Nissan Almera Tino V10 (2001 year). Manual — part 179

SMT747D

a.

Using dial gauge as shown in the figure, measure dimension
“P1” between transaxle case end face and mainshaft rear
bearing.

SMT748D

b.

Using dial gauge as shown in the figure, measure dimension
“P2” between adjusting shim mounting face of rear cover and
transaxle mounting face.

SMT646D

16. Using snap ring pliers as shown in the figure, install snap ring.

CAUTION:

Do not reuse snap ring.
17. Install selected mainshaft adjusting shim.

SMT753DA

18. Install reverse idler gear, O-ring, thrust washers (front, rear),

and bearing onto reverse idler shaft.

19. Install snap ring into transaxle case using snap ring pliers.

CAUTION:

+

Do not reuse snap ring.

+

Do not reuse O-ring.

+

Before installation, apply gear oil to O-ring.

SMT754D

20. Using feeler gauge, measure the end play of snap ring, and

select a snap ring suitable to satisfy the following specification.

End play:

0.05 - 0.25 mm (0.0020 - 0.0098 in)

Available snap ring:

Refer to SDS, MT-90.

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-60

SMT644D

21. Install selected snap ring.

CAUTION:

Do not reuse snap ring.
22. Apply gear oil to rear cover O-ring, and install rear cover, side

cover gasket, and side cover. Then tighten mounting bolts with
specified torque.

Tightening torque:

Refer to MT-24.

CAUTION:

Do not reuse mounting bolts for rear cover and side cover.

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-61

NLMT0009

Case Components

NLMT0009S02

SMT943D

1.

Speedometer pinion

2.

Differential oil seal

3.

Drain plug

4.

Boot

5.

Striking rod oil seal

6.

Magnet

7.

Clutch housing

8.

Input shaft oil seal

9.

Oil channel (Mainshaft)

10. Oil pocket
11. Oil gutter
12. Oil channel (Input shaft)
13. Transmission case

14. Filler plug
15. O-ring
16. Movable plate assembly
17. PNP switch (where fitted)
18. Breather hose
19. Breather pipe

OVERHAUL

RS5F50A

Case Components

MT-62

Gear Components

NLMT0009S03

SMT937D

1.

Input shaft

2.

Input shaft front bearing

3.

3rd input gear

4.

3rd & 4th synchronizer hub

5.

Snap ring

6.

Coupling sleeve

7.

4th baulk ring

8.

4th input gear

9.

Reverse baulk ring

10. Reverse synchronizer cone
11. 5th synchronizer hub
12. Input shaft rear bearing
13. Input shaft bearing adjusting shim
14. 3rd baulk ring
15. Insert spring
16. 4th input gear thrust washer
17. Thrust washer ring
18. 5th input gear

19. 5th baulk ring
20. 1st outer baulk ring
21. 2nd inner baulk ring
22. Snap ring
23. Mainshaft bearing spacer
24. Mainshaft front bearing
25. Mainshaft
26. 1st main gear
27. 1st & 2nd synchronizer hub
28. Reverse main gear & 1st-2nd cou-

pling sleeve

29. 2nd outer baulk ring
30. 2nd gear synchronizer cone
31. 2nd main gear
32. 3rd main gear
33. 4th main gear
34. 5th main gear
35. Mainshaft rear bearing
36. Mainshaft bearing adjusting shim

37. Differential side bearing
38. Speedometer drive gear
39. Differential case
40. Pinion mate shaft
41. Side gear
42. Side gear thrust washer
43. Pinion mate gear
44. Pinion mate gear thrust washer
45. Retaining pin
46. Final gear
47. Differential side bearing
48. Differential side bearing adjusting

shim

49. Reverse idler gear
50. Bushing
51. Reverse idler shaft
52. 1st gear synchronizer cone
53. 1st inner baulk ring

OVERHAUL

RS5F50A

Gear Components

MT-63

Shift Control Components

NLMT0009S04

SMT862CA

1.

Retaining pin

2.

1st & 2nd shift fork

3.

1st & 2nd check plug

4.

Return spring

5.

Check ball

6.

1st & 2nd fork rod

7.

1st & 2nd bracket

8.

Interlock plunger

9.

3rd & 4th bracket

10. Return spring
11. Reverse gate
12. Select arm
13. Return bearing
14. Bush

15. Yoke
16. Striking rod
17. Striking lever
18. Selector
19. Selector shaft
20. O-ring
21. Return spring
22. Cam pin
23. Reverse check cam
24. Check ball
25. Select check spring
26. Interlock plunger
27. 3rd & 4th fork rod

28. Interlock ball
29. Stopper ring
30. 3rd & 4th check plug
31. 3rd & 4th shift fork
32. 5th shift fork
33. 5th fork rod
34. 5th & reverse check plug
35. Reverse lever spring
36. Reverse lock spring
37. 5th & reverse bracket
38. Reverse lever assembly
39. Reverse arm shaft
40. Control lever spring

OVERHAUL

RS5F50A

Shift Control Components

MT-64

NLMT0010

SMT626D

1.

Before removing transmission case, remove bolts, check
plugs, springs and check balls as shown left.

+

Be careful not to lose check balls.

2.

Remove transmission case.

SMT017AA

3.

Remove PNP switch.

SMT659C

4.

Mesh 4th gear, and then remove reverse idler shaft and
reverse idler gear.

SMT660C

5.

Pull out retaining pin.

SMT661C

6.

Remove reverse lever spring and reverse lock spring from
reverse lever assembly.

DISASSEMBLY

RS5F50A

MT-65

SMT662C

7.

Remove reverse arm shaft while rotating it.

SMT663C

8.

Remove reverse lever assembly and check ball.

+

Be careful not to lose check ball.

SMT018B

9.

Remove 5th & reverse check plug, spring and ball.

+

Be careful not to lose check ball.

SMT664C

10. Remove stopper rings and retaining pins from 5th and 3rd &

4th fork rods.
When removing stopper rings. Use snap ring remover and
installer.

11. Remove 5th and 3rd & 4th fork rods. Then remove forks and

brackets.

SMT105C

12. Remove both input and mainshafts with 1st & 2nd fork and fork

rod as a set.

13. Remove final drive assembly.

+

Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.

DISASSEMBLY

RS5F50A

MT-66

SMT138A

14. Remove reverse check assembly and check ball.

+

Be careful not to lose check ball.

SMT618AA

SMT027A

15. Remove retaining pin and detach the selector.

SMT028A

16. Remove drain plug for convenience in removing retaining pin

which holds striking lever to striking rod.

SMT619AA

17. Remove retaining pin and then withdraw striking lever and

striking rod.

DISASSEMBLY

RS5F50A

MT-67

SMT121C

Input Shaft and Gears

DISASSEMBLY

NLMT0011

1.

Before disassembly, check 3rd, 4th and 5th input gear end
plays.

Gear end play:

Refer to SDS, MT-97.

SMT476C

+

If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Check clearance of snap ring
groove. Refer to “ASSEMBLY”, MT-70.

SMT634AA

2.

Remove input shaft rear bearing.

SMT205BA

3.

Remove 5th & reverse synchronizer and 5th input gear.

SMT474CA

4.

Remove thrust washer ring, 4th input gear thrust washers and
4th input gear.

REPAIR FOR COMPONENT PARTS

RS5F50A

Input Shaft and Gears

MT-68

SMT040A

5.

Remove snap ring.

SMT041AA

6.

Remove 3rd & 4th synchronizer and 3rd input gear.

SMT042AA

7.

Remove input shaft front bearing.

SMT636A

INSPECTION

NLMT0012

Input shaft and Gears

NLMT0012S01

+

Check input shaft for cracks, wear or bending.

+

Check gears for excessive wear, chips or cracks.

SMT637A

Synchronizer

NLMT0012S02

+

Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.

+

Check baulk rings for cracks or deformation.

+

Check insert springs for wear or deformation.

REPAIR FOR COMPONENT PARTS

RS5F50A

Input Shaft and Gears (Cont’d)

MT-69

SMT140

+

Measure clearance between baulk ring and gear (3rd, 4th and
5th).

Clearance between baulk ring and gear:

Standard

1.0 - 1.35 mm (0.0394 - 0.0531 in)

Wear limit

0.7 mm (0.028 in)

SMT516B

+

Measure wear of reverse baulk ring.

1.

Place reverse baulk ring on disc and then place reverse syn-
chronizer cone on reverse baulk ring.

+

Make sure projection of synchronizer cone is positioned
over the recess on Tool.

2.

While holding reverse synchronizer cone against reverse baulk
ring as firmly as possible, measure dimension “A” with dial
indicator.

Wear limit:

Dimension “A” 1.2 mm (0.047 in)

3.

If dimension “A” is smaller than the wear limit, replace baulk
ring.

SMT148A

Bearing

NLMT0012S03

+

Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

SMT122C

ASSEMBLY

NLMT0013

REPAIR FOR COMPONENT PARTS

RS5F50A

Input Shaft and Gears (Cont’d)

MT-70

SMT441C

1.

Place inserts in three grooves on coupling sleeve (3rd & 4th
synchronizer).

SMT477C

SMT123C

2.

Install 3rd input gear and 3rd baulk ring.

3.

Press on 3rd & 4th synchronizer hub.

+

Pay attention to its direction.

4.

Select proper snap ring of 3rd & 4th synchronizer hub to mini-
mize clearance of groove, and then install it.

Allowable clearance of groove:

0 - 0.1 mm (0 - 0.004 in)

Snap ring of 3rd & 4th synchronizer hub:

Refer to SDS, MT-98.

SMT442C

5.

Install 4th input gear.

6.

Select proper thrust washers to minimize clearance of groove.
Then install them and thrust washer ring.

Allowable clearance of groove:

0 - 0.06 mm (0 - 0.0024 in)

4th input gear thrust washer:

Refer to SDS, MT-98.

SMT206B

7.

Install 5th & reverse synchronizer assembly.

a.

Hook insert springs on reverse baulk ring.

REPAIR FOR COMPONENT PARTS

RS5F50A

Input Shaft and Gears (Cont’d)

MT-71

SMT752C

b.

Install insert springs with reverse baulk ring onto coupling
sleeve.

+

Pay attention to position of insert springs.

c.

Place 5th baulk ring on 5th input gear.

d.

Install reverse synchronizer cone on reverse baulk ring.

SMT208B

e.

Place reverse synchronizer assembly on 5th input gear.

+

Mesh recesses of 5th input gear with projections of
reverse synchronizer cone.

+

Put insert spring mounts on reverse baulk ring upon those
on 5th baulk ring.

SMT124C

f.

Press on 5th & reverse synchronizer assembly with 5th input
gear.

SMT753CA

8.

Install input shaft front and rear bearings.

9.

Measure

gear

end

play

as

a

final

check.

Refer

to

“DISASSEMBLY”, MT-68.

REPAIR FOR COMPONENT PARTS

RS5F50A

Input Shaft and Gears (Cont’d)

MT-72

SMT191A

Mainshaft and Gears

DISASSEMBLY

NLMT0014

1.

Before disassembly, check 1st and 2nd main gear end plays.

Gear end play:

Refer to SDS, MT-97.

If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Check clearance of snap ring
groove. Refer to “ASSEMBLY”, MT-75.

SMT638AA

2.

Press out mainshaft rear bearing.

SMT044A

3.

Remove thrust washer and snap ring.

SMT045AA

4.

Press out 5th main gear and 4th main gear.

SMT131AA

5.

Press out 3rd main gear and 2nd main gear.

REPAIR FOR COMPONENT PARTS

RS5F50A

Mainshaft and Gears

MT-73

SMT047A

6.

Remove snap ring.

SMT048A

7.

Remove 1st & 2nd synchronizer hub and 1st main gear.

SMT639AA

8.

Remove mainshaft front bearing.

SMT640A

INSPECTION

NLMT0015

Mainshaft and Gears

NLMT0015S01

+

Check mainshaft for cracks, wear or bending.

+

Check gears for excessive wear, chips or cracks.

SMT637A

Synchronizer

NLMT0015S02

+

Check spline portion of coupling sleeves, hubs and gears for
wear or cracks.

+

Check baulk rings for cracks or deformation.

+

Check insert springs for deformation.

REPAIR FOR COMPONENT PARTS

RS5F50A

Mainshaft and Gears (Cont’d)

MT-74

SMT420CA

+

Measure wear of 1st and 2nd double baulk rings.

a)

Place baulk rings in position on synchronizer cone.

b)

While holding baulk ring against synchronizer cone as far as it
will go, measure dimensions “A” and “B”.

Standard:

A 0.6 - 0.8 mm (0.024 - 0.031 in)
B 0.6 - 1.1 mm (0.024 - 0.043 in)

Wear limit:

0.2 mm (0.008 in)

c)

If dimension “A” or “B” is smaller than the wear limit, replace
outer baulk ring, inner baulk ring and synchronizer cone as a
set.

SPD715

Bearing

NLMT0015S03

+

Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

+

When replacing tapered roller bearing, replace outer and
inner race as a set.

SMT996B

ASSEMBLY

NLMT0016

REPAIR FOR COMPONENT PARTS

RS5F50A

Mainshaft and Gears (Cont’d)

MT-75