NISSAN TERRANO 2002 Service Repair Manual

IMeasure wear of reverse baulk ring.
a. Place baulk ring in position on reverse cone.
b. While holding baulk ring against reverse cone as far as it will
go, measure dimension ªAº with dial indicator.
Unit: mm (in)
Standard Wear limit
Dimension ªAºþ0.1 to 0.35
(þ0.0039 to 0.0138)0.7 (0.028)
c. If dimension ªAº is larger than the wear limit, replace baulk ring.
BEARINGS
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT424A
SMT418A
INSPECTION
Gear Components (Cont'd)
MT-22

Gear Components
1. Install bearings into case components.
2. Install main drive gear bearing.
a. Press main drive gear bearing.
b. Install main drive gear spacer.
c. Select proper main drive gear snap ring to minimize clearance
of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Main drive gear snap ring
Thickness mm (in) Part number
1.89 (0.0744) 32204-01G00
1.98 (0.0780) 32204-01G01
2.05 (0.0807) 32204-01G02
2.12 (0.0835) 32204-01G03
2.19 (0.0862) 32204-01G04
SMT395A
SMT425A
SMT426A
ASSEMBLY
MT-23

d. Install selected snap ring on main drive gear.
3. Install components on counter gear.
a. Install sub-gear components.
When installing sub-gear snap ring, tap sub-gear snap ring
into position on counter gear.
b. Install counter gear rear thrust bearing.
4. Install front side components on mainshaft.
a. Assemble 1st & 2nd synchronizer.
b. Assemble 3rd & 4th synchronizer.
SMT577A
SMT405A
SMT421A
SMT422A
ASSEMBLY
Gear Components (Cont'd)
MT-24

c. Press on 3rd & 4th synchronizer assembly together with 3rd
main gear and 3rd gear needle bearing.
Pay attention to direction of synchronizer assembly.
d. Select proper snap ring to minimize clearance of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Mainshaft front snap ring
Thickness mm (in) Part number
1.89 (0.0744) 32204-01G00
1.98 (0.0780) 32204-01G01
2.05 (0.0807) 32204-01G02
2.12 (0.0835) 32204-01G03
2.19 (0.0862) 32204-01G04
e. Install selected snap ring on mainshaft.
f. Press on 1st & 2nd synchronizer assembly together with 2nd
main gear and 2nd gear needle bearing.
g. Press on 1st gear bushing using 1st gear washer.
h. Install 1st main gear and needle bearing.
SMT399A
SMT400A
SMT401A
SMT402A
ASSEMBLY
Gear Components (Cont'd)
MT-25

i. Install steel ball and 1st gear washer.
Apply multi-purpose grease to steel ball and 1st gear washer
before installing.
5. Select proper counter gear front bearing shim when replacing
transmission case, counter gear, counter gear thrust bearing or
sub-gear components.
a. Install counter gear with sub-gear components, counter gear
front and rear thrust bearing on adapter plate.
b. Remove counter gear front bearing shim from transmission
case.
c. Place adapter plate and counter gear assembly in transmission
case (case inverted).
d. Tighten adapter plate to transmission case using 2 bolts.
e. Place dial indicator on rear end of counter gear.
f. Move counter gear up and down and measure dial indicator
deflection.
g. Select proper shim using table below as a guide.
Counter gear end play:
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Table for selecting proper counter gear front bearing shim
Dial indicator deflection
mm (in)Thickness of
proper washer
mm (in)Part number
0.93 - 1.02 (0.0366 - 0.0402) 0.88 (0.0346) 32216-01G11
1.03 - 1.12 (0.0406 - 0.0441) 0.96 (0.0378) 32216-01G12
1.13 - 1.22 (0.0445 - 0.0480) 1.04 (0.0409) 32216-01G13
1.23 - 1.32 (0.0484 - 0.0520) 1.12 (0.0441) 32216-01G14
1.33 - 1.42 (0.0524 - 0.0559) 1.28 (0.0504) 32216-01G15
1.43 - 1.52 (0.0563 - 0.0598) 1.36 (0.0535) 32216-01G16
1.53 - 1.62 (0.0602 - 0.0638) 1.44 (0.0567) 32216-01G17
SMT403A
SMT427A
SMT578A
ASSEMBLY
Gear Components (Cont'd)
MT-26

6. Select proper reverse idler rear trust washer when replacing
OD gear case, reverse idler gear, reverse idler shaft or reverse
idler thrust washer.
a. Install reverse idler gear, reverse idler needle bearings, reverse
idler thrust washers and reverse idler shaft into OD gear case.
When replacing reverse idler rear washer, install either A or B.
Reverse idler rear thrust washer.
Thickness mm (in) Part number
A 1.97 (0.0776) 32284-01G10
B 2.07 (0.0815) 32284-01G11
b. Place dial indicator on front end of reverse idler shaft.
c. Put straightedge on front surface of OD gear case as a stop-
per for reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse
idler gear end play.
Reverse idler gear end play:
0.30 - 0.53 mm (0.0118 - 0.0209 in)
e. If not within specification, replace reverse idler rear thrust
washer with the other (A or B) and check again.
SMT442B
SMT433A
ASSEMBLY
Gear Components (Cont'd)
MT-27

7. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.
a. Mount adapter plate on vise and apply multi-purpose grease to
counter gear rear bearing.
b. Install mainshaft a little on mainshaft front bearing.
To allow for installation of counter gear, do not install main-
shaft completely.
c. Install counter gear on counter gear rear bearing and install
main drive gear, pilot bearing and spacer on mainshaft.
When installing counter gear into counter gear rear bearing,
push up on upper roller of counter gear rear bearing with
screwdriver.
d. Install mainshaft and counter gear completely by tapping rear
side of adapter plate and pulling mainshaft.
SMT436A
SMT440A
SMT441A
SMT442A
SMT443A
ASSEMBLY
Gear Components (Cont'd)
MT-28

8. Install rear side components on mainshaft and counter gear.
a. Install OD gear bushing while pushing on the front of counter
gear.
b. Install OD main gear.
Pay attention to direction of OD main gear. (B is wider than A
as shown at left.)
c. Install adapter plate with gear assembly onto transmission
case.
d. Install OD gear needle bearing and then install OD counter gear
and reverse idler shaft.
e. Install reverse cone.
f. Install insert springs and reverse baulk ring on OD coupling
sleeve. Then install them and OD baulk ring on OD counter
gear.
Pay attention to direction of OD coupling sleeve.
SMT444A
SMT580A
SMT582A
SMT571A
SMT583A
ASSEMBLY
Gear Components (Cont'd)
MT-29

g. Install reverse counter gear.
h. Install reverse gear needle bearing and then install reverse
main gear, reverse idler gear and reverse idler thrust washers.
i. Install reverse hub.
Pay attention to its direction.
j. Install counter rear gear end bearing.
k. Separate adapter plate from transmission case and mount
adapter plate on vice again.
l. Select proper mainshaft C-ring to minimize clearance of
groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Mainshaft C-ring
Thickness
mm (in)Part numberThickness
mm (in)Part number
2.63 (0.1035) 32348-01G15 3.19 (0.1256) 32348-01G07
2.70 (0.1063) 32348-01G00 3.26 (0.1283) 32348-01G08
2.77 (0.1091) 32348-01G01 3.33 (0.1311) 32348-01G09
2.84 (0.1118) 32348-01G02 3.40 (0.1339) 32348-01G10
2.91 (0.1146) 32348-01G03 3.47 (0.1366) 32348-01G11
2.98 (0.1173) 32348-01G04 3.54 (0.1394) 32348-01G12
3.05 (0.1201) 32348-01G05 3.61 (0.1421) 32348-01G13
3.12 (0.1228) 32348-01G06 3.68 (0.1449) 32348-01G14
m. Install selected C-ring, C-ring holder and mainshaft rear snap
ring.
SMT584A
SMT585A
SMT587A
SMT452A
SMT454A
ASSEMBLY
Gear Components (Cont'd)
MT-30

n. Install spacer and then select proper counter gear rear snap
ring to minimize clearance of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Counter gear rear snap ring
Thickness mm (in) Part number
1.26 (0.0496) 32236-01G08
1.32 (0.0520) 32236-01G00
1.38 (0.0543) 32236-01G01
1.44 (0.0567) 32236-01G02
1.50 (0.0591) 32236-01G03
1.56 (0.0614) 32236-01G04
1.62 (0.0638) 32236-01G05
1.68 (0.0661) 32236-01G06
1.74 (0.0685) 32236-01G07
o. Install selected counter gear rear snap ring.
p. Install reverse coupling sleeve.
Pay attention to its direction.
q. Measure each gear end play as a final check. Ð Refer to
``DISASSEMBLY'', MT-14.
Shift Control Components
1. Install OD fork rod and OD shift fork. Then install retaining pin
into OD shift fork.
2. Install 1st & 2nd, 3rd & 4th and reverse shift fork onto coupling
sleeve.
3. Install striking rod into hole of shift forks, striking lever and
interlock and then install retaining pin into striking lever.
Make sure that striking rod moves smoothly.
SMT453A
SMT455A
SMT456A
SMT457A
SMT374A
ASSEMBLY
Gear Components (Cont'd)
MT-31