NISSAN ALMERA N16 2003 Electronic Repair Manual

Gear Components=NJMT0039S02
NMT135
1. Reverse idler gear
2. Reverse idler bushing
3. Reverse idler spacer
4. Snap ring
5. Spacer
6. Input shaft front bearing
7. Input shaft
8. Oil plug
9. 5th gear needle bearing
10. 5th input gear
11. Coupling sleeve
12. Baulk ring
13. 5th synchronizer hub
14. Spread spring
15. Shifting insert
16. 5th stopper
17. Input shaft rear bearing
18. Mainshaft front bearing
19. Mainshaft20. 1st main gear
21. 1st gear needle bearing
22. Steel ball
23. 2nd & 3rd bushing
24. 4th main gear
25. 5th main gear
26. Thrust washer
27. Mainshaft C-ring
28. C-ring holder
29. Mainshaft rear bearing
30. Spacer
31. Mainshaft rear bearing adjusting
shim
32. 4th bushing
33. 3rd & 4th synchronizer hub
34. 3rd main gear
35. 2nd main gear
36. 1st & 2nd synchronizer hub
37. Reverse main gear (Coupling
sleeve)38. Differential case
39. Final gear
40. Differential side bearing adjusting
shim
41. Differential side bearing
42. Retaining pin
43. Pinion mate thrust washer
44. Speedometer drive gear
45. Speedometer stopper
46. Side gear
47. Pinion mate gear
48. Pinion mate shaft
49. Side gear thrust washer
50. Snap ring
51. 1st inner baulk ring
52. 1st synchronizer cone
53. 1st outer baulk ring
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OVERHAULRS5F30A
Gear Components
MT-31

Shift Control Components=NJMT0039S03
SMT592D
1. Reverse check spring
2. Reverse check plug
3. Check ball plug
4. Shift check ball
5. Shift check spring
6. Fork shaft support spring
7. Shifter cap
8. Fork shaft
9. 5th shift fork10. 3rd & 4th shift fork
11. 1st & 2nd shift fork
12. Control bracket
13. Striking interlock
14. Retaining pin
15. Retaining pin
16. Yoke
17. Striking rod18. Striking lever
19. Check ball (Large)
20. Check ball (Small)
21. Check sleeve
22. O-ring
23. Select return spring
24. Check plunger
25. Stopper pin
OVERHAULRS5F30A
Shift Control Components
MT-32

NJMT0040
SMT571
1. Remove transmission case while slightly tilting it to prevent 5th
shift fork from interfering with case.
SMT188A
2. Draw out reverse idler spacer and fork shaft, then remove 5th
and 3rd & 4th shift forks.
Be careful not to lose shifter cap.
SMT082A
3. Remove control bracket with 1st & 2nd shift fork.
Be careful not to lose shifter cap.
SMT577
4. Remove gear components from clutch housing.
a. Remove three screws and detach bearing retainer.
One of these three screws is torx type and should be
removed with a suitable tool, as shown.
SMT579
b. Remove input shaft together with mainshaft by tapping lightly.
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
Do not draw out reverse idler shaft from clutch housing
because these fittings will be loose.
When removing input shaft, be careful not to scratch oil
seal lip with shaft spline.
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DISASSEMBLYRS5F30A
MT-33

SMT580
c. Remove reverse idler gear and final drive assembly.
SMT648AA
5. Remove oil pocket, shift check ball, shift check spring and
check ball plug.
SMT599AA
6. Drive retaining pin out of striking lever, then remove striking
rod, striking lever and striking interlock.
Select a position where retaining pin does not interfere
with clutch housing when removing retaining pin.
SMT583
Be careful not to damage oil seal lip, when removing strik-
ing rod. If necessary, tape edges of striking rod.
SMT584
7. Remove reverse check plug, then detach reverse check spring
and check balls.
DISASSEMBLYRS5F30A
MT-34

SMT585
8. Remove check sleeve assembly.
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LC
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FE
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DISASSEMBLYRS5F30A
MT-35

SMT734A
Input Shaft and Gears
DISASSEMBLYNJMT00421. Before disassembly, check 5th input gear end play.
Gear end play:
Refer to SDS, MT-119.
If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Then check clearance of snap ring
groove. Refer to “ASSEMBLY”, MT-37.
SMT750BA
2. Remove snap ring and rear bearing.
3. Remove snap ring and 5th stopper.
4. Remove 5th synchronizer, 5th input gear and 5th gear needle
bearing.
SMT697C
5. Remove snap ring of input shaft front bearing and input gear
spacer.
SMT601A
6. Pull out input shaft front bearing.
7. Remove bearing retainer.
REPAIR FOR COMPONENT PARTSRS5F30A
Input Shaft and Gears
MT-36

SMT602A
INSPECTIONNJMT0043Input Shaft and GearsNJMT0043S01Check shaft for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.
SMT387A
SynchronizerNJMT0043S02Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
SMT140
Measure clearance between baulk ring and 5th input gear.
Clearance between baulk ring and 5th input gear:
Standard
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)
SMT148A
BearingNJMT0043S03Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT736A
ASSEMBLYNJMT00441. Assemble 5th synchronizer.
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REPAIR FOR COMPONENT PARTSRS5F30A
Input Shaft and Gears (Cont’d)
MT-37

SMT761B
Be careful not to hook front and rear ends of spread
spring to the same insert.
SMT731-A
2. Install bearing retainer.
3. Press on input shaft front bearing.
4. Install spacer.
SMT735A
5. Select and install snap ring that gives the proper clearance of
input shaft groove.
Allowable clearance of groove:
0-0.1mm(0-0.004in)
Snap ring of input shaft front bearing:
Refer to SDS, MT-119.
SMT779AA
6. Install 5th gear needle bearing, 5th input gear, 5th synchro-
nizer and 5th stopper.
7. Measure gear end play as the final check. Refer to
“DISASSEMBLY”, MT-36.
SMT591
8. Select and install snap ring that gives the proper clearance of
input shaft groove.
Allowable clearance of groove:
0-0.1mm(0-0.004in)
Snap ring of input shaft 5th synchronizer hub:
Refer to SDS, MT-120.
REPAIR FOR COMPONENT PARTSRS5F30A
Input Shaft and Gears (Cont’d)
MT-38

SMT938D
9. Install input shaft rear bearing.
10. Select and install snap ring that gives the proper clearance of
input shaft groove.
Allowable clearance of groove:
0-0.1mm(0-0.004in)
Snap ring of input shaft rear bearing:
Refer to SDS, MT-120.
SMT605
Mainshaft and Gears
DISASSEMBLYNJMT00451. Before disassembly, check 1st, 2nd, 3rd and 4th main gear end
plays.
Gear end play:
Refer to SDS, MT-119.
If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Then check clearance of C-ring
groove. Refer to “ASSEMBLY”, MT-42.
SMT641-A
2. Press out mainshaft front bearing.
SMT638-A
3. Press out mainshaft rear bearing.
SMT592-A
4. Remove C-ring holder, mainshaft C-rings and thrust washer.
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REPAIR FOR COMPONENT PARTSRS5F30A
Input Shaft and Gears (Cont’d)
MT-39

SMT593-A
5. Press out 5th main gear.
SMT687C
6. Remove 4th main gear, 4th bushing and steel ball.
Be careful not to lose steel ball.
SMT780AA
7. Remove 3rd & 4th synchronizer, 3rd main gear, 2nd & 3rd
bushing, steel ball and 2nd main gear.
Be careful not to lose steel ball.
SMT594
8. Remove 1st & 2nd synchronizer and 1st main gear, then
remove 1st gear needle bearing.
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont’d)
MT-40