NISSAN ALMERA N15 1995 Service Manual

AUTOMATICTRANSAXLE

SECTION
AT
CONTENTS
PREPARATION ANDPRECAUTIONS
3

Special Service Tools 3
Commercial ServiceTools 6
Service Notice 7
Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System) 7
Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System) 7
DESCRIPTION
8

Cross-sectional View 8
Hydraulic ControlCircuit 10
Shift Mechanism 14
Control System 15
TROUBLE DIAGNOSES 17
Preliminary Check(PriortoRoad Testing) 17
Road Testing 17
Stall Tasting 24
Pressure Testing 26
Wiring Diagram -AT - 28
Electrical Components Inspection 30
ON-VEHICLE SERVICE 31
Control ValveAssembly andAccumulator 31
Throttle WireAdjustment.. 33
Control CableInstallation andAdjustment 35
Governor Valve 36
Inhibitor SwitchAdjustment 37
Differential SideOilSeal Replacement.. 37
REMOVAL ANDINSTALLATION
39

Removal 39
Installation .40MAJOR
OVERHAUL.. 42
All Models 42
Except Model34X81 .44
Model 34X81 45•
Shift Control Components 46
i

Oil Channel 47
Locations ofAdjusting Shims,Needle
Bearings, ThrustWashers andSnap Rings -
Except Model34X81 .48
Locations ofAdjusting Shims,Needle
Bearings, ThrustWashers andSnap Rings -
Model 34X81 .49
DiSASSEMBLy 50
REPAIR FORCOMPONENT PARTS 66
Manual ShaftandThrottle Lever 66
Oil Pump 70
Control ValveAssembly 74
Control ValveUpper Body 86
Control ValveLower Body 90
Reverse Clutch 93
High Clutch 97
Forward ClutchandOverrun Clutch 102
Low &Reverse Brake 108
Rear Internal Gear,Forward ClutchHuband
Overrun ClutchHub 112
Output Shaft,Output Gear,IdlerGear,
Reduction PinionGearandBearing Retainer
- Except Model34X81 116
Output Shaft,IdlerGear, Reduction Pinion
Gear andBearing Retainer -Model 34X81 121
Band Servo Piston Assembly 126
Final Drive -Except Model34X81 131
Final Drive -Model 34X81 135

CONTENTS(Cont'd.)
ASSEMBLy 138

Assembly
1 138

Adjustment
1 139

Assembly 2 147
Adjustment
2 151

Assembly
3 155
Adjustment

3 157

Assembly
4 158
SERVICE DATAANDSPECIFICATIONS (SOS)165

General Specifications
165

Specifications andAdjustments 165

When youread wiring diagrams:
• Read GIsection, "HOWTOREAD WIRING DIAGRAMS" .
• See ELsection, "POWER SUPPLYROUTING" forpower distribution circuit.

Toolnumber
Tool name
PREPARATION
ANDPRECAUTIONS
Special Service Tools

Description
8T25058001
Oil pressure gaugeset

G)
8T25051001
Oil pressure gauge
@ 8T25052000
Hose

@
8T25053000
Joint pipe

@
8T25054000
Adapter

@
8T25055000
Adapter Measuring
linepressure andgovernor
pressure

NT097

KV31103000
Drift
8T35325000 Drift
KV31103200
Clutch spring compressor
8T23540000 Pin punch
KV32101000
Pin punch
NT105
NT417
NT425
NT442
NT410
AT-3
Installing
differential sideoilseal
(Use with8T35325000)

a: 59 mm (2.32 in)dia.
b: 49 mm (1.93 in)dia.

Installing differential sideoilseal
(Use withKV31103000)

a: 215 mm (8.46 in)
b: 25 mm (0.98 in)dia.
c: M12 x1.5P

Removing andinstalling clutchreturn
spring

a: 179 mm (7.05 in)
b: 76 mm (2.99 in)dia.
c: 174 mm (6.85 in)

Removing andinstalling parkingrodplate
and manual plate

a: 2.3 mm (0.091 in)dia.
b: 4mm (0.16 in)dia.

Installing throttleleverandmanual shaft
retaining pins
Removing andinstalling differential pinion
mate shaft lockpin.

a: 4mm (0.16 in)dia.
•

Toolnumber
Tool name
PREPARATION
ANDPRECAUTIONS
Special Service Tools(Cont'd)

Description
ST3306S001
Differential sidebearing
puller set

CD
ST33051 001
Puller

@
ST33061000
Adapter
KV381054S0
(ST33290001) Puller
NT413
NT414 ,~

a
Removing
differential sidebearing inner
race
a: 38 mm (1.50 in)dia.
b: 28.5 mm(1.122 in)dia.
c: 130 mm (5.12 in)
d: 135 mm (5.31 in)
e: 100 mm (3.94 In)
• Removing differential sideoilseal
• Removing idlergear bearing outerrace
- EXCEPT MODEL34X81-
• Removing outputshaftbearing outer
race from bearing retainer
• Removing outputgearbearing outer
race from bearing retainer
- MODEL 34X81-
• Removing differential sidebearing outer
race
• Removing needlebearing frombearing
retainer
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST27180001 Puller

NT424

ST30031000 Puller

NT411

ST30021 000
Puller

NT411

ST35272000 Drift

~
NT426
AT-4
•
Removing idlergear
• Removing outputgear(Except model
34X81)
a: 100 mm (3.94 In)
b: 110 mm (4.33 in)
c: M8 x1.25P
Removing reductionpiniongearbearing
inner race(Except model34X81)
a: 90 mm (3.54 In)dia.
b: 50 mm (1.97 in)dia.
Removing differential sidebearing
(Except model34X81)
a: 110 mm (4.33 in)dia.
b: 68 mm (2.68 in)dia.
• Installing reduction piniongearbearing
inner race
• Installing idlergear bearing innerrace
• Installing outputgearbearing innerrace
(Except model34X81)
a: 72 mm (2.83 in)dia.
b: 35.5 mm(1.398 in)dia.

Toolnumber
Tool name
PREPARATION
ANDPRECAUTIONS
Special Service Tools(Cont'd)

Description
8T37830000 Drift
8T33200000 Drift
8T35271000 Drift
8T33400001
Drift
KV40104840
Drift
KV38105710
Preload adapter
8T35321000
Drift
ST30633000 Drift
NT427
NT091
NT115
NT086
NT108
NT087
NT073 NT073
AT-5
Installing
idlergear bearing outerrace

a: 62 mm (2.44 in)dia.
b: 39 mm (1.54 in)dia.

Installing differential sidebearing (Except
model 34X81)

a: 60 mm (2.36 in)dia.
b: 44.5 mm(1.752 in)dia.

• Installing idlergear
• Installing outputgear(Except model
34X81)

a: 72 mm (2.83 in)dia.
b: 44 mm (1.73 in)dia.

• Installing oilpump housing oilseal
• Installing outputgearbearing outerrace
onto bearing retainer (Exceptmodel •
34X81)

a: 60 mm (2.36 in)dia.
b: 47 mm (1.85 in)dia.

Installing outputshaftbearing outerrace
onto bearing retainer (Exceptmodel
34X81)

a: 49 mm (1.93 in)dia.
b: 42 mm (1.65 in)dia.

- MODEL 34X81-
• Measuring turningtorqueoffinal drive
assembly
• Measuring clearancebetweensidegear
and differential casewithwasher
• Selecting differential sidebearing
adjusting shim
Installing outputshaftbearing
(Model 34X81)

a: 49 mm (1.93 in)dia.
b: 41 mm (1.61 in)dia.

Installing differential sidebearing outer
race (Model 34X81)

a: 67 mm (2.64 in)dia.
b: 49 mm (1.93 in)dia.

PREPARATIONANDPRECAUTIONS
Commercial ServiceTools

Tool name
Description
Puller •Removing idlergear bearing innerrace
• Removing andinstalling bandservo pis-

=m
ton
snap ring

o
0
-
EXCEPT MODEL34X81-
• Removing outputgearbearing inner
race

NT077
•
Removing differential sidebearing
Drift

~
Removing
idlergear bearing innerrace
(Except model34X81)
a: 34 mm (1.34 in)dia.

NT109

Drift

~
Installing
needlebearing ontobearing
retainer (Model34X81)
a: 36 mm (1.42 in)dia.

NT109

Drift

~
Removing
outputgearbearing innerrace
(Except model34X81)
a: 33 mm (1.30 in)dia.

NT109

Drift

~
Removing
differential sidebearing (Except
model 34X81)
a: 38 mm (1.50 in)dia.

NT109

Drift

~
Removing
outputshaftbearing innerrace
(Except model34X81)
a: 70 mm (2.76 in)dia.

NT110
b:
30 mm (1.18 in)dia.
Drift Installing
outputshaftbearing innerrace

~d
(Except
model34X81)
a: 70 mm (2.76 in)dia.
b: 34 mm (1.34 in)dia.
c: 30 mm (1.18 in)dia.

NT111
d:
2mm (0.08 in)

AT-6

PREPARATIONANDPRECAUTIONS
Service Notice
Supplemental RestraintSystem(SRS)"AIR
BAG" (DualAirBag System)

The Supplemental RestraintSystem"AirBag" usedalong withaseat belt, helps toreduce therisk or
severity ofinjury tothe driver andfront passenger inafrontal collision. TheSupplemental Restraint
System consists ofair bag modules (locatedinthe center ofthe steering wheelandonthe instrument
panel onthe passenger side),adiagnosis sensorunit,warning lamp,wiring harness andspiral cable.
Information necessarytoservice thesystem safelyisincluded inthe
RSsection
ofthis Service Manual.

WARNING:
• Toavoid rendering theSRS inoperative, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.

Ii
Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual. SRSwiring harnesses arecovered withyellow insulation eitherjustbefore the
harness connectors orfor the complete harness,foreasy identification.

•
Before proceeding withdisassembly, thor-
oughly cleantheoutside ofthe transaxle. Itis
important toprevent theinternal partsfrom
becoming contaminated bydirt orother for-
eign matter.
• Disassembly shouldbedone inaclean work
area.
• Use lint-free clothortowels forwiping parts
clean. Common shopragscanleave fibers
that could interfere withtheoperation ofthe
transaxle.
• Place disassembled partsinorder, onaparts
rack, foreasier andproper assembly.
• Allparts should becarefully cleaned-witha
general purpose, non-flammable solvent
before inspection orreassembly.
• Gaskets, sealsandO-rings shouldbe
replaced anytime thetransaxle isdisassem-
bled.
• Itis very important toperform functional tests
whenever theyareindicated. •
The valve bodycontains precision partsand
requires extremecarewhen partsare
removed andserviced. Placedisassembled
valve bodyparts inorder, onaparts rack,for
easier andproper assembly. Carewillalso
prevent springs andsmall partsfrombecom-
ing scattered orlost.
• Properly installedvales,sleeves, plugs,etc.
will slide along theirbores inthe valve body
under theirownweight.
• Before assembly, applyacoat ofrecom-
mended ATFtoall parts. Apply petroleum
jelly toprotect O-ringandseals, orhold bear-
ings andwashers inplace during assembly.
Do not use grease.
• Extremely careshould betaken toavoid dam-
age toO-rings, sealsandgaskets when
assembling.
• After overhaul, refillthetransaxle withnew
ATF.

•

Supplemental RestraintSystem(SRS)"AIR
BAG" (Single AirBag System)

The Supplemental RestraintSystem"AirBag" andused along withaseat belt,helps toreduce therisk
or severity ofinjury tothe driver inafrontal collision. TheSupplemental RestraintSystemconsists of
an air bag module (located inthe center ofthe steering wheel),adiagnosis sensorunit,warning lamp,
wiring harness andspiral cable. Information necessarytoservice thesystem safelyisincluded inthe

RS section
ofthis Service Manual.

WARNING:
• Toavoid rendering theSRS inoperative, whichcouldincrease therisk ofpersonal injuryordeath
in the event ofacollision whichwould resultinair bag inflation, allmaintenance mustbeperformed
by an authorized NISSANdealer.
• Improper maintenance, includingincorrectremovalandinstallation ofthe SRS, canlead topersonal
injury caused byunintentional activationofthe system.
• Donot use electrical testequipment onany circuit related tothe SRS unless instructed tointhis
Service Manual.
AT-7

EXCEPTMODEL34X81

Reverse clutchdrum
DESCRIPTION
Cross-sectional View

Band servo piston
High clutch
Brake band

AT-8
Converter
housing
Torqueconverter

SAT502HB

MODEL34X81 DESCRIPTION
Cross-sectional View(Cant' d)

Reverse clutchdrum Band
servo piston
High clutch
Front planetary gear
Reduction piniongear
Low

&
reverse brake
Idler gear
Forward one-way clutch Low
one-way clutch
Rear planetary gear
Forward clutch
Overrun clutch

,"'I
Reverse
clutch
Brake band
Final gear

AT-9
Oil
pump assembly
Converterhousing
Torque converter
Input shaft

c
...
-;-

I

L_

Differential case

SAT101EA
•

MODEL34X68

4th

speed cut
valve
Overrunclutch
control
valve
Lock-up
control
valve
Torque '~..•.•
converter
>..•.••••

relief ..••.....
valve ..
Governor
valve
X:Drain port
: Orifice DESCRIPTION
Hydraulic ControlCircuit
Low
&
reverse
brake
High clutch
Detent valve
AT-10 Forward
clutch
1-2
shift
valve

SAT1961