2003 NISSAN ALMERA N16 Front

Special Service ToolsNJFE0029
Tool number
Tool nameDescription
KV10114400
Heated oxygen sensor
wrench
NT636
Loosening or tightening front and rear
heated oxygen sensors
a: 22 mm (0.87 in)
KV999G0010
Fuel tank lock ring
socket
NT057
Removing and installing fuel tank lock
ring
Commercial Service ToolsNJFE0030
Tool number
Tool nameDescription
Oxygen sensor thread
cleaner
AEM488
Reconditioning the exhaust system threads
before installing a new oxygen sensor (Use
with anti-seize lubricant shown below.)
a: 18 mm dia. with pitch 1.5 mm for zir-
conia oxygen sensor
b: 12 mm dia. with pitch 1.25 mm for
titania oxygen sensor
Anti-seize lubricant
(Permatex 133AR or
equivalent meeting MIL
specification MIL-A-
907)
AEM489
Lubricating oxygen sensor thread cleaning
tool when reconditioning exhaust system
threads
PREPARATIONQG
Special Service Tools
FE-2

DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>9
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>1
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>2
Final Drive<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[.............43
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>3
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>4
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>4
Shift Control Components .........................................46
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>6
Case Components .....................................................46
DISASSEMBLY AND ASSEMBLY..............................46
ADJUSTMENT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[49
Differential Side Bearing Preload ..............................49
Mainshaft Bearing Preload ........................................50
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.....51
RS5F70A
OVERHAUL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....54
Case Components .....................................................54
Gear Components .....................................................55
Shift Control Components .........................................56
Final Drive Components ............................................57
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011001100110011>58
Transaxle Case ..........................................................58
Clutch Housing ..........................................................60
REPAIR FOR COMPONENT PARTS...........................64
Input Shaft and Gears ...............................................64
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>4
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>5
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>6
Mainshaft and Gears .................................................69
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>9
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>0
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>2
Final Drive<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[.............77
PRE-INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11>7
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>8
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>9
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>9
Shift Control Components .........................................81
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>1
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.....82
Clutch Housing ..........................................................82
Transaxle Case ..........................................................86
RS5F50A
OVERHAUL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....92
Case Components .....................................................92
Gear Components .....................................................93
Shift Control Components .........................................94
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011001100110011>95
REPAIR FOR COMPONENT PARTS...........................98Input Shaft and Gears ...............................................98
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>8
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>9
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>0
Mainshaft and Gears ...............................................103
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>3
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>4
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>5
Final Drive<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[...........107
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011>7
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>7
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>8
Shift Control Components .......................................109
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>9
Case Components ...................................................109
REMOVAL AND INSTALLATION.............................109
ADJUSTMENT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011[ 111
Input Shaft End Play and Differential Side
Bearing Preload ....................................................... 111
DIFFERENTIAL SIDE............................................. 111
INPUT SHAFT SIDE............................................... 112
Mainshaft Bearing Preload ...................................... 112
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[... 114
RS5F30A
SERVICE DATA AND SPECIFICATIONS (SDS)....... 118
General Specifications ............................................. 118
TRANSAXLE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011[ 118
FINAL GEAR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011[ 118
Gear End Play <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..... 119
Clearance Between Baulk Ring and Gear .............. 119
1ST, 2ND, 3RD, 4TH & 5TH BAULK RING............... 119
Available Check Plugs .............................................119
REVERSE CHECK PLUGS..................................... 119
Available Snap Rings ..............................................119
INPUT SHAFT FRONT BEARING........................... 119
INPUT SHAFT 5TH SYNCHRONIZER HUB.............120
INPUT SHAFT REAR BEARING..............................120
Available C-rings......................................................120
MAINSHAFT C-RING.............................................120
Available Washers ...................................................120
DIFFERENTIAL SIDE GEAR THRUST WASHER......120
Available Shims - Mainshaft and Differential Side
Bearing Preload and Adjusting Shim.......................121
BEARING PRELOAD (REUSED BEARING).............121
TURNING TORQUE (NEW BEARING).....................121
MAINSHAFT REAR BEARING ADJUSTING SHIMS..121
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIMS
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...122
RS5F70A
SERVICE DATA AND SPECIFICATIONS (SDS).......123
General Specifications .............................................123
CONTENTS(Cont’d)
MT-2

Special Service ToolsNJMT0030
Tool number
Tool nameDescription
KV38105900
Preload adapter
NT087
Measuring turning torque of final drive assembly
Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
(Use with KV38106000.)
KV38106000
Height gauge adapter
(differential side bear-
ing)
NT418
Selecting differential side bearing adjusting shim
(Use with KV38105900.)
a:140mm(5.51in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d:M8x1.25P
KV32101000
Pin punch
NT410
Removing and installing retaining pin
a: 4 mm (0.16 in) dia.
ST22730000
Puller
NT411
Removing mainshaft front and rear bearing inner
race
Removing 5th main gear
a: 82 mm (3.23 in) dia.
b: 30 mm (1.18 in) dia.
ST30031000
Puller
NT411
Removing differential side bearing inner race
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
Puller
NT411
Removing 5th synchronizer
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
ST33290001
Puller
NT414
Removing differential oil seal
Removing mainshaft front bearing outer race
Removing differential side bearing outer race
a:250mm(9.84in)
b: 160 mm (6.30 in)
PREPARATIONRS5F30A
Special Service Tools
MT-4

Tool number
Tool nameDescription
ST33400001
Drift
NT086
Installing differential oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
KV38102100
Drift
NT427
Installing input shaft rear bearing
a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
ST33200000
Drift
NT091
Installing mainshaft front bearing outer race
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ST22350000
Drift
NT065
Installing input shaft front bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
ST22452000
Drift
NT065
Installing 1st & 2nd synchronizer
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
ST37750000
Drift
NT065
Installing 5th main gear
Installing 3rd & 4th synchronizer
Installing input shaft oil seal
Installing 5th synchronizer
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
ST22360002
Drift
NT065
Installing mainshaft rear bearing inner race
a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.
ST30621000
Drift
NT073
Installing differential side bearing outer race
(Use with ST30611000.)
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATIONRS5F30A
Special Service Tools (Cont’d)
MT-5

Tool number
Tool nameDescription
ST30611000
Drift handle
NT419
Installing differential side bearing outer race
(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
Commercial Service ToolsNJMT0031
Tool name Description
Puller
NT077
Removing input shaft front bearing
Drift
NT065
Installing mainshaft front bearing inner race
a: 26 mm (1.02 in) dia.
b: 21 mm (0.83 in) dia.
Drift
NT065
Installing differential side bearing inner race
a: 56 mm (2.20 in) dia.
b: 50.5 mm (1.988 in) dia.
Drift
NT065
Installing striking rod oil seal
a: 38 mm (1.50 in) dia.
b: 32 mm (1.26 in) dia.
PREPARATIONRS5F30A
Special Service Tools (Cont’d)
MT-6

Special Service ToolsNJMT0032
Tool number
Tool nameDescription
KV38107700
Preload adapter
NT087
Measuring turning torque of final drive assembly
Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
(Use with KV38106000.)
KV38106000
Height gauge adapter
(differential side bearing)
NT418
Selecting differential side bearing adjusting shim
(Use with KV38107700.)
a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8 x 1.25P
KV32101000
Pin punch
NT410
Removing and installing retaining pin
Removing and installing lock pin
Removing selector shaft
Removing welch plug
a: 4 mm (0.16 in) dia.
KV31100300
Pin punch
NT410
Removing and installing retaining pin
a: 4.5 mm (0.177 in) dia.
ST30031000
Puller
NT411
Removing 3rd, 5th input gear
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
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
Puller
NT411
Removing input shaft front and rear bearing
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
a:110mm(4.33in)dia.
b: 68 mm (2.68 in) dia.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATIONRS5F70A
Special Service Tools
MT-7

Tool number
Tool nameDescription
ST33290001
Puller
NT414
Removing idler gear bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
ST33230000
Drift
NT084
Removing differential oil seal
Installing differential side bearing
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
ST30720000
Drift
NT115
Installing differential side bearing outer race
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST22350000
Drift
NT065
Installing input shaft front and rear bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
ST22452000
Drift
NT065
Installing 3rd and 4th main gear
Installing 5th gear bush
Installing 5th & Rev synchronizer hub
Installing Rev gear bush
Installing mainshaft rear bearing
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
ST37750000
Drift
NT065
Installing input shaft oil seal
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
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
Commercial Service ToolsNJMT0033
Tool name Description
Drift
NT065
Installing welch plug
a: 12 mm (0.47 in) dia.
b: 10 mm (0.39 in) dia.
PREPARATIONRS5F70A
Special Service Tools (Cont’d)
MT-8

Tool name Description
Drift
NT065
Removing input shaft rear bearing
Removing mainshaft rear bearing
a: 22 mm (0.87 in) dia.
b: 16 mm (0.63 in) dia.
Drift
NT065
Installing differential oil seal
a: 58 mm (2.28 in) dia.
b: 50 mm (1.97 in) dia.
Drift
NT065
Installing differential oil seal
a: 54 mm (2.13 in) dia.
b: 50 mm (1.97 in) dia.
Drift
NT065
Installing 2nd gear bush
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
Drift
NT065
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.
Drift
NT065
Installing input shaft oil seal
Installing 5th input gear
a: 39 mm (1.54 in) dia.
b: 30 mm (1.18 in) dia.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATIONRS5F70A
Commercial Service Tools (Cont’d)
MT-9