NISSAN TERRANO 2004 Service Repair Manual

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
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c. Press on 3rd & 4th synchronizer assembly together with 3rdmain 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
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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 replacingtransmission 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
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6. Select proper reverse idler rear trust washer when replacingOD 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
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7. Install mainshaft and counter gear on adapter plate and maindrive 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
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8. Install rear side components on mainshaft and counter gear.
a. Install OD gear bushing while pushing on the front of countergear.
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
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g. Install reverse counter gear.
h. Install reverse gear needle bearing and then install reversemain 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 number Thickness
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
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n. Install spacer and then select proper counter gear rear snapring 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
ªDISASSEMBLYº, MT-14.
Shift Control Components
1. Install OD fork rod and OD shift fork. Then install retaining pininto 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
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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
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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
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