NISSAN TERRANO 2002 Service Repair Manual

7. Press out mainshaft front bearing from mainshaft.
INSPECTION
Gear and shaft
ICheck gears for excessive wear, chips or cracks.
ICheck shaft for cracks, wear of bending.
ICheck coupling sleeve for wear or damage.
Baulk ring
ICheck baulk ring for cracks or deformation.
IMeasure clearance between baulk ring and gear.
Baulk ring to gear clearance:
Unit: mm (in)
Standard Wear limit
1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020)
Bearing
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT293A
SMT348A
SMT349A
SMT350A
SMT351A
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont'd)
TF-18

ASSEMBLY
1. Press mainshaft front bearing onto mainshaft.
Pay special attention to its direction.
2. Install spacer.
3. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring
Thickness mm (in) Part number
3.1 (0.122)
3.2 (0.126)
3.3 (0.130)
3.4 (0.134)33138-33G10
33138-33G11
33138-33G12
33138-33G13
4. Regarding further procedures, refer to ªASSEMBLYº above.
Front Drive Shaft
DISASSEMBLY
IFront drive shaft front bearing
IFront drive shaft rear bearing
SMT294A
SMT295A
SMT296A
SMT297A
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont'd)
TF-19

INSPECTION
Sprocket and shaft
ICheck sprocket for excessive wear, chips or cracks.
ICheck shaft for cracks or wear.
Bearing
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
ASSEMBLY
IFront drive shaft front bearing
IRear drive shaft rear bearing
Counter Gear
DISASSEMBLY
1. Press out counter gear front bearing and then remove front
sub-gear, spacer and dish spring.
2. Press out counter gear rear bearing and then remove rear
sub-gear, spacer and dish spring.
SMT357A
SMT298A
SMT299A
YMT020
YMT021
REPAIR FOR COMPONENT PARTS
Front Drive Shaft (Cont'd)
TF-20

INSPECTION
Gear and shaft
ICheck gears for excessive wear, chips or cracks.
ICheck shaft for cracks of wear.
Bearing
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
ASSEMBLY
1. Install front sub-gear, dish spring and spacer, and then press on
counter gear front bearing.
2. Install rear sub-gear, dish spring and spacer, and then press on
counter gear rear bearing.
Main Gear
DISASSEMBLY
Main gear bearing
1. Remove snap ring and spacer.
2. Pull out main gear bearing.
SMT358A
SMT302A
SMT303A
SMT304A
YMT022
REPAIR FOR COMPONENT PARTS
Counter Gear (Cont'd)
TF-21

Plug
Always replace it with new one whenever it is removed.
INSPECTION
Gear and shaft
ICheck gears for excessive wear, chips or cracks.
ICheck shaft for cracks or wear.
Bearing
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
ASSEMBLY
Main gear bearing
1. Press on main gear bearing.
2. Install spacer.
3. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring
Thickness mm (in) Part number
2.6 (0.102)
2.7 (0.106)
2.8 (0.110)
2.9 (0.114)33114-33G00
33114-33G01
33114-33G02
33114-33G03
Plug
Apply sealant to plug and install it.
SMT306A
SMT359A
YMT023
SMT308A
SMT309A
REPAIR FOR COMPONENT PARTS
Main Gear (Cont'd)
TF-22

Front Case
SHIFT SHAFT OIL SEAL
Removal
Remove the oil seal. Be careful not to damage its housing. Always
replace after every disassembly.
Installation
Install a new oil seal, using a suitable tool.
Front Case Cover
COVER OIL SEAL
Removal
Remove the oil seal. Be careful not to damage its housing. Always
replace after every disassembly.
Installation
Install a new oil seal, using the Special Tool.
Bearing Retainer
OIL CATCHER
Removal
Remove the oil seal. Be careful not to damage its housing. Always
replace after every disassembly.
SMT310A
SMT311A
SMT312A
YMT024
SMT314A
REPAIR FOR COMPONENT PARTS
TF-23

Installation
Install a new oil seal, using a suitable tool.
Rear Case
REAR OIL SEAL
Removal
Remove the oil seal. Be careful not to damage its housing. Always
replace after every disassembly.
Installation
Install a new oil seal, using the Special Tool.
AIR BREATHER
Install as shown in the illustration.
Shift Control Components
INSPECTION
ICheck contact surface and sliding surface for wear, scratches,
projections or other faulty conditions.
SMT315A
YMT025
YMT026
SMT318A
SMT360A
REPAIR FOR COMPONENT PARTS
Bearing Retainer (Cont'd)
TF-24

L & H SHIFT ROD & FORK
Assemble as shown in the illustration.
* This pin is the same size as the one for 2-4 shift rod.
2-4 SHIFT ROD & FORK
Assemble as shown in the illustration.
* These pins are the same size.
Pay special attention to the direction of fork guide collar.
SMT319A
SMT320A
SMT321A
REPAIR FOR COMPONENT PARTS
Shift Control Components (Cont'd)
TF-25

1. Assemble front case.
a. Install main gear assembly by tapping lightly.
b. Apply sealant to the mating surface and bolts of front case
cover and install it on front case.
IThese ten bolts should be coated with sealant.
Tightening torque
q
A: 16-21N×m
(1.6 - 2.1 kg-m, 12 - 15 ft-lb)
q
B: 19-24N×m
(1.9 - 2.4 kg-m, 14 - 17 ft-lb)
c. Apply gear oil to needle bearing and install it into main gear.
d. Install counter gear assembly by tapping lightly.
e. Install cross shaft and inner shift lever.
When replacing cross shaft, outer shift lever of lock pin of
outer shift lever, replace them as a set.
SMT323A
YMT027
SMT326A
SMT327A
SMT798A
ASSEMBLY
TF-26

f. Apply sealant to plug and install it into front case.
g. Insert interlock plunger into front case.
h. Install L & H shift rod and fork assembly with coupling sleeve.
i. Install 2-4 shift rod.
j. Install switches, check balls, check springs and plugs.
Apply sealant to switches and plugs.
SMT330A
SMT331A
SMT332A
SMT333A
NMT011
ASSEMBLY
TF-27