unit NISSAN TERRANO 2002 Service Repair Manual

Wheel runout
Unit: mm (in)
Wheel typeSteel Aluminum
16²x7J 16²x7J
Radial runout limit 0.5 (0.020) 0.3 (0.012)
Lateral runout limit 0.8 (0.031) 0.3 (0.012)
Wheel bearing
Axial end play limit mm (in) 0
Lock nut
Tightening torque
N×m (kg-m, ft-lb)78-98
(7.9 - 10, 57 - 72)
Retightening torque
N×m (kg-m, in-lb)0.5 - 1.5
(0.05 - 0.15,4-13)
TIGHTENING TORQUE
Unit N×m kg-m ft-lb
Clutch
Pedal stopper lock nut 12 - 15 1.2 - 1.5 8.7 - 10.8
Master cylinder push rod
lock nut8 - 11 0.8 - 1.1 5.8 - 8.0
Manual transmission
Drain and filler plugs
FS5R30A 25 - 34 2.5 - 3.5 18 - 25
Differential carrier
Drain and filler plugs
R180A 39 - 59 4 - 6 28.8 - 43.5
H233B 59 - 98 6 - 10 43.5 - 72.3
Front axle and front suspen-
sion
Tie-rod lock nut 60 - 70 6.1 - 7.1 44.3 - 51.6
Brake system
Air bleeder valve 7 - 9 0.7 - 0.9 5.1 - 6.5
Wheel and tire
Wheel nut 118 - 147 12.0 - 15.087.0 -
108.4
SERVICE AND SPECIFICATIONS (SDS)
Chassis and Body Maintenance (Cont'd)
MA-50

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
1. Remove check ball plug, check spring and check ball. Then
remove interlock stopper.
If interlock assembly is removed as a unit, the check ball can
fall into transmission case.
2. Remove control housing, return spring and check ball.
3. Drive out retaining pin from striking arm.
4. Remove OD gear case together with striking arm by tapping
lightly.
SMT366A
SMT438B
SMT439B
SMT440B
SMT444B
DISASSEMBLY
MT-14

Shift Control Components
ICheck contact surface and sliding surface for wear, scratches,
projections or other damage.
Gear Components
GEARS AND SHAFTS
ICheck shafts for cracks, wear or bending.
ICheck gears for excessive wear, chips or cracks.
SYNCHRONIZERS
ICheck spline portion of coupling sleeves, hubs, and gears for
wear or cracks.
ICheck baulk rings for cracks or deformation.
ICheck shifting inserts for wear or deformation.
ICheck insert springs for deformation.
Clearance between baulk ring and gear
Unit: mm (in)
Standard Wear limit
1st & 2nd 1.05 - 1.3 (0.0413 - 0.0512) 0.7 (0.028)
3rd & main drive 1.05 - 1.3 (0.0413 - 0.0512) 0.7 (0.028)
OD 1.05 - 1.3 (0.0413 - 0.0512) 0.7 (0.028)
If the clearance is smaller than the wear limit, replace baulk ring.
SMT398A
SMT386A
SMT423A
SMT387A
SMT140
INSPECTION
MT-21

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

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

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