NISSAN ALMERA N16 2003 Electronic Repair Manual

REPAIR FOR COMPONENT PARTS
AT-455
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
Reverse ClutchECS007TF
COMPONENTS
DISASSEMBLY
1. Check operation of reverse clutch
a. Install seal ring onto drum support of oil pump cover and install
reverse clutch assembly. Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring:
●D-ring might be damaged.
●Oil seal might be damaged.
●Fluid might be leaking past piston check ball.
2. Remove snap ring.
3. Remove drive plates, driven plates, retaining plate, and dish
plates.
4. Set Tool on spring retainer and remove snap ring from reverse
clutch drum while compressing return springs.
●Set Tool directly over springs.
●Do not expand snap ring excessively.
5. Remove spring retainer and return springs.
SAT485JA
SAT155D
SAT156D
AAT489

AT-456
[ALL]
REPAIR FOR COMPONENT PARTS
●Do not remove return spring from spring retainer.
6. Remove piston from reverse clutch drum by turning it.
7. Remove D-ring and oil seal from piston.
INSPECTION
Reverse Clutch Snap Ring, Spring Retainer and Return Springs
●Check for deformation, fatigue or damage.
●If necessary, replace.
●When replacing spring retainer and return springs, replace them as a set.
Reverse Clutch Drive Plates
●Check facing for burns, cracks or damage.
●Measure thickness of facing.
●If not within wear limit, replace.
SAT301E
SAT159D
SAT138E
Thickness of drive plate:
Standard value: 2.0 mm (0.079 in)
Wear limit: 1.8 mm (0.071 in)
SAT162D

REPAIR FOR COMPONENT PARTS
AT-457
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
Reverse Clutch Dish Plates
●Check for deformation or damage.
●Measure thickness of dish plate.
●If deformed or fatigued, replace.
Reverse Clutch Piston
●Make sure that check balls are not fixed.
●Apply compressed air to check ball oil hole opposite the return
spring. Make sure there is no air leakage.
●Apply compressed air to oil hole on return spring side to make
sure that air leaks past ball.
ASSEMBLY
1. Install D-ring and oil seal on piston.
●Take care with the direction of oil seal.
●Apply ATF to both parts.
2. Install piston assembly by turning it slowly.
●Apply ATF to inner surface of drum.Thickness of dish plate “T”: 2.8 mm (0.110 in)
SAT163D
SAT164D
SAT160DA
SAT159D

AT-458
[ALL]
REPAIR FOR COMPONENT PARTS
3. Install return springs and spring retainer on piston.
4. Set Tool on spring retainer and install snap ring while compress-
ing return springs.
●Set Tool directly over return springs.
5. Install drive plates, driven plates, retaining plate and dish plates.
●Do not align the projections of any two dish plates.
●Take care with order and direction of plates.
6. Install snap ring.
7. Measure clearance between retaining plate and snap ring. If not
within allowable limit, select proper retaining plate.
8. Check operation of reverse clutch.
Refer to AT- 4 5 5 , "
Reverse Clutch" .
SAT168D
AAT489
SAT156D
Specified clearance:
Standard: 0.5 - 0.8mm (0.020 - 0.031 in)
Allowable limit: 1.2 mm (0.047 in)
Retaining plate:
Refer to AT-515, "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
SAT174D
SAT173D

REPAIR FOR COMPONENT PARTS
AT-459
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
High ClutchECS007TG
COMPONENTS
DISASSEMBLY
1. Check operation of high clutch.
a. Apply compressed air to oil hole of input shaft with nylon cloth.
●Stop up hole on opposite side of input shaft with nylon
cloth.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring:
●D-ring might be damaged.
●Oil seal might be damaged.
●Fluid might be leaking past piston check ball.
2. Remove seal rings from input shaft.
●Always replace when removed.
SAT874J
SAT176D
SAT177D

AT-460
[ALL]
REPAIR FOR COMPONENT PARTS
3. Remove snap ring.
4. Remove drive plates, driven plates and retaining plate.
5. Set Tool on spring retainer and remove snap ring from high
clutch drum while compressing return springs.
●Set Tool directly over springs.
●Do not expand snap ring excessively.
6. Remove spring retainer and return springs.
●Do not remove return spring from spring retainer.
7. Remove piston from high clutch drum by turning it.
8. Remove D-ring and oil seal from piston.
SAT178D
AAT683
SAT302E
SAT189D
SAT139E

REPAIR FOR COMPONENT PARTS
AT-461
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
INSPECTION
High Clutch Snap Ring, Spring Retainer and Return Springs
●Check for deformation, fatigue or damage.
●If necessary, replace.
●When replacing spring retainer and return springs, replace them as a set.
High Clutch Drive Plates
●Check facing for burns, cracks or damage.
●Measure thickness of facing.
●If not within wear limit, replace.
High Clutch Piston
●Make sure that check balls are not fixed.
●Apply compressed air to check ball oil hole opposite the return
spring. Make sure there is no air leakage.
●Apply compressed air to oil hole on return spring side to make
sure that air leaks past ball.
Seal Ring Clearance
●Install new seal rings onto input shaft.
●Measure clearance between seal ring and ring groove.
●If not within allowable limit, replace input shaft assembly.
ASSEMBLY
1. Install D-ring and oil seal on piston.
●Take care with the direction of the oil seal.
●Apply ATF to both parts.Thickness of drive plate:
Standard value 2.0 mm (0.079 in)
Wear limit 1.8 mm (0.071 in)
SAT162D
SAT186D
Standard clearance: 0.08 - 0.23 mm (0.0031 - 0.0091 in)
Allowable limit: 0.23 mm (0.0091 in)
SAT187D
SAT182DA

AT-462
[ALL]
REPAIR FOR COMPONENT PARTS
2. Install piston assembly by turning it slowly.
●Apply ATF to inner surface of drum.
3. Install return springs and spring retainer on piston.
4. Set Tool on spring retainer and install snap ring while compress-
ing return springs.
●Set Tool directly over return springs.
●Do not align snap ring gap with spring retainer stopper.
5. Install drive plates, driven plates and retaining plate.
●Take care with the order and direction of plates.
6. Install snap ring.
SAT189D
SAT191D
AAT683
SAT193D
SAT195D

REPAIR FOR COMPONENT PARTS
AT-463
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
7. Measure clearance between retaining plate and snap ring. If not
within allowable limit, select proper retaining plate.
8. Check operation of high clutch.
Refer to AT-459, "
High Clutch" .
9. Install seal rings to input shaft.
●Apply petroleum jelly to seal rings.
●Always replace when removed.
●Roll paper around seal rings to prevent seal rings from
spreading.Specified clearance:
Standard 1.4 - 1.8 mm (0.055 - 0.071 in)
Allowable limit 2.4 mm (0.094 in)
Retaining plate:
Refer to AT-515, "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
SAT199D
SAT196D
SAT197D
SAT198D

AT-464
[ALL]
REPAIR FOR COMPONENT PARTS
Forward and Overrun Clutches
ECS007TH
COMPONENTS
DISASSEMBLY
1. Check operation of forward clutch and overrun clutch.
a. Install bearing retainer on forward clutch drum.
b. Apply compressed air to oil hole of forward clutch drum.
c. Check to see that retaining plate moves to snap ring.
d. If retaining plate does not contact snap ring:
●D-ring might be damaged.
●Oil seal might be damaged.
●Fluid might be leaking past piston check ball.
SAT932J
SAT201D
SAT202D