clutch NISSAN TIIDA 2009 Service Repair Manual

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11. Remove reverse idler shaft assembly (1) according to the follow-
ing procedures.
a. Pull up input shaft assembly (2), mainshaft assembly (3), fork rod (4), and 1st-2nd fork rod (5).
NOTE:
It is easier to pull up when shifting each fork rod to each shaft
side.
b. Remove reverse idler shaft assembly and reverse fork rod (6) from clutch housing.
12. Remove spring washer from clutch housing.
13. Pull up and remove input shaft assembly (1), mainshaft assem- bly (2), fork rod (3), and 1st-2nd fork rod (4) from clutch housing.
NOTE:
It is easier to pull up when shifting each fork rod to each shaft
side.
14. Remove final drive assembly (1) from clutch housing.
15. Remove magnet from clutch housing.
16. Remove differential side oil seals (1) from clutch housing and transaxle case.
CAUTION:
Never damage clutch housing and transaxle case.
17. Remove differential side bearing outer race (1) from clutch hous- ing using a suitable tool.
CAUTION:
Never damage clutch housing. JPDIC0607ZZ
PCIB1703E
PCIB1716E

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25. Remove mainshaft rear bearing outer race from transaxle case
using a suitable tool.
26. Remove mainshaft rear bearing adjusting shim from transaxle case.
27. Remove snap ring (1) and oil channel (2) from transaxle case.
28. Remove input shaft oil seal (1) from clutch housing using a suit- able tool.
CAUTION:
Never damage clutch housing.
29. Remove mainshaft front bearing outer race (1) from clutch hous- ing using Tool (A) and a spacer (B).
30. Remove oil channel (2) from clutch housing.
31. Remove bushing (1) from clutch housing using a suitable tool. PCIB1708E
PCIB1714E
PCIB1717E

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4. Install bushings (1) so that they becomes even to clutch housing
edge surface using a suitable tool (A).
5. Install oil channel to clutch housing. CAUTION:
Never reuse oil channel.
6. Install mainshaft front bearing outer race to clutch housing using Tool (A).
CAUTION:
Replace mainshaft front bearing outer race and mainshaft
front bearing inner race as a set.
7. Install input shaft oil seal (1) to clutch housing using Tool (A).
8. Install snap ring (1) and oil channel (2) to transaxle case. CAUTION:
• Select and install snap ring that has the same thickness
as previous one.
• Replace transaxle assembly wh en replacing transaxle
case.
9. Install mainshaft rear bearing adjusting shim to transaxle case. CAUTION:
Select mainshaft rear bearin g adjusting shim according to
the following procedures when replacing mainshaft adjust-
ing shim, 6th main gear, 5th main gear, or 4th main gear.
• Replace mainshaft adjusting shim.
- If new mainshaft adjusting shim is thinner th an previous one, offset the thickness difference by
selecting thicker mainshaft r ear bearing adjusting shim.
- If new mainshaft adjusting shim is thicker th an previous one, offset the thickness difference by
selecting thinner mainshaft r ear bearing adjusting shim.
• Replace 6th main gear, 5th main gear, or 4th main gear.
- Measure the thickness of the main gear used before and the new main gear
- Increase the thickness of the mainshaft rear bearin g adjusting shim, if the difference is smaller
than 0.025 mm (0.0010 in).
- Decrease the thickness of the mainshaft rear beari ng adjusting shim, if the difference is greater
than 0.025 mm (0.0010 in).

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17. Install differential side bearing outer race (transaxle case side)
to transaxle case using Tool (A).
CAUTION:
Replace differential side bearing outer race (transaxle case
side) and differential side bearing inner race (transaxle case
side) as a set.
18. Install differential side bearing outer race (clutch housing side) to clutch housing using Tool (A).
CAUTION:
Replace differential side bearing outer race (clutch housing
side) and differential side bearing inner race (clutch hous-
ing side) as a set.
19. Install differential side oil seals (1) to clutch housing and tran- saxle case using Tool.
• A: Transaxle case side
• B: Clutch housing side
20. Install magnet to clutch housing.
21. Install final drive assembly to clutch housing.
22. Set fork rod (1) to input shaft assembly (2), and then install them to clutch housing.Tool number A: ST33400001 (J-26082)
JPDIC0608ZZ

MT-74< SERVICE INFORMATION >
[RS6F94R]
TRANSAXLE ASSEMBLY
23. Install mainshaft assembly (1) according to the following proce- dures.
a. Pull up input shaft assembly (2) and fork rod (3).
b. Set 1st-2nd fork rod (4) to mainshaft assembly, and then install them to clutch housing.
24. Install reverse idler shaft assembly (1) according to the following procedures.
a. Install spring washer to clutch housing.
b. Pull up input shaft assembly (2), mainshaft assembly (3), fork rod (4), and 1st-2nd fork rod (5).
NOTE:
It is easier to pull up when shifting each fork rod to each shaft
side.
c. Set reverse fork rod (6) to reverse idler shaft assembly, and then install them to clutch housing.
25. Shift 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to the neutral position.
26. Install selector (4) to clutch housing. CAUTION:
Replace select lever and selector as a set.
27. Install selector spring (1) to return bushing (A).
28. Apply recommended sealant to transaxle case mounting sur- face.
• Use Genuine Silicone RTV or an equivalent. Refer to GI-42, " Recommended Chemical Product and Sealant " .
CAUTION:
• Never allow old liquid gasket , moisture, oil, or foreign
matter to remain on mounting surface.
• Check that mounting surface is not damaged.
• Apply liquid gasket bead continuously.
29. Install transaxle case to clutch housing while rotating shift lever A (1) in the direction as shown. JPDIC0609ZZ
JPDIC0606ZZ
SCIA7782E
JPDIC0445ZZ
JPDIC0110ZZ

TRANSAXLE ASSEMBLY
MT-75
< SERVICE INFORMATION >
[RS6F94R] D
E
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G H
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M A
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30. Install reverse idler shaft bolt ( ) according to the following pro-
cedures.
a. Install seal washer to reverse idler shaft bolt, and install reverse idler shaft bolt to transaxle case.
CAUTION:
Never reuse seal washer.
b. Tighten reverse idler shaft bolt to the specified torque. Refer to MT-59, " Disassembly and Assembly " .
31. Tighten transaxle case bolts ( ) to the specified torque. Refer to MT-59, " Disassembly and Assembly " .
32. Install position switch (1) according to the following procedures.
a. Apply recommended sealant to position switch thread. •Use Genuine Silicone RTV or an equivalent. Refer to GI-42, " Recommended Chemical Product and Sealant " .
CAUTION:
Never allow old liquid gasket, mo isture, oil, or foreign mat-
ter to remain on thread.
b. Install position switch to transaxle case, and tighten it to the specified torque. Refer to MT-59, " Disassembly and Assembly " .
33. Install bracket (2) to transaxle case, and tighten bolt to the spec- ified torque. Refer to MT-59, " Disassembly and Assembly " .
34. Install select lever (3) according to following the procedures.
a. Install select lever to transaxle case. CAUTION:
Replace select lever and selector as a set.
b. Install retaining pin to select lever using a suitable tool. CAUTION:
Never reuse retaining pin.
35. Install drain plug according to the following procedures.
a. Install gasket to drain plug. CAUTION:
Never reuse gasket.
b. Install drain plug to clutch housing.
c. Tighten drain plug to the specified torque. Refer to MT-59, " Disassembly and Assembly " .
36. Install filler plug according to the following procedures.
a. Install gasket to filler plug, and then install them to transaxle case. CAUTION:
Never reuse gasket.
b. Tighten filler plug to the specified torque. Refer to MT-59, " Disassembly and Assembly " .
CAUTION:
Fill with gear oil before tighten fi ller plug to the specified torque. PCIB1695E
PCIB1694E
SCIA7784E

MT-88< SERVICE INFORMATION >
[RS6F94R]
FINAL DRIVE
FINAL DRIVE
Disassembly and Assembly INFOID:0000000004305283
DISASSEMBLY
1. Remove differential side bearing inner race (clutch housing side) (1) according to the following procedures.
a. Set a suitable toolto differential side bearing inner race (clutch housing side).
b. Remove differential side bearing inner race (clutch housing side) using Tool (A).
2. Remove speedometer drive gear.
3. Remove final gear bolts, and then remove final gear (1).
4. Remove differential side bearing inner race (transaxle case side) (1) according to the following procedures.
a. Set a suitable tool to differential side bearing inner race (tran- saxle case side).
b. Remove differential side bearing inner race (transaxle case side) using a suitable tool (A).
INSPECTION AFTER DISASSEMBLY
Gear and Case
Check final gear and differential case. Replace if necessary.
Bearing
Check bearing for damage and unsmooth rotation. Replace if neces-
sary.
CAUTION:
• Replace differential side bear ing outer race (clutch housing
side) and differential side bear ing inner race (clutch housing
side) as a set.
• Replace differential side bearing inner race (transaxle case side) and differential side bearing outer race (transaxle case
side) as a set.
ASSEMBLY Tool number A: ST33061000 (J-8107-2) PCIB1767E
JPDIC0446ZZ
JPDIC0114ZZ
SPD715

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1. Install final gear, and then tighten final gear bolts to the specified torque. Refer to
MT-88, " Disassembly
and Assembly " .
CAUTION:
Replace final gear and differential case as a set.
2. Install speedometer drive gear.
3. Install differential side bearing inner race (clutch housing side) using a suitable tool (A).
CAUTION:
Replace differential side bear ing inner race (clutch housing
side) and differential side bearing outer race (clutch hous-
ing side) as a set.
4. Install differential side bearing inner race (transaxle case side) using a suitable tool (A).
CAUTION:
Replace differential side bearing inner race (transaxle case
side) and differential side bearing outer race (transaxle
case side) as a set. JPDIC0116ZZ

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CONTENTS
MANUAL AIR CONDITIONER
SERVICE INFORMATION .. ..........................3
PRECAUTIONS .............................................. .....3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
3
Precaution Necessary fo r Steering Wheel Rota-
tion After Battery Disconnect ............................... ......
3
Precaution for Procedure without Cowl Top Cover ......4
Precaution for Working with HFC-134a (R-134a) ......4
General Refrigerant Precaution .......................... ......4
Oil Precaution ...................................................... ......5
Precaution for Refrigeran t Connection ......................5
Precaution for Service of Compressor ................ ......7
Precaution for Service Equipment ....................... ......8
Precaution for Leak Detection Dye ..................... ......9
PREPARATION .............................................. ....11
HFC-134a (R-134a) Service Tool and Equipment ....11
Commercial Service Tool .................................... ....13
REFRIGERATION SYSTEM .......................... ....15
Refrigerant Cycle ................................................ ....15
Refrigerant System Protec tion ................................15
Component Part Location ................................... ....16
OIL .................................................................. ....17
Maintenance of Oil Quantity in Compressor ....... ....17
AIR CONDITIONER CONTROL ..................... ....19
Control Operation ................................................ ....19
Discharge Air Flow .............................................. ....20
System Description ............................................. ....20
TROUBLE DIAGNOSIS ................................. ....22
CONSULT-II Function (BCM) .............................. ....22
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ........... ...........................................
22
Component Parts and Harness Connector Loca-
tion ...................................................................... ....
23
Schematic ........................................................... ....25
Wiring Diagram - Heater - ................................... ....26 Wiring Diagram - A/C,M - ....................................
....27
Operational Check ............................................... ....30
Mode Door ........................................................... ....31
Air Mix Door ......................................................... ....32
Intake Door .......................................................... ....33
Front Blower Motor Circuit .......................................33
Magnet Clutch Circuit (If Equipped) ..................... ....37
Insufficient Cooling .............................................. ....45
Insufficient Heating .............................................. ....52
Noise ................................................................... ....53
CONTROLLER .................................................. 55
Removal and Installation ..................................... ....55
Disassembly and Assembly ................................. ....56
THERMO CONTROL AMPLIFIER .................... 57
Removal and Installation ..................................... ....57
A/C UNIT ASSEMBLY ...................................... 58
Removal and Installation ..................................... ....58
Disassembly and Assembly ................................. ....60
BLOWER MOTOR ............................................ 62
Removal and Installation ..................................... ....62
INTAKE DOOR .................................................. 63
Intake Door Cable Adjustment ............................. ....63
AIR MIX DOOR ................................................. 64
Air Mix Door Cable Adjustment ........................... ....64
MODE DOOR .................................................... 65
Mode Door Cable Adjustment ............................. ....65
BLOWER FAN RESISTOR ............................... 66
Removal and Installation ..................................... ....66
HEATER CORE ................................................. 67
Removal and Installation ..................................... ....67
AIR CONDITIONER FILTER ............................. 68
Removal and Installation ..................................... ....68

Maintenance of Oil Quantity in Compressor " .
• Keep friction surfaces between clut ch and pulley clean. If the surface is contaminated, with oil, wipe
it off by using a clean waste cloth moistened with thinner.
• After compressor service operation, turn the compresso r shaft by hand more than five turns in both
directions. This will equally dist ribute oil inside the compressor. After the compressor is installed,
let the engine idle and operat e the compressor for one hour.
• After replacing the compressor magnet clutch, ap ply voltage to the new one and check for usual
operation.
Precaution for Service Equipment INFOID:0000000004307048
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer’s instruct ions for tester operation and tester maintenance.
VACUUM PUMP
The oil contained inside the vacuum pump is not compatible with the
specified oil for HFC-134a (R-134a) A/C systems. The vent side of
the vacuum pump is exposed to atmospheric pressure. So the vac-
uum pump oil may migrate out of the pump into the service hose.
This is possible when the pump is switched off after evacuation (vac-
uuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows.
• Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolat e the service hose from the pump.
• For pumps without an isolator, use a hose equipped with a manual
shut-off valve near the pump end. Close the valve to isolate the
hose from the pump.
• If the hose has an automatic shut -off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is open
and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a or R-134a. Be
sure the gauge set has 1/2 ″-16 ACME threaded connections for ser-
vice hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified oils.
SERVICE HOSES SHA533D