Almera Tino V10 (2003 year). Manual

SMT727D

Install new oil channel (mainshaft).

CAUTION:

Pay attention to installation direction of oil channel.

SMT728DA

Align the notches on mainshaft front bearing and transaxle
case. Then, install mainshaft front bearing.

SMT729D

Install mainshaft bearing retainer, and tighten bolts with speci-
fied torque.

SMT667DB

Attach boot, striking rod, and striking lever to clutch housing.
And install retaining pin for selector lever.

CAUTION:

Before installing striking rod, wrap the end with a vinyl
tape or the like to prevent oil seal from being damaged.

Do not reuse retaining pin.

SMT730D

10. Hammer the welch plug (striking lever side) with a general-

purpose drift [OD: 12 mm (0.47 in)].

CAUTION:

Do not reuse welch plug.

ASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

MT-54

SMT731D

11. Install selector, selector shaft, and selector shaft pin into clutch

housing.

SMT732D

12. Hammer the welch plug (selector shaft side) with a general-

purpose drift [OD: 12 mm (0.47 in)].

CAUTION:

Do not reuse welch plug.

SMT733DA

SMT734D

13. Install select check leaf spring, return spring, steel ball, reverse

gate, selector arm, bushing, and return bearing. Then, tighten
two reamer bolts with specified torque.

CAUTION:

Use correct reamer bolts for each installation point, because
each bolt has a different length.

SMT735D

14. Install oil pocket.

IDX

ASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

MT-55

SMT736D

15. Install differential assembly, input shaft assembly, and main-

shaft assembly into clutch housing.

CAUTION:

Be careful not to damage input shaft oil seal during installa-
tion of input shaft assembly.

SMT659DC

16. Install 5th & reverse shift fork.
17. Install 1st & 2nd shift fork, bracket, and fork rod.
18. Install retaining pin for 1st & 2nd bracket.

CAUTION:

Do not reuse retaining pin.
19. Install two check balls.

SMT657DC

20. Install interlock pin into 5th & reverse fork rod.
21. Install reverse switch bracket, 5th & reverse bracket, and fork

rod.

22. Install retaining pin for 5th & reverse shift fork and reverse

switch bracket.

CAUTION:

Do not reuse retaining pin.
23. Install 5th & reverse bracket stopper ring.

CAUTION:

Do not reuse stopper pin.

SMT656DC

24. Install check ball and interlock plunger.
25. Install 3rd & 4th shift fork, bracket, and fork rod.
26. Install 3rd & 4th bracket retaining pin.

CAUTION:

Do not reuse retaining pin.

SMT655D

27. Install 3rd & 4th shift fork stopper ring.

CAUTION:

Do not reuse stopper ring.
28. Install check ball, check pin, and check spring, and apply

Three Bond TB1215, Loctite Part No. 51813 or equivalent onto
check plug. Then, tighten it with specified torque.

Tightening torque:

Refer to MT-27.

ASSEMBLY

RS5F70A

Clutch Housing (Cont’d)

MT-56

SMT737DA

Transaxle Case

NLMT0067S02

Insert differential oil seal into differential case until it becomes
flush with case end face.

SMT739D

Install welch plug into transaxle case.

SMT740D

Calculate dimension “N” (thickness of adjusting shim) using
the following procedure to satisfy specification of end play for
differential side bearing.

End play: 0.15 - 0.21 mm (0.0059 - 0.0083 in)

Dimension “N” = (N1 – N2) + End play

N: Thickness of adjusting shim
N1: Distance between clutch housing case end
face and mounting face of adjusting shim
N2: Distance between differential side bearing and
transaxle case

Differential side bearing adjusting shims:

Refer to SDS, MT-96.

SMT741D

Using dial gauge and scale, measure dimension “N1” between
clutch housing case end face and mounting face of adjusting
shim.

IDX

ASSEMBLY

RS5F70A

Transaxle Case

MT-57

SMT742D

Install outer race onto differential side bearing on final gear
side. Holding lightly the outer race horizontally by hand, rotate
final gear five times or more (for smooth movement of bearing
roller).

Using dial gauge and scale as shown in the figure, measure
dimension “N2” between differential side bearing outer race
and transaxle case end face.

SMT738DB

Install selected shim and bearing outer race.

SMT600-F

Measure turning torque of final drive assembly.

Turning torque of final drive assembly
(New bearing):

2.9 - 6.9 N·m (30 - 70 kg-cm, 26 - 61 in-lb)

When old bearing is used again, turning torque will be
slightly less than the above.

Make sure torque is close to the specified range.

Changes in turning torque of final drive assembly per
revolution should be within 1.0 N·m (10 kg-cm, 8.7 in-lb)
without binding.

SMT743D

Calculate dimension “O” (thickness of adjusting shim) using
the following procedure to satisfy specification of end play for
input shaft rear bearing.

End play: 0 - 0.06 mm (0 - 0.0024 in)

Dimension “O” = (O1 – O2) + End play

O: Thickness of adjusting shim
O1: Distance between transaxle case end face and
mounting face of adjusting shim
O2: Distance between clutch housing case end
face and end face of input shaft rear bearing

Input shaft rear bearing adjusting shims:

Refer to SDS, MT-93.

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-58

SMT744D

Using block gauge, scale, and dial gauge, measure dimension
“O1” between transaxle case end face and mounting face of
adjusting shim.

SMT745D

Using gauge block, scale, and dial gauge as shown in the
figure, measure dimension “O2” between clutch housing case
end face and end face of input shaft rear bearing.

Install selected input shaft rear bearing adjusting shim onto
input shaft.

SMT650D

Install oil gutter into transaxle case.

SMT755D

Install two magnets.

SMT802D

10. Clean mating surfaces of clutch housing and transaxle case.

Check for cracks and damage. Then, apply Three Bond
TB1215, Loctite Part No. 51813 or equivalent.

IDX

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-59

SMT649D

11. Install transaxle case onto clutch housing, and tighten mount-

ing bolts with specified torque.

Tightening torque:

Refer to MT-25.

SMT648D

12. Apply Three Bond TB1215, Loctite Part No. 51813 or equiva-

lent to threads of reverse switch, PNP switch, and drain plug,
and install them. (Fill the case with oil before installation of filler
plug.)

13. Install speedometer pinion assembly.

CAUTION:

Do not reuse O-ring.

SMT749D

14. Install check springs and check balls. Apply sealant to the

thread on the check plug, and install it.

SMT746D

15. Calculate thickness of adjusting shim using the following pro-

cedure to satisfy specification of end play for mainshaft rear
bearing.

End play: 0 - 0.06 mm (0 - 0.0024 in)

Dimension “P” = (P1 – P2) + End play

P: Thickness of adjusting shim
P1: Distance between transaxle case end face and
mainshaft rear bearing
P2: Distance between adjusting shim end face of
rear cover and transaxle mounting face

Mainshaft rear bearing adjusting shims:

Refer to SDS, MT-94.

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-60

SMT747D

Using dial gauge as shown in the figure, measure dimension
“P1” between transaxle case end face and mainshaft rear
bearing.

SMT748D

Using dial gauge as shown in the figure, measure dimension
“P2” between adjusting shim mounting face of rear cover and
transaxle mounting face.

SMT646D

16. Using snap ring pliers as shown in the figure, install snap ring.

CAUTION:

Do not reuse snap ring.
17. Install selected mainshaft adjusting shim.

SMT753DA

18. Install reverse idler gear, O-ring, thrust washers (front, rear),

and bearing onto reverse idler shaft.

19. Install snap ring into transaxle case using snap ring pliers.

CAUTION:

Do not reuse snap ring.

Do not reuse O-ring.

Before installation, apply gear oil to O-ring.

SMT754D

20. Using feeler gauge, measure the end play of snap ring, and

select a snap ring suitable to satisfy the following specification.

End play:

0.05 - 0.25 mm (0.0020 - 0.0098 in)

Available snap ring:

Refer to SDS, MT-91.

IDX

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-61

SMT644D

21. Install selected snap ring.

CAUTION:

Do not reuse snap ring.
22. Apply gear oil to rear cover O-ring, and install rear cover, side

cover gasket, and side cover. Then tighten mounting bolts with
specified torque.

Tightening torque:

Refer to MT-25.

CAUTION:

Do not reuse mounting bolts for rear cover and side cover.

ASSEMBLY

RS5F70A

Transaxle Case (Cont’d)

MT-62

NLMT0009

Case Components

NLMT0009S02

SMT943D

Speedometer pinion

Differential oil seal

Drain plug

Boot

Striking rod oil seal

Magnet

Clutch housing

Input shaft oil seal

Oil channel (Mainshaft)

10. Oil pocket
11. Oil gutter
12. Oil channel (Input shaft)
13. Transmission case

14. Filler plug
15. O-ring
16. Movable plate assembly
17. PNP switch (where fitted)
18. Breather hose
19. Breather pipe

IDX

OVERHAUL

RS5F50A

Case Components

MT-63

Gear Components

NLMT0009S03

SMT937D

Input shaft

Input shaft front bearing

3rd input gear

3rd & 4th synchronizer hub

Snap ring

Coupling sleeve

4th baulk ring

4th input gear

Reverse baulk ring

10. Reverse synchronizer cone
11. 5th synchronizer hub
12. Input shaft rear bearing
13. Input shaft bearing adjusting shim
14. 3rd baulk ring
15. Insert spring
16. 4th input gear thrust washer
17. Thrust washer ring
18. 5th input gear

19. 5th baulk ring
20. 1st outer baulk ring
21. 2nd inner baulk ring
22. Snap ring
23. Mainshaft bearing spacer
24. Mainshaft front bearing
25. Mainshaft
26. 1st main gear
27. 1st & 2nd synchronizer hub
28. Reverse main gear & 1st-2nd cou-

pling sleeve

29. 2nd outer baulk ring
30. 2nd gear synchronizer cone
31. 2nd main gear
32. 3rd main gear
33. 4th main gear
34. 5th main gear
35. Mainshaft rear bearing
36. Mainshaft bearing adjusting shim

37. Differential side bearing
38. Speedometer drive gear
39. Differential case
40. Pinion mate shaft
41. Side gear
42. Side gear thrust washer
43. Pinion mate gear
44. Pinion mate gear thrust washer
45. Retaining pin
46. Final gear
47. Differential side bearing
48. Differential side bearing adjusting

shim

49. Reverse idler gear
50. Bushing
51. Reverse idler shaft
52. 1st gear synchronizer cone
53. 1st inner baulk ring

OVERHAUL

RS5F50A

Gear Components

MT-64

Shift Control Components

NLMT0009S04

SMT862CA

Retaining pin

1st & 2nd shift fork

1st & 2nd check plug

Return spring

Check ball

1st & 2nd fork rod

1st & 2nd bracket

Interlock plunger

3rd & 4th bracket

10. Return spring
11. Reverse gate
12. Select arm
13. Return bearing
14. Bushing

15. Yoke
16. Striking rod
17. Striking lever
18. Selector
19. Selector shaft
20. O-ring
21. Return spring
22. Cam pin
23. Reverse check cam
24. Check ball
25. Select check spring
26. Interlock plunger
27. 3rd & 4th fork rod

28. Interlock ball
29. Stopper ring
30. 3rd & 4th check plug
31. 3rd & 4th shift fork
32. 5th shift fork
33. 5th fork rod
34. 5th & reverse check plug
35. Reverse lever spring
36. Reverse lock spring
37. 5th & reverse bracket
38. Reverse lever assembly
39. Reverse arm shaft
40. Control lever spring

IDX

OVERHAUL

RS5F50A

Shift Control Components

MT-65

NLMT0010

SMT626D

Before removing transmission case, remove bolts, check
plugs, springs and check balls as shown left.

Be careful not to lose check balls.

Remove transmission case.

SMT017AA

Remove PNP switch.

SMT659C

Mesh 4th gear, and then remove reverse idler shaft and
reverse idler gear.

SMT660C

Pull out retaining pin.

SMT661C

Remove reverse lever spring and reverse lock spring from
reverse lever assembly.

DISASSEMBLY

RS5F50A

MT-66

SMT662C

Remove reverse arm shaft while rotating it.

SMT663C

Remove reverse lever assembly and check ball.

Be careful not to lose check ball.

SMT018B

Remove 5th & reverse check plug, spring and ball.

Be careful not to lose check ball.

SMT664C

10. Remove stopper rings and retaining pins from 5th and 3rd &

4th fork rods.
When removing stopper rings. Use snap ring remover and
installer.

11. Remove 5th and 3rd & 4th fork rods. Then remove forks and

brackets.

SMT105C

12. Remove both input and mainshafts with 1st & 2nd fork and fork

rod as a set.

13. Remove final drive assembly.

Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.

IDX

DISASSEMBLY

RS5F50A

MT-67

SMT138A

14. Remove reverse check assembly and check ball.

Be careful not to lose check ball.

SMT618AA

SMT027A

15. Remove retaining pin and detach the selector.

SMT028A

16. Remove drain plug for convenience in removing retaining pin

which holds striking lever to striking rod.

SMT619AA

17. Remove retaining pin and then withdraw striking lever and

striking rod.

DISASSEMBLY

RS5F50A

MT-68

SMT121C

Input Shaft and Gears

DISASSEMBLY

NLMT0011

Before disassembly, check 3rd, 4th and 5th input gear end
plays.

Gear end play:

Refer to SDS, MT-98.

SMT476C

If not within specification, disassemble and check contact sur-
face of gear, shaft and hub. Check clearance of snap ring
groove. Refer to “ASSEMBLY”, MT-71.

SMT634AA

Remove input shaft rear bearing.

SMT205BA

Remove 5th & reverse synchronizer and 5th input gear.

SMT474CA

Remove thrust washer ring, 4th input gear thrust washers and
4th input gear.

IDX

REPAIR FOR COMPONENT PARTS

RS5F50A

Input Shaft and Gears

MT-69

Almera Tino V10 (2003 year). Manual - part 229