031. Remove mainshaft front bearing outer race.
2. Remove oil channel.
REPAIR FOR COMPONENT PARTSRS5F30A
Case Components (Cont'd)
MT-47

SMT595
3. Install oil channel.
+Ensure the oil groove faces the oil pocket.
SMT752BA
4. Install mainshaft front bearing outer race.
Mainshaft Rear Bearing Outer RaceNJMT0052S04+Refer to ªMainshaft Bearing Preloadº, MT-121.
Differential Side Bearing Outer RaceNJMT0052S06+Refer to ªDifferential Side Bearing Preloadº, MT-121.
REPAIR FOR COMPONENT PARTSRS5F30A
Case Components (Cont'd)
MT-48