2004 NISSAN TERRANO Service Repair Manual

Installation
Install a new oil seal, using a suitable tool.
Rear Case
REAR OIL SEAL
Removal
Remove the oil seal. Be careful not to damage its housing. Always
replace after every disassembly.
Installation
Install a new oil seal, using the Special Tool.
AIR BREATHER
Install as shown in the illustration.
Shift Control Components
INSPECTION
ICheck contact surface and sliding surface for wear, scratches,
projections or other faulty conditions.
SMT315A
YMT025
YMT026
YTF005
SMT360A
REPAIR FOR COMPONENT PARTS
Bearing Retainer (Cont'd)
TF-24
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L & H SHIFT ROD & FORK
Assemble as shown in the illustration.
* This pin is the same size as the one for 2-4 shift rod.
2-4 SHIFT ROD & FORK
Assemble as shown in the illustration.
* These pins are the same size.
Pay special attention to the direction of fork guide collar.
SMT319A
SMT320A
SMT321A
REPAIR FOR COMPONENT PARTS
Shift Control Components (Cont'd)TF-25
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1. Assemble front case.
a. Install main gear assembly by tapping lightly.
b. Apply sealant to the mating surface and bolts of front casecover and install it on front case.
I These ten bolts should be coated with sealant.
Tightening torque
q
A: 20-23N ×m
(2.1 - 2.3 kg-m, 15 - 16 ft-lb)
q
B: 24-28N ×m
(2.5 - 2.8 kg-m, 18 - 20 ft-lb)
c. Apply gear oil to needle bearing and install it into main gear.
d. Install counter gear assembly by tapping lightly.
e. Install cross shaft and inner shift lever.
When replacing cross shaft, outer shift lever of lock pin of
outer shift lever, replace them as a set.
SMT323A
YMT027
SMT326A
SMT327A
SMT798A
ASSEMBLY
TF-26
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f. Apply sealant to plug and install it into front case.
g. Insert interlock plunger into front case.
h. Install L & H shift rod and fork assembly with coupling sleeve.
i. Install 2-4 shift rod.
j. Install switches, check balls, check springs and plugs.
Apply sealant to switches and plugs.
SMT330A
SMT331A
SMT332A
SMT333A
YTF004
ASSEMBLY
TF-27
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2. Select counter gear rear bearing shim.Counter gear end play:0 - 0.2 mm (0 - 0.008 in)
a. Measure distance ªAº between upper surface of counter gear rear bearing and mating surface of front case.
b. Select suitable shim using chart below.
Distance ªAº mm (in) Suitable shim
Thickness mm (in) Part number
32.65 - 32.55
(1.2854 - 1.2815) Not necessary
32.55 - 32.45
(1.2815 - 1.2776) 0.1 (0.004) 33112-C6900
32.45 - 32.35
(1.2776 - 1.2736) 0.2 (0.008) 33112-C6901
32.35 - 32.25
(1.2736 - 1.2697) 0.3 (0.012) 33112-C6902
32.25 - 32.15
(1.2697 - 1.2657) 0.4 (0.016) 33112-C6903
32.15 - 32.05
(1.2657 - 1.2618) 0.5 (0.020) 33112-33G00
32.05 - 31.95
(1.2618 - 1.2579) 0.6 (0.024) 33112-33G01
3. Place suitable shim on counter gear rear bearing with grease.
4. Apply gear oil to each part in front case.
5. Assemble center case assembly.
a. Install mainshaft on center case by tapping lightly.
Apply gear oil to mainshaft front bearing.
SMT335A
SMT334A
SMT336A
SMT406A
ASSEMBLY
TF-28
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b. Install bearing retainer.
c. Put drive chain onto the front drive sprocket and front driveshaft, and then put them in center case.
d. Install front drive shaft by tapping lightly.
e. Apply gear oil to needle bearings and install them into front drive sprocket.
These needle bearings will be installed more easily if front
drive sprocket is rotated while installing them.
SMT407A
SMT408A
SMT409A
SMT410A
SMT411A
ASSEMBLY
TF-29
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f. Install 2-4 coupling sleeve with 2-4 shift fork.
Pay special attention to direction of coupling sleeve.
g. Install shifting inserts and spread spring.
Pay special attention to direction of shifting inserts.
h. Install baulk ring and then install clutch gear and mainshaft rearbearing.
Place wooden block under mainshaft in order to protect main-
shaft front bearing.
i. Install spacer.
j. 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
1.8 (0.071)
1.9 (0.075)
2.0 (0.079)
2.1 (0.083)
2.2 (0.087) 33138-73P20
33138-73P21
33138-73P22
33138-73P23
33138-73P24
SMT412A
SMT353A
SMT413A
SMT414A
ASSEMBLY
TF-30
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k. Install steel ball, speedometer drive gear and retainer ring.
Steel ball is the smallest of check balls for this unit.
l. Install low gear and its bearing to mainshaft.
Apply gear oil to needle bearing.
m. Install L & H hub and snap ring to mainshaft.
Pay special attention to direction of L & H hub.
n. Measure end play of low gear.Standard:0 - 0.15 mm (0 - 0.0059 in)
6. Apply sealant to mating surface and put center case assembly onto front case and tighten bolts.
SMT415A
SMT340A
SMT760A
YMT017
SMT343A
ASSEMBLY
TF-31
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