2002 NISSAN TERRANO Service Repair Manual

1. Remove nut of companion flange.
2. Remove rear case.
Be careful not to damage the mating surface.
3. Remove companion flange.
4. Remove oil cover and oil gutter.
5. Remove snap ring from 2-4 shift rod.
SMT268A
SMT270A
SMT269A
SMT271A
SMT272A
DISASSEMBLY
TF-12

6. Remove bolts securing bearing retainer.
This step is necessary to remove mainshaft from center case.
7. Remove bolts securing center case to front case and then
separate center case and front case.
8. Measure end play of low gear.
Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
If end play is beyond the maximum value, check low gear and
L & H hub for wear.
9. Disassemble center case assembly.
a. Remove snap ring from mainshaft.
b. Pull out low gear with L & H hub.
SMT273A
SMT274A
YMT017
SMT275A
YMT018
DISASSEMBLY
TF-13

c. Remove needle bearing of low gear.
d. Remove mainshaft, front drive and drive chain as a set by tap-
ping front end of mainshaft and front drive shaft alternately.
Be careful not to bend drive chain.
10. Disassemble front case assembly.
a. Remove switches, check plugs, check springs and check balls.
b. Remove outer shift lever.
c. Remove lock pin of inner shift lever and drive out cross shaft
with plug.
SMT758A
SMT279A
NMT011
SMT797A
SMT282A
DISASSEMBLY
TF-14

d. Remove 2-4 shift rod.
e. Remove L & H shift rod and fork assembly with coupling sleeve.
f. Remove needle bearing from main gear.
g. Remove bolts securing front case cover and then remove case.
h. Remove counter gear by tapping lightly.
SMT283A
SMT284A
SMT286A
SMT287A
SMT759A
DISASSEMBLY
TF-15

i. Remove main gear by tapping lightly.
SMT288A
DISASSEMBLY
TF-16

Mainshaft
DISASSEMBLY
1. Check end play of front drive sprocket.
Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
If end play is beyond the maximum value, check front drive
sprocket and clutch gear for wear.
2. Remove retaining ring, speedometer drive gear and steel ball.
Be careful not to lose the steel ball.
3. Remove snap ring and spacer.
4. Press out front drive sprocket with mainshaft rear bearing and
clutch gear together.
5. Remove needle bearing.
6. Remove bearing retainer and then remove snap ring and
spacer.
SMT347A
YMT019
SMT290A
SMT291A
SMT292A
REPAIR FOR COMPONENT PARTS
TF-17

7. Press out mainshaft front bearing from mainshaft.
INSPECTION
Gear and shaft
ICheck gears for excessive wear, chips or cracks.
ICheck shaft for cracks, wear of bending.
ICheck coupling sleeve for wear or damage.
Baulk ring
ICheck baulk ring for cracks or deformation.
IMeasure clearance between baulk ring and gear.
Baulk ring to gear clearance:
Unit: mm (in)
Standard Wear limit
1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020)
Bearing
IMake sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT293A
SMT348A
SMT349A
SMT350A
SMT351A
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont'd)
TF-18

ASSEMBLY
1. Press mainshaft front bearing onto mainshaft.
Pay special attention to its direction.
2. Install spacer.
3. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring
Thickness mm (in) Part number
3.1 (0.122)
3.2 (0.126)
3.3 (0.130)
3.4 (0.134)33138-33G10
33138-33G11
33138-33G12
33138-33G13
4. Regarding further procedures, refer to ªASSEMBLYº above.
Front Drive Shaft
DISASSEMBLY
IFront drive shaft front bearing
IFront drive shaft rear bearing
SMT294A
SMT295A
SMT296A
SMT297A
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont'd)
TF-19