Almera Tino V10 (2003 year). Manual — part 230

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

I

Check input shaft for cracks, wear or bending.

I

Check gears for excessive wear, chips or cracks.

SMT637A

Synchronizer

NLMT0012S02

I

Check spline portion 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.

REPAIR FOR COMPONENT PARTS

RS5F50A

Input Shaft and Gears (Cont’d)

MT-70

SMT140

I

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

I

Measure wear of reverse baulk ring.

1.

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

I

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

I

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

SMT122C

ASSEMBLY

NLMT0013

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

REPAIR FOR COMPONENT PARTS

RS5F50A

Input Shaft and Gears (Cont’d)

MT-71

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.

I

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-99.

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-99.

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-72

SMT752C

b.

Install insert springs with reverse baulk ring onto coupling
sleeve.

I

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.

I

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

I

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-69.

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

REPAIR FOR COMPONENT PARTS

RS5F50A

Input Shaft and Gears (Cont’d)

MT-73

SMT191A

Mainshaft and Gears

DISASSEMBLY

NLMT0014

1.

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

Gear end play:

Refer to SDS, MT-98.

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-76.

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-74

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

I

Check mainshaft for cracks, wear or bending.

I

Check gears for excessive wear, chips or cracks.

SMT637A

Synchronizer

NLMT0015S02

I

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

I

Check baulk rings for cracks or deformation.

I

Check insert springs for deformation.

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

REPAIR FOR COMPONENT PARTS

RS5F50A

Mainshaft and Gears (Cont’d)

MT-75

SMT420CA

I

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

I

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

I

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-76

SMT804BA

SMT472C

1.

Press on 1st main gear, 1st synchronizer cone, inner & outer
baulk rings and 1st & 2nd synchronizer hub.
Refer to the illustration for step 3.

I

Pay attention to direction of 1st & 2nd synchronizer hub.

2.

Select proper snap ring of 1st & 2nd 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 1st & 2nd synchronizer hub:

Refer to SDS, MT-99.

SMT805B

3.

Install 2nd synchronizer cone, inner & outer baulk rings. Insert
springs and 1st & 2nd coupling sleeve.

4.

Install 2nd main gear.

I

Ensure four protrusions of 2nd synchronizer cone are set in
holes of 2nd main gear.

SMT600CA

5.

Press on 3rd main gear.

6.

Press on 4th main gear.

SMT473CA

7.

Press on 5th main gear.

8.

Select proper snap ring of 5th main gear to minimize clearance
of groove and then install it.

Allowable clearance of groove:

0 - 0.15 mm (0 - 0.0059 in)

Snap ring of 5th main gear:

Refer to SDS, MT-99.

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

REPAIR FOR COMPONENT PARTS

RS5F50A

Mainshaft and Gears (Cont’d)

MT-77

SMT059A

9.

Press on thrust washer and press on mainshaft rear bearing.

10. Press on mainshaft front bearing.
11. Measure

gear

end

play

as

a

final

check.

Refer

to

“DISASSEMBLY”, MT-74.

SMT744AA

Final Drive

DISASSEMBLY

NLMT0017

1.

Remove final gear.

2.

Remove speedometer drive gear by cutting it.

3.

Press out differential side bearings.

I

Be careful not to mix up the right and left bearings.

SMT612AA

4.

Drive out retaining pin and draw out pinion mate shaft.

5.

Remove pinion mate gears and side gears.

SMT083A

INSPECTION

NLMT0018

Gear, Washer, Shaft and Case

NLMT0018S01

I

Check mating surfaces of differential case, side gears and
pinion mate gears.

I

Check washers for wear.

SPD715

Bearings

NLMT0018S03

I

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

I

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

REPAIR FOR COMPONENT PARTS

RS5F50A

Mainshaft and Gears (Cont’d)

MT-78

SMT062A

ASSEMBLY

NLMT0019

1.

Attach side gear thrust washers to side gears, then install pin-
ion mate washers and pinion mate gears in place.

SMT087A

2.

Insert pinion mate shaft.

I

When inserting, be careful not to damage pinion mate
thrust washers.

SMT610AH

3.

Measure clearance between side gear and differential case
with washers following the procedure below:

a.

Set Tool and dial indicator on side gear.

b.

Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.

Clearance between side gear and differential case with
washers:

0.1 - 0.2 mm (0.004 - 0.008 in)

SMT611A

c.

If not within specification, adjust clearance by changing thick-
ness of side gear thrust washers.

Differential side gear thrust washer:

Refer to SDS, MT-99.

SMT612AA

4.

Install retaining pin.

I

Make sure that retaining pin is flush with case.

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

REPAIR FOR COMPONENT PARTS

RS5F50A

Final Drive (Cont’d)

MT-79

SMT609A

5.

Install final gear.

6.

Install speedometer drive gear.

SMT648

7.

Press on differential side bearings.

SMT665C

Shift Control Components

INSPECTION

NLMT0020

I

Check contact surface and sliding surface for wear, scratches,
projections or other damage.

SMT030A

Case Components

REMOVAL AND INSTALLATION

NLMT0021

Input Shaft Oil Seal

NLMT0021S01

REPAIR FOR COMPONENT PARTS

RS5F50A

Final Drive (Cont’d)

MT-80

SMT031A

I

Apply multi-purpose grease to seal lip of oil seal before
installing.

SMT034A

Mainshaft Front Bearing Outer Race

NLMT0021S02

I

Extract the oil channel and remove the mainshaft front bear-
ing outer race.

Mainshaft Rear Bearing Outer Race

NLMT0021S03

Refer to “Mainshaft Bearing Preload”, MT-100.

Differential Side Bearing Outer Race

NLMT0021S04

Refer to “Input Shaft End Play and Differential Side Bearing
Preload”, MT-100.

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

REPAIR FOR COMPONENT PARTS

RS5F50A

Case Components (Cont’d)

MT-81

NLMT0022

Input Shaft End Play and Differential Side
Bearing Preload

NLMT0022S01

If any of the following parts are replaced, adjust input shaft end
play.

I

Input shaft

I

Input shaft bearing

I

Clutch housing

I

Transmission case

If any of the following parts are replaced, adjust differential side
bearing preload.

I

Differential case

I

Differential side bearing

I

Clutch housing

I

Transmission case

SMT132AA

1.

Remove differential side bearing outer race (transmission case
side) and shim(s).

SMT845B

2.

Reinstall differential side bearing outer race without shim(s).

3.

Install input shaft and final drive assembly on clutch housing.

4.

Install transmission case without input shaft bearing shim(s).
Then tighten it to the specified torque.
Refer to “Case Components”, MT-63.

SMT074A

5.

Using the following procedures, measure clearance between
bearings and transmission case.

DIFFERENTIAL SIDE

NLMT0022S0101

1.

Attach dial indicator. If clamp diameter of dial indicator is too
small or too large, attach dial indicator using a magnetic stand.

ADJUSTMENT

RS5F50A

Input Shaft End Play and Differential Side Bearing Preload

MT-82

SMT075AA

2.

Insert Tool all the way into differential side gear. Move Tool up
and down and measure dial indicator deflection.

SMT076A

INPUT SHAFT SIDE

NLMT0022S0102

1.

Set dial indicator on end of input shaft.

2.

Move input shaft up and down and measure dial indicator
deflection.

3.

Select shims with proper thickness with SDS table as a guide.
Refer to SDS, MT-102.

4.

Install selected differential side bearing adjusting shim and dif-
ferential side bearing outer race.

SMT475C

5.

Check differential side bearing turning torque.

a.

Install final drive assembly on clutch housing.

b.

Install transmission case on clutch housing.

I

Tighten transmission case fixing bolts to the specified
torque. Refer to “Case Components”, MT-63.

Mainshaft Bearing Preload

NLMT0022S02

If any of the following parts are replaced, adjust mainshaft bearing
preload.

I

Mainshaft

I

Mainshaft bearings

I

Clutch housing

I

Transmission case

SMT077AA

1.

Remove mainshaft rear bearing outer race and shim(s).

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

ADJUSTMENT

RS5F50A

Input Shaft End Play and Differential Side Bearing Preload (Cont’d)

MT-83

SMT644AA

2.

Reinstall mainshaft rear bearing outer race without shims.

3.

Clean mating surfaces of clutch housing and transmission
case with solvent.

4.

Install mainshaft and mainshaft front bearing outer race into
transmission case. Turn mainshaft while holding bearing outer
race so that bearings are properly seated.

SMT078A

SMT079A

5.

Put straightedge [width must be more than 50 mm (1.97 in)] on
transmission case, and measure the distance from upper sur-
face of straightedge to surface of the bearing outer race using
a depth micrometer.

I

Measure at three places on bearing outer race, and take
the average.

6.

Determine dimension A to be used by the following equation.

Dimension A = Width of straightedge − measured dis-
tance

7.

Measure the distance from mating surface of clutch housing to
portion with which mainshaft front bearing outer race is to be
mated.

I

Measure at three places on the portion, and take the aver-
age.

Dimension B = Measured distance

8.

Determine dimension C to be used by the following equation.

Dimension “C” = B − A

9.

Determine total thickness of shims with SDS table as a guide.

Mainshaft bearing adjusting shim:

Refer to SDS, MT-100.

10. Install selected mainshaft bearing adjusting shim and main-

shaft bearing outer race.

11. Check total turning torque after assembly — Refer to

“ASSEMBLY”, MT-85.

ADJUSTMENT

RS5F50A

Mainshaft Bearing Preload (Cont’d)

MT-84

NLMT0093

SMT029AA

1.

Install striking lever and striking rod.

SMT645AA

2.

Install selector and retaining pin.

SMT138A

3.

Install check ball and reverse check assembly.

I

Before installation, rotate striking rod as shown in the fig-
ure to avoid interference.

SAT601C

4.

Install final drive assembly.

5.

Install input shaft and mainshaft with 1st & 2nd shift fork
assembly.

I

Be careful not to damage input shaft oil seal.

SMT065A

6.

Install interlock balls and plunger.

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

ASSEMBLY

RS5F50A

MT-85