NISSAN ALMERA 2001 Service Manual

SMT760D
Mainshaft and Gears
DISASSEMBLYNJMT00591. Before disassembly, measure gear end play.
Gear end play:
Refer to SDS, MT-124.
+If end play is not within the specificed limit, disassemble and
check the parts.
SMT677D
2. Remove snap ring.
SMT678D
3. Remove C-ring holder and mainshaft C-ring.
SMT679DB
4. Press out mainshaft rear bearing from mainshaft.
SMT680D
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.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears
MT-69

SMT681DB
7. Place bearing replacer between 5th & reverse synchronizer
hub and 5th main gear, and press out both reverse gear bush-
ing and 5th & reverse synchronizer assembly.
8. Remove 5th main gear, 5th gear baulk ring, and 5th gear
needle bearing.
SMT682DB
9. Place bearing replacer between 3rd and 4th main gears, and
press out both 5th gear bushing and 4th main gear.
SMT683D
10. Remove mainshaft adjusting shim and spacer.
11. Place bearing replacer between 2nd main gear and 1st & 2nd
synchronizer hub, and press out both 3rd and 2nd main gears.
SMT684DB
12. Remove 2nd double cone assembly, 2nd gear bushing, and
coupling sleeve assembly.
13. Place bearing replacer on 1st gear front side, and press out all
of 2nd gear bushing, 1st & 2nd synchronizer hub, 1st main
gear, and 1st double cone.
14. Remove 1st gear needle bearing.
SMT693D
INSPECTIONNJMT0060Mainshaft and GearsNJMT0060S01+Check shaft for cracks, wear or bending.
+Check gears for excessive wear, chips or cracks.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-70

SMT637A
SynchronizersNJMT0060S02+Check spline area of coupling sleeves, hubs and gears for
wear or cracks.
+Check baulk rings for cracks or deformation.
+Check insert springs for wear or deformation.
SMT867D
+If any crack, damage, or excessive wear is found on cam face
of baulk ring or working face of insert, replace it.
SMT868D
+Measure the movement (play, dimension ªLº) of 1st & 2nd
coupling sleeve and 5th & reverse coupling 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:
Refer to SDS, MT-124.
SMT140
+Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to SDS, MT-124.
SMT714CD
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-71

+Measure wear of 1st and 2nd baulk ring.
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 0.6 - 0.8 mm (0.024 - 0.031 in)
B 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit:
0.2 mm (0.008 in)
+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.
SMT148A
BearingNJMT0060S03+Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT706D
ASSEMBLYNJMT00611. Install 1st gear needle bearing and 1st main gear onto main-
shaft.
2. Install 1st double cone assembly onto mainshaft.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-72

SMT695D
3. Install 1st & 2nd synchronizer hub with its three grooves fac-
ing the front side (1st main gear side) onto mainshaft.
CAUTION:
Do not reuse 1st & 2nd synchronizer hub.
SMT707DB
4. Install 1st & 2nd synchronizer hub.
SMT994BB
5. Install insert spring onto 1st & 2nd coupling sleeve.
SMT708D
6. Install 1st & 2nd coupling sleeve with its chamfered surface
facing the 1st main gear side onto 1st & 2nd synchronizer hub.
SMT709DB
7. Install 2nd gear bushing with its flange surface facing 1st & 2nd
synchronizer hub side.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-73

SMT710DB
8. Install 2nd needle bearing, 2nd double cone assembly, and
2nd main gear onto mainshaft.
9. Position 3rd main gear as shown in the figure, and install it.
CAUTION:
Do not reuse 3rd main gear.
SMT711D
10. Install spacer and mainshaft adjusting shim onto mainshaft.
11. Select a mainshaft adjusting shim suitable to satisfy the follow-
ing specification of dimension ªLº and install it onto mainshaft.
Specification of dimension ªLº:
151.35 - 151.45 mm (5.9586 - 5.9626 in)
Mainshaft adjusting shims:
Refer to SDS, MT-128.
SMT713D
12. Position 4th main gear as shown in the figure, and install it onto
mainshaft.
SMT712DB
13. Install 4th main gear onto mainshaft.
CAUTION:
Do not reuse 4th main gear.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-74

SMT714DB
14. Install 5th gear bushing with its flange surface facing the 4th
main gear side.
SMT761D
15. Install 5th needle bearing, 5th main gear, and 5th gear baulk
ring onto mainshaft.
SMT694D
16. Being careful of the following points, install spread spring, shift-
ing insert, and 5th & reverse synchronizer hub onto 5th &
reverse coupling sleeve.
+Pay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting insert.
SMT695D
+Install synchronizer hub with its three grooves facing the front
side (5th main gear side).
CAUTION:
Do not reuse 5th & reverse synchronizer hub.
SMT716D
+Install 5th & reverse coupling sleeve with its chamfered surface
facing the reverse main gear side.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-75

SMT715DB
17. Install 5th & reverse synchronizer hub assembly.
SMT717DB
18. Install reverse gear baulk ring.
19. Install reverse gear busing.
20. Install reverse gear needle bearing.
SMT718D
21. Install sub-gear, sub-gear washer, and snap ring onto reverse
main gear.
CAUTION:
+Pay attention to direction of sub-gear washer.
+Do not reuse snap ring.
SMT719D
22. Install reverse main gear assembly onto mainshaft.
23. Select a thrust washer suitable to satisfy the following specifi-
cation of dimension ªMº (as shown in the figure), and install it
onto mainshaft.
Specification of dimension ªMº:
244.20 - 244.30 mm (9.6142 - 9.6181 in)
Available mainshaft thrust washers:
Refer to SDS, MT-129.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-76

SMT720DB
24. Install mainshaft rear bearing.
SMT721D
25. Install mainshaft C-ring.
26. Using feeler gauge, measure the end play of mainshaft rear
bearing, and check if it satisfies the following specification.
End play:
0 - 0.06 mm (0 - 0.0024 in)
Mainshaft C-rings:
Refer to SDS, MT-126.
SMT678D
27. Install C-ring holder.
SMT677D
28. Install snap ring.
29. Measure gear end play as a final check. Refer to, MT-69.
SMT610AH
Final Drive
PRE-INSPECTIONNJMT0062+Check the clearance between side gear and differential case
as follows.
1. Clean final drive assembly sufficiently to prevent side gear
thrust washer, differential case, side gear, and other parts from
sticking by gear oil.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-77

SMT685DC
2. Upright the differential case so that the side gear to be mea-
sured faces upward.
3. Place final drive adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.
Clearance between side gear and differential case:
0.1 - 0.2 mm (0.004 - 0.008 in)
4. If not within specification, adjust the clearance by changing
thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
SMT609A
DISASSEMBLYNJMT00631. Remove mounting bolts. Then, separate the final gear from
differential case.
2. Make a notch and remove speedometer drive gear using a
scraper or other suitable tool.
+Bearing replacer cannot be positioned unless speedom-
eter drive gear is removed.
SMT647-C
3. Remove differential side bearing of final gear side.
4. Turn differential case upside down, and remove differential
side bearing of speedometer drive gear side.
+Be careful not to mix up the differential side bearings.
5. Remove speedometer stopper.
SMT689DB
6. Remove lock pins from pinion mate shaft.
SMT839
7. Remove pinion mate shaft.
8. Rotate pinion mate gear, and remove pinion mate gear, pinion
mate thrust washer, side gear, and side gear thrust washer
from differential case.
REPAIR FOR COMPONENT PARTSRS5F70A
Final Drive (Cont'd)
MT-78