NISSAN TIIDA 2007 Service Repair Manual

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

TRANSAXLE ASSEMBLY
TM-651
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
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35. Install adapter plate (1), bushing (2) and 5th input gear (3) to
input shaft.
: Transaxle case side
CAUTION:
Be careful with the orientation of adapter plate.
36. Install 5th baulk ring, 5th-reverse synchronizer hub, 5th-reverse coupling sleeve, lock washer, reverse
synchronizer cone and reverse baulk ring to input shaft.
CAUTION:
 Be careful with the orientation of 5th-reverse synchro-
nizer hub.
: 5th input gear side
37. Set 5th-reverse shift fork (1) and reverse gear assembly (4) to
5th-reverse coupling sleeve, and then assemble input shaft and
5th-reverse fork rod.
CAUTION:
Be careful with the orientation of 5th-reverse coupling
sleeve.
: 5th input gear side
38. Make sure that the shift lever of control shaft assembly is shifted
to 3rd gear position. And then, push in 5th-reverse shift fork (1)
to shift it to 5th gear position.
NOTE:
When it is shifted to the 5th gear and 3rd gear at the same time,
the input shaft and mainshaft may not be rotated.
39. Install mainshaft bolt (2) to mainshaft, and then tighten main-
shaft bolt to the specified torque. Refer to TM-635, "
Exploded
View".
40. Install input shaft nut (3) to input shaft, and then tighten input
shaft nut to the specified torque. Refer to TM-635, "
Exploded
View".
41. Install retaining pin (5) to 5th-reverse shift fork using a pin
punch.
PCIB1555E
PCIB1556E
PCIB1641E

TM-652
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
TRANSAXLE ASSEMBLY
42. Shift the shift lever (1) of control shaft assembly to neutral posi-
tion. And then, pull 5th-reverse shift fork to shift it to neutral posi-
tion.
43. Install O-ring to rear housing and then install them to transaxle
case. Tighten bolts to the specified torque. Refer to TM-635,
"Exploded View".
CAUTION:
 Rear housing oil channel is inserted to input shaft. There-
fore, when installing rear housing, install it to axial direc-
tion of input shaft.
 Be careful to pinch O-ring when installing rear housing.
44. Install CSC (1) to clutch housing. Refer to TM-635, "
Exploded
View".
45. Install gaskets onto drain plug and filler plug, and then install
them to clutch housing and transaxle case. Refer to TM-635,
"Exploded View".
CAUTION:
 Do not reuse gasket.
 After oil is filled, tighten filler plug to specified torque.
SCIA7130E
PCIB1558E
PCIB1523E

INPUT SHAFT AND GEAR
TM-653
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
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INPUT SHAFT AND GEAR
Exploded ViewINFOID:0000000001381697
Refer to TM-635, "Exploded View".
DisassemblyINFOID:0000000001381698
Refer to TM-639, "Disassembly" for dissassembly procedure.
AssemblyINFOID:0000000001381699
Refer to TM-645, "Assembly" for assembly procedure.
InspectionINFOID:0000000001381700
INPUT SHAFT AND GEARS
Check items below. If necessary, replace them with new ones.
 Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
 Excessive wear, damage, peeling, and other non-standard condi-
tions of the gears.
SYNCHRONIZER
Synchronizer
Check items below. If necessary, replace them with new ones.
 Damage and excessive wear of contact surfaces of coupling
sleeve, synchronizer hub.
 Coupling sleeve and synchronizer hub must move smoothly.
 If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
BEARING
PCIB0987J
SCIA1753J
SCIA0608J

TM-654
< DISASSEMBLY AND ASSEMBLY >[5MT: RS5F91R]
INPUT SHAFT AND GEAR
Check for damage and rough rotation of bearing. If necessary,
replace with new one.
MTF0041D