1987 NISSAN PULSAR lock

Clutch 125
(3) Remove the nuts retaining the outer cable
flange to the vehicle bulkhead.
(4) Working inside the ve hicle, disconnect the
inner cable from the top of the clutch pedal. (5) Pull the clutch cable through the bulkhead
into the engine compartment. (6) Release the clip retaining the centre of the
clutch cable and remove the cable from the vehicle. (7) Check the inner cable for fraying, wear and
damage. Check the outer cable for kinks, wear and
damage. If necessary, renew the cable assembly. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Lubricate the inner cable ends with lithium
base molybdenum disulphide grease prior to installa-
tion. (2) Tighten the nuts retaining the outer cable
flange to a torque of 11 Nm. (3) Check and if necessary , adjust the clutch
pedal height and free play as described under the
heading Clutch Adjustments.
6. CLUTCH ADJUSTMENTS
TO ADJUST PEDAL HEIGHT (1) Fold back the floor carpet and the sound
insulation from the drivers side floor panel.
(2) Measure the distance at right angles from the
floor panel to the centre of the pedal pad. (3) If the pedal height is not as specified, adjust
the pedal stop bolt until the correct pedal height is
obtained.

TO ADJUST PEDAL AND RELEASE LEVER
FREE PLAY
(1) Loosen the inner cable locknut at the release
lever clevis. (2) Push the release lever until resistance is felt
when the release bearing contacts the pressure plate
fingers and hold the release lever in this position.
(3) Tighten the inner cable adjusting nut until
the inner cable is taut.
(4) Loosen the adjusting nut 2.5-3.5 turns and
tighten the inner cable locknut. (5) Measure the release lever free play. If the free
play is not as specified, loosen the locknut and turn
the adjusting nut until the correct free play is
obtained.

View of the clutch release lever free play adjusting
nut.
(6) Lightly depress the clutch pedal until resis-
tance is felt when the release bearing contacts the
pressure plate fingers. Measure the distance from the
centre of the pedal pad in this position to the centre
of the pedal pad when the pedal is contacting the stop
bolt. If necessary, check and adjust the release lever
free play which should bring the pedal free play within
Specifications.

Measuring the clutch pedal height with the carpet
removed.

130 Manual Transaxle and Drive Shafts


Internal view of the transaxle showing the installed positions of the shift forks and control bracket.
the clutch housing. Refer to the Clutch section for the
correct procedure.

(2) Thoroughly clean the outsi de of the transaxle
assembly using solvent and compressed air. (3) Remove the bolts retaining the transaxle case
to the clutch housing and using a soft faced hammer,
tap the transaxle case to separate the mating surfaces.
(4) Carefully lift the transaxle case from the
clutch housing. Tilt the cas e to provide clearance for
the fifth gear shift fork. (5) Withdraw the spacer from the reverse idler
shaft and withdraw the fork shaft and spring from the
transaxle. (6) Remove the fifth and third/fourth shift forks
taking care not to lose the shift cap. (7) Remove the retaining bolts and remove the
control bracket and the first/second shift fork taking
care not to lose the shift cap. (8) Lift the mainshaft out of the clutch housing.
NOTE: When lifting, do not tilt the main-
shaft as the resin oil channel behind the
front mainshaft bearing could be damaged.

(9) Lift the differential assembly out of the
clutch housing.

NOTE: For information on the overhaul of

Dismantled view of the striking rod components.
the differential assembly refer to the Differ-
ential and Final Drive Assembly heading.

(10) Remove the retaining bolts from the input
shaft front bearing retainer. (11) Position the transaxle assembly on its side
and tap the input shaft out of the clutch housing using
a soft faced hammer. Remove the input shaft, bearing
retainer and reverse idler gear from the clutch hous-
ing.
(12) Remove the shift check ball, plug and spring
from the passage adjacent to the upper control
bracket retaining bolt on the clutch housing.
(13) Position the striking lever so that the retain-
ing pin will not contact the clutch housing and remove
the pin using a suitable punch.
(14) Remove the striking rod, striking lever and
striking interlock from the clutch housing.
(15) Remove the reverse check plug, spring and
balls from the clutch housing noting the installed
position of the small check ball.
(16) Remove the screws retaining the reverse and
fifth gear check assembly and remove the assembly
from the clutch housing.
(17) Remove and discard the input shaft and
striking rod oil seals from the clutch housing noting
the installed direction of the seals.
(18) Renew the rear input shaft bearing as fol-
lows:
(a) Remove the plastic oil channel from the
transaxle case.

(b) Using a suitable punch through the hole
adjacent to the r ear input shaft bearing, tap the small
welch plug out of the transaxle case.
(c) Using a suitable punch through the small
welch plug opening, tap the rear input shaft bearing
out of the transaxle case. (d) Using a suitable mandrel, tap the new rear
input shaft bearing into the transaxle case.
NOTE: It may be necessary to use a hydrau-
lic press if the bearing is a tight fit in the
housing.

(e) Apply sealer to a new welch plug and tap the
plug squarely into the transaxle case until the edge of
the plug is level with the case.
Dismantled view of the shift fork components.

132 Manual Transaxle and Drive Shafts


Check the mainshaft for pitting.
(6) Inspect the striking rod, lever and interlock
for wear and damage paying particular attention to
the detent grooves in the end of the striking rod.
Renew parts as necessary. (7) Inspect the shift check and reverse check
balls and springs for wear, cracks and loss of tension
in the springs. Renew parts as necessary.

Check clearance A between the synchro ring and the
gear synchro teeth and compare with Specifications.

(8) Inspect the reverse and fifth gear check
assembly for wear, damage and loss of spring tension.
Renew the assembly as necessary. (9) Inspect all the bearings for pitting, wear and
damage. Renew the bearings as necessary.
NOTE: If the transaxle has seen consider-
able service, it is advisable to renew all the
bearings, oil seals, O rings and snap rings
during the overhaul.

(10) Inspect the various synchro components for
wear and damage paying par ticular attention to the
shift plates and springs and the internal teeth of the
synchro sleeves. Renew parts as necessary. (11) Compare the various gear end floats mea- sured during dismantling with the Specifications and
if the end floats are excessive, check the contact
surfaces of the ge
ars, shaft and synchro hubs. Renew
worn parts as necessary.

TO ASSEMBLE
(1) Lubricate all the components with the spec-
ified gear oil prior to assembly. (2) Install new input shaft and striking rod
oil
seals to the clutch housing in the direction noted on
removal. Lubricate the oil seal lips with multipurpose
grease prior to installation. (3) Assemble the components of the fifth gear
synchro assembly aligning the marks made on dis-
mantling. Ensure that the ends of the shift plate
springs are not aligned.
(4) Install the split bearing to the rear of the
input shaft and install the fifth gear.
(5) Install the fifth gear sy nchro assembly and the
shift retainer to the rear of the input shaft. Ensure that
the slots in the synchro ring are aligned with the shift
plates.

Check the friction surfaces of the input shaft for pitting. Dismantled view of the fifth gear synchro assembly.
Illustration showing the correct positioning of the shift plates and springs.

134 Manual Transaxle and Drive Shafts
(32) Install and tighten the retaining bolts to
the specified torque.
(33) Repeat operation (29). The total turning
torque should be 5.9-13.7 Nm if new bearings have
been installed or slightly l ess if the original bearings
have been installed. If the turning torque is no t as specified, adjust the
mainshaft turning torque as follows:

(a) Remove the transaxle case rear cover, O ring,
spacer and adjusting shim from the transaxle case.
(b) Ensure that the mainsh aft rear bearing outer
race is fully seated on the bearing cone. (c) Using micrometer depth gauge, measure the
distance from the transaxle case to the bearing outer
race and note the reading. (d) Referring to the following table, select the
appropriate shim, according to the reading noted in
operation (c), required to correct the mainshaft turn-
ing torque.
READING SHIM

2.35-2.40 mm............................................... 0.10 mm
2.40-2.45 mm............................................... 0.15 mm
2.45-2.50 mm...............................................0.20 mm
2.50-2.55 mm...............................................0.25 mm
2.55-2.60 mm...............................................0.30 mm
2.60-2.65 mm............................................... 0.35 mm
2.65-2.70 mm............................................... 0.40 mm
2.70-2.75 mm............................................... 0.45 mm
2.75-2.80 mm............................................... 0.50 mm
2.80-2.85 mm............................................... 0.55 mm
2.85-2.90 mm............................................... 0.60 mm
2.90-2.95 mm............................................... 0.65 mm
2.95-3.00 mm............................................... 0.70 mm
3.00-3.05 mm............................................... 0.75 mm
3.05-3.10 mm............................................... 0.80 mm
3.10-3.15 mm............................................... 0.85 mm
3.15-3.20 mm............................................... 0.90 mm
3.20-3.25 mm............................................... 0.95 mm
3.25-3.30 mm...............................................1.00 mm.
(e) Install the spacer, shim, O ring and rear
cover to the transaxle case. Tighten the retaining
bolts securely.

(34) Measure the total turning torque as previ-
ously described. (35) Install the striking interlock and striking lever
to the clutch housing. (36) Install the striking ro d to the clutch housing
sliding the rod through the lever and interlock. Take
care that the end of the rod does not damage the seal. (37) Install a new retaining pin to the striking rod
using a pin punch. (38) Install the reverse and fifth gear check
assembly to the clutch housing. Tighten the retaining
screws securely. (39) Install the balls, spring and reverse check
plug to the clutch housing ensuring that the smaller
diameter ball enters the hole in the body of the
reverse and fifth gear check assembly body. Apply locking com-
pound and tighten the reverse check plug securely.

(40) Using a bar clamped to the end of the
striking rod, check that a force of 4.9-7.4 Nm is
required to overcome the spring loading of the reverse
and fifth gear check assembly. If necessary, renew the
springs to achieve this correct spring loading.

NOTE: Ensure that the reverse check plug is
coated with locking compound when finally
installed.

(41) Install the shift check ball, spring and plug to
the clutch housing. Ensure that the ball is centrally
located in the plug.
(42) If removed, install the oil reservoir to the
clutch housing.
(43) Install the input shaft assembly and the
reverse idler gear to the clutch housing taking care not
to damage the seal.
(44) Apply locking compound to the bearing
retainer bolts and tighten the bolts to the specified
torque.
(45) Install the spacer to the reverse idler shaft.
(46) Install the differential assembly to the clutch
housing.
(47) Install the mainshaft to the clutch housing
ensuring that the resin oil ch annel is located centrally
in the end of the mainshaft. (48) Install the shift cap to the slot in the first/
second shift fork and install the shift fork and control
bracket to the clutch housing. Use grease to hold the
shift cap in the shift fork slot. Ensure that the reverse
idler shift fork is correctly located over the gear.
(49) Apply locking compound to the threads of
the control bracket retaining bolts and tighten the
bolts to the specified torque. (50) Install the shift cap in the slot in the third/
fourth shift fork and install the fork to the transaxle
assembly. Use grease to hold the shift cap in the shift
fork slot. (51) Install the fifth gear shift fork to the transaxle
ensuring that the shift fork slot engages the control
finger.
(52) Install the fork shaft an d spring to the clutch
housing sliding the shaft through the shift forks. Use
grease to hold the spring in the end of the shaft. (53) Apply a continuous bead of sealant to the
mating face of the clutch housing so that the bead is
located inside the row of bolt holes.
NOTE: Sealant is available from Nissan
spare parts using the part number KP
610-00250.

(54) Install the transaxle case to the clutch hous-
ing. Install and tighten the retaining bolts to the
specified torque. (55) Select each gear in turn and check that the
transaxle turns freely in each gear. Ensure that it is not

136 Manual Transaxle and Drive Shafts
right hand side gear and the adjacent spacer in an area
where there is no oil groove in the differential case.
(d) Insert another 0.03 mm feeler gauge diago-
nally opposite the first feeler gauge to avoid tilting the
side gear.

(e) Insert a splined adaptor into the right hand
side gear and attempt to rotate the gear by hand.
(f) If the gear cannot be rotated, change the
thickness of the left hand side gear spacer, repeating
the test until the gear can be rotated.
NOTE: Spacers are available in thicknesses
from 0.8 mm to 1.5 mm in increments of
0.1 mm.

(g) Remove the 0.03 mm feel er gauges and insert
0.09 mm feeler gauges to the same position. The gear
should lock.

(h) The spacer selection is correct when the right
hand side gear can be rotated with 0.03 mm feeler
gauges inserted but locks when 0.09 mm feeler gauges
are inserted.

(18) Install the ring gear to the differential case
with the chamfered edge of the ring gear inwards. (19) Install and tighten the retaining bolts in
a
diagonal sequence to the specified torque.
(20) Install a new speedometer drive gear to
the
differential case. Install the stopper adjacent to the
drive gear.
(21) Install the differentia] carrier bearing
cones
and roller assemblies to the differential case.
(22) Remove the adjusting shim from behind the
carrier bearing outer race in the transaxle case and
replace the outer race in the transaxle case.
(23) Install the differential assembly to the clutch
housing. (24) Install the transaxle case to the clutch housing
and tighten the retaining bolts to the specified torque.
(25) Mount a dial gauge to the clutch housing so
that the contact point is resting on the differential
case. (26) Insert a bar through the opposite side gear
and, contacting the pinion shaft, raise and lower the
differential case and measure the end float in the
carrier bearings. (27) Using the following table, select a shim to
correspond to the relevant end float.
END FLOAT SHIM THICKNESS

0.30-0.34 mm....................................................0.64 mm
0.34-0.38 mm................................................... 0.68 mm
0.38-0.42 mm................................................... 0.72 mm
0.42-0.46 mm................................................... 0.76 mm
0.46-0.50 mm................................................... 0.80 mm
0.50-0.54 mm................................................... 0.84 mm
0.54-0.58 mm................................................... 0.88 mm
0.58-0.62 mm................................................... 0.92 mm
0.62-0.66 mm................................................... 0.96 mm
0.66-0.70 mm................................................... 1.00 mm
0.70-0.74 mm................................................... 1.04 mm
0.74-0.78 mm ................................................... 1.08 mm
0.78-0.82 mm ................................................... 1.12 mm
0.82-0.86 mm ................................................... 1.16 mm
0.86-0.90 mm ................................................... 1.20 mm
0.90-0.94 mm ................................................... 1.24 mm
0.94-0.98 mm ................................................... 1.28 mm
0.98-1.02 mm ................................................... 1.32 mm
1.02-1.06 mm ................................................... 1.36 mm
1.06-1.10 mm ................................................... 1.40 mm
1.10-1.14 mm ................................................... 1.44 mm
1.14-1.18 mm ................................................... 1.48 mm
1.18-1.22 mm ................................................... 1.52 mm
1.22-1.26 mm ................................................... 1.56 mm
1.26-1.30 mm ................................................... 1.60 mm
1.30-1.34 mm ................................................... 1.64 mm
1.34-1.38 mm ................................................... 1.68 mm
1.38-1.42 mm ................................................... 1.72 mm
1.42-1.46 mm ................................................... 1.76 mm
The thickest shim available is 0.88 mm. Multiple
shims are required above this thickness.

(28) Install the shim behind the carrier
bearing
outer race in the transaxle case and assemble the unit
once more. (29) Using a suitable slotted adaptor engage the
pinion shaft and using a to rque gauge, measure the
differential turning torque. The turning torque when new carrier bearings
have been installed should be 3.9-7.8 Nm or slightly
lower if the original carrier bearings have been
replaced.

(30) Assemble the transaxle and measure the total
turning torque of the diff erential assembly and the
mainshaft. The total turning torque should be 5.9 to
13.7 Nm with new bearings or slightly lower if the
original bearings have been replaced.

5. GEAR LEVER ASSEMBLY
TO DISMANTLE AND ASSEMBLE
(1) Remove the gear lever knob and remove the
centre console as described in the Body section. If not
previously removed, remove the rubber boot sur-
rounding the gear lever. (2) Raise the front of the vehicle and support it
on chassis stands. Remove the catalytic converter and
heat shield as described in the Engine section.
(3) Remove the bolt and disconnect the control
rod from the bottom of the gear lever, noting the
position of the return spring and bracket.
(4) Remove the nuts retaining the gear lever
socket to the support rod. (5) Working inside the vehicle, lift the gear lever
out of the floor bracket. (6) Separate the lower rubber boot, socket,
spring seat, spring, upper ball seat and lower ball seat
from the gear lever, noting the location of each
component to aid assembly.

Manual Transaxle and Drive Shafts 139

SNAP RING
Assembled view of the inner C.V. joint.
(10) Slide the large end of the inner C.V. joint
boot over the inner C.V. joint housing and locate the
boot in the groove in the housing.
(11) Pull the C.V. joint until the boot is the
normal length. Deformation of the boot could occur if
this operation is neglected. (12) With no vacuum or pressure present in the
C.V. joint boot, install the two C.V. joint boot
retaining clips.

Install the C.V. joint retain ing ring into the C.V. joint
housing. Ensure that the retaining ring is correctly
seated.
NOTE: Ensure that the retaining dips are
securely installed preven ting the entry of
damaging dust or water and that the lock
tabs on the retaining clips are correctly bent
over.

(13) Install the remaining snap ring onto the inner
C.V. joint housing shaft and install the drive shaft to
the vehicle as previously described.

140
AUTOMATIC TRANSAXLE
SPECIFICATIONS
Make .............................................. JATCO RL3F01A
Type .....................3 speed and reverse epicyclic gear
train with lock up torque converter
Operation .................................... Automatic hydraulic
Lubricant:
Type....................................................... Dexron IT
Capacity................................................. 6.3 liters
TORQUE WRENCH SETTINGS
Drive plate to crankshaft bolls ........................60 Nm
Drive plate to torque converter bolts ..............49 Nm
Convener housing to engine ...........................22 Nm
Converter housing to transaxle ........................23 Nm
Transaxle sump to transaxle ............................. 7 Nm
Oil cooler pipe to transaxle .............................49 Nm
Selector shaft locknut .......................................42 Nm
Transaxle filter bolts.........................................12 Nm
1. AUTOMATIC TRANSAXLE TROUBLE SHOOTING
NO DRIVE IN D RANGE
{1) Low fluid level in transaxle: Check the fluid
level in the transaxle and top up if required.

(2) Incorrectly adjusted selector cable: Check
and adjust the selector cable as detailed. (3) Incorrect or contaminated transaxle fluid:
Drain and refill with the recommend type and quan-
tity of transaxle fluid.
NOTE: Check the possible causes in the
order given.

NO REVERSE IN R RANGE
(1) Low fluid level in transaxle: Check the fluid
level and top up if required. (2) Incorrectly adjusted selector linkage: Check
the condition of the selector cable, selector quadrant
and selector arm for wear and damage. Adjust as
required.

Check the drive shaft oil seals as a likely leak source.
SLIPPING OR ROUGH UPSHIFT
(1) Incorrectly adjusted selector linkage: Check
and adjust the selector linkage. (2) Low fluid level in transaxle: Check the fluid
level and top up if required.
NO TRANSAXLE KICKDOWN
(1) Incorrectly adjusted throttle cable: Check
and adjust the cable as detailed in the Fuel and Engine
Management section.
Check the oil cooler hose connections for leaks if the
fluid level is low.

142 Automatic Transaxle
(8) Install the dipstick and start the engine and
recheck the fluid level.

NOTE; Do not overfill the transaxle or
foaming and unsatisfactory operation of the
transaxle will result.

TO DRAIN AND REFILL
This is not a normal maintenance and lubrication
procedure. It is only necessary to drain the complete
system, including the torq ue converter and the oil
cooler, when the transaxle assembly is removed for
overhaul or the renewal of transaxle components such
as bearings, clutches or as semblies. When this condi-
tion arises, the torque converter and the cooler should
be cleaned and flushed to remove any dirt or sludge.

After transaxle overhaul, install approximately 6
liters of new transaxle fluid, and top up as previously
described.

4. BRAKE BAND
Band adjustment is not a normal maintenance
procedure.

The adjustment entails removal of the valve body
and for this reason the vehicle should be taken to an
authorized dealer.

5. KICKDOWN CABLE
TO ADJUST
(1) On models with a 1.6 liter engine, remove
the air cleaner assembly. (2) With the aid of an assistant, ensure that the
throttle valve is fully open when the throttle pedal is
fully depressed. (3) Push the clip on the outer kickdown cable
and pull the cable away from the throttle linkage.


View of the kickdown cable adjustment point. 1.6 liter
engine.
(4) Slowly depress the throttle pedal to the full
throttle position.

The outer kickdown cable will automatically ad-
just and emit a clicking noise.

6. TRANSAXLE SELECTOR LINKAGE
TO ADJUST CONTROL CABLE
(1) Place the selector lever in the Park position.
(2) Loosen the control cable locknuts and ensure
that the transaxle selector lever is in the Park position.

View of the transaxle selector linkage control cable
adjustment.
(3) Hold the selector rod horizontal and adjust
the outer locknut until it touches the selector rod.

(4) Tighten the inner locknut securely.
7. NEUTRAL SAFETY SWITCH
The neutral safety switch, incorporating the re-
verse lamp switch is located on the transaxle case

View of the kickdown cable adjustment point. The
arrow indicates the direction in which the outer kick-
down cable must be pulled to initiate the automatic adjustment. 1.8 liter engine.