NISSAN NOTE 2016 Service Repair Manual

TM-40
< UNIT DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
TRANSAXLE ASSEMBLY
• Be careful with the orientat
ion of 3rd-4th coupling sleeve.
• Install 3rd input gear of in put shaft assembly so that it is
set under reverse main gear of 3rd-4th coupling sleeve.
• Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer hub as a set.
c. Install springs and insert keys to 3rd-4th synchronizer hub.
d. Apply gear oil to 4th baulk ring.
e. Install 4th baulk ring.
27. Install 5th-reverse fork rod (1) to clutch housing. CAUTION:
Replace 5th-reverse fork rod and 5th-reverse shift fork as a
set.
a. Pull gear of reverse gear (2) up.
b. Temporarily install 5th-reverse fork rod to clutch housing.
c. Press gear of reverse gear (1) down and then install 5th-reverse fork rod (2) to clutch housing.
CAUTION:
Set levers of 5th-reverse fork rod so as to align with reverse
gear groove ( ).
28. Install 4th main gear (2) and spacer (1) to mainshaft. CAUTION:
Install spacer so that spacer protrusion faces rear side of
transaxle.
29. Press 3rd-4th shift fork down and then shift 3rd-4th coupling sleeve to 3rd gear side.
(A) : 4th main gear side
(B) : 3rd main gear side
PCIB1551E
MCIB0061E
PCIB1629E
PCIB1552E
PCIB1529E
Revision: August 2015 2016 Versa Note

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TRANSAXLE ASSEMBLYTM-41
< UNIT DISASSEMBLY AND ASSEMBLY > [5MT: RS5F91R]
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30. Move the shifter lever A (1) to the 3rd gear position. NOTE:
• If it is not moved to the 3rd gear position, transaxle case can-not be installed to clutch housing.
• The 3rd gear position means that shifter lever A is fully rotated clockwise and it is returned approximately 10 degrees.
31. Apply recommended sealant to transaxle case mating surface of clutch housing.
CAUTION:
• Use Genuine Silicone RTV or equivalent. Refer to GI-22,
"Recommended Chemical Products and Sealants".
• Do not allow old Silicone RTV, moisture, oil, or foreign matter to remain on mating surface.
• Check that mating surface is not damaged.
• Apply a continuous bead of Si licone RTV to the mating surface.
32. Install transaxle case to clutch hous ing. If it is difficult to install,
slightly rotate shifter lever A counterclockwise, and then install.
CAUTION:
• Do not damage Silicone RTV bead with transaxle case or
other objects during installation.
• Be careful to align the lever of 5th-reverse fork rod with
reverse gear groove.
33. Rotate input shaft so that bearing and shaft fit each other, and then tighten transaxle bolts ( ) to the specified torque.
34. Apply recommended sealant to position switch thread and check ball plug thread. Install to transaxle case and tighten to specified
torque.
CAUTION:
• Use Genuine Silicone RTV or equivalent. Refer to GI-22,
"Recommended Chemical Products and Sealants".
• Do not allow old Silicone RTV, moisture, oil, or foreign matter to remain on thread.
35. Apply gear oil to mainshaft spline.
36. Install 5th main gear (1) to mainshaft, using a suitable bolt (A) [M10 x 1.0] and a suitable nut (B).
PCIB1524E
(1) : Selector
(2) : Shift fork
PCIB1553E
JPDIC0610ZZ
PCIB1554E
Revision: August 2015 2016 Versa Note

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TM-42
< UNIT DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
TRANSAXLE ASSEMBLY
37. Install adapter plate (1), bushing (2), and 5th input gear (3) to
input shaft.
CAUTION:
Be careful with the orientation of adapter plate.
38. Install 5th-reverse synchronizer hub, 5th-reve rse coupling sleeve, and 5th-reverse shift fork.
a. Apply gear oil to 5th-reverse baulk ring.
b. Install 5th-reverse baulk ring (1) to 5th input gear.
CAUTION:
Be careful with the orientat ion of 5th-reverse baulk ring.
c. Install synchronizer levers (2) to 5th-reverse synchronizer hub (3).
CAUTION:
• Replace 5th-reverse synchronizer hub and 5th-reversecoupling sleeve as a set.
• Be careful with the orientation of synchronizer lever.
d. Install 5th-reverse synchronizer hub assembly and lock washer to input shaft. CAUTION:
• Be careful with the orientation of 5th-reverse synchro-nizer hub.
• Do not allow synchronizer lever (1) to overlap 5th-reverse baulk ring protrusion (A).
: Transaxle case side
PCIB1555E
: 5th-reverse synchronizer hub side
: 5th input gear side
JPDIC0421ZZ
PCIB1556E
(2) : 5th-reverse baulk ring
(3) : 5th-reverse synchronizer hub
JPDIC0408ZZ
Revision: August 2015 2016 Versa Note

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TRANSAXLE ASSEMBLYTM-43
< UNIT DISASSEMBLY AND ASSEMBLY > [5MT: RS5F91R]
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e. Set 5th-reverse shift fork (1) to 5th-reverse coupling sleeve, and then install them to 5th-reverse fork rod and input shaft.
CAUTION:
Do not reuse nut.
CAUTION:
• Be careful with the orient ation of 5th-reverse coupling
sleeve.
• Replace 5th-reverse synchronizer hub and 5th-reverse coupling sleeve as a set.
• Replace 5th-reverse shift fork and 5th-reverse fork rod as a set.
f. Check that the shifter lever A is in the 3rd position. Press 5th-
reverse shift fork (1) and move shifter lever A to 5th gear.
g. Tighten bolt (B) to the specified torque.
h. Tighten nut (C) to the specified torque. CAUTION:
Do not reuse nut.
i. Install retaining pin to 5th-reverse shift fork, using suitable tool. CAUTION:
Do not reuse retaining pin.
39. Move shifter lever A (1) to the neutral position.
40. Install O-ring to rear housing. CAUTION:
Do not reuse O-ring.
(A) : Suitable tool
(B) : Bolt
(C) : Nut
JPDIC0532ZZ
: 5th input gear side
JPDIC0409ZZ
(A) : Suitable tool
JPDIC0532ZZ
SCIA7130E
Revision: August 2015 2016 Versa Note

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TM-44
< UNIT DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
TRANSAXLE ASSEMBLY
41. Install rear housing to transaxle case, and tighten bolts ( ) to
the specified torque.
CAUTION:
• Do not reuse O-ring.
• Do not pinch O-ring when installing rear housing.
42. Install drain plug.
a. Install gasket to drain plug. CAUTION:
Do not reuse gasket.
b. Install drain plug to clutch housing, using suitable tool.
c. Tighten drain plug to the specified torque.
43. Install filler plug.
a. Install gasket to filler plug, and then install filler plug to transaxle case. CAUTION:
Do not reuse gasket.
b. Tighten filler plug to the specified torque. CAUTION:
Fill with gear oil before tightening filler plug to the specified torque.
InspectionINFOID:0000000012430967
INSPECTION AFTER DISASSEMBLY
Check contact surface and sliding surface of fork rod and shift fork
for excessive wear, uneven wear, and damage. Replace if neces-
sary.
PCIB1558E
PCIB1571E
Revision: August 2015 2016 Versa Note

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INPUT SHAFT AND GEARTM-45
< UNIT DISASSEMBLY AND ASSEMBLY > [5MT: RS5F91R]
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INPUT SHAFT AND GEAR
Exploded ViewINFOID:0000000012430968
DisassemblyINFOID:0000000012430969
Refer to TM-30, "Disassembly" for disassembly procedure.
AssemblyINFOID:0000000012430970
Refer to TM-36, "Assembly" for assembly procedure.
InspectionINFOID:0000000012430971
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gear
1. Input shaft front bearing 2. Input shaft 3. Snap ring
4. Input shaft rear bearing 5. Adapter plate 6. Bushing
7. 5th input gear 8. 5th-reverse baulk ring 9. Synchronizer lever
10. 5th-reverse synchronizer hub 11. 5th-reverse coupling sleeve 12. Lock washer
13. Retaining pin 14. Reverse gear
: Apply gear oil.
: Replace the parts as a set.
JPDIC0820GB
Revision: August 2015 2016 Versa Note

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TM-46
< UNIT DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
INPUT SHAFT AND GEAR
Check the following items and replace if necessary.
• Damage, peeling, uneven wear, and distortion of shaft.
• Excessive wear, damage, and peeling of gear.
Synchronizer
Check for the following and replace if necessary.
• Contact surface breakage, damage, and unusual wear of coupling
sleeve, synchronizer hub, and synchronizer lever.
• Coupling sleeve and synchronizer hub move smoothly.
• Breakage, damage, and excessive wear of baulk ring cam surface
and synchronizer lever contact surface.
Bearing
Check bearing for damage and rough rotation. Replace if necessary.
PCIB0987J
SCIA1753J
SCIA0608J
MTF0041D
Revision: August 2015 2016 Versa Note

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MAINSHAFT AND GEARTM-47
< UNIT DISASSEMBLY AND ASSEMBLY > [5MT: RS5F91R]
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MAINSHAFT AND GEAR
Exploded ViewINFOID:0000000012430972
DisassemblyINFOID:0000000012430973
CAUTION:
• Secure mainshaft in a vise usin g blocks of wood to prevent dama ge, and then remove gears and
snap rings.
1. Mainshaft front bearing 2. Mainshaft 3. 1st main gear
4. 1st inner baulk ring 5. 1st synchronizer cone 6. 1st outer baulk ring
7. 1st-2nd synchronizer hub 8. 1st-2nd coupling sleeve 9. Spring
10. Insert key 11. 2nd outer baulk ring 12. 2nd synchronizer cone
13. 2nd inner baulk ring 14. Snap ring 15. Thrust washer
16. 2nd main gear 17. 3rd main gear 18. 3rd baulk ring
19. 3rd-4th synchronizer hub 20. 3rd-4th coupling sleeve 21. 4th baulk ring
22. 4th main gear 23. Spacer 24. Mainshaft rear bearing
25. 5th main gear
: Apply gear oil.
: Replace the parts as a set.
JPDIC0531GB
Revision: August 2015 2016 Versa Note

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TM-48
< UNIT DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
MAINSHAFT AND GEAR
• For removal of snap ring, set sn
ap ring pliers and flat pliers at
both sides of snap ring. While expanding snap ring with snap
ring pliers, remove snap ring with flat pliers.
• Mark gear component direction for assembly without damag- ing component contact locations.
1. Remove 3rd-4th synchronizer hub and 3rd baulk ring.
2. Remove snap ring (1) and thrust washer (2). CAUTION:
Do not reuse snap ring.
3. Remove 3rd main gear (1) and thrust washer (2).
4. Remove snap ring (1) and thrust washer (2). CAUTION:
Do not reuse snap ring.
SCIA1755J
PCIB1559E
PCIB1560E
PCIB1561E
Revision: August 2015 2016 Versa Note

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MAINSHAFT AND GEARTM-49
< UNIT DISASSEMBLY AND ASSEMBLY > [5MT: RS5F91R]
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5. Remove 2nd main gear (1) and thrust washer (2).
6. Remove snap ring (1), and then remove 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring.
7. Remove 1st-2nd coupling sleeve, insert keys, springs, and 1st- 2nd synchronizer hub.
8. Remove 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, and 1st main gear (2).
AssemblyINFOID:0000000012430974
Assembly is in the reverse order of disassembly.
CAUTION:
• Do not reuse snap ring.
• For installation of snap ring, set snap ring pliers and flat pliers
at both sides of snap ring. While expanding snap ring with
snap ring pliers, remove sn ap ring with flat pliers.
• Check that snap ring is secu rely installed to the groove.
• Apply gear oil to 1st outer ba ulk ring, 1st synchronizer cone,
1st inner baulk ring, 2nd oute r baulk ring, 2nd synchronizer
cone, 2nd inner baulk ring, and 3rd baulk ring.
• Replace 1st outer baulk ring, 1st synchronizer cone, and 1st inner baulk ring as a set.
• Replace 2nd outer baulk ring, 2nd synchronizer cone, and 2nd
inner baulk ring as a set.
• Be careful with the orientation of 1st-2nd synchronizer hub.
• Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.
PCIB1562E
JPDIC0541ZZ
SCIA1755J
(A) : 1st main gear side
(B) : 2nd main gear side
PCIB1566E
Revision: August 2015 2016 Versa Note

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