Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Maxima 2000-2005 Approved Nissan Maxima 2002 MT
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MANUAL TRANSAXLE GI
SECTION MT MA
EM
LC
EC
CONTENTS FE
PREPARATION ...............................................................3 INSPECTION ...........................................................37
CL
Special Service Tools ..................................................3 ASSEMBLY .............................................................38
Commercial Service Tools ...........................................5 Final Drive..................................................................38
NOISE, VIBRATION AND HARSHNESS (NVH) PRE-INSPECTION ...................................................38
TROUBLESHOOTING .....................................................7 DISASSEMBLY ........................................................39
INSPECTION ...........................................................39 AT
NVH Troubleshooting Chart.........................................7
ASSEMBLY .............................................................40
MANUAL TRANSAXLE ...............................................7
Shift Control Components .........................................42
DESCRIPTION .................................................................8
Cross-sectional View ...................................................8
INSPECTION ...........................................................42 AX
ADJUSTMENT ...............................................................43
DOUBLE-CONE SYNCHRONIZER ..............................9
REVERSE GEAR NOISE PREVENTION
Input Shaft End Play..................................................43
FUNCTION (SYNCHRONIZING METHOD)...................9 Mainshaft End Play....................................................44 SU
ON-VEHICLE SERVICE ................................................10 Differential Side Bearing Preload ..............................45
Replacing Oil Seal .....................................................10 Reverse Idler Gear End Play ....................................46
ASSEMBLY....................................................................48
BR
DIFFERENTIAL OIL SEAL ........................................10
Position Switch Check ...............................................10 SERVICE DATA AND SPECIFICATIONS (SDS) .........54
BACK-UP LAMP SWITCH ........................................10 General Specifications...............................................54 ST
PARK/NEUTRAL POSITION SWITCH .......................10 TRANSAXLE ...........................................................54
Control Device and Cable .........................................11 FINAL GEAR ...........................................................55
Air Breather Hose ......................................................12 Gear End Play ...........................................................55 RS
REMOVAL AND INSTALLATION .................................13 Clearance Between Baulk Ring and Gear ................55
Removal.....................................................................13 3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING .......55
Installation..................................................................14 1ST AND 2ND DOUBLE BAULK RING ......................55 BT
OVERHAUL ...................................................................15 Available Snap Rings ................................................56
6TH BUSHING.........................................................56
Case and Housing Components ...............................15
Available C-rings........................................................56 HA
Gear Components .....................................................16
MAINSHAFT C-RING ...............................................56
Shift Control Components .........................................18
Available Thrust Washer............................................56
Final Drive Components ............................................19
INPUT SHAFT THRUST WASHER ............................56
SC
DISASSEMBLY..............................................................20
DIFFERENTIAL SIDE GEAR THRUST WASHER ........57
REPAIR FOR COMPONENT PARTS ...........................24 Available Adjusting Shims .........................................57
Input Shaft and Gears ...............................................24 MAINSHAFT ADJUSTING SHIM................................57
EL
DISASSEMBLY ........................................................24 INPUT SHAFT REAR BEARING ADJUSTING
INSPECTION ...........................................................25 SHIM ......................................................................57
ASSEMBLY .............................................................26 IDX
MAINSHAFT REAR BEARING ADJUSTING SHIM ......58
Mainshaft and Gears .................................................29 REVERSE IDLER GEAR ADJUSTING SHIM ..............58
DISASSEMBLY ........................................................29 6TH MAIN GEAR ADJUSTING SHIM .........................58
INSPECTION ...........................................................30 Available Shims - Differential Side Bearing
ASSEMBLY .............................................................32 Preload and Adjusting Shim ......................................58
Reverse Idler Shaft and Gears..................................37 BEARING PRELOAD ...............................................58
DISASSEMBLY ........................................................37
CONTENTS (Cont'd)
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM(S) ..................................................................59
MT-2
PREPARATION
Special Service Tools
Special Service Tools NFMT0001
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
GI
Tool number
(Kent-Moore No.) Description
Tool name
MA
KV381054S0 Side bearing outer race removal
(J34286) Mainshaft front bearing removal
Puller EM
LC
ZZA0601D EC
ST35321000 Input shaft oil seal installation
( -- ) Reverse main gear installation
Drift 1st bushing installation FE
1st-2nd synchronizer hub installation
2nd bushing installation
3rd main gear installation CL
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
ZZA1000D
ST30720000 Differential oil seal installation
(J25405) Differential side bearing outer race installation
Drift Mainshaft rear bearing installation AT
Differential side bearing installation
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia. AX
ZZA0811D SU
ST33200000 Mainshaft front bearing installation
(J26082) 6th bushing installation
Drift 4th main gear installation BR
5th main gear installation
6th main gear installation
a: 60 mm (2.36 in) dia. ST
b: 44.5 mm (1.752 in) dia.
ZZA1002D RS
ST33061000 Bore plug installation
(J8107-2) Differential side bearing removal
Drift a: 38 mm (1.50 in) dia. BT
b: 28.5 mm (1.122 in) dia.
HA
ZZA1000D SC
EL
IDX
MT-3
PREPARATION
Special Service Tools (Cont'd)
Tool number
(Kent-Moore No.) Description
Tool name
ST33052000 Welch plug installation
( -- ) Input shaft rear bearing removal
Drift 5th bushing, thrust washer, 4th input gear, 4th gear
bushing, 3rd-4th synchronizer hub and 3rd input
gear removal
Input shaft front bearing installation
6th input gear and 6th bushing removal
Mainshaft rear bearing removal
4th main gear and 5th main gear removal
6th main gear removal
ZZA1023D a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
KV40105020 5th input gear and synchronizer hub removal
( -- ) 3rd main gear, 2nd main gear, 2nd bushing, 1st-
Drift 2nd synchronizer hub, 1st main gear, reverse main
gear and 1st bushing removal
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)
ZZA1133D
KV40105710 3rd-4th synchronizer hub installation
( -- ) 4th bushing installation
Press stand 5th bushing installation
5th-6th synchronizer hub installation
2nd bushing installation
3rd main gear installation
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in)
ZZA1058D
ST38220000 Reverse main gear installation
( -- ) 1st bushing installation
Press stand 1st-2nd synchronizer hub installation
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)
ZZA1058D
ST30032000 Input shaft front bearing installation
(J26010-01) a: 80 mm (3.15 in) dia.
Drift b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
ZZA0978D
ST30901000 Input shaft rear bearing installation
(J26010-01) 4th main gear installation
Drift 5th main gear installation
6th main gear installation
Mainshaft rear bearing installation
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
ZZA0978D
MT-4
PREPARATION
Special Service Tools (Cont'd)
Tool number
(Kent-Moore No.) Description
Tool name GI
ST30031000 Measuring wear of 1st and 2nd baulk ring
(J22912-01) MA
Puller
EM
ZZA0537D
LC
KV40101630 Reverse main gear installation
(J35870) a: 68 mm (2.68 in) dia. EC
Drift b: 60 mm (2.36 in) dia.
FE
ZZA1003D
CL
KV38102510 1st bushing installation
( -- ) 1st-2nd synchronizer hub installation
Drift Differential side bearing installation
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
AT
AX
ZZA0838D
(J39713) Checking differential side gear end play
Preload adapter SU
NT087 BR
Commercial Service Tools NFMT0002
ST
Tool name Description
Puller Each bearing gear and bushing removal
RS
BT
HA
ZZB0823D
Puller Each bearing gear and bushing removal
SC
EL
NT077
IDX
MT-5
PREPARATION
Commercial Service Tools (Cont'd)
Tool name Description
Pin punch Each retaining pin removal and installation
Tip diameter: 4.5 mm (0.177 in) dia.
ZZA0815D
Power tool Loosening bolts and nuts
PBIC0190E
MT-6
NFMT0003
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
NVH Troubleshooting Chart NFMT0003S01
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts. GI
MANUAL TRANSAXLE NFMT0003S0101
MA
Refer to MA-20, "Checking M/T Oil".
EM
LC
MT-15
MT-15
MT-15
MT-18
MT-18
MT-16
MT-16
MT-16
MT-16
MT-11
Reference page
EC
FE
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
CL
AT
AX
SUSPECTED PARTS
(Possible cause) SU
SHIFT CONTROL LINKAGE (Worn)
BAULK RING (Worn or damaged)
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
INSERT SPRING (Damaged)
O-RING (Worn or damaged)
BR
GEAR (Worn or damaged)
GASKET (Damaged)
SHIFT FORK (Worn)
ST
(Oil level is high.)
(Oil level is low.)
(Wrong oil.)
RS
BT
Noise 1 2 3 3
Oil leakage 3 1 2 2 2 HA
Symptoms
Hard to shift or will not shift 1 1 2 3 3
Jumps out of gear 1 2 3 3 SC
EL
IDX
MT-7
NFMT0004
DESCRIPTION
Cross-sectional View
Cross-sectional View NFMT0004S01
SMT115E
MT-8
DESCRIPTION
Cross-sectional View (Cont'd)
DOUBLE-CONE SYNCHRONIZER NFMT0004S0101
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever. GI
MA
EM
SCIA0750E LC
REVERSE GEAR NOISE PREVENTION FUNCTION
(SYNCHRONIZING METHOD) NFMT0004S0102 EC
The gear can be matched smoothly in a structure by setting syn-
chronizer hub, coupling sleeve, baulk ring and insert spring to
reverse gear, and letting gear be synchronized. FE
CL
SCIA0751E
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
MT-9
ON-VEHICLE SERVICE
Replacing Oil Seal
Replacing Oil Seal NFMT0005
DIFFERENTIAL OIL SEAL NFMT0005S01
1. Drain gear oil from transaxle.
2. Remove driveshaft. Refer to AX-10, "Drive Shaft".
3. Remove differential oil seals.
CAUTION:
Be careful not to damage the case surface when removing the
oil seal.
SCIA0824E
4. Using a drift (special service tool), drive the oil seal straight
until it protrudes from the case end equal to dimension A
shown in the figure.
Dimension "A":
Within 0.5 mm (0.020 in) of flush with the case.
Drift to be used:
ST30720000 (J25405)
CAUTION:
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