Manual trans 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

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

Fluidleakage TROUBLE
DIAGNOSES
Preliminary Check(PriortoRoad Testing)
AIT FLUID CHECK
Fluid leakage check

1. Clean areasuspected ofleaking, -for example, mating
surface ofconverter housingandtransmission case.
2. Start engine, applyfootbrake, placeselector leverin"0"
position andwait afew minutes.
3. Stop engine.
4. Check forfresh leakage.

SAT288G
Fluidcondition check
Fluid levelcheck -Refer toMA section (CHASSIS AND
BODY MAINTENANCE).
Fluid
color
Oark orblack withburned odor
Milky pink
Varnished fluid,lighttodark brown
and tacky Suspected
problem
Wear offrictional material
Water contamination
- Road water entering through
filler tubeorbreather
Oxidation
- Over orunder filling
- Overheating

•

Road Testing

Perform roadtests using "Symptom" chart.Refertopage

AT-20.

"P"
POSITION

1. Place selector leverin"P" position andstart engine. Stop
engine andrepeat theprocedure inall positions, including
neutral position.
2. Stop vehicle onaslight upgrade andplace selector leverin
"P" position. Releaseparkingbraketomake surevehicle
remains locked.

"R"
POSITION

1. Manually moveselector leverfrom"P"to"R", andnote
shift quality.
2. Drive vehicle inreverse longenough todetect slippage or
other abnormalities.

"N"
POSITION

1. Manually moveselector leverfrom"R"and"0"to"N" and
note shift quality.
2. Release parkingbrakewithselector leverin"N" position.
Lightly depress accelerator pedaltomake surevehicle
does notmove. (When vehicle isnew orsoon afterclutches
have been replaced, vehiclemaymove slightly. Thisisnot
a problem.)

AT-17

SAT497GTROUBLE
DIAGNOSES
Road Testing (Cont'd)

"0"
POSITION

1. Manually moveselector leverfrom"N"to"D" position, and
note shiftquality.
2. Using theshift schedule asareference, drivevehicle in"D"
position. Record,onsymptom chart,respective vehicle
speeds atwhich up-shifting anddown-shifting occur.These
speeds aretobe read atthree different throttlepositions
(light, halfandfull), respectively. Alsodetermine thetiming
at which shocks areencountered duringshifting andwhich
clutches areengaged.

SAT612GA
3.Determine whetherlock-upproperly occurswhiledriving
vehicle inproper gearposition andatproper vehicle speed.
4. Check todetermine ifshifting tooverdrive gearcannot be
made whileODcontrol switchis"OFF".
5. Drive vehicle in"D
3"
position athalf tolight throttle posi-
tion. Keep driving at60 to70 km/h (34to43 MPH). FUlly
depress accelerator pedaltomake suretransaxle down-
shifts from3rdto2nd gear.
6. Drive vehicle in"D
2"
position athalf tolight throttle posi-
tion. Keep driving at25 to35 km/h (16to22 MPH). Fully
depress accelerator pedaltomake suretransaxle down-
shifts from2ndto1st gear.

"2"
POSITION

1. Shift to"2" position andmake surevehicle startsin1st
gear.
2. Increase vehiclespeedtomake suretransaxle upshiftsfrom
1st to2nd gear.
3. Further increase vehiclespeed.Makesuretransaxle does
not upshift to3rd gear.
4. Drive vehicle in"2
2"
position athalf tolight throttle position.
Keep driving at25 to35 km/h (16to22 MPH). Fullydepress
accelerator pedaltomake suretransaxle downshifts from
2nd to1st gear.
5. Allow vehicle torun idle while in"2" position tomake sure
that transaxle downshifts to1st gear.
6. Move selector leverto"D" position andallow vehicle to
operate at30 to40 km/h (19to25 MPH). Then,shiftto"2"
position tomake suretransaxle downshifts to2nd gear.

"1"
POSITION

1. Place selector leverin"1" position andaccelerate vehicle.
Make suretransaxle doesnotshift from 1stto2nd gear
although vehiclespeedincreases.
2. Drive vehicle in"1" position. Releaseaccelerator pedalto
make surethatengine compression actsasabrake.
3. Place selector leverin"D" or"2" position andallow vehi-
cle torun at15 to25 km/h (9to 16 MPH). Thenmove selec-
tor lever to"1" position tomake suretransaxle downshifts
to 1st gear.

AT-18

(atP,)
p,
(Full throttle position)
~ThrOttle drum
Direction U

, ,-- p,
t

I ~.
(Idling

--r ~_ .)
position)
I

Direction T
Engine side"
bracket (at

P,)

~ Adjusting tube
Lock plate ON-VEHICLE
SERVICE
Throttle WireAdjustment (Cont'd)

1. Turn ignition switchtoOFF.
2. While pressing lockplate, moveadjusting tubeindirection
"T" (Transaxle side).
3. Return lockplate.
(Adjusting tubeislocked atthis time.)
4. Move throttle drumfrom
"P2"
to
"P
1"
quickly. Adjusting
tube moves indirection "U"(Engine side)while depressing
the lock plate. Ensure thatthrottle wirestroke "L"iswithin
the specified range,between fullthrottle andidle.
Throttle wirestroke "L":

40 -42
mm
(1.57 -1.65
in)
• Adjust throttle wirestroke afteraccelerator wireisinstalled
and adjusted.
• When connecting throttlewiretothrottle drum,donot use
tools. Manually hookit.
• Put mark onthrottle wiretofacilitate measuring wirestroke.
5. Clamp throttle wireatproper positions showninthe illus-
tration afteradjusting throttlewire.
6. After properly adjusting andclamping throttlewire,ensure
the parting lineisas straight aspossible.

SAT551D

4/4

Vehiclespeed
If
throttle wirestroke isimproperly adjustedthefollowing prob-
lems mayarise.
• "P
1"
isthe throttle drumfully-open position.When"P
1"
is
too farindirection
"T",
theshift schedule willbe
@
inthe
figure. Andthekickdown rangewillgreatly increase.
• When
"P1"
istoo farindirection "U",theshift schedule will
be
CD
inthe figure. Andthekickdown willnotoccur.

SAT669H

I

I

Normal :

,- .J

,/

/

,,~/~
/

---------1--
,/

'//
r-/

I

I

o

0>

c:

C

Q)

0-

o

~
2

£
I-

AT-34

ON-VEHICLESERVICE
Control CableInstallation andAdjustment

• Move selector leverfromthe"P" range tothe "1" range.
You should beable tofeel thedetents ineach range.
• The control cableneeds adjustment inthe following cases:
1) When thedetents cannotbefelt;
2) When thepointer indicating therange isimproperly
aligned.
• Always adjustcontrol cablewhenitis removed fromselec-
tor lever ormanual shaft.

SEC. 349

Floorpanel

\.~ 4.4-5.9 (0.45 •0.60. 39.1-52.1)

Front

<;:::J

~ 4.4 -5.9 (0.45 -0.60, 39.1-52.1)
Transax1,e
Cable bracket

•

~4.4 -5.9

(0.45 •0.60.
'I

39.1 -52.1)
~ 17.5 -23.7 (1.8•2.4, 13•17)

Sub frame Selector
leverassembly

~ 4.4•5.9 (0.45 -0.60, 39.1-52.1)

AIT control cableassembly
~:N.m (kg-m, in-Ib)
~ :N.m (kg-m, ft-Ib)

SAT499HA
•

SAT230EA

-{'

.~

did
Selector lever

I'y-
Clamp ,I.
'OJ} "

\ '4'i"" \.,)
I
,i

Selector leverbracket
\Vu
7//

;( ( .tll@:::(-c/",/.I

'''J)!I'r.
cY'?1I/'

i
j\\-.. )
~j
'.-It

( t:J-.,'-' ,
'.~/;,J~

A
'j
(,k;;.
l~\.\:\
D
eee:::
Control cable

t;-\
'II
Lock nut
~i'
l~}
I'
I

p
/.f .----
u

/,<\,:.~
4.4•5.9 N.m .."

- (0.45 -0.6
kg-m,

'~-39.1 -52.1 in-Ib)
INSTALLATION

1. Place selector leverandmanual shaftat"P" position.
2. Connect controlcabletoselector leverandtighten control
cable locknut.Clamp control cabletoselector lever
bracket.

AT-35

ON-VEHICLESERVICE
Control CableInstallation andAdjustment
(Cont'd)

3. Connect controlcabletomanual shaftandclamp control
cable tobracket attransaxle.
4. Pull control cableinthe direction ofthe arrow shown inthe
illustration byspecified force.

Specified force:6.9N(0.7 kg,1.5Ib)

5. Return control cableinthe opposite direction ofthe arrow
for 1.0mm (0.039 in).
6. Tighten controlcablelocknut.
7, Move selector leverfrom"P"position to"1" position. Make
sure thatselector levercanbemoved smoothly withoutany
sliding noise.
8. Apply grease tocontacting areasofselector leverandcon-
trol cable. Installanypart removed.

SAT576E
SAT577E ADJUSTMENT

1. Loosen controlcablelocknutattransaxle side.
2. Place selector leverandmanual shaftat"P" position.
3. Pull control cableinthe direction ofthe arrow shown inthe
illustration byspecified force.

Specified force:6.9N
(0.7
kg,1.5 Ib)

4. Return control cableinthe opposite direction ofthe arrow
for 1.0mm (0.039 in).
5. Tighten controlcablelocknut.
6. Move selector leverfrom"P"position to"1" position. Make
sure thatselector levercanbemoved smoothly withoutany
sliding noise.
7. Apply grease tocontacting areasofselector leverandcon-
trol cable.

Governor Valve

1. Remove airduct.
2. Remove governor capsnap ring.
3, Remove governor cap,

AT-36

InhibitorSwitchAdjustment

1. Remove controlcableendfrom manual shaft.
2. Set manual shaftin"N" position.
3." Loosen inhibitor switchfixingbolts.
Use a4 mm (0.16 in)pin forthis adjustment. •
Insert thepinstraight intothemanual shaftadjustment hole.
Rotate inhibitor switchuntilthepincan also beinserted
straight intohole ininhibitor switch.
Tighten inhibitor switchfixingbolts.
Remove pinfrom adjustment holeafter adjusting inhibitor
switch.
Reinstall anypart removed.
Adjust control cable-Refer to"Control CableInstallation
and Adjustment", AT-35.
Check continuity ofinhibitor switch-Refer to"Electrical
Components Inspection",AT-30.

ON-VEHICLE
SERVICE
Governor Valve(Cont'd)

4. Remove governor valveassembly fromtransaxle.
5. Check governor valveassembly ifnecessary -Refer to
"DISASSEMBLY", AT-65.

4. a.b.
5.

6.
7.

8.
SAT580E 9.
Differential SideOilSeal Replacement

1. Remove driveshaftassemblies. -Refer toFA section
("Removal", "FRONTAXLE-Drive Shaft").
2. Remove oilseals.

AT-37

Model

34X68

SAT496HB
SAT0170
DISASSEMBL
Y

b. Remove stopperringfrom terminal body.
c. Push terminal bodyintotransmission caseanddraw out
solenoid harness.
10. Remove manualvalvefromcontrol valveassembly.
11. Remove returnspring fromSIRaccumulator piston.
12. Remove SIRaccumulator pistonwithcompressed air.
13. Remove O-ringsfromSIRaccumulator piston.

AT-52

Parkingshaft

SAT064D
SAT702D DISASSEMBL
V

44. Remove forwardclutchassembly fromtransmission case.
45. Remove thrustwasher andbearing racefrom transmission
case.

- All models - •

46. Remove returnspring fromparking shaftusing ascrew-
i

driver.

- Except model34X81-

47. Remove outputshaft,output gearandreduction piniongear
according tothe following procedures.
a. Remove sidecover.

• Donot reuse sidecover bolts.

b. Set manual leverto"p" position tofix idler gear andout-
put gear.
c. Unlock bothidlergear andoutput gearlocknuts using apin
punch.

AT-61