Almera Tino V10 (2003 year). Manual — part 226
Tool name
Description
Drift
NT065
Removing input shaft rear bearing
Removing mainshaft rear bearing
a: 22 mm (0.87 in) dia.
b: 16 mm (0.63 in) dia.
Drift
NT065
Installing differential oil seal
a: 58 mm (2.28 in) dia.
b: 50 mm (1.97 in) dia.
Drift
NT065
Installing differential oil seal
a: 54 mm (2.13 in) dia.
b: 50 mm (1.97 in) dia.
Drift
NT065
Installing 2nd gear bush
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
Drift
NT065
Installing 3rd & 4th and 1st & 2nd synchronizer
hub
Installing mainshaft front bearing
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
Drift
NT065
Installing input shaft oil seal
Installing 5th input gear
a: 39 mm (1.54 in) dia.
b: 30 mm (1.18 in) dia.
PREPARATION
RS5F70A
Commercial Service Tools (Cont’d)
MT-6
Special Service Tools
NLMT0001
Tool number
Tool name
Description
KV38105210
Preload adapter
NT075
Measuring turning torque of final drive assembly
Measuring total turning torque
KV32101000
Pin punch
NT410
Removing and installing retaining pin
a: 4 mm (0.16 in) dia.
ST22730000
Puller
NT411
Removing mainshaft front and rear bearing inner
race
a: 82 mm (3.23 in) dia.
b: 30 mm (1.18 in) dia.
ST30031000
Puller
NT411
Removing input shaft front and rear bearing
Removing 4th & 5th main gear
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST30021000
Puller
NT411
Removing 5th synchronizer
Removing 3rd & 4th synchronizer
Removing 2nd & 3rd main gear
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.
ST3306S001
Differential side bearing
puller set
1 ST33051001
Puller
2 ST33061000
Adapter
NT675
Removing differential side bearing inner race
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
c: 130 mm (5.12 in)
d: 135 mm (5.31 in)
e: 100 mm (3.94 in)
ST33290001
Puller
NT414
Removing differential oil seal
Removing mainshaft rear bearing outer race
Removing differential side bearing outer race
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATION
RS5F50A
Special Service Tools
MT-7
Tool number
Tool name
Description
ST33400001
Drift
NT086
Installing differential oil seal
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
ST30600000
Drift
NT065
Installing input shaft front bearing
a: 36 mm (1.42 in) dia.
b: 31 mm (1.22 in) dia.
ST22452000
Drift
NT065
Installing 3rd, 4th and 5th main gear
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
ST30621000
Drift
NT073
Installing mainshaft rear bearing outer race
(Use with ST30611000.)
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
ST30611000
NT419
(Use with ST30621000.)
a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 in) dia.
d: M12 x 1.5P
KV38107700
Preload adapter
NT087
Measuring clearance between side gear and differ-
ential case with washer
KV38106500
Preload adapter
NT087
Measuring turning torque of final drive assembly
Commercial Service Tools
NLMT0002
Tool name
Description
Drift
NT065
Installing differential side bearing inner race
a: 45 mm (1.77 in) dia.
b: 41 mm (1.61 in) dia.
PREPARATION
RS5F50A
Special Service Tools (Cont’d)
MT-8
Tool name
Description
Drift
NT065
Installing differential side bearing outer race
a: 69 mm (2.72 in) dia.
b: 64 mm (2.52 in) dia.
Drift
NT065
Installing striking rod oil seal
a: 38 mm (1.50 in) dia.
b: 20 mm (0.79 in) dia.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
PREPARATION
RS5F50A
Commercial Service Tools (Cont’d)
MT-9
NLMT0003
NVH Troubleshooting Chart
NLMT0003S01
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
NLMT0003S0101
Reference page
MT
-1
1
(RS5F70A),
(RS5F50A)
MT
-1
1
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
(RS5F70A),
(RS5F50A)
SUSPECTED PARTS
(Possible cause)
(Oil
level
is
low
.)
(W
rong
oil)
(Oil
level
is
high.)
GASKET
(Damaged)
OIL
SEAL
(W
orn
or
damaged)
O-RING
(W
orn
or
damaged)
SHIFT
CONTROL
ROD
(W
orn)
CHECK
PLUG
RETURN
SPRING
AND
CHECK
BALL
(W
orn
or
damaged)
SHIFT
FORK
(W
orn)
GEAR
(W
orn
or
damaged)
BEARING
(W
orn
or
damaged)
BAULK
RING
(W
orn
or
damaged)
INSER
T
SPRING
(Damaged)
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
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING
RS5F70A, RS5F50A
NVH Troubleshooting Chart
MT-10
SMA145AA
SMT512C
Changing M/T Oil
NLMT0086
1.
Drain oil from drain plug and refill with new gear oil.
2.
Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-20, “RECOMMENDED FLUIDS AND
LUBRICANTS”.
Capacity:
RS5F70A 3.0
(5-1/4 Imp pt)
Oil level (Reference data):
RS5F70A 75.5 - 80.5 mm (2.972 - 3.169 in)
Drain plug:
: 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
SMA066C
Checking
NLMT0087
OIL LEAK AND OIL LEVEL
NLMT0087S01
1.
Check that oil is not leaking from transaxle or around it.
2.
Check oil level.
Never start engine while checking oil level.
Filler plug:
: 10 - 19 N·m (1.0 - 2.0 kg-m, 87 - 173 in-lb)
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
M/T OIL
RS5F70A
Changing M/T Oil
MT-11
SMA067C
Changing M/T Oil
NLMT0088
1.
Drain oil from drain plug and refill with new gear oil.
2.
Check oil level.
Oil grade:
API GL-4
Viscosity:
Refer to MA-20, “RECOMMENDED FLUIDS AND
LUBRICANTS”.
Capacity:
RS5F50A 4.5 - 4.8
(7-7/8 - 8-1/2 Imp pt)
Drain plug:
: 15 - 20 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SMA066C
Checking
NLMT0089
OIL LEAK AND OIL LEVEL
NLMT0089S01
Check for oil leakage and oil level.
Never start engine while checking oil level.
Filler plug:
: 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
M/T OIL
RS5F50A
Changing M/T Oil
MT-12
NLMT0034
Cross-sectional View — RS5F70A
NLMT0034S03
SMT924D
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
DESCRIPTION
RS5F70A, RS5F50A
Cross-sectional View — RS5F70A
MT-13
Cross-sectional View — RS5F50A
NLMT0034S04
SMT196DA
DESCRIPTION
RS5F70A, RS5F50A
Cross-sectional View — RS5F50A
MT-14
SMT837DA
DOUBLE-CONE SYNCHRONIZER
NLMT0034S0403
— RS5F70A and RS5F50A —
Double-cone synchronizer is adopted for 1st and 2nd gears to
reduce operating force of the shift lever.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
DESCRIPTION
RS5F70A, RS5F50A
Cross-sectional View — RS5F50A (Cont’d)
MT-15
SMT563AA
Replacing Oil Seal
NLMT0035
DIFFERENTIAL OIL SEAL
NLMT0035S01
1.
Drain gear oil from transaxle.
2.
Remove drive shafts. Refer to AX-11, “Removal”.
3.
Remove differential oil seal.
SMT564AB
4.
Install differential oil seal.
I
Apply multi-purpose grease to seal lip of oil seal before
installing.
5.
Install drive shafts. Refer to AX-11, “Installation”.
SMT926DA
SMT927D
I
Install differential oil seal so that dimension “A” and “B”
are within specifications.
Unit: mm (in)
Item
Model
A
B
Dimension
RS5F70A
−0.5 (−0.020) to 0.5 (0.020)
RS5F50A
SMT143DC
STRIKING ROD OIL SEAL
NLMT0035S02
1.
Remove transaxle control rod from yoke.
2.
Remove retaining pin of yoke.
I
Be careful not to damage boot.
ON-VEHICLE SERVICE
RS5F70A, RS5F50A
Replacing Oil Seal
MT-16
SMT566A
3.
Remove striking rod oil seal.
SMT570A
4.
Install striking rod oil seal.
I
Apply multi-purpose grease to seal lip of oil seal before
installing.
SMT876D
I
Drive it in as far as it will go.
SMT715BD
Position Switch Check
NLMT0036
BACK-UP LAMP SWITCH
NLMT0036S01
— RS5F70A —
NLMT0036S0101
I
Check continuity.
Gear position
Continuity
Reverse
Yes
Except reverse
No
PNP SWITCH
NLMT0036S02
— RS5F70A —
NLMT0036S0201
I
Check continuity.
Gear position
Continuity
Neutral
Yes
Except neutral
No
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
ON-VEHICLE SERVICE
RS5F70A, RS5F50A
Replacing Oil Seal (Cont’d)
MT-17
SMT939D
BACK-UP LAMP SWITCH AND PNP SWITCH
NLMT0036S03
— RS5F50A —
NLMT0036S0301
I
Check continuity.
Gear position
Continuity
Reverse
1 - 3
Neutral
2 - 4
Except reverse and neutral
No
ON-VEHICLE SERVICE
RS5F70A, RS5F50A
Position Switch Check (Cont’d)
MT-18
NLMT0008
SMT928D
Removal
NLMT0008S01
CAUTION:
Remove the crankshaft position sensor (POS) from transaxle
assembly before separating transaxle from engine.
Be careful not to damage sensor edge.
1.
Remove battery and its bracket.
2.
Remove air cleaner box with mass air flow sensor.
SMT130DB
3.
Remove clutch operating cylinder from transaxle.
4.
Remove clutch hose clamp.
5.
Disconnect speedometer pinion, back-up lamp, PNP switch
(F70A) harness connectors and ground harness.
6.
Remove starter motor from transaxle.
7.
Remove crankshaft position sensor (POS) from transaxle front
side.
8.
Remove shift control rod and support rod bracket from tran-
saxle.
9.
Drain gear oil from transaxle.
10. Draw out drive shafts from transaxle. Refer to AX-11,
“Removal”.
11. Support engine of transaxle by placing a jack under oil pan.
CAUTION:
Do not place jack under oil pan drain plug.
12. Remove bolts securing center member.
SMT133D
13. Remove LH mount and rear side mounting bolts. Refer to
EM-70, “Removal and Installation”.
14. Remove bolts securing gusset and transaxle.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
REMOVAL AND INSTALLATION
RS5F70A
Removal
MT-19
SMT652C
15. Lower transaxle while supporting it with a jack.
Installation
NLMT0008S02
I
Tighten LH mount, rear side mount and center member bolts.
Refer to EM-70, “Removal and Installation”.
I
Tighten clutch operating cylinder bolts. Refer to CL-15, “Instal-
lation”.
I
Tighten starter motor bolts. Refer to SC-19, “Removal and
Installation”.
I
Install drive shafts. Refer to AX-11, “Installation”.
I
Tighten all transaxle bolts and any part removed.
SMT931D
MODEL QG18DE ENGINE
NLMT0008S0202
Bolt No.
Tightening torque
N·m (kg-m, ft-lb)
“
”
mm (in)
1
31 - 40 (3.1 - 4.1, 23 - 29)
70 (2.76)
2
31 - 40 (3.1 - 4.1, 23 - 29)
80 (3.15)
3
16 - 21 (1.6 - 2.2, 12 - 15)
25 (0.98)
4
31 - 40 (3.1 - 4.1, 23 - 29)
30 (1.18)
A
31 - 40 (3.1 - 4.1, 23 - 29)
20 (0.79)
B
31 - 40 (3.1 - 4.1, 23 - 29)
20 (0.79)
C
15 - 20 (1.5 - 2.1, 11 - 15)
17.5 (0.69)
REMOVAL AND INSTALLATION
RS5F70A
Removal (Cont’d)
MT-20
NLMT0090
SMT928D
Removal
NLMT0090S01
CAUTION:
Remove the crankshaft position sensor (POS) from transaxle
assembly before separating transaxle from engine.
Be careful not to damage sensor edge.
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 bolts.
SMT650CB
6.
Remove terminal and connector from starter motor.
7.
Remove starter motor from transaxle.
8.
Remove clutch hose clamp.
9.
Remove clutch operating cylinder from transaxle.
10. Disconnect speedometer pinion, PNP switch harness connec-
tors and ground harness.
11. Remove crankshaft position sensor (POS) from transaxle front
side.
12. Remove front exhaust tube.
SMT929D
13. Remove shift control rod and support rod bracket from tran-
saxle.
14. Drain gear oil from transaxle.
15. Draw out drive shafts from transaxle. Refer to AX-11,
“Removal”.
16. Support engine and transaxle by placing a jack under the tran-
saxle.
17. Remove bolts securing center member.
SMT950D
18. Take out engine mounting bracket and transaxle installation
bolts. Refer to EM-197, “Removal and Installation”.
19. Remove bolts securing transaxle under side.
20. Temporarily tighten center member.
21. Lower the lift.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
REMOVAL AND INSTALLATION
RS5F50A
Removal
MT-21
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