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

SMT747D
a. Using dial gauge as shown in the figure, measure dimension
ªP1º between transaxle case end face and mainshaft rear
bearing.
SMT748D
b. Using dial gauge as shown in the figure, measure dimension
ªP2º between adjusting shim mounting face of rear cover and
transaxle mounting face.
SMT646D
16. Using snap ring pliers as shown in the figure, install snap ring.
CAUTION:
Do not reuse snap ring.
17. Install selected mainshaft adjusting shim.
SMT753DA
18. Install reverse idler gear, O-ring, thrust washers (front, rear),
and bearing onto reverse idler shaft.
19. Install snap ring into transaxle case using snap ring pliers.
CAUTION:
+Do not reuse snap ring.
+Do not reuse O-ring.
+Before installation, apply gear oil to O-ring.
SMT754D
20. Using feeler gauge, measure the end play of snap ring, and
select a snap ring suitable to satisfy the following specification.
End play:
0.05 - 0.25 mm (0.0020 - 0.0098 in)
Available snap ring:
Refer to SDS, MT-125.
ASSEMBLYRS5F70A
Transaxle Case (Cont'd)
MT-90

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

NJMT0009
Case ComponentsNJMT0009S02
SMT943D
1. Speedometer pinion
2. Differential oil seal
3. Drain plug
4. Boot
5. Striking rod oil seal
6. Magnet
7. Clutch housing8. Input shaft oil seal
9. Oil channel (Mainshaft)
10. Oil pocket
11. Oil gutter
12. Oil channel (Input shaft)
13. Transmission case14. Filler plug
15. O-ring
16. Movable plate assembly
17. PNP switch
18. Breather hose
19. Breather pipe
OVERHAULRS5F50A
Case Components
MT-92

Gear ComponentsNJMT0009S03
SMT937D
1. Input shaft
2. Input shaft front bearing
3. 3rd input gear
4. 3rd & 4th synchronizer hub
5. Snap ring
6. Coupling sleeve
7. 4th baulk ring
8. 4th input gear
9. Reverse baulk ring
10. Reverse synchronizer cone
11. 5th synchronizer hub
12. Input shaft rear bearing
13. Input shaft bearing adjusting shim
14. 3rd baulk ring
15. Insert spring
16. 4th input gear thrust washer
17. Thrust washer ring
18. 5th input gear19. 5th baulk ring
20. 1st outer baulk ring
21. 2nd inner baulk ring
22. Snap ring
23. Mainshaft bearing spacer
24. Mainshaft front bearing
25. Mainshaft
26. 1st main gear
27. 1st & 2nd synchronizer hub
28. Reverse main gear & 1st-2nd cou-
pling sleeve
29. 2nd outer baulk ring
30. 2nd gear synchronizer cone
31. 2nd main gear
32. 3rd main gear
33. 4th main gear
34. 5th main gear
35. Mainshaft rear bearing
36. Mainshaft bearing adjusting shim37. Differential side bearing
38. Speedometer drive gear
39. Differential case
40. Pinion mate shaft
41. Side gear
42. Side gear thrust washer
43. Pinion mate gear
44. Pinion mate gear thrust washer
45. Retaining pin
46. Final gear
47. Differential side bearing
48. Differential side bearing adjusting
shim
49. Reverse idler gear
50. Bushing
51. Reverse idler shaft
52. 1st gear synchronizer cone
53. 1st inner baulk ring
OVERHAULRS5F50A
Gear Components
MT-93

Shift Control ComponentsNJMT0009S04
SMT862CA
1. Retaining pin
2. 1st & 2nd shift fork
3. 1st & 2nd check plug
4. Return spring
5. Check ball
6. 1st & 2nd fork rod
7. 1st & 2nd bracket
8. Interlock plunger
9. 3rd & 4th bracket
10. Return spring
11. Reverse gate
12. Select arm
13. Return bearing
14. Bush15. Yoke
16. Striking rod
17. Striking lever
18. Selector
19. Selector shaft
20. O-ring
21. Return spring
22. Cam pin
23. Reverse check cam
24. Check ball
25. Select check spring
26. Interlock plunger
27. 3rd & 4th fork rod28. Interlock ball
29. Stopper ring
30. 3rd & 4th check plug
31. 3rd & 4th shift fork
32. 5th shift fork
33. 5th fork rod
34. 5th & reverse check plug
35. Reverse lever spring
36. Reverse lock spring
37. 5th & reverse bracket
38. Reverse lever assembly
39. Reverse arm shaft
40. Control lever spring
OVERHAULRS5F50A
Shift Control Components
MT-94

NJMT0010
SMT626D
1. Before removing transmission case, remove bolts, check
plugs, springs and check balls as shown left.
+Be careful not to lose check balls.
2. Remove transmission case.
SMT017AA
3. Remove PNP switch.
SMT659C
4. Mesh 4th gear, and then remove reverse idler shaft and
reverse idler gear.
SMT660C
5. Pull out retaining pin.
SMT661C
6. Remove reverse lever spring and reverse lock spring from
reverse lever assembly.
DISASSEMBLYRS5F50A
MT-95

SMT662C
7. Remove reverse arm shaft while rotating it.
SMT663C
8. Remove reverse lever assembly and check ball.
+Be careful not to lose check ball.
SMT018B
9. Remove 5th & reverse check plug, spring and ball.
+Be careful not to lose check ball.
SMT664C
10. Remove stopper rings and retaining pins from 5th and 3rd &
4th fork rods.
When removing stopper rings. Use snap ring remover and
installer.
11. Remove 5th and 3rd & 4th fork rods. Then remove forks and
brackets.
SMT105C
12. Remove both input and mainshafts with 1st & 2nd fork and fork
rod as a set.
13. Remove final drive assembly.
+Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
DISASSEMBLYRS5F50A
MT-96

SMT138A
14. Remove reverse check assembly and check ball.
+Be careful not to lose check ball.
SMT618AA
SMT027A
15. Remove retaining pin and detach the selector.
SMT028A
16. Remove drain plug for convenience in removing retaining pin
which holds striking lever to striking rod.
SMT619AA
17. Remove retaining pin and then withdraw striking lever and
striking rod.
DISASSEMBLYRS5F50A
MT-97

SMT121C
Input Shaft and Gears
DISASSEMBLYNJMT00111. Before disassembly, check 3rd, 4th and 5th input gear end
plays.
Gear end play:
Refer to SDS, MT-132.
SMT476C
+If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Check clearance of snap ring
groove. Refer to ªASSEMBLYº, MT-100.
SMT634AA
2. Remove input shaft rear bearing.
SMT205BA
3. Remove 5th & reverse synchronizer and 5th input gear.
SMT474CA
4. Remove thrust washer ring, 4th input gear thrust washers and
4th input gear.
REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears
MT-98