Almera Tino V10 (2003 year). Manual

SMT940D

SMT951D

22. Pick up EGI harness clamp and install engine slinger. Next, set

chain block.

23. Jack up the air compressor engine bracket.
24. Remove engine front mounting.
25. Remove LH side mounting. Refer to EM-197, “Removal and

Installation”.

SMT952D

26. Jack up until engine oil filter bracket bolts are just about to

touch the side frame.

SMT941D

27. Remove bolts securing transaxle.
28. While the transaxle is suspended, withdraw the transaxle case

from the engine without hitting suspension member.

Open the front of the transaxle when the clutch cover
appears. Then, lower the transaxle pulling it toward the
right front.

The spacer between the engine and transaxle should be
left at the engine side.

29. Remove spacer.

REMOVAL AND INSTALLATION

RS5F50A

Removal (Cont’d)

MT-22

SMT941D

Installation

NLMT0090S02

Put transaxle under the engine compartment.

Set chain block on transaxle and hang.

Lift up transaxle case so as not to hit against the side frame
and suspension member.

Assemble transaxle to engine.

Tighten LH mount, rear side mount and center member bolts.
Refer to EM-197, “Removal and Installation”.

Tighten clutch operating cylinder bolts. Refer to CL-15, “Instal-
lation”.

Tighten starter motor bolts. Refer to SC-19, “Removal and
Installation”.

Install drive shafts. Refer to AX-11, “Installation”.

Tighten all transaxle bolts and any part removed.

SMT932D

MODEL YD ENGINE

NLMT0090S0201

Bolt No.

Tightening torque

N·m (kg-m, ft-lb)

“

”

mm (in)

40 - 49 (4.0 - 5.0, 29 - 36)

70 (2.76)

30.4 - 36.3 (3.1 - 3.7, 23 - 26)

60 (2.36)

30.4 - 36.3 (3.1 - 3.7, 23 - 26)

55 (2.17)

IDX

REMOVAL AND INSTALLATION

RS5F50A

Installation

MT-23

NLMT0038

Components

NLMT0038S01

NMT133

Control lever knob

Boot

Control lever socket

Control lever

Bearing seat spring

Seat

Bushing

O-ring

Hand lever socket

10. Plate bolt
11. Transaxle hole cover
12. Mass damper
13. Holder bracket
14. Return spring rubber
15. Return spring
16. Control rod

17. Bushing
18. Collar
19. Bushing
20. Collar
21. Support rod
22. Plate
23. Support rod bracket

TRANSAXLE GEAR CONTROL

RS5F70A, RS5F50A

Components

MT-24

NLMT0054

Case Components

NLMT0054S02

SMT942D

Clutch housing

Dust seal

Oil pocket

Check plug

Input shaft oil seal

Oil channel

Mainshaft front bearing

Bearing retainer

Bushing

10. Reverse idler gear front thrust

washer

11. Reverse idler gear
12. Reverse idler gear bearing
13. Reverse idler gear rear thrust

washer

14. O-ring
15. Reverse idler gear shaft
16. Snap ring
17. Reverse switch
18. Filler plug
19. Side cover gasket
20. Side cover
21. Welch plug
22. Mainshaft bearing snap ring
23. Mainshaft rear bearing adjusting

shim

24. O-ring
25. Rear cover

26. Differential oil seal
27. Drain plug
28. PNP switch
29. Transmission case
30. Oil gutter
31. Welch plug
32. Magnet
33. Boot
34. Striking rod oil seal
35. Welch plug
36. Differential oil seal
37. O-ring
38. Speedometer pinion

IDX

OVERHAUL

RS5F70A

Case Components

MT-25

Gear Components

=NLMT0054S03

SMT641DA

Reverse idler gear front thrust
washer

Reverse idler gear

Reverse idler gear bearing

Reverse idle gear rear thrust
washer

O-ring

Reverse idler gear shaft

Snap ring

Input shaft front bearing

Input shaft

10. 3rd gear needle bearing
11. 3rd input gear
12. 3rd gear baulk ring
13. Coupling sleeve
14. Spread spring
15. Shifting insert
16. 3rd & 4th synchronizer hub
17. Spread spring
18. 4th gear C-ring
19. 4th gear needle bearing
20. 4th gear baulk ring
21. 4th input gear
22. 5th gear front C-ring
23. 5th input gear

24. 5th gear rear C-ring
25. C-ring holder
26. Input shaft rear bearing
27. Oil channel
28. Input shaft rear bearing adjusting

shim

29. Mainshaft front bearing
30. Mainshaft
31. 1st gear needle bearing
32. 1st main gear
33. 1st inner baulk ring
34. 1st synchronizer cone
35. 1st outer baulk ring
36. 1st & 2nd synchronizer hub
37. Coupling sleeve
38. Insert spring
39. 2nd gear bush
40. 2nd gear needle bearing
41. 2nd gear outer baulk ring
42. 2nd gear synchronizer cone
43. 2nd inner baulk ring
44. 2nd main gear
45. 3rd main gear
46. Spacer

47. Mainshaft adjusting shim
48. 4th main gear
49. 5th gear bush
50. 5th gear needle bearing
51. 5th main gear
52. 5th gear baulk ring
53. Spread spring
54. Shifting insert
55. 5th & reverse synchronizer hub
56. Spread spring
57. Coupling sleeve
58. Reverse gear bush
59. Reverse gear needle bearing
60. Reverse gear baulk ring
61. Reverse main gear
62. Sub-gear
63. Sub-gear washer
64. Snap ring
65. Mainshaft thrust washer
66. Mainshaft rear bearing
67. Mainshaft C-ring
68. C-ring holder
69. Snap ring

OVERHAUL

RS5F70A

Gear Components

MT-26

Shift Control Components

=NLMT0054S04

SMT642DB

Clutch housing

3rd & 4th bracket

3rd & 4th shift fork

Retaining pin

Check ball

Check pin

Check spring

Check plug

Stopper ring

10. 3rd & 4th fork rod
11. Selector shaft pin
12. Selector
13. 5th & reverse bracket
14. Reverse switch bracket
15. Retaining pin
16. 5th & reverse shift fork

17. Interlock plunger
18. Check ball
19. Interlock pin
20. Stopper ring
21. 5th & reverse fork rod
22. Striking lever
23. Retaining pin
24. 1st & 2nd bracket
25. 1st & 2nd shift fork
26. Check ball
27. 1st & 2nd fork rod
28. Transaxle case
29. Check ball
30. Check spring
31. Check plug

32. Select check leaf spring
33. Return spring
34. Steel ball
35. Reverse gate
36. Return bearing
37. Selector arm
38. Bushing
39. Welch plug
40. Selector shaft
41. Striking yoke
42. Retaining pin
43. Striking rod
44. Dust boot
45. Striking rod oil seal
46. Welch plug

IDX

OVERHAUL

RS5F70A

Shift Control Components

MT-27

Final Drive Components

=NLMT0054S05

YMT001

Differential side bearing adjusting
shim

Differential side bearing outer race

Differential side bearing

Final gear

Differential case

Speedometer drive gear

Speedometer stopper

Differential side bearing

Differential side bearing outer race

10. Pinion mate thrust washer

11. Pinion mate gear
12. Side gear thrust washer
13. Side gear
14. Pinion mate shaft
15. Lock pin

OVERHAUL

RS5F70A

Final Drive Components

MT-28

NLMT0055

SMT648D

Transaxle Case

NLMT0055S01

Remove reverse switch, PNP switch, drain plug, and filler plug
from transaxle case.

SMT644D

Remove snap rings from reverse idler shaft.

Remove side cover and rear cover from case.

Remove O-ring and mainshaft bearing adjusting shim.

SMT645D

Remove reverse idler gear shaft.

Attach bolt (M6) to thread of reverse idler gear shaft end.

Pull out the attached bolt, and remove reverse idler gear shaft
from case.

Remove reverse idler gear, thrust washer (front, rear), and
bearing from case.

SMT646D

Remove snap ring of mainshaft bearing from case.

SMT647D

Remove check plugs, springs, and check balls from case.

IDX

DISASSEMBLY

RS5F70A

Transaxle Case

MT-29

SMT649D

Remove mounting bolts.

10. Remove input shaft rear bearing adjusting shim from transaxle

case.

SMT650D

11. Remove oil gutter from case.

SMT651DB

12. Remove differential side bearing outer race and adjusting shim

from case.

SMT653DB

13. Remove differential oil seal from case.

SMT839DB

14. Remove welch plugs from case.

DISASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-30

SMT654D

Clutch Housing

NLMT0055S02

Remove transaxle case from clutch housing.

Remove magnet from housing.

Remove check plugs, check springs, check pins, and check
balls from housing.

SMT656DC

Remove 3rd & 4th bracket retaining pin.

SMT655D

Remove 3rd & 4th shift fork stopper ring.

Remove 3rd & 4th fork rod.

Remove 3rd & 4th shift fork and bracket.

SMT658D

Remove interlock plunger and check ball.

Remove 5th & reverse bracket stopper ring.

SMT657DC

10. Remove retaining pin from 5th & reverse shift fork and reverse

switch bracket.

11. Remove 5th & reverse fork rod.
12. Remove interlock pin from 5th & reverse fork rod.
13. Remove reverse switch bracket and 5th & reverse bracket.

IDX

DISASSEMBLY

RS5F70A

Clutch Housing

MT-31

SMT659DC

14. Remove check ball from housing.
15. Remove retaining pin for 1st & 2nd shift fork and bracket.
16. Remove 1st & 2nd fork rod.
17. Remove 5th & reverse and 1st & 2nd shift forks, and 1st & 2nd

bracket.

SMT660D

18. Remove both input shaft and mainshaft assemblies from hous-

ing.

SMT661D

19. Remove final drive assembly from housing.
20. Remove oil pocket from housing.

SMT662D

21. Remove mainshaft bearing retainer from housing.
22. Cut off oil channel using a cutter as shown in the figure.

SMT663DB

23. Remove mainshaft front bearing from housing.

DISASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

MT-32

SMT664D

24. Using a magnet or other suitable tool, remove retaining pin

from selector shaft.

SMT665DB

25. Remove selector shaft and plug, then remove selector.

SMT666DA

26. Remove reamer bolt, then remove select check leaf spring,

return spring, steel ball, reverse gate, selector arm, bearing,
and bushing.

CAUTION:

Be careful not to lose the steel ball.

SMT667DB

27. Remove retaining pin and plug from striking lever.
28. Remove striking rod, then striking lever from housing.

SMT668D

29. Using a flat-head screwdriver or other suitable tool, remove

dust seal, input shaft oil seal, and striking rod oil seal from
housing.

CAUTION:

When removing dust and oil seals, be careful not to damage
mounting surfaces of dust seal and oil seal.

IDX

DISASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

MT-33

SMT759D

Input Shaft and Gears

DISASSEMBLY

NLMT0056

Before disassembly, measure the end plays of 3rd and 4th
input gears.

Gear end play:

Refer to SDS, MT-90.

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

SMT671D

Remove oil channel from input shaft rear bearing.

SMT672DB

Press out input shaft rear bearing.

SMT673D

Remove C-ring holder.

Remove 5th gear rear C-ring.

SMT674DB

Remove 5th input gear from input shaft.

Remove 5th gear front C-ring.

IDX

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears

MT-35

SMT675DB

Remove 4th input gear, baulk ring, 4th gear needle bearing,
and 4th gear C-ring from input shaft.

Press out both 3rd & 4th synchronizer hub assembly and 3rd
input gear from input shaft.

10. Remove 3rd gear needle bearing.

SMT676DB

11. Press out input shaft front bearing from input shaft.

SMT693D

INSPECTION

NLMT0057

Input Shaft and Gears

NLMT0057S01

Check shaft for cracks, wear or bending.

Check gears for excessive wear, chips or cracks.

SMT637A

Synchronizers

NLMT0057S02

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.

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears (Cont’d)

MT-36

SMT841D

Measure the movement (play, dimension “L”) of 3rd & 4th cou-
pling 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.

SMT148A

Bearing

NLMT0057S03

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

SMT696DB

ASSEMBLY

NLMT0058

Press on input shaft front bearing.

Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring
bearing to input shaft.

SMT694D

Install spread spring, shifting insert, and 3rd & 4th synchronizer
hub onto 3rd & 4th 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.

CAUTION:

Do not reuse 3rd & 4th synchronizer hub.

IDX

REPAIR FOR COMPONENT PARTS

RS5F70A

Input Shaft and Gears (Cont’d)

MT-37

Almera Tino V10 (2003 year). Manual - part 227