Nissan Versa 2011 Owner's Manual

TRANSMISSION/TRANSAXLE

SECTION MT

CONTENTS

RS5F91R

SERVICE INFORMATION ............................

PRECAUTIONS ................................................... 3

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-

SIONER" ...................................................................

Precaution Necessary for Steering Wheel Rota-

tion After Battery Disconnect .....................................

Precaution for Procedure without Cowl Top Cover ......4

Service Notice or Precaution .....................................4

PREPARATION ................................................... 5

Special Service Tools ..............................................5

Commercial Service Tools .......................................7

NOISE, VIBRATION AND HARSHNESS

(NVH) TROUBLESHOOTING .............................

NVH Troubleshooting Chart ......................................8

DESCRIPTION .................................................... 9

System Diagram ........................................................9

System Description ...................................................9

M/T OIL ...............................................................11

Draining ...................................................................11

Refilling ...................................................................11

Inspection ................................................................11

SIDE OIL SEAL ..................................................12

Removal and Installation ......................................... 12

POSITION SWITCH ............................................13

Checking .................................................................13

CONTROL LINKAGE .........................................14

Exploded View ........................................................ 14

Removal and Installation ......................................... 14

Inspection ................................................................15

AIR BREATHER HOSE ......................................16

Exploded View ........................................................ 16

MANUAL TRANSAXLE

Removal and Installation .........................................16

TRANSAXLE ASSEMBLY ................................17

Exploded View .........................................................17

Removal and Installation .........................................17

Disassembly and Assembly .....................................18

INPUT SHAFT AND GEAR ...............................36

Disassembly and Assembly .....................................36

MAINSHAFT AND GEAR .................................37

Disassembly and Assembly .....................................37

FINAL DRIVE ....................................................41

Disassembly and Assembly .....................................41

SHIFT CONTROL ..............................................42

Inspection ................................................................42

SERVICE DATA AND SPECIFICATIONS

(SDS) .................................................................

General Specification ..............................................43

RS6F94R

SERVICE INFORMATION ...........................

PRECAUTIONS .................................................44

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-

SIONER" .................................................................

Precaution Necessary for Steering Wheel Rota-

tion After Battery Disconnect ...................................

Precaution for Procedure without Cowl Top Cover ....45

Precaution ...............................................................45

PREPARATION .................................................46

Special Service Tool ................................................46

Commercial Service Tool ........................................48

NOISE, VIBRATION AND HARSHNESS

(NVH) TROUBLESHOOTING ...........................

NVH Troubleshooting Chart ....................................51

Revision: May 2010 2011 Versa

MT-1

DESCRIPTION ................................................... 52

Cross-Sectional View ............................................. 52

M/T OIL .............................................................. 54

Changing M/T Oil .................................................... 54

Checking M/T Oil .................................................... 54

VEHICLE SPEED SENSOR .............................. 55

Removal and Installation ........................................ 55

SIDE OIL SEAL ................................................. 56

Removal and Installation ........................................ 56

POSITION SWITCH ........................................... 57

Checking ................................................................. 57

CONTROL LINKAGE ........................................ 58

Component of Control Device and Cable ............... 58

Removal and Installation ........................................ 58

TRANSAXLE ASSEMBLY ................................ 61

Component ............................................................. 61

Removal and Installation ......................................... 61

Disassembly and Assembly .................................... 62

INPUT SHAFT AND GEARS ............................. 80

Disassembly and Assembly .................................... 80

MAINSHAFT AND GEARS ............................... 85

Disassembly and Assembly .................................... 85

REVERSE IDLER SHAFT AND GEARS ........... 90

Disassembly and Assembly .................................... 90

FINAL DRIVE ..................................................... 92

Disassembly and Assembly .................................... 92

SHIFT CONTROL .............................................. 94

Inspection ................................................................ 94

AIR BREATHER HOSE ..................................... 60

Removal and Installation ........................................ 60

SERVICE DATA AND SPECIFICATIONS

(SDS) .................................................................

General Specification .............................................. 95

Revision: May 2010 2011 Versa

MT-2

< SERVICE INFORMATION >

PRECAUTIONS

[RS5F91R]

SERVICE INFORMATION

PRECAUTIONS

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual.

WARNING:

• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.

• Improper maintenance, including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section.

• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury.

• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the battery, and wait at least 3 minutes before performing any service.

INFOID:0000000005929653

Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

INFOID:0000000005929654

NOTE:

• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYSTEM).

• Remove and install all control units after disconnecting both battery cables with the ignition knob in the ″LOCK″ position.

• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.

For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mechanism is adopted on the key cylinder. For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible. If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation.

OPERATION PROCEDURE

1. Connect both battery cables.

NOTE:

Supply power using jumper cables if battery is discharged.

2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the

steering lock will be released.

3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be

rotated.

4. Perform the necessary repair operation.

Revision: May 2010 2011 Versa

MT-3

PRECAUTIONS

< SERVICE INFORMATION >

5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting the battery cables. (At this time, the steering lock mechanism will engage.)

6. Perform a self-diagnosis check of all control units using CONSULT-III.

[RS5F91R]

Precaution for Procedure without Cowl Top Cover INFOID:0000000005929655

When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc.

PIIB3706J

Service Notice or Precaution INFOID:0000000005929656

• Use recommended brake fluid when adding fluid to the clutch reservoir tank. Refer to MA-14.

• Never reuse fluid drained from clutch system.

• Be careful not to splash brake fluid on painted areas.

• Use new brake fluid to clean or wash all parts of master cylinder and operating cylinder.

• Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic sys-

tem.

• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylinder).

Return CSC to original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage CSC seal and may cause clutch fluid leakage.

• Do not disassemble clutch master cylinder and CSC.

WARNING:

After cleaning clutch disc, clean it with a dust collector. Do not use compressed air.

Revision: May 2010 2011 Versa

MT-4

< SERVICE INFORMATION >

PREPARATION

[RS5F91R]

PREPARATION

Special Service Tools INFOID:0000000005929657

The actual shapes of tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

— ( J-46534 ) Trim tool set

AWJIA0483ZZ

KV32500QAA (—) (Renault SST: B.vi 1666) Drift set

JPDIC0730ZZ

KV32300QAC (—) Puller

Description

For removing trim

Installing differential side oil seal

1. ( – ) (Stamping number: B.vi 1666-A) Drift a: 54.3 mm (2.138 in) dia b: 45 mm (1.77 in) dia c: 26.6 mm (1.047 in) dia

2. ( – ) (Stamping number: B.vi 1666-B) Drift a: 54 mm (2.13 in) dia b: 48.6 mm (1.913 in) dia c: 26.6 mm (1.047 in) dia

Removing 5th main gear

KV32300QAD (—) Puller

ST35300000 (—) Drift

SCIA1781J

SCIA1782J

ZZA0969D

Removing 5th main gear

• Removing and installing input shaft rear bearing

• Removing and installing mainshaft rear bearing

a: 45 mm (1.77 in) dia. b: 59 mm (2.23 in) dia.

Revision: May 2010 2011 Versa

MT-5

< SERVICE INFORMATION >

Tool number (Kent-Moore No.) Tool name

KV 111011S0 (—) Val v e seat re m o v er

ST33400001 (J-26082) Drift

KV40100900 (—) Drift

PREPARATION

[RS5F91R]

Description

Removing mainshaft front bearing

ZZA0872D

Installing mainshaft front bearing

a: 60 mm (2.36 in) dia. a: 47 mm (1.85 in) dia.

ZZA0814D

Installing input shaft front bearing

a: 52 mm (2.05 in) dia. a: 39.5 mm (1.55 in) dia.

KV32300QAE (—) Drift

ST33052000 (—) Drift

KV40104920 (—) Drift

NT084

Installing differential side bearing outer race

a: 65 mm (2.56 in) dia. a: 63 mm (2.48 in) dia.

SCIA1783J

Removing differential side bearing

a: 22 mm (0.87 in) dia. a: 28 mm (1.10 in) dia.

ZZA0969D

Installing differential side bearing

a: 21.7 mm (0.85 in) dia. a: 44.7 mm (1.76 in) dia.

ZZA0969D

Revision: May 2010 2011 Versa

MT-6

PREPARATION

< SERVICE INFORMATION >

[RS5F91R]

Commercial Service Tools INFOID:0000000005929658

Tool name Description

Drift Removing input shaft front bearing

a: 38 mm (1.50 in) dia.

S-NT063

Drift Installing bushing

a: 14.5 mm (0.571 in) dia.

S-NT063

Socket Removing and installing drain plug

a: 8 mm (0.31 in) b: 5 mm (0.20 in)

PCIB1776E

Puller • Removing 5th-reverse synchronizer hub

• Removing differential side bearing

NT077

Bearing remover Removing bushing

S-NT134

Revision: May 2010 2011 Versa

MT-7

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

< SERVICE INFORMATION >

[RS5F91R]

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart INFOID:0000000005929659

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

Reference page

SUSPECTED PARTS (Possible cause)

Noise 1 2 3 3

Symptoms

Oil leakage 31222

Hard to shift or will not shift 1 1 2 3 3

Jumps out of gear 1 2 2

MT-18

OIL (Oil level is low.)

OIL (Wrong oil.)

OIL (Oil level is high.)

MT-18

GASKET (Damaged)

OIL SEAL (Worn or damaged)

MT-14

MT-18

O-RING (Worn or damaged)

SHIFT CONTROL LINKAGE (Worn)

SHIFT FORK (Worn)

GEAR (Worn or damaged)

MT-18

BEARING (Worn or damaged)

BAULK RING (Worn or damaged)

INSERT SPRING (Damaged)

Revision: May 2010 2011 Versa

MT-8

< SERVICE INFORMATION >

DESCRIPTION

[RS5F91R]

DESCRIPTION

System Diagram INFOID:0000000005929660

CROSS-SECTIONAL VIEW

JPDIC0580ZZ

1. Clutch housing 2. 1st-2nd synchronizer hub assembly 3. 3rd-4th synchronizer hub assembly

4. 5th input gear 5. 5th-reverse synchronizer hub assembly 6. 5th-reverse baulk ring

7. 5th main gear 8. 4th main gear 9. 3rd main gear

10. 2nd main gear 11. 2nd double cone synchronizer 12. 1st double cone synchronizer

13. 1st main gear 14. Differential side bearing 15. Differential

16. Final gear 17. Mainshaft 18. Input shaft

System Description INFOID:0000000005929661

DOUBLE-CONE SYNCHRONIZER

Revision: May 2010 2011 Versa

MT-9

DESCRIPTION

< SERVICE INFORMATION >

Double-cone synchronizer is adopted for 1st and 2nd gears to reduce operating force of the shift lever. (1): Outer baulk ring (2): 2nd main gear (3): Synchronizer cone (4): Inner baulk ring (5): 1st main gear (6): 1st-2nd coupling sleeve

REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)

Description Soon after the clutch is disengaged, the input shaft is still rotating due to inertia. This may cause a gear noise when the gear is shifted to reverse position. The reverse gear noise prevention function stops the rotation of the input shaft and enables smooth gear shifting when the reverse gear is selected.

Operation Principle

1. When the gear is shifted to reverse position, 5th-reverse coupling sleeve (1) slides in the reverse direction( )

5: 5th input gear

2. Synchronizer levers (2) with support point (A) at 5th-reverse synchronizer hub (3) presses 5th-reverse baulk ring (4).( )

3. Friction that is generated at 5-reverse baulk ring presses synchronizer lever on 5th-reverse coupling sleeve. ( )

4. 5th-reverse coupling sleeve that is presses by synchronizer lever stops the rotation of input shaft.

[RS5F91R]

SCIA7117E

JPDIC0415ZZ

Revision: May 2010 2011 Versa

MT-10

< SERVICE INFORMATION >

M/T OIL

[RS5F91R]

M/T OIL

Draining INFOID:0000000005929662

1. Start engine and let it run to warm up transaxle.

2. Stop engine. Remove drain plug (1) and drain oil.

3. Set a new gasket on drain plug (1) and install it to transaxle and tighten drain plug to the specified torque. Refer to MT-18, "

assembly and Assembly".

CAUTION:

Do not reuse gasket.

Refilling INFOID:0000000005929663

1. Remove filler plug (1). Fill with new oil until oil level reaches the specified limit near filler plug hole as shown.

Oil grade and capacity : Refer to MA-14, "Fluids and

Lubricants".

2. After refilling oil, check oil level.

3. Set a new gasket on filler plug (1), then install it to transaxle and tighten to the specified torque. Refer to MT-18, "

Disassembly

and Assembly".

CAUTION:

Do not reuse gasket.

Inspection INFOID:0000000005929664

Dis-

PCIB1504E

SCIA7119E

LEAKAGE

Make sure that oil is not leaking from transaxle or around it.

LEVEL

1. Remove filler plug (1) and check oil level at filler plug hole as shown.

CAUTION:

Do not start engine while checking oil level.

2. Set a new gasket on filler plug (1) and install it to the transaxle case.

CAUTION:

Do not reuse gasket.

3. Tighten filler plug to the specified torque. Refer to MT-18, "

assembly and Assembly".

Dis-

SCIA7119E

Revision: May 2010 2011 Versa

MT-11

SIDE OIL SEAL

< SERVICE INFORMATION >

[RS5F91R]

SIDE OIL SEAL

Removal and Installation INFOID:0000000005929665

REMOVAL

1. Remove front drive shafts from transaxle assembly. Refer to FAX-9, "Removal and Installation (Left Side)" and FAX-10, "Removal and Installation (Right Side)".

2. Remove differential side oil seal (1) using suitable tool.

CAUTION:

Do not damage transaxle case or clutch housing.

PCIB1505E

INSTALLATION

Installation is in the reverse order of removal.

Tool number KV32500QAA ( – ) B.vi 1666-B

Dimension

1 : 5.7 – 6.3 mm (0.224 – 0.248 in)

2 : 2.4 – 3.0 mm (0.094 – 0.118 in)

• B: Transaxle case side

• C: Clutch housing side

CAUTION:

• Do not reuse differential side oil seal

• Never incline differential side oil seal.

• Never damage clutch housing and transaxle case.

JPDIC0401ZZ

Revision: May 2010 2011 Versa

MT-12

< SERVICE INFORMATION >

POSITION SWITCH

[RS5F91R]

POSITION SWITCH

Checking INFOID:0000000005929666

NOTE:

For removal and installation of the switches, refer to MT-18, "

BACK-UP LAMP SWITCH

• Check continuity between terminals 1 and 2.

Gear position Continuity

Reverse Yes

Except reverse No

PARK/NEUTRAL POSITION SWITCH

• Check continuity between terminals 2 and 3.

Gear position Continuity

Neutral Yes

Except neutral No

Disassembly and Assembly"

MCIA0157E

JPDIC0092ZZ

Revision: May 2010 2011 Versa

MT-13

CONTROL LINKAGE

< SERVICE INFORMATION >

[RS5F91R]

CONTROL LINKAGE

Exploded View INFOID:0000000005929667

PCIB1508E

1. Shift selector handle 2. Shift selector lever 3. M/T shift selector assembly

4. Select cable 5. Shift selector cable 6. Clutch housing

7. Cable mounting bracket 8. Bracket

A: Black color B: White color

Removal and Installation INFOID:0000000005929668

REMOVAL

1. Remove the battery. Refer to SC-7, "Removal and Installation".

2. Remove the air duct and air cleaner case. Refer to EM-25, "

3. Press the release button (1) of select cable and shift selector cable, and then remove select cable and shift selector cable from select lever of control shaft (2).

4. Move shift selector to neutral position.

5. Remove shift selector handle.

6. Remove center console assembly. Refer to IP-12, "

Removal and

Installation".

7. Remove M/T shift selector assembly bolts.

8. Remove exhaust front tube, center muffler and heat plate. Refer to EX-5, "

Removal and Installation".

9. Remove cable support bracket.

10. Remove select cable and shift selector cable from cable mounting bracket.

11. Remove M/T shift selector assembly from the vehicle.

Removal and Installation" .

SCIA7077E

INSTALLATION

Installation is in the reverse order of removal.

Revision: May 2010 2011 Versa

MT-14

CONTROL LINKAGE

< SERVICE INFORMATION >

• Move the shift selector to the neutral position.

• Securely assemble each of the cables to each select lever of control shaft, mounting bracket, and the M/T shift selector assembly.

• Be careful about the installation direction, and push shift selector handle onto shift selector.

CAUTION:

Do not reuse shift selector handle.

• Make sure that the front/rear claws (1) of M/T shift selector assembly are in contact with flange of the floor (2).

[RS5F91R]

PCIB1509E

PCIB1510E

Inspection INFOID:0000000005929669

Inspect the following items:

• When shift selector is moved to 1st-2nd side and 5th-reverse side, confirm shift selector returns to neutral position smoothly.

• When the shift selector is shifted to each position, make sure there is no binding or disconnection in each boot.

Revision: May 2010 2011 Versa

MT-15

AIR BREATHER HOSE

< SERVICE INFORMATION >

[RS5F91R]

AIR BREATHER HOSE

Exploded View INFOID:0000000005929670

PCIB1511E

1. Air cleaner case 2. Air breather hose 3. Air duct

4. Clip 5. Transaxle assembly 6. Two way connector

Removal and Installation INFOID:0000000005929671

REMOVAL

1. Remove the battery. Refer to SC-7, "Removal and Installation".

2. Remove the air duct and air cleaner case. Refer to EM-16, "

3. Remove air breather hose.

CAUTION:

When air breather hose is removed, be sure to hold two way connector securely.

INSTALLATION

Installation is in the reverse order of removal.

CAUTION:

Make sure air breather hose is not collapsed or blocked due to folding or bending when installed.

• When installing air breather hose on two way connector, aim paint mark toward the vehicle rear.

• When installing air breather hose on two way connector, push it until it hits the transaxle case.

• When installing air breather hose to air duct and air cleaner case, make sure that clips are fully inserted.

Removal and Installation".

Revision: May 2010 2011 Versa

MT-16

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

[RS5F91R]

TRANSAXLE ASSEMBLY

Exploded View INFOID:0000000005929672

PCIB1514E

1. LH engine mount bracket (transaxle side)

4. Washer 5. Rear torque rod Front

Refer to installation.

2. Transaxle assembly 3. Rear engine mount bracket

Removal and Installation INFOID:0000000005929673

CAUTION:

If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause clutch fluid leakage. Refer to CL-13, "

tion".

REMOVAL

1. Drain clutch fluid and remove clutch tube from CSC. Refer to CL-13, "Removal and Installation".

CAUTION:

Do not depress clutch pedal during removal procedure.

2. Remove the engine and transaxle as an assembly from the vehicle. Refer to EM-82, "

lation".

3. Remove the transaxle to engine and engine to transaxle bolts.

4. Separate the transaxle assembly from the engine.

Removal and Installa-

Removal and Instal-

INSTALLATION

Installation is in the reverse order of removal.

Revision: May 2010 2011 Versa

MT-17

TRANSAXLE ASSEMBLY

< SERVICE INFORMATION >

CAUTION:

• Make sure the transaxle assembly does not interfere with the wire harnesses and clutch tube.

• When installing transaxle assembly, do not bring input shaft into contact with clutch cover.

• If transaxle is removed from the vehicle, always replace CSC. Refer to CL-13, "

Removal and Installa-

tion".

• When installing the transaxle assembly to the engine, install the bolts according to the following: (A): Transaxle to engine (B): Engine to transaxle

Bolt No. 1 2 3 4

Quantity 2 2 1 3

Bolt length “ ” mm (in)

Tightening torque N·m (kg-m, ft-lb)

(2.17)

(1.93)

48.0

(4.9, 35)

(2.72)

(2.17)

• After installation perform the following:

- Bleed the air from the clutch hydraulic system. Refer to CL-9, "

- Check for oil leakage and oil level. Refer to MT-11, "

- Check the control linkage. Refer to MT-15, "

Inspection".

Air Bleeding Procedure".

[RS5F91R]

PCIB1517E

Disassembly and Assembly INFOID:0 000000005929674

COMPONENTS

Case and Housing Component

Revision: May 2010 2011 Versa

MT-18

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

[RS5F91R]

1. Differential side oil seal 2. Clutch housing 3. Dowel pin

4. Magnet 5. Drain plug 6. Gasket

7. Oil channel 8. Plug (with ABS models) 9. Vehicle speed sensor (w/o ABS models)

10. Two way connector 11. Oil gutter 12. Air breather inner tube

13. Filler plug 14. Transaxle case 15. O-ring

16. Rear housing 17. Position switch Replace parts as a set

Gear Component

AWDIA0791GB

Revision: May 2010 2011 Versa

MT-19

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

[RS5F91R]

1. Input shaft front bearing 2. Input shaft 3. Snap ring

4. Input shaft rear bearing 5. Adapter plate 6. Bushing

7. 5th input gear 8. 5th-reverse baulk ring 9. Synchronizer lever

10. 5th-reverse synchronizer hub 11. 5th-reverse coupling sleeve 12. Retaining pin

13. Reverse gear assembly Replace parts as a set

JPDIC0480GB

JPDIC0531GB

Revision: May 2010 2011 Versa

MT-20

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

[RS5F91R]

1. Mainshaft front bearing 2. Mainshaft 3. 1st main gear

4. 1st inner baulk ring 5. 1st synchronizer cone 6. 1st outer baulk ring

7. 1st-2nd synchronizer hub 8. 1st-2nd coupling sleeve 9. Spring

10. Insert key 11. 2nd outer baulk ring 12. 2nd synchronizer cone

13. 2nd inner baulk ring 14. Snap ring 15. Thrust washer

16. 2nd main gear 17. 3rd main gear 18. 3rd baulk ring

19. 3rd-4th synchronizer hub 20. 3rd-4th coupling sleeve 21. 4th baulk ring

22. 4th main gear 23. Spacer 24. Mainshaft rear bearing

25. 5th main gear Replace parts as a set

Shift Control Component

1. Retaining pin 2. 1st-2nd shift fork 3. Bushing

4. 1st-2nd fork rod 5. Lock pin 6. 5th-reverse fork rod

7. 5th-reverse shift fork 8. Check ball 9. 3rd-4th shift fork

10. 3rd-4th fork rod 11. Control shaft 12. O-ring

13. Selector 14. Check ball plug 15. Bushing

16. Spring 17. Gear catch Replace parts as a set

Final Drive Component

JPDIC0485GB

Revision: May 2010 2011 Versa

MT-21

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

[RS5F91R]

JPDIC0602ZZ

1. Differential side bearing outer race 2. Differential side bearing 3. Speedometer drive gear

4. Pinion gear 5. Pinion shaft 6. Final drive assembly

Replace parts as a set

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 rear housing and O-ring.

CAUTION:

Remove to axial direction of input shaft ( ) because rear housing oil channel is inserted to input shaft center hole.

4. Shift control shaft shift lever (1) to the 3rd gear position.

NOTE:

• If it is not shifted to the 3rd gear position, transaxle case cannot be removed from clutch housing.

• The 3rd gear position means that control shaft select lever is fully rotated clockwise and it is returned approximately 10 degrees.

SCIA1709J

PCIB1524E

Revision: May 2010 2011 Versa

MT-22

TRANSAXLE ASSEMBLY

< SERVICE INFORMATION >

5. Remove 5th-reverse shift fork (1) and 5th-reverse coupling sleeve according to the following procedures.

a. Remove retaining pin from 5th-reverse shift fork using a suitable

tool (A).

b. Press 5th-reverse shift fork, shift to 5th, and then engage it with

3rd gear.

c. Remove bolt (B). d. Remove nut (C) and washer.

CAUTION:

Never use an impact wrench for removal, or otherwise each gear may be damaged.

e. Remove 5th-reverse shift fork and 5th-reverse coupling sleeve from 5th-reverse synchronizer hub.

6. Remove 5th-reverse synchronizer hub from input shaft using a suitable tool.

CAUTION:

Set claw of the puller to the wider side of the hub when setting the puller in 5th-reverse synchronizer hub.

7. Remove synchronizer levers, 5th-reverse baulk ring, 5th input gear, bushing, and adapter plate from input shaft.

[RS5F91R]

JPDIC0532ZZ

8. Remove 5th main gear from mainshaft using the pullers.

Tool number A: KV32300QAC ( — )

B: KV32300QAD ( — )

9. Remove position switch from transaxle case.

PCIB1526E

PCIB1527E

PCIB1627E

Revision: May 2010 2011 Versa

MT-23

TRANSAXLE ASSEMBLY

< SERVICE INFORMATION >

10. Remove transaxle case bolts ( ).

11. Remove transaxle case from clutch housing.

12. Remove spacer (1) and 4th main gear (2) from mainshaft.

[RS5F91R]

JPDIC0610ZZ

13. Remove 5th-reverse fork rod (1) according to the following procedures.

a. Pull 5th-reverse fork rod up until it contacts claw ( ) of reverse

gear assembly (2).

b. Press gear portion of reverse gear assembly down, and then

remove 5th-reverse fork rod from clutch housing.

14. Remove 3rd-4th fork rod assembly (1), 3rd-4th coupling sleeve (2), and input shaft assembly (3) according to the following procedures.

a. Remove 4th baulk ring, insert keys, and springs from mainshaft. b. Pull gear of reverse gear assembly (4) up. c. Pull 1st-2nd fork rod (5) up, and then maintain the neutral posi-

tion.

d. Remove 3rd-4th fork rod assembly, 3rd-4th coupling sleeve, and

input shaft assembly from clutch housing at the same time.

15. Remove retaining pin from 3rd-4th shift fork using a suitable tool.

16. Remove 3rd-4th shift fork from 3rd-4th shift fork rod.

17. Remove lock pins ( ) from clutch housing.

PCIB1529E

PCIB1530E

PCIB1531E

JPDIC0534ZZ

Revision: May 2010 2011 Versa

MT-24

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

[RS5F91R]

18. Remove 1st-2nd fork rod assembly (1) and mainshaft assembly (2) from clutch housing at the same time.

19. Remove retaining pin from 1st-2nd shift fork using a suitable tool.

20. Remove 1st-2nd shift fork from 1st-2nd shift fork rod.

21. Remove retaining pin from reverse gear assembly using a suitable tool.

22. Remove reverse gear assembly from clutch housing.

23. Remove final drive assembly (1) from clutch housing.

24. Remove plug from the clutch housing (with ABS models).

25. Remove the vehicle speed sensor (without ABS models).

26. Remove pinion shaft and pinion gear from clutch housing.

27. Remove magnet and dowel pins (2) from clutch housing.

PCIB1532E

MCIB0033E

28. Remove input shaft front bearing from clutch housing using a suitable tool.

29. Cut oil channel tube at the root.

30. Remove mainshaft front bearing and oil channel from clutch housing using Tool (A).

Tool number A: KV111011S0 ( — )

PCIB1533E

MCIB0044E

PCIB1536E

Revision: May 2010 2011 Versa

MT-25

TRANSAXLE ASSEMBLY

< SERVICE INFORMATION >

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

32. Remove differential side oil seals (1) from clutch housing and transaxle case using a suitable tool.

CAUTION:

Never damage transaxle case and clutch housing.

[RS5F91R]

PCIB1537E

33. Remove differential side bearing outer races (1) from clutch housing and transaxle case using a suitable tool.

CAUTION:

Never damage transaxle case and clutch housing.

34. Pull two way connector (1) straight to remove it from air breather inner tube (2).

35. Remove air breather inner tube from transaxle case.

PCIB1534E

JPDIC0484ZZ

PCIB1541E

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

37. Remove retaining pin ( ) from selector using a suitable tool.

38. Remove selector from control shaft.

39. Remove oil gutter from transaxle case.

PCIB1538E

Revision: May 2010 2011 Versa

MT-26

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

[RS5F91R]

40. Remove bolt ( ), and then remove bushing, spring, and gear catch from transaxle case.

41. Remove check ball plug from transaxle case.

42. Remove bolts ( ), and then remove control shaft (1) from transaxle case.

43. Remove O-ring from control shaft.

44. Expand snap rings (1) and remove input shaft rear bearing and mainshaft rear bearing from transaxle case using Tool (A).

JPDIC0533ZZ

PCIB1540E

Tool number A: ST35300000 ( — )

45. Remove snap rings from transaxle case.

46. Remove check balls (2) from transaxle case.

ASSEMBLY

1. Install snap rings (1) along transaxle case groove so that notch mates with housing as shown.

CAUTION:

Check snap ring installing direction. Never misassemble.

PCIB1535E

PCIB1547E

Revision: May 2010 2011 Versa

MT-27

TRANSAXLE ASSEMBLY

< SERVICE INFORMATION >

2. Expand snap rings (1) and install input shaft rear bearing and mainshaft rear bearing to transaxle case using Tool (A).

Tool number A: ST35300000 ( — )

CAUTION:

Check that snap ring is correctly installed within bearing groove.

3. Install check balls (2) to transaxle case.

4. Install bushings (1) until they reach transaxle case using a suitable tool (A).

5. Apply gear oil to O-ring, and then install it to control shaft.

[RS5F91R]

PCIB1548E

6. Install control shaft (1) to transaxle case, and tighten bolts ( ) to the specified torque. Refer to MT-17, "

Exploded View".

CAUTION:

Replace control shaft and selector as a set.

7. Install selector to control shaft, and then install retaining pin ( ) to selector using a suitable tool.

CAUTION:

• Be careful with the orientation of selector.

• Replace control shaft and selector as a set.

• Never reuse retaining pin.

JPDIC0636ZZ

PCIB1540E

SCIA1726J

8. Install gear catch, spring, and bushing to transaxle case, and then tighten bolt ( ) to the specified torque. Refer to MT-17,

"Exploded View".

CAUTION:

Replace gear catch, spring, and bushing as a set.

9. Install oil gutter to transaxle case.

JPDIC0533ZZ

Revision: May 2010 2011 Versa

MT-28

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

[RS5F91R]

10. Install air breather inner tube (2) to transaxle case.

CAUTION:

Never damage air breather inner tube. NOTE:

It is easier to install when air breather inner tube end is wrapped and narrowed by tape. Remove tape after installation.

11. Insert two way connector (1) straight, and then install it to air breather inner tube.

CAUTION:

Check air breather inner tube for twists after installing.

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

Tool number KV32500QAA ( – ) B.vi 1666-B

Dimension

1 : 5.7 – 6.3 mm (0.224 – 0.248 in)

2 : 2.4 – 3.0 mm (0.094 – 0.118 in)

• B: Transaxle case side

• C: Clutch housing side

CAUTION:

• Never incline differential side oil seal.

• Never damage clutch housing and transaxle case.

PCIB1541E

JPDIC0401ZZ

13. Install differential side bearing outer races until they reach clutch housing and transaxle case using the Tool (A).

Tool number A: KV32300QAE ( — )

CAUTION:

Replace differential side bearing outer race and differential side bearing as a set.

14. Install bushings (1) until they reach clutch housing using a suitable tool (A).

15. Install oil channel to clutch housing.

CAUTION:

Never reuse oil channel.

PCIB1549E

JPDIC0637ZZ

Revision: May 2010 2011 Versa

MT-29

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