2002 NISSAN TERRANO Service Repair Manual

7. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.
a. Mount adapter plate on vise and apply multi-purpose grease to
counter gear rear bearing.
b. Install mainshaft a little on mainshaft front bearing.
To allow for installation of counter gear, do not install main-
shaft completely.
c. Install counter gear on counter gear rear bearing and install
main drive gear, pilot bearing and spacer on mainshaft.
When installing counter gear into counter gear rear bearing,
push up on upper roller of counter gear rear bearing with
screwdriver.
d. Install mainshaft and counter gear completely by tapping rear
side of adapter plate and pulling mainshaft.
SMT436A
SMT440A
SMT441A
SMT442A
SMT443A
ASSEMBLY
Gear Components (Cont'd)
MT-28

8. Install rear side components on mainshaft and counter gear.
a. Install OD gear bushing while pushing on the front of counter
gear.
b. Install OD main gear.
Pay attention to direction of OD main gear. (B is wider than A
as shown at left.)
c. Install adapter plate with gear assembly onto transmission
case.
d. Install OD gear needle bearing and then install OD counter gear
and reverse idler shaft.
e. Install reverse cone.
f. Install insert springs and reverse baulk ring on OD coupling
sleeve. Then install them and OD baulk ring on OD counter
gear.
Pay attention to direction of OD coupling sleeve.
SMT444A
SMT580A
SMT582A
SMT571A
SMT583A
ASSEMBLY
Gear Components (Cont'd)
MT-29

g. Install reverse counter gear.
h. Install reverse gear needle bearing and then install reverse
main gear, reverse idler gear and reverse idler thrust washers.
i. Install reverse hub.
Pay attention to its direction.
j. Install counter rear gear end bearing.
k. Separate adapter plate from transmission case and mount
adapter plate on vice again.
l. Select proper mainshaft C-ring to minimize clearance of
groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Mainshaft C-ring
Thickness
mm (in)Part numberThickness
mm (in)Part number
2.63 (0.1035) 32348-01G15 3.19 (0.1256) 32348-01G07
2.70 (0.1063) 32348-01G00 3.26 (0.1283) 32348-01G08
2.77 (0.1091) 32348-01G01 3.33 (0.1311) 32348-01G09
2.84 (0.1118) 32348-01G02 3.40 (0.1339) 32348-01G10
2.91 (0.1146) 32348-01G03 3.47 (0.1366) 32348-01G11
2.98 (0.1173) 32348-01G04 3.54 (0.1394) 32348-01G12
3.05 (0.1201) 32348-01G05 3.61 (0.1421) 32348-01G13
3.12 (0.1228) 32348-01G06 3.68 (0.1449) 32348-01G14
m. Install selected C-ring, C-ring holder and mainshaft rear snap
ring.
SMT584A
SMT585A
SMT587A
SMT452A
SMT454A
ASSEMBLY
Gear Components (Cont'd)
MT-30

n. Install spacer and then select proper counter gear rear snap
ring to minimize clearance of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Counter gear rear snap ring
Thickness mm (in) Part number
1.26 (0.0496) 32236-01G08
1.32 (0.0520) 32236-01G00
1.38 (0.0543) 32236-01G01
1.44 (0.0567) 32236-01G02
1.50 (0.0591) 32236-01G03
1.56 (0.0614) 32236-01G04
1.62 (0.0638) 32236-01G05
1.68 (0.0661) 32236-01G06
1.74 (0.0685) 32236-01G07
o. Install selected counter gear rear snap ring.
p. Install reverse coupling sleeve.
Pay attention to its direction.
q. Measure each gear end play as a final check. Ð Refer to
``DISASSEMBLY'', MT-14.
Shift Control Components
1. Install OD fork rod and OD shift fork. Then install retaining pin
into OD shift fork.
2. Install 1st & 2nd, 3rd & 4th and reverse shift fork onto coupling
sleeve.
3. Install striking rod into hole of shift forks, striking lever and
interlock and then install retaining pin into striking lever.
Make sure that striking rod moves smoothly.
SMT453A
SMT455A
SMT456A
SMT457A
SMT374A
ASSEMBLY
Gear Components (Cont'd)
MT-31

Case Components
1. Install front cover oil seal.
Apply multi-purpose grease to seal lip.
2. Install selected counter gear front bearing shim onto transmis-
sion case.
Apply multi-purpose grease.
3. Apply sealant to mating surface of transmission case.
4. Install gear assembly onto transmission case.
5. Install check spring and check ball into interlock stopper.
Apply multi-purpose grease to check ball.
6. Install interlock stopper assembly and then tighten check ball
plug.
Apply sealant to thread of check ball plug.
7. Install stopper ring and main drive bearing snap ring.
8. Install front cover and gasket.
Apply sealant to thread of 3 bolts shown left.
9. Apply sealant to mating surface of adapter plate.
SMT393A
SMT588A
SMT460A
SMT371A
SMT443B
ASSEMBLY
MT-32

10. Install OD gear case together with striking arm.
11. Install retaining pin into striking arm.
12. Install return spring and check ball and then install control hous-
ing.
Apply sealant to mating surface of OD gear case.
13. Tighten control housing bolts.
Bolt head size:
A bolts 12 mm
B bolts 13 mm
SMT444B
SMT439B
SMT445B
SMT446B
ASSEMBLY
Case Components (Cont'd)
MT-33

General Specifications
Engine TD27Ti and ZD30DDTi
Transmission model FS5R30A
No. of speeds 5
Shift pattern
Synchromesh type Warner
Gear ratio
1st 3.580
2nd 2.077
3rd 1.360
4th 1.000
OD 0.811
Reverse 3.631
No. of teeth
Mainshaft
drive
1st 32
2nd 30
3rd 29
4th 22
OD 24
Reverse 30
Countershaft
Drive
1st 13
2nd 21
3rd 31
4th 32
OD 43
Reverse 12
Reverse idler gear 22
Oil capacity(lmp pt) 3.6 (6-3/8)
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-34

Inspection and Adjustment
GEAR END PLAY
Gear End play mm (in)
1st main gear 0.23 - 0.33 (0.0091 - 0.0130)
2nd main gear 0.23 - 0.33 (0.0091 - 0.0130)
3rd main gear 0.23 - 0.33 (0.0091 - 0.0130)
OD counter gear 0.23 - 0.33 (0.0091 - 0.0130)
Reverse main gear 0.33 - 0.43 (0.0130 - 0.0169)
Counter gear 0.10 - 0.25 (0.0039 - 0.0098)
Reverse idler gear 0.30 - 0.53 (0.0118 - 0.0209)
CLEARANCE BETWEEN BAULK RING AND
GEAR
Unit: mm (in)
Standard Wear limit
1st & 2nd1.05 - 1.3
(0.0413 - 0.0512)0.7 (0.028)
3rd & main-
drive1.05 - 1.3
(0.0413 - 0.0512)0.7 (0.028)
OD1.05 - 1.3
(0.0413 - 0.0512)0.7 (0.028)
DISTANCE BETWEEN REAR SURFACE OF
REVERSE CONE AND
REVERSE BAULK RING
Unit: mm (in)
Standard Wear limit
Dimension
ªAºþ0.1 to 0.36
(þ0.0039 to 0.0142)0.7 (0.028)
AVAILABLE SNAP RING
Main drive gear snap ring
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in) Part number
1.89 (0.0744) 32204-01G00
1.98 (0.0780) 32204-01G01
2.05 (0.0807) 32204-01G02
2.12 (0.0835) 32204-01G03
2.19 (0.0862) 32204-01G04
Mainshaft front snap ring
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in) Part number
1.89 (0.0744) 32204-01G00
1.98 (0.0780) 32204-01G01
2.05 (0.0807) 32204-01G02
2.12 (0.0835) 32204-01G03
2.19 (0.0862) 32204-01G04
Counter gear rear snap ring
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
Thickness mm (in) Part number
1.26 (0.0496) 32236-01G08
1.32 (0.0520) 32236-01G00
1.38 (0.0543) 32236-01G01
1.44 (0.0567) 32236-01G02
1.50 (0.0591) 32236-01G03
1.56 (0.0614) 32236-01G04
1.62 (0.0638) 32236-01G05
1.68 (0.0661) 32236-01G06
1.74 (0.0685) 32236-01G07
AVAILABLE C-RING
Mainshaft C-ring
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)
Thickness
mm(in)Part numberThickness
mm (in)Part number
2.63 (0.1035) 32348-01G15 3.19 (0.1256) 32348-01G07
2.70 (0.1063) 32348-01G00 3.26 (0.1283) 32348-01G08
2.77 (0.1091) 32348-01G01 3.33 (0.1311) 32348-01G09
2.84 (0.1118) 32348-01G02 3.40 (0.1339) 32348-01G10
2.91 (0.1146) 32348-01G03 3.47 (0.1366) 32348-01G11
2.98 (0.1173) 32348-01G04 3.54 (0.1394) 32348-01G12
3.05 (0.1201) 32348-01G05 3.61 (0.1421) 32348-01G13
3.12 (0.1228) 32348-01G06 3.68 (0.1449) 32348-01G14
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-35