NISSAN TERRANO 2002 Service Repair Manual

Case Components
1. Install front cover oil seal.
Apply multi-purpose grease to seal lip.
2. Install selected counter gear front bearing shim onto transmis-
sion case.
Apply multi-purpose grease.
3. Apply sealant to mating surface of transmission case.
4. Install gear assembly onto transmission case.
5. Install check spring and check ball into interlock stopper.
Apply multi-purpose grease to check ball.
6. Install interlock stopper assembly and then tighten check ball
plug.
Apply sealant to thread of check ball plug.
7. Install stopper ring and main drive bearing snap ring.
8. Install front cover and gasket.
Apply sealant to thread of 3 bolts shown left.
9. Apply sealant to mating surface of adapter plate.
SMT393A
SMT588A
SMT460A
SMT371A
SMT443B
ASSEMBLY
MT-32

10. Install OD gear case together with striking arm.
11. Install retaining pin into striking arm.
12. Install return spring and check ball and then install control hous-
ing.
Apply sealant to mating surface of OD gear case.
13. Tighten control housing bolts.
Bolt head size:
A bolts 12 mm
B bolts 13 mm
SMT444B
SMT439B
SMT445B
SMT446B
ASSEMBLY
Case Components (Cont'd)
MT-33

General Specifications
Engine TD27Ti and ZD30DDTi
Transmission model FS5R30A
No. of speeds 5
Shift pattern
Synchromesh type Warner
Gear ratio
1st 3.580
2nd 2.077
3rd 1.360
4th 1.000
OD 0.811
Reverse 3.631
No. of teeth
Mainshaft
drive
1st 32
2nd 30
3rd 29
4th 22
OD 24
Reverse 30
Countershaft
Drive
1st 13
2nd 21
3rd 31
4th 32
OD 43
Reverse 12
Reverse idler gear 22
Oil capacity(lmp pt) 3.6 (6-3/8)
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-34

Inspection and Adjustment
GEAR END PLAY
Gear End play mm (in)
1st main gear 0.23 - 0.33 (0.0091 - 0.0130)
2nd main gear 0.23 - 0.33 (0.0091 - 0.0130)
3rd main gear 0.23 - 0.33 (0.0091 - 0.0130)
OD counter gear 0.23 - 0.33 (0.0091 - 0.0130)
Reverse main gear 0.33 - 0.43 (0.0130 - 0.0169)
Counter gear 0.10 - 0.25 (0.0039 - 0.0098)
Reverse idler gear 0.30 - 0.53 (0.0118 - 0.0209)
CLEARANCE BETWEEN BAULK RING AND
GEAR
Unit: mm (in)
Standard Wear limit
1st & 2nd1.05 - 1.3
(0.0413 - 0.0512)0.7 (0.028)
3rd & main-
drive1.05 - 1.3
(0.0413 - 0.0512)0.7 (0.028)
OD1.05 - 1.3
(0.0413 - 0.0512)0.7 (0.028)
DISTANCE BETWEEN REAR SURFACE OF
REVERSE CONE AND
REVERSE BAULK RING
Unit: mm (in)
Standard Wear limit
Dimension
ªAºþ0.1 to 0.36
(þ0.0039 to 0.0142)0.7 (0.028)
AVAILABLE SNAP RING
Main drive gear snap ring
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
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
Mainshaft front snap ring
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
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
Counter gear rear snap ring
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
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
AVAILABLE C-RING
Mainshaft C-ring
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
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
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-35

AVAILABLE SHIM AND WASHER
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) 32218-01G11
1.03 - 1.12 (0.0406 - 0.0441) 0.96 (0.0378) 32218-01G12
1.13 - 1.22 (0.0445 - 0.0480) 1.04 (0.0409) 32218-01G13
1.23 - 1.32 (0.0484 - 0.0520) 1.12 (0.0441) 32218-01G14
1.33 - 1.42 (0.0524 - 0.0559) 1.28 (0.0504) 32218-01G15
1.43 - 1.52 (0.0563 - 0.0598) 1.36 (0.0535) 32218-01G16
1.53 - 1.62 (0.0602 - 0.0638) 1.44 (0.0567) 32218-01G17
Reverse idler rear thrust washer
Thickness mm (in) Part number
1.97 (0.0776) 32284-01G10
2.07 (0.0815) 32284-01G11
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont'd)
MT-36

PROPELLER SHAFT &
DIFFERENTIAL CARRIER
SECTION
PD
CONTENTS
PREPARATION................................................................2
PROPELLER SHAFT......................................................5
On-Vehicle Service ......................................................6
Removal and Installation .............................................7
Inspection.....................................................................7
Disassembly.................................................................7
Assembly .....................................................................8
ON-VEHICLE SERVICE................................................10
Front Oil Seal Replacement
(Front final drive: R180A) ..........................................10
Front Oil Seal Replacement
(Rear final drive: H233B) ...........................................10
REMOVAL AND INSTALLATION (Front final drive
- R180A).........................................................................12
Removal .....................................................................12
Installation ..................................................................12
REMOVAL AND INSTALLATION (Rear final drive
- H233B).........................................................................13
Removal .....................................................................13
Installation ..................................................................13
FRONT FINAL DRIVE (R180A)....................................14
DISASSEMBLY (R180A)...............................................15
Pre-inspection ............................................................15
Final Drive Housing ...................................................15
Differential Case ........................................................18
Extension Tube and Differential Side Shaft ..............19
INSPECTION (R180A)...................................................20
Ring Gear and Drive Pinion ......................................20
Differential Case Assembly........................................20
Bearing.......................................................................20
ADJUSTMENT (R180A)................................................21
Drive Pinion Height ....................................................21Side Bearing Preload.................................................24
Tooth Contact.............................................................27
ASSEMBLY (R180A).....................................................28
Extension Tube and Differential Side Shaft ..............28
Differential Case ........................................................29
Final Drive Housing ...................................................30
REAR FINAL DRIVE (H233B).......................................35
Air Breather................................................................36
DISASSEMBLY (H233B)...............................................37
Pre-inspection ............................................................37
Differential Carrier......................................................38
Differential Case ........................................................40
INSPECTION (H233B)...................................................42
Ring Gear and Drive Pinion ......................................42
Differential Case Assembly........................................42
Bearing.......................................................................42
LIMITED SLIP DIFFERENTIAL (H233B)......................43
Preparation for Disassembly .....................................43
Disassembly...............................................................44
Inspection...................................................................44
Adjustment .................................................................45
Assembly ...................................................................47
ADJUSTMENT (H233B)................................................49
Drive Pinion Height ....................................................49
Tooth Contact.............................................................52
ASSEMBLY (H233B).....................................................53
Differential Carrier......................................................53
SERVICE DATA AND SPECIFICATIONS (SDS)..........57
Propeller Shaft ...........................................................57
Final Drive..................................................................58

SPECIAL SERVICE TOOLS
*: Special tool or commercial equivalent
Tool number
Tool nameDescriptionUnit application
R180A H233B
ST31211000
Height gauge
Selecting pinion height adjusting washer
XÐ
ST31212000
Dummy shaft
Selecting pinion height adjusting washer
XÐ
ST31852000
Stopper
Selecting pinion height adjusting washer
XÐ
ST3125S000
Drive pinion height
setting gauge set
q
1ST31251000
Drive pinion
height gauge
q
2ST31181001
Dummy shaft
Selecting pinion height adjusting washer
ÐX
ST32501000
Weight block
Selecting side bearing adjusting shim
XÐ
KV38101900
Master gauge
[20.0 mm (0.787 in)]
Selecting side bearing adjusting shim
XÐ
ST0501S000
Engine stand
q
1ST05011000
Engine stand
q
2ST05012000
Base
Mounting differential attachment
XX
KV38100800
Differential attach-
ment
Mounting final drive
XÐ
ST06340000
Differential attach-
ment
Mounting final drive
ÐX
PREPARATION
PD-2

*: Special tool or commercial equivalent
Tool number
Tool nameDescriptionUnit application
R180A H233B
ST32580000
Diff. side bearing
adjusting nut wrench
Adjusting side bearing preload and back-
lash (ring gear drive pinion)
ÐX
KV381052S0
Rear axle shaft
dummy
q
1KV38105210
Torque wrench
side
q
2KV38105220
Vice side
Checking differential torque on limited slip
differential
ÐX
ST33290001*
Side bearing outer
race puller
Removing side bearing outer race and
side oil seal
XÐ
ST38060002*
Drive pinion flange
wrench
Removing and installing propeller shaft
lock nut, and drive pinion lock nut
XÐ
KV38104700*
Drive pinion flange
wrench
Removing and installing propeller shaft
lock nut, and drive pinion lock nut
ÐX
ST3090S000*
Drive pinion rear inner
race puller set
q
1ST30031000
Puller
q
2ST30901000*
Base
Removing and installing drive pinion rear
inner cone
A: 79 mm (3.11 in) dia.
B: 45 mm (1.77 in) dia.
C: 35 mm (1.38 in) dia.XX
ST3306S001
Diff. side bearing
puller set
q
1ST33051001*
Body
q
2ST33061000*
Adapter
Removing and installing differential side
bearing inner cone
A: 28.5 mm (1.122 in) dia.
B: 38 mm (1.50 in) dia.XX
ST33230000*
Diff. side bearing drift
Installing side bearing inner cone
A: 51 mm (2.01 in) dia.
B: 28.5 mm (1.122 in) dia.XÐ
PREPARATION
PD-3

*: Special tool or commercial equivalent
Tool number
Tool nameDescriptionUnit application
R180A H233B
ST33190000*
Diff. side bearing drift
Installing side bearing inner cone
A: 52 mm (2.05 in) dia.
B: 34 mm (1.34 in) dia.ÐX
ST33081000*
Side bearing puller
adapter
Installing side bearing inner cone
A: 43 mm (1.69 in) dia.
B: 33.5 mm (1.319 in) dia.ÐX
ST30611000*
Drift
Installing pinion rear bearing outer race
XX
ST30621000*
Drift
Installing pinion rear bearing outer race
A: 79 mm (3.11 in) dia.
B: 59 mm (2.32 in) dia.XX
ST30701000*
Drift
Installing pinion front bearing outer race
A: 61.5 mm (2.421 in) dia.
B: 41 mm (1.61 in) dia.XÐ
ST30613000*
Drift
Installing pinion front bearing outer race
A: 71.5 mm (2.815 in) dia.
B: 47.5 mm (1.870 in) dia.ÐX
KV381025S0*
Oil seal fitting tool
q
1ST30720000
Drift bar
q
2KV38102510
Drift
Installing front oil seal
A: 77 mm (3.03 in) dia.
B: 55 mm (2.17 in) dia.
C: 71 mm (2.80 in) dia.
D: 65 mm (2.56 in) dia.XX
ST33720000
Diff. side retainer
guide
Installing side retainer
XÐ
ST33270000
Side oil seal drift
Installing side oil seal
A: 62 mm (2.44 in) dia.
B: 28 mm (1.10 in) dia.XÐ
PREPARATION
PD-4

Front propeller shaft (Model 0F71H)
Rear propeller shaft (Model 2S80B)
SPD724
SPD725
PROPELLER SHAFT
PD-5