Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Almera 2000-2003.2006 Approved Nissan Almera 2001 N16 2001 Nissan Almera UK mt
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MANUAL TRANSAXLE
SECTION MT
CONTENTS
RS5F30A Cross-sectional View - RS5F70A ..............................17
Cross-sectional View - RS5F50A ..............................18
PREPARATION ...............................................................4
DOUBLE-CONE SYNCHRONIZER ............................19
Special Service Tools ..................................................4
ON-VEHICLE SERVICE ................................................20
Commercial Service Tools ...........................................6
Replacing Oil Seal .....................................................20
DIFFERENTIAL OIL SEAL ........................................20
RS5F70A STRIKING ROD OIL SEAL .......................................21
Position Switch Check ...............................................21
PREPARATION ...............................................................7
BACK-UP LAMP SWITCH ........................................21
Special Service Tools ..................................................7
PNP SWITCH ..........................................................22
Commercial Service Tools ...........................................9
BACK-UP LAMP SWITCH AND PNP SWITCH ...........22
RS5F50A RS5F30A, RS5F70A
PREPARATION .............................................................10 REMOVAL AND INSTALLATION .................................23
Special Service Tools ................................................10 Removal.....................................................................23
Commercial Service Tools .........................................12 Installation..................................................................24
MODEL QG15DE ENGINE .......................................24
MODEL QG18DE ENGINE .......................................25
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...................................................13
RS5F50A
NVH Troubleshooting Chart.......................................13
MANUAL TRANSAXLE .............................................13 REMOVAL AND INSTALLATION .................................26
Removal.....................................................................26
RS5F30A, RS5F70A Installation..................................................................28
MODEL YD ENGINE ................................................28
M/T OIL ..........................................................................14
Changing M/T Oil.......................................................14
Checking ....................................................................14 TRANSAXLE GEAR CONTROL ...................................29
OIL LEAK AND OIL LEVEL .......................................14 Components...............................................................29
RS5F50A RS5F30A
M/T OIL ..........................................................................15 OVERHAUL ...................................................................30
Changing M/T Oil.......................................................15 Case Components .....................................................30
Checking ....................................................................15 Gear Components .....................................................31
OIL LEAK AND OIL LEVEL .......................................15 Shift Control Components .........................................32
DISASSEMBLY..............................................................33
REPAIR FOR COMPONENT PARTS ...........................36
DESCRIPTION ...............................................................16
Input Shaft and Gears ...............................................36
Cross-sectional View - RS5F30A ..............................16
DISASSEMBLY ........................................................36
CONTENTS (Cont'd)
INSPECTION ...........................................................37 DISASSEMBLY..............................................................95
ASSEMBLY .............................................................37 REPAIR FOR COMPONENT PARTS ...........................98
Mainshaft and Gears .................................................39 Input Shaft and Gears ...............................................98
DISASSEMBLY ........................................................39 DISASSEMBLY ........................................................98
INSPECTION ...........................................................41 INSPECTION ...........................................................99
ASSEMBLY .............................................................42 ASSEMBLY ...........................................................100
Final Drive..................................................................43 Mainshaft and Gears ...............................................103
DISASSEMBLY ........................................................43 DISASSEMBLY ......................................................103
INSPECTION ...........................................................44 INSPECTION .........................................................104
ASSEMBLY .............................................................44 ASSEMBLY ...........................................................105
Shift Control Components .........................................46 Final Drive................................................................107
INSPECTION ...........................................................46 DISASSEMBLY ......................................................107
Case Components .....................................................46 INSPECTION .........................................................107
DISASSEMBLY AND ASSEMBLY..............................46 ASSEMBLY ...........................................................108
ADJUSTMENT ...............................................................49 Shift Control Components .......................................109
Differential Side Bearing Preload ..............................49 INSPECTION .........................................................109
Mainshaft Bearing Preload ........................................50 Case Components ...................................................109
ASSEMBLY....................................................................51 REMOVAL AND INSTALLATION .............................109
ADJUSTMENT ............................................................. 111
RS5F70A Input Shaft End Play and Differential Side
Bearing Preload ....................................................... 111
OVERHAUL ...................................................................54 DIFFERENTIAL SIDE ............................................. 111
Case Components .....................................................54 INPUT SHAFT SIDE...............................................112
Gear Components .....................................................55 Mainshaft Bearing Preload ......................................112
Shift Control Components .........................................56 ASSEMBLY..................................................................114
Final Drive Components ............................................57
DISASSEMBLY..............................................................58 RS5F30A
Transaxle Case..........................................................58
Clutch Housing ..........................................................60 SERVICE DATA AND SPECIFICATIONS (SDS) .......118
REPAIR FOR COMPONENT PARTS ...........................64 General Specifications.............................................118
Input Shaft and Gears ...............................................64 TRANSAXLE .........................................................118
DISASSEMBLY ........................................................64 FINAL GEAR .........................................................118
INSPECTION ...........................................................65 Gear End Play .........................................................119
ASSEMBLY .............................................................66 Clearance Between Baulk Ring and Gear ..............119
Mainshaft and Gears .................................................69 1ST, 2ND, 3RD, 4TH & 5TH BAULK RING...............119
DISASSEMBLY ........................................................69 Available Check Plugs.............................................119
INSPECTION ...........................................................70 REVERSE CHECK PLUGS .....................................119
ASSEMBLY .............................................................72 Available Snap Rings ..............................................119
Final Drive..................................................................77 INPUT SHAFT FRONT BEARING ...........................119
PRE-INSPECTION ...................................................77 INPUT SHAFT 5TH SYNCHRONIZER HUB .............120
DISASSEMBLY ........................................................78 INPUT SHAFT REAR BEARING..............................120
INSPECTION ...........................................................79 Available C-rings......................................................120
ASSEMBLY .............................................................79 MAINSHAFT C-RING .............................................120
Shift Control Components .........................................81 Available Washers ...................................................120
INSPECTION ...........................................................81 DIFFERENTIAL SIDE GEAR THRUST WASHER ......120
ASSEMBLY....................................................................82 Available Shims - Mainshaft and Differential Side
Clutch Housing ..........................................................82 Bearing Preload and Adjusting Shim.......................121
Transaxle Case..........................................................86 BEARING PRELOAD (REUSED BEARING) .............121
TURNING TORQUE (NEW BEARING) .....................121
MAINSHAFT REAR BEARING ADJUSTING SHIMS ..121
RS5F50A
DIFFERENTIAL SIDE BEARING ADJUSTING
OVERHAUL ...................................................................92 SHIMS ..................................................................122
Case Components .....................................................92
Gear Components .....................................................93
Shift Control Components .........................................94
MT-2
CONTENTS (Cont'd)
RS5F70A RS5F50A
SERVICE DATA AND SPECIFICATIONS (SDS) .......123 SERVICE DATA AND SPECIFICATIONS (SDS) .......131
General Specifications.............................................123 General Specifications.............................................131
TRANSAXLE .........................................................123 TRANSAXLE .........................................................131
FINAL GEAR .........................................................123 FINAL GEAR .........................................................131
Gear End Play .........................................................124 Gear End Play .........................................................132
Clearance Coupling Sleeve .....................................124 Clearance Between Baulk Ring and Gear ..............132
1ST, 2ND, 3RD, 4TH, 5TH & REVERSE 3RD, 4TH & 5TH BAULK RING ...............................132
COUPLING SLEEVE ..............................................124 1ST AND 2ND DOUBLE BAULK RING ....................132
Clearance Between Baulk Ring and Gear ..............124 REVERSE BAULK RING ........................................132
3RD, 4TH, 5TH, REVERSE BAULK RING ................124 Available Snap Rings ..............................................133
1ST AND 2ND DOUBLE BAULK RING ....................124 1ST & 2ND SYNCHRONIZER HUB (AT
Available Snap Rings ..............................................125 MAINSHAFT) .........................................................133
SNAP RING...........................................................125 3RD & 4TH SYNCHRONIZER HUB (AT INPUT
Available C-rings......................................................125 SHAFT) .................................................................133
4TH INPUT GEAR C-RING .....................................125 5TH MAIN GEAR (AT MAINSHAFT) ........................133
5TH INPUT GEAR REAR C-RING ...........................125 Available Thrust Washer..........................................133
MAINSHAFT C-RING .............................................126 4TH INPUT GEAR (AT INPUT SHAFT) ....................133
Available Adjusting Shims .......................................127 DIFFERENTIAL SIDE GEAR THRUST WASHER ......133
INPUT SHAFT REAR BEARING ADJUSTING Available Shims .......................................................134
SHIM ....................................................................127 BEARING PRELOAD AND END PLAY ....................134
MAINSHAFT ADJUSTING SHIM..............................128 TOTAL TURNING TORQUE (NEW BEARING) ..........134
MAINSHAFT REAR BEARING ADJUSTING SHIM ....128 MAINSHAFT BEARING ADJUSTING SHIM ..............134
Available Thrust Washer..........................................129 TABLE FOR SELECTING MAINSHAFT BEARING
MAINSHAFT THRUST WASHER .............................129 ADJUSTING SHIM(S) .............................................134
Available Washers ...................................................129 INPUT SHAFT BEARING ADJUSTING SHIM ...........135
DIFFERENTIAL SIDE GEAR THRUST WASHER ......129 TABLE FOR SELECTING INPUT SHAFT BEARING
Available Shims - Differential Side Bearing ADJUSTING SHIM(S) .............................................135
DIFFERENTIAL SIDE BEARING ADJUSTING
Preload and Adjusting Shim ....................................130
SHIM ....................................................................135
BEARING PRELOAD .............................................130
TABLE FOR SELECTING DIFFERENTIAL SIDE
DIFFERENTIAL SIDE BEARING ADJUSTING
BEARING ADJUSTING SHIM(S) .............................136
SHIMS ..................................................................130
MT-3
PREPARATION RS5F30A
Special Service Tools
Special Service Tools NJMT0030
Tool number
Description
Tool name
KV38105900 Measuring turning torque of final drive assembly
Preload adapter Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
NT087 (Use with KV38106000.)
KV38106000 Selecting differential side bearing adjusting shim
Height gauge adapter (Use with KV38105900.)
(differential side bear- a: 140 mm (5.51 in)
ing) b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 x 1.25P
NT418
KV32101000 Removing and installing retaining pin
Pin punch a: 4 mm (0.16 in) dia.
NT410
ST22730000 Removing mainshaft front and rear bearing inner
Puller race
Removing 5th main gear
a: 82 mm (3.23 in) dia.
b: 30 mm (1.18 in) dia.
NT411
ST30031000 Removing differential side bearing inner race
Puller a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
NT411
ST30021000 Removing 5th synchronizer
Puller a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
NT411
MT-4
PREPARATION RS5F30A
Special Service Tools (Cont'd)
Tool number
Description
Tool name
ST33290001 Removing differential oil seal
Puller Removing mainshaft front bearing outer race
Removing differential side bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
NT414
ST33400001 Installing differential oil seal
Drift a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
NT086
KV38102100 Installing input shaft rear bearing
Drift a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
NT427
ST33200000 Installing mainshaft front bearing outer race
Drift a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
NT091
ST22350000 Installing input shaft front bearing
Drift a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
NT065
ST22452000 Installing 1st & 2nd synchronizer
Drift a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
NT065
ST37750000 Installing 5th main gear
Drift Installing 3rd & 4th synchronizer
Installing input shaft oil seal
Installing 5th synchronizer
a: 40 mm (1.57 in) dia.
NT065 b: 31 mm (1.22 in) dia.
ST22360002 Installing mainshaft rear bearing inner race
Drift a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.
NT065
MT-5
PREPARATION RS5F30A
Special Service Tools (Cont'd)
Tool number
Description
Tool name
ST30621000 Installing differential side bearing outer race
Drift (Use with ST30611000.)
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
NT073
ST30611000 Installing differential side bearing outer race
Drift handle (Use with ST30621000.)
a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 in) dia.
d: M12 x 1.5P
NT419
Commercial Service Tools NJMT0031
Tool name Description
Puller Removing input shaft front bearing
NT077
Drift Installing mainshaft front bearing inner race
a: 26 mm (1.02 in) dia.
b: 21 mm (0.83 in) dia.
NT065
Drift Installing differential side bearing inner race
a: 56 mm (2.20 in) dia.
b: 50.5 mm (1.988 in) dia.
NT065
Drift Installing striking rod oil seal
a: 38 mm (1.50 in) dia.
b: 32 mm (1.26 in) dia.
NT065
MT-6
PREPARATION RS5F70A
Special Service Tools
Special Service Tools NJMT0032
Tool number
Description
Tool name
KV38107700 Measuring turning torque of final drive assembly
Preload adapter Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
NT087 (Use with KV38106000.)
KV38106000 Selecting differential side bearing adjusting shim
Height gauge adapter (Use with KV38107700.)
(differential side bearing) a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 x 1.25P
NT418
KV32101000 Removing and installing retaining pin
Pin punch Removing and installing lock pin
Removing selector shaft
Removing welch plug
a: 4 mm (0.16 in) dia.
NT410
KV31100300 Removing and installing retaining pin
Pin punch a: 4.5 mm (0.177 in) dia.
NT410
ST30031000 Removing 3rd, 5th input gear
Puller Removing 3rd & 4th and 5th & Rev synchronizer
hub
Removing mainshaft rear bearing
Removing 2nd gear, 5th gear bush
Removing 1st & 2nd synchronizer hub, 1st and
4th main gear
Removing and installing differential side bearing
NT411 a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000 Removing input shaft front and rear bearing
Puller Installing input shaft front and rear bearing
Installing 5th input gear, 3rd main gear and 4th
main gear
Installing 1st & 2nd, 3rd & 4th and 5th & Rev syn-
chronizer hub
Installing 2nd gear bush, 5th gear bush, Rev gear
bush
Installing mainshaft rear bearing
NT411 a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
MT-7
PREPARATION RS5F70A
Special Service Tools (Cont'd)
Tool number
Description
Tool name
ST33290001 Removing idler gear bearing outer race
Puller a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
NT414
ST33230000 Removing differential oil seal
Drift Installing differential side bearing
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
NT084
ST30720000 Installing differential side bearing outer race
Drift a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
NT115
ST22350000 Installing input shaft front and rear bearing
Drift a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
NT065
ST22452000 Installing 3rd and 4th main gear
Drift Installing 5th gear bush
Installing 5th & Rev synchronizer hub
Installing Rev gear bush
Installing mainshaft rear bearing
a: 45 mm (1.77 in) dia.
NT065
b: 36 mm (1.42 in) dia.
ST37750000 Installing input shaft oil seal
Drift Installing 5th synchronizer
Installing mainshaft rear bearing
Installing 5th main gear
Installing 3rd & 4th synchronizer hub
Installing striking rod oil seal
Installing clutch housing dust seal
NT065
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
MT-8
PREPARATION RS5F70A
Commercial Service Tools
Commercial Service Tools NJMT0033
Tool name Description
Drift Installing welch plug
a: 12 mm (0.47 in) dia.
b: 10 mm (0.39 in) dia.
NT065
Drift Removing input shaft rear bearing
Removing mainshaft rear bearing
a: 22 mm (0.87 in) dia.
b: 16 mm (0.63 in) dia.
NT065
Drift Installing differential oil seal
a: 58 mm (2.28 in) dia.
b: 50 mm (1.97 in) dia.
NT065
Drift Installing differential oil seal
a: 54 mm (2.13 in) dia.
b: 50 mm (1.97 in) dia.
NT065
Drift Installing 2nd gear bush
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
NT065
Drift Installing 3rd & 4th and 1st & 2nd synchronizer
hub
Installing mainshaft front bearing
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
NT065
Drift Installing input shaft oil seal
Installing 5th input gear
a: 39 mm (1.54 in) dia.
b: 30 mm (1.18 in) dia.
NT065
MT-9
PREPARATION RS5F50A
Special Service Tools
Special Service Tools NJMT0001
Tool number
Description
Tool name
KV38105210 Measuring turning torque of final drive assembly
Preload adapter Measuring total turning torque
NT075
KV32101000 Removing and installing retaining pin
Pin punch a: 4 mm (0.16 in) dia.
NT410
ST22730000 Removing mainshaft front and rear bearing inner
Puller race
a: 82 mm (3.23 in) dia.
b: 30 mm (1.18 in) dia.
NT411
ST30031000 Removing input shaft front and rear bearing
Puller Removing 4th & 5th main gear
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
NT411
ST30021000 Removing 5th synchronizer
Puller Removing 3rd & 4th synchronizer
Removing 2nd & 3rd main gear
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
NT411
ST3306S001 Removing differential side bearing inner race
Differential side bearing a: 38 mm (1.50 in) dia.
puller set b: 28.5 mm (1.122 in) dia.
1 ST33051001 c: 130 mm (5.12 in)
Puller d: 135 mm (5.31 in)
2 ST33061000 e: 100 mm (3.94 in)
Adapter
NT675
MT-10
PREPARATION RS5F50A
Special Service Tools (Cont'd)
Tool number
Description
Tool name
ST33290001 Removing differential oil seal
Puller Removing mainshaft rear bearing outer race
Removing differential side bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
NT414
ST33400001 Installing differential oil seal
Drift a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
NT086
ST30600000 Installing input shaft front bearing
Drift a: 36 mm (1.42 in) dia.
b: 31 mm (1.22 in) dia.
NT065
ST22452000 Installing 3rd, 4th and 5th main gear
Drift a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
NT065
ST30621000 Installing mainshaft rear bearing outer race
Drift (Use with ST30611000.)
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
NT073
ST30611000 (Use with ST30621000.)
a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 in) dia.
d: M12 x 1.5P
NT419
KV38107700 Measuring clearance between side gear and differ-
Preload adapter ential case with washer
NT087
KV38106500 Measuring turning torque of final drive assembly
Preload adapter
NT087
MT-11
PREPARATION RS5F50A
Commercial Service Tools
Commercial Service Tools NJMT0002
Tool name Description
Drift Installing differential side bearing inner race
a: 45 mm (1.77 in) dia.
b: 41 mm (1.61 in) dia.
NT065
Drift Installing differential side bearing outer race
a: 69 mm (2.72 in) dia.
b: 64 mm (2.52 in) dia.
NT065
Drift Installing striking rod oil seal
a: 38 mm (1.50 in) dia.
b: 20 mm (0.79 in) dia.
NT065
MT-12
Symptoms
Reference page
(Possible cause)
SUSPECTED PARTS
Noise
Oil leakage
MANUAL TRANSAXLE
Jumps out of gear
Hard to shift or will not shift
1
(Oil level is low.) MT-15 (RS5F30A, RS5F70A), MT-16 (RS5F50A)
1
3
2
(Wrong oil) MT-15 (RS5F30A, RS5F70A), MT-16 (RS5F50A)
tion. If necessary, repair or replace these parts.
1
1
(Oil level is high.) MT-15 (RS5F30A, RS5F70A), MT-16 (RS5F50A)
2
GASKET (Damaged) MT-93
MT-13
2
OIL SEAL (Worn or damaged) MT-93
2
O-RING (Worn or damaged) MT-93
1
2
SHIFT CONTROL ROD (Worn) MT-30
2
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged) MT-95
NVH Troubleshooting Chart
3
SHIFT FORK (Worn) MT-95
3
3
GEAR (Worn or damaged) MT-94
3
BEARING (Worn or damaged) MT-94
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
3
BAULK RING (Worn or damaged) MT-94
3
INSERT SPRING (Damaged) MT-94
NJMT0003S0101
NJMT0003S01
NJMT0003
NVH Troubleshooting Chart
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
M/T OIL RS5F30A, RS5F70A
Changing M/T Oil
Changing M/T Oil NJMT0086
1. Drain oil from drain plug and refill with new gear oil.
2. Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-20, "RECOMMENDED FLUIDS AND
LUBRICANTS".
Capacity:
SMA145AA RS5F30A 2.8 - 3.0 ! (4-7/8 - 5-1/4 Imp pt)
RS5F70A 3.0 ! (5-1/4 Imp pt)
Oil level (Reference data):
RS5F30A 58 - 66 mm (2.28 - 2.60 in)
RS5F70A 75.5 - 80.5 mm (2.969 - 3.166 in)
Drain plug:
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