check oil NISSAN PULSAR 1987 Repair Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 122 of 238
122 Clutch
Check the engine mountings for damage and deterio- ration.
NOTE: Clutch shudder is usually most
evident when reversing up an incline. As
loose or damaged engine mountings are a
cause for clutch shudder, thoroughly check
the engine mounting rubbers and mounting
hardware for damage or looseness before
removing the clutch for inspection.
CLUTCH GRAB
(1) Oil soaked driven plate facings: Renew the
clutch driven plate. Invest igate and rectify the source
of the oil leak.
(2) Cracked pressure plate face: Renew the pres-
sure plate assembly. (3) Loose or broken engine mountings: Check
and renew the engine mountings as necessary.
(4) Binding release mechanism: Check the oper-
ation of the release mechanism.
NOTE: Visually check the operation of the
cable actuated release mechanism. Check
the inner cable for fraying and jamming in
the outer cable.
INSUFFICIENT CLUTCH RELEASE
(1) Stretched, frayed or broken clutch cable:
Check and renew the clutch cable. (2) Worn or damaged release mechanism: Check
and renew components as necessary. (3) Insufficient pedal height: Check and adjust
the pedal height.
(4) Warped clutch driven plate: Renew the
clutch driven plate. (5) Excessive clutch release lever free play:
Check and adjust the release lever free play to
Specifications.
NOTE: Visually check that the clutch cable
operates the release lever before removing
the clutch for inspection.
RELEASE BEARING NOISE
(1) Dry or worn release bearing: Check and
renew the release bearing.
(2) Damaged pressure plate diaphragm spring;
Check and renew the pressure plate assembly.
NOTE: Lightly depress the clutch pedal with
the engine running to check for release
bearing noise. If the release bearing is faulty
and has to be renewed, always check the
other clutch components.
Check the diaphragm spring fingers for scoring and damage.
2. DESCRIPTION
The clutch consists of a single, dry, driven plate
assembly, splined to slide on the transaxle input shaft.
A diaphragm spring type pr essure plate assembly is
bolted to the engine flywheel.
The driven plate is sandwiched between the
pressure plate and the flywheel and transmits the
drive from the engine to the transaxle.
Cushion rubbers are interposed between the hub
of the driven plate assembly and the plate friction
surfaces in order to cushion the drive.
The release mechanism is actuated by the clutch
pedal through a cable to the release lever and bearing.
Operation of the clutch pedal moves the release
lever which pushes the release bearing into contact
with the diaphragm spring fingers, forcing the dia-
phragm centre towards the flywheel. When the outer
edge of the diaphragm deflects, the clutch is caused to
disengage.
Clutch pedal free play is adjusted at the release
lever end of the clutch cable.
Clutch pedal height is adjusted at the pedal stop
on the pedal mounting bracket located under the
dashboard.
Page 123 of 238
Clutch 123
3. CLUTCH UNIT AND RELEASE MECHANISM
Special Equipment Required:
To Install — Clutch aligning tool
TO REMOVE
(1) Remove the transaxle from the vehicle as
described in the Manual Transaxle section. (2) Mark the pressure plate cover in relation to
the flywheel to ensure installation to the original
location. (3) Progressively loosen and remove the pressure
plate assembly retaining bolts working in a diagonal
sequence across the assembly. (4) Remove the pressure plate and driven plate
assemblies from the flywheel. Note the installed
direction of the driven plate to aid assembly.
(5) Disengage the clips retaining the release
bearing carrier to the release fork and slide the release
bearing assembly out of the clutch housing. Note the
installed position of the re taining clips to aid assem-
bly. (6) Align the release fork retaining pins with the
slots in the clutch housing and remove the pins using
a pin punch.
(7) Remove the release lever and shaft and
withdraw the release fork and return spring from the
clutch housing.
TO CHECK AND INSPECT
(1) Check the driven plate facings. Renew the
driven plate if the facings are worn down to within
0.3 mm of the rivet heads or are gummy and oil
soaked.
(2) Check the driven plate hub cushion rubbers
for deterioration and damage. Renew the driven plate
if the hub is damaged. (3) Mount the driven plate on the transaxle
input shaft and measure the spline backlash at the
outer edge of the driven plate. Renew the driven plate
if the spline backlash is beyond Specifications. (4) Check the pressure pl ate assembly for wear
on the diaphragm spring fingers, cracked diaphragm
spring and a cracked or distorted cover. Check that
the pressure plate face is not badly scored.
(5) Check the flywheel face for heat cracks, burn
marks and scoring. Renew the flywheel if it is badly
scored.
NOTE: Slight glazing or burn marks on the
pressure plate or flywheel faces can be
corrected using emery paper. Minor scoring
on the flywheel face may be corrected by
machining the flywheel.
(6) Rotate the release bearing by hand and check
for noise or roughness. Renew the bearing and carrier
as an assembly if fa ults are found.
(7) Check the release lever and shaft for wear
and damage. Renew as necessary.
(8) Check the release shaft bushes and seal for
wear or damage. Renew as necessary.
(9) Check the release fork for wear and the
return spring for fatigue. Renew as necessary.
TO INSTAL
(1) Sparingly apply lithium base molybdenum
disulphide grease to the tr ansaxle input shaft splines,
release bearing carrier bore and rear contact surfaces,
release shaft bushes and release fork contact surfaces.
Slide the driven plate onto the transaxle input shaft
and remove the excess grease from the splines. (2) Install the release shaft to the clutch housing,
return spring and release fork. Install the retaining pins
Dismantled view of the flywheel, driven plate and
clutch pressure plate.
Dismantled view of the clutch release components.
Page 127 of 238
Manual Transaxle and Drive Shafts 127
(6) Lubricating oil too thick: Drain the transaxle
and refill with the corre ct amount and grade of
lubricating oil. (7) Excessive end float in the mainshaft or input
shaft gears: Overhaul the transaxle.
NOTE: Check the clutch for correct opera-
tion. If reverse gear can be selected without
any gear clash this is a good indication that
the clutch is operating normally. Also check
that the correct type and grade of lubricating
oil is being used.
SLIPPING OUT OF GEAR
(1) Worn gear control rod assembly bushes:
Check and renew the worn components as necessary. (2) Faulty gear lever assembly: Check and renew
the faulty components. (3) Faulty synchroniser mechanism: Overhaul
the transaxle.
Check the engine mountings for damage and deterio-
ration.
(4) Worn or fatigued detent components: Renew
the faulty components as necessary.
(5) Excessive end float in the mainshaft or input
shaft: Overhaul the transaxle. Check and renew the
faulty components.
NOTE: In most cases, slipping out of gear is
caused by wear or damage to internal
components of (he tran saxle. However, prior
to removing and dismantling the transaxle
assembly, check the engine mounting rub-
bers and mounting hardware as vibrations
caused by loose or deteriorated engine
mountings can cause the transaxle to slip
out of gear.
GEARS CLASH ON CHANGING DOWN
(1) Faulty clutch or clutch release mechanism:
Check, adjust or overhaul the clutch or the clutch
release mechanism.
Check the friction surface of the synchro rings and cones
for wear or damage.
(2) Faulty synchro rings or cones: Overhaul the
transaxle assembly.
(3) Lubricating oil too thick: Drain the transaxle
and refill with the correct grade and quantity of
lubricating oil. (4) Broken, weak or incorrect positioning of the
springs in the synchro asse mblies: Overhaul the tran-
saxle assembly.
(5) Excessive end float in the mainshaft or input
shaft gears: Overhaul the transaxle assembly.
NOTE: Check the clutch as previously de-
scribed prior to removing and dismantling
the transaxle. Also check that the correct
grade of transaxle oil is being used.
TRANSAXLE NOISE (IN NEUTRAL)
(1) Insufficient lubricant: Fill the transaxle with
the correct quantity and grade of lubricant. (2) Worn input shaft bearings: Overhaul the
transaxle and renew the bearings. (3) Chipped or pitted constant mesh gears:
Overhaul the transaxle and renew the damaged com-
ponents as necessary. (4) Worn mainshaft bearings: Overhaul the tran-
saxle as necessary.
NOTE: First check the oil level in the
transaxle. To isolate the noise in neutral,
run the engine, depress the clutch and
engage any gear. If the noise ceases with the
clutch depressed it indicates that the noise is
in the transaxle.
Check the input shaft for damaged gears.
Page 128 of 238
128 Manual Transaxle and Drive Shafts
TRANSAXLE NOISE (FORWARD GEARS
ENGAGED, VEHICLE MOVING)
(1) Insufficient lubricant: Fill the transaxle with
the correct grade and quantity of oil. (2) Worn input shaft or mainshaft bearings:
Overhaul the transaxle and renew the faulty bearings. (3) Chipped or pitted gears: Check and overhaul
the transaxle and renew the faulty gears. (4) Damaged or worn sync hroniser assemblies:
Overhaul the transaxle and renew the synchroniser
assemblies.
FINAL DRIVE GEAR NOISE
(1) Insufficient lubricant: Fill the transaxle case
with the correct grade and quantity of oil. (2) Chipped or pitted final drive gear and/or ring
gear: Overhaul the transaxle and renew components as
necessary. (3) Worn differential carrier bearings: Overhaul
the differential assembly.
(4) Worn mainshaft or input shaft bearings:
Overhaul the transaxle.
NOTE: Check the oil level in the transaxle
case and the condition of the front hub
bearings and drive shaft joints prior to
overhauling the transaxle.
EXCESSIVE BACKLASH IN FINAL DRIVE
(1) Excessive end float in the differential carrier
bearings due to worn or incorrect bearing preload
adjustment: Check and adjust the bearing preload or
renew the bearings.
(2) Ring gear to differential case bolts loose:
Overhaul the transaxle and tighten the bolts to the
specified torque.
(3) Excessive wear in the final drive gear: Check
and overhaul the transaxle. (4) Excessive wear in the differential pinions,
side gears or pinion shaft: Overhaul the differential
assembly.
NOTE: Prior to overhauling the differential,
check the serviceability of the C.V joints on
the drive shafts.
NO DRIVE IN ANY GEAR
(1) Sheared ring gear to differential case bolts:
Overhaul the differential assembly.
(2) Broken drive shaft: Check and renew com-
ponents as necessary.
(3) Inner C.V. joint shaft out of mesh with
differential side gear: Weak or broken inner C.V. joint
shaft snap ring. Renew as necessary.
NOISE OR VIBRATION IN DRIVE SHAFTS
( 1 ) Bent or twisted drive shafts: Check and
renew the drive shafts as necessary.
Check the drive shaft rubber boots for deterioration.
(2) Worn or damaged inner or outer C.V. joint:
Check and renew components as necessary. (3) Lack of lubricant due to damaged C.V. joint
boots: Check the C.V. joints for wear, repack the C. V.
joints and renew th e C.V. joint boot.
(4) Loose drive shaft hub nut: Tighten the hub
nut to Specifications. (5) Worn splines on the drive shaft or C.V. joint
inner race. Check and renew the faulty components or
drive shaft as an assembly.
NOTE: Noise or vibration in the front end
can also be caused by excessive tire or wheel
unbalance.
2. DESCRIPTION
The five speed transaxle installed in the Pulsar
range of vehicles covered by this manual has synchro-
mesh on all the forward gears.
The reverse gear is a spur idler gear which is
selected by sliding the idler gear into mesh with the
input shaft and the mainshaft.
The transaxle and differential assemblies are ac-
commodated in the same housing and the one oil level
check covers both assemblies.
Gear selection is by mean s of selector forks and a
striking rod which is operated by a floor mounted gear
lever assembly. A mechanism inside the transaxle
prevents the selection of re verse gear from fifth gear
until the gear lever is moved sideways in neutral. The
differential and final dr ive assembly runs on two
tapered roller bearings. Pr eload on these bearings is
adjusted by shims installed behind the bearing cups.
The assembly is driven by the mainshaft pinion
engaging the ring gear on the differential case.
The drive shafts are engaged with the differential
side gears at the inner end and the front wheel hubs at
the outer end.
The drive shafts and each C.V. joint can be
Page 129 of 238
Manual Transaxle and Drive Shafts 129
renewed as individual units. The C.V. joints are
lubricated in manufacture and need no attention in
service unless one of the r ubber boots is damaged. In
this case the joint can be cl eaned and repacked with
the recommended grease and a new boot installed.
From July 1989, Pulsar Q and Vector SSS manual
transaxle models are equipped with a limited slip
differential incorporating a viscous coupling. The
coupling is not repairable and must be renewed as an
assembly if unserviceable. A test procedure for the
viscous coupling is included in the text in this section.
3. TRANSAXLE ASSEMBLY
Special Equipment Required:
To Dismantle and Assemble — Puller set, press
and press plates, dial gauge
To Measure Mainshaft Turning Torque —
Suitable slotted adaptor and torque gauge
TO REMOVE AND INSTAL
(1) Raise the front of the vehicle and support it
on chassis stands.
(2) Remove the battery as described in the
Electrical System section. (3) Remove the drive shafts as described later in
this section. (4) Disconnect and remove the starter motor as
described in the Elect rical System section.
Front view of the transaxle removed from the vehicle.
(5) Support the rear of the engine using a jack
with a piece of timber between the jack head and the
engine sump.
(6) Remove the bolts retaining the clutch hous-
ing to the engine. (7) Disconnect the vehicle speed sensor wiring,
the reverse lamp wiring, the gear lever control rod and
the gear lever support rod from the transaxle. (8) Remove the transaxle mounting through bolt
and remove the bolts retaining the mounting bracket
to the transaxle.
(9) With the left hand front wheel removed,
remove the left hand inner mudguard panel. (10) Maneuver the transaxle away from the
engine. Lower and withdraw the transaxle from under
the vehicle.
NOTE: Do not allow the transaxle to hang
on the clutch driven plate during removal.
Support the transaxle on a trolley jack if
necessary.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Lubricate the input shaft splines sparingly
with lithium base molybdenum disulphide grease. (2) Support the transaxle during installation. Do
not allow the transaxle to hang on the clutch driven
plate. (3) Tighten all bolts to the specified torque.
(4) Fill the transaxle with the specified quantity
and grade of oil. (5) Road test the vehicle and check for correct
transaxle operation. Also ch eck for transaxle oil leaks
and rectify as necessary.
TO DISMANTLE
(1) Remove the clutch release components from Rear view of the transaxle removed from the vehicle.
Page 130 of 238
130 Manual Transaxle and Drive Shafts
Internal view of the transaxle showing the installed positions of the shift forks and control bracket.
the clutch housing. Refer to the Clutch section for the
correct procedure.
(2) Thoroughly clean the outsi de of the transaxle
assembly using solvent and compressed air. (3) Remove the bolts retaining the transaxle case
to the clutch housing and using a soft faced hammer,
tap the transaxle case to separate the mating surfaces.
(4) Carefully lift the transaxle case from the
clutch housing. Tilt the cas e to provide clearance for
the fifth gear shift fork. (5) Withdraw the spacer from the reverse idler
shaft and withdraw the fork shaft and spring from the
transaxle. (6) Remove the fifth and third/fourth shift forks
taking care not to lose the shift cap. (7) Remove the retaining bolts and remove the
control bracket and the first/second shift fork taking
care not to lose the shift cap. (8) Lift the mainshaft out of the clutch housing.
NOTE: When lifting, do not tilt the main-
shaft as the resin oil channel behind the
front mainshaft bearing could be damaged.
(9) Lift the differential assembly out of the
clutch housing.
NOTE: For information on the overhaul of
Dismantled view of the striking rod components.
the differential assembly refer to the Differ-
ential and Final Drive Assembly heading.
(10) Remove the retaining bolts from the input
shaft front bearing retainer. (11) Position the transaxle assembly on its side
and tap the input shaft out of the clutch housing using
a soft faced hammer. Remove the input shaft, bearing
retainer and reverse idler gear from the clutch hous-
ing.
(12) Remove the shift check ball, plug and spring
from the passage adjacent to the upper control
bracket retaining bolt on the clutch housing.
(13) Position the striking lever so that the retain-
ing pin will not contact the clutch housing and remove
the pin using a suitable punch.
(14) Remove the striking rod, striking lever and
striking interlock from the clutch housing.
(15) Remove the reverse check plug, spring and
balls from the clutch housing noting the installed
position of the small check ball.
(16) Remove the screws retaining the reverse and
fifth gear check assembly and remove the assembly
from the clutch housing.
(17) Remove and discard the input shaft and
striking rod oil seals from the clutch housing noting
the installed direction of the seals.
(18) Renew the rear input shaft bearing as fol-
lows:
(a) Remove the plastic oil channel from the
transaxle case.
(b) Using a suitable punch through the hole
adjacent to the r ear input shaft bearing, tap the small
welch plug out of the transaxle case.
(c) Using a suitable punch through the small
welch plug opening, tap the rear input shaft bearing
out of the transaxle case. (d) Using a suitable mandrel, tap the new rear
input shaft bearing into the transaxle case.
NOTE: It may be necessary to use a hydrau-
lic press if the bearing is a tight fit in the
housing.
(e) Apply sealer to a new welch plug and tap the
plug squarely into the transaxle case until the edge of
the plug is level with the case.
Dismantled view of the shift fork components.
Page 132 of 238
132 Manual Transaxle and Drive Shafts
Check the mainshaft for pitting.
(6) Inspect the striking rod, lever and interlock
for wear and damage paying particular attention to
the detent grooves in the end of the striking rod.
Renew parts as necessary. (7) Inspect the shift check and reverse check
balls and springs for wear, cracks and loss of tension
in the springs. Renew parts as necessary.
Check clearance A between the synchro ring and the
gear synchro teeth and compare with Specifications.
(8) Inspect the reverse and fifth gear check
assembly for wear, damage and loss of spring tension.
Renew the assembly as necessary. (9) Inspect all the bearings for pitting, wear and
damage. Renew the bearings as necessary.
NOTE: If the transaxle has seen consider-
able service, it is advisable to renew all the
bearings, oil seals, O rings and snap rings
during the overhaul.
(10) Inspect the various synchro components for
wear and damage paying par ticular attention to the
shift plates and springs and the internal teeth of the
synchro sleeves. Renew parts as necessary. (11) Compare the various gear end floats mea- sured during dismantling with the Specifications and
if the end floats are excessive, check the contact
surfaces of the ge
ars, shaft and synchro hubs. Renew
worn parts as necessary.
TO ASSEMBLE
(1) Lubricate all the components with the spec-
ified gear oil prior to assembly. (2) Install new input shaft and striking rod
oil
seals to the clutch housing in the direction noted on
removal. Lubricate the oil seal lips with multipurpose
grease prior to installation. (3) Assemble the components of the fifth gear
synchro assembly aligning the marks made on dis-
mantling. Ensure that the ends of the shift plate
springs are not aligned.
(4) Install the split bearing to the rear of the
input shaft and install the fifth gear.
(5) Install the fifth gear sy nchro assembly and the
shift retainer to the rear of the input shaft. Ensure that
the slots in the synchro ring are aligned with the shift
plates.
Check the friction surfaces of the input shaft for pitting. Dismantled view of the fifth gear synchro assembly.
Illustration showing the correct positioning of the shift plates and springs.
Page 134 of 238
134 Manual Transaxle and Drive Shafts
(32) Install and tighten the retaining bolts to
the specified torque.
(33) Repeat operation (29). The total turning
torque should be 5.9-13.7 Nm if new bearings have
been installed or slightly l ess if the original bearings
have been installed. If the turning torque is no t as specified, adjust the
mainshaft turning torque as follows:
(a) Remove the transaxle case rear cover, O ring,
spacer and adjusting shim from the transaxle case.
(b) Ensure that the mainsh aft rear bearing outer
race is fully seated on the bearing cone. (c) Using micrometer depth gauge, measure the
distance from the transaxle case to the bearing outer
race and note the reading. (d) Referring to the following table, select the
appropriate shim, according to the reading noted in
operation (c), required to correct the mainshaft turn-
ing torque.
READING SHIM
2.35-2.40 mm............................................... 0.10 mm
2.40-2.45 mm............................................... 0.15 mm
2.45-2.50 mm...............................................0.20 mm
2.50-2.55 mm...............................................0.25 mm
2.55-2.60 mm...............................................0.30 mm
2.60-2.65 mm............................................... 0.35 mm
2.65-2.70 mm............................................... 0.40 mm
2.70-2.75 mm............................................... 0.45 mm
2.75-2.80 mm............................................... 0.50 mm
2.80-2.85 mm............................................... 0.55 mm
2.85-2.90 mm............................................... 0.60 mm
2.90-2.95 mm............................................... 0.65 mm
2.95-3.00 mm............................................... 0.70 mm
3.00-3.05 mm............................................... 0.75 mm
3.05-3.10 mm............................................... 0.80 mm
3.10-3.15 mm............................................... 0.85 mm
3.15-3.20 mm............................................... 0.90 mm
3.20-3.25 mm............................................... 0.95 mm
3.25-3.30 mm...............................................1.00 mm.
(e) Install the spacer, shim, O ring and rear
cover to the transaxle case. Tighten the retaining
bolts securely.
(34) Measure the total turning torque as previ-
ously described. (35) Install the striking interlock and striking lever
to the clutch housing. (36) Install the striking ro d to the clutch housing
sliding the rod through the lever and interlock. Take
care that the end of the rod does not damage the seal. (37) Install a new retaining pin to the striking rod
using a pin punch. (38) Install the reverse and fifth gear check
assembly to the clutch housing. Tighten the retaining
screws securely. (39) Install the balls, spring and reverse check
plug to the clutch housing ensuring that the smaller
diameter ball enters the hole in the body of the
reverse and fifth gear check assembly body. Apply locking com-
pound and tighten the reverse check plug securely.
(40) Using a bar clamped to the end of the
striking rod, check that a force of 4.9-7.4 Nm is
required to overcome the spring loading of the reverse
and fifth gear check assembly. If necessary, renew the
springs to achieve this correct spring loading.
NOTE: Ensure that the reverse check plug is
coated with locking compound when finally
installed.
(41) Install the shift check ball, spring and plug to
the clutch housing. Ensure that the ball is centrally
located in the plug.
(42) If removed, install the oil reservoir to the
clutch housing.
(43) Install the input shaft assembly and the
reverse idler gear to the clutch housing taking care not
to damage the seal.
(44) Apply locking compound to the bearing
retainer bolts and tighten the bolts to the specified
torque.
(45) Install the spacer to the reverse idler shaft.
(46) Install the differential assembly to the clutch
housing.
(47) Install the mainshaft to the clutch housing
ensuring that the resin oil ch annel is located centrally
in the end of the mainshaft. (48) Install the shift cap to the slot in the first/
second shift fork and install the shift fork and control
bracket to the clutch housing. Use grease to hold the
shift cap in the shift fork slot. Ensure that the reverse
idler shift fork is correctly located over the gear.
(49) Apply locking compound to the threads of
the control bracket retaining bolts and tighten the
bolts to the specified torque. (50) Install the shift cap in the slot in the third/
fourth shift fork and install the fork to the transaxle
assembly. Use grease to hold the shift cap in the shift
fork slot. (51) Install the fifth gear shift fork to the transaxle
ensuring that the shift fork slot engages the control
finger.
(52) Install the fork shaft an d spring to the clutch
housing sliding the shaft through the shift forks. Use
grease to hold the spring in the end of the shaft. (53) Apply a continuous bead of sealant to the
mating face of the clutch housing so that the bead is
located inside the row of bolt holes.
NOTE: Sealant is available from Nissan
spare parts using the part number KP
610-00250.
(54) Install the transaxle case to the clutch hous-
ing. Install and tighten the retaining bolts to the
specified torque. (55) Select each gear in turn and check that the
transaxle turns freely in each gear. Ensure that it is not
Page 138 of 238
138 Manual Transaxle and Drive Shafts
Brakes section if necessary. Suspend the caliper with
wire or cord attached to the coil spring.
(9) Hold the steering knuckle and hub assembly
and tap the drive shaft out of the hub using a soft
faced hammer.
(10) Drain the oil from the transaxle into a
container.
(11) Prise the drive shaft out of the transaxle and
remove the drive shaft from the vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Ensure that the drive sh aft is firmly attached
to the differential side gear by attempting to pull the
shaft out of the gear. (2) Tighten all nuts securely and install new split
pins. (3) Fill the transaxle with the specified grade and
quantity of oil.
TO DISMANTLE AND ASSEMBLE
(1) Remove the drive shaft from the vehicle as
previously described.
(2) Remove and discard both the inner C.V.
joint boot retaining clips from the inner C.V. joint. (3) Roll back the large en d of the inner C.V.-
joint boot using a thin blade screwdriver, prise out the
C.V. joint retaining ring.
(4) Withdraw the C.V. joint housing from the
drive shaft and ball assembly. (5) Remove the inner snap ring retaining the ball
assembly to the drive shaft and withdraw the ball
assembly. (6) Remove the remaining inner C.V. joint re-
taining snap ring and the C.V. joint boot from the
drive shaft. (7) Noting their installed positions remove the
cage and ball assembly off the inner race and press the
balls out of the cage. (8) Remove and discard the clips retaining the
outer C.V. joint boot to the drive shaft and remove
the C.V. joint boot.
NOTE: The outer C.V. joint cannot be
dismantled.
(9) Wash all parts in a suitable solvent and blow
dry with compressed air.
(10) Inspect the ball contact faces of the inner ball
race and C.V. joint housing for pitting and wear.
(11) Inspect the ball cage and the balls for wear
and damage. (12) Rotate the drive shaft with the outer C.V.
joint at a sharp angle and inspect the internal
components of the outer C.V. joint for wear and
damage. Renew if necessary by tapping the C.V. joint
from the drive shaft.
NOTE: Do not reuse the retaining snap ring
if the C. V. joint is removed from the drive
shaft.
(13) Check the C.V. joint boots for damage and
deterioration. (14) Renew all worn or damaged components as
necessary. Assembly is a reversal of the dismantling proce-
dure with attention to the following points:
(1) Thoroughly pack the outer C.V. joint with
molybdenum disulphide grease. (2) Install the outer C.V. joint boot and retain in
position using new retaining clips. Ensure that the
boot and the clips ar e correctly seated.
(3) Install the inner C.V. joint boot, small
end
first, onto the drive shaft and pull it well down the
shaft. (4) Install the outer snap ri ng for the inner C.V.
joint into its locating groove in the drive shaft. (5) Position the inner ball race inside the ball
cage with the chamfered end of the ball race towards
the small end of the cage. (6) Press the balls firmly into the ball cage,
ensure that the balls are fully seated. (7) Install the ball assem bly onto the drive
shaft
with the small end of the cage towards the outer C.V.
joint and install the inner snap ring retaining the
ball
assembly onto the drive shaft.
(8) Pack the C.V. joint with the prescribed
amount of molybdenum disul phide grease. Refer to
Specifications. (9) Install the C.V. joint retaining ring into the
C.V. joint housing. Ensure that the retaining ring is
correctly seated.
Dismantled view of the inner C.V. joint. Install the ball assembly onto the drive shaft, with the
small end of the cage towards the outer C.V. joint.
Page 140 of 238
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AUTOMATIC TRANSAXLE
SPECIFICATIONS
Make .............................................. JATCO RL3F01A
Type .....................3 speed and reverse epicyclic gear
train with lock up torque converter
Operation .................................... Automatic hydraulic
Lubricant:
Type....................................................... Dexron IT
Capacity................................................. 6.3 liters
TORQUE WRENCH SETTINGS
Drive plate to crankshaft bolls ........................60 Nm
Drive plate to torque converter bolts ..............49 Nm
Convener housing to engine ...........................22 Nm
Converter housing to transaxle ........................23 Nm
Transaxle sump to transaxle ............................. 7 Nm
Oil cooler pipe to transaxle .............................49 Nm
Selector shaft locknut .......................................42 Nm
Transaxle filter bolts.........................................12 Nm
1. AUTOMATIC TRANSAXLE TROUBLE SHOOTING
NO DRIVE IN D RANGE
{1) Low fluid level in transaxle: Check the fluid
level in the transaxle and top up if required.
(2) Incorrectly adjusted selector cable: Check
and adjust the selector cable as detailed. (3) Incorrect or contaminated transaxle fluid:
Drain and refill with the recommend type and quan-
tity of transaxle fluid.
NOTE: Check the possible causes in the
order given.
NO REVERSE IN R RANGE
(1) Low fluid level in transaxle: Check the fluid
level and top up if required. (2) Incorrectly adjusted selector linkage: Check
the condition of the selector cable, selector quadrant
and selector arm for wear and damage. Adjust as
required.
Check the drive shaft oil seals as a likely leak source.
SLIPPING OR ROUGH UPSHIFT
(1) Incorrectly adjusted selector linkage: Check
and adjust the selector linkage. (2) Low fluid level in transaxle: Check the fluid
level and top up if required.
NO TRANSAXLE KICKDOWN
(1) Incorrectly adjusted throttle cable: Check
and adjust the cable as detailed in the Fuel and Engine
Management section.
Check the oil cooler hose connections for leaks if the
fluid level is low.