NISSAN ALMERA N15 1995 Service Manual

REPAIRFORCOMPONENT PARTS
I

RS5F30A &RS5F31 A
I

Mainshaft andGears
DISASSEMBL Y

1. Before disassembly, check1st,2nd, 3rdand 4thmain gear
end plays.

Gear endplay:
Refer to50S, MT-61.

• Ifnot within specification, disassembleandcheck contact
surface ofgear, shaftandhub. Then check clearance of
C-ring groove. Referto"ASSEMBLY", MT-21.
2. Press outmainshaft frontbearing.

ST22730000
SMT641-A
3.Press outmainshaft rearbearing.

SMT638-A
•

~ C-ringholder
~~ Mainshaft C-ring

8---
Thrustwasher
SMT592-A
5T,22730, OOO~~""~/
i~;~<~:(

-----~"
"~"

-'::-.
,---'/Hooktoolunder

-', """.•".~, >~\ .
J.
flange asindicated
'. '.~ byarrows.

"-~,
",'
.'
//

" /!~'(';Y

I -\--...

Y:<"~_.
~~w"-,~

--...' ....~"'I "
SMT593-A
4.
Remove C-ringholder, mainshaft C-ringsandthrust
washer.
5. Press out5th main gear.

MT-19

SMT687C
Steel
ball

7.Remove 3rd
&
4th synchronizer, 3rdmain gear, 2nd
&
3rd
bushing, steelballand2nd main gear.

• Becareful nottolose steel ball.
REPAIR
FORCOMPONENT PARTS
I
RS5F30A
&
RS5F31A
I

Mainshaft andGears (Conl'd)

6. Remove 4thmain gear, 4thbushing andsteel ball.

• Becareful nottolose steel ball.

r
ST30031 000

3rd

&
4th
synchronizer hub
SMT780AA
8.Remove 1st
&
2nd synchronizer and1stmain gear, then
remove 1stgear needle bearing.

1st &2nd
, synchronizer
/ /1st main

.~/\ gear

t-r=-~~'c
SMT594
INSPECTION
Gear andshaft

• Check shaftforcracks, wearorbending.
• Check gearsforexcessive wear,chipsorcracks.

MT-20

Shiftinginsert

t
Baulkringto
gear clearance
REPAIR
FORCOMPONENT PARTS
I
RS5F30A
&
RS5F31A
I

Mainshaft andGears (Cont'd)
Synchronizer

• Check spline portion ofcoupling sleeves,hubsandgears
for wear orcracks.
• Check baulkringsforcracks ordeformation.
• Check shifting insertsforwear ordeformation.
• Measure clearance betweenbaulkringandgear.

Clearance betweenbaulkringsand1st-4th maingears:
Standard 1.0 -1.35 mm(0.0394 -0.0531 in)
Wear limit
0.7 mm (0.028 in)
SMT140
•

SMT761B Bearing

• Make surebearings rollfreely andarefree from noise,
cracks, pittingorwear.

• When replacing taperedrollerbearing, replaceouterand
inner raceasaset.
ASSEMBLY
1. Assemble 1st
&
2nd and 3rd
&
4th synchronizers.

• Becareful nottohook frontandrear ends ofspread spring
to the same insert.
MT-21

ST22452000
ST37750000 -

3rd
&
4th

synchronizer hub
REPAIR
FORCOMPONENT PARTS
I
RS5F30A &RS5F31A
I

Mainshaft andGears (Cont'd)

2. Install 1stgear needle bearing and1stmain gear.
3. Press on1st
&
2nd synchronizer.

SMT605AA
4.Install steelball,2ndmain gear, 2nd
&
3rd bushing, 3rd
main gearand3rd
&
4th synchronizer.

• Apply multi-purpose greasetosteel ballbefore installing it.
• 2nd
&
3rd bushing hasagroove inwhich steelballfits.
SMT085CA
5.Install steelball,4thbushing and4thmain gear.

• Apply multi-purpose greasetosteel ballbefore installing it.
• 4th bushing hasagroove inwhich steelballfits.

Steel ball

SMT687C
6.Press on5th main gear.

/ 5th main gear

SMT606AA

~ C-ringholder
~~ Mainshaft C-ring
@---Thrust washer

SMT592-A
7.
Install thrustwasher.
8. Select andinstall mainshaft C-ringthatgives proper clear-
ance ofgroove inmainshaft.

Allowable clearanceofgroove:
0-0.1 mm(O.0.004 in)
Mainshaft C-ring:
Refer to50S, MT-61.

9. Install C-ring holder.

MT-22

ST22360002
REPAIR
FORCOMPONENT PARTS
I
RSSF30A
&
RSSF31A
I

Mainshaft andGears (Cont'd)

10. Press onmainshaft rearbearing.

SMT607AA
11.Press onmainshaft frontbearing.
12. Measure gearendplayas thefinal check -Refer to
"DISASSEM BL
y",
MT-19.

SMT639 FinalDrive
DISASSEMBL Y

1. Remove finalgear.
2. Remove speedometer drivegearbycutting it.
3. Press outdifferential sidebearings.

• Becareful nottomix upthe right andleftbearings.
•

[ .

SMT647-A

4.Drive outretaining pinand draw outpinion mateshaft.
5. Remove pinionmategears andside gears.

Retaining
pin
SMT147AA INSPECTION
Gear, washer, shaftandcase

• Check mating surfaces ofdifferential case,sidegears and
pinion mategears.
• Check washers forwear.

SMT083A MT-23

KV38105900
REPAIR
FORCOMPONENT PARTS
I
RS5F30A
&
RS5F31A
I

Final Drive (Conl'd)
Bearing

• Make surebearings rollfreely andarefree from noise,
cracks, pittingorwear.

• When replacing taperedrollerbearing, replaceouterand
inner raceasaset.
SPD715 ASSEMBLY
1. Attach sidegear thrust washers toside gears andinstall in
differential case.
2. Install pinion matethrust washers andpinion mategears.

SMT839
3.Insert pinion mateshaft.

• When inserting, becareful nottodamage pinionmatethrust
washers.
SMT087A
4.Measure clearance betweensidegear anddifferential case
with washers following theprocedure below:
a. Set Tool anddial indicator onside gear.

SMT610AB
b.Move sidegear upand down tomeasure dialindicator
deflection. Alwaysmeasure indicatordeflection onboth
side gears.

Clearance betweensidegear anddifferential casewith
washers: 0.1 -0.2 mm (0.004 -0.008 in)

c. Ifnot within specification, adjustclearance bychanging
thickness ofside gear thrust washers.

Side gear thrust washer:
Refer to50S, MT-62.
SMT611A
MT-24

1/
REPAIR
FORCOMPONENT PARTS
I
RS5F30A
&
RS5F31A
I

Final Drive (Cont'd)

5. Install retaining pin.

• Make surethatretaining pinisflush withcase.
Retaining

pin

SMT147AA
6.Install finalgear.

• Apply locking sealant tofinal gear fixing boltsbefore install-
ing them.

7-. Install speedometer drivegearandstopper .

SMT609A
•

;?
Control
b~'Ck:t ,

.. ~-t'

If
0

Shift forkandshifter cap
",0

~ SMT086C
8.
Press ondifferential sidebearings.

Shift Control Components
INSPECTION

• Check contact surface andsliding surface forwear,
scratches, projections orother damage.

Case Components
Input shaftoilseal

1. Drive outinput shaftoilseal.

MT-25

REPAIRFORCOMPONENT PARTS
Case Components (Cont'd)

2. Install inputshaft oilseal.

• Apply multi-purpose greaseto
installing.
SMT751BA
I

RSSF30A
&
RSSF31A
I

seal lipofoil seal before
Input shaftrearbearing

1. Remove welchplugfrom transmission case.

SMT688C
2.Remove inputshaft rearbearing bytapping itfrom welch
plug hole.

r
Welch plughole

SMT633
3.Install welchplug.

• Apply recommended sealanttomating surface oftransmis-
sion case.

4. Install inputshaft rearbearing.

MT-26

Toward
oil pocket
REPAIR
FORCOMPONENT PARTS
I
RS5F30A
&
RS5F31A
I

Case Components (Cont'd)
Mainshaft frontbearing outerraceandoilchannel

1. Remove mainshaft frontbearing outerrace.
2. Remove oilchannel.

SMT636-A
3.Install oilchannel.

• Ensure theoilgroove facestheoilpocket.
SMT595
•

4. Install mainshaft frontbearing outerrace.

Mainshaft rearbearing outerrace
• Refer to"Differential SideBearing Preload", MT-29.
Differential sidebearing outerrace
• Refer to"Mainshaft BearingPreload", MT-28.
MT-27

ADJUSTMENT
I

RS5F30A
&
RS5F31 A
I

SMT646-A

I"
KV38106000
SMT454-ADifferential
SideBearing Preload

If any ofthe following partsarereplaced, adjustdifferential side
bearing preload.

• Differential case
• Differential sidebearing
• Clutch housing
• Transmission case

1. Remove differential sidebearing outerrace(transmission
case side) andshim(s).
2. Reinstall differential sidebearing outerracewithout
shim(s).
3. Install finaldrive assembly onclutch housing.
4. Install transmission caseonclutch housing.

• Tighten transmission casefixing boltstothe specified
torque. RefertoMT-10.

5. Set dial indicator onfront endofdifferential case.
6. Insert Toolallthe way intodifferential sidegear.
7. Move Toolupand down andmeasure dialindicator deflec-
tion.
8. Select shimconsidering bearingpreload.

Suitable shimthickness =
Dial
indicat~r
deflection
+ specified bearingpreload
Differential sidebearing preload andadjusting shims:
Refer to50S, MT-62, 63.

9. Install selected shim(s)anddifferential sidebearing outer
race.
10. Check differential sidebearing turningtorque.
a. Install finaldrive assembly onclutch housing.
b. Install transmission caseonclutch housing.

• Tighten transmission casefixing boltstothe specified
torque. RefertoMT-10.
MT-28