NISSAN ALMERA TINO 2001 Service Repair Manual

ASSEMBLY.............................................................42
Final Drive..................................................................47
PRE-INSPECTION...................................................47
DISASSEMBLY........................................................48
INSPECTION...........................................................49
ASSEMBLY.............................................................49
Shift Control Components .........................................51
INSPECTION...........................................................51
ASSEMBLY....................................................................52
Clutch Housing ..........................................................52
Transaxle Case ..........................................................56
RS5F50A
OVERHAUL...................................................................62
Case Components .....................................................62
Gear Components .....................................................63
Shift Control Components .........................................64
DISASSEMBLY..............................................................65
REPAIR FOR COMPONENT PARTS...........................68
Input Shaft and Gears ...............................................68
DISASSEMBLY........................................................68
INSPECTION...........................................................69
ASSEMBLY.............................................................70
Mainshaft and Gears .................................................73
DISASSEMBLY........................................................73
INSPECTION...........................................................74
ASSEMBLY.............................................................75
Final Drive..................................................................77
DISASSEMBLY........................................................77
INSPECTION...........................................................77
ASSEMBLY.............................................................78
Shift Control Components .........................................79
INSPECTION...........................................................79
Case Components .....................................................79
REMOVAL AND INSTALLATION...............................79
ADJUSTMENT...............................................................81
Input Shaft End Play and Differential Side
Bearing Preload .........................................................81
DIFFERENTIAL SIDE...............................................81
INPUT SHAFT SIDE.................................................82
Mainshaft Bearing Preload ........................................82
ASSEMBLY....................................................................84
RS5F70A
SERVICE DATA AND SPECIFICATIONS (SDS).........88
General Specifications ...............................................88
TRANSAXLE...........................................................88
FINAL GEAR...........................................................88
Gear End Play ...........................................................89
Clearance Coupling Sleeve .......................................89
1ST, 2ND, 3RD, 4TH, 5TH & REVERSE
COUPLING SLEEVE
................................................89
Clearance Between Baulk Ring and Gear ................89
3RD, 4TH, 5TH, REVERSE BAULK RING..................89
1ST AND 2ND DOUBLE BAULK RING......................89
Available Snap Rings ................................................90
SNAP RING.............................................................90
Available C-rings........................................................90
4TH INPUT GEAR C-RING.......................................90
5TH INPUT GEAR REAR C-RING.............................90
MAINSHAFT C-RING...............................................91
Available Adjusting Shims .........................................92
INPUT SHAFT REAR BEARING ADJUSTING
SHIM
......................................................................92
MAINSHAFT ADJUSTING SHIM................................93
MAINSHAFT REAR BEARING ADJUSTING SHIM......93
Available Thrust Washer............................................94
MAINSHAFT THRUST WASHER...............................94
Available Washers .....................................................94
DIFFERENTIAL SIDE GEAR THRUST WASHER........94
Available Shims - Differential Side Bearing
Preload and Adjusting Shim ......................................95
BEARING PRELOAD...............................................95
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIMS
....................................................................95
RS5F50A
SERVICE DATA AND SPECIFICATIONS (SDS).........96
General Specifications ...............................................96
TRANSAXLE...........................................................96
FINAL GEAR...........................................................96
Gear End Play ...........................................................97
Clearance Between Baulk Ring and Gear ................97
3RD, 4TH & 5TH BAULK RING.................................97
1ST AND 2ND DOUBLE BAULK RING......................97
REVERSE BAULK RING..........................................97
Available Snap Rings ................................................98
1ST & 2ND SYNCHRONIZER HUB (AT
MAINSHAFT)
...........................................................98
3RD & 4TH SYNCHRONIZER HUB (AT INPUT
SHAFT)
...................................................................98
5TH MAIN GEAR (AT MAINSHAFT)..........................98
Available Thrust Washer............................................98
4TH INPUT GEAR (AT INPUT SHAFT)......................98
DIFFERENTIAL SIDE GEAR THRUST WASHER........98
Available Shims .........................................................99
BEARING PRELOAD AND END PLAY......................99
TOTAL TURNING TORQUE (NEW BEARING)............99
MAINSHAFT BEARING ADJUSTING SHIM................99
TABLE FOR SELECTING MAINSHAFT BEARING
ADJUSTING SHIM(S)
...............................................99
INPUT SHAFT BEARING ADJUSTING SHIM...........100
TABLE FOR SELECTING INPUT SHAFT BEARING
ADJUSTING SHIM(S)
.............................................100
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM
....................................................................100
TABLE FOR SELECTING DIFFERENTIAL SIDE
BEARING ADJUSTING SHIM(S)
.............................101
CONTENTS(Cont’d)
MT-2

Special Service ToolsNLMT0032
Tool number
Tool nameDescription
KV38107700
Preload adapter
NT087
Measuring turning torque of final drive assembly
Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
(Use with KV38106000.)
KV38106000
Height gauge adapter
(differential side bearing)
NT418
Selecting differential side bearing adjusting shim
(Use with KV38107700.)
a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 x 1.25P
KV32101000
Pin punch
NT410
Removing and installing retaining pin
Removing and installing lock pin
Removing selector shaft
Removing welch plug
a: 4 mm (0.16 in) dia.
KV31100300
Pin punch
NT410
Removing and installing retaining pin
a: 4.5 mm (0.177 in) dia.
ST30031000
Puller
NT411
Removing 3rd, 5th input gear
Removing 3rd & 4th and 5th & Rev synchronizer
hub
Removing mainshaft rear bearing
Removing 2nd gear, 5th gear bush
Removing 1st & 2nd synchronizer hub, 1st and
4th main gear
Removing and installing differential side bearing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
Puller
NT411
Removing input shaft front and rear bearing
Installing input shaft front and rear bearing
Installing 5th input gear, 3rd main gear and 4th
main gear
Installing 1st & 2nd, 3rd & 4th and 5th & Rev syn-
chronizer hub
Installing 2nd gear bush, 5th gear bush, Rev gear
bush
Installing mainshaft rear bearing
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
PREPARATIONRS5F70A
Special Service Tools
MT-3

Tool number
Tool nameDescription
ST33290001
Puller
NT414
Removing idler gear bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST33230000
Drift
NT084
Removing differential oil seal
Installing differential side bearing
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
ST30720000
Drift
NT115
Installing differential side bearing outer race
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST22350000
Drift
NT065
Installing input shaft front and rear bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
ST22452000
Drift
NT065
Installing 3rd and 4th main gear
Installing 5th gear bush
Installing 5th & Rev synchronizer hub
Installing Rev gear bush
Installing mainshaft rear bearing
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
ST37750000
Drift
NT065
Installing input shaft oil seal
Installing 5th synchronizer
Installing mainshaft rear bearing
Installing 5th main gear
Installing 3rd & 4th synchronizer hub
Installing striking rod oil seal
Installing clutch housing dust seal
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
PREPARATIONRS5F70A
Special Service Tools (Cont’d)
MT-4

Commercial Service ToolsNLMT0033
Tool name Description
Drift
NT065
Installing welch plug
a: 12 mm (0.47 in) dia.
b: 10 mm (0.39 in) dia.
Drift
NT065
Removing input shaft rear bearing
Removing mainshaft rear bearing
a: 22 mm (0.87 in) dia.
b: 16 mm (0.63 in) dia.
Drift
NT065
Installing differential oil seal
a: 58 mm (2.28 in) dia.
b: 50 mm (1.97 in) dia.
Drift
NT065
Installing differential oil seal
a: 54 mm (2.13 in) dia.
b: 50 mm (1.97 in) dia.
Drift
NT065
Installing 2nd gear bush
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
Drift
NT065
Installing 3rd & 4th and 1st & 2nd synchronizer
hub
Installing mainshaft front bearing
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
Drift
NT065
Installing input shaft oil seal
Installing 5th input gear
a: 39 mm (1.54 in) dia.
b: 30 mm (1.18 in) dia.
PREPARATIONRS5F70A
Commercial Service Tools
MT-5

Special Service ToolsNLMT0001
Tool number
Tool nameDescription
KV38105210
Preload adapter
NT075
Measuring turning torque of final drive assembly
Measuring total turning torque
KV32101000
Pin punch
NT410
Removing and installing retaining pin
a: 4 mm (0.16 in) dia.
ST22730000
Puller
NT411
Removing mainshaft front and rear bearing inner
race
a: 82 mm (3.23 in) dia.
b: 30 mm (1.18 in) dia.
ST30031000
Puller
NT411
Removing input shaft front and rear bearing
Removing 4th & 5th main gear
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
Puller
NT411
Removing 5th synchronizer
Removing 3rd & 4th synchronizer
Removing 2nd & 3rd main gear
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
ST3306S001
Differential side bearing
puller set
1 ST33051001
Puller
2 ST33061000
Adapter
NT675
Removing differential side bearing inner race
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
c: 130 mm (5.12 in)
d: 135 mm (5.31 in)
e: 100 mm (3.94 in)
PREPARATIONRS5F50A
Special Service Tools
MT-6

Tool number
Tool nameDescription
ST33290001
Puller
NT414
Removing differential oil seal
Removing mainshaft rear bearing outer race
Removing differential side bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST33400001
Drift
NT086
Installing differential oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
ST30600000
Drift
NT065
Installing input shaft front bearing
a: 36 mm (1.42 in) dia.
b: 31 mm (1.22 in) dia.
ST22452000
Drift
NT065
Installing 3rd, 4th and 5th main gear
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
ST30621000
Drift
NT073
Installing mainshaft rear bearing outer race
(Use with ST30611000.)
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
ST30611000
NT419
(Use with ST30621000.)
a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 in) dia.
d: M12 x 1.5P
KV38107700
Preload adapter
NT087
Measuring clearance between side gear and differ-
ential case with washer
KV38106500
Preload adapter
NT087
Measuring turning torque of final drive assembly
PREPARATIONRS5F50A
Special Service Tools (Cont’d)
MT-7

Commercial Service ToolsNLMT0002
Tool name Description
Drift
NT065
Installing differential side bearing inner race
a: 45 mm (1.77 in) dia.
b: 41 mm (1.61 in) dia.
Drift
NT065
Installing differential side bearing outer race
a: 69 mm (2.72 in) dia.
b: 64 mm (2.52 in) dia.
Drift
NT065
Installing striking rod oil seal
a: 38 mm (1.50 in) dia.
b: 20 mm (0.79 in) dia.
PREPARATIONRS5F50A
Commercial Service Tools
MT-8

NLMT0003
NVH Troubleshooting ChartNLMT0003S01Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
MANUAL TRANSAXLENLMT0003S0101
Reference page
MT-10 (RS5F70A),
MT-11 (RS5F50A)
MT-10 (RS5F70A),
MT-11 (RS5F50A)
MT-10 (RS5F70A),
MT-11 (RS5F50A)
MT-62
MT-62
MT-62
MT-23
MT-64
MT-64
MT-63
MT-63
MT-63
MT-63
SUSPECTED PARTS
(Possible cause)
(Oil level is low.)
(Wrong oil)
(Oil level is high.)
GASKET (Damaged)
OIL SEAL (Worn or damaged)
O-RING (Worn or damaged)
SHIFT CONTROL ROD (Worn)
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SHIFT FORK (Worn)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
INSERT SPRING (Damaged)
SymptomsNoise 1 2 3 3
Oil leakage31222
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear1233
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
MT-9

SMA145AA
SMT512C
Changing M/T OilNLMT00861. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-20,“RECOMMENDED FLUIDS AND
LUBRICANTS”.
Capacity:
RS5F70A 3.0!(5-1/4 Imp pt)
Oil level (Reference data):
RS5F70A 75.5 - 80.5 mm (2.972 - 3.196 in)
Drain plug:
:25-34N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
SMA066C
CheckingNLMT0087OIL LEAK AND OIL LEVELNLMT0087S011. Check that oil is not leaking from transaxle or around it.
2. Check oil level.
Never start engine while checking oil level.
Filler plug:
:10-19N·m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
M/T OILRS5F70A
Changing M/T Oil
MT-10

SMA067C
Changing M/T OilNLMT00881. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-20,“RECOMMENDED FLUIDS AND
LUBRICANTS”.
Capacity:
RS5F50A 4.5 - 4.8!(7-7/8 - 8-1/2 Imp pt)
Drain plug:
:15-20N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SMA066C
CheckingNLMT0089OIL LEAK AND OIL LEVELNLMT0089S01Check for oil leakage and oil level.
Never start engine while checking oil level.
Filler plug:
:25-34N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
M/T OILRS5F50A
Changing M/T Oil
MT-11