2004 NISSAN TERRANO Service Repair Manual

General Specifications
CLUTCH CONTROL SYSTEM
Type of clutch controlHydraulic
CLUTCH MASTER CYLINDER
Inner diametermm (in) 15.87 (5/8)
CLUTCH OPERATING CYLINDER
Inner diameter mm (in)
LHD 17.46 (11/16)
RHD 19.05 (3/4)
CLUTCH DISC
Unit: mm (in)
EngineTD27Ti ZD30DDTi
Model 250 260
Facing size
(Outer dia. x inner dia. x
thickness) 250 x 160 x 3.7
(9.84 x 6.30 x 0.1457)
Thickness of disc assembly
under load 7.0 - 7.4 (0.276 - 0.291)
Under a load of 5,884 N (600 kg, 1,323 lb)
CLUTCH COVER
Engine TD27TiZD30DDTi
Model 250 260
Full load N (kg, lb) 5,884 (600, 1,323) 6,760 (689, 1,520)
Inspection and Adjustment
CLUTCH PEDAL
Unit: mm (in)
Handle LHDRHD
Pedal height* 227 - 237
(8.94 - 9.33) 210 - 220
(8.27 - 8.66)
Pedal stroke 155 - 160 (6.10 - 6.30)
Pedal free play
(Backlash at clevis) 1.0 - 3.0 (0.039 - 0.118)
*: Measured from surface of melt sheet to surface of pedal
pad
CLUTCH DISC
Unit: mm (in)
Engine TD27TiZD30DDTi
Disc model 250 260
Rear limit of facing
surface to rivet head 0.3 (0.012)
Runout limit of facing 1 (0.04)
Distance of runout
check point (from the
hub center) 120 (4.72)
Maximum of spline
backlash of spline (at
outer edge of disc) 1.0 (0.039)
CLUTCH COVER
Unit: mm (in)
Engine
TD27TiZD30DDTi
Cover model 250 260
Diaphragm spring height 36.5 - 38.5 (1.437 - 1.516)
Uneven limit of dia-
phragm spring toe height
ªAº 0.7 (0.028)
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-14
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MANUAL TRANSMISSIONSECTION
MT
CONTENTS
PREPARATION ................................................................2
Special Service Tools ..................................................2
Commercial Service Tools ...........................................4
TRANSMISSION FS5R30A .............................................5
Replacing the Rear Oil Seal ........................................5
FS5R30A
ON-VEHICLE SERVICE ..................................................6
Check of Position Switches .........................................6
REMOVAL AND INSTALLATION ....................................7
Removal .......................................................................7
Installation ....................................................................8
MAJOR OVERHAUL .....................................................10
Case Components .....................................................10
Gear Components ..................................................... 11 Shift Control Components .........................................13
DISASSEMBLY ..............................................................14
Case Components .....................................................14
Shift Control Components .........................................15
Gear Components .....................................................16
INSPECTION..................................................................21 Shift Control Components .........................................21
Gear Components .....................................................21
ASSEMBLY ....................................................................23
Gear Components .....................................................23
Shift Control Components .........................................31
Case Components .....................................................32
SERVICE DATA AND SPECIFICATIONS (SDS) ..........34
General Specifications ...............................................34
Inspection and Adjustment ........................................35
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Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST23540000*
Pin punch
Removing and installing retaining pin
ST30031000*
Puller
Removing 1st & 2nd synchronizer assembly
Removing counter gear rear thrust bearing
Removing main drive bearing
ST33290001*
Puller
Removing rear oil seal
ST33230000*
Drift
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
Removing mainshaft and counter gear
ST22350000*
Drift
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
Removing counter gear front bearing
(Use with KV38100300)
KV38100300*
Drift
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.
Removing counter gear front bearing
(Use with ST22350000)
Installing counter gear rear bearing
ST30720000*
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
Removing mainshaft front bearing
Installing mainshaft front bearing
PREPARATION
MT-2
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*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST33210000*
Drift
a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
Installing counter gear front bearing
Installing front cover oil seal
ST33220000*
Drift
a: 37 mm (1.46 in) dia.
b: 22 mm (0.87 in) dia.
Removing and installing counter gear rear end
bearing
ST30613000*
Drift
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
Installing main drive gear bearing
ST37750000*
Drift
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
Removing counter gear rear bearing
Installing OD gear bushing
Installing reverse cone
Installing reverse counter gear
Installing counter gear rear end bearing
ST22452000*
Drift
a: 40 mm (1.57 in) dia.
b: 36 mm (1.42 in) dia.
Installing reverse hub
Installing mainshaft rear bearing
ST33400001*
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
Installing rear oil seal
ST36730000*
Drift
a: 50 mm (1.97 in) dia.
b: 39 mm (1.54 in) dia.
Installing sub-gear on reverse
idler gear
PREPARATION
Special Service Tools (Cont'd)
MT-3
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Commercial Service Tools
Tool nameDescription
Puller
NT077
Removing counter gear rear end bearing
Removing mainshaft rear bearing
Removing reverse synchronizer hub
Removing reverse counter gear
Drift
ST22452000
a: 44.5 mm (1.752 in) dia.
b: 38.5 mm (1.516 in) dia.
Installing sub-gear snap ring
Drift
ST22452000
a: 44.5 mm (1.752 in) dia.
b: 40.5 mm (1.594 in) dia.
Installing OD main gear
Installing reverse gear bushing
PREPARATION
MT-4
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Replacing the Rear Oil Seal
REMOVAL
1. Remove transfer assembly. See Section TF.
2. Remove rear oil seal.
REPLACEMENT
1. Install rear oil seal.Before installation, apply multi-purpose grease to oil seal lip.
2. Install transfer assembly. See Section TF.
SMT321B
SMT453B
TRANSMISSION FS5R30A
MT-5
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Check of Position Switches
SwitchGear position Continuity
q
14WD* Transfer case 4WD Yes
Except 4WD No
q
2Back-up lamp Transmission
case Reverse Yes
Except reverse No
*: Ensure both sides of 4WD 2-pole double-throw switch is operational, refer to ªWarning lampsº wiring diagram in EL-Section.
YMT009
ON-VEHICLE SERVICEFS5R30A
MT-6
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Removal
Transmission has to be removed as a unit together with transfer
box.
Remove transmission assembly as follows:
IDisconnect negative battery terminal.
I Remove shift levers of transmission and transfer.
I Remove front and rear propeller shafts. Ð Refer to PD section.
I Insert plug into rear oil seal after removing propeller shaft.
I Remove RPM-sensor from transmission upper side.
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal,
when removing propeller shaft.
I Remove torsion bar spring. Ð Refer to FA Section.
I Remove third crossmember (the one supporting front differen-
tial).
I Remove fifth crossmember (the one situated at the rear of
transfer).
I Support transmission and transfer with a suitable transmission
jack.
WARNING:
Support transmission and transfer with suitable jacks, while
removing them.
I Remove fourth crossmember (the one supporting transmis-
sion).
I Remove clutch operating cylinder.
I Remove starter motor.
I Remove exhaust tube bracket from transmission.
I Disconnect electrical connectors.
I Remove transmission from engine.
REMOVAL AND INSTALLATIONFS5R30A
MT-7
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