NISSAN ALMERA N16 2003 Electronic Repair Manual

SMT441C
1. Place inserts in three grooves on coupling sleeve (3rd & 4th
synchronizer).
SMT477C
SMT123C
2. Install 3rd input gear and 3rd baulk ring.
3. Press on 3rd & 4th synchronizer hub.
Pay attention to its direction.
4. Select proper snap ring of 3rd & 4th synchronizer hub to mini-
mize clearance of groove, and then install it.
Allowable clearance of groove:
0-0.1mm(0-0.004in)
Snap ring of 3rd & 4th synchronizer hub:
Refer to SDS, MT-133.
SMT442C
5. Install 4th input gear.
6. Select proper thrust washers to minimize clearance of groove.
Then install them and thrust washer ring.
Allowable clearance of groove:
0 - 0.06 mm (0 - 0.0024 in)
4th input gear thrust washer:
Refer to SDS, MT-133.
SMT206B
7. Install 5th & reverse synchronizer assembly.
a. Hook insert springs on reverse baulk ring.
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REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears (Cont’d)
MT-101

SMT752C
b. Install insert springs with reverse baulk ring onto coupling
sleeve.
Pay attention to position of insert springs.
c. Place 5th baulk ring on 5th input gear.
d. Install reverse synchronizer cone on reverse baulk ring.
SMT208B
e. Place reverse synchronizer assembly on 5th input gear.
Mesh recesses of 5th input gear with projections of
reverse synchronizer cone.
Put insert spring mounts on reverse baulk ring upon those
on 5th baulk ring.
SMT124C
f. Press on 5th & reverse synchronizer assembly with 5th input
gear.
SMT753CA
8. Install input shaft front and rear bearings.
9. Measure gear end play as a final check. Refer to
“DISASSEMBLY”, MT-98.
REPAIR FOR COMPONENT PARTSRS5F50A
Input Shaft and Gears (Cont’d)
MT-102

SMT191A
Mainshaft and Gears
DISASSEMBLYNJMT00141. Before disassembly, check 1st and 2nd main gear end plays.
Gear end play:
Refer to SDS, MT-132.
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-105.
SMT638AA
2. Press out mainshaft rear bearing.
SMT044A
3. Remove thrust washer and snap ring.
SMT045AA
4. Press out 5th main gear and 4th main gear.
SMT131AA
5. Press out 3rd main gear and 2nd main gear.
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REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears
MT-103

SMT047A
6. Remove snap ring.
SMT048A
7. Remove 1st & 2nd synchronizer hub and 1st main gear.
SMT639AA
8. Remove mainshaft front bearing.
SMT640A
INSPECTIONNJMT0015Mainshaft and GearsNJMT0015S01Check mainshaft for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.
SMT637A
SynchronizerNJMT0015S02Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check insert springs for deformation.
REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears (Cont’d)
MT-104

SMT420CA
Measure wear of 1st and 2nd double baulk rings.
a) Place baulk rings in position on synchronizer cone.
b) While holding baulk ring against synchronizer cone as far as it
will go, measure dimensions “A” and “B”.
Standard:
A 0.6 - 0.8 mm (0.024 - 0.031 in)
B 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit:
0.2mm(0.008in)
c) If dimension “A” or “B” is smaller than the wear limit, replace
outer baulk ring, inner baulk ring and synchronizer cone as a
set.
SPD715
BearingNJMT0015S03Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
When replacing tapered roller bearing, replace outer and
inner race as a set.
SMT996B
ASSEMBLYNJMT0016
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REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears (Cont’d)
MT-105

SMT804BA
SMT472C
1. Press on 1st main gear, 1st synchronizer cone, inner & outer
baulk rings and 1st & 2nd synchronizer hub.
Refer to the illustration for step 3.
Pay attention to direction of 1st & 2nd synchronizer hub.
2. Select proper snap ring of 1st & 2nd synchronizer hub to mini-
mize clearance of groove and then install it.
Allowable clearance of groove:
0-0.1mm(0-0.004in)
Snap ring of 1st & 2nd synchronizer hub:
Refer to SDS, MT-133.
SMT805B
3. Install 2nd synchronizer cone, inner & outer baulk rings. Insert
springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.
Ensure four protrusions of 2nd synchronizer cone are set in
holes of 2nd main gear.
SMT600CA
5. Press on 3rd main gear.
6. Press on 4th main gear.
SMT473CA
7. Press on 5th main gear.
8. Select proper snap ring of 5th main gear to minimize clearance
of groove and then install it.
Allowable clearance of groove:
0 - 0.15 mm (0 - 0.0059 in)
Snap ring of 5th main gear:
Refer to SDS, MT-133.
REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears (Cont’d)
MT-106

SMT059A
9. Press on thrust washer and press on mainshaft rear bearing.
10. Press on mainshaft front bearing.
11. Measure gear end play as a final check. Refer to
“DISASSEMBLY”, MT-103.
SMT744AA
Final Drive
DISASSEMBLYNJMT00171. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
Be careful not to mix up the right and left bearings.
SMT612AA
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
SMT083A
INSPECTIONNJMT0018Gear, Washer, Shaft and CaseNJMT0018S01Check mating surfaces of differential case, viscous coupling,
side gears and pinion mate gears.
Check washers for wear.
SPD715
BearingsNJMT0018S03Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
When replacing taper roller bearing, replace outer and
inner race as a set.
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REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears (Cont’d)
MT-107

SMT062A
ASSEMBLYNJMT00191. Attach side gear thrust washers to side gears, then install pin-
ion mate washers and pinion mate gears in place.
SMT087A
2. Insert pinion mate shaft.
When inserting, be careful not to damage pinion mate
thrust washers.
SMT610AH
3. Measure clearance between side gear and differential case
with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.
Clearance between side gear and differential case with
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
c. If not within specification, adjust clearance by changing thick-
ness of side gear thrust washers.
Differential side gear thrust washer:
Refer to SDS, MT-133.
SMT612AA
4. Install retaining pin.
Make sure that retaining pin is flush with case.
REPAIR FOR COMPONENT PARTSRS5F50A
Final Drive (Cont’d)
MT-108

SMT609A
5. Install final gear.
6. Install speedometer drive gear.
SMT648
7. Press on differential side bearings.
SMT665C
Shift Control Components
INSPECTIONNJMT0020Check contact surface and sliding surface for wear, scratches,
projections or other damage.
SMT030A
Case Components
REMOVAL AND INSTALLATIONNJMT0021Input Shaft Oil SealNJMT0021S01
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REPAIR FOR COMPONENT PARTSRS5F50A
Final Drive (Cont’d)
MT-109

SMT031A
Apply multi-purpose grease to seal lip of oil seal before
installing.
SMT034A
Mainshaft Front Bearing Outer RaceNJMT0021S02Extract the oil channel and remove the mainshaft front bear-
ing outer race.
Mainshaft Rear Bearing Outer RaceNJMT0021S03Refer to “Mainshaft Bearing Preload”, MT-134.
Differential Side Bearing Outer RaceNJMT0021S04Refer to “Input Shaft End Play and Differential Side Bearing
Preload”, MT-134.
REPAIR FOR COMPONENT PARTSRS5F50A
Case Components (Cont’d)
MT-110