NISSAN PRIMERA 1999 Electronic Repair Manual

7. Place bearing replacer between 5th & reverse synchronizer
hub and 5th main gear, and press out both reverse gear bush-
ing and 5th & reverse synchronizer assembly.
8. Remove 5th main gear, 5th gear baulk ring, and 5th gear
needle bearing.
9. Place bearing replacer between 3rd and 4th main gears, and
press out both 5th gear bushing and 4th main gear.
10. Remove mainshaft adjusting shim and spacer.
11. Place bearing replacer between 2nd main gear and 1st & 2nd
synchronizer hub, and press out both 3rd and 2nd main gears.
12. Remove 2nd double cone assembly, 2nd gear bushing, and
coupling sleeve assembly.
13. Place bearing replacer on 1st gear front side, and press out all
of 2nd gear bushing, 1st & 2nd synchronizer hub, 1st main
gear, and 1st double cone.
14. Remove 1st gear needle bearing.
INSPECTIONNCMT0014
Gear and ShaftNCMT0014S01
ICheck shaft for cracks, wear or bending.
ICheck gears for excessive wear, chips or cracks.
SMT681D Reverse gear bush
5th & reverse
synchronizer
hub assembly
SMT682D 5th gear bush
4th main gear
SMT683D 3rd main gear
Bearing replacer
2nd main
gear
SMT684D 2nd gear bush
1st & 2nd
synchronizer hub
1st main gear
SMT693D
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-64

SynchronizersNCMT0014S02
ICheck spline area of coupling sleeves, hubs and gears for
wear or cracks.
ICheck baulk rings for cracks or deformation.
ICheck insert springs for wear or deformation.
IIf any crack, damage, or excessive wear is found on cam face
of baulk ring or working face of insert, replace it.
IMeasure the movement (play, dimension ªLº) of 1st & 2nd
coupling sleeve and 5th & reverse coupling sleeve with their
end fixed and the other end lifted as shown in the figure. If the
movement exceeds specification, replace the sleeve.
Coupling sleeve Length ªLº
1st & 2nd0 - 0.68 mm (0 - 0.0268 in)
5th & Reverse0 - 0.89 mm (0 - 0.0350 in)
IMeasure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to SDS, MT-90.
BearingNCMT0014S03
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT637A
SMT867D
SMT868D Fixed
Dimension ªLº
Fixed
Dimension ªLº 1st & 2nd coupling sleeve
5th & reverse coupling sleeve
SMT140 Baulk ring to
gear clearance
SMT148A
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-65

IMeasure wear of 1st and 2nd baulk ring.
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 ªAº and ªBº.
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:
0.2 mm (0.008 in)
IIf dimension ªAº or ªBº is smaller than the wear limit,
replace outer baulk ring, inner baulk ring and synchro-
nizer cone as a set.
ASSEMBLYNCMT0015
1. Install 1st gear needle bearing and 1st main gear onto main-
shaft.
2. Install 1st double cone assembly onto mainshaft.
3. Install 1st & 2nd synchronizer hub with its three grooves fac-
ing the front side (1st main gear side) onto mainshaft.
CAUTION:
Do not reuse 1st & 2nd synchronizer hub.
SMT714CB Inner baulk ringSynchronizer
coneOuter baulk ring
Synchronizer cone
SMT706D 1st gear needle bearing
1st main gear
Mainshaft
SMT695D Front
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-66

4. Install 1st & 2nd synchronizer hub.
5. Install insert spring onto 1st & 2nd coupling sleeve.
6. Install 1st & 2nd coupling sleeve with its chamfered surface
facing the 1st main gear side onto 1st & 2nd synchronizer hub.
7. Install 2nd gear bushing with its flange surface facing 1st & 2nd
synchronizer hub side.
8. Install 2nd needle bearing, 2nd double cone assembly, and
2nd main gear onto mainshaft.
9. Position 3rd main gear as shown in the figure, and install it.
CAUTION:
Do not reuse 3rd main gear.
SMT707D 1st & 2nd
synchronizer hub
1st gear double
cone assembly
SMT994BB 1st & 2nd coupling sleeve
SMT708D 2nd main gear
1st main gear
1st & 2nd coupling sleeve
SMT709D 2nd gear bush
SMT710D 2nd main
gear4th main
gear
3rd main gear3rd main gear
2nd needle
bearing
2nd main
gear
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-67

10. Install spacer and mainshaft adjusting shim onto mainshaft.
11. Select a mainshaft adjusting shim suitable to satisfy the follow-
ing specification of dimension ªLº and install it onto mainshaft.
Specification of dimension ªLº:
151.35 - 151.45 mm (5.9586 - 5.9626 in)
Available mainshaft adjusting shims:
Refer to SDS, MT-91.
12. Position 4th main gear as shown in the figure, and install it onto
mainshaft.
13. Install 4th main gear onto mainshaft.
CAUTION:
Do not reuse 4th main gear.
14. Install 5th gear bushing with its flange surface facing the 4th
main gear side.
SMT711D 3rd main gear
shim
151.35 - 151.45 mm
(5.9586 - 5.9626 in)
Dimension ªLº
SMT713D 5th main gear
3rd main gear
4th main gear
SMT712D 4th main gear
SMT714D 5th gear bush
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-68

15. Install 5th needle bearing, 5th main gear, and 5th gear baulk
ring onto mainshaft.
16. Being careful of the following points, install spread spring, shift-
ing insert, and 5th & reverse synchronizer hub onto 5th &
reverse coupling sleeve.
IPay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting insert.
IInstall synchronizer hub with its three grooves facing the front
side (5th main gear side).
CAUTION:
Do not reuse 5th & reverse synchronizer hub.
IInstall 5th & reverse coupling sleeve with its chamfered surface
facing the reverse main gear side.
17. Install 5th & reverse synchronizer hub assembly.
SMT761D Reverse
SMT694D Shifting insert
(3rd & 4th) (5th & reverse)
Flat shape R-shape
Spread spring
Shifting insert
SMT695D Front
SMT716D Reverse
main gear5th main gear
5th & reverse coupling sleeve
SMT715D 5th & reverse
synchronizer
hub assembly
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-69

18. Install reverse gear baulk ring.
19. Install reverse gear bushing.
20. Install reverse gear needle bearing.
21. Install sub-gear, sub-gear washer, and snap ring onto reverse
main gear.
CAUTION:
IPay attention to direction of sub-gear washer.
IDo not reuse snap ring.
22. Install reverse main gear assembly onto mainshaft.
23. Select a thrust washer suitable to satisfy the following specifi-
cation of dimension ªMº (as shown in the figure), and install it
onto mainshaft.
Specification of dimension ªMº:
244.20 - 244.30 mm (9.6142 - 9.6181 in)
Available thrust washers:
Refer to SDS, MT-92.
24. Install mainshaft rear bearing.
SMT717D Reverse gear bush
Reverse gear baulk ring
SMT718D Reverse main gear
Sub-gearSub-gear
washer
Reverse
main gear
Sub-gear washer
Snap ring
SMT719D 244.20 - 244.30 mm
(9.6142 - 9.6181 in)
Thrust washer
Dimension ªMº
SMT720D Mainshaft
rear bearing
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-70

25. Install mainshaft C-ring.
26. Using feeler gauge, measure the end play of mainshaft rear
bearing, and check if it satisfies the following specification.
End play specification:
0 - 0.06 mm (0 - 0.0024 in)
Available mainshaft C-rings:
Refer to SDS, MT-91.
27. Install C-ring holder.
28. Install snap ring.
29. Measure gear end play as a final check. Refer to, MT-63.
CAUTION:
IDo not reuse snap ring.
Final Drive
PRE-INSPECTIONNCMT0036
ICheck the clearance between side gear and differential case
as follows.
1. Clean final drive assembly sufficiently to prevent side gear
thrust washer, differential case, side gear, and other parts from
sticking by gear oil.
2. Upright the differential case so that the side gear to be mea-
sured faces upward.
3. Place final drive adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.
Clearance between side gear and differential case:
0.1 - 0.2 mm (0.004 - 0.008 in)
4. If not within specification, adjust the clearance by changing
thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
SMT721D Feeler gauge
Mainshaft C-ring
SMT678D C-ring holder
Mainshaft C-ring
SMT677D Snap ring
SMT610AE Dial gauge
SMT685D
REPAIR FOR COMPONENT PARTSRS5F70A
Mainshaft and Gears (Cont'd)
MT-71

DISASSEMBLYNCMT00161. Remove mounting bolts. Then, separate the final gear from
differential case.
2. Make a notch and remove speedometer drive gear using a
scraper or other suitable tool.
IBearing replacer cannot be positioned unless speedom-
eter drive gear is removed.
3. Remove differential side bearing of final gear side.
4. Turn differential case upside down, and remove differential
side bearing of speedometer drive gear side.
5. Remove speedometer stopper.
6. Remove lock pins from pinion mate shaft.
7. Remove pinion mate shaft.
8. Rotate pinion mate gear, and remove pinion mate gear, pinion
mate thrust washer, side gear, and side gear thrust washer
from differential case.
INSPECTIONNCMT0017
Gear, Washer, Shaft and CaseNCMT0017S01
ICheck side gear, side gear thrust washer, pinion mate shaft,
pinion mate gear, pinion mate gear washer, and differential
case.
ICheck washers for wear.
SMT609A Chamfer
SMT840D Puller
Puller
SMT689D
SMT839
SMT083A
REPAIR FOR COMPONENT PARTSRS5F70A
Final Drive (Cont'd)
MT-72

BearingNCMT0017S04
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
IWhen replacing tapered roller bearing, replace outer and
inner race as a set.
ASSEMBLYNCMT0018
1. Apply gear oil to sliding area of differential case, each gear,
and thrust washer.
2. Install side gear thrust washer and side gear into differential
case.
3. Position pinion mate gear and pinion mate thrust washer
diagonally, and install them into differential case while rotating.
4. Insert pinion mate shaft into differential case.
5. Upright the differential case so that its side gear to be mea-
sured faces upward.
6. Place preload adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.
7. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
Clearance of side gear and differential case:
0.1 - 0.2 mm (0.004 - 0.008 in)
Available differential thrust washers:
Refer to SDS, MT-92.
8. Hammer the retaining pin into pinion mate shaft.
CAUTION:
Do not reuse retaining pin.
SPD715
SMT062A
SMT087A
SMT685D
SMT750D
REPAIR FOR COMPONENT PARTSRS5F70A
Final Drive (Cont'd)
MT-73