Nissan PULSAR N13 Series / ASTRA LD Series. Manual - part 32

Manual Transaxle and Drive Shafts

 

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renewed as individual units. The C.V. joints are 
lubricated in manufacture and need no attention in 
service unless one of the rubber boots is damaged. In 
this case the joint can be cleaned and repacked with 
the recommended grease and a new boot installed.

 

From July 1989, Pulsar Q and Vector SSS manual 

transaxle models are equipped with a limited slip 
differential incorporating a viscous coupling. The 
coupling is not repairable and must be renewed as an 
assembly if unserviceable. A test procedure for the 
viscous coupling is included in the text in this section.

 

3.    TRANSAXLE ASSEMBLY

 

Special Equipment Required:

 

To Dismantle and Assemble — Puller set, press 
and press plates, dial gauge 
To Measure Mainshaft Turning Torque — 
Suitable slotted adaptor and torque gauge

 

TO REMOVE AND INSTAL

 

(1)  Raise the front of the vehicle and support it 

on chassis stands. 

(2)  Remove the  battery as described  in  the 

Electrical System section. 

(3)  Remove the drive shafts as described later in 

this section. 

(4)  Disconnect and remove the starter motor as 

described in the Electrical System section. 

 

Front view of the transaxle removed from the vehicle. 

(5)  Support the rear of the engine using a jack 

with a piece of timber between the jack head and the 
engine sump. 

(6)  Remove the bolts retaining the clutch hous- 

ing to the engine. 

(7)  Disconnect the vehicle speed sensor wiring, 

the reverse lamp wiring, the gear lever control rod and 
the gear lever support rod from the transaxle. 

(8)  Remove the transaxle mounting through bolt 

and remove the bolts retaining the mounting bracket 
to the transaxle. 

(9)  With the left hand front wheel removed, 

remove the left hand inner mudguard panel. 

(10)  Maneuver  the  transaxle  away  from  the 

engine. Lower and withdraw the transaxle from under 
the vehicle. 

NOTE: Do not allow the transaxle to hang 
on the clutch driven plate during removal. 
Support the transaxle on a trolley jack if 
necessary.

 

Installation is a reversal of the removal procedure 

with attention to the following points:

 

(1)  Lubricate the input shaft splines sparingly 

with lithium base molybdenum disulphide grease. 

(2)  Support the transaxle during installation. Do 

not allow the transaxle to hang on the clutch driven 
plate. 

(3)  Tighten all bolts to the specified torque. 
(4)  Fill the transaxle with the specified quantity 

and grade of oil. 

(5)  Road test the vehicle and check for correct 

transaxle operation. Also check for transaxle oil leaks 
and rectify as necessary. 

TO DISMANTLE

 

(1)   Remove the clutch release components from

 

Rear view of the transaxle removed from the vehicle.

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Manual Transaxle and Drive Shafts

 

 

 

Internal view of the transaxle showing the installed 

positions of the shift forks and control bracket. 

the clutch housing. Refer to the Clutch section for the 
correct procedure.

 

(2)  Thoroughly clean the outside of the transaxle 

assembly using solvent and compressed air. 

(3)  Remove the bolts retaining the transaxle case 

to the clutch housing and using a soft faced hammer, 
tap the transaxle case to separate the mating surfaces. 

(4)  Carefully lift the transaxle case from the 

clutch housing. Tilt the case to provide clearance for 
the fifth gear shift fork. 

(5)  Withdraw the spacer from the reverse idler 

shaft and withdraw the fork shaft and spring from the 
transaxle. 

(6)  Remove the fifth and third/fourth shift forks 

taking care not to lose the shift cap. 

(7)  Remove the retaining bolts and remove the 

control bracket and the first/second shift fork taking 
care not to lose the shift cap. 

(8)  Lift the mainshaft out of the clutch housing. 

NOTE: When lifting, do not tilt the main- 
shaft as the resin oil channel behind the 
front mainshaft bearing could be damaged.

 

(9)  Lift   the   differential   assembly  out  of the 

clutch housing.

 

NOTE: For information on the overhaul of

 

 

Dismantled view of the striking rod components. 

the differential assembly refer to the Differ- 
ential and Final Drive Assembly heading.

 

(10)  Remove the retaining bolts from the input 

shaft front bearing retainer. 

(11)  Position the transaxle assembly on its side 

and tap the input shaft out of the clutch housing using 
a soft faced hammer. Remove the input shaft, bearing 
retainer and reverse idler gear from the clutch hous- 
ing. 

(12)  Remove the shift check ball, plug and spring 

from  the passage adjacent  to the  upper control 
bracket retaining bolt on the clutch housing. 

(13)  Position the striking lever so that the retain- 

ing pin will not contact the clutch housing and remove 
the pin using a suitable punch. 

(14)  Remove the striking rod, striking lever and 

striking interlock from the clutch housing. 

(15)  Remove the reverse check plug, spring and 

balls from the clutch housing noting the installed 
position of the small check ball. 

(16)  Remove the screws retaining the reverse and 

fifth gear check assembly and remove the assembly 
from the clutch housing. 

(17)  Remove and discard the input shaft and 

striking rod oil seals from the clutch housing noting 
the installed direction of the seals. 

(18)  Renew the rear input shaft bearing as fol- 

lows: 

(a) 

Remove the plastic oil channel  from the 

transaxle case.

 

(b)  Using a suitable punch through the hole 

adjacent to the rear input shaft bearing, tap the small 
welch plug out of the transaxle case. 

(c)  Using a suitable punch through the small 

welch plug opening, tap the rear input shaft bearing 
out of the transaxle case. 

(d)  Using a suitable mandrel, tap the new rear 

input shaft bearing into the transaxle case. 

NOTE: It may be necessary to use a hydrau- 
lic press if the bearing is a tight fit in the 
housing.

 

(e)  Apply sealer to a new welch plug and tap the 

plug squarely into the transaxle case until the edge of 
the plug is level with the case.

 

Dismantled view of the shift fork components.

Manual Transaxle and Drive Shafts

 

131

 

 

(19)  Renew the rear mainshaft bearing outer race 

as follows:

 

(a)  Remove the bolts retaining the rear cover to 

the transaxle case. 

(b)  Remove the rear cover. O ring, spacer and 

adjusting shim from the transaxle case. Discard the O 
ring. 

(c)  Using a suitable punch, tap the bearing outer 

race out of the transaxle case. 

(e) Install the adjusting shim, spacer and a new O 

ring to the transaxle case. Install the rear cover and 
tighten the retaining bolts securely.

 

(20)  Renew  the  front  mainshaft  bearing outer 

race as follows:

 

(a)  Using a suitable puller, pull the outer race 

out of the clutch housing. 

(b)  Ensure that the oil groove in the resin oil 

channel is facing the oil pocket in the clutch housing. 

(c)  Install  the  new  outer  race  to  the  clutch 

housing. 

 

(21)  Measure the end float of the input shaft fifth 

gear using feeler gauges between the fifth gear and the 
adjacent gear shoulder. Note the measurement for 
later reference. 

(22)  Dismantle the input shaft as follows: 

 

(a)  Remove the snap ring and spacer from the 

front of the input shaft. 

(b)  Using a suitable puller, remove the bearing 

from the front of the input shaft. Remove the bearing 
retainer noting the installed direction. 

(c)  Remove the snap ring from the rear of the 

input shaft. 

(d)  Remove the shift retainer, fifth gear synchro 

assembly, fifth gear and the split bearing from the rear 
of the input shaft. 

 

(23)  Measure the end float of the mainshaft first, 

second,  third and  fourth gears  using feeler gauges 
between the gear and the adjacent shaft shoulder. 
Note the measurements for later reference. 

(24)  Dismantle the mainshaft as follows: 

(a) Remove the front and rear bearing cones 

using a suitable puller.

 

 

Dismantled view of the mainshaft

. 

(b)  Remove the C ring holder, the C rings and 

the thrust washer from the rear of the mainshaft. 

(c)  Using a puller positioned on the fifth gear 

rear flange, remove the fifth gear from the mainshaft. 

(d)  Remove the fourth gear, bush and steel ball 

from the mainshaft. 

(e)  Remove the third/fourth synchro assembly, 

using a suitable puller if necessary. 

(f)  Remove the third gear, bush, steel ball and 

second gear from the mainshaft. 

(g)  Remove the first/second synchro assembly, 

using a suitable puller if necessary. 

(h)   Remove  first gear and  the   needle  roller 

bearing from the mainshaft.

 

(25)  Suitably mark the assembled positions of the 

synchro   assemblies   components   and   remove   the 
springs from the assemblies. 

(26)  Slide the sleeves off the hubs and remove the 

shift plates. 

(27)  Arrange   the  various  synchro  components 

separately to avoid  mixing the components on 
assembly. 

TO CLEAN AND INSPECT

 

(1)  Clean all the components in cleaning solvent 

and allow to dry. 

(2)  Inspect the teeth on all the gears for wear, 

pitting and damage. 

(3)  Push each synchro ring onto its respective 

gear cone and measure the distance between the 
synchro ring and the synchro teeth on the gear. Renew 
the synchro ring and/or the gear if the distance is less 
than 0.7 mm. 

(4)  Inspect the shift forks for excessive clearance 

in the synchro sleeves and the control fingers. Renew 
the forks as necessary if the clearance is excessive. 

(5)  Inspect   the   components   of  the   control 

bracket for wear and damage. Inspect the shift caps 
for wear. Renew the control bracket and/or the shift 
caps as necessary. 

218/680       INPUTSHAFT

M AI N B E AF I N G

SPACER

Dismantled view of the input shaft. 

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Manual Transaxle and Drive Shafts

 

 

 

Check the mainshaft for pitting.

 

(6)  Inspect the striking rod, lever and interlock 

for wear and damage paying particular attention to 
the detent grooves in the end of the striking rod. 
Renew parts as necessary. 

(7)  Inspect  the shift check and  reverse check 

balls and springs for wear, cracks and loss of tension 
in the springs. Renew parts as necessary. 

 

Check clearance A between the synchro ring and the 
gear synchro teeth and compare with Specifications.

 

(8)  Inspect  the reverse  and  fifth  gear check 

assembly for wear, damage and loss of spring tension. 
Renew the assembly as necessary. 

(9)  Inspect all the bearings for pitting, wear and 

damage. Renew the bearings as necessary. 

NOTE: If the transaxle has seen consider- 
able service, it is advisable to renew all the 
bearings, oil seals, O rings and snap rings 
during the overhaul.

 

(10)  Inspect the various synchro components for 

wear and damage paying particular attention to the 
shift plates and springs and the internal teeth of the 
synchro sleeves. Renew parts as necessary. 

(11)  Compare the various gear end floats mea- 

sured during dismantling with the Specifications and 
if the end floats are excessive, check the contact 
surfaces of the gears, shaft and synchro hubs. Renew 
worn parts as necessary.

 

TO ASSEMBLE

 

(1)  Lubricate all the components with the spec- 

ified gear oil prior to assembly. 

(2)  Install new input shaft and striking rod 

oil 
seals to the clutch housing in the direction noted on 
removal. Lubricate the oil seal lips with multipurpose 
grease prior to installation. 

(3)  Assemble the components of the fifth gear 

synchro assembly aligning the marks made on dis- 
mantling. Ensure that the ends of the shift plate 
springs are not aligned. 

(4)  Install the split bearing to the rear of the 

input shaft and install the fifth gear. 

(5)  Install the fifth gear synchro assembly and the 

shift retainer to the rear of the input shaft. Ensure that 
the slots in the synchro ring are aligned with the shift 

plates. 

 

Check the friction surfaces of the input shaft for pitting.

Dismantled view of the fifth gear synchro assembly.

Illustration showing the correct positioning of the shift

plates and springs.