Nissan Primera P11. Manual — part 521

8.

Remove 4th input gear, baulk ring, 4th gear needle bearing,
and 4th gear C-ring from input shaft.

9.

Press out both 3rd & 4th synchronizer hub assembly and 3rd
input gear from input shaft.

10. Remove 3rd gear needle bearing.

11. Press out input shaft front bearing from input shaft.

INSPECTION

NCMT0011

Gear and Shaft

NCMT0011S01

I

Check shaft for cracks, wear or bending.

I

Check gears for excessive wear, chips or cracks.

Synchronizers

NCMT0011S02

I

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

I

Check baulk rings for cracks or deformation.

I

Check insert springs for wear or deformation.

I

If any crack, damage, or excessive wear is found on cam face
of baulk ring or working face of insert, replace it.

SMT675D

3rd & 4th
synchronizer
hub assembly

3rd input gear

SMT676D

Input shaft
front bearing

SMT693D

SMT637A

SMT867D

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears (Cont’d)

MT-59

I

Measure the movement (play, dimension “L”) of 3rd & 4th cou-
pling sleeve with their end fixed and the other end lifted as
shown in the figure. If the movement exceeds specification,
replace the sleeve.

Coupling sleeve

Length “L”

3rd & 4th

0 - 0.95 mm (0 - 0.0374 in)

I

Measure clearance between baulk ring and gear.

Clearance between baulk ring and gear:

Refer to SDS, MT-90.

Bearing

NCMT0011S03

I

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

ASSEMBLY

NCMT0012

1.

Press on input shaft front bearing.

2.

Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring
bearing to input shaft.

3.

Install spread spring, shifting insert, and 3rd & 4th synchronizer
hub onto 3rd & 4th coupling sleeve.

I

Pay attention to the shape of spread spring and shifting insert
for correct assembly.
Do not install spread spring hook onto the same shifting insert.

CAUTION:

Do not reuse 3rd & 4th synchronizer hub.

SMT841D

Fixed

3rd & 4th coupling sleeve

Dimension “L”

SMT140

Baulk ring to
gear clearance

SMT148A

SMT696D

Input shaft
front bearing

Input shaft

SMT694D

Shifting insert

(3rd & 4th) (5th & reverse)

Flat shape

R-shape

Spread spring

Shifting insert

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears (Cont’d)

MT-60

I

Install synchronizer hub with its three grooves facing the front
side (3rd input gear side).

I

Install 3rd & 4th coupling sleeve with its chamfered surface
facing the 4th input gear side.

4.

Position bearing replacer to the front side of input shaft front
bearing.

I

Align grooves of shifting insert and 3rd gear baulk ring. Then,
press it onto 3rd & 4th synchronizer hub assembly using a drift.

5.

Install 4th gear C-ring onto input shaft.

6.

Measure the end play of 3rd & 4th synchronizer hub, and
check if it is within allowable specification below.

End play specification:

0 - 0.06 mm (0 - 0.0024 in)

7.

If not within specification, adjust the end play by changing
thickness of 4th gear C-ring.

Available C-ring:

Refer to SDS, MT-90.

8.

Install 4th gear needle bearing, 4th gear baulk ring, and 5th
gear front C-ring.

9.

Install 4th input gear.

SMT695D

Front

SMT699D

4th input gear

3rd input gear

SMT698D

3rd & 4th
synchronizer
hub assembly

SMT700D

Feeler gauge

3rd & 4th
synchronizer
hub assembly

4th gear C-ring

SMT701D

5th gear front C-ring

4th gear needle
bearing

4th gear baulk ring

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears (Cont’d)

MT-61

10. Position 5th input gear as shown in the figure, and install it on

input shaft.

11. Install 5th input gear.

CAUTION:

Do not reuse 5th input gear.
12. Install 5th gear rear C-ring onto input shaft.

13. Measure the end play of 5th input gear, and check if it is within

the allowable specification below.

End play specification:

0 - 0.06 mm (0 - 0.0024 in)

14. If not within specification, adjust the end play by changing

thickness of the 5th gear rear C-ring.

Available C-ring:

Refer to SDS, MT-90.

15. Install C-ring holder onto 5th gear rear C-ring.

CAUTION:

Do not reuse C-ring holder.
16. Install input shaft rear bearing.

CAUTION:

Install input shaft rear bearing with its brown surface facing
the input gear side.

17. Install oil channel onto input shaft.
18. Measure gear end play as a final check. Refer to, MT-58.

SMT703D

5th input gear

4th input gear

SMT702D

5th input gear

4th input gear

SMT704D

5th input gear

5th rear C-ring

Feeler gauge

SMT705D

Input shaft rear bearing

C-ring holder

SMT671D

Oil channel

Input shaft

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears (Cont’d)

MT-62