Nissan Sentra manuals

Nissan Sentra Service Manual: Unit disassembly and assembly

TRANSAXLE ASSEMBLY

Exploded View

CASE AND HOUSING


  1. Filler plug
  2. Gasket
  3. Transaxle case
  4. Bushing
  5. Snap ring
  6. Oil channel
  7. Oil gutter
  8. Position switch
  9. Bracket
  10. Differential side oil seal
  11. Magnet
  12. Drain plug
  13. Input shaft oil seal
  14. Clutch housing
  15. 2 way connector
  16. Plug
  17. Pinion shaft
  18. Pinion gear

Shaft and gear


  1. Input shaft front bearing
  2. Input shaft
  3. 3rd input gear
  4. Spacer
  5. Snap ring
  6. 3rd baulk ring
  7. 3rd-4th coupling sleeve
  8. 3rd-4th synchronizer hub
  9. Insert key
  10. 4th baulk ring
  11. 4th input gear
  12. 5th input gear
  13. 5th baulk ring
  14. 5th-6th coupling sleeve
  15. 5th-6th synchronizer hub
  16. 6th baulk ring
  17. Needle bearing
  18. 6th input gear
  19. Input shaft rear bearing
  1. First step
  2. Final step


  1. Mainshaft front bearing outer race
  2. Mainshaft front bearing inner race
  3. Mainshaft
  4. 1st main gear
  5. 1st inner baulk ring
  6. 1st synchronizer cone
  7. 1st outer baulk ring
  8. 1st-2nd coupling sleeve
  9. Insert key
  10. 1st-2nd synchronizer hub
  11. 2nd outer baulk ring
  12. 2nd synchronizer cone
  13. 2nd inner baulk ring
  14. 2nd main gear
  15. Bushing
  16. 3rd main gear
  17. Mainshaft adjusting shim
  18. 4th main gear
  19. 5th main gear
  20. 6th main gear
  21. Mainshaft rear bearing inner race
  22. Mainshaft rear bearing outer race
  23. Snap ring
  24. Mainshaft rear bearing adjusting shim


  1. Reverse output gear
  2. Snap ring
  3. Reverse baulk ring
  4. Return spring
  5. Needle bearing
  6. Seal washer
  7. Reverse idler shaft
  8. Spacer
  9. Reverse input gear
  10. Lock washer
  11. Spring washer

Shift fork and fork rod


  1. Shifter lever A
  2. Shifter lever B
  3. Retaining pin
  4. Selector
  5. Selector lever
  6. Reverse fork rod
  7. 1st-2nd fork rod
  8. Fork rod

Final drive


  1. Shim
  2. Differential side bearing outer race (transaxle case side)
  3. Differential side bearing inner race (transaxle case side)
  4. Final gear
  5. Differential case
  6. Differential side bearing inner race (clutch housing side)
  7. Differential side bearing outer race (clutch housing side)

Disassembly

  1. Remove drain plug and gasket from clutch housing, using a suitable tool and drain gear oil.
  2. Remove filler plug and gasket from transaxle case.
  3. Remove selector lever (1) retaining pin with a pin punch to remove selector lever.
  4. Remove bracket (2) and position switch (3) from transaxle case.


  1. Remove transaxle case bolts ( ).


  1. Remove reverse idler shaft bolt ( ) and sealing washer.


  1. Remove transaxle case (2) while rotating shifter lever a (1) in the direction as shown.


  1. Remove selector spring (1) from return bushing (a).


  1. Shift 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to the neutral position.
  2. Remove selector (4) from clutch housing.


  1. Remove reverse idler shaft assembly (1), with the following procedure.
  1. Pull up input shaft assembly (2), mainshaft assembly (3), fork rod (4), and 1st-2nd fork rod (5).

Note:

It is easier to pull up when shifting each fork rod to each shaft side.

  1. Remove reverse idler shaft assembly and reverse fork rod (6) from clutch housing
  1. Remove spring washer from clutch housing.


  1. Pull up and remove input shaft assembly (1), mainshaft assembly (2), fork rod (3), and 1st-2nd fork rod (4) from clutch housing.

Note:

It is easier to pull up when shifting each fork rod to each shaft side.


  1. Remove final drive assembly (1) from clutch housing.
  2. Remove magnet from clutch housing.


  1. Remove differential side oil seals (1) from clutch housing and transaxle case.

Caution:

Do not damage clutch housing and transaxle case.

Do not reuse differential side oil seal.


  1. Remove differential side bearing outer race (1) from clutch housing, using a suitable tool.

Caution:

Do not damage clutch housing.


  1. Remove differential side bearing outer race (1) from transaxle case, using a suitable tool.

Caution:

Do not damage transaxle case.

  1. Remove shim (2) from transaxle case.


  1. Remove shifter lever a (1) retaining pin, using a suitable tool.

Caution:

Do not reuse retaining pin.

  1. Remove shifter lever a from transaxle case.


  1. Remove shifter lever B (1) from transaxle case.


  1. Remove oil gutter (1) from transaxle case.


  1. Remove bushings (1) from transaxle case, using a suitable tool.

Caution:

Do not reuse bushings.


  1. Remove mainshaft rear bearing outer race from transaxle case, using a suitable tool.
  2. Remove mainshaft rear bearing adjusting shim from transaxle case.


  1. Remove snap ring (1) and oil channel (2) from transaxle case.

Caution:

Do not reuse snap ring or oil channel.


  1. Remove input shaft oil seal (1) from clutch housing, using a suitable tool.

Caution:

Do not damage clutch housing.

Do not reuse input shaft oil seal.


  1. Remove mainshaft front bearing outer race (1) from clutch housing, using Tool (A) and a suitable tool (B).

Tool number (a) : kv381054s0 (j-34286)

  1. Remove oil channel (2) from clutch housing.

Caution:

Do not reuse oil channel.


  1. Remove bushings (1) from clutch housing, using a suitable tool.

Caution:

Do not reuse bushings.


  1. Remove 2 way connector (1) from clutch housing.

Assembly


Assembly

  1. Install 2 way connector (1) to clutch housing.


  1. Install bushings (1) so that they becomes even with clutch housing surface, using suitable tool (A).
  2. Install oil channel to clutch housing.

CAUTION:

Do not reuse oil channel.


  1. Install mainshaft front bearing outer race to clutch housing using Tool (A).

CAUTION:

Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set.

Do not reuse mainshaft front bearing inner or outer race.

Tool number (A) : KV38100200 ( — )


  1. Install input shaft oil seal (1) to clutch housing using the Tool (A).

Tool number (A) : ST33220000 ( — )


  1. Install snap ring (1) and oil channel (2) to transaxle case.

CAUTION:

  1. Install mainshaft rear bearing adjusting shim to transaxle case.

CAUTION:


CAUTION:

Select mainshaft rear bearing adjusting shim, with the following procedure when replacing mainshaft adjusting shim, 6th main gear, 5th main gear, or 4th main gear.

  1. Install mainshaft rear bearing outer race to transaxle case using suitable tool (A).

CAUTION:

Replace mainshaft rear bearing outer race and mainshaft rear bearing inner race as a set.

Tool number : KV38100200 ( — )


  1. Install bushings (1) to transaxle case, using suitable tool (A).


  1. Install oil gutter (1) to transaxle case.


  1. Install shifter lever B (1) to transaxle case.

CAUTION:

Replace shifter lever A and shifter lever B as a set.

  1. Install shifter lever A to transaxle case.

CAUTION:

Replace shifter lever A and shifter lever B as a set.


  1. Install retaining pin to shifter lever A (1) using a suitable tool.

CAUTION:

Do not reuse retaining pin.

  1. Install shim to transaxle case.


  1. Install differential side bearing outer race (transaxle case side) to transaxle case, using Tool (A).

CAUTION:

Replace differential side bearing outer race (transaxle case side) and differential side bearing inner race (transaxle case side) as a set.

Do not reuse differential side bearing inner or outer race.

Tool number : ST33400001 (J-26082)


  1. Install differential side bearing outer race (clutch housing side) to clutch housing, using Tool (A).

CAUTION:

Replace differential side bearing outer race (clutch housing side) and differential side bearing inner race (clutch housing side) as a set.

Do not reuse differential side bearing inner or outer race.

Tool number : KV38100200 ( — )


  1. Install differential side oil seals (1) to clutch housing and transaxle case, using Tools.

Tool number : KV32500QAA

Tool number : B.vi 1666-B

(A) : Transaxle case side

(B) : Clutch housing side

Dimension (L1) : 1.2 – 1.8 mm (0.047 – 0.071 in)


Dimension (L1) : 1.2 – 1.8 mm (0.047 – 0.071 in)

Dimension (L2) : 2.7 – 3.3 mm (0.106 – 0.130 in)

CAUTION:

  1. Install magnet to clutch housing.
  2. Install final drive assembly to clutch housing.
  3. Set fork rod (1) to input shaft assembly (2), and then install them to clutch housing.


  1. Install mainshaft assembly (1), with the following procedure.
  1. Pull up input shaft assembly (2) and fork rod (3).
  2. Set 1st-2nd fork rod (4) to mainshaft assembly and install them to clutch housing.


  1. Install reverse idler shaft assembly (1) with the following procedure.
  1. Install spring washer to clutch housing.
  2. Pull up input shaft assembly (2), mainshaft assembly (3), fork rod (4), and 1st-2nd fork rod (5).

NOTE:

It is easier to pull up when shifting each fork rod to each shaft side.

  1. Set reverse fork rod (6) to reverse idler shaft assembly and install them to clutch housing.


  1. Move 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to the neutral position.
  2. Install selector (4) to clutch housing.

CAUTION:

Replace selector lever and selector as a set.


  1. Install selector spring (1) to return bushing (A).
  2. Apply recommended sealant to the gasket surface of transaxle case.

CAUTION:


  1. Install transaxle case to clutch housing while rotating shifter lever A (1) in the direction as shown.


  1. Install reverse idler shaft bolt ( procedure. ), as per the following
    procedure.
  1. Install sealing washer to reverse idler shaft bolt, and install reverse idler shaft bolt to transaxle case.

CAUTION:

Do not reuse sealing washer.

  1. Tighten reverse idler shaft bolt to the specified torque.


  1. Tighten transaxle case bolts () to the specified torque.
    ) to the specified torque.


  1. Install position switch (1), with the following procedure.
  1. Apply recommended sealant to threads of position switch.

CAUTION:

Do not allow old liquid gasket, moisture, oil, or foreign matter to remain on thread.


  1. Install position switch to transaxle case and tighten it to the specified torque.
  1. Install bracket (2) to transaxle case and tighten bolt to the specified torque.
  2. Install selector lever (3) with the following procedure.
  1. Install selector lever to transaxle case.

CAUTION:

Replace selector lever and selector as a set.

  1. Install retaining pin to selector lever using a suitable tool.

CAUTION:

Do not reuse retaining pin.

  1. Install drain plug with the following procedure.
  1. Install gasket to drain plug.

CAUTION:

Do not reuse gasket.

  1. Install drain plug to clutch housing using a suitable tool.
  2. Tighten drain plug to the specified torque.

CAUTION:

Do not overtighten drain plug as this could cause the transaxle case to crack.

  1. Install filler plug with the following procedure.
  1. Install gasket to filler plug and install it to the transaxle case.

CAUTION:

Do not reuse gasket.

  1. Tighten filler plug to the specified torque.

CAUTION:

Fill with gear oil before tighten filler plug to the specified torque.

Do not overtighten the filler plug as this could cause the transaxle case to crack.

Inspection

INSPECTION AFTER DISASSEMBLY

Check contact surface (sliding surface (  ) for excessive ) and
sliding surface ( wear, uneven wear, bend, and damage. Replace if necessary. ) for excessive
wear, uneven wear, bend, and damage. Replace if necessary.

Input shaft and gear


Input shaft and gear

Exploded View


  1. Input shaft front bearing
  2. Input shaft
  3. 3rd input gear
  4. Spacer
  5. Snap ring
  6. 3rd baulk ring
  7. 3rd-4th coupling sleeve
  8. 3rd-4th synchronizer hub
  9. Insert key
  10. 4th baulk ring
  11. 4th input gear
  12. 5th input gear
  13. 5th baulk ring
  14. 5th-6th coupling sleeve
  15. 5th-6th synchronizer hub
  16. 6th baulk ring
  17. Needle bearing
  18. 6th input gear
  19. Input shaft rear bearing
  1. First step
  2. Final step

Disassembly

CAUTION:


  1. Remove input shaft rear bearing bolt (1), using Tool (A).

CAUTION:

Do not reuse rear bearing bolt.

Tool number (A) : KV32300QAM ( — )


  1. Remove input shaft rear bearing (1) with the following procedure.
  1. Set a suitable tool to input shaft rear bearing.
  2. Remove input shaft rear bearing using suitable tool (A).


  1. Remove spacer (1), 6th input gear (2), needle bearing, 6th baulk ring, and 5th-6th synchronizer hub assembly (3).
  2. Remove insert keys and 5th-6th coupling sleeve from 5th-6th synchronizer hub.


  1. Remove snap ring (1).

CAUTION:

Do not reuse snap ring.

  1. Remove spacer, 5th baulk ring, 5th input gear (2), and spacer.
  2. Remove snap ring (1).

CAUTION:

Do not reuse snap ring.

  1. Remove spacer, 4th input gear (2), 4th baulk ring, and 3rd-4th synchronizer hub assembly (3).
  2. Remove insert keys and 3rd-4th coupling sleeve from 3rd-4th synchronizer hub.


  1. Remove snap ring (1).

CAUTION:

Do not reuse snap ring.

  1. Remove spacer, 3rd baulk ring, and 3rd input gear (2).


  1. Set a suitable tool to input shaft front bearing (1), and then remove input shaft front bearing.

Assembly


Assembly

Assembly is in the reverse order of disassembly.

CAUTION:


  1.  3rd input gear side
  2. 4th input gear side


  1. 5th input gear side
  2. 6th input gear side



Tool number : ST36720030 ( — )

CAUTION:

Follow the procedures. Otherwise it may cause a transaxle malfunction.

Do not reuse rear bearing bolt.


  1. Fix the Tool (A) in a vise and set input shaft assembly.

Tool number : KV32300QAM ( — )

  1. Install input shaft rear bearing bolt and tighten it to the specified torque of the first step.
  2. Loosen input shaft rear bearing bolt by a half turn.
  3. Tighten input shaft rear bearing bolt to the specified torque of the final step.

Inspection

INSPECTION AFTER DISASSEMBLY

Input Shaft and Gear

Check the following items and replace if necessary.

Synchronizer Hub and Coupling Sleeve


Synchronizer Hub and Coupling Sleeve

Check the following items and replace if necessary.

Baulk Ring


Baulk Ring

Check contact surface of baulk ring cam and insert key for excessive wear, uneven wear, bend, and damage. Replace if necessary.

Check bearing for damage and uneven rotation. Replace if necessary.


Check bearing for damage and uneven rotation. Replace if necessary.

Mainshaft and gear


Mainshaft and gear

Exploded View


  1. Mainshaft front bearing outer race
  2. Mainshaft front bearing inner race
  3. Mainshaft
  4. 1st main gear
  5. 1st inner baulk ring
  6. 1st synchronizer cone
  7. 1st outer baulk ring
  8. 1st-2nd coupling sleeve
  9. Insert key
  10. 1st-2nd synchronizer hub
  11. 2nd outer baulk ring
  12. 2nd synchronizer cone
  13. 2nd inner baulk ring
  14. 2nd main gear
  15. Bushing
  16. 3rd main gear
  17. Mainshaft adjusting shim
  18. 4th main gear
  19. 5th main gear
  20. 6th main gear
  21. Mainshaft rear bearing inner race
  22. Mainshaft rear bearing outer race
  23. Snap ring
  24. Mainshaft rear bearing adjusting shim

Disassembly

CAUTION:


  1. Remove snap ring (1).

CAUTION:

Do not reuse snap ring.


  1. Remove 6th main gear (1) and mainshaft rear bearing inner race (2), with the following procedure.
  1. Set a suitable tool to 6th main gear.
  2. Remove mainshaft rear bearing inner race and 6th main gear, using Tool (A).

Tool number : ST33052000 ( — )


  1. Remove 4th main gear (1) and 5th main gear (2) with the following procedure.
  1. Set a suitable tool to 4th main gear.
  2. Remove 5th main gear and 4th main gear, using Tool (A).

Tool number : ST33052000 ( — )

  1. Remove mainshaft adjusting shim.


  1. Remove 1st main gear (1), 1st-2nd synchronizer hub assembly (2), 2nd main gear (3), and 3rd main gear (4) with the following procedure.
  1. Set a suitable tool to 1st main gear.
  2. Remove 3rd main gear, busing, 2nd main gear, 2nd inner baulk ring, 2nd synchronizer cone, 2nd outer baulk ring, 1st-2nd synchronizer hub assembly, 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, and 1st main gear using Tool (A).

Tool number : ST33052000 ( — )

Tool number : ST33052000 ( — )


Tool number : ST33052000 ( — )

  1. Remove insert keys and 1st-2nd coupling sleeve from 1st-2nd synchronizer hub.
  1. Remove mainshaft front bearing inner race (1) with the following procedure.
  1. Set a suitable tool to mainshaft front bearing inner race.
  2. Remove mainshaft front bearing inner race using Tool (A).

Tool number : ST33052000 ( — )

Assembly


Assembly

CAUTION:


  1. Install mainshaft front bearing inner race (1) using Tool (A).

CAUTION:

Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set.

Do not reuse mainshaft front bearing inner or outer race.

Tool number : ST36720030 ( — )

  1. Apply gear oil to 1st inner baulk ring, 1st synchronizer cone, 1st outer baulk ring, 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring.

CAUTION:

Tool number : ST36720030 ( — )


Tool number : ST36720030 ( — )

  1. Apply gear oil to 1st inner baulk ring, 1st synchronizer cone, 1st outer baulk ring, 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring.

CAUTION:

  1. Install insert keys and 1st-2nd coupling sleeve to 1st-2nd synchronizer hub.

CAUTION:

Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.

Install 1st main gear (1), 1st inner baulk ring, 1st synchronizer cone, 1st outer baulk ring, 1st-2nd synchronizer hub assembly (2), 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring.

  1. Install bushing (3) using Tool (A).

Tool number : ST32102700 ( — )


  1. Install 3rd main gear (1) and 2nd main gear (2) using Tool (A).

Tool number : KV32102700 ( — )


  1. Measure dimension (L) as shown in the figure. Select mainshaft adjusting shim (1) according to the following list, and then install it to mainshaft.
  1. Mainshaft
  2. 3rd main gear


 


 

 

 

 

  1. Install 4th main gear (1) using Tool (A).

Tool number : KV32102700 ( — )


  1. Install 5th main gear (1) using Tool (A).

Tool number : KV32102700 ( — )


  1. Install 6th main gear (1) using Tool (A).

Tool number : KV32102700 ( — )


  1. Install mainshaft rear bearing inner race (1) using Tool (A).

CAUTION:

Replace mainshaft rear bearing inner race and mainshaft rear bearing outer race as a set.

Tool number : ST30901000 (J-26010-01)


  1. Install snap ring.

CAUTION:

Do not reuse snap ring.

Inspection


Inspection

INSPECTION AFTER DISASSEMBLY

Mainshaft and Gear

Check the following items and replace if necessary.

Synchronizer Hub and Coupling Sleeve


Synchronizer Hub and Coupling Sleeve

Check the following items and replace if necessary.

Baulk Ring


Baulk Ring

Check contact surface of baulk ring cam and insert key for excessive wear, uneven wear, bend, and damage. Replace if necessary.

Bearing


Bearing

Check bearing for damage and uneven rotation. Replace if necessary.

CAUTION:

Reverse idler shaft and gear


Reverse idler shaft and gear

Exploded View


  1. Reverse output gear
  2. Snap ring
  3. Reverse baulk ring
  4. Return spring
  5. Needle bearing
  6. Seal washer
  7. Reverse idler shaft
  8. Spacer
  9. Reverse input gear
  10. Lock washer
  11. Spring washer

Disassembly

  1. Remove reverse output gear (1).


  1. Remove snap ring (1).

CAUTION:

Do not reuse snap ring.


  1. Remove reverse baulk ring (1) and return spring (2).


  1. Remove snap ring (1), lock washer (2), and reverse input gear (3).

CAUTION:

Do not reuse snap ring.


  1. Remove needle bearings (1) and washer.

Assembly


Assembly

Assembly is in the reverse order of disassembly.

CAUTION:

Inspection

INSPECTION AFTER DISASSEMBLY

Shaft and Gear

Check the following items. Replace reverse output gear, snap ring, reverse baulk ring, return spring, needle bearing, reverse idler shaft, spacer, reverse input gear, and lock washer as a set, if necessary.

Bearing

Check damage and rotation of bearing. Replace reverse output gear, snap ring, reverse baulk ring, return spring, needle bearing, reverse idler shaft, spacer, reverse input gear, and lock washer as a set, if necessary.

Final drive

Exploded View


  1. Shim
  2. Differential side bearing outer race (transaxle case side)
  3. Differential side bearing inner race (transaxle case side)
  4. Final gear
  5. Differential case
  6. Differential side bearing inner race (clutch housing side)
  7. Differential side bearing outer race (clutch housing side)

Disassembly

  1. Remove differential side bearing inner race (clutch housing side) (1) with the following procedure.
  1. Set a suitable tool to differential side bearing inner race (clutch housing side).
  2. Remove differential side bearing inner race (clutch housing side) using Tool (A).

Tool number : ST33061000 (J-8107-2)


  1. Remove final gear mounting bolts and remove final gear (1).


  1. Remove differential side bearing inner race (transaxle case side) (1) with the following procedure.
  1. Set a suitable tool to differential side bearing inner race (transaxle case side).
  2. Remove differential side bearing inner race (transaxle case side) using a suitable tool (A).

Assembly


Assembly

  1. Install final gear, and then tighten final gear mounting bolts to the specified torque.

CAUTION:

Replace final gear and differential case as a set.

  1. Install differential side bearing inner race (clutch housing side) using a suitable tool (A).

CAUTION:

Replace differential side bearing inner race (clutch housing side) and differential side bearing outer race (clutch housing side) as a set.


  1. Install differential side bearing inner race (transaxle case side) using a suitable tool (A).

CAUTION:

Replace differential side bearing inner race (transaxle case side) and differential side bearing outer race (transaxle case side) as a set.

Inspection


Inspection

INSPECTION AFTER DISASSEMBLY

Gear and Case

Check final gear and differential case. Replace if necessary.

Bearing

Check bearing for damage and uneven rotation. Replace if necessary.

Service data and specifications (SDS)


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Service data and specifications (SDS)
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