transaxle NISSAN TIIDA 2007 Service Repair Manual

TRANSAXLE ASSEMBLY
TM-641
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
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14. Remove position switch from transaxle case.
15. Remove clutch housing bolts.
16. Remove clutch housing from transaxle case.
17. Remove oil gutter from transaxle case.
18. Remove washer (1) and 4th main gear (2) from mainshaft.
19. Remove 5th-reverse fork rod (1) according to the following.
a. Lift up 5th-reverse fork rod (1) until it contacts the claw ( ) of
reverse gear assembly (2).
b. Push down gear of reverse gear assembly (2), and then remove
5th-reverse fork rod (1) from clutch housing.
20. Remove 3rd-4th fork rod assembly (1), 3rd-4th coupling sleeve
(2) and input shaft assembly (3) according to the following.
a. Remove 4th baulk ring, insert keys and springs from 3rd-4th
synchronizer hub.
b. Lift the gear of the reverse gear assembly (4) up.
c. Lift up 1st-2nd fork rod (5), and then maintain neutral position.
d. Remove 3rd-4th fork rod assembly (1), 3rd-4th coupling sleeve
(2) and input shaft assembly (3) together.
PCIB1627E
PCIB1528E
PCIB1529E
PCIB1530E
PCIB1531E

TM-642
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
TRANSAXLE ASSEMBLY
21. Remove lock pins (1) from clutch housing.
22. Remove 1st-2nd fork rod assembly (1) and mainshaft assembly
(2) together from clutch housing.
23. Remove retaining pin from reverse gear assembly using a pin
punch.
24. Remove reverse gear assembly from clutch housing.
25. Remove final drive assembly (1) from clutch housing.
26. Remove magnet and dowel pins (2) from clutch housing.
27. Remove differential side oil seals (1) from clutch housing and
transaxle case using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage clutch housing and transaxle
case.
PCIB1640E
PCIB1532E
MCIB0033E
PCIB1533E
PCIB1534E

TRANSAXLE ASSEMBLY
TM-643
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
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28. Remove differential side bearing outer races from clutch hous-
ing and transaxle case using a brass bar.
CAUTION:
Be careful not to damage clutch housing and transaxle
case.
29. Using the drift, with snap rings (1) stretched, press out input
shaft rear bearing and mainshaft rear bearing from transaxle
case.
30. Remove check balls (2) and check ball plugs from transaxle
case.
31. Remove input shaft oil seal and input shaft front bearing from
clutch housing using a suitable drift.
32. Separate oil channel tube at the root.
33. Remove mainshaft front bearing and oil channel from clutch
housing using the valve seat remover.
34. Remove bushings (1) from clutch housing using a suitable
remover.
MCIB0050E
Tool number A: ST35300000
PCIB1535E
MCIB0044E
Tool number A: KV111038S0
PCIB1536E
PCIB1537E

TM-644
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
TRANSAXLE ASSEMBLY
35. Remove retaining pin from selector using a pin punch.
36. Remove bushings (1) from transaxle case using a suitable
remover.
37. Remove interlock bolt (1), bushing, spring and striking interlock
from transaxle case.
38. Remove control shaft (1) from transaxle case.
39. Pull out 2 way connector (1) straight from air breather inner tube
(2).
40. Remove air breather inner tube (2) from transaxle case.
PCIB1538E
PCIB1539E
PCIB1540E
PCIB1541E

TRANSAXLE ASSEMBLY
TM-645
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
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AssemblyINFOID:0000000001381696
1. Install air breather inner tube (2) to transaxle case.
CAUTION:
Be careful not to damage air breather inner tube.
NOTE:
It is easy to install the air breather inner tube when its end is
closed with tape. Remove the tape after the installation.
2. Insert 2 way connector (1) straight to air breather inner tube (2).
CAUTION:
Check air breather inner tube for twists after installing.
3. Apply gear oil to O-ring and install it to control shaft.
CAUTION:
Do not reuse O-ring.
4. Install control shaft (1) to transaxle case and then install selector
to control shaft. Tighten bolts to the specified torque. Refer to
TM-635, "
Exploded View".
CAUTION:
Be careful with the orientation of selector.
5. Install selector onto control shaft, and then install retaining pin
(1) to selector.
6. Install bushings (1) until it is flush with end face of transaxle
case using a suitable drift (A).
PCIB1541E
PCIB1540E
PCIB1645E
PCIB1542E

TM-646
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
TRANSAXLE ASSEMBLY
7. Install striking interlock, spring, bushing and interlock bolt (1) to
transaxle case, and then tighten interlock bolt to the specified
torque. Refer to TM-635, "
Exploded View".
8. Install bushings (1) until it is flush with end face of clutch housing
using a suitable drift (A).
9. Install oil channel to clutch housing.
CAUTION:
Do not reuse oil channel.
10. Install mainshaft front bearing until it is flush with end face of
clutch housing using Tool (A).
11. Install input shaft front bearing until it is flush with end face of
clutch housing using Tool (A).
12. Install input shaft oil seal (1) until it is flush with end face of
clutch housing using Tool (A).
PCIB1539E
PCIB1543E
Tool number A: ST33061000
PCIB1544E
Tool number A: KV40100900
PCIB1545E
Tool number A: ST33220000
PCIB1546E

TRANSAXLE ASSEMBLY
TM-647
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
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13. Install snap ring (1) to transaxle case as shown in the figure.
CAUTION:
Be careful with the orientation of snap ring.
14. Using Tool (A), with snap rings (1) stretched, press in input shaft
rear bearing and mainshaft rear bearing into transaxle case.
CAUTION:
Make sure that snap ring is installed to bearing groove
properly.
15. Install check balls (2) to transaxle case.
16. Install differential side bearing outer races until it is flush with
end face of clutch housing and transaxle case using Tool (A).
17. Install differential side oil seals (1) to clutch housing and tran-
saxle case using Tool (A).
PCIB1547E
Tool number A: ST35300000
PCIB1548E
Tool number A: KV32300QA
PCIB1549E
Tool number A: ST27862000
Dimension “H
1” : 5.7 - 6.3 mm (0.224 - 0.248 in)
Dimension “H
2” : 16.4 - 17.0 mm (0.646 - 0.669 in)
PCIB1550E

TM-648
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
TRANSAXLE ASSEMBLY
18. Install final drive assembly (1) to clutch housing.
19. Install dowel pins (2) and magnet to clutch housing.
20. Install reverse gear assembly onto clutch housing, and then
install retaining pin (1) to reverse gear assembly.
21. Set 1st-2nd fork rod assembly (1) to mainshaft assembly (2),
and then install them to clutch housing.
22. Install lock pins (1) to clutch housing.
23. Install 3rd-4th fork rod assembly (1), 3rd-4th coupling sleeve (2)
and input shaft assembly (3) according to the following.
a. Lift up 1st-2nd fork rod (4), and then maintain neutral position.
b. Set 3rd-4th fork rod assembly (1) to 3rd-4th coupling sleeve (2),
and then install it together with input shaft assembly (3) to clutch
housing.
CAUTION:
 Set lock pin (3rd-4th fork rod side) to 1st-2nd fork rod
groove, and then install 3rd-4th fork rod assembly.
PCIB1533E
PCIB1644E
PCIB1532E
PCIB1640E
PCIB1628E

TRANSAXLE ASSEMBLY
TM-649
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
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 Be careful with the orientation of 3rd-4th coupling sleeve.
(A): 4th main gear
(B): 3rd main gear
 Install 3rd input gear of input shaft assembly so that it is
lower than reverse main gear of 3rd-4th coupling sleeve.
c. Install springs and Insert keys to 3rd-4th synchronizer hub.
d. Install 4th baulk ring.
24. Install 5th-reverse fork rod (1) according to the following.
a. Lift the gear of the reverse gear assembly (2) up.
b. Temporarily install 5th-reverse fork rod (1) to clutch housing.
c. Push down gear of reverse gear assembly (1), and then install
5th-reverse fork rod (2) to clutch housing.
CAUTION:
Set lever of 5th-reverse fork rod so as to align with reverse
gear assembly groove ( ).
25. Install 4th main gear (2) and washer (1) to mainshaft.
CAUTION:
Install the washer with the convex side facing the rear side
of the transaxle.
26. Pull down 3rd-4th shift fork, and then shift 3rd-4th coupling
sleeve to 3rd gear side.
PCIB1551E
MCIB0061E
PCIB1629E
PCIB1552E
PCIB1529E

TM-650
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
TRANSAXLE ASSEMBLY
27. Shift the shift lever (1) of control shaft assembly to 3rd gear posi-
tion.
NOTE:
 If not, the transaxle case cannot be removed from clutch hous-
ing.
 3rd gear position means that the shift lever of control shaft
assembly is fully rotated clockwise and it is returned approxi-
mately 10°.
28. Install oil gutter to transaxle case.
29. Apply recommended sealant to mating surface of clutch hous-
ing.
CAUTION:
 Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign
material adhering to both mating surfaces.
 Check for damage on the mounting surface.
 Apply a continuous bead of liquid gasket to the mounting surface.
30. Install transaxle case to clutch housing.
(1): Selector
(2): Shift fork
CAUTION:
 Do not allow sealant to contact the transaxle case so as
not to break the bead when installing.
 Be careful to align the lever of 5th-reverse fork rod with
reverse gear assembly sleeve.
NOTE:
If installation is difficult, gently return shift lever of control shaft
assembly counterclockwise slightly.
31. Fit shaft with bearing by rotating input shaft. Then, tighten bolts
to the specified torque. Refer to TM-635, "
Exploded View".
32. Apply recommended sealant to threads of position switch and
check ball plug. Then install them to transaxle case and tighten
to the specified torque. Refer to TM-635, "
Exploded View".
33. Apply gear oil to spline of mainshaft and then press in 5th main
gear (1) to mainshaft using a suitable bolt (A) [M10 x 1.0] and
nut (B).
34. Install spread springs to 5th-reverse synchronizer hub.
PCIB1524E
PCIB1553E
PCIB1528E
PCIB1554E