1995 NISSAN ALMERA N15 Service Manual

SEC.328 MAJOR
OVERHAUL
Shift Control Components
I

RSSF32A
I

/

r
~~

CV-~
~

CID~
6~~
~~

~ ~lil6.3-8.3

~ (0.64•0.85,

5 ~
55.6•73.8)

*~- ...12 -16
(1.2 -1.6, 9-12)

~ Cbl
Plug thread

/~
I

I

J


"@lEa!
lil:
N.m(kg-m, in-Ib)
~ :N.m (kg-m, ft-Ib)

~ Cbl :
Apply locking sealant.

* :
Select proper length.
~ :Select proper part.Adjustment isrequired.

SMT695CB
•

CD
Check plunger

@
Select returnspring

@
Stopper pin

@
Striking lever

@
Striking interlock

@
E-ring

(J)
Reverse brakecam

@
Check ballplug

@
Shift check ball

@)
Shift check spring

@
Reverse brakecamspring
@

Fork shaft

@
Fork shaft support spring

@
5thshift fork

@
Shifter cap

@
3rd
&
4th shift fork

@
Shifter cap

@
1st
&
2nd shift fork

@
Control bracket

@J
Interlock pin

@
Retaining pin

@
Striking rod

MT-35
@

Retaining pin

@
Yoke

@
Reverse checkplug

@
Check ball(Large)

@
Check ball(Small)

@
Check sleeve

@
O-ring

@
Reverse checkspring

SMT6648DISASSEMBL
Y

1. Remove casecover.
I

RS5F32A
I

SMT6668
2.
Remove mainshaft bearingsnapring.
3. Remove transmission casewhile slightly tilting
it
to prevent
5th shift forkfrom interfering withcase.

5th shift
fork SMT6678
4.
Draw outreverse idlerspacer andfork shaft.
5. Remove 5thand 3rd
&
4th shift forks.

• Becareful nottolose shifter cap.
MT-36

DISASSEMBlY
I

RS5F32A
I

SMT6708
SMT6718
SMT64BAA
6.
Remove controlbracket with1st
&
2nd shift fork.
7. Remove gearcomponents fromclutch housing.
a. Remove inputshaftfrontbearing retainer securing bolts.
b. Remove inputshaftwithbearing retainer, mainshaft assem-
bly and reverse idlergear.

• Always withdraw mainshaft straightout.Failure todo so
can damage resinoilchannel onclutch housing side.
• Do not draw outreverse idlershaft fromclutch housing
because thesefittings willbeloose.
When removing inputshaft, becareful nottoscratch oilseal
lip with shaft spline.

c. Remove finaldrive assembly.
8. Remove oilpocket, shiftcheck ball,shiftcheck spring and
check ballplug.

MT-37
•

DISASSEMBLV
I

RS5F32A
I

SMT599AA SMT583
9.
Drive retaining pinout ofstriking lever,thenremove strik-
ing rod, striking leverandstriking interlock.

• Select aposition whereretaining pindoes notinterfere with
clutch housing whenremoving retainingpin.
• Becareful nottodamage oilseal lip,when removing strik-
ing rod. Ifnecessary, tapeedges ofstriking rod.

10. Remove reversecheckplug,thendetach reverse check
spring andcheck balls.

• Ifthe smaller balldoes notcome out,remove ittogether
with check sleeve assembly.
Check sleeve
assembly SMT585
11.
Remove checksleeve assembly.

MT-38

REPAIRFORCOMPONENT PARTS
I

RS5F32A
I

•

Input
Shaft andGears
DISASSEMBL Y

1. Before disassembly, check5thinput gearendplay.

Gear endplay:
Refer to50S, MT-64.

• Ifnot within specification, disassembleandcheck contact
surface ofgear, shaftandhub. Check clearance ofsnap ring
groove. Referto"ASSEMBLY", MT-40.
2. Remove snapringand5thstopper.
3. Remove 5thsynchronizer, 5thinput gearand5thgear nee-
dle bearing.
4. Remove snapringofinput shaftfrontbearing andinput gear
spacer.

SMT674B
SMT417CA

Input shaft
front bearing

-
r
5th synchronizer hub

/ ST30021 000

5th
input gear
~ SetTool below
5th input gear.
Spacer
5.Remove inputshaftfrontbearing.
6. Remove bearingretainer.

MT-39

I
RS5F32A
I

Shifting insert
Baulkringto
gear clearance
REPAIR
FORCOMPONENT PARTS
Input Shaft andGears (Cont'd)
INSPECTION
Gear andshaft

• Check shaftforcracks, wearorbending.
• Check gearsforexcessive wear,chipsorcracks.

SMT602A 5thsynchronizer

• Check splineportion ofcoupling sleeves,hubsandgears
for wear orcracks.
• Check baulkringsforcracks ordeformation.
• Check insertsprings forwear ordeformation.

SMT387A
•Measure clearance betweenbaulkringandgear.

Clearance betweenbaulkringandgear:
Standard 0.90 -1.50 mm(0.0354 -0.0591 in)
Wear limit
0.7 mm (0.028 in)
SMT140 Bearing

• Make surebearings rollfreely andarefree from noise,
cracks, pittingorwear.

ASSEMBLY
1. Assemble 5thsynchronizer.

MT-40

SMT761B
REPAIR
FORCOMPONENT PARTS
I
RS5F32A
I

Input Shaft andGears (Cont'd)
• Becareful nottohook frontandrear ends ofspread spring
to the same insert.

•

5. Select andinstall snapringthatgives proper clearance of
input shaftgroove.

Allowable clearance ofgroove:

o -
0.1 mOl (0-0.004 in)
Snap ringsofinput shaftfrontbearing:
Refer toSOS, MT-65.

2.
Install bearing retainer.
3. Press oninput shaft frontbearing.
4. Install inputgearspacer.

• Besure toreplace 5thgear synchronizer hubwith newone
when itis removed.

6. Install 5thgear needle bearing, 5thinput gear, 5thsynchro-
nizer and5thstopper.

• Input shaftmustbevertical topress onsynchronizer hub.

7. Measure gearendplayas afinal check. Referto
"DISASSEMBLY", MT-39.
8. Select andinstall snapringthatgives proper clearance of
input shaft groove.

Allowable clearance ofgroove:

o -
0.1 mm (0-0.004 in)
Snap ringof5th synchronizer:
Refer toSOS, MT-65.
SMT708B
SMT731-A
SMT779AA

Snap
ring
5th synchronizer hub

~
=
Bearing retainer

ST37750000 ~
SMT591MT-41

REPAIRFORCOMPONENT PARTS
I

RS5F32A
I

Snap ring End
play
Mainshaft
andGears
DISASSEMBL Y

1. Before disassembly, measuregearendplay.

Gear endplay:
Refer to50S, MT-64.

• Ifend play isnot within thespecified limit,disassemble and
check theparts.
2. Remove mainshaft rearbearing snapring,Coring holder
and mainshaft C-rings.

C-ring holder

SMT709B

~Snapring

@---
C-ringholder
~~ MalnshaftC-r1ng
Puller-
Mainshaft rear
bearing -
Mainshaft rear
bearing

SMT676BB
3.Remove mainshaft rearbearing andspacer.

./- Suitable
drift

SMT677BA
4.Remove 5thmain gear.

SMT593-A MT-42