Almera Tino V10 (2003 year). Manual — part 221

Maintenance Under Severe Driving Conditions
(Annual Driving Distance < 30,000 km/year)

=NLMA0043S03

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.

A — Driving under dusty conditions
B — Driving repeatedly short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity areas or in mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K — Sustained high speed driving
L — For models without Euro-OBD system

Driving condition

Maintenance item

Maintenance

operation

Maintenance interval

A

B

C

D

.

.

.

.

.

.

.

.

Engine oil & engine oil filter

Petrol models

Replace

Every 7,500 km (4,500 miles) or 6
months

Diesel models

Replace

Every 10,000 km (6,000 miles) or 6
months

A

.

.

.

.

.

.

.

.

.

.

.

Air cleaner filter

Petrol models

Replace

Every 30,000 km (18,000 miles) or
24 months

Diesel models

Replace

Every 30,000 km (18,000 miles) or
18 months

A

.

.

.

E

.

.

.

.

.

.

.

Fuel filter

Diesel models

Replace

Every 20,000 km (12,000 miles) or
12 months

.

.

.

.

.

.

.

.

.

.

.

L

Heated Oxygen Sensor 1 (Front)

Petrol models

Inspect

Every 30,000 km (18,000 miles) or
24 months

.

.

.

.

.

.

.

.

.

.

.

L

Heated Oxygen Sensor 2 (Rear)

Petrol models

Inspect

Every 30,000 km (18,000 miles) or
24 months

A

.

.

.

.

.

.

.

.

.

.

.

Ventilation air filter

Petrol models

Replace

Every 15,000 km (9,000 miles) or
12 months

Diesel models

Replace

Every 10,000 km (6,000 miles) or 6
months

.

.

.

.

.

F

.

.

.

.

.

.

Brake fluid

Petrol models

Replace

Every 15,000 km (9,000 miles) or
12 months

Diesel models

Replace

Every 20,000 km (12,000 miles) or
12 months

PERIODIC MAINTENANCE (FOR EUROPE)

Maintenance Under Severe Driving Conditions (Annual Driving Distance < 30,000 km/year)

MA-12

Driving condition

Maintenance item

Maintenance

operation

Maintenance interval

.

.

C

.

.

.

.

H

.

.

.

.

Automatic transaxle fluid

Petrol models

Replace

Every 30,000 km (18,000 miles) or
24 months

A

.

C

.

.

.

G

H

I

.

.

.

Brake pads, rotors & other brake system components

Petrol models

Inspect

Every 7,500 km (4,500 miles) or 6
months

Diesel models

Inspect

Every 10,000 km (6,000 miles) or 6
months

.

.

.

.

.

.

G

H

.

.

.

.

Steering gear & linkage, axle & suspension parts, drive shafts,
exhaust system

Petrol models

Inspect

Every 15,000 km (9,000 miles) or
12 months

Diesel models

Inspect

Every 20,000 km (12,000 miles) or
12 months

GI

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

PERIODIC MAINTENANCE (FOR EUROPE)

Maintenance Under Severe Driving Conditions (Annual Driving Distance < 30,000 km/year) (Cont’d)

MA-13

Maintenance Schedule for Petrol Engines
(Annual Mileage > 30,000 km/year)

=NLMA0043S08

QG18DE ENGINE

NLMA0043S0801

Abbreviations: R = Replace

I = Inspect: Correct or replace if necessary

MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Refer-

ence

pages

Perform on a kilometer basis only.

km x 1,000
(miles x 1,000)

15

(9)

30

(18)

45

(27)

60

(36)

75

(45)

90

(54)

105

(63)

120

(72)

Engine compartment and under vehicle

Engine oil (Use recommended oil)

★

R

R

R

R

R

R

R

R

LC-8

Engine oil filter (Use NISSAN genuine
part or equivalent)

★

R

R

R

R

R

R

R

R

LC-9

Drive belts

I

I

I

I

I

I

I

I

EM-13

Cooling system

I

I

I

I

LC-12

Engine anti-freeze coolant (Use genu-
ine NISSAN Anti-Freeze Coolant
(L250) or equivalent)

See NOTE (1)

I

R

I

LC-18

Air cleaner filter

★

R

R

EM-16

Intake & exhaust valve clearance

See NOTE (2)

EM-45

Fuel and EVAP vapor lines

I

I

FE-5/

EC-542

Spark plugs

R

R

R

R

—

Fuel filter

See NOTE (3)

FE-9

Heated oxygen sensor

★

See NOTE (4)

GI-40/

EC-188

or

EC-194

NOTE:
(1) First replace at 90,000 km (54,000 miles), then every 60,000 km (36,000 miles). Perform “I” (checking the mixture ratio and
correcting the mixture ratio if necessary) at the middle of replacement interval.
(2) Periodic maintenance is not required. However, if valve noise increases, check valve clearance.
(3) Fuel filter is maintenance-free. For service procedures, refer to FE section.
(4) Perform only according to “Maintenance Under Severe Driving Conditions” for models without Euro-OBD system. For
models with Euro-OBD system, periodic maintenance is not required.

★

Maintenance items with “

★

” should be performed more frequently according to “Maintenance Under Severe Driving Con-

ditions”.

PERIODIC MAINTENANCE (FOR EUROPE)

Maintenance Schedule for Petrol Engines (Annual Mileage > 30,000 km/year)

MA-14

CHASSIS AND BODY MAINTENANCE

=NLMA0043S0802

Abbreviations: R = Replace

I = Inspect: Correct or replace if necessary

MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Refer-

ence

pages

Perform on a kilometer basis only.

km x 1,000
(miles x 1,000)

15

(9)

30

(18)

45

(27)

60

(36)

75

(45)

90

(54)

105

(63)

120

(72)

Underhood and under vehicle

Headlamp aiming

I

I

I

I

EL-44

Wheel alignment (if necessary, balance
& rotate wheels)

I

I

I

I

SU-6/

SU-19

Brake pads, rotors & other brake com-
ponents

★

I

I

I

I

BR-27
BR-28

Foot brake, parking brake & clutch (for
free play, stroke & operation)

I

I

I

I

BR-14/
BR-44/

CL-9

Brake booster vacuum hoses,
connections, check valve

I

I

BR-20

Brake & clutch, systems and fluid (for
level and leaks)

I

I

I

I

BR-10

Brake fluid

★

R

R

BR-10

Power steering fluid and lines (for level
and leaks)

I

I

I

I

ST-7

Supplemental air bag systems

See NOTE (1)

RS-20

Ventilation air filter

★

R

R

R

R

ATC-124

Manual transaxle gear oil (check for
leakage. Use genuine NISSAN XZ
gear oil or exact equivalent)

I

I

I

I

MT-11

MT-12

Automatic transaxle fluid (for level and
leaks)

★

I

I

I

I

AT-13

Steering gear and linkage, axle & sus-
pension parts, drive shafts, exhaust
system

★

I

I

ST-7/

SU-6/

SU-19/

FE-11

Body corrosion

See NOTE (2)

BT-6

NOTE:
(1) Inspect after 10 years, then every 2 years.
(2) Inspect once per year.

★

Maintenance items with “

★

” should be performed more frequently according to “Maintenance Under Severe Driving Con-

ditions”.

GI

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

PERIODIC MAINTENANCE (FOR EUROPE)

Maintenance Schedule for Petrol Engines (Annual Mileage > 30,000 km/year) (Cont’d)

MA-15

Maintenance Schedule for Diesel Engines
(Annual Mileage > 30,000 km/year)

=NLMA0043S05

YD22 ENGINE

NLMA0043S0501

Abbreviations: R = Replace

I = Inspect: Correct or replace if necessary

MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Reference pages

Perform on a kilometer basis
only.

km x 1,000
(miles x 1,000)

20

(12)

40

(24)

60

(36)

80

(48)

100

(60)

120

(72)

Engine compartment and under vehicle

Engine oil (Use recommended
oil)

★

R

R

R

R

R

R

LC-27

Engine oil filter (Use NISSAN
genuine part or equivalent)

★

See NOTE (1)

R

R

R

R

R

R

LC-28

Drive belts

I

I

I

I

I

I

EM-117

Cooling system

I

I

I

I

I

I

LC-33

Engine anti-freeze coolant (Use
genuine NISSAN Anti-Freeze
Coolant (L250) or equivalent)

See NOTE (2)

I

I

LC-40

Air cleaner filter

★

R

R

EM-119

Intake & exhaust valve clearance

See NOTE (3)

EM-167

Fuel lines

I

I

FE-17

Injection nozzles

See NOTE (4)

EM-147

Fuel filter

★

R

R

FE-17

NOTE:
(1) Oil filter and O-ring seal are replacement parts.
(2) First replace at 100,000 km (60,000 miles), then every 60,000 km (36,000 miles). After first replacement, perform “I” (check-
ing the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval.
(3) If valve noise increases, check valve clearance.
(4) If engine power decreases, black exhaust smoke is emitted or engine noise increases, check injection nozzles and if
necessary, replace injection nozzle assembly.

★

Maintenance items with “

★

” should be performed more frequently according to “Maintenance Under Severe Driving Con-

ditions”.

PERIODIC MAINTENANCE (FOR EUROPE)

Maintenance Schedule for Diesel Engines (Annual Mileage > 30,000 km/year)

MA-16

CHASSIS AND BODY MAINTENANCE

=NLMA0043S0502

Abbreviations: R = Replace

I = Inspect: Correct or replace if necessary

MAINTENANCE OPERATION

MAINTENANCE INTERVAL

Refer-

ence

pages

Perform on a kilometer basis
only.

km x 1,000
(miles x
1,000)

10

(6)

20

(12)

30

(18)

40

(24)

50

(30)

60

(36)

70

(42)

80

(48)

90

(54)

100

(60)

110

(66)

120

(72)

Underhood and under vehicle

Headlamp aiming

I

I

I

EL-44

Wheel alignment (if
necessary, balance & rotate
wheels)

I

I

I

SU-15
SU-27

Brake pads, rotors & other
brake components

★

I

I

I

I

I

I

BR-27
BR-31

Foot brake, parking brake &
clutch (for free play, stroke &
operation)

I

I

I

I

I

I

BR-14
BR-43

CL-5

Brake booster vacuum hoses,
connections, check valve

I

I

BR-19

Brake & clutch, systems and
fluid (for level and leaks)

I

I

I

I

I

I

BR-10

CL-5

Brake fluid

★

R

R

BR-10

Power steering fluid and lines
(for level and leaks)

I

I

I

I

I

I

ST-7

Supplemental air bag systems

See NOTE
(1)

RS-16

Ventilation air filter

★

R

R

R

R

R

R

ATC-

124

Manual transaxle gear oil
(check for leakage. Use genu-
ine NISSAN XZ gear oil or
exact equivalent)

I

I

I

MT-11

MT-12

Steering gear & linkage, axle
& suspension parts, drive
shafts, exhaust system

★

I

I

ST-7

SU-5

SU-18

FE-11

FE-24

Body corrosion

See NOTE
(2)

BT-6

NOTE:
(1) Inspect after 10 years, then every 2 years.
(2) Inspect once per year.

★

Maintenance items with “

★

” should be performed more frequently according to “Maintenance Under Severe Driving Con-

ditions”.

GI

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

PERIODIC MAINTENANCE (FOR EUROPE)

Maintenance Schedule for Diesel Engines (Annual Mileage > 30,000 km/year) (Cont’d)

MA-17

Maintenance Under Severe Driving Conditions
(Annual Driving Distance > 30,000 km/year)

=NLMA0043S06

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance must be per-
formed on the following items as shown in the table.

A — Driving under dusty conditions
B — Driving repeatedly short distances
C — Towing a trailer or caravan
D — Extensive idling
E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either
extremely low or extremely high
F — Driving in high humidity areas or in mountainous areas
G — Driving in areas using salt or other corrosive materials
H — Driving on rough and/or muddy roads or in the desert
I — Driving with frequent use of braking or in mountainous areas
J — Frequent off road use or driving in water
K — Sustained high speed driving
L — For models without Euro-OBD system

Driving condition

Maintenance item

Maintenance

operation

Maintenance interval

A

B

C

D

.

.

.

.

.

.

.

.

Engine oil & engine oil filter

Petrol models

Replace

Every 7,500 km (4,500 miles)

Diesel models

Replace

Every 10,000 km (6,000 miles)

A

.

.

.

.

.

.

.

.

.

.

.

Air cleaner filter

Petrol models

Replace

Every 30,000 km (18,000 miles)

Diesel models

Replace

Every 30,000 km (18,000 miles)

A

.

.

.

E

.

.

.

.

.

.

.

Fuel filter

Diesel models

Replace

Every 30,000 km (18,000 miles)

.

.

.

.

.

.

.

.

.

.

.

L

Heated Oxygen Sensor 1 (Front)

Petrol models

Inspect

Every 60,000 km (36,000 miles)

.

.

.

.

.

.

.

.

.

.

.

L

Heated Oxygen Sensor 2 (Rear)

Petrol models

Inspect

Every 60,000 km (36,000 miles)

A

.

.

.

.

.

.

.

.

.

.

.

Ventilation air filter

Petrol models

Replace

Every 15,000 km (9,000 miles)

Diesel models

Replace

Every 10,000 km (6,000 miles)

.

.

.

.

.

F

.

.

.

.

.

.

Brake fluid

Petrol models

Replace

Every 30,000 km (18,000 miles)

Diesel models

Replace

Every 30,000 km (18,000 miles)

.

.

C

.

.

.

.

H

.

.

.

.

Automatic transaxle fluid

Petrol models

Replace

Every 60,000 km (36,000 miles)

A

.

C

.

.

.

G

H

I

.

.

.

Brake pads, rotors & other brake system components

Petrol models

Inspect

Every 15,000 km (9,000 miles)

Diesel models

Inspect

Every 10,000 km (6,000 miles)

PERIODIC MAINTENANCE (FOR EUROPE)

Maintenance Under Severe Driving Conditions (Annual Driving Distance > 30,000 km/year)

MA-18

Driving condition

Maintenance item

Maintenance

operation

Maintenance interval

.

.

.

.

.

.

G

H

.

.

.

.

Steering gear & linkage, axle & suspension parts, drive shafts,
exhaust system

Petrol models

Inspect

Every 30,000 km (18,000 miles)

Diesel models

Inspect

Every 30,000 km (18,000 miles)

GI

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

PERIODIC MAINTENANCE (FOR EUROPE)

Maintenance Under Severe Driving Conditions (Annual Driving Distance > 30,000 km/year) (Cont’d)

MA-19

NLMA0006

Fluids and Lubricants

NLMA0006S01

Recommended fluids and lubricants

Engine oil

QG engine

I

Except for Europe
API SE, SF, SG, SH, SJ or SL*1
ILSAC grade GF-I, GF-II or GF-III*1

I

For Europe
API SG, SH, SJ or SL*1
ILSAC grade GF-I, GF-II or GF-III*1
ACEA 96-A2

YD engine

I

Except for Europe
API CD, CE, CF or CF-4*1, *2

I

For Europe
API CF-4*1, *2
ACEA B1, B3

Cooling system

I

Except for Europe
Nissan genuine engine coolant, or equivalent in its quality*3

I

For Europe
Genuine Nissan Anti-freeze Coolant (L250) or equivalent*3

Manual transaxle gear oil

I

Except for Europe
API GL-4
Viscosity SAE 75W-90

I

For Europe
Genuine Nissan XZ gear oil or exact equivalent.

Automatic transaxle fluid

Genuine Nissan ATF or equivalent*4

Power steering fluid

Type Dexron

TM

III or equivalent

Brake and clutch fluid

I

Except for Europe
DOT 3 (US FMVSS No. 116)

I

For Europe
DOT 3 or DOT 4 (US FMVSS No. 116)*5

Multi-purpose grease

NLGI No. 2 (Lithium soap base)

*1: For further details, see “SAE Viscosity Number”.
*2: Never use API CG-4.
*3: Use Nissan genuine engine coolant [For Europe, use Genuine Nissan Anti-freeze Coolant (L250)] or equivalent in its quality, in order
to avoid possible aluminum corrosion within the engine cooling system caused by the use of non-genuine engine coolant.
Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be
covered by the warranty even if such incidents occurred during the warranty period.
*4: Contact a Nissan dealership for more information regarding suitable fluids, including recommended brand(s) of Dexron

TM

III/Mercon

TM

Automatic Transmission Fluid.
*5: Never mix different types of fluids (DOT 3 and DOT 4).

RECOMMENDED FLUIDS AND LUBRICANTS

Fluids and Lubricants

MA-20

SMA084D

SAE Viscosity Number

=NLMA0006S02

GASOLINE ENGINE

NLMA0006S0206

I

For warm and cold areas: 10W-30 is preferable for ambient
temperature above −20°C (−4°F).

I

5W-30 will positively improve fuel economy.

I

For hot areas: 20W-40 and 20W-50 are suitable.

SMA090D

DIESEL ENGINE

NLMA0006S0205

I

For cold areas: 5W-30 is preferable. On turbocharger models,
5W-20 is not recommended.

I

For hot and warm areas: 20W-40 and 20W-50 are suitable.

GI

EM

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

RECOMMENDED FLUIDS AND LUBRICANTS

SAE Viscosity Number

MA-21

SMA089D

Engine Coolant Mixture Ratio

=NLMA0006S03

The engine cooling system is filled at the factory with a high-quality,
year-round and extended life engine coolant. The high quality
engine coolant contains the specific solutions effective for the anti-
corrosion and the anti-freeze function. Therefore, additional cool-
ing system additives are not necessary.

CAUTION:

I

For Europe
When adding or replacing coolant, be sure to use only
Genuine NISSAN Anti-freeze Coolant (L250) or equivalent.
Because L250 is premixed type coolant.

I

Except for Europe
When adding or replacing coolant, be sure to use only a
Nissan Genuine Engine Coolant or equivalent in its qual-
ity with the proper mixture ratio. See the examples shown
left.

The use of other types of engine coolant may damage your
cooling system.

I

When checking the engine coolant mixture ratio by the coolant
hydrometer, use the chart below to correct your hydrometer
reading (specific gravity) according to coolant temperature.

Mixed coolant specific gravity

Unit: specific gravity

Engine coolant mixture

ratio

Coolant temperature °C (°F)

15 (59)

25 (77)

35 (95)

45 (113)

30%

1.046 - 1.050

1.042 - 1.046

1.038 - 1.042

1.033 - 1.038

50%

1.076 - 1.080

1.070 - 1.076

1.065 - 1.071

1.059 - 1.065

WARNING:

Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator. Wait until the engine and radiator cool down.

RECOMMENDED FLUIDS AND LUBRICANTS

Engine Coolant Mixture Ratio

MA-22

MT-1

MANUAL TRANSAXLE

C TRANSMISSION/TRANSAXLE

CONTENTS

D

E

F

G

H

I

J

K

L

M

SECTION

MT

A

B

MT

MANUAL TRANSAXLE

RS6F51R

PRECAUTIONS . . . . . . . . . . . . . . .. 3

Caution . . . . . . . . . . . . . . . . . . 3

PREPARATION . . . . . . . . . . . . . . ... 4

Special Service Tools . . . . . . . . . . . ... 4
Commercial Service Tools . . . . . . . . . . 6

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . . 7

NVH Troubleshooting Chart . . . . . . . . . . 7

MANUAL TRANSAXLE . . . . . . . . . . . 7

DESCRIPTION . . . . . . . . . . . . . . . 8

Cross-Sectional View . . . . . . . . . . . ... 8

DOUBLE-CONE SYNCHRONIZER . . . . . .. 9
REVERSE GEAR NOISE PREVENTION FUNC-
TION (SYNCHRONIZING METHOD) . . . . ... 9

M/T OIL . . . . . . . . . . . . . . . . . . 10

Changing M/T Oil . . . . . . . . . . . . ... 10

DRAINING . . . . . . . . . . . . . . ... 10
FILLING . . . . . . . . . . . . . . . ... 10

Checking M/T Oil . . . . . . . . . . . . . 10

OIL LEAKAGE AND OIL LEVEL . . . . . . . 10

SIDE OIL SEAL . . . . . . . . . . . . . . .11

Removal and Installation . . . . . . . . . . .11

REMOVAL . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . 11

POSITION SWITCH . . . . . . . . . . . . .. 12

Checking . . . . . . . . . . . . . . . . 12

BACK-UP LAMP SWITCH . . . . . . . . .. 12
NEUTRAL POSITION SWITCH . . . . . . .. 12

CONTROL LINKAGE . . . . . . . . . . . ... 13

Removal and Installation of Control Device and
Cable . . . . . . . . . . . . . . . . . .. 13

AIR BREATHER HOSE . . . . . . . . . . . 14

Removal and Installation . . . . . . . . . . 14

TRANSAXLE ASSEMBLY . . . . . . . . . . 15

Removal and Installation . . . . . . . . . . 15

REMOVAL . . . . . . . . . . . . . . ... 15
INSTALLATION . . . . . . . . . . . . ... 16

Component Parts . . . . . . . . . . . . ... 17

CASE AND HOUSING COMPONENTS . . . . 17

GEAR COMPONENTS . . . . . . . . . ... 18
SHIFT CONTROL COMPONENTS . . . . . . 20
FINAL DRIVE COMPONENTS . . . . . . ... 21

Disassembly and Assembly . . . . . . . . . 21

DISASSEMBLY . . . . . . . . . . . . ... 21
ASSEMBLY . . . . . . . . . . . . . . . 25

Adjustment . . . . . . . . . . . . . . . .. 32

INPUTSHAFT END PLAY . . . . . . . . ... 32
DIFFERENTIAL SIDE BEARING PRELOAD . .. 33
MAINSHAFT END PLAY . . . . . . . . . . 34
REVERSE IDLER GEAR END PLAY . . . . .. 35

INPUT SHAFT AND GEARS . . . . . . . . . 37

Assembly and Disassembly . . . . . . . . . 37

DISASSEMBLY . . . . . . . . . . . . ... 37
INSPECTION AFTER DISASSEMBLY . . . . 38
ASSEMBLY . . . . . . . . . . . . . . . 39

MAINSHAFT AND GEARS . . . . . . . . . ... 44

Assembly and Disassembly . . . . . . . . . 44

DISASSEMBLY . . . . . . . . . . . . ... 44
INSPECTION AFTER DISASSEMBLY . . . . 45
ASSEMBLY . . . . . . . . . . . . . . . 47

REVERSE IDLER SHAFT AND GEARS . . . . .. 53

Assembly and Disassembly . . . . . . . . . 53

DISASSEMBLY . . . . . . . . . . . . ... 53
INSPECTION AFTER DISASSEMBLY . . . . 53
ASSEMBLY . . . . . . . . . . . . . . . 54

FINAL DRIVE . . . . . . . . . . . . . . . 55

Assembly and Disassembly . . . . . . . . . 55

PRE-INSPECTION . . . . . . . . . . . .. 55
DISASSEMBLY . . . . . . . . . . . . ... 55
INSPECTION AFTER DISASSEMBLY . . . . 56
ASSEMBLY . . . . . . . . . . . . . . . 56

SHIFT CONTROL . . . . . . . . . . . . . . 59

Inspection . . . . . . . . . . . . . . . ... 59

SHIFT FORK . . . . . . . . . . . . . ... 59

SERVICE DATA AND SPECIFICATIONS (SDS) . .. 60

General Specifications . . . . . . . . . . . 60

TRANSAXLE . . . . . . . . . . . . . ... 60
FINAL GEAR . . . . . . . . . . . . . ... 60

Gear End Play . . . . . . . . . . . . . . 61

MT-2

Clearance Between Baulk Ring and Gear . . . .. 61

3RD, 4TH, 5TH, 6TH & REVERSE BAULK RING... 61
1ST AND 2ND DOUBLE BAULK RING . . . ... 61

Available Snap Rings . . . . . . . . . . . .. 61

6TH BUSHING . . . . . . . . . . . . . 61

Available C-rings . . . . . . . . . . . . . . 62

MAINSHAFT C-RING . . . . . . . . . . .. 62

Available Thrust Washer . . . . . . . . . . . 62

INPUT SHAFT THRUST WASHER . . . . . . 62
DIFFERENTIALSIDEGEARTHRUSTWASHER

... 62

Available Adjusting Shims . . . . . . . . . .. 63

MAINSHAFT ADJUSTING SHIM . . . . . . .63
INPUT SHAFT REAR BEARING ADJUSTING
SHIM . . . . . . . . . . . . . . . . . 63
MAINSHAFT REAR BEARING ADJUSTING
SHIM . . . . . . . . . . . . . . . . . 63
REVERSE IDLER GEAR ADJUSTING SHIM . ..63
6TH MAIN GEAR ADJUSTING SHIM . . . . ..64

Available Shims . . . . . . . . . . . . . ..64

BEARING PRELOAD . . . . . . . . . . ...64
DIFFERENTIAL SIDE BEARING ADJUSTING
SHIM (S) . . . . . . . . . . . . . . . ..64

PRECAUTIONS

MT-3

[RS6F51R]

D

E

F

G

H

I

J

K

L

M

A

B

MT

[RS6F51R]

PRECAUTIONS

PFP:00001

Caution

ECS0095I

●

If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder). CSC
insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts may damage
CSC seal and may cause clutch fluid leak.

●

Do not reuse transaxle oil, once it has been drained.

●

Check oil level or replace oil with vehicle on level ground.

●

During removal or installation, keep inside of transaxle clear of dust or dirt.

●

Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.

●

In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.

●

Be careful not to damage sliding surfaces and mating surfaces.

MT-4

[RS6F51R]

PREPARATION

PREPARATION

PFP:00002

Special Service Tools

ECS0095J

Tool number
Tool name

Description

KV381054S0
Puller

●

Side bearing outer race removal

●

Mainshaft front bearing removal

ST35321000
Drift
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.

●

Input shaft oil seal installation

●

Reverse main gear installation

●

1st bushing installation

●

1st-2nd synchronizer hub installation

●

2nd bushing installation

●

3rd main gear installation

ST30720000
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.

●

Differential oil seal installation

●

Differential side bearing outer race
installation

●

Mainshaft rear bearing installation

●

Differential side bearing installation

ST33200000
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.

●

Mainshaft front bearing installation

●

6th bushing installation

●

4th main gear installation

●

5th main gear installation

●

6th main gear installation

ST33061000
Drift
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.

●

Bore plug installation

●

Differential side bearing removal

ST33052000
Drift
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.

●

Welch plug installation

●

Input shaft rear bearing removal

●

5th bushing, thrust washer, 4th input gear,
4th gear bushing, 3rd-4th synchronizer hub
and 3rd input gear removal

●

Input shaft front bearing installation

●

6th input gear and 6th bushing removal

●

Mainshaft rear bearing removal

●

4th main gear and 5th main gear removal

●

6th main gear removal

ZZA0601D

ZZA1000D

ZZA0811D

ZZA1002D

ZZA1000D

ZZA1023D

PREPARATION

MT-5

[RS6F51R]

D

E

F

G

H

I

J

K

L

M

A

B

MT

KV40105020
Drift
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)

●

5th input gear and synchronizer hub
removal

●

3rd main gear, 2nd main gear, 2nd bushing,
1st-2nd synchronizer hub, 1st main gear,
reverse main gear and 1st bushing removal

KV40105710
Press stand
a: 46 mm (1.81 in) dia.
b: 41 mm (1.61 in)

●

3rd-4th synchronizer hub installation

●

4th bushing installation

●

5th busing installation

●

5th-6th synchronizer hub installation

●

2nd bushing installation

●

3rd main gear installation

ST38220000
Press stand
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)

●

Reverse main gear installation

●

1st bushing installation

●

1st-2nd synchronizer hub installation

ST30032000
Drift
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.

●

Input shaft front bearing installation

ST30901000
Drift
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.

●

Input shaft rear bearing installation

●

4th main gear installation

●

5th main gear installation

●

6th main gear installation

●

Mainshaft rear bearing installation

ST30031000
Puller

●

Measuring wear of 1st and 2nd baulk ring

KV40101630
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.

●

Reverse main gear installation

Tool number
Tool name

Description

ZZA1133D

ZZA1058D

ZZA1058D

ZZA0978D

ZZA0978D

ZZA0537D

ZZA1003D