NISSAN ALMERA N16 2003 Electronic Repair Manual

SMT644D
21. Install selected snap ring.
CAUTION:
Do not reuse snap ring.
22. Apply gear oil to rear cover O-ring, and install rear cover, side
cover gasket, and side cover. Then tighten mounting bolts with
specified torque.
Tightening torque:
Refer to MT-54.
CAUTION:
Do not reuse mounting bolts for rear cover and side cover.
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ASSEMBLYRS5F70A
Transaxle Case (Cont’d)
MT-91

NJMT0009
Case ComponentsNJMT0009S02
SMT943D
1. Speedometer pinion
2. Differential oil seal
3. Drain plug
4. Boot
5. Striking rod oil seal
6. Magnet
7. Clutch housing8. Input shaft oil seal
9. Oil channel (Mainshaft)
10. Oil pocket
11. Oil gutter
12. Oil channel (Input shaft)
13. Transmission case14. Filler plug
15. O-ring
16. Movable plate assembly
17. PNP switch
18. Breather hose
19. Breather pipe
OVERHAULRS5F50A
Case Components
MT-92

Gear ComponentsNJMT0009S03
SMT937D
1. Input shaft
2. Input shaft front bearing
3. 3rd input gear
4. 3rd & 4th synchronizer hub
5. Snap ring
6. Coupling sleeve
7. 4th baulk ring
8. 4th input gear
9. Reverse baulk ring
10. Reverse synchronizer cone
11. 5th synchronizer hub
12. Input shaft rear bearing
13. Input shaft bearing adjusting shim
14. 3rd baulk ring
15. Insert spring
16. 4th input gear thrust washer
17. Thrust washer ring
18. 5th input gear19. 5th baulk ring
20. 1st outer baulk ring
21. 2nd inner baulk ring
22. Snap ring
23. Mainshaft bearing spacer
24. Mainshaft front bearing
25. Mainshaft
26. 1st main gear
27. 1st & 2nd synchronizer hub
28. Reverse main gear & 1st-2nd cou-
pling sleeve
29. 2nd outer baulk ring
30. 2nd gear synchronizer cone
31. 2nd main gear
32. 3rd main gear
33. 4th main gear
34. 5th main gear
35. Mainshaft rear bearing
36. Mainshaft bearing adjusting shim37. Differential side bearing
38. Speedometer drive gear
39. Differential case
40. Pinion mate shaft
41. Side gear
42. Side gear thrust washer
43. Pinion mate gear
44. Pinion mate gear thrust washer
45. Retaining pin
46. Final gear
47. Differential side bearing
48. Differential side bearing adjusting
shim
49. Reverse idler gear
50. Bushing
51. Reverse idler shaft
52. 1st gear synchronizer cone
53. 1st inner baulk ring
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OVERHAULRS5F50A
Gear Components
MT-93

Shift Control ComponentsNJMT0009S04
SMT862CA
1. Retaining pin
2. 1st & 2nd shift fork
3. 1st & 2nd check plug
4. Return spring
5. Check ball
6. 1st & 2nd fork rod
7. 1st & 2nd bracket
8. Interlock plunger
9. 3rd & 4th bracket
10. Return spring
11. Reverse gate
12. Select arm
13. Return bearing
14. Bush15. Yoke
16. Striking rod
17. Striking lever
18. Selector
19. Selector shaft
20. O-ring
21. Return spring
22. Cam pin
23. Reverse check cam
24. Check ball
25. Select check spring
26. Interlock plunger
27. 3rd & 4th fork rod28. Interlock ball
29. Stopper ring
30. 3rd & 4th check plug
31. 3rd & 4th shift fork
32. 5th shift fork
33. 5th fork rod
34. 5th & reverse check plug
35. Reverse lever spring
36. Reverse lock spring
37. 5th & reverse bracket
38. Reverse lever assembly
39. Reverse arm shaft
40. Control lever spring
OVERHAULRS5F50A
Shift Control Components
MT-94

NJMT0010
SMT626D
1. Before removing transmission case, remove bolts, check
plugs, springs and check balls as shown left.
Be careful not to lose check balls.
2. Remove transmission case.
SMT017AA
3. Remove PNP switch.
SMT659C
4. Mesh 4th gear, and then remove reverse idler shaft and
reverse idler gear.
SMT660C
5. Pull out retaining pin.
SMT661C
6. Remove reverse lever spring and reverse lock spring from
reverse lever assembly.
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DISASSEMBLYRS5F50A
MT-95

SMT662C
7. Remove reverse arm shaft while rotating it.
SMT663C
8. Remove reverse lever assembly and check ball.
Be careful not to lose check ball.
SMT018B
9. Remove 5th & reverse check plug, spring and ball.
Be careful not to lose check ball.
SMT664C
10. Remove stopper rings and retaining pins from 5th and 3rd &
4th fork rods.
When removing stopper rings. Use snap ring remover and
installer.
11. Remove 5th and 3rd & 4th fork rods. Then remove forks and
brackets.
SMT105C
12. Remove both input and mainshafts with 1st & 2nd fork and fork
rod as a set.
13. Remove final drive assembly.
Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
DISASSEMBLYRS5F50A
MT-96

SMT138A
14. Remove reverse check assembly and check ball.
Be careful not to lose check ball.
SMT618AA
SMT027A
15. Remove retaining pin and detach the selector.
SMT028A
16. Remove drain plug for convenience in removing retaining pin
which holds striking lever to striking rod.
SMT619AA
17. Remove retaining pin and then withdraw striking lever and
striking rod.
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DISASSEMBLYRS5F50A
MT-97

SMT121C
Input Shaft and Gears
DISASSEMBLYNJMT00111. Before disassembly, check 3rd, 4th and 5th input gear end
plays.
Gear end play:
Refer to SDS, MT-132.
SMT476C
If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Check clearance of snap ring
groove. Refer to “ASSEMBLY”, MT-100.
SMT634AA
2. Remove input shaft rear bearing.
SMT205BA
3. Remove 5th & reverse synchronizer and 5th input gear.
SMT474CA
4. Remove thrust washer ring, 4th input gear thrust washers and
4th input gear.
REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears
MT-98

SMT040A
5. Remove snap ring.
SMT041AA
6. Remove 3rd & 4th synchronizer and 3rd input gear.
SMT042AA
7. Remove input shaft front bearing.
SMT636A
INSPECTIONNJMT0012Input shaft and GearsNJMT0012S01Check input shaft for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.
SMT637A
SynchronizerNJMT0012S02Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check insert springs for wear or deformation.
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REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears (Cont’d)
MT-99

SMT140
Measure clearance between baulk ring and gear (3rd, 4th and
5th).
Clearance between baulk ring and gear:
Standard
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)
SMT516B
Measure wear of reverse baulk ring.
1. Place reverse baulk ring on Disc and then place reverse syn-
chronizer cone on reverse baulk ring.
Make sure projection of synchronizer cone is positioned
over the recess on Tool.
2. While holding reverse synchronizer cone against reverse baulk
ring as firmly as possible, measure dimension “A” with dial
indicator.
Wear limit:
Dimension “A” 1.2 mm (0.047 in)
3. If dimension “A” is smaller than the wear limit, replace baulk
ring.
SMT148A
BearingNJMT0012S03Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT122C
ASSEMBLYNJMT0013
REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears (Cont’d)
MT-100