Nissan PULSAR N13 Series / ASTRA LD Series. Instruction — part 32

Instruction Transaxle and Drive Shafts

129

renewed as individual units. The C.V. joints are
lubricated in manufacture and need no attention in
service unless one of the rubber boots is damaged. In
this case the joint can be cleaned and repacked with
the recommended grease and a new boot installed.

From July 1989, Pulsar Q and Vector SSS instruction

transaxle models are equipped with a limited slip
differential incorporating a viscous coupling. The
coupling is not repairable and must be renewed as an
assembly if unserviceable. A test procedure for the
viscous coupling is included in the text in this section.

3. TRANSAXLE ASSEMBLY

Special Equipment Required:

To Dismantle and Assemble — Puller set, press
and press plates, dial gauge
To Measure Mainshaft Turning Torque —
Suitable slotted adaptor and torque gauge

TO REMOVE AND INSTAL

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

on chassis stands.

(2) Remove the battery as described in the

Electrical System section.

(3) Remove the drive shafts as described later in

this section.

(4) Disconnect and remove the starter motor as

described in the Electrical System section.

Front view of the transaxle removed from the vehicle.

(5) Support the rear of the engine using a jack

with a piece of timber between the jack head and the
engine sump.

(6) Remove the bolts retaining the clutch hous-

ing to the engine.

(7) Disconnect the vehicle speed sensor wiring,

the reverse lamp wiring, the gear lever control rod and
the gear lever support rod from the transaxle.

(8) Remove the transaxle mounting through bolt

and remove the bolts retaining the mounting bracket
to the transaxle.

(9) With the left hand front wheel removed,

remove the left hand inner mudguard panel.

(10) Maneuver the transaxle away from the

engine. Lower and withdraw the transaxle from under
the vehicle.

NOTE: Do not allow the transaxle to hang
on the clutch driven plate during removal.
Support the transaxle on a trolley jack if
necessary.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Lubricate the input shaft splines sparingly

with lithium base molybdenum disulphide grease.

(2) Support the transaxle during installation. Do

not allow the transaxle to hang on the clutch driven
plate.

(3) Tighten all bolts to the specified torque.
(4) Fill the transaxle with the specified quantity

and grade of oil.

(5) Road test the vehicle and check for correct

transaxle operation. Also check for transaxle oil leaks
and rectify as necessary.

TO DISMANTLE

(1) Remove the clutch release components from

Rear view of the transaxle removed from the vehicle.

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Instruction Transaxle and Drive Shafts

Internal view of the transaxle showing the installed

positions of the shift forks and control bracket.

the clutch housing. Refer to the Clutch section for the
correct procedure.

(2) Thoroughly clean the outside of the transaxle

assembly using solvent and compressed air.

(3) Remove the bolts retaining the transaxle case

to the clutch housing and using a soft faced hammer,
tap the transaxle case to separate the mating surfaces.

(4) Carefully lift the transaxle case from the

clutch housing. Tilt the case to provide clearance for
the fifth gear shift fork.

(5) Withdraw the spacer from the reverse idler

shaft and withdraw the fork shaft and spring from the
transaxle.

(6) Remove the fifth and third/fourth shift forks

taking care not to lose the shift cap.

(7) Remove the retaining bolts and remove the

control bracket and the first/second shift fork taking
care not to lose the shift cap.

(8) Lift the mainshaft out of the clutch housing.

NOTE: When lifting, do not tilt the main-
shaft as the resin oil channel behind the
front mainshaft bearing could be damaged.

(9) Lift the differential assembly out of the

clutch housing.

NOTE: For information on the overhaul of

Dismantled view of the striking rod components.

the differential assembly refer to the Differ-
ential and Final Drive Assembly heading.

(10) Remove the retaining bolts from the input

shaft front bearing retainer.

(11) Position the transaxle assembly on its side

and tap the input shaft out of the clutch housing using
a soft faced hammer. Remove the input shaft, bearing
retainer and reverse idler gear from the clutch hous-
ing.

(12) Remove the shift check ball, plug and spring

from the passage adjacent to the upper control
bracket retaining bolt on the clutch housing.

(13) Position the striking lever so that the retain-

ing pin will not contact the clutch housing and remove
the pin using a suitable punch.

(14) Remove the striking rod, striking lever and

striking interlock from the clutch housing.

(15) Remove the reverse check plug, spring and

balls from the clutch housing noting the installed
position of the small check ball.

(16) Remove the screws retaining the reverse and

fifth gear check assembly and remove the assembly
from the clutch housing.

(17) Remove and discard the input shaft and

striking rod oil seals from the clutch housing noting
the installed direction of the seals.

(18) Renew the rear input shaft bearing as fol-

lows:

(a)

Remove the plastic oil channel from the

transaxle case.

(b) Using a suitable punch through the hole

adjacent to the rear input shaft bearing, tap the small
welch plug out of the transaxle case.

(c) Using a suitable punch through the small

welch plug opening, tap the rear input shaft bearing
out of the transaxle case.

(d) Using a suitable mandrel, tap the new rear

input shaft bearing into the transaxle case.

NOTE: It may be necessary to use a hydrau-
lic press if the bearing is a tight fit in the
housing.

(e) Apply sealer to a new welch plug and tap the

plug squarely into the transaxle case until the edge of
the plug is level with the case.

Dismantled view of the shift fork components.

Instruction Transaxle and Drive Shafts

131

(19) Renew the rear mainshaft bearing outer race

as follows:

(a) Remove the bolts retaining the rear cover to

the transaxle case.

(b) Remove the rear cover. O ring, spacer and

adjusting shim from the transaxle case. Discard the O
ring.

(c) Using a suitable punch, tap the bearing outer

race out of the transaxle case.

(e) Install the adjusting shim, spacer and a new O

ring to the transaxle case. Install the rear cover and
tighten the retaining bolts securely.

(20) Renew the front mainshaft bearing outer

race as follows:

(a) Using a suitable puller, pull the outer race

out of the clutch housing.

(b) Ensure that the oil groove in the resin oil

channel is facing the oil pocket in the clutch housing.

(c) Install the new outer race to the clutch

housing.

(21) Measure the end float of the input shaft fifth

gear using feeler gauges between the fifth gear and the
adjacent gear shoulder. Note the measurement for
later reference.

(22) Dismantle the input shaft as follows:

(a) Remove the snap ring and spacer from the

front of the input shaft.

(b) Using a suitable puller, remove the bearing

from the front of the input shaft. Remove the bearing
retainer noting the installed direction.

(c) Remove the snap ring from the rear of the

input shaft.

(d) Remove the shift retainer, fifth gear synchro

assembly, fifth gear and the split bearing from the rear
of the input shaft.

(23) Measure the end float of the mainshaft first,

second, third and fourth gears using feeler gauges
between the gear and the adjacent shaft shoulder.
Note the measurements for later reference.

(24) Dismantle the mainshaft as follows:

(a) Remove the front and rear bearing cones

using a suitable puller.

Dismantled view of the mainshaft

.

(b) Remove the C ring holder, the C rings and

the thrust washer from the rear of the mainshaft.

(c) Using a puller positioned on the fifth gear

rear flange, remove the fifth gear from the mainshaft.

(d) Remove the fourth gear, bush and steel ball

from the mainshaft.

(e) Remove the third/fourth synchro assembly,

using a suitable puller if necessary.

(f) Remove the third gear, bush, steel ball and

second gear from the mainshaft.

(g) Remove the first/second synchro assembly,

using a suitable puller if necessary.

(h) Remove first gear and the needle roller

bearing from the mainshaft.

(25) Suitably mark the assembled positions of the

synchro assemblies components and remove the
springs from the assemblies.

(26) Slide the sleeves off the hubs and remove the

shift plates.

(27) Arrange the various synchro components

separately to avoid mixing the components on
assembly.

TO CLEAN AND INSPECT

(1) Clean all the components in cleaning solvent

and allow to dry.

(2) Inspect the teeth on all the gears for wear,

pitting and damage.

(3) Push each synchro ring onto its respective

gear cone and measure the distance between the
synchro ring and the synchro teeth on the gear. Renew
the synchro ring and/or the gear if the distance is less
than 0.7 mm.

(4) Inspect the shift forks for excessive clearance

in the synchro sleeves and the control fingers. Renew
the forks as necessary if the clearance is excessive.

(5) Inspect the components of the control

bracket for wear and damage. Inspect the shift caps
for wear. Renew the control bracket and/or the shift
caps as necessary.

218/680 INPUTSHAFT

M AI N B E AF I N G

SPACER

Dismantled view of the input shaft.

132

Instruction Transaxle and Drive Shafts

Check the mainshaft for pitting.

(6) Inspect the striking rod, lever and interlock

for wear and damage paying particular attention to
the detent grooves in the end of the striking rod.
Renew parts as necessary.

(7) Inspect the shift check and reverse check

balls and springs for wear, cracks and loss of tension
in the springs. Renew parts as necessary.

Check clearance A between the synchro ring and the
gear synchro teeth and compare with Specifications.

(8) Inspect the reverse and fifth gear check

assembly for wear, damage and loss of spring tension.
Renew the assembly as necessary.

(9) Inspect all the bearings for pitting, wear and

damage. Renew the bearings as necessary.

NOTE: If the transaxle has seen consider-
able service, it is advisable to renew all the
bearings, oil seals, O rings and snap rings
during the overhaul.

(10) Inspect the various synchro components for

wear and damage paying particular attention to the
shift plates and springs and the internal teeth of the
synchro sleeves. Renew parts as necessary.

(11) Compare the various gear end floats mea-

sured during dismantling with the Specifications and
if the end floats are excessive, check the contact
surfaces of the gears, shaft and synchro hubs. Renew
worn parts as necessary.

TO ASSEMBLE

(1) Lubricate all the components with the spec-

ified gear oil prior to assembly.

(2) Install new input shaft and striking rod

oil
seals to the clutch housing in the direction noted on
removal. Lubricate the oil seal lips with multipurpose
grease prior to installation.

(3) Assemble the components of the fifth gear

synchro assembly aligning the marks made on dis-
mantling. Ensure that the ends of the shift plate
springs are not aligned.

(4) Install the split bearing to the rear of the

input shaft and install the fifth gear.

(5) Install the fifth gear synchro assembly and the

shift retainer to the rear of the input shaft. Ensure that
the slots in the synchro ring are aligned with the shift

plates.

Check the friction surfaces of the input shaft for pitting.

Dismantled view of the fifth gear synchro assembly.

Illustration showing the correct positioning of the shift

plates and springs.