Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Almera 2000-2003.2006 Approved Nissan Almera 2002 Tino mt
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MANUAL TRANSAXLE
SECTION MT
CONTENTS
RS5F70A Position Switch Check ...............................................16
BACK-UP LAMP SWITCH ........................................16
PREPARATION ...............................................................3 PNP SWITCH ..........................................................16
Special Service Tools ..................................................3 BACK-UP LAMP SWITCH AND PNP SWITCH ...........17
Commercial Service Tools ...........................................5
RS5F70A
RS5F50A
REMOVAL AND INSTALLATION .................................18
PREPARATION ...............................................................6 Removal.....................................................................18
Special Service Tools ..................................................6 Installation..................................................................19
Commercial Service Tools ...........................................8 MODEL QG18DE ENGINE .......................................19
RS5F50A
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .....................................................9 REMOVAL AND INSTALLATION .................................20
NVH Troubleshooting Chart.........................................9 Removal.....................................................................20
MANUAL TRANSAXLE ...............................................9 Installation..................................................................22
MODEL YD ENGINE ................................................22
RS5F70A
M/T OIL ..........................................................................10 TRANSAXLE GEAR CONTROL ...................................23
Changing M/T Oil.......................................................10 Components...............................................................23
Checking ....................................................................10
OIL LEAK AND OIL LEVEL .......................................10 RS5F70A
RS5F50A OVERHAUL ...................................................................24
Case Components .....................................................24
M/T OIL ..........................................................................11 Gear Components .....................................................25
Changing M/T Oil.......................................................11 Shift Control Components .........................................26
Checking ....................................................................11 Final Drive Components ............................................27
OIL LEAK AND OIL LEVEL .......................................11 DISASSEMBLY..............................................................28
Transaxle Case..........................................................28
Clutch Housing ..........................................................30
DESCRIPTION ...............................................................12
REPAIR FOR COMPONENT PARTS ...........................34
Cross-sectional View - RS5F70A ..............................12
Input Shaft and Gears ...............................................34
Cross-sectional View - RS5F50A ..............................13
DISASSEMBLY ........................................................34
DOUBLE-CONE SYNCHRONIZER ............................14
INSPECTION ...........................................................35
ON-VEHICLE SERVICE ................................................15 ASSEMBLY .............................................................36
Replacing Oil Seal .....................................................15 Mainshaft and Gears .................................................39
DIFFERENTIAL OIL SEAL ........................................15 DISASSEMBLY ........................................................39
STRIKING ROD OIL SEAL .......................................15 INSPECTION ...........................................................40
CONTENTS (Cont'd)
ASSEMBLY .............................................................42 3RD, 4TH, 5TH, REVERSE BAULK RING ..................89
Final Drive..................................................................47 1ST AND 2ND DOUBLE BAULK RING ......................89
PRE-INSPECTION ...................................................47 Available Snap Rings ................................................90
DISASSEMBLY ........................................................48 SNAP RING.............................................................90
INSPECTION ...........................................................49 Available C-rings........................................................90
ASSEMBLY .............................................................49 4TH INPUT GEAR C-RING .......................................90
Shift Control Components .........................................51 5TH INPUT GEAR REAR C-RING .............................90
INSPECTION ...........................................................51 MAINSHAFT C-RING ...............................................91
ASSEMBLY....................................................................52 Available Adjusting Shims .........................................92
Clutch Housing ..........................................................52 INPUT SHAFT REAR BEARING ADJUSTING
Transaxle Case..........................................................56 SHIM ......................................................................92
MAINSHAFT ADJUSTING SHIM................................93
MAINSHAFT REAR BEARING ADJUSTING SHIM ......93
RS5F50A
Available Thrust Washer............................................94
OVERHAUL ...................................................................62 MAINSHAFT THRUST WASHER ...............................94
Case Components .....................................................62 Available Washers .....................................................94
Gear Components .....................................................63 DIFFERENTIAL SIDE GEAR THRUST WASHER ........94
Shift Control Components .........................................64 Available Shims - Differential Side Bearing
DISASSEMBLY..............................................................65 Preload and Adjusting Shim ......................................95
REPAIR FOR COMPONENT PARTS ...........................68 BEARING PRELOAD ...............................................95
Input Shaft and Gears ...............................................68 DIFFERENTIAL SIDE BEARING ADJUSTING
DISASSEMBLY ........................................................68 SHIMS ....................................................................95
INSPECTION ...........................................................69
ASSEMBLY .............................................................70 RS5F50A
Mainshaft and Gears .................................................73
SERVICE DATA AND SPECIFICATIONS (SDS) .........96
DISASSEMBLY ........................................................73
INSPECTION ...........................................................74
General Specifications...............................................96
ASSEMBLY .............................................................75 TRANSAXLE ...........................................................96
FINAL GEAR ...........................................................96
Final Drive..................................................................77
DISASSEMBLY ........................................................77
Gear End Play ...........................................................97
INSPECTION ...........................................................77 Clearance Between Baulk Ring and Gear ................97
ASSEMBLY .............................................................78 3RD, 4TH & 5TH BAULK RING .................................97
Shift Control Components .........................................79 1ST AND 2ND DOUBLE BAULK RING ......................97
INSPECTION ...........................................................79 REVERSE BAULK RING ..........................................97
Case Components .....................................................79 Available Snap Rings ................................................98
REMOVAL AND INSTALLATION ...............................79 1ST & 2ND SYNCHRONIZER HUB (AT
MAINSHAFT) ...........................................................98
ADJUSTMENT ...............................................................81
3RD & 4TH SYNCHRONIZER HUB (AT INPUT
Input Shaft End Play and Differential Side
SHAFT) ...................................................................98
Bearing Preload .........................................................81
5TH MAIN GEAR (AT MAINSHAFT) ..........................98
DIFFERENTIAL SIDE ...............................................81
Available Thrust Washer............................................98
INPUT SHAFT SIDE.................................................82
4TH INPUT GEAR (AT INPUT SHAFT) ......................98
Mainshaft Bearing Preload ........................................82
DIFFERENTIAL SIDE GEAR THRUST WASHER ........98
ASSEMBLY....................................................................84 Available Shims .........................................................99
BEARING PRELOAD AND END PLAY ......................99
RS5F70A TOTAL TURNING TORQUE (NEW BEARING) ............99
MAINSHAFT BEARING ADJUSTING SHIM ................99
SERVICE DATA AND SPECIFICATIONS (SDS) .........88
TABLE FOR SELECTING MAINSHAFT BEARING
General Specifications...............................................88 ADJUSTING SHIM(S) ...............................................99
TRANSAXLE ...........................................................88 INPUT SHAFT BEARING ADJUSTING SHIM ...........100
FINAL GEAR ...........................................................88 TABLE FOR SELECTING INPUT SHAFT BEARING
Gear End Play ...........................................................89 ADJUSTING SHIM(S) .............................................100
Clearance Coupling Sleeve .......................................89 DIFFERENTIAL SIDE BEARING ADJUSTING
1ST, 2ND, 3RD, 4TH, 5TH & REVERSE SHIM ....................................................................100
COUPLING SLEEVE ................................................89 TABLE FOR SELECTING DIFFERENTIAL SIDE
Clearance Between Baulk Ring and Gear ................89 BEARING ADJUSTING SHIM(S) .............................101
MT-2
PREPARATION RS5F70A
Special Service Tools
Special Service Tools NLMT0032
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-3
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-4
PREPARATION RS5F70A
Commercial Service Tools
Commercial Service Tools NLMT0033
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-5
PREPARATION RS5F50A
Special Service Tools
Special Service Tools NLMT0001
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-6
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-7
PREPARATION RS5F50A
Commercial Service Tools
Commercial Service Tools NLMT0002
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-8
Symptoms
Reference page
(Possible cause)
SUSPECTED PARTS
Noise
Oil leakage
MANUAL TRANSAXLE
Jumps out of gear
Hard to shift or will not shift
MT-10 (RS5F70A),
1
(Oil level is low.)
MT-11 (RS5F50A)
MT-10 (RS5F70A),
1
3
2
(Wrong oil)
tion. If necessary, repair or replace these parts.
MT-11 (RS5F50A)
MT-10 (RS5F70A),
1
1
(Oil level is high.)
MT-11 (RS5F50A)
MT-9
2
GASKET (Damaged) MT-62
2
OIL SEAL (Worn or damaged) MT-62
2
O-RING (Worn or damaged) MT-62
1
2
SHIFT CONTROL ROD (Worn) MT-23
2
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged) MT-64
NVH Troubleshooting Chart
3
SHIFT FORK (Worn) MT-64
3
3
GEAR (Worn or damaged) MT-63
3
BEARING (Worn or damaged) MT-63
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
3
BAULK RING (Worn or damaged) MT-63
3
INSERT SPRING (Damaged) MT-63
NLMT0003S0101
NLMT0003S01
NLMT0003
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 RS5F70A
Changing M/T Oil
Changing M/T Oil NLMT0086
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 RS5F70A 3.0 ! (5-1/4 Imp pt)
Oil level (Reference data):
RS5F70A 75.5 - 80.5 mm (2.972 - 3.196 in)
Drain plug:
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