Nissan PULSAR N13 Series / ASTRA LD Series. Manual - part 33

Manual Transaxle and Drive Shafts

 

133

 

 

Dismantled    view    of   the    1st/2nd    gear   synchro 

assembly. 

(6)  Select a snap ring to obtain the minimum 

clearance in the input shaft groove and install the snap 
ring to the rear of the input shaft.

 

NOTE: The maximum allowable clearance 
is O.I mm. Snap rings are available from 
2.00 mm to 2.30 mm in increments of 
.05 mm.

 

(7)  Ensure that the fifth gear end float is within 

the specifications. 

(8)  Install the bearing retainer to the front of the 

input shaft in the direction noted on removal. 

(9)  Install the front bearing and spacer to 

the input shaft. 

(10)  Select a snap ring to obtain the minimum 

clearance in the input shaft groove and install the snap 
ring to the front of the input shaft. 

NOTE: The maximum allowable clearance 
is 0.1 mm. Snap rings are available from 
1.27 mm to 1.45 mm in increments of 
.06 mm.

 

(11)  Assemble   the   components   of  the   first/ 

second and third/fourth synchro assemblies aligning

 

the marks made on dismantling. Ensure that the ends 
of the shift plate springs are not aligned.

 

(12)  Install the needle roller bearing and first gear 

to the mainshaft. 

(13)  Install the first/second synchro assembly to 

the mainshaft. Ensure that the slots in the synchro 

ring are aligned with the shift plates. 

(14)  Install the steel ball to the mainshaft 

using 
grease to retain the ball. 

(15)  Install second gear to the mainshaft and 

install 
the bush aligning the groove in the bush with the steel 
ball. 

(16)  Install third gear to the mainshaft. 
(17)  Install the third/fourth synchro assembly to 

the mainshaft ensuring that the slots in the synchro 
ring are aligned with the shift plates. 

(18)  Install the other steel ball to the mainshaft 

using grease to retain the ball. 

(19)  Install the fourth gear bush to the mainshaft 

aligning the groove in the bush with the ball. 

(20)  Install the fourth gear to the mainshaft. 
(21)  Install the fifth gear to the mainshaft. 
(22)  Install the thrust washer to the mainshaft. 
(23)  Select C rings to obtain the minimum clear- 

ance in the mainshaft grooves and install the C rings to 
the mainshaft groove. Install the C ring holder to the 
mainshaft. 

NOTE: The maximum allowable clearance 
is 0.1 mm. C rings are available in thick- 
nesses of 3.63 mm to 4.54 mm in incre- 
ments of 0.07 mm.

 

(24)  Install the rear and front bearing cones to the 

mainshaft using a press and press plates. 

(25)  Ensure that the mainshaft first, second, third 

and fourth gear end floats are within the Specifica- 
tions. 

(26)  Temporarily install the differential assembly 

to the clutch housing. 

(27)  Install the transaxle case to the clutch 

hous- 
ing. 

(28)  Tighten the transaxle case retaining bolts to 

the specified torque. 

(29)  Install a suitable slotted adaptor into 

the 
differential pinion shaft and, using a torque gauge, 
measure the differential turning torque. The turning 
torque  should  be  in  a  range  from  slightly  below 
3.9 Nm to 7.9 Nm. 

If the turning torque is not as specified, proceed to 

the Differential and Final Drive heading and perform 
operations (22) to (29).

 

If the turning torque is as specified, proceed as 

follows:

 

(30)  Remove the transaxle case and install 

the 
mainshaft to the clutch housing ensuring that the resin 
oil channel is located centrally in the end of the 
mainshaft. 

(31)  Install the transaxle case to the clutch hous- 

ing. 

Dismantled    view    of    the    3rd/4th    gear    synchro

assembly. 

134

 

Manual Transaxle and Drive Shafts

 

 

(32)  Install and tighten the retaining bolts to 

the specified torque. 

(33)  Repeat  operation  (29).   The  total   turning 

torque should be 5.9-13.7 Nm if new bearings have 
been installed or slightly less if the original bearings 
have been installed. 

If the turning torque is not as specified, adjust the 

mainshaft turning torque as follows:

 

(a)  Remove the transaxle case rear cover, O ring, 

spacer and adjusting shim from the transaxle case. 

(b)  Ensure that the mainshaft rear bearing outer 

race is fully seated on the bearing cone. 

(c)  Using micrometer depth gauge, measure the 

distance from the transaxle case to the bearing outer 
race and note the reading. 

(d)  Referring to the following table, select the 

appropriate shim, according to the reading noted in 
operation (c), required to correct the mainshaft turn- 
ing torque. 

READING SHIM

 

2.35-2.40 mm ............................................... 0.10 mm

 

2.40-2.45 mm ............................................... 0.15 mm

 

2.45-2.50 mm ...............................................0.20 mm

 

2.50-2.55 mm ............................................... 0.25 mm

 

2.55-2.60 mm ............................................... 0.30 mm

 

2.60-2.65 mm ............................................... 0.35 mm

 

2.65-2.70 mm ............................................... 0.40 mm

 

2.70-2.75 mm ............................................... 0.45 mm

 

2.75-2.80 mm ............................................... 0.50 mm

 

2.80-2.85 mm ............................................... 0.55 mm

 

2.85-2.90 mm ............................................... 0.60 mm

 

2.90-2.95 mm ............................................... 0.65 mm

 

2.95-3.00 mm ............................................... 0.70 mm

 

3.00-3.05 mm ............................................... 0.75 mm

 

3.05-3.10 mm ............................................... 0.80 mm

 

3.10-3.15 mm ............................................... 0.85 mm

 

3.15-3.20 mm ...............................................  0.90 mm

 

3.20-3.25 mm...............................................  0.95 mm

 

3.25-3.30 mm ............................................... 1.00 mm.

 

(e)  Install the spacer, shim, O ring and rear 

cover to  the  transaxle  case.  Tighten  the  retaining  
bolts securely.

 

(34)  Measure the total turning torque as previ- 

ously described. 

(35)  Install the striking interlock and striking lever 

to the clutch housing. 

(36)  Install the striking rod to the clutch housing 

sliding the rod through the lever and interlock. Take 
care that the end of the rod does not damage the seal. 

(37)  Install a new retaining pin to the striking rod 

using a pin punch. 

(38)  Install the reverse and fifth gear check 

assembly to the clutch housing. Tighten the retaining 
screws securely. 

(39)  Install the balls, spring and reverse check 

plug to the clutch housing ensuring that the smaller 
diameter ball enters the hole in the body of the 
reverse and 

fifth gear check assembly body. Apply locking com- 
pound and tighten the reverse check plug securely.

 

(40)  Using a bar clamped to the end of the 

striking rod, check that a force of 4.9-7.4 Nm is 
required to overcome the spring loading of the reverse 
and fifth gear check assembly. If necessary, renew the 
springs to achieve this correct spring loading.

 

NOTE: Ensure that the reverse check plug is 
coated with locking compound when finally 
installed.

 

(41)  Install the shift check ball, spring and plug to 

the clutch housing. Ensure that the ball is centrally 
located in the plug. 

(42)  If removed, install the oil reservoir to the 

clutch housing. 

(43)  Install  the  input   shaft  assembly  and  the 

reverse idler gear to the clutch housing taking care not 
to damage the seal. 

(44)  Apply  locking compound  to  the  bearing 

retainer bolts and tighten the bolts to the specified 
torque. 

(45)  Install the spacer to the reverse idler shaft. 
(46)  Install the differential assembly to the clutch 

housing. 

(47)  Install the mainshaft to the clutch housing 

ensuring that the resin oil channel is located centrally 
in the end of the mainshaft. 

(48)  Install the shift cap to the slot in the first/ 

second shift fork and install the shift fork and control 
bracket to the clutch housing. Use grease to hold the 
shift cap in the shift fork slot. Ensure that the reverse 
idler shift fork is correctly located over the gear. 

(49)  Apply locking compound to the threads of 

the control bracket retaining bolts and tighten the 
bolts to the specified torque. 

(50)  Install the shift cap in the slot in the third/ 

fourth shift fork and install the fork to the transaxle 
assembly. Use grease to hold the shift cap in the shift 
fork slot. 

(51)  Install the fifth gear shift fork to the transaxle 

ensuring that the shift fork slot engages the control 
finger. 

(52)  Install the fork shaft and spring to the clutch 

housing sliding the shaft through the shift forks. Use 
grease to hold the spring in the end of the shaft. 

(53)  Apply a continuous bead of sealant to the 

mating face of the clutch housing so that the bead is 
located inside the row of bolt holes. 

NOTE: Sealant is available from Nissan 
spare parts using the part number KP 
610-00250.

 

(54)  Install the transaxle case to the clutch hous- 

ing.  Install and tighten the retaining bolts to the 
specified torque. 

(55)  Select each gear in turn and check that the 

transaxle turns freely in each gear. Ensure that it is not 

Manual Transaxle and Drive Shafts

 

135

 

 

possible to move the striking rod from fifth gear to 
reverse without first moving sideways in the neutral 
gate.

 

4.    DIFFERENTIAL AND FINAL DRIVE 

ASSEMBLY 

Special Equipment Required: 

To Measure Differential Turning Torque — 
Suitable slotted adaptor and torque gauge 

TO CHECK VISCOUS COUPLING 

From July 1989, Manual transaxle Pulsar Q and 

Vector SSS models are equipped with a limited slip 
differential incorporating a viscous coupling.

 

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

on chassis stands. 

(2)  Rotate one front wheel and check the rota- 

tional direction of the opposite wheel. 

(3)  If both   front wheels  rotate  in the same 

direction, the viscous coupling is functioning nor- 
mally. 

(4)  If the front wheels rotate in opposite direc- 

tions, the viscous coupling is unserviceable and must 
be renewed as an assembly. 

TO DISMANTLE AND ASSEMBLE

 

It is necessary to remove and dismantle the 

transaxle assembly to gain access to the differential 
and final drive assembly.

 

Refer to the Transaxle Assembly heading for the

 

removal of the transaxle from the vehicle. Operations 
1-9 of the dismantling procedure under the same 
heading describe the removal of the differential and 
final drive assembly from the transaxle.

 

(1)  If necessary, cut and remove the speedome- 

ter drive gear from the differential case. 

(2)  Using a suitable puller, remove the differen- 

tial carrier bearing cone and roller assemblies from the 
differential case and remove the speedometer drive 
gear stopper. 

(3)  Remove the ring gear retaining bolts and 

separate the ring gear from the differential case using 
a soft faced hammer. 

(4)  Using a pin punch, remove the retaining pin 

from the differential pinion shaft. 

(5)  Remove the pinion shaft from the differen- 

tial case. 

(6)  Remove the pinion gears and thrust washers 

from the differential case. 

(7)  Remove the side gears and spacers from the 

differential case. 

NOTE: If applicable, the viscous coupling is 
integral with the left hand side gear.

 

(8)  Wash all the differential components with 

cleaning solvent. 

(9)  Check the gears, spacers, thrust washers, 

pinion shaft and differential case for wear, pitting and 
damage. Renew parts as necessary. 

(10)  Install the side gears and  spacers to 

the 
differential case. 

(11)  Install the pinion gears and thrust washers 

to 
the differential case. 

(12)  Install the pinion shaft to the differential case 

aligning the retaining pin hole. 

(13)  Install the retaining pin to the pinion shaft 

until the end of the pin is level with the differential 
case. 

(14)  With a dial gauge contacting the end of the 

side gear, lift the side gear evenly and measure the 
clearance between the side gear and the differential 
case. The clearance should be 0.1-0.2 mm. 

NOTE: Do not tilt the side gear or the dial 
gauge reading will be incorrect.

 

(15)  If necessary, adjust the side gear clearance 

using selective fit spacers.

 

NOTE: Spacers are available from 0.15 mm 
to 1.00 mm in increments of 0.05 mm.

 

(16)  Measure and if necessary, adjust the other 

side gear clearance. 

(17)  On models equipped with a viscous cou- 

pling, adjust the side gear clearance as follows: 

 

(a)  Temporarily secure the differential case with 

two bolts. 

(b)  Position the differential case so that the right 

hand side gear is uppermost. 

(c)  Insert a 0.03 mm feeler gauge between the 

View of the differential assembly removed from the

transaxle. 

136

 

Manual Transaxle and Drive Shafts

 

 

right hand side gear and the adjacent spacer in an area 
where there is no oil groove in the differential case. 
(d)   Insert another 0.03 mm feeler gauge diago- 
nally opposite the first feeler gauge to avoid tilting the 
side gear.

 

(e)  Insert a splined adaptor into the right hand 

side gear and attempt to rotate the gear by hand. 

(f)  If the gear cannot be rotated, change the 

thickness of the left hand side gear spacer, repeating 
the test until the gear can be rotated. 

NOTE: Spacers are available in thicknesses 
from 0.8 mm to 1.5 mm in increments of 
0.1 mm.

 

(g)  Remove the 0.03 mm feeler gauges and insert 

0.09 mm feeler gauges to the same position. The gear 
should lock.

 

(h) The spacer selection is correct when the right 

hand side gear can be rotated with 0.03 mm feeler 
gauges inserted but locks when 0.09 mm feeler gauges 
are inserted.

 

(18)  Install the ring gear to the differential case 

with the chamfered edge of the ring gear inwards. 

(19)  Install and tighten the retaining bolts in 

a 
diagonal sequence to the specified torque. 

(20)  Install a new speedometer drive gear to 

the 
differential case. Install the stopper adjacent to the 
drive gear. 

(21)  Install the differentia] carrier bearing 

cones 
and roller assemblies to the differential case. 

(22)  Remove the adjusting shim from behind the 

carrier bearing outer race in the transaxle case and 
replace the outer race in the transaxle case. 

(23)  Install the differential assembly to the clutch 

housing. 

(24)  Install the transaxle case to the clutch housing 

and tighten the retaining bolts to the specified torque. 

(25)  Mount a dial gauge to the clutch housing so 

that the contact point is resting on the differential 
case. 

(26)  Insert a bar through the opposite side gear 

and, contacting the pinion shaft, raise and lower the 
differential case and measure the end float in the 
carrier bearings. 

(27)  Using the following table, select a shim to 

correspond to the relevant end float. 

END FLOAT 

SHIM THICKNESS

 

0.30-0.34 mm....................................................0.64 mm

 

0.34-0.38 mm...................................................   0.68 mm

 

0.38-0.42 mm...................................................   0.72 mm

 

0.42-0.46 mm...................................................   0.76 mm

 

0.46-0.50 mm...................................................   0.80 mm

 

0.50-0.54 mm...................................................   0.84 mm

 

0.54-0.58 mm...................................................   0.88 mm

 

0.58-0.62 mm...................................................   0.92 mm

 

0.62-0.66 mm...................................................   0.96 mm

 

0.66-0.70 mm...................................................   1.00 mm

 

0.70-0.74 mm...................................................   1.04 mm

 

0.74-0.78 mm...................................................   1.08 mm

 

0.78-0.82 mm...................................................   1.12 mm

 

0.82-0.86 mm...................................................   1.16 mm

 

0.86-0.90 mm...................................................   1.20 mm

 

0.90-0.94 mm...................................................   1.24 mm

 

0.94-0.98 mm...................................................   1.28 mm

 

0.98-1.02 mm...................................................   1.32 mm

 

1.02-1.06 mm...................................................   1.36 mm

 

1.06-1.10 mm...................................................   1.40 mm

 

1.10-1.14 mm...................................................   1.44 mm

 

1.14-1.18 mm...................................................   1.48 mm

 

1.18-1.22 mm...................................................   1.52 mm

 

1.22-1.26 mm...................................................   1.56 mm

 

1.26-1.30 mm...................................................   1.60 mm

 

1.30-1.34 mm...................................................   1.64 mm

 

1.34-1.38 mm...................................................   1.68 mm

 

1.38-1.42 mm...................................................   1.72 mm

 

1.42-1.46 mm...................................................   1.76 mm

 

The thickest shim available is 0.88 mm. Multiple 

shims are required above this thickness.

 

(28)  Install the shim behind the carrier 

bearing 
outer race in the transaxle case and assemble the unit 
once more. 

(29)  Using a suitable slotted adaptor engage the 

pinion shaft and using a torque gauge, measure the 
differential turning torque. 

The turning torque when new carrier bearings 

have been installed should be 3.9-7.8 Nm or slightly 
lower if the original carrier bearings have been 
replaced.

 

(30)  Assemble the transaxle and measure the total 

turning torque of the differential assembly and the 
mainshaft. The total turning torque should be 5.9 to 
13.7 Nm with new bearings or slightly lower if the 
original bearings have been replaced.

 

5.    GEAR LEVER ASSEMBLY 

TO DISMANTLE AND ASSEMBLE

 

(1)  Remove the gear lever knob and remove the 

centre console as described in the Body section. If not 
previously removed, remove the rubber boot sur- 
rounding the gear lever. 

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

on chassis stands. Remove the catalytic converter and 
heat shield as described in the Engine section. 

(3)  Remove the bolt and disconnect the control 

rod from the bottom of the gear lever, noting the 
position of the return spring and bracket. 

(4)  Remove the  nuts retaining the gear lever 

socket to the support rod. 

(5)  Working inside the vehicle, lift the gear lever 

out of the floor bracket. 

(6)  Separate   the   lower   rubber  boot,   socket, 

spring seat, spring, upper ball seat and lower ball seat 
from the gear lever, noting the location of each 
component to aid assembly.