Almera Tino V10 (2003 year). Manual — part 222
MT-6
[RS6F51R]
PREPARATION
Commercial Service Tools
ECS0095K
KV38102510
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
●
1st bushing installation
●
1st-2nd synchronizer hub installation
●
Differential side bearing installation
KV38105900
Preload adapter
●
Checking differential side gear end play
Tool number
Tool name
Description
ZZA0838D
NT087
Tool name
Description
Puller
●
Each bearing gear and bushing removal
Puller
●
Each bearing gear and bushing removal
Pin punch
Tip diameter: 4.5 mm (0.177 in) dia.
●
Each retaining pin removal and installation
Power tool
●
Loosening bolts and nuts
ZZB0823D
NT077
ZZA0815D
PBIC0190E
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
MT-7
[RS6F51R]
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting Chart
ECS0095L
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
MANUAL TRANSAXLE
Reference page
SUSPECTED PARTS
(Possible cause)
OIL
(O
il
le
v
e
l
is
lo
w
.)
O
IL
(Wron
g
oil
.)
OIL
(O
il
le
v
e
l
is
h
ig
h
.)
G
A
S
KET
(D
am
age
d)
OIL
SEAL
(W
or
n
o
r
dam
age
d)
O
-R
IN
G
(Wor
n
o
r
dam
age
d)
S
H
IFT
C
ONTROL
L
INK
AG
E
(W
o
rn
)
C
H
E
C
K
PLU
G
R
E
TU
R
N
SPR
IN
G
A
N
D
C
H
E
C
K
BALL
(W
o
rn
or
dam
a
ged)
S
H
IFT
F
ORK
(W
o
rn
)
G
E
A
R
(W
or
n
o
r
dam
ag
ed)
B
EAR
IN
G
(Worn
or
dam
age
d)
B
A
U
L
K
R
IN
G
(W
o
rn
or
d
a
m
aged
)
IN
SER
T
SPR
IN
G
(D
a
ma
ged)
Symptoms
Noise
1
2
3
3
Oil leakage
3
1
2
2
2
Hard to shift or will not shift
1
1
2
3
3
Jumps out of gear
1
2
3
3
MT-8
[RS6F51R]
DESCRIPTION
DESCRIPTION
PFP:00000
Cross-Sectional View
ECS0095M
MCIA0009E
DESCRIPTION
MT-9
[RS6F51R]
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DOUBLE-CONE SYNCHRONIZER
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.
REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)
The gear can be matched smoothly in a structure by setting synchro-
nizer hub, coupling sleeve, baulk ring and insert spring to reverse
gear, and letting gear be synchronized.
SCIA0750E
SCIA0751E
MT-10
[RS6F51R]
M/T OIL
M/T OIL
PFP:KLD20
Changing M/T Oil
ECS0095N
DRAINING
1.
Start the engine and let it run to warm up the transaxle.
2.
Stop the engine. Remove drain plug and drain oil.
3.
Set a gasket on the drain plug and install it to the transaxle.
CAUTION:
Do not reuse gasket.
FILLING
1.
Remove filler plug. Fill with new oil until oil level reaches the specified limit near filler plug mounting hole.
2.
After refilling oil, check oil level. Assemble gasket to filler plug, then install it to transaxle body.
CAUTION:
Do not reuse gasket.
Checking M/T Oil
ECS0095O
OIL LEAKAGE AND OIL LEVEL
●
Check that oil is not leaking from transaxle or around it.
●
Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Never start engine while checking oil level.
●
Set a new gasket on the filler plug and install it on the transaxle.
CAUTION:
Do not reuse gasket.
Drain plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
Oil grade
: Genuine Nissan gear oil, SAE viscosity
75w - 80 or exact equivalent
Capacity (reference)
: Approx. 2.3
(4 lmp pt)
Filler plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
Filler plug:
: 30 - 39 N·m (3.1 - 3.9 kg-m, 23 - 28 ft-lb)
SCIA0361E
SIDE OIL SEAL
MT-11
[RS6F51R]
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SIDE OIL SEAL
PFP:32113
Removal and Installation
ECS0095P
REMOVAL
1.
Remove the drive shaft from the transaxle. Refer to AX-11, “Removal”.
2.
Remove oil seal with a slotted screwdriver.
CAUTION:
Be careful not to damage the case surface when removing
the oil seal.
INSTALLATION
1.
Using a drift (special service tool), drive the oil seal straight until
it protrudes from the case end equal to dimension A shown in
the figure.
Drift to be used:
CAUTION:
●
When installing oil seals, apply multi-purpose grease to oil seal lips.
●
Do not reuse oil seal.
2.
Install all parts in reverse order of removal and check oil level after installation.
SCIA0824E
Dimension A
: Within 0.5 mm of flush with the case.
MCIA0141E
Transaxle case side
ST3072 0000
Clutch housing side
MT-12
[RS6F51R]
POSITION SWITCH
POSITION SWITCH
PFP:32005
Checking
ECS0095Q
BACK-UP LAMP SWITCH
●
Check continuity.
NEUTRAL POSITION SWITCH
●
Check continuity.
Gear position
Continuity
Reverse
Yes
Except reverse
No
SCIA0708E
Gear position
Continuity
Neutral
Yes
Except neutral
No
CONTROL LINKAGE
MT-13
[RS6F51R]
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CONTROL LINKAGE
PFP:34103
Removal and Installation of Control Device and Cable
ECS0095R
Refer to the figure for removal and installation procedure.
CAUTION:
●
Keep in mind that the select side lock plate for securing the control cable is different from the one
on the shift side.
●
After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st,
2nd, or Reverse.
MCIA0120E
MT-14
[RS6F51R]
AIR BREATHER HOSE
AIR BREATHER HOSE
PFP:31098
Removal and Installation
ECS0095S
Refer to the figure for air breather hose removal and installation information.
CAUTION:
●
Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
●
Be sure to insert hose into the transaxle tube until overlap area reaches the spool.
SCIA0747E
TRANSAXLE ASSEMBLY
MT-15
[RS6F51R]
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MT
TRANSAXLE ASSEMBLY
PFP:32010
Removal and Installation
ECS0095T
REMOVAL
1.
Remove battery and its bracket.
2.
Remove fuse box from battery bracket.
3.
Remove air cleaner box with mass air flow sensor.
4.
Remove air breather hose and vacuum pump hose.
5.
Remove fuel filter bracket.
6.
Remove clutch operating cylinder.
CAUTION:
Do not depress clutch pedal during removal procedure.
7.
Disconnect control cable from transaxle.
8.
Drain gear oil from transaxle.
9.
Disconnect neutral switch and back-up lamp switch harness connectors.
10. Remove starter motor.
11. Remove crankshaft position sensor (POS) from transaxle.
12. Remove exhaust front tube and the drive shaft.
13. Place a jack onto the transaxle.
CAUTION:
When setting jack, be careful not to bring it into contact with the switch.
14. Remove center member, engine insulator and engine mount bracket.
15. Support engine by placing a jack under oil pan.
16. Remove bolts securing transaxle to engine.
MCIA0121E
MT-16
[RS6F51R]
TRANSAXLE ASSEMBLY
17. Remove transaxle from vehicle.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
●
When installing the transaxle to the engine, tighten to the specified torque.
CAUTION:
When installing transaxle, be careful not to bring transaxle input shaft into contact with the clutch
cover.
●
After installation, check oil level, and look for leaks and loose
mechanisms.
MTD0062D
Bolt No.
1
2
3
4
5
6
Quantity
2
2
1
1
3
1
“
” mm (in)
55
(2.17)
70
(2.76)
120
(4.72)
45
(1.77)
40
(1.57)
35
(1.38)
Tightening torque
N·m (kg-m, ft-lb)
39 - 49
(4.0 - 5.0, 29 - 36)
42 - 52
(4.2 - 5.3, 30 - 38)
MCIA0014E
TRANSAXLE ASSEMBLY
MT-17
[RS6F51R]
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Component Parts
ECS0095U
CASE AND HOUSING COMPONENTS
1.
Clutch housing
2.
Input shaft oil seal
3.
Oil channel
4.
Magnet
5.
Differential oil seal
6.
Ball pin
7.
Washer
8.
Transaxle case
9.
Welch plug
10. Bore plug
11. Differential oil seal
12. Park/Neutral position switch
13. Oil gutter
14. Back-up lamp switch
15. Air breather tube
16. Baffle plate
17. Filler plug
18. Gasket
19. Drain plug
20. Gasket
MCIA0122E
MT-18
[RS6F51R]
TRANSAXLE ASSEMBLY
GEAR COMPONENTS
1.
Input shaft front bearing
2.
Input shaft
3.
Needle bearing
4.
3rd input gear
5.
3rd baulk ring
6.
Spread spring
7.
3rd & 4th shifting insert
8.
3rd & 4th synchronizer hub
9.
4th baulk ring
10.
3rd & 4th coupling sleeve
11.
Bushing
12. Needle bearing
13.
4th input gear
14. Thrust washer
15. Bushing
16.
Needle bearing
17. 5th input gear
18. 5th baulk ring
19.
5th & 6th shifting insert
20. 5th & 6th synchronizer hub
21. 5th & 6th coupling sleeve
22.
6th baulk ring
23. 6th input gear
24. Needle bearing
25.
Bushing
26. Snap ring
27. Input shaft rear bearing
28.
Oil channel
29. Input shaft rear bearing adjusting
shim
30. Retaining pin
31.
Reverse idler shaft
32. Thrust bearing washer
33. Thrust bearing
34.
Needle bearing
35. Reverse idler gear (Front)
36. Reverse baulk ring
37.
Reverse coupling sleeve
38. Insert spring
39. Reverse idler gear (Rear)
40.
Reverse idler gear adjusting shim
MCIA0143E
TRANSAXLE ASSEMBLY
MT-19
[RS6F51R]
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MT
1.
Mainshaft front bearing
2.
Mainshaft bearing retainer
3.
Mainshaft
4.
Reverse main gear
5.
1st main gear
6.
Bushing
7.
Needle bearing
8.
1st inner baulk ring
9.
1st gear synchronizer cone
10. 1st outer baulk ring
11.
Spread spring
12. 1st & 2nd shifting insert
13. 1st & 2nd synchronizer hub
14. 2nd outer baulk ring
15. 2nd gear synchronizer cone
16. 2nd inner baulk ring
17. 1st & 2nd coupling sleeve
18. Bushing
19. Needle bearing
20. 2nd main gear
21. 3rd main gear
22. 3rd & 4th mainshaft spacer
23. 4th main adjusting shim
24. 4th main gear
25. 5th main gear
26. 6th main gear
27. Mainshaft rear bearing
28. Mainshaft C ring
29. C ring holder
30. Snap ring
31. Snap ring
32. Mainshaft rear bearing adjusting
shim
33. 5th & 6th mainshaft spacer
34. 6th main adjusting shim
SCIA0957E
MT-20
[RS6F51R]
TRANSAXLE ASSEMBLY
SHIFT CONTROL COMPONENTS
1.
Reverse shift fork
2.
Shifter cap
3.
Reverse fork rod
4.
Reverse lever assembly
5.
5th & 6th bracket
6.
5th & 6th fork rod
7.
5th & 6th shift fork
8.
Retaining pin
9.
3rd & 4th bracket
10. 3rd & 4th shift fork
11. 3rd & 4th fork rod
12. 1st & 2nd shift fork
13. 1st & 2nd bracket
14. 1st & 2nd fork rod
15. Shift check sleeve
16. Inter lock pin
17. Check ball
18. Shift check sleeve
19. Check spring
20. Check plug
21. Control assembly
22. O ring
23. Shift check
24. Stopper bolt
25. Stopper ring
26. Reverse bracket fork rod
27. Reverse bracket
SCIA0958E
TRANSAXLE ASSEMBLY
MT-21
[RS6F51R]
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MT
FINAL DRIVE COMPONENTS
Disassembly and Assembly
ECS0095V
DISASSEMBLY
1.
Remove drain plug and filler plug.
2.
Remove park/neutral position switch and back-up lamp switch.
3.
After removing shift check and stopper bolt, remove control
assembly.
1.
Differential side bearing outer race
2.
Differential side bearing
3.
Speedometer drive gear
4.
Differential case
5.
Final gear
6.
Differential side bearing
7.
Differential side bearing outer race
8.
Differential side bearing adjusting
shim
9.
Pinion mate shaft
10. Side gear
11. Side gear thrust washer
12. Pinion mate gear
13. Pinion mate gear washer
14. Retaining pin
SCIA0998E
SCIA0389E
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