NISSAN ALMERA N16 2001 Electronic Repair Manual

SMT659DC
14. Remove check ball from housing.
15. Remove retaining pin for 1st & 2nd shift fork and bracket.
16. Remove 1st & 2nd fork rod.
17. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd
bracket.
SMT660D
18. Remove both input shaft and mainshaft assemblies from hous-
ing.
SMT661D
19. Remove final drive assembly from housing.
20. Remove oil pocket from housing.
SMT662D
21. Remove mainshaft bearing retainer from housing.
22. Cut off oil channel using a cutter as shown in the figure.
SMT663DB
23. Remove mainshaft front bearing from housing.
DISASSEMBLYRS5F70A
Clutch Housing (Cont'd)
MT-61

SMT664D
24. Using a magnet or other suitable tool, remove retaining pin
from selector shaft.
SMT665DB
25. Remove selector shaft and plug, then remove selector.
SMT666DA
26. Remove reamer bolt, then remove select check leaf spring,
return spring, steel ball, reverse gate, selector arm, bearing,
and bushing.
CAUTION:
Be careful not to lose the steel ball.
SMT667DB
27. Remove retaining pin and plug from striking lever.
28. Remove striking rod, then striking lever from housing.
SMT668D
29. Using a flat-head screwdriver or other suitable tool, remove
dust seal, input shaft oil seal, and striking rod oil seal from
housing.
CAUTION:
When removing dust and oil seals, be careful not to damage
mounting surfaces of dust seal and oil seal.
DISASSEMBLYRS5F70A
Clutch Housing (Cont'd)
MT-62

SMT669DB
30. Remove differential oil seal from housing.
SMT670DB
31. Remove differential side outer race from housing.
DISASSEMBLYRS5F70A
Clutch Housing (Cont'd)
MT-63

SMT759D
Input Shaft and Gears
DISASSEMBLYNJMT00561. Before disassembly, measure the end plays of 3rd and 4th
input gears.
Gear end play:
Refer to SDS, MT-125.
+If end play is not within specification, disassemble and check
the parts.
SMT671D
2. Remove oil channel from input shaft rear bearing.
SMT672DB
3. Press out input shaft rear bearing.
SMT673D
4. Remove C-ring holder.
5. Remove 5th gear rear C-ring.
SMT674DB
6. Remove 5th input gear from input shaft.
7. Remove 5th gear front C-ring.
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears
MT-64

SMT675DB
8. Remove 4th input gear, baulk ring, 4th gear needle bearing,
and 4th gear C-ring from input shaft.
9. Press out both 3rd & 4th synchronizer hub assembly and 3rd
input gear from input shaft.
10. Remove 3rd gear needle bearing.
SMT676DB
11. Press out input shaft front bearing from input shaft.
SMT693D
INSPECTIONNJMT0057Input Shaft and GearsNJMT0057S01+Check shaft for cracks, wear or bending.
+Check gears for excessive wear, chips or cracks.
SMT637A
SynchronizersNJMT0057S02+Check spline area of coupling sleeves, hubs and gears for
wear or cracks.
+Check baulk rings for cracks or deformation.
+Check insert springs for wear or deformation.
SMT867D
+If any crack, damage, or excessive wear is found on cam face
of baulk ring or working face of insert, replace it.
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont'd)
MT-65

SMT841D
+Measure the movement (play, dimension ªLº) of 3rd & 4th cou-
pling sleeve with their end fixed and the other end lifted as
shown in the figure. If the movement exceeds specification,
replace the sleeve.
Coupling sleeve length ªLº:
Refer to SDS, MT-125.
SMT140
+Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to SDS, MT-125.
SMT148A
BearingNJMT0057S03+Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT696DB
ASSEMBLYNJMT00581. Press on input shaft front bearing.
2. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring
bearing to input shaft.
SMT694D
3. Install spread spring, shifting insert, and 3rd & 4th synchronizer
hub onto 3rd & 4th coupling sleeve.
+Pay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting insert.
CAUTION:
Do not reuse 3rd & 4th synchronizer hub.
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont'd)
MT-66

SMT695D
+Install synchronizer hub with its three grooves facing the front
side (3rd input gear side).
SMT699D
+Install 3rd & 4th coupling sleeve with its chamfered surface
facing the 4th input gear side.
SMT698DB
4. Position bearing replacer to the front side of input shaft front
bearing.
+Align grooves of shifting insert and 3rd gear baulk ring. Then,
press it onto 3rd & 4th synchronizer hub assembly using a drift.
5. Install 4th gear C-ring onto input shaft.
SMT700DA
6. Measure the end play of 3rd & 4th synchronizer hub, and
check if it is within allowable specification below.
End play:
0 - 0.06 mm (0 - 0.0024 in)
7. If not within specification, adjust the end play by changing
thickness of 4th input gear C-ring.
4th input gear C-ring:
Refer to SDS, MT-126.
SMT701DB
8. Install 4th gear needle bearing, 4th gear baulk ring, and 5th
gear front C-ring.
9. Install 4th input gear.
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont'd)
MT-67

SMT703D
10. Position 5th input gear as shown in the figure, and install it on
input shaft.
SMT702DB
11. Install 5th input gear.
CAUTION:
Do not reuse 5th input gear.
12. Install 5th gear rear C-ring onto input shaft.
SMT704DA
13. Measure the end play of 5th input gear, and check if it is within
the allowable specification below.
End play:
0 - 0.06 mm (0 - 0.0024 in)
14. If not within specification, adjust the end play by changing
thickness of the 5th input gear rear C-ring.
5th input gear rear C-ring:
Refer to SDS, MT-126.
SMT705DB
15. Install C-ring holder onto 5th gear rear C-ring.
CAUTION:
Do not reuse C-ring holder.
16. Install input shaft rear bearing.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the input gear side.
SMT671D
17. Install oil channel onto input shaft.
18. Measure gear end play as a final check. Refer to, MT-64.
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont'd)
MT-68

SMT760D
Mainshaft and Gears
DISASSEMBLYNJMT00591. Before disassembly, measure gear end play.
Gear end play:
Refer to SDS, MT-125.
+If end play is not within the specificed limit, disassemble and
check the parts.
SMT677D
2. Remove snap ring.
SMT678D
3. Remove C-ring holder and mainshaft C-ring.
SMT679DB
4. Press out mainshaft rear bearing from mainshaft.
SMT680D
5. Remove mainshaft thrust washer.
6. Remove snap ring from mainshaft. Then, remove reverse main
gear assembly, reverse gear needle bearing, and reverse gear
baulk ring.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears
MT-69

SMT681DB
7. Place bearing replacer between 5th & reverse synchronizer
hub and 5th main gear, and press out both reverse gear bush-
ing and 5th & reverse synchronizer assembly.
8. Remove 5th main gear, 5th gear baulk ring, and 5th gear
needle bearing.
SMT682DB
9. Place bearing replacer between 3rd and 4th main gears, and
press out both 5th gear bushing and 4th main gear.
SMT683D
10. Remove mainshaft adjusting shim and spacer.
11. Place bearing replacer between 2nd main gear and 1st & 2nd
synchronizer hub, and press out both 3rd and 2nd main gears.
SMT684DB
12. Remove 2nd double cone assembly, 2nd gear bushing, and
coupling sleeve assembly.
13. Place bearing replacer on 1st gear front side, and press out all
of 2nd gear bushing, 1st & 2nd synchronizer hub, 1st main
gear, and 1st double cone.
14. Remove 1st gear needle bearing.
SMT693D
INSPECTIONNJMT0060Mainshaft and GearsNJMT0060S01+Check shaft for cracks, wear or bending.
+Check gears for excessive wear, chips or cracks.
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-70