Almera Tino V10 (2003 year). Manual

SMT695D

Install synchronizer hub with its three grooves facing the front
side (3rd input gear side).

SMT699D

Install 3rd & 4th coupling sleeve with its chamfered surface
facing the 4th input gear side.

SMT698DB

Position bearing replacer to the front side of input shaft front
bearing.

Align grooves of shifting insert and 3rd gear baulk ring. Then,
press it onto 3rd & 4th synchronizer hub assembly using a drift.

Install 4th gear C-ring onto input shaft.

SMT700DA

Measure the end play of 3rd & 4th synchronizer hub, and
check if it is within allowable specification below.

End play:

0 - 0.06 mm (0 - 0.0024 in)

If not within specification, adjust the end play by changing
thickness of 4th input gear C-ring.

4th input gear C-ring:

Refer to SDS, MT-91.

SMT701DB

Install 4th gear needle bearing, 4th gear baulk ring, and 5th
gear front C-ring.

Install 4th input gear.

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears (Cont’d)

MT-38

SMT703D

10. Position 5th input gear as shown in the figure, and install it on

input shaft.

SMT702DB

11. Install 5th input gear.

CAUTION:

Do not reuse 5th input gear.
12. Install 5th gear rear C-ring onto input shaft.

SMT704DA

13. Measure the end play of 5th input gear, and check if it is within

the allowable specification below.

End play:

0 - 0.06 mm (0 - 0.0024 in)

14. If not within specification, adjust the end play by changing

thickness of the 5th input gear rear C-ring.

5th input gear rear C-ring:

Refer to SDS, MT-91.

SMT705DB

15. Install C-ring holder onto 5th gear rear C-ring.

CAUTION:

Do not reuse C-ring holder.
16. Install input shaft rear bearing.

CAUTION:

Install input shaft rear bearing with its brown surface facing
the input gear side.

SMT671D

17. Install oil channel onto input shaft.
18. Measure gear end play as a final check. Refer to, MT-35.

IDX

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears (Cont’d)

MT-39

SMT760D

Mainshaft and Gears

DISASSEMBLY

NLMT0059

Before disassembly, measure gear end play.

Gear end play:

Refer to SDS, MT-90.

If end play is not within the specificed limit, disassemble and
check the parts.

SMT677D

Remove snap ring.

SMT678D

Remove C-ring holder and mainshaft C-ring.

SMT679DB

Press out mainshaft rear bearing from mainshaft.

SMT680D

Remove mainshaft thrust washer.

Remove snap ring from mainshaft. Then, remove reverse main
gear assembly, reverse gear needle bearing, and reverse gear
baulk ring.

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears

MT-40

SMT681DB

Place bearing replacer between 5th & reverse synchronizer
hub and 5th main gear, and press out both reverse gear bush-
ing and 5th & reverse synchronizer assembly.

Remove 5th main gear, 5th gear baulk ring, and 5th gear
needle bearing.

SMT682DB

Place bearing replacer between 3rd and 4th main gears, and
press out both 5th gear bushing and 4th main gear.

SMT683D

10. Remove mainshaft adjusting shim and spacer.
11. Place bearing replacer between 2nd main gear and 1st & 2nd

synchronizer hub, and press out both 3rd and 2nd main gears.

SMT684DB

12. Remove 2nd double cone assembly, 2nd gear bushing, and

coupling sleeve assembly.

13. Place bearing replacer on 1st gear front side, and press out all

of 2nd gear bushing, 1st & 2nd synchronizer hub, 1st main
gear, and 1st double cone.

14. Remove 1st gear needle bearing.

SMT693D

INSPECTION

NLMT0060

Mainshaft and Gears

NLMT0060S01

Check shaft for cracks, wear or bending.

Check gears for excessive wear, chips or cracks.

IDX

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-41

SMT637A

Synchronizers

NLMT0060S02

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

Check baulk rings for cracks or deformation.

Check insert springs for wear or deformation.

SMT867D

If any crack, damage, or excessive wear is found on cam face
of baulk ring or working face of insert, replace it.

SMT868D

Measure the movement (play, dimension “L”) of 1st & 2nd
coupling sleeve and 5th & reverse coupling sleeve with their
end fixed and the other end lifted as shown in the figure. If the
movement exceeds specification, replace the sleeve.

Coupling sleeve length “L”:

Refer to SDS, MT-90.

SMT140

Measure clearance between baulk ring and gear.

Clearance between baulk ring and gear:

Refer to SDS, MT-90.

SMT714CD

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-42

Measure wear of 1st and 2nd baulk ring.

Place baulk rings in position on synchronizer cone.

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)

If dimension “A” or “B” is smaller than the wear limit,
replace outer baulk ring, inner baulk ring and synchro-
nizer cone as a set.

SMT148A

Bearing

NLMT0060S03

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

SMT706D

ASSEMBLY

NLMT0061

Install 1st gear needle bearing and 1st main gear onto main-
shaft.

Install 1st double cone assembly onto mainshaft.

SMT695D

Install 1st & 2nd synchronizer hub with its three grooves fac-
ing the front side (1st main gear side) onto mainshaft.

CAUTION:

Do not reuse 1st & 2nd synchronizer hub.

IDX

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-43

SMT707DB

Install 1st & 2nd synchronizer hub.

SMT994BB

Install insert spring onto 1st & 2nd coupling sleeve.

SMT708D

Install 1st & 2nd coupling sleeve with its chamfered surface
facing the 1st main gear side onto 1st & 2nd synchronizer hub.

SMT709DB

Install 2nd gear bushing with its flange surface facing 1st & 2nd
synchronizer hub side.

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.

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-44

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-94.

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.

SMT714DB

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

main gear side.

IDX

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-45

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.

SMT715DB

17. Install 5th & reverse synchronizer hub assembly.

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-46

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-95.

SMT720DB

24. Install mainshaft rear bearing.

IDX

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-47

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-92.

SMT678D

27. Install C-ring holder.

SMT677D

28. Install snap ring.
29. Measure gear end play as a final check. Refer to, MT-40.

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.

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.

REPAIR FOR COMPONENT PARTS

RS5F70A

Mainshaft and Gears (Cont’d)

MT-48

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.

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.

IDX

REPAIR FOR COMPONENT PARTS

RS5F70A

Final Drive (Cont’d)

MT-49

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-95.

SMT699BB

Install retaining pin.

Make sure that retaining pin is flush with case.

REPAIR FOR COMPONENT PARTS

RS5F70A

Final Drive (Cont’d)

MT-50

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-28.

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)

IDX

REPAIR FOR COMPONENT PARTS

RS5F70A

Final Drive (Cont’d)

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.

IDX

ASSEMBLY

RS5F70A

Clutch Housing

MT-53

Almera Tino V10 (2003 year). Manual - part 228