2003 NISSAN ALMERA N16 Srs

SMT734A
Input Shaft and Gears
DISASSEMBLYNJMT00421. Before disassembly, check 5th input gear end play.
Gear end play:
Refer to SDS, MT-119.
If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Then check clearance of snap ring
groove. Refer to “ASSEMBLY”, MT-37.
SMT750BA
2. Remove snap ring and rear bearing.
3. Remove snap ring and 5th stopper.
4. Remove 5th synchronizer, 5th input gear and 5th gear needle
bearing.
SMT697C
5. Remove snap ring of input shaft front bearing and input gear
spacer.
SMT601A
6. Pull out input shaft front bearing.
7. Remove bearing retainer.
REPAIR FOR COMPONENT PARTSRS5F30A
Input Shaft and Gears
MT-36

SMT602A
INSPECTIONNJMT0043Input Shaft and GearsNJMT0043S01Check shaft for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.
SMT387A
SynchronizerNJMT0043S02Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
SMT140
Measure clearance between baulk ring and 5th input gear.
Clearance between baulk ring and 5th input gear:
Standard
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)
SMT148A
BearingNJMT0043S03Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT736A
ASSEMBLYNJMT00441. Assemble 5th synchronizer.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
REPAIR FOR COMPONENT PARTSRS5F30A
Input Shaft and Gears (Cont’d)
MT-37

SMT761B
Be careful not to hook front and rear ends of spread
spring to the same insert.
SMT731-A
2. Install bearing retainer.
3. Press on input shaft front bearing.
4. Install spacer.
SMT735A
5. Select and install snap ring that gives the proper clearance of
input shaft groove.
Allowable clearance of groove:
0-0.1mm(0-0.004in)
Snap ring of input shaft front bearing:
Refer to SDS, MT-119.
SMT779AA
6. Install 5th gear needle bearing, 5th input gear, 5th synchro-
nizer and 5th stopper.
7. Measure gear end play as the final check. Refer to
“DISASSEMBLY”, MT-36.
SMT591
8. Select and install snap ring that gives the proper clearance of
input shaft groove.
Allowable clearance of groove:
0-0.1mm(0-0.004in)
Snap ring of input shaft 5th synchronizer hub:
Refer to SDS, MT-120.
REPAIR FOR COMPONENT PARTSRS5F30A
Input Shaft and Gears (Cont’d)
MT-38

SMT938D
9. Install input shaft rear bearing.
10. Select and install snap ring that gives the proper clearance of
input shaft groove.
Allowable clearance of groove:
0-0.1mm(0-0.004in)
Snap ring of input shaft rear bearing:
Refer to SDS, MT-120.
SMT605
Mainshaft and Gears
DISASSEMBLYNJMT00451. Before disassembly, check 1st, 2nd, 3rd and 4th main gear end
plays.
Gear end play:
Refer to SDS, MT-119.
If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Then check clearance of C-ring
groove. Refer to “ASSEMBLY”, MT-42.
SMT641-A
2. Press out mainshaft front bearing.
SMT638-A
3. Press out mainshaft rear bearing.
SMT592-A
4. Remove C-ring holder, mainshaft C-rings and thrust washer.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
REPAIR FOR COMPONENT PARTSRS5F30A
Input Shaft and Gears (Cont’d)
MT-39

SMT593-A
5. Press out 5th main gear.
SMT687C
6. Remove 4th main gear, 4th bushing and steel ball.
Be careful not to lose steel ball.
SMT780AA
7. Remove 3rd & 4th synchronizer, 3rd main gear, 2nd & 3rd
bushing, steel ball and 2nd main gear.
Be careful not to lose steel ball.
SMT594
8. Remove 1st & 2nd synchronizer and 1st main gear, then
remove 1st gear needle bearing.
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont’d)
MT-40

SMT604A
INSPECTIONNJMT0046Mainshaft and GearsNJMT0046S01Check shaft for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.
SMT387A
SynchronizerNJMT0046S02Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check shifting inserts for wear or deformation.
SMT140
Measure clearance between baulk ring and 1st-4th main
gears.
Clearance between baulk rings and 1st-4th main gears:
Standard
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)
If dimension “A” or “B” is smaller than the wear limit,
replace outer baulk ring, inner baulk ring and synchro-
nizer cone as a set.
SPD715
BearingNJMT0046S03Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
When replacing tapered roller bearing, replace outer and
inner race as a set.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont’d)
MT-41

SMT603A
ASSEMBLYNJMT00471. Assemble 1st & 2nd and 3rd & 4th synchronizers.
SMT761B
Be careful not to hook front and rear ends of spread
spring to the same insert.
SMT605AA
2. Install 1st gear needle bearing and 1st main gear.
3. Press on 1st & 2nd synchronizer.
SMT085CA
4. Install steel ball, 2nd main gear, 2nd & 3rd bushing, 3rd main
gear and 3rd & 4th synchronizer.
Apply multi-purpose grease to steel ball before installing
it.
2nd & 3rd bushing has a groove in which steel ball fits.
SMT687C
5. Install steel ball, 4th bushing and 4th main gear.
Apply multi-purpose grease to steel ball before installing
it.
4th bushing has a groove in which steel ball fits.
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont’d)
MT-42

SMT606AA
6. Press on 5th main gear.
SMT592-A
7. Install thrust washer.
8. Select and install mainshaft C-ring that gives proper clearance
of groove in mainshaft.
Allowable clearance of groove:
0-0.1mm(0-0.004in)
Mainshaft C-ring:
Refer to SDS, MT-120.
9. Install C-ring holder.
SMT607AA
10. Press on mainshaft rear bearing.
SMT639
11. Press on mainshaft front bearing.
12. Measure gear end play as the final check — Refer to
“DISASSEMBLY”, MT-39.
SMT647-A
Final Drive
DISASSEMBLYNJMT00481. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
Be careful not to mix up the right and left bearings.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
REPAIR FOR COMPONENT PARTSRS5F30A
Mainshaft and Gears (Cont’d)
MT-43