Nissan PULSAR N13 Series / ASTRA LD Series. Instruction — part 31

Clutch

125

(3) Remove the nuts retaining the outer cable

flange to the vehicle bulkhead.

(4) Working inside the vehicle, disconnect the

inner cable from the top of the clutch pedal.

(5) Pull the clutch cable through the bulkhead

into the engine compartment.

(6) Release the clip retaining the centre of the

clutch cable and remove the cable from the vehicle.

(7) Check the inner cable for fraying, wear and

damage. Check the outer cable for kinks, wear and
damage. If necessary, renew the cable assembly.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Lubricate the inner cable ends with lithium

base molybdenum disulphide grease prior to installa-
tion.

(2) Tighten the nuts retaining the outer cable

flange to a torque of 11 Nm.

(3) Check and if necessary, adjust the clutch

pedal height and free play as described under the
heading Clutch Adjustments.

6. CLUTCH ADJUSTMENTS

TO ADJUST PEDAL HEIGHT

(1) Fold back the floor carpet and the sound

insulation from the drivers side floor panel.

(2) Measure the distance at right angles from the

floor panel to the centre of the pedal pad.

(3) If the pedal height is not as specified, adjust

the pedal stop bolt until the correct pedal height is
obtained.

TO ADJUST PEDAL AND RELEASE LEVER
FREE PLAY

(1) Loosen the inner cable locknut at the release

lever clevis.

(2) Push the release lever until resistance is felt

when the release bearing contacts the pressure plate
fingers and hold the release lever in this position.

(3) Tighten the inner cable adjusting nut until

the inner cable is taut.

(4) Loosen the adjusting nut 2.5-3.5 turns and

tighten the inner cable locknut.

(5) Measure the release lever free play. If the free

play is not as specified, loosen the locknut and turn
the adjusting nut until the correct free play is
obtained.

View of the clutch release lever free play adjusting

nut.

(6) Lightly depress the clutch pedal until resis-

tance is felt when the release bearing contacts the
pressure plate fingers. Measure the distance from the
centre of the pedal pad in this position to the centre
of the pedal pad when the pedal is contacting the stop
bolt. If necessary, check and adjust the release lever
free play which should bring the pedal free play within
Specifications.

Measuring the clutch pedal height with the carpet

removed.

126

MANUAL TRANSAXLE AND

DRIVE SHAFTS

SPECIFICATIONS

TRANSAXLE

Type . . . . . . . . . .Five speed, synchromesh

on all forward gears

Model . . . . . . . . . . . . . . .. RS5F31A

Gear ratios:

1.6 liter -

First . . . . . . . . . . . . . . .. 3.333:1

Second. . . . . . . . . . . . . .. 1.955:1

Third. . . . . . . . . . . . . . . 1.286:1

Fourth. . . . . . . . . . . . . ... 0.975:1

Fifth. . . . . . . . . . . . . . .. 0.810:1

Reverse . . . . . . . . . . . . . 3.417:1

1.8 liter -

First . . . . . . . . . . . . . . .. 3.063:1

Second. . . . . . . . . . . . . .. 1.826:1

Third. . . . . . . . . . . . . . . 1.286:1

Fourth. . . . . . . . . . . . . ... 0.975:1

Fifth. . . . . . . . . . . . . . .. 0.810:1

Reverse . . . . . . . . . . . . . 3.417:1

Gear end float:

Fifth. . . . . . . . . . . ...0.18-0.41 mm

Second, third and fourth. . . . 0.20-0.40 mm

First . . . . . . . . . . . ...0.18-0.31 mm

Synchro ring to gear clearance:

Standard . . . . . . . . . . . 1.0-1.3 mm

Minimum . . . . . . . . . . . . . 0.7 mm

Turning torque (new bearings):

Differential assembly . . . . . . 3.9-7.8 Nm

Total differential and mainshaft __ 5.9-13.7 Nm

Differential and final drive:

Type . . . . . . Helical ring gear and pinion

Ratio. . . . . . . . . . . . . . . 4.167:1

Lubricant:

Grade. . . . . . . . . . . . 80W-90 GL-4

Capacity . . . . . . . . . . . . ..2.7 liters

DRIVE SHAFTS

C.V. joint lubrication:

Lubricant. . Valvoline Special Moly EP grease

Amount . . . . . . . . . . . . . 40 grams

TORQUE WRENCH SETTINGS

Transaxle case retaining bolts . .

Cover plate to transaxle case . . . . . . .. 8.3 Nm

Input shaft bearing retainer bolts. . . . . . 21 Nm

Control bracket bolts . . . . . . . . . .. 8.3 Nm

Reverse check plug. . . . . . . . . . .. 25 Nm

Ring gear to differential case. . . . . . ... 88 Nm

Filler and drain plugs. . . . . . . . . ... 34 Nm

Reverse lamps switch . . . . . . . . . .. 29 Nm

Upper and centre clutch housing to engine…...49 Nm
Lower clutch housing to engine . . . . . .. 21 Nm

1. MANUAL TRANSAXLE AND DRIVE

SHAFT
TROUBLE SHOOTING

DIFFICULT GEAR CHANGE

(1) Faulty clutch or clutch release mechanism:

Check and adjust or overhaul the clutch or the clutch
release mechanism.

(2) Loose control bracket retaining bolts: Dis-

mantle the transaxle and tighten the control bracket
retaining bolts. Apply Loctite or an equivalent to the
bolt threads to prevent a repeat of the problem.

(3) Faulty gear lever assembly: Check and

renew
or repair the gear lever assembly.

(4) Bent or worn gear lever control rod: Repair

or renew the faulty components.

(5) Worn transaxle selector mechanism: Over-

haul the transaxle assembly. Renew components as
necessary.

.21 Nm

Check the synchronizing teeth on the gears and synchro

rings for chipping or wear.

Instruction Transaxle and Drive Shafts

127

(6) Lubricating oil too thick: Drain the transaxle

and refill with the correct amount and grade of
lubricating oil.

(7) Excessive end float in the mainshaft or input

shaft gears: Overhaul the transaxle.

NOTE: Check the clutch for correct opera-
tion. If reverse gear can be selected without
any gear clash this is a good indication that
the clutch is operating normally. Also check
that the correct type and grade of lubricating
oil is being used.

SLIPPING OUT OF GEAR

(1) Worn gear control rod assembly bushes:

Check and renew the worn components as necessary.

(2) Faulty gear lever assembly: Check and renew

the faulty components.

(3) Faulty synchroniser mechanism: Overhaul

the transaxle.

Check the engine mountings for damage and deterio-

ration.

(4) Worn or fatigued detent components: Renew

the faulty components as necessary.

(5) Excessive end float in the mainshaft or input

shaft: Overhaul the transaxle. Check and renew the
faulty components.

NOTE: In most cases, slipping out of gear is
caused by wear or damage to internal
components of (he transaxle. However, prior
to removing and dismantling the transaxle
assembly, check the engine mounting rub-
bers and mounting hardware as vibrations
caused by loose or deteriorated engine
mountings can cause the transaxle to slip
out of gear.

GEARS CLASH ON CHANGING DOWN

(1) Faulty clutch or clutch release mechanism:

Check, adjust or overhaul the clutch or the clutch
release mechanism.

Check the friction surface of the synchro rings and cones

for wear or damage.

(2) Faulty synchro rings or cones: Overhaul the

transaxle assembly.

(3) Lubricating oil too thick: Drain the transaxle

and refill with the correct grade and quantity of
lubricating oil.

(4) Broken, weak or incorrect positioning of the

springs in the synchro assemblies: Overhaul the tran-
saxle assembly.

(5) Excessive end float in the mainshaft or input

shaft gears: Overhaul the transaxle assembly.

NOTE: Check the clutch as previously de-
scribed prior to removing and dismantling
the transaxle. Also check that the correct
grade of transaxle oil is being used.

TRANSAXLE NOISE (IN NEUTRAL)

(1) Insufficient lubricant: Fill the transaxle with

the correct quantity and grade of lubricant.

(2) Worn input shaft bearings: Overhaul the

transaxle and renew the bearings.

(3) Chipped or pitted constant mesh gears:

Overhaul the transaxle and renew the damaged com-
ponents as necessary.

(4) Worn mainshaft bearings: Overhaul the tran-

saxle as necessary.

NOTE: First check the oil level in the
transaxle. To isolate the noise in neutral,
run the engine, depress the clutch and
engage any gear. If the noise ceases with the
clutch depressed it indicates that the noise is
in the transaxle.

Check the input shaft for damaged gears.

128

Instruction Transaxle and Drive Shafts

TRANSAXLE NOISE (FORWARD GEARS
ENGAGED, VEHICLE MOVING)

(1) Insufficient lubricant: Fill the transaxle with

the correct grade and quantity of oil.

(2) Worn input shaft or mainshaft bearings:

Overhaul the transaxle and renew the faulty bearings.

(3) Chipped or pitted gears: Check and overhaul

the transaxle and renew the faulty gears.

(4) Damaged or worn synchroniser assemblies:

Overhaul the transaxle and renew the synchroniser
assemblies.

FINAL DRIVE GEAR NOISE

(1) Insufficient lubricant: Fill the transaxle case

with the correct grade and quantity of oil.

(2) Chipped or pitted final drive gear and/or ring

gear: Overhaul the transaxle and renew components as
necessary.

(3) Worn differential carrier bearings: Overhaul

the differential assembly.

(4) Worn mainshaft or input shaft bearings:

Overhaul the transaxle.

NOTE: Check the oil level in the transaxle
case and the condition of the front hub
bearings and drive shaft joints prior to
overhauling the transaxle.

EXCESSIVE BACKLASH IN FINAL DRIVE

(1) Excessive end float in the differential carrier

bearings due to worn or incorrect bearing preload
adjustment: Check and adjust the bearing preload or
renew the bearings.

(2)

Ring gear to differential case bolts loose:

Overhaul the transaxle and tighten the bolts to the
specified torque.

(3) Excessive wear in the final drive gear: Check

and overhaul the transaxle.

(4) Excessive wear in the differential pinions,

side gears or pinion shaft: Overhaul the differential
assembly.

NOTE: Prior to overhauling the differential,
check the serviceability of the C.V joints on
the drive shafts.

NO DRIVE IN ANY GEAR

(1) Sheared ring gear to differential case bolts:

Overhaul the differential assembly.

(2)

Broken drive shaft: Check and renew com-

ponents as necessary.

(3) Inner C.V. joint shaft out of mesh with

differential side gear: Weak or broken inner C.V. joint
shaft snap ring. Renew as necessary.

NOISE OR VIBRATION IN DRIVE SHAFTS

( 1 ) Bent or twisted drive shafts: Check and

renew the drive shafts as necessary.

Check the drive shaft rubber boots for deterioration.

(2) Worn or damaged inner or outer C.V. joint:

Check and renew components as necessary.

(3) Lack of lubricant due to damaged C.V. joint

boots: Check the C.V. joints for wear, repack the C. V.
joints and renew the C.V. joint boot.

(4) Loose drive shaft hub nut: Tighten the hub

nut to Specifications.

(5) Worn splines on the drive shaft or C.V. joint

inner race. Check and renew the faulty components or
drive shaft as an assembly.

NOTE: Noise or vibration in the front end
can also be caused by excessive tire or wheel
unbalance.

2. DESCRIPTION

The five speed transaxle installed in the Pulsar

range of vehicles covered by this instruction has synchro-
mesh on all the forward gears.

The reverse gear is a spur idler gear which is

selected by sliding the idler gear into mesh with the
input shaft and the mainshaft.

The transaxle and differential assemblies are ac-

commodated in the same housing and the one oil level
check covers both assemblies.

Gear selection is by means of selector forks and a

striking rod which is operated by a floor mounted gear
lever assembly. A mechanism inside the transaxle
prevents the selection of reverse gear from fifth gear
until the gear lever is moved sideways in neutral. The
differential and final drive assembly runs on two
tapered roller bearings. Preload on these bearings is
adjusted by shims installed behind the bearing cups.
The assembly is driven by the mainshaft pinion
engaging the ring gear on the differential case.

The drive shafts are engaged with the differential

side gears at the inner end and the front wheel hubs at
the outer end.

The drive shafts and each C.V. joint can be