Nissan Almera Tino V10 (2001 year). Manual

SMT710DB

Install 2nd needle bearing, 2nd double cone assembly, and
2nd main gear onto mainshaft.

Position 3rd main gear as shown in the figure, and install it.

CAUTION:

Do not reuse 3rd main gear.

SMT711D

10. Install spacer and mainshaft adjusting shim onto mainshaft.
11. Select a mainshaft adjusting shim suitable to satisfy the follow-

ing specification of dimension “L” and install it onto mainshaft.

Specification of dimension “L”:

151.35 - 151.45 mm (5.9586 - 5.9626 in)

Mainshaft adjusting shims:

Refer to SDS, MT-93.

SMT713D

12. Position 4th main gear as shown in the figure, and install it onto

mainshaft.

SMT712DB

13. Install 4th main gear onto mainshaft.

CAUTION:

Do not reuse 4th main gear.

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-44

SMT714DB

14. Install 5th gear bushing with its flange surface facing the 4th

main gear side.

SMT761D

15. Install 5th needle bearing, 5th main gear, and 5th gear baulk

ring onto mainshaft.

SMT694D

16. Being careful of the following points, install spread spring, shift-

ing insert, and 5th & reverse synchronizer hub onto 5th &
reverse coupling sleeve.

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.

SMT695D

Install synchronizer hub with its three grooves facing the front
side (5th main gear side).

CAUTION:

Do not reuse 5th & reverse synchronizer hub.

SMT716D

Install 5th & reverse coupling sleeve with its chamfered surface
facing the reverse main gear side.

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-45

SMT715DB

17. Install 5th & reverse synchronizer hub assembly.

SMT717DB

18. Install reverse gear baulk ring.
19. Install reverse gear busing.
20. Install reverse gear needle bearing.

SMT718D

21. Install sub-gear, sub-gear washer, and snap ring onto reverse

main gear.

CAUTION:

Pay attention to direction of sub-gear washer.

Do not reuse snap ring.

SMT719D

22. Install reverse main gear assembly onto mainshaft.
23. Select a thrust washer suitable to satisfy the following specifi-

cation of dimension “M” (as shown in the figure), and install it
onto mainshaft.

Specification of dimension “M”:

244.20 - 244.30 mm (9.6142 - 9.6181 in)

Available mainshaft thrust washers:

Refer to SDS, MT-94.

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-46

SMT720DB

24. Install mainshaft rear bearing.

SMT721D

25. Install mainshaft C-ring.
26. Using feeler gauge, measure the end play of mainshaft rear

bearing, and check if it satisfies the following specification.

End play:

0 - 0.06 mm (0 - 0.0024 in)

Mainshaft C-rings:

Refer to SDS, MT-91.

SMT678D

27. Install C-ring holder.

SMT677D

28. Install snap ring.
29. Measure gear end play as a final check. Refer to, MT-39.

SMT610AH

Final Drive

PRE-INSPECTION

NLMT0062

Check the clearance between side gear and differential case
as follows.

Clean final drive assembly sufficiently to prevent side gear
thrust washer, differential case, side gear, and other parts from
sticking by gear oil.

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-47

SMT685DC

Upright the differential case so that the side gear to be mea-
sured faces upward.

Place final drive adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.

Clearance between side gear and differential case:

0.1 - 0.2 mm (0.004 - 0.008 in)

If not within specification, adjust the clearance by changing
thrust washer thickness.

Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.

SMT609A

DISASSEMBLY

NLMT0063

Remove mounting bolts. Then, separate the final gear from
differential case.

Make a notch and remove speedometer drive gear using a
scraper or other suitable tool.

Bearing replacer cannot be positioned unless speedom-
eter drive gear is removed.

SMT647-C

Remove differential side bearing of final gear side.

Turn differential case upside down, and remove differential
side bearing of speedometer drive gear side.

Be careful not to mix up the differential side bearings.

Remove speedometer stopper.

SMT689DB

Remove lock pins from pinion mate shaft.

SMT839

Remove pinion mate shaft.

Rotate pinion mate gear, and remove pinion mate gear, pinion
mate thrust washer, side gear, and side gear thrust washer
from differential case.

REPAIR FOR COMPONENT PARTS

RS5F70A

Final Drive (Cont’d)

MT-48

SMT083A

INSPECTION

NLMT0064

Gear, Washer, Shaft and Case

NLMT0064S01

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

Check washers for wear.

SPD715

Bearing

NLMT0064S03

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

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

SMT062A

ASSEMBLY

NLMT0065

Apply gear oil to sliding area of differential case, each gear,
and thrust washer.

Install side gear thrust washer and side gear into differential
case.

Position pinion mate gear and pinion mate thrust washer
diagonally, and install them into differential case while rotating.

SMT087A

Insert pinion mate shaft into differential case.

SMT685DC

Upright the differential case so that its side gear to be mea-
sured faces upward.

Place preload adapter and dial gauge onto side gear. Move
side gear up and down, and measure the clearance.

Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.

Clearance of side gear and differential case:

0.1 - 0.2 mm (0.004 - 0.008 in)

Differential side gear thrust washers:

Refer to SDS, MT-94.

REPAIR FOR COMPONENT PARTS

RS5F70A

Final Drive (Cont’d)

MT-49

SMT699BB

Install retaining pin.

Make sure that retaining pin is flush with case.

SMT842D

Align and install speedometer drive gear into differential case.

10. Install speedometer stopper.

SMT751DB

11. Install differential side bearing.
12. Turn differential case upside down, and install another differ-

ential side bearing on the other side in the same way.

SMT752D

13. Install differential gear into differential case. Apply sealant onto

mounting bolts, and tighten them in order as shown in the fig-
ure with specified torque.

Tightening torque:

Refer to MT-27.

REPAIR FOR COMPONENT PARTS

RS5F70A

Final Drive (Cont’d)

MT-50

SMT801D

Shift Control Components

INSPECTION

=NLMT0066

Check if the width of shift fork hook (sliding area with coupling
sleeve) is within allowable specification below.

Item

One-side wear specifi-

cation

Sliding width of new part

1st & 2nd

0.2 mm (0.008 in)

7.80 - 7.93 mm

(0.3071 - 0.3122 in)

3rd & 4th

0.2 mm (0.008 in)

7.80 - 7.93 mm

(0.3071 - 0.3122 in)

5th & reverse

0.2 mm (0.008 in)

7.80 - 7.93 mm

(0.3071 - 0.3122 in)

SMT692D

Check if shift check groove of fork rod or 5th & reverse check
groove is worn, or has any other abnormalities.

REPAIR FOR COMPONENT PARTS

RS5F70A

Shift Control Components

MT-51

NLMT0067

SMT722DB

Clutch Housing

NLMT0067S01

Hammer the striking rod oil seal into clutch housing as far as
it will go.

CAUTION:

Do not reuse striking rod oil seal.

SMT723DA

Hammer the differential oil seal into clutch housing until it
becomes flush with clutch housing end face.

CAUTION:

Do not reuse differential oil seal.

SMT724DA

Hammer input shaft oil seal into clutch housing as far as it will
go.

CAUTION:

Do not reuse input shaft oil seal.

SMT725DB

Hammer the dust seal into clutch housing as far as it will go.

CAUTION:

Do not reuse dust seal.

SMT726DB

Install outer race of differential side bearing.

ASSEMBLY

RS5F70A

Clutch Housing

MT-52

SMT727D

Install new oil channel (mainshaft).

CAUTION:

Pay attention to installation direction of oil channel.

SMT728DA

Align the notches on mainshaft front bearing and transaxle
case. Then, install mainshaft front bearing.

SMT729D

Install mainshaft bearing retainer, and tighten bolts with speci-
fied torque.

SMT667DB

Attach boot, striking rod, and striking lever to clutch housing.
And install retaining pin for selector lever.

CAUTION:

Before installing striking rod, wrap the end with a vinyl
tape or the like to prevent oil seal from being damaged.

Do not reuse retaining pin.

SMT730D

10. Hammer the welch plug (striking lever side) with a general-

purpose drift [OD: 12 mm (0.47 in)].

CAUTION:

Do not reuse welch plug.

ASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

MT-53

SMT731D

11. Install selector, selector shaft, and selector shaft pin into clutch

housing.

SMT732D

12. Hammer the welch plug (selector shaft side) with a general-

purpose drift [OD: 12 mm (0.47 in)].

CAUTION:

Do not reuse welch plug.

SMT733DA

SMT734D

13. Install select check leaf spring, return spring, steel ball, reverse

gate, selector arm, bushing, and return bearing. Then, tighten
two reamer bolts with specified torque.

CAUTION:

Use correct reamer bolts for each installation point, because
each bolt has a different length.

SMT735D

14. Install oil pocket.

ASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

MT-54

SMT736D

15. Install differential assembly, input shaft assembly, and main-

shaft assembly into clutch housing.

CAUTION:

Be careful not to damage input shaft oil seal during installa-
tion of input shaft assembly.

SMT659DC

16. Install 5th & reverse shift fork.
17. Install 1st & 2nd shift fork, bracket, and fork rod.
18. Install retaining pin for 1st & 2nd bracket.

CAUTION:

Do not reuse retaining pin.
19. Install two check balls.

SMT657DC

20. Install interlock pin into 5th & reverse fork rod.
21. Install reverse switch bracket, 5th & reverse bracket, and fork

rod.

22. Install retaining pin for 5th & reverse shift fork and reverse

switch bracket.

CAUTION:

Do not reuse retaining pin.
23. Install 5th & reverse bracket stopper ring.

CAUTION:

Do not reuse stopper pin.

SMT656DC

24. Install check ball and interlock plunger.
25. Install 3rd & 4th shift fork, bracket, and fork rod.
26. Install 3rd & 4th bracket retaining pin.

CAUTION:

Do not reuse retaining pin.

SMT655D

27. Install 3rd & 4th shift fork stopper ring.

CAUTION:

Do not reuse stopper ring.
28. Install check ball, check pin, and check spring, and apply

Three Bond TB1215, Loctite Part No. 51813 or equivalent onto
check plug. Then, tighten it with specified torque.

Tightening torque:

Refer to MT-26.

ASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

MT-55

SMT737DA

Transaxle Case

NLMT0067S02

Insert differential oil seal into differential case until it becomes
flush with case end face.

SMT739D

Install welch plug into transaxle case.

SMT740D

Calculate dimension “N” (thickness of adjusting shim) using
the following procedure to satisfy specification of end play for
differential side bearing.

End play: 0.15 - 0.21 mm (0.0059 - 0.0083 in)

Dimension “N” = (N1 – N2) + End play

N: Thickness of adjusting shim
N1: Distance between clutch housing case end
face and mounting face of adjusting shim
N2: Distance between differential side bearing and
transaxle case

Differential side bearing adjusting shims:

Refer to SDS, MT-95.

SMT741D

Using dial gauge and scale, measure dimension “N1” between
clutch housing case end face and mounting face of adjusting
shim.

ASSEMBLY

RS5F70A

Transaxle Case

MT-56

SMT742D

Install outer race onto differential side bearing on final gear
side. Holding lightly the outer race horizontally by hand, rotate
final gear five times or more (for smooth movement of bearing
roller).

Using dial gauge and scale as shown in the figure, measure
dimension “N2” between differential side bearing outer race
and transaxle case end face.

SMT738DB

Install selected shim and bearing outer race.

SMT600-F

Measure turning torque of final drive assembly.

Turning torque of final drive assembly
(New bearing):

2.9 - 6.9 N·m (30 - 70 kg-cm, 26 - 61 in-lb)

When old bearing is used again, turning torque will be
slightly less than the above.

Make sure torque is close to the specified range.

Changes in turning torque of final drive assembly per
revolution should be within 1.0 N·m (10 kg-cm, 8.7 in-lb)
without binding.

SMT743D

Calculate dimension “O” (thickness of adjusting shim) using
the following procedure to satisfy specification of end play for
input shaft rear bearing.

End play: 0 - 0.06 mm (0 - 0.0024 in)

Dimension “O” = (O1 – O2) + End play

O: Thickness of adjusting shim
O1: Distance between transaxle case end face and
mounting face of adjusting shim
O2: Distance between clutch housing case end
face and end face of input shaft rear bearing

Input shaft rear bearing adjusting shims:

Refer to SDS, MT-92.

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-57

SMT744D

Using block gauge, scale, and dial gauge, measure dimension
“O1” between transaxle case end face and mounting face of
adjusting shim.

SMT745D

Using gauge block, scale, and dial gauge as shown in the
figure, measure dimension “O2” between clutch housing case
end face and end face of input shaft rear bearing.

Install selected input shaft rear bearing adjusting shim onto
input shaft.

SMT650D

Install oil gutter into transaxle case.

SMT755D

Install two magnets.

SMT802D

10. Clean mating surfaces of clutch housing and transaxle case.

Check for cracks and damage. Then, apply Three Bond
TB1215, Loctite Part No. 51813 or equivalent.

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-58

SMT649D

11. Install transaxle case onto clutch housing, and tighten mount-

ing bolts with specified torque.

Tightening torque:

Refer to MT-24.

SMT648D

12. Apply Three Bond TB1215, Loctite Part No. 51813 or equiva-

lent to threads of reverse switch, PNP switch, and drain plug,
and install them. (Fill the case with oil before installation of filler
plug.)

13. Install speedometer pinion assembly.

CAUTION:

Do not reuse O-ring.

SMT749D

14. Install check springs and check balls. Apply sealant to the

thread on the check plug, and install it.

SMT746D

15. Calculate thickness of adjusting shim using the following pro-

cedure to satisfy specification of end play for mainshaft rear
bearing.

End play: 0 - 0.06 mm (0 - 0.0024 in)

Dimension “P” = (P1 – P2) + End play

P: Thickness of adjusting shim
P1: Distance between transaxle case end face and
mainshaft rear bearing
P2: Distance between adjusting shim end face of
rear cover and transaxle mounting face

Mainshaft rear bearing adjusting shims:

Refer to SDS, MT-93.

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-59

Nissan Almera Tino V10 (2001 year). Manual - part 178