2003 NISSAN ALMERA N16 Srs

SMT147AA
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
SMT083A
INSPECTIONNJMT0049Gear, Washer, Shaft and CaseNJMT0049S01Check mating surfaces of differential case, side gears and
pinion mate gears.
Check washers for wear.
SPD715
BearingsNJMT0049S03Make 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.
SMT839
ASSEMBLYNJMT00501. Attach side gear thrust washers to side gears and install in
differential case.
2. Install pinion mate thrust washers and pinion mate gears.
SMT087A
3. Insert pinion mate shaft.
When inserting, be careful not to damage pinion mate
thrust washers.
REPAIR FOR COMPONENT PARTSRS5F30A
Final Drive (Cont’d)
MT-44

SMT610AB
4. Measure clearance between side gear and differential case
with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
SMT611A
b. Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.
Clearance between side gear and differential case with
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
c. If not within specification, adjust clearance by changing thick-
ness of side gear thrust washers.
Differential side gear thrust washer:
Refer to SDS, MT-120.
SMT147AA
5. Install retaining pin.
Make sure that retaining pin is flush with case.
SMT609A
6. Install final gear.
Apply locking sealant to final gear fixing bolts before
installing them.
7. Install speedometer drive gear and stopper.
SMT648
8. Press on differential side bearings.
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REPAIR FOR COMPONENT PARTSRS5F30A
Final Drive (Cont’d)
MT-45

SMT086C
Shift Control Components
INSPECTIONNJMT0051Check contact surface and sliding surface for wear, scratches,
projections or other damage.
SMT660A
Case Components
DISASSEMBLY AND ASSEMBLYNJMT0052Input Shaft Oil SealNJMT0052S011. Drive out input shaft oil seal.
SMT751BA
2. Install input shaft oil seal.
Apply multi-purpose grease to seal lip of oil seal before
installing.
SMT688C
Input Shaft Rear BearingNJMT0052S021. Remove welch plug from transmission case.
SMT633
2. Remove input shaft rear bearing by tapping it from welch plug
hole.
REPAIR FOR COMPONENT PARTSRS5F30A
Shift Control Components
MT-46

SMT634
3. Install welch plug.
Apply recommended sealant to mating surface of trans-
mission case.
SMT635-A
4. Install input shaft rear bearing.
SMT636-A
Mainshaft Front Bearing Outer Race and Oil ChannelNJMT0052S031. Remove mainshaft front bearing outer race.
2. Remove oil channel.
SMT595
3. Install oil channel.
Ensure the oil groove faces the oil pocket.
SMT752BA
4. Install mainshaft front bearing outer race.
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REPAIR FOR COMPONENT PARTSRS5F30A
Case Components (Cont’d)
MT-47

Mainshaft Rear Bearing Outer RaceNJMT0052S04Refer to “Mainshaft Bearing Preload”, MT-121.
Differential Side Bearing Outer RaceNJMT0052S06Refer to “Differential Side Bearing Preload”, MT-121.
REPAIR FOR COMPONENT PARTSRS5F30A
Case Components (Cont’d)
MT-48

SMT759D
Input Shaft and Gears
DISASSEMBLYNJMT00561. Before disassembly, measure the end plays of 3rd and 4th
input gears.
Gear end play:
Refer to SDS, MT-124.
If end play is not within specification, disassemble and check
the parts.
SMT671D
2. Remove oil channel from input shaft rear bearing.
SMT672DB
3. Press out input shaft rear bearing.
SMT673D
4. Remove C-ring holder.
5. Remove 5th gear rear C-ring.
SMT674DB
6. Remove 5th input gear from input shaft.
7. Remove 5th gear front C-ring.
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears
MT-64

SMT675DB
8. Remove 4th input gear, baulk ring, 4th gear needle bearing,
and 4th gear C-ring from input shaft.
9. Press out both 3rd & 4th synchronizer hub assembly and 3rd
input gear from input shaft.
10. Remove 3rd gear needle bearing.
SMT676DB
11. Press out input shaft front bearing from input shaft.
SMT693D
INSPECTIONNJMT0057Input Shaft and GearsNJMT0057S01Check shaft for cracks, wear or bending.
Check gears for excessive wear, chips or cracks.
SMT637A
SynchronizersNJMT0057S02Check spline area of coupling sleeves, hubs and gears for
wear or cracks.
Check baulk rings for cracks or deformation.
Check insert springs for wear or deformation.
SMT867D
If any crack, damage, or excessive wear is found on cam face
of baulk ring or working face of insert, replace it.
GI
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LC
EC
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CL
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BR
ST
RS
BT
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EL
IDX
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont’d)
MT-65

SMT841D
Measure the movement (play, dimension “L”) of 3rd & 4th cou-
pling sleeve with their end fixed and the other end lifted as
shown in the figure. If the movement exceeds specification,
replace the sleeve.
Coupling sleeve length “L”:
Refer to SDS, MT-124.
SMT140
Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to SDS, MT-124.
SMT148A
BearingNJMT0057S03Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT696DB
ASSEMBLYNJMT00581. Press on input shaft front bearing.
2. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring
bearing to input shaft.
SMT694D
3. Install spread spring, shifting insert, and 3rd & 4th synchronizer
hub onto 3rd & 4th coupling sleeve.
Pay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting insert.
CAUTION:
Do not reuse 3rd & 4th synchronizer hub.
REPAIR FOR COMPONENT PARTSRS5F70A
Input Shaft and Gears (Cont’d)
MT-66