NISSAN ALMERA N15 1995 Service Manual

REPAIRFORCOMPONENT PARTS
I

RS5F32A
I

•

Input
Shaft andGears
DISASSEMBL Y

1. Before disassembly, check5thinput gearendplay.

Gear endplay:
Refer to50S, MT-64.

• Ifnot within specification, disassembleandcheck contact
surface ofgear, shaftandhub. Check clearance ofsnap ring
groove. Referto"ASSEMBLY", MT-40.
2. Remove snapringand5thstopper.
3. Remove 5thsynchronizer, 5thinput gearand5thgear nee-
dle bearing.
4. Remove snapringofinput shaftfrontbearing andinput gear
spacer.

SMT674B
SMT417CA

Input shaft
front bearing

-
r
5th synchronizer hub

/ ST30021 000

5th
input gear
~ SetTool below
5th input gear.
Spacer
5.Remove inputshaftfrontbearing.
6. Remove bearingretainer.

MT-39

I
RS5F32A
I

Shifting insert
Baulkringto
gear clearance
REPAIR
FORCOMPONENT PARTS
Input Shaft andGears (Cont'd)
INSPECTION
Gear andshaft

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

SMT602A 5thsynchronizer

• Check splineportion ofcoupling sleeves,hubsandgears
for wear orcracks.
• Check baulkringsforcracks ordeformation.
• Check insertsprings forwear ordeformation.

SMT387A
•Measure clearance betweenbaulkringandgear.

Clearance betweenbaulkringandgear:
Standard 0.90 -1.50 mm(0.0354 -0.0591 in)
Wear limit
0.7 mm (0.028 in)
SMT140 Bearing

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

ASSEMBLY
1. Assemble 5thsynchronizer.

MT-40

SMT761B
REPAIR
FORCOMPONENT PARTS
I
RS5F32A
I

Input Shaft andGears (Cont'd)
• Becareful nottohook frontandrear ends ofspread spring
to the same insert.

•

5. Select andinstall snapringthatgives proper clearance of
input shaftgroove.

Allowable clearance ofgroove:

o -
0.1 mOl (0-0.004 in)
Snap ringsofinput shaftfrontbearing:
Refer toSOS, MT-65.

2.
Install bearing retainer.
3. Press oninput shaft frontbearing.
4. Install inputgearspacer.

• Besure toreplace 5thgear synchronizer hubwith newone
when itis removed.

6. Install 5thgear needle bearing, 5thinput gear, 5thsynchro-
nizer and5thstopper.

• Input shaftmustbevertical topress onsynchronizer hub.

7. Measure gearendplayas afinal check. Referto
"DISASSEMBLY", MT-39.
8. Select andinstall snapringthatgives proper clearance of
input shaft groove.

Allowable clearance ofgroove:

o -
0.1 mm (0-0.004 in)
Snap ringof5th synchronizer:
Refer toSOS, MT-65.
SMT708B
SMT731-A
SMT779AA

Snap
ring
5th synchronizer hub

~
=
Bearing retainer

ST37750000 ~
SMT591MT-41

REPAIRFORCOMPONENT PARTS
I

RS5F32A
I

Snap ring End
play
Mainshaft
andGears
DISASSEMBL Y

1. Before disassembly, measuregearendplay.

Gear endplay:
Refer to50S, MT-64.

• Ifend play isnot within thespecified limit,disassemble and
check theparts.
2. Remove mainshaft rearbearing snapring,Coring holder
and mainshaft C-rings.

C-ring holder

SMT709B

~Snapring

@---
C-ringholder
~~ MalnshaftC-r1ng
Puller-
Mainshaft rear
bearing -
Mainshaft rear
bearing

SMT676BB
3.Remove mainshaft rearbearing andspacer.

./- Suitable
drift

SMT677BA
4.Remove 5thmain gear.

SMT593-A MT-42

2nd&3rd~
bushing -'-~)
2nd gear ~
1 st main gear REPAIR
FORCOMPONENT PARTS
I
RSSF32A
I

Mainshaft andGears (Cont'd)

5. Remove 4thmain gear, bushing andsteel ball.

• Take carenottolose steel ball.

SMT418C
6.Remove 3rd
&
4th synchronizer and3rdmain gear.

SMT766BA
7.Remove 2nd
&
3rd bushing and2ndmain gear.

• Take carenottolose thesteel ball.

AMT053
8.Remove 1st
&
2nd synchronizer huband 1stmain gear.

AMT056 INSPECTION
Gear andshaft

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

SMT604A MT-43
•

t
REPAIR
FORCOMPONENT PARTS
I
RS5F32A
I

Mainshaft andGears (Cont'd)
Synchronizer

• Check spline portion ofcoupling sleeves,hubsandgears
for wear orcracks.
• Check baulkringsforcracks ordeformation.
• Check insertsprings fordeformation.

SMT7198

Baulk ringto
gear clearance

SMT140

Synchronizer

, fli
10M'
baolk
'fOM FA

ST30031000 ~
•
Measure clearance betweenbaulkringandgear.

Clearance betweenbaulkringsandgears,
for 1st and 4thgear only:
Standard 1st 0.95. 1.45mm(0.0374 •0.0571 in)
4th 0.90. 1.45mm(0.0354 •0.0571 in)
Wear limit
0.7 mm (0.028 in)
• 2nd and 3rdgears haveinner andouter baulk ringsandso
have different measurements.

Outerbaulkring--\

B

SMT714CA

• Measure wearof2nd and3rdbaulk rings.
a. Place innerbaulk ringinposition onsynchronizer cone.
b. Hold baulk ringevenly against synchronizer coneandmea-
sure distance "A".
c. Place outerbaul.k ringinposition onsynchronizer cone.
d. Hold baulk ringevenly against synchronizer coneandmea-
sure distance "B".

Standard: Inner-A 0.7-0.9 mm (0.028 -0.035 in)
Outer-B 0.6-1.1 mm (0.024 -0.043 in)
Wear limit:
0.2 mm (0.008 in)

e.
If
distance "A"or"B" issmaller thanthewear limit,replace
baulk ring.

MT-44

SPD715
•

I

RS5F32A
I

Ensure correct fittingof1st
&
2nd synchronizer hub.
ASSEMBLY

1. Install 1stgear needle bearing, 1stmain gearandbaulk
ring.
2. Press on1st
&
2nd synchronizer hub.

•
SMT089CA
REPAIR
FORCOMPONENT PARTS
Mainshaft andGears (Cont'd)
Bearing

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

• The mainshaft frontbearing cannotbere-used. Itmust be
replaced onceremoved.

1st main.

gear •
2ndmain
gear
SMT7018
3.Install 2ndsynchronizer cone,outer
&
inner baulk ringand
reverse maingear(coupling sleeve).

SMT6838
ST23860000
Front
.....

rr=DJ
KV31100401-
4.
Install steelball,2ndmain gear, 2nd
&
3rd bushing.

• Apply gearoilto2nd
&
3rd bushing beforeinstalling it.
• Apply multi-purpose greasetosteel ballbefore installing it.
• 2nd
&
3rd bushing hasagroove inwhich steelballfits.
SMT412CA MT-45

4thmain .....
gear ...... REPAIR
FORCOMPONENT PARTS
I
RS5F32A
I

Mainshaft andGears (Cont'd)

5. Install 3rdmain gear, synchronizer cone,outer
&
inner
baulk ring.
6. Press on3rd
&
4th synchronizer hub.

SMT090CA •Ensure correct fittingof3rd &4th synchronizer hub.

7. Install 3rd
&
4th coupling sleeveand4thbaulk ring.

..... 3rdmain
.".. gear
SMT7028

~ 4thm.lo
g.. '

~-

~ 4thbushing

mAr-51""'"
l(~J

SMT422C
8.
Install steelball,4thbushing and4thmain gear.

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

ST3n50000
SMT091CA
9.
Press on5th main gear.

Mainshaft rearbearing
Mainshaft adjusting
spacer

c
SMT6938
10.
Select proper mainshaft bearingspacertogive correct
bearing distance.

Bearing distance
"e":

230.15 -230.25 mm(9.0610 -9.0649 in)
Spacers available:
Refer toSOS, MT-65.
MT-46

SMT092CA
REPAIR
FORCOMPONENT PARTS
Mainshaft andGears (Cont'd)

11. Press onmainshaft rearbearing.

•

I

RS5F32A
I

12. Select andinstall mainshaft C-ringthatgives proper clear-
ance ofgroove inmainshaft.

Allowable clearanceofgroove:

o -
0.1
mm
(0-0.004
in)
Mainshaft C-rings:
Refer to50S, MT-65.

13. Install C-ring holder andsnap ring.
14. Measure gearendplayas thefinal check. Referto
"DISASSEMBLY", MT-42.

ST37750000
SMT676BB

Mainshaft
rear
bearing
@-Snapring

e---
C-ringholder
~~ MainshaftC-ring
C-ring
SMT712B 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.

MT-47

SPD715
SMT083A
ASSEMBLY
1. Attach sidegear thrust washers toside gears, theninstall
pinion matewashers andpinion mategears inplace.

I

RS5F32A
I

Gear, washer, shaftandcase

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

Bearing

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

• When replacing taperedrollerbearing, replaceouterand
inner raceasaset.
REPAIR
FORCOMPONENT PARTS
Final Drive (Cont'd)
INSPECTION
SMT839
KV381 05900
2.
Insert pinion mateshaft.

• When inserting, becareful nottodamage pinionmatethrust
washers.

3. Measure clearance betweensidegear anddifferential case
with washers following theprocedure below:
a. Set Tool anddial indicator onside gear.

SMT610AB MT-48