NISSAN TERRANO 2004 Service Repair Manual

c. Remove needle bearing of low gear.
d. Remove mainshaft, front drive and drive chain as a set by tap-ping front end of mainshaft and front drive shaft alternately.
Be careful not to bend drive chain.
10. Disassemble front case assembly.
a. Remove switches, check plugs, check springs and check balls.
b. Remove outer shift lever.
c. Remove lock pin of inner shift lever and drive out cross shaft with plug.
SMT758A
SMT279A
YTF004
SMT797A
SMT282A
DISASSEMBLY
TF-14
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d. Remove 2-4 shift rod.
e. Remove L & H shift rod and fork assembly with coupling sleeve.
f. Remove needle bearing from main gear.
g. Remove bolts securing front case cover and then remove case.
h. Remove counter gear by tapping lightly.
SMT283A
SMT284A
SMT286A
SMT287A
SMT759A
DISASSEMBLY
TF-15
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i. Remove main gear by tapping lightly.
SMT288A
DISASSEMBLY
TF-16
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Mainshaft
DISASSEMBLY
1. Check end play of front drive sprocket.Standard:0 - 0.15 mm (0 - 0.0059 in)
If end play is beyond the maximum value, check front drive
sprocket and clutch gear for wear.
2. Remove retaining ring, speedometer drive gear and steel ball.
Be careful not to lose the steel ball.
3. Remove snap ring and spacer.
4. Press out front drive sprocket with mainshaft rear bearing and clutch gear together.
5. Remove needle bearing.
6. Remove bearing retainer and then remove snap ring and spacer.
SMT347A
YMT019
SMT290A
SMT291A
SMT292A
REPAIR FOR COMPONENT PARTS
TF-17
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7. Press out mainshaft front bearing from mainshaft.
INSPECTION
Gear and shaft
ICheck gears for excessive wear, chips or cracks.
I Check shaft for cracks, wear of bending.
I Check coupling sleeve for wear or damage.
Baulk ring
ICheck baulk ring for cracks or deformation.
I Measure 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
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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) 33138-73P10
33138-73P11
33138-73P12
4. Regarding further procedures, refer to ªASSEMBLYº above.
Front Drive Shaft
DISASSEMBLY
I Front drive shaft front bearing
I Front drive shaft rear bearing
SMT294A
SMT295A
SMT296A
SMT297A
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont'd)
TF-19
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INSPECTION
Sprocket and shaft
ICheck sprocket for excessive wear, chips or cracks.
I Check 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
I Rear 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
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INSPECTION
Gear and shaft
ICheck gears for excessive wear, chips or cracks.
I Check 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
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Plug
Always replace it with new one whenever it is removed.
INSPECTION
Gear and shaft
ICheck gears for excessive wear, chips or cracks.
I Check 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) 33114-73P00
33114-73P01
33114-73P02
Plug
Apply sealant to plug and install it.
SMT306A
SMT359A
YMT023
SMT308A
SMT309A
REPAIR FOR COMPONENT PARTS
Main Gear (Cont'd)
TF-22
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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
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