Nissan PULSAR N13 Series / ASTRA LD Series. Instruction — part 33

Instruction Transaxle and Drive Shafts

133

Dismantled view of the 1st/2nd gear synchro

assembly.

(6) Select a snap ring to obtain the minimum

clearance in the input shaft groove and install the snap
ring to the rear of the input shaft.

NOTE: The maximum allowable clearance
is O.I mm. Snap rings are available from
2.00 mm to 2.30 mm in increments of
.05 mm.

(7) Ensure that the fifth gear end float is within

the specifications.

(8) Install the bearing retainer to the front of the

input shaft in the direction noted on removal.

(9) Install the front bearing and spacer to

the input shaft.

(10) Select a snap ring to obtain the minimum

clearance in the input shaft groove and install the snap
ring to the front of the input shaft.

NOTE: The maximum allowable clearance
is 0.1 mm. Snap rings are available from
1.27 mm to 1.45 mm in increments of
.06 mm.

(11) Assemble the components of the first/

second and third/fourth synchro assemblies aligning

the marks made on dismantling. Ensure that the ends
of the shift plate springs are not aligned.

(12) Install the needle roller bearing and first gear

to the mainshaft.

(13) Install the first/second synchro assembly to

the mainshaft. Ensure that the slots in the synchro

ring are aligned with the shift plates.

(14) Install the steel ball to the mainshaft

using
grease to retain the ball.

(15) Install second gear to the mainshaft and

install
the bush aligning the groove in the bush with the steel
ball.

(16) Install third gear to the mainshaft.
(17) Install the third/fourth synchro assembly to

the mainshaft ensuring that the slots in the synchro
ring are aligned with the shift plates.

(18) Install the other steel ball to the mainshaft

using grease to retain the ball.

(19) Install the fourth gear bush to the mainshaft

aligning the groove in the bush with the ball.

(20) Install the fourth gear to the mainshaft.
(21) Install the fifth gear to the mainshaft.
(22) Install the thrust washer to the mainshaft.
(23) Select C rings to obtain the minimum clear-

ance in the mainshaft grooves and install the C rings to
the mainshaft groove. Install the C ring holder to the
mainshaft.

NOTE: The maximum allowable clearance
is 0.1 mm. C rings are available in thick-
nesses of 3.63 mm to 4.54 mm in incre-
ments of 0.07 mm.

(24) Install the rear and front bearing cones to the

mainshaft using a press and press plates.

(25) Ensure that the mainshaft first, second, third

and fourth gear end floats are within the Specifica-
tions.

(26) Temporarily install the differential assembly

to the clutch housing.

(27) Install the transaxle case to the clutch

hous-
ing.

(28) Tighten the transaxle case retaining bolts to

the specified torque.

(29) Install a suitable slotted adaptor into

the
differential pinion shaft and, using a torque gauge,
measure the differential turning torque. The turning
torque should be in a range from slightly below
3.9 Nm to 7.9 Nm.

If the turning torque is not as specified, proceed to

the Differential and Final Drive heading and perform
operations (22) to (29).

If the turning torque is as specified, proceed as

follows:

(30) Remove the transaxle case and install

the
mainshaft to the clutch housing ensuring that the resin
oil channel is located centrally in the end of the
mainshaft.

(31) Install the transaxle case to the clutch hous-

ing.

Dismantled view of the 3rd/4th gear synchro

assembly.

134

Instruction Transaxle and Drive Shafts

(32) Install and tighten the retaining bolts to

the specified torque.

(33) Repeat operation (29). The total turning

torque should be 5.9-13.7 Nm if new bearings have
been installed or slightly less if the original bearings
have been installed.

If the turning torque is not as specified, adjust the

mainshaft turning torque as follows:

(a) Remove the transaxle case rear cover, O ring,

spacer and adjusting shim from the transaxle case.

(b) Ensure that the mainshaft rear bearing outer

race is fully seated on the bearing cone.

(c) Using micrometer depth gauge, measure the

distance from the transaxle case to the bearing outer
race and note the reading.

(d) Referring to the following table, select the

appropriate shim, according to the reading noted in
operation (c), required to correct the mainshaft turn-
ing torque.

READING SHIM

2.35-2.40 mm . . . . . . . . . . . ... 0.10 mm

2.40-2.45 mm . . . . . . . . . . . ... 0.15 mm

2.45-2.50 mm . . . . . . . . . . . ...0.20 mm

2.50-2.55 mm . . . . . . . . . . . ... 0.25 mm

2.55-2.60 mm . . . . . . . . . . . ... 0.30 mm

2.60-2.65 mm . . . . . . . . . . . ... 0.35 mm

2.65-2.70 mm . . . . . . . . . . . ... 0.40 mm

2.70-2.75 mm . . . . . . . . . . . ... 0.45 mm

2.75-2.80 mm . . . . . . . . . . . ... 0.50 mm

2.80-2.85 mm . . . . . . . . . . . ... 0.55 mm

2.85-2.90 mm . . . . . . . . . . . ... 0.60 mm

2.90-2.95 mm . . . . . . . . . . . ... 0.65 mm

2.95-3.00 mm . . . . . . . . . . . ... 0.70 mm

3.00-3.05 mm . . . . . . . . . . . ... 0.75 mm

3.05-3.10 mm . . . . . . . . . . . ... 0.80 mm

3.10-3.15 mm . . . . . . . . . . . ... 0.85 mm

3.15-3.20 mm . . . . . . . . . . . ... 0.90 mm

3.20-3.25 mm. . . . . . . . . . . ... 0.95 mm

3.25-3.30 mm . . . . . . . . . . . ... 1.00 mm.

(e) Install the spacer, shim, O ring and rear

cover to the transaxle case. Tighten the retaining
bolts securely.

(34) Measure the total turning torque as previ-

ously described.

(35) Install the striking interlock and striking lever

to the clutch housing.

(36) Install the striking rod to the clutch housing

sliding the rod through the lever and interlock. Take
care that the end of the rod does not damage the seal.

(37) Install a new retaining pin to the striking rod

using a pin punch.

(38) Install the reverse and fifth gear check

assembly to the clutch housing. Tighten the retaining
screws securely.

(39) Install the balls, spring and reverse check

plug to the clutch housing ensuring that the smaller
diameter ball enters the hole in the body of the
reverse and

fifth gear check assembly body. Apply locking com-
pound and tighten the reverse check plug securely.

(40) Using a bar clamped to the end of the

striking rod, check that a force of 4.9-7.4 Nm is
required to overcome the spring loading of the reverse
and fifth gear check assembly. If necessary, renew the
springs to achieve this correct spring loading.

NOTE: Ensure that the reverse check plug is
coated with locking compound when finally
installed.

(41) Install the shift check ball, spring and plug to

the clutch housing. Ensure that the ball is centrally
located in the plug.

(42) If removed, install the oil reservoir to the

clutch housing.

(43) Install the input shaft assembly and the

reverse idler gear to the clutch housing taking care not
to damage the seal.

(44) Apply locking compound to the bearing

retainer bolts and tighten the bolts to the specified
torque.

(45) Install the spacer to the reverse idler shaft.
(46) Install the differential assembly to the clutch

housing.

(47) Install the mainshaft to the clutch housing

ensuring that the resin oil channel is located centrally
in the end of the mainshaft.

(48) Install the shift cap to the slot in the first/

second shift fork and install the shift fork and control
bracket to the clutch housing. Use grease to hold the
shift cap in the shift fork slot. Ensure that the reverse
idler shift fork is correctly located over the gear.

(49) Apply locking compound to the threads of

the control bracket retaining bolts and tighten the
bolts to the specified torque.

(50) Install the shift cap in the slot in the third/

fourth shift fork and install the fork to the transaxle
assembly. Use grease to hold the shift cap in the shift
fork slot.

(51) Install the fifth gear shift fork to the transaxle

ensuring that the shift fork slot engages the control
finger.

(52) Install the fork shaft and spring to the clutch

housing sliding the shaft through the shift forks. Use
grease to hold the spring in the end of the shaft.

(53) Apply a continuous bead of sealant to the

mating face of the clutch housing so that the bead is
located inside the row of bolt holes.

NOTE: Sealant is available from Nissan
spare parts using the part number KP
610-00250.

(54) Install the transaxle case to the clutch hous-

ing. Install and tighten the retaining bolts to the
specified torque.

(55) Select each gear in turn and check that the

transaxle turns freely in each gear. Ensure that it is not

Instruction Transaxle and Drive Shafts

135

possible to move the striking rod from fifth gear to
reverse without first moving sideways in the neutral
gate.

4. DIFFERENTIAL AND FINAL DRIVE

ASSEMBLY

Special Equipment Required:

To Measure Differential Turning Torque —
Suitable slotted adaptor and torque gauge

TO CHECK VISCOUS COUPLING

From July 1989, Instruction transaxle Pulsar Q and

Vector SSS models are equipped with a limited slip
differential incorporating a viscous coupling.

(1) Raise the front of the vehicle and support it

on chassis stands.

(2) Rotate one front wheel and check the rota-

tional direction of the opposite wheel.

(3) If both front wheels rotate in the same

direction, the viscous coupling is functioning nor-
mally.

(4) If the front wheels rotate in opposite direc-

tions, the viscous coupling is unserviceable and must
be renewed as an assembly.

TO DISMANTLE AND ASSEMBLE

It is necessary to remove and dismantle the

transaxle assembly to gain access to the differential
and final drive assembly.

Refer to the Transaxle Assembly heading for the

removal of the transaxle from the vehicle. Operations
1-9 of the dismantling procedure under the same
heading describe the removal of the differential and
final drive assembly from the transaxle.

(1) If necessary, cut and remove the speedome-

ter drive gear from the differential case.

(2) Using a suitable puller, remove the differen-

tial carrier bearing cone and roller assemblies from the
differential case and remove the speedometer drive
gear stopper.

(3) Remove the ring gear retaining bolts and

separate the ring gear from the differential case using
a soft faced hammer.

(4) Using a pin punch, remove the retaining pin

from the differential pinion shaft.

(5) Remove the pinion shaft from the differen-

tial case.

(6) Remove the pinion gears and thrust washers

from the differential case.

(7) Remove the side gears and spacers from the

differential case.

NOTE: If applicable, the viscous coupling is
integral with the left hand side gear.

(8) Wash all the differential components with

cleaning solvent.

(9) Check the gears, spacers, thrust washers,

pinion shaft and differential case for wear, pitting and
damage. Renew parts as necessary.

(10) Install the side gears and spacers to

the
differential case.

(11) Install the pinion gears and thrust washers

to
the differential case.

(12) Install the pinion shaft to the differential case

aligning the retaining pin hole.

(13) Install the retaining pin to the pinion shaft

until the end of the pin is level with the differential
case.

(14) With a dial gauge contacting the end of the

side gear, lift the side gear evenly and measure the
clearance between the side gear and the differential
case. The clearance should be 0.1-0.2 mm.

NOTE: Do not tilt the side gear or the dial
gauge reading will be incorrect.

(15) If necessary, adjust the side gear clearance

using selective fit spacers.

NOTE: Spacers are available from 0.15 mm
to 1.00 mm in increments of 0.05 mm.

(16) Measure and if necessary, adjust the other

side gear clearance.

(17) On models equipped with a viscous cou-

pling, adjust the side gear clearance as follows:

(a) Temporarily secure the differential case with

two bolts.

(b) Position the differential case so that the right

hand side gear is uppermost.

(c) Insert a 0.03 mm feeler gauge between the

View of the differential assembly removed from the

transaxle.

136

Instruction Transaxle and Drive Shafts

right hand side gear and the adjacent spacer in an area
where there is no oil groove in the differential case.
(d) Insert another 0.03 mm feeler gauge diago-
nally opposite the first feeler gauge to avoid tilting the
side gear.

(e) Insert a splined adaptor into the right hand

side gear and attempt to rotate the gear by hand.

(f) If the gear cannot be rotated, change the

thickness of the left hand side gear spacer, repeating
the test until the gear can be rotated.

NOTE: Spacers are available in thicknesses
from 0.8 mm to 1.5 mm in increments of
0.1 mm.

(g) Remove the 0.03 mm feeler gauges and insert

0.09 mm feeler gauges to the same position. The gear
should lock.

(h) The spacer selection is correct when the right

hand side gear can be rotated with 0.03 mm feeler
gauges inserted but locks when 0.09 mm feeler gauges
are inserted.

(18) Install the ring gear to the differential case

with the chamfered edge of the ring gear inwards.

(19) Install and tighten the retaining bolts in

a
diagonal sequence to the specified torque.

(20) Install a new speedometer drive gear to

the
differential case. Install the stopper adjacent to the
drive gear.

(21) Install the differentia] carrier bearing

cones
and roller assemblies to the differential case.

(22) Remove the adjusting shim from behind the

carrier bearing outer race in the transaxle case and
replace the outer race in the transaxle case.

(23) Install the differential assembly to the clutch

housing.

(24) Install the transaxle case to the clutch housing

and tighten the retaining bolts to the specified torque.

(25) Mount a dial gauge to the clutch housing so

that the contact point is resting on the differential
case.

(26) Insert a bar through the opposite side gear

and, contacting the pinion shaft, raise and lower the
differential case and measure the end float in the
carrier bearings.

(27) Using the following table, select a shim to

correspond to the relevant end float.

END FLOAT

SHIM THICKNESS

0.30-0.34 mm. . . . . . . . . . . . . 0.64 mm

0.34-0.38 mm. . . . . . . . . . . . ... 0.68 mm

0.38-0.42 mm. . . . . . . . . . . . ... 0.72 mm

0.42-0.46 mm. . . . . . . . . . . . ... 0.76 mm

0.46-0.50 mm. . . . . . . . . . . . ... 0.80 mm

0.50-0.54 mm. . . . . . . . . . . . ... 0.84 mm

0.54-0.58 mm. . . . . . . . . . . . ... 0.88 mm

0.58-0.62 mm. . . . . . . . . . . . ... 0.92 mm

0.62-0.66 mm. . . . . . . . . . . . ... 0.96 mm

0.66-0.70 mm. . . . . . . . . . . . ... 1.00 mm

0.70-0.74 mm. . . . . . . . . . . . ... 1.04 mm

0.74-0.78 mm. . . . . . . . . . . . ... 1.08 mm

0.78-0.82 mm. . . . . . . . . . . . ... 1.12 mm

0.82-0.86 mm. . . . . . . . . . . . ... 1.16 mm

0.86-0.90 mm. . . . . . . . . . . . ... 1.20 mm

0.90-0.94 mm. . . . . . . . . . . . ... 1.24 mm

0.94-0.98 mm. . . . . . . . . . . . ... 1.28 mm

0.98-1.02 mm. . . . . . . . . . . . ... 1.32 mm

1.02-1.06 mm. . . . . . . . . . . . ... 1.36 mm

1.06-1.10 mm. . . . . . . . . . . . ... 1.40 mm

1.10-1.14 mm. . . . . . . . . . . . ... 1.44 mm

1.14-1.18 mm. . . . . . . . . . . . ... 1.48 mm

1.18-1.22 mm. . . . . . . . . . . . ... 1.52 mm

1.22-1.26 mm. . . . . . . . . . . . ... 1.56 mm

1.26-1.30 mm. . . . . . . . . . . . ... 1.60 mm

1.30-1.34 mm. . . . . . . . . . . . ... 1.64 mm

1.34-1.38 mm. . . . . . . . . . . . ... 1.68 mm

1.38-1.42 mm. . . . . . . . . . . . ... 1.72 mm

1.42-1.46 mm. . . . . . . . . . . . ... 1.76 mm

The thickest shim available is 0.88 mm. Multiple

shims are required above this thickness.

(28) Install the shim behind the carrier

bearing
outer race in the transaxle case and assemble the unit
once more.

(29) Using a suitable slotted adaptor engage the

pinion shaft and using a torque gauge, measure the
differential turning torque.

The turning torque when new carrier bearings

have been installed should be 3.9-7.8 Nm or slightly
lower if the original carrier bearings have been
replaced.

(30) Assemble the transaxle and measure the total

turning torque of the differential assembly and the
mainshaft. The total turning torque should be 5.9 to
13.7 Nm with new bearings or slightly lower if the
original bearings have been replaced.

5. GEAR LEVER ASSEMBLY

TO DISMANTLE AND ASSEMBLE

(1) Remove the gear lever knob and remove the

centre console as described in the Body section. If not
previously removed, remove the rubber boot sur-
rounding the gear lever.

(2) Raise the front of the vehicle and support it

on chassis stands. Remove the catalytic converter and
heat shield as described in the Engine section.

(3) Remove the bolt and disconnect the control

rod from the bottom of the gear lever, noting the
position of the return spring and bracket.

(4) Remove the nuts retaining the gear lever

socket to the support rod.

(5) Working inside the vehicle, lift the gear lever

out of the floor bracket.

(6) Separate the lower rubber boot, socket,

spring seat, spring, upper ball seat and lower ball seat
from the gear lever, noting the location of each
component to aid assembly.