NISSAN ALMERA N16 2003 Electronic Repair Manual

REPAIR FOR COMPONENT PARTS
AT-465
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
2. Remove snap ring for forward clutch.
3. Remove drive plates, driven plates, retaining plate and dish
plate for forward clutch.
4. Remove snap ring for overrun clutch.
5. Remove drive plates, driven plates, retaining plate and dish
plate for overrun clutch.
6. Set Tool on spring retainer and remove snap ring from forward
clutch drum while compressing return springs.
●Set Tool directly over return springs.
●Do not expand snap ring excessively.
7. Remove spring retainer and return springs.
●Do not remove return springs from spring retainer.
8. Remove forward clutch piston with overrun clutch piston from
forward clutch drum by turning it.
9. Remove overrun clutch piston from forward clutch piston by
turning it.
SAT203D
SAT204D
AAT685
SAT216D
SAT215D

AT-466
[ALL]
REPAIR FOR COMPONENT PARTS
10. Remove D-rings and oil seals from forward clutch piston and
overrun clutch piston.
INSPECTION
Snap Rings, Spring Retainer
●Check for deformation, fatigue or damage.
●Replace if necessary.
Forward Clutch and Overrun Clutch Return
●Check for deformation or damage.
●Measure free length and outer diameter.
●Replace if deformed or fatigued.
Forward Clutch and Overrun Clutch Drive Plates
●Check facing for burns, cracks or damage.
●Measure thickness of facing.
●If not within wear limit, replace.
Forward Clutch and Overrun Clutch Dish Plates
●Check for deformation or damage.
●Measure thickness of dish plate.
●If deformed or fatigued, replace.
SAT140E
Inspection standard:
Refer to AT- 5 1 5 , "
SERVICE DATA
AND SPECIFICATIONS (SDS)" .
SAT138D
Thickness of drive plate:
Forward clutch
Standard value: 1.8 mm (0.071 in)
Wear limit: 1.6 mm (0.063 in)
Overrun clutch
Standard value: 1.6 mm (0.063 in)
Wear limit: 1.4 mm (0.055 in)
SAT162D
Thickness of dish plate “t”:
Forward clutch 2.5 mm (0.098 in)
Overrun clutch 2.15 mm (0.0846 in)
SAT163D

REPAIR FOR COMPONENT PARTS
AT-467
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
Forward Clutch Drum
●Make sure that check balls are not fixed.
●Apply compressed air to check ball oil hole from outside of for-
ward clutch drum. Make sure air leaks past ball.
●Apply compressed air to oil hole from inside of forward clutch
drum. Make sure there is no air leakage.
Overrun 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. Make
sure that air leaks past ball.
ASSEMBLY
1. Install D-rings and oil seals on forward clutch piston and overrun
clutch piston.
●Take care with direction of oil seal.
●Apply ATF to both parts.
2. Install overrun clutch piston assembly on forward clutch piston
by turning it slowly.
●Apply ATF to inner surface of forward clutch piston.
SAT213D
SAT212D
SAT208DA
SAT215D

AT-468
[ALL]
REPAIR FOR COMPONENT PARTS
3. Install forward clutch piston assembly on forward clutch drum by
turning it slowly.
●Apply ATF to inner surface of drum.
4. Align notch in forward clutch piston with groove in forward clutch
drum.
5. Install return spring on piston.
6. Install spring retainer on return springs.
7. 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.
SAT216D
SAT217D
SAT218D
AAT685
SAT220D

REPAIR FOR COMPONENT PARTS
AT-469
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
8. Install drive plates, driven plates, retaining plate and dish plate
for overrun clutch.
●Take care with order of plates.
9. Install snap ring for overrun clutch.
10. Measure clearance between overrun clutch retaining plate and
snap ring.
If not within allowable limit, select proper retaining plate.
11. Install drive plates, driven plates, retaining plate and dish plate
for forward clutch.
●Take care with order and direction of plates.
12. Install snap ring for forward clutch.
13. Measure clearance between forward clutch retaining plate and
snap ring.
If not within allowable limit, select proper retaining plate.
14. Check operation of forward clutch.
Refer to AT-464, "
Forward and Overrun Clutches" .
SAT204D
Specified clearance:
Standard 1.0 - 1.4 mm (0.039 - 0.055 in)
Allowable limit 2.0 mm (0.079 in)
Overrun clutch retaining plate:
Refer to AT- 5 1 5 , "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .SAT227D
SAT203D
Specified clearance:
Standard 0.45 - 0.85 mm (0.0177 - 0.0335 in)
Allowable limit 1.85 mm (0.0728 in)
Forward clutch retaining plate:
Refer to AT- 5 1 5 , "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .SAT228D
SAT201D

AT-470
[ALL]
REPAIR FOR COMPONENT PARTS
15. Check operation of overrun clutch.
Refer to AT- 4 6 4 , "
Forward and Overrun Clutches" .
Low & Reverse BrakeECS007TI
COMPONENTS
DISASSEMBLY
1. Check operation of low & reverse brake.
a. Apply compressed air to oil hole of transmission case.
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. Stand transmission case.
3. Remove snap ring.
4. Remove drive plates, driven plates, retaining plate from trans-
mission case.
SAT202D
SAT486JA
SAT230D
SAT231D

REPAIR FOR COMPONENT PARTS
AT-471
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
5. Set Tool on spring retainer and remove snap ring while com-
pressing return springs.
●Set Tool directly above return springs.
●Do not expand snap ring excessively.
6. Remove spring retainer and return springs.
●Do not remove return springs from spring retainer.
7. Apply compressed air to oil hole of transmission case while
holding piston.
8. Remove piston from transmission case by turning it.
9. Remove D-ring and oil seal from piston.
AAT687
SAT303E
SAT234D
SAT767G

AT-472
[ALL]
REPAIR FOR COMPONENT PARTS
INSPECTION
Low & Reverse Brake 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.
Low & Reverse Brake Drive Plate
●Check facing for burns, cracks or damage.
●Measure thickness of facing.
●If not within wear limit, replace.
ASSEMBLY
1. Install D-ring and oil seal on piston.
●Take care with the direction of the oil seal.
●Apply ATF to both parts.
2. Stand transmission case.
3. Install piston assembly on transmission case while turning it
slowly.
●Apply ATF to inner surface of transmission case.
4. Install return springs and spring retainer on piston.Thickness of drive plate:
Standard value 2.0 mm (0.079 in)
Wear limit 1.8 mm (0.071 in)
SAT162D
SAT235DA
SAT239D
SAT241D

REPAIR FOR COMPONENT PARTS
AT-473
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
5. Install snap ring while compressing return springs.
●Set Tool directly above return springs.
6. Install drive plates, driven plates, retaining plates and dished
plates.
●Do not align the projections on the two dished plates.
●Make sure to put the plates in the correct order and direc-
tion.
7. Install snap ring.
8. Measure clearance between retaining plate and snap ring. If not
within allowable limit, select proper retaining plate (front side).
9. Check operation of low & reverse brake. Refer to AT- 4 7 0 , "
DIS-
ASSEMBLY" .
AAT687
SAT254E
SAT231D
Specified clearance:
Standard 1.4 - 1.8 mm (0.055 - 0.071 in)
Allowable limit 2.8 mm (0.110 in)
Retaining plate:
Refer to AT- 5 1 5 , "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
SAT246D
SAT230D

AT-474
[ALL]
REPAIR FOR COMPONENT PARTS
Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub
ECS007TJ
COMPONENTS
DISASSEMBLY
1. Remove snap ring from overrun clutch hub.
2. Remove overrun clutch hub from forward clutch hub.
3. Remove thrust washer from forward clutch hub.
4. Remove forward clutch hub from rear internal gear.
SAT875J
SAT249D
SAT250D
SAT251D