NISSAN ALMERA 2001 Service Manual

SMT083A
INSPECTIONNJMT0064Gear, Washer, Shaft and CaseNJMT0064S01+Check mating surfaces of differential case, side gears and
pinion mate gears.
+Check washers for wear.
SPD715
BearingNJMT0064S03+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.
SMT062A
ASSEMBLYNJMT00651. Apply gear oil to sliding area of differential case, each gear,
and thrust washer.
2. Install side gear thrust washer and side gear into differential
case.
3. Position pinion mate gear and pinion mate thrust washer
diagonally, and install them into differential case while rotating.
SMT087A
4. Insert pinion mate shaft into differential case.
SMT685DC
5. Upright the differential case so that its side gear to be mea-
sured faces upward.
6. Place preload adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.
7. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
Clearance of side gear and differential case:
0.1 - 0.2 mm (0.004 - 0.008 in)
Differential side gear thrust washers:
Refer to SDS, MT-129.
REPAIR FOR COMPONENT PARTSRS5F70A
Final Drive (Cont'd)
MT-79

SMT699BB
8. Install retaining pin.
+Make sure that retaining pin is flush with case.
SMT842D
9. Align and install speedometer drive gear into differential case.
10. Install speedometer stopper.
SMT751DB
11. Install differential side bearing.
12. Turn differential case upside down, and install another differ-
ential side bearing on the other side in the same way.
SMT752D
13. Install differential gear into differential case. Apply sealant onto
mounting bolts, and tighten them in order as shown in the fig-
ure with specified torque.
Tightening torque:
Refer to MT-57.
REPAIR FOR COMPONENT PARTSRS5F70A
Final Drive (Cont'd)
MT-80

SMT801D
Shift Control Components
INSPECTION=NJMT0066+Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.
ItemOne-side wear specifi-
cationSliding width of new part
1st & 2nd 0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
3rd & 4th 0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
5th & reverse 0.2 mm (0.008 in)7.80 - 7.93 mm
(0.3071 - 0.3122 in)
SMT692D
+Check if shift check groove of fork rod or 5th & reverse check
groove is worn, or has any other abnormalities.
REPAIR FOR COMPONENT PARTSRS5F70A
Shift Control Components
MT-81

NJMT0067
SMT722DB
Clutch HousingNJMT0067S011. Hammer the striking rod oil seal into clutch housing as far as
it will go.
CAUTION:
Do not reuse striking rod oil seal.
SMT723DA
2. Hammer the differential oil seal into clutch housing until it
becomes flush with clutch housing end face.
CAUTION:
Do not reuse differential oil seal.
SMT724DA
3. Hammer input shaft oil seal into clutch housing as far as it will
go.
CAUTION:
Do not reuse input shaft oil seal.
SMT725DB
4. Hammer the dust seal into clutch housing as far as it will go.
CAUTION:
Do not reuse dust seal.
SMT726DB
5. Install outer race of differential side bearing.
ASSEMBLYRS5F70A
Clutch Housing
MT-82

SMT727D
6. Install new oil channel (mainshaft).
CAUTION:
Pay attention to installation direction of oil channel.
SMT728DA
7. Align the notches on mainshaft front bearing and transaxle
case. Then, install mainshaft front bearing.
SMT729D
8. Install mainshaft bearing retainer, and tighten bolts with speci-
fied torque.
SMT667DB
9. Attach boot, striking rod, and striking lever to clutch housing.
And install retaining pin for selector lever.
CAUTION:
+Before installing striking rod, wrap the end with a vinyl
tape or the like to prevent oil seal from being damaged.
+Do not reuse retaining pin.
SMT730D
10. Hammer the welch plug (striking lever side) with a general-
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Do not reuse welch plug.
ASSEMBLYRS5F70A
Clutch Housing (Cont'd)
MT-83

SMT731D
11. Install selector, selector shaft, and selector shaft pin into clutch
housing.
SMT732D
12. Hammer the welch plug (selector shaft side) with a general-
purpose drift [OD: 12 mm (0.47 in)].
CAUTION:
Do not reuse welch plug.
SMT733DA
SMT734D
13. Install select check leaf spring, return spring, steel ball, reverse
gate, selector arm, bushing, and return bearing. Then, tighten
two reamer bolts with specified torque.
CAUTION:
Use correct reamer bolts for each installation point, because
each bolt has a different length.
SMT735D
14. Install oil pocket.
ASSEMBLYRS5F70A
Clutch Housing (Cont'd)
MT-84

SMT736D
15. Install differential assembly, input shaft assembly, and main-
shaft assembly into clutch housing.
CAUTION:
Be careful not to damage input shaft oil seal during installa-
tion of input shaft assembly.
SMT659DC
16. Install 5th & reverse shift fork.
17. Install 1st & 2nd shift fork, bracket, and fork rod.
18. Install retaining pin for 1st & 2nd bracket.
CAUTION:
Do not reuse retaining pin.
19. Install two check balls.
SMT657DC
20. Install interlock pin into 5th & reverse fork rod.
21. Install reverse switch bracket, 5th & reverse bracket, and fork
rod.
22. Install retaining pin for 5th & reverse shift fork and reverse
switch bracket.
CAUTION:
Do not reuse retaining pin.
23. Install 5th & reverse bracket stopper ring.
CAUTION:
Do not reuse stopper pin.
SMT656DC
24. Install check ball and interlock plunger.
25. Install 3rd & 4th shift fork, bracket, and fork rod.
26. Install 3rd & 4th bracket retaining pin.
CAUTION:
Do not reuse retaining pin.
SMT655D
27. Install 3rd & 4th shift fork stopper ring.
CAUTION:
Do not reuse stopper ring.
28. Install check ball, check pin, and check spring, and apply
Three Bond TB1215, Loctite Part No. 51813 or equivalent onto
check plug. Then, tighten it with specified torque.
Tightening torque:
Refer to MT-56.
ASSEMBLYRS5F70A
Clutch Housing (Cont'd)
MT-85

SMT737DA
Transaxle CaseNJMT0067S021. Insert differential oil seal into differential case until it becomes
flush with case end face.
SMT739D
2. Install welch plug into transaxle case.
SMT740D
3. Calculate dimension ªNº (thickness of adjusting shim) using
the following procedure to satisfy specification of end play for
differential side bearing.
End play: 0.15 - 0.21 mm (0.0059 - 0.0083 in)
Dimension ªNº = (N1 ± N2) + End play
N: Thickness of adjusting shim
N1: Distance between clutch housing case end
face and mounting face of adjusting shim
N2: Distance between differential side bearing and
transaxle case
Differential side bearing adjusting shims:
Refer to SDS, MT-130.
SMT741D
a. Using dial gauge and scale, measure dimension ªN1º between
clutch housing case end face and mounting face of adjusting
shim.
ASSEMBLYRS5F70A
Transaxle Case
MT-86

SMT742D
b. Install outer race onto differential side bearing on final gear
side. Holding lightly the outer race horizontally by hand, rotate
final gear five times or more (for smooth movement of bearing
roller).
c. Using dial gauge and scale as shown in the figure, measure
dimension ªN2º between differential side bearing outer race
and transaxle case end face.
SMT738DB
4. Install selected shim and bearing outer race.
SMT600-F
5. Measure turning torque of final drive assembly.
Turning torque of final drive assembly
(New bearing):
2.9 - 6.9 N´m (30 - 70 kg-cm, 26 - 61 in-lb)
+When old bearing is used again, turning torque will be
slightly less than the above.
+Make sure torque is close to the specified range.
+Changes in turning torque of final drive assembly per
revolution should be within 1.0 N´m (10 kg-cm, 8.7 in-lb)
without binding.
SMT743D
6. Calculate dimension ªOº (thickness of adjusting shim) using
the following procedure to satisfy specification of end play for
input shaft rear bearing.
End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension ªOº = (O1 ± O2) + End play
O: Thickness of adjusting shim
O1: Distance between transaxle case end face and
mounting face of adjusting shim
O2: Distance between clutch housing case end
face and end face of input shaft rear bearing
Input shaft rear bearing adjusting shims:
Refer to SDS, MT-127.
ASSEMBLYRS5F70A
Transaxle Case (Cont'd)
MT-87

SMT744D
a. Using block gauge, scale, and dial gauge, measure dimension
ªO1º between transaxle case end face and mounting face of
adjusting shim.
SMT745D
b. Using gauge block, scale, and dial gauge as shown in the
figure, measure dimension ªO2º between clutch housing case
end face and end face of input shaft rear bearing.
7. Install selected input shaft rear bearing adjusting shim onto
input shaft.
SMT650D
8. Install oil gutter into transaxle case.
SMT755D
9. Install two magnets.
SMT802D
10. Clean mating surfaces of clutch housing and transaxle case.
Check for cracks and damage. Then, apply Three Bond
TB1215, Loctite Part No. 51813 or equivalent.
ASSEMBLYRS5F70A
Transaxle Case (Cont'd)
MT-88