NISSAN TERRANO 2002 Service Repair Manual

Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST23540000*
Pin punch
Removing and installing retaining pin
ST30031000*
Puller
Removing 1st & 2nd synchronizer assembly
Removing counter gear rear thrust bearing
Removing main drive bearing
ST33290001*
Puller
Removing rear oil seal
ST33230000*
Drift
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
Removing mainshaft and counter gear
ST22350000*
Drift
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
Removing counter gear front bearing
(Use with KV38100300)
KV38100300*
Drift
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.
Removing counter gear front bearing
(Use with ST22350000)
Installing counter gear rear bearing
ST30720000*
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
Removing mainshaft front bearing
Installing mainshaft front bearing
PREPARATION
MT-2

*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST33210000*
Drift
a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
Installing counter gear front bearing
Installing front cover oil seal
ST33220000*
Drift
a: 37 mm (1.46 in) dia.
b: 22 mm (0.87 in) dia.
Removing and installing counter gear rear end
bearing
ST30613000*
Drift
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
Installing main drive gear bearing
ST37750000*
Drift
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
Removing counter gear rear bearing
Installing OD gear bushing
Installing reverse cone
Installing reverse counter gear
Installing counter gear rear end bearing
ST22452000*
Drift
a: 40 mm (1.57 in) dia.
b: 36 mm (1.42 in) dia.
Installing reverse hub
Installing mainshaft rear bearing
ST33400001*
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
Installing rear oil seal
ST36730000*
Drift
a: 50 mm (1.97 in) dia.
b: 39 mm (1.54 in) dia.
Installing sub-gear on reverse
idler gear
PREPARATION
Special Service Tools (Cont'd)
MT-3

Commercial Service Tools
Tool name Description
Puller
NT077
Removing counter gear rear end bearing
Removing mainshaft rear bearing
Removing reverse synchronizer hub
Removing reverse counter gear
Drift
ST22452000
a: 44.5 mm (1.752 in) dia.
b: 38.5 mm (1.516 in) dia.
Installing sub-gear snap ring
Drift
ST22452000
a: 44.5 mm (1.752 in) dia.
b: 40.5 mm (1.594 in) dia.
Installing OD main gear
Installing reverse gear bushing
PREPARATION
MT-4

Replacing the Rear Oil Seal
REMOVAL
1. Remove transfer assembly. See Section TF.
2. Remove rear oil seal.
REPLACEMENT
1. Install rear oil seal.
Before installation, apply multi-purpose grease to oil seal lip.
2. Install transfer assembly. See Section TF.
SMT321B
SMT453B
TRANSMISSION FS5R30A
MT-5

Check of Position Switches
Switch Gear position Continuity
q
14WD* Transfer case4WD Yes
Except 4WD No
q
2Back-up lampTransmission
caseReverse Yes
Except reverse No
*: Ensure both sides of 4WD 2-pole double-throw switch is operational, refer to
ªWarning lampsº wiring diagram in EL-Section.
YMT009
ON-VEHICLE SERVICEFS5R30A
MT-6

Removal
Transmission has to be removed as a unit together with transfer
box.
Remove transmission assembly as follows:
IDisconnect negative battery terminal.
IRemove shift levers of transmission and transfer.
IRemove front and rear propeller shafts. Ð Refer to PD section.
IInsert plug into rear oil seal after removing propeller shaft.
IRemove RPM-sensor from transmission upper side.
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal,
when removing propeller shaft.
IRemove torsion bar spring. Ð Refer to FA Section.
IRemove third crossmember (the one supporting front differen-
tial).
IRemove fifth crossmember (the one situated at the rear of
transfer).
ISupport transmission and transfer with a suitable transmission
jack.
WARNING:
Support transmission and transfer with suitable jacks, while
removing them.
IRemove fourth crossmember (the one supporting transmis-
sion).
IRemove clutch operating cylinder.
IRemove starter motor.
IRemove exhaust tube bracket from transmission.
IDisconnect electrical connectors.
IRemove transmission from engine.
REMOVAL AND INSTALLATIONFS5R30A
MT-7

Installation
Transmission has to be installed as a unit together with transfer
box.
Install transmission assembly as follows:
IApply sealant as below:
Bolt No. Tightening torque N×m (kg-m, ft-lb)Bolt length ªLº -
mm (in)
1 39 - 49 (4.0 - 5.0, 29 - 36) 57 (2.244)
2 18 - 22 (1.9 - 2.2, 14 - 16) 11 (0.433)
3 29 - 39 (3.0 - 4.0, 22 - 29) 100 (3.94)
NMT002
NMT027
REMOVAL AND INSTALLATIONFS5R30A
MT-8

IRaise the unit with a hoist.
IPosition the transmission assembly on a portable jack and
secure it with a suitable tool.
Lift the assembly until the gearbox input shaft faces its hous-
ing.
Move the assembly towards the engine. The assembly must be
rotated slightly so that the starter motor housing clears the
projection on the companion floor. Insert input shaft into its
housing (slightly raising the rear of the transfer box may facili-
tate the introduction of the shaft into its housing).
ITighten the screws securing the gearbox to the engine.
:39-49N×m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
IConnect the electrical wiring. Secure with the respective clips.
IFit the RPM-sensor to the transmission upper side.
IFit the exhaust pipe support bracket to the transfer box.
:13-16N×m (1.3 - 1.6 kg-m,9-12ft-lb)
IFit the starter motor. Secure the earth wire to the starter motor
lower screw.
:31-41N×m (3.2 - 4.2 kg-m, 23 - 30 ft-lb)
IFit the clutch slave cylinder.
:30-40N×m (3.1 - 4.1 kg-m, 22 - 30 ft-lb)
IInstall fourth crossmember (Note the ªfrontº mark).
Crossmember fixing bolts to chassis:
:41-52N×m (4.2 - 5.3 kg-m, 30 - 38 ft-lb)
Crossmember fixing bolts to transmission:
:68-87N×m (6.9 - 8.9 kg-m, 50 - 64 ft-lb)
ITake away the portable jack holding boxes assembly.
IInstall fifth crossmember.
:59-78N×m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
IInstall third crossmember.
: Screws: 41 - 52 N×m (4.2 - 5.3 kg-m,
30 - 38 ft-lb)
Nuts: 68 - 87 N×m (6.9 - 8.9 kg-m,
50 - 64 ft-lb)
IInstall torsion bar springs. Ð Refer to FA section.
IInstall front and rear propeller shafts. Ð Refer to PD section.
IInstall shift levers of transmission and transfer.
:14-18N×m (1.4 - 1.8 kg-m, 10 - 13 ft-lb)
Bolt head dimensions:
Bolt A: 12 mm (0.472 in)
Bolt B: 13 mm (0.512 in)
IConnect negative battery cable.
SMT446B
REMOVAL AND INSTALLATIONFS5R30A
Installation (Cont'd)
MT-9

Case Components
NMT041
MAJOR OVERHAULFS5R30A
MT-10

Gear Components
MT-3010
MAJOR OVERHAULFS5R30A
MT-11