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MT - 4 8 15 16 23 42

1. 12 15 18 21 24 RS6F94R SFIA3293E Mainshaft 1st synchronizer cone Insert key 2nd synchronizer cone Bushing 4th main gear Mainshaft rear bearing inner race Mainshaft rear bearing adjusting shim 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R 0 3 1 22 1 Reverse output gear 2 Snap ring 3 Reverse baulk ring Return spring 5 Needle bearing 6 Seal washer 7 Reverse idler shaft 8 Spacer 9 Reverse input gear 10 Lock washer 11 Spring washer Replace the parts as a set Shift Control Component Revision October 2008 MT 63 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R JPDICO603ZZ 1 Shift lever Shift lever B 3 Retaining pin Selector 5 Select lever 6 Reverse fork rod 7 _1st 2nd fork rod 8 Fork rod Replace the parts as a set Final Drive Component Revision October 2008 MT 64 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R SEC 381 2 130 13 96 1 Shim 2 Differential side bearing outer race Differential side bearing inner race transaxle case side transaxle case side 4 Final gear 5 Differential case 6 Speedometer drive gear 7 Differential side bearing inner race 8 Differential side bearing outer race clutch housing side clutch housing side Replace the parts as a set DISASSEMBLY 1 Remove drain plug and gasket from clutch housing using a suitable tool and dr
2. ASSEMBLY Revision October 2008 MT 88 2009 Versa FINAL DRIVE SERVICE INFORMATION RS6F94R 1 Install final gear and then tighten final gear bolts to the specified torque Refer to MT 88 Disassembly and Assembly CAUTION Replace final gear and differential case as a set Install soeedometer drive gear 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 hous ing side as a set Se Mes 4 0 011577 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 JPDICO 116ZZ Revision October 2008 MT 89 2009 Versa SHIFT CONTROL SERVICE INFORMATION RS6F94R SHIFT CONTROL 5 cti O n INFOID 0000000004305284 FORK ROD AND SHIFT FORK Check contact surface and sliding surface for excessive wear uneven wear bend and damage Replace if necessary SCIA7785E Revision October 2008 MT 90 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt RS6F94R SERVICE DATA AND SPECIFICATIONS SDS General Specification
3. ASSEMBLY 1 Install speedometer drive gear 2 Install differential side bearings using Tool A Tool number KV40104920 CAUTION Replace differential side bearing outer race and differential side bearing as a set PCIB1570E Revision October 2008 MT 41 2009 Versa SHIFT CONTROL SERVICE INFORMATION RSSF91R SHIFT CONTROL 5 cti O n INFOID 0000000004788553 Check contact surface and sliding surface of fork rod and shift fork for excessive wear uneven wear bend and damage Replace if necessary PCIB1571E Revision October 2008 MT 42 2009 Versa SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE INFORMATION gt RSSF91R SERVICE DATA AND SPECIFICATIONS SDS General Specification INFOID 0000000004764251 TRANSAXLE Transaxletype Engine type HR16DE Number of speed 5 Synchromesh type Warner Shift pattern 1 3 5 KE SCIA0821E Gear ratio 1st 3 7272 2nd 2 0476 3rd 1 3928 4th 1 0294 5th 0 8205 Reverse 3 5454 Final gear 4 0666 Number of teeth Input gear 1st 11 2nd 21 3rd 28 4th 34 5th 39 Reverse 11 Main gear 1st 41 2nd 43 3rd 39 4th 35 5th 32 Reverse 39 Reverse idler gear 26 Final gear Final gear Pinion 61 15 E 13 9 Cil capacity Reference US pt Imp pt Approx 2 6 5 1 2 4 5 8 Remarks Reverse synchronizer Installed Double cone synchronizer 1st and 2nd Revision October
4. Remove transaxle assembly to engine bolts Separate transaxle assembly from engine INSTALLATION Revision October 2008 MT 58 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R Installation is in the reverse order of removal CAUTION When installing transaxle assembly be careful not to bring transaxle input shaft into contact with clutch cover f transaxle is removed from the vehicle always replace CSC Refer to CL 12 Removal and Installation When installing the transaxle assembly to the engine install the bolts as shown A to engine B Engine to M T Bolt No 1 2 Quantity 3 6 Bolt length _ mm 60 2 36 50 1 97 Tightening torque N m kg m ft Ib PCIB1786E e After installation bleed the air from the clutch hydraulic system Refer to CL 8 Air Bleeding Procedure e After installation check oil level and check for leaks and loose mechanisms Refer to MT 52 Checking M T Oil Disassembly and Assembly INFOID 0000000004305279 COMPONENTS Case and Housing Components Revision October 2008 MT 59 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RS6F94R SEC 3219327 2 28 2 9 21 C 1 Filler plug 2 Gasket 3 Transaxle case 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
5. A Toolnumber A KV38100200 CAUTION Replace mainshaft rear bearing outer race and mainshaft rear bearing inner race as a set 11 Install bushings 1 to transaxle case using a suitable tool A 12 Install oil gutter 1 to transaxle case 13 Install shift lever B 1 to transaxle case CAUTION Replace shift lever A and shift lever B as a set 14 Install shift lever A to transaxle case CAUTION Replace shift lever A and shift lever B as a set 15 Install retaining pin to shift lever A 1 using a suitable tool CAUTION Never reuse retaining pin 16 Install shim to transaxle case BCIA0047E Revision October 2008 MT 72 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R 17 Install differential side bearing outer race transaxle case side to transaxle case using Tool A Tool number A 5733400001 J 26082 CAUTION Replace differential side bearing outer race transaxle case side and differential side bearing inner race transaxle case side as a set 18 Install differential side bearing outer race clutch housing side to clutch housing using Tool A Tool number KV38100200 CAUTION Replace differential side bearing outer race clutch housing side and differential side bearing inner race clutch hous ing side as a set PCIB1722E 19 Install differential side oil seals 1 to clutch housing and tran saxle case using Tool Tool number
6. Exploded View CAUTION Never pinch O ring when installing rear housing 42 Install drain plug according to the following procedures a Install gasket to drain plug CAUTION Never reuse gasket Install drain plug to clutch housing using a suitable tool c Tighten drain plug to the specified torque Refer to MT 16 Exploded View 43 Install filler plug according to the following procedures a Install gasket to filler plug and then install them to transaxle case CAUTION Never reuse gasket b Tighten filler plug to the specified torque Refer to MT 16 Exploded View CAUTION Fill with gear oil before tightening filler plug to the specified torque PCIB1558E Revision October 2008 MT 35 2009 Versa INPUT SHAFT AND GEAR SERVICE INFORMATION RSSF91R INPUT SHAFT AND GEAR Disassembly and Assembly INFOID 0000000004788550 INSPECTION AFTER DISASSEMBLY Input Shaft and Gears Check the following items and replace if necessary e Damage peeling bend uneven wear and distortion of shaft Excessive wear damage and peeling of gear PCIB0987J oynchronizer Check for the following and replace if necessary Contact surface breakage damage and unusual wear of coupling sleeve synchronizer hub and synchronizer lever Coupling sleeve and synchronizer hub move smoothly SCIA1753J Breakage damage and excessive wear of baulk ring cam surface and synchronizer lever contact surface SCI
7. Tool number A 133220000 8 Install snap ring 1 and oil channel 2 to transaxle case gm 2 CAUTION 2 6 R yat Select and install snap ring that has the same thickness ans A as previous one a X e Replace transaxle assembly when replacing transaxle A 9 Install mainshaft rear bearing adjusting shim to transaxle case CAUTION Select mainshaft rear bearing adjusting shim according to the following procedures when replacing mainshaft adjust ing shim 6th main gear 5th main gear or 4th main gear Replace mainshaft adjusting shim f new mainshaft adjusting shim is thinner than previous one offset the thickness difference by selecting thicker mainshaft rear bearing adjusting shim If new mainshaft adjusting shim is thicker than previous one offset the thickness difference by selecting thinner mainshaft rear bearing adjusting shim Replace 6th main gear 5th main gear or 4th main gear Measure the thickness of the main gear used before and the new main gear Increase the thickness of the mainshaft rear bearing adjusting shim if the difference is smaller than 0 025 mm 0 0010 in Decrease the thickness of the mainshaft rear bearing adjusting shim if the difference is greater than 0 025 mm 0 0010 in Revision October 2008 MT 71 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RS6F94R 10 Install mainshaft rear bearing outer race to transaxle case using Tool
8. 10 SRS AIR BAG and SEAT BELT PRE TEN e TEE 44 SIDE QOIL SEAL 11 Precaution for Procedure without Cowl Top Cover 44 Removal and Installation 11 FTeCAUUON T 44 POSITION SWITCH 12 PREPARATION 2 45 CHECKING sarang ea a 12 Special Service Tool 45 Commercial Service Tool 47 CONTROL LINKAGE 13 Exploded VIEW ee 13 NOISE VIBRATION AND HARSHNESS Removal and Installation 13 NVH TROUBLESHOOTING 49 14 NVH Troubleshooting Chart 49 AIR BREATHER HOSE 15 DESCRIPTION gege dee 50 Exploded View 15 Cross Sectional View ccc ccc ccc ccc ccc cecccccceceeceeee 50 Removal and Installation 15 LIA Bal 52 TRANSAXLE ASSEMBLY 16 Changing OU 52 Exploded View Aer me 16 Checking M T EE 52 Revision October 2008 2009 Versa SIDE OIL SEAL ee 53 Removal and Installation 53 POSITION SWITCH 54 CRECKINO EE 54 CONTROL LINKAGE 55 Componen
9. 2008 MT 43 2009 Versa PRECAUTIONS SERVICE INFORMATION RS6F94R SERVICE INFORMATION PRECAUTIONS Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER INFOID 0000000004305264 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 Man ual 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
10. 8106 5 8097 1 600 0 0630 147 565 147 541 5 8096 5 8087 1 625 0 0640 147 540 147 516 5 8086 5 8077 1 650 0 0650 147 515 147 491 5 8077 5 8067 1 675 0 0659 147 490 147 466 5 8067 5 8057 1 700 0 0669 147 465 147 441 5 8057 5 8048 1 725 0 0679 147 440 147 416 5 8047 5 8038 1 750 0 0689 147 415 147 391 5 8037 5 8028 1 775 0 0699 8 Install 4th main gear 1 using Tool A Tool number KV32102700 Revision October 2008 MT 84 RS6F94R PCIB1734E PCIB1735E PCIB1736E PCIB1737E 2009 Versa MAINSHAFT AND GEARS SERVICE INFORMATION RS6F94R 9 Install 5th main gear 1 using Tool Tool number KV32102700 been eed AI PCIB1738E 10 Install 6th main gear 1 using Tool A Tool number KV32102700 AXI WEE PCIB1739E 11 Install mainshaft rear bearing inner race 1 usingTool A Tool number A ST30901000 J 26010 01 CAUTION Replace mainshaft rear bearing inner mainshaft gt SN rear bearing outer race as a set 12 Install snap ring CAUTION Never reuse snap ring PCIB1740E Revision October 2008 MT 85 2009 Versa REVERSE IDLER SHAFT AND GEARS lt SERVICE INFORMATION gt RS6F94R REVERSE IDLER SHAFT AND GEARS Disassembly and Assembly INFOID 0000000004305282 DISASSEMBLY 1 Remove reverse output
11. Manual SRS wiring harnesses can be identified by yellow and or orange harnesses or har ness connectors Precaution for Procedure without Cowl Top Cover INFOID 0000000004305265 When performing the procedure after removing cowl top cover cover the lower end of windshield with urethane etc PIIB3706J P re ca u ti O n INFOID 0000000004305266 If transaxle assembly is removed from the vehicle always replace CSC Concentric Slave Cylinder Installed CSC returns to the original position when removing transaxle assembly Dust on clutch disc sliding parts may damage CSC seal and may cause clutch fluid leakage Do not reuse transaxle oil Drain fill and check transaxle oil with the vehicle on level surface During removal or installation keep inside of transaxle clear of dust or dirt Check for the correct installation orientation prior to removal or disassembly If matching marks are required be certain they do not interfere with the function of the parts they are applied to In principle tighten bolts or nuts gradually in several steps working diagonally from inside to outside If tight ening sequence is specified follow it Be careful not to damage the sliding surfaces and mating surfaces of parts Revision October 2008 MT 44 2009 Versa PREPARATION SERVICE INFORMATION RS6F94R Special Service Tool INFOID 0000000004505267 The actual shapes of Kent Moore tools may differ from those of special serv
12. ST35300000 CAUTION Check that snap ring is correctly installed within bearing groove Install check balls 2 to transaxle case Install bushings 1 until they reach transaxle case using a suit able tool A Apply gear oil to O ring and then install it to control shaft Install control shaft 1 to transaxle case and tighten bolts to the specified torque Refer to 16 Exploded View CAUTION Replace control shaft and selector as a set PCIB1540E 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 SCIA1726J Install gear catch spring and bushing to transaxle case and then tighten bolt to the specified torque Refer to MT 16 Exploded View CAUTION Replace gear catch spring and bushing as a set Install oil gutter to transaxle case JPDICO533ZZ Revision October 2008 MT 28 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt 10 11 12 13 14 15 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 Insert two way connector 1 straight and then install it to air breather inne
13. gear 1 PCIB1760E 2 Remove snap ring 1 using suitable tool PCIB1759E 3 Remove reverse baulk ring 1 and return spring 2 PCIB1758E 4 Remove snap ring 1 lock washer 2 and reverse input gear 3 using suitable tool PCIB1757E Revision October 2008 86 2009 Versa REVERSE IDLER SHAFT AND GEARS lt SERVICE INFORMATION gt RS6F94R 5 Remove needle bearings 1 and spacer PCIB1761E 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 e Damage peeling bend uneven wear and distortion of shaft Excessive wear damage and peeling of gear 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 ASSEMBLY Note the following procedures and assemble in the reverse order of disassembly CAUTION Never reuse snap ring Check that snap ring is securely installed in a groove 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 Revision October 2008 MT 87 2009 Versa FINAL DRIVE SERVICE INFORMATION
14. inner baulk ring 2nd synchronizer cone and 2nd outer baulk ring CAUTION Replace 1st inner baulk ring 1st synchronizer cone and 1st outer baulk ring as a set Replace 2nd inner baulk ring 2nd synchronizer cone and 2nd outer baulk ring as a set 3 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 PCIB1733E Revision October 2008 MT 83 2009 Versa lt SERVICE INFORMATION gt 4 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 5 Install bushing 3 using the Tool Tool number KV32102700 6 Install 3rd main gear 1 and 2nd main gear 2 using Tool A Tool number ST32102700 7 Measure dimension L as shown Select mainshaft adjusting shim 1 according to the following list and then install it to main shaft 2 Mainshaft 3 3rd main gear Dimension L 147 690 147 666 5 8146 5 8136 Mainshaft adjusting shim thickness MAINSHAFT AND GEARS EJ Unit mm in 1 500 0 0591 147 665 147 641 5 8136 5 8126 1 525 0 0600 147 640 147 616 5 8126 5 8116 1 550 0 0610 147 615 147 591 5 8116 5 8107 1 575 0 0620 147 590 147 566 5
15. page d d d d d gt gt gt gt gt SUSPECTED PARTS m Possible cause 5 D 9 S D ge LLI c D D 5 2 O H as O O c o he i C D e Ps O bel els HI KE E Si 9 5 9 509 2 a 9 ii lt 5 LL c Z P i 2 2 2 O Se Se O m o lt Noise 1 2 3 3 Oil leakage 3 1 2 2 2 Symptoms Hard to shift or will not shift 1 2 3 3 Jumps out of gear 1 2 2 Revision October 2008 7 2009 Versa lt SERVICE INFORMATION gt DESCRIPTION oystem Diagram CROSS SECTIONAL VIEW DESCRIPTION ih 1 Clutch housing 2 4 5th input gear 5 7 Sth main gear 8 10 2nd main gear 11 13 1st main gear 14 16 Final gear 17 System Description 1 1st 2nd synchronizer hub assembly oth reverse synchronizer hub assembly 4th main gear 2nd double cone synchronizer Differential side bearing Mainshaft DOUBLE CONE SYNCHRONIZER Revision October 2008 MT 8 RS5F91R INFOID 0000000004784209 3rd 4th synchronizer hub assembly oth reverse baulk ring main gear 1st double cone synchronizer Differential Input shaft INFOID 0000000004784210 2009 Versa DESCRIPTION SERVICE INFORMATION RSSF91R Double cone synchronizer is adop
16. seal 14 Clutch housing 15 Two way connector 16 Plug 17 Pinion shaft 18 Pinion gear Apply Genuine Silicone RTV or an equivalent Refer to GI 42 Recommended Chemical Product and Sealant Gear Component Revision October 2008 MT 60 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R SEC 322 9 100 10 74 0 165 17 122 1 Input shaft front bearing 2 Input shaft 3 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 step 2nd step Apply gear oil Replace the parts as a set Revision October 2008 MT 61 2009 Versa lt SERVICE INFORMATION gt 10 13 16 19 22 322 Mainshaft front bearing outer 2 race 1st main gear 5 1st outer baulk ring 8 1st 2nd synchronizer hub 11 2nd inner baulk ring 14 3rd main gear 17 oth main gear 20 Mainshaft rear bearing outer race 23 Apply gear oil Replace the parts as a set Revision October 2008 TRANSAXLE ASSEMBLY Mainshaft front bearing inner race 1st inner baulk ring 1st 2nd coupling sleeve 2nd outer baulk ring 2nd main gear Mainshaft adjusting shim 6th main gear Snap ring MT 62
17. side oil seal 1 using a suitable tool CAUTION Be careful not to damage transaxle case and clutch housing INSTALLATION Installation is in the reverse order of removal Install differential side oil seals 1 to clutch housing and transaxle case using Tool A B Transaxle case side e C Clutch housing side Tool number A KV38100300 J 25523 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 Never reuse differential side oil seal When installing never incline differential side oil seal Never damage clutch housing and transaxle case Check oil level and oil leakage after installation Refer to MT 52 Checking M T Oil L2 JPDICO120ZZ Revision October 2008 MT 53 2009 Versa POSITION SWITCH SERVICE INFORMATION RS6F94R POSITION SWITCH C h ki n INFOID 0000000004305274 NOTE For removal and installation of the switches refer to MT 59 Disassembly and Assembly BACK UP LAMP SWITCH Check continuity between terminals 1 and 2 Gear position Continuity Reverse Yes Except reverse PCIB1781E PARK NEUTRAL POSITION SWITCH Check continuity between terminals 2 and 3 Gear position Continuity Neutral Yes Except neutral No Revision October 2008 MT 54 2009 Versa CONTROL LINKAGE lt SERVICE INFORMATION gt RS6F94R CONTROL LINKAGE Component of Control Device and Cable INFOID 0000000
18. 004305275 SEC 341 07 25 2 6 18 WCIA0626E 1 Control lever knob 2 Control lever 3 Control device assembly 4 Select cable 5 Shift cable 6 Lock plate Clutch housing 8 Cable bracket 9 Tapping bolt 10 Cable support bracket 11 Adapter plate Removal and Installation INFOID 0000000004305276 REMOVAL 1 Remove battery Refer to SC 7 Removal and Installation Remove air duct front air duct Inlet and air cleaner case Refer to EM 139 Removal and Installation Remove shift cable from shift lever Remove select cable according to the following Move stopper 1 to the unlocked position D icm S SCIA7842bE Revision October 2008 MT 55 2009 Versa CONTROL LINKAGE SERVICE INFORMATION b Pullthe release button 1 of select cable 2 and then remove it from select lever 3 5 Shift control lever to neutral position 6 Remove control lever knob 7 Remove center console assembly Refer to IP 12 Removal and Installation 8 Remove control device assembly bolts 9 Remove exhaust front tube center muffler and heat plate Refer to EX 9 Removal and Installation 10 Remove cable support bracket 11 Remove select cable and shift cable from cable bracket 12 Remove control device assembly from the vehicle INSTALLATION Installation is in the reverse order of removal NOTE Self tapping bolts are used to attach cables to the clutch housing e Securely assemble each cable an
19. 38100300 J 25523 A Transaxle case side e B Clutch housing side Dimension L1 1 2 1 8 mm 0 047 0 071 in Dimension L2 2 7 3 3 mm 0 106 0 130 in 20 Install magnet to clutch housing 21 Install final drive assembly to clutch housing 22 Set fork rod 1 to input shaft assembly 2 and then install them to clutch housing JPDICO454ZZ JPDICO608ZZ Revision October 2008 73 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RS6F94R 23 Install mainshaft assembly 1 according to the following proce dures a Pull up input shaft assembly 2 and fork rod 3 b Set 1st 2nd fork rod 4 to mainshaft assembly and then install them to clutch housing ROS DI js e uS x ED EX cam Well A Tom AN SS 24 Install reverse idler shaft assembly 1 according to the following procedures a Install spring washer to clutch housing b Pull up input shaft assembly 2 mainshaft assembly 3 fork BA rod 4 and 1st 2nd fork rod 5 O NOTE dl 2N It is easier to pull up when shifting each fork rod to each shaft RIE 752 d side el S EE C Setreverse fork rod 6 to reverse idler shaft assembly and then install them to clutch housing JPDICOG606ZZ 25 Shift 1st 2nd fork rod 1 fork rod 2 and reverse fork rod 3 to the neutral position 26 Install selector 4 to clutch housing CAUTION Repla
20. A0608J Bearing Check bearing for damage and unsmooth rotation Replace if neces sary MTF0041D Revision October 2008 MT 36 2009 Versa MAINSHAFT AND GEAR SERVICE INFORMATION RSSF91R MAINSHAFT AND GEAR Disassembly and Assembly INFOID 0000000004788551 GENERAL PRECAUTIONS Never reuse snap ring e Secure mainshaft in a vise with backplate and then remove gears and snap rings For installation and removal of snap ring set snap ring pliers and flat pliers at both sides of snap ring While expanding snap ring with snap ring pliers move snap ring with flat pliers Disassemble gear components putting direction marks on the parts that never affect any functions I SCIA1755J DISASSEMBLY 1 Remove 3rd 4th synchronizer hub and 3rd baulk ring 2 Remove snap ring 1 and thrust washer 2 using suitable tools 3 Remove 3rd main gear 1 and thrust washer 2 PCIB1560E 4 Remove snap ring 1 and thrust washer 2 using suitable tools md Ae P 6 N DA po PCIB1561E Revision October 2008 MT 37 2009 Versa MAINSHAFT AND GEAR lt SERVICE INFORMATION gt RSSF91R o Remove 2nd main gear 1 and thrust washer 2 PCIB1562E 6 Remove snap ring 1 and then remove 2nd inner baulk ring 2nd synchronizer cone and 2nd outer baulk ring 7 Remove 1st 2nd coupling sleeve insert keys springs and 1st 2nd synchronizer hub 8 Remove 1st outer b
21. CE INFORMATION RSSF91R CONTROL LINKAGE Exploded View INFOID 0000000004784225 SEC 341 K9 6 0 61 53 Sa 77 BA TS 0 35 3 6 26 PCIB1508E 1 Control lever knob 2 Control lever 3 Control device assembly 4 Select cable 5 Shift cable 6 Clutch housing 7 Cable mounting bracket 8 Bracket A Black color B White color He m OVa d n d n sta ati O n INFOID 0000000004784226 REMOVAL 1 the battery Refer to SC 7 Removal and Installation 2 Remove the air duct and air cleaner case Refer to EM 26 Removal and Installation HR16DE or EM 139 Removal and Installation MR18DE 3 Press the release button 1 of select cable and shift cable and then remove select cable and shift cable from lever of control shaft 2 4 Shift control lever to neutral position Remove control lever knob 6 Remove center console assembly Refer to IP 12 Removal and Installation 7 Remove control device assembly bolts 8 Remove exhaust front tube center muffler and heat plate Refer to EX 5 Removal and Installation HR16DE or EX 9 Removal and Installation MR18DE 9 Remove bracket 10 Remove select cable and shift cable from cable mounting bracket 11 Remove control device assembly from the vehicle e SCIA7077E Revision October 2008 MT 13 2009 Versa CONTROL LINKAGE lt SERVICE INFORMATION gt RSSF91R INSTALLATION Installatio
22. CE INFORMATION gt RSSF91R 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 PCIB1532E 21 Remove retaining pin from reverse gear assembly using a suit able tool 22 Remove reverse gear assembly from clutch housing MCIBOOSSE 23 Remove final drive assembly 1 from clutch housing 24 Remove pinion shaft and pinion gear from clutch housing 25 Remove magnet and dowel pins 2 from clutch housing PCIB1533E 26 Remove input shaft front bearing from clutch housing using a suitable tool 27 Cut oil channel tube at the root 28 Remove mainshaft front bearing and oil channel from clutch housing using Tool Tool number KV11101180 PCIB1536E Revision October 2008 MT 25 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RSSF91R 29 Remove bushings 1 from clutch housing using a suitable tool PCIB1537E 30 Remove differential side oil seals 1 from clutch housing and transaxle case using a suitable tool CAUTION Never damage transaxle case and clutch housing 31 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 JPDICO484ZZ 32 Pull two way connector 1 straight to
23. Disassembly and Assembly INFOID 0000000004305281 GENERAL PRECAUTIONS Never reuse snap ring e Secure mainshaft in a vise with backplate and then remove gears and snap rings For installation and removal of snap ring set snap ring pliers and flat pliers at both sides of snap ring While expanding snap ring with snap ring pliers move snap ring with flat pliers Disassemble gear components putting direction marks on the parts that never affect any functions it I d SCIA1755J DISASSEMBLY 1 Remove snap ring 1 using suitable tool PCIB1745E 2 Remove 6th main gear 1 and mainshaft rear bearing inner race 2 according to the following procedures a Seta suitable puller to 6th main gear b Remove mainshaft rear bearing inner race and 6th main gear ui using the Tool A tmm D Tool number A ST33052000 ASD u ld a w PCIB1744E 3 Remove 4th main gear 1 and 5th main gear 2 according to the following procedures a Seta suitable tool to 4th main gear b Remove 5th main gear and 4th main gear using Tool A Tool number A ST33052000 4 Remove mainshaft adjusting shim JL SN PCIB1743E Revision October 2008 MT 81 2009 Versa MAINSHAFT AND GEARS lt SERVICE INFORMATION gt RS6F94R o Remove 1st main gear 1 1st 2nd synchronizer hub assembly 2 2nd main gear 3 and 3rd main gear 4 according to the following
24. INFOID 0000000004305285 Transaxle type RS6F9I4R Engine type MR18DE Number of speed 6 Synchromesh type Warner Shift pattern R 1 3 5 2 4 6 PCIB1769E Gear ratio 1st 3 727 2 2 105 1 452 4th 1 171 5th 0 971 eth 0 811 Reverse 3 687 Final gear 3 933 Number of teeth Input gear 1st 11 2nd 19 3rd 31 4th 35 5th 35 eth 37 Reverse 11 Main gear 1st 41 2nd 40 3rd 45 4th 41 5th 34 eth 30 Reverse 42 Reverse idler gear Input Output 28 29 Final gear Final gear Pinion 59 15 an M 24 8 Cil capacity Reference US pt Imp pt Approx 2 0 4 1 4 3 1 2 Remarks Reverse synchronizer Installed Triple cone synchronizer 1st and 2nd Revision October 2008 MT 91 2009 Versa
25. MBLY SERVICE INFORMATION Be careful with the orientation of 5th reverse synchro nizer hub 5th input gear side Never allow synchronizer lever 1 to mount on to 5th reverse baulk ring 2 protrusion A e Sth reverse sychronizer hub e Set 5th reverse shift fork 1 to 5th reverse coupling sleeve and then install them to 5th reverse fork rod and input shaft e A Pin punch e B Bolt e C Nut CAUTION Be careful with the orientation of 5th reverse coupling sleeve 5th input gear side Replace 5th reverse synchronizer hub and 5th reverse coupling sleeve as a set Replace 5th reverse shift fork and 5th reverse fork rod as a set f Check that the gear position is in the 3rd position Press 5th reverse shift fork and shift to 5th gear g Tighten bolt to the specified torque Refer to MT 16 Exploded View h Tighten nut to the specified torque Refer to MT 16 Exploded View CAUTION Never reuse nut i Install retaining pin to 5th reverse shift fork using a suitable tool CAUTION Never reuse retaining pin Revision October 2008 MT 34 RS5F91R PCIB1556E JPDICO408ZZ JPDICO409ZZ 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RSSF91R 39 Shift control shaft shift lever 1 to the neutral position 40 Install O ring to rear housing 41 Install rear housing to transaxle case and tighten bolts to the specified torque Refer to 16
26. RS6F94R FINAL DRIVE Disassembly and Assembly INFOID 0000000004305283 DISASSEMBLY 1 Remove differential side bearing inner race clutch housing side 1 according to the following procedures a Seta suitable toolto differential side bearing inner race clutch housing side b Remove differential side bearing inner race clutch housing side using Tool A Tool number 5733061000 J 8107 2 2 Remove speedometer drive gear 3 Remove final gear bolts and then remove final gear 1 J oe JPDICO446ZZ 4 Remove differential side bearing inner race transaxle case side 1 according to the following procedures a Set a suitable tool to differential side bearing inner race tran saxle case side b Remove differential side bearing inner race transaxle case side using a suitable tool A 1 A Um p a 2 kl AIS t t e JPDICO114ZZ INSPECTION AFTER DISASSEMBLY Gear and Case Check final gear and differential case Replace if necessary Bearing Check bearing for damage and unsmooth rotation Replace if neces sary CAUTION e Replace differential side bearing outer race clutch housing side and differential side bearing inner race clutch housing side as a set e Replace differential side bearing inner race transaxle case side and differential side bearing outer race transaxle case side as a set
27. Shift control shaft shift lever 1 to the 3rd gear position NOTE e If it is not shifted to the 3rd gear position transaxle case can not be installed to clutch housing e The 3rd gear position means that control shaft select lever is fully rotated clockwise and it is returned approximately 10 degrees Apply recommended sealant to transaxle case mounting surface of clutch housing e Use Genuine Silicone RTV or an equivalent 1 42 Rec ommended Chemical Product and Sealant CAUTION Never allow old liquid gasket moisture oil or foreign matter to remain on mounting surface Check that mounting surface is not damaged Apply a continuous bead of liquid gasket to the mounting surface PCIB1524E Install transaxle case to clutch housing If it is difficult to install slightly rotate control shaft shift lever counterclockwise and then install e 1 Selector e 2 Shift fork CAUTION Never disrupt liquid gasket bead with transaxle case or other objects during installation Be careful to align the lever of 5th reverse fork rod with reverse gear assembly groove PCIB1553E Revision October 2008 MT 32 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RSSF91R 33 34 35 36 37 38 Rotate input shaft so that bearing and shaft fit each other and then tighten transaxle bolts to the specified torque Refer to MT 16 Exploded View Apply recommended sealant to p
28. TRANSMISSION TRANSAXLE SECTION M MANUAL TRANSAXLE 8 CONTENTS RS5F91R Removal and Installation 16 Disassembly and Assembly 17 SERVICE INFORMATION 3 INPUT SHAFT AND GEAR 36 BRECAUTIONS 3 Disassembly and Assembly 36 Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TEN MAINSHAFT AND GEAR 37 SEET ee 3 Disassembly and Assembly 37 PREPARATION _ _ uuu 4A PINAL DRIVE 41 Special Service Tools 4 Disassembly and Assembly 41 5 SHIFT CONTROL nnn 42 NOISE VIBRATION AND HARSHNESS E 42 NVH TROUBLESHOOTING M 7 SERVICE DATA AND SPECIFICATIONS NVH Troubleshooting Chart 7 SDS cate 43 DESCRIPTION 8 General Specification 43 e ERT Lal EE 8 RS6F94R System Description 8 SERVICE INFORMATION a EE 10 BEA oe emm crc 10 PRECAUTIONS nennen nennen 44 10 Precaution for Supplemental Restraint System SDE NONE Enten
29. aft front bearing 1 and then remove input shaft front bearing PCIB1751E INSPECTION AFTER DISASSEMBLY Input shaft and gear Check the following items and replace if necessary Revision October 2008 77 2009 Versa INPUT SHAFT AND GEARS lt SERVICE INFORMATION gt RS6F94R e Damage peeling bend uneven wear and distortion of shaft Excessive wear damage and peeling of gear SCIA7736E oynchronizer e Synchronizer hub and coupling sleeve Check the following items and replace if necessary Breakage damage and unusual wear on contact surface of cou pling sleeve synchronizer hub and insert key Coupling sleeve and synchronizer hub move smoothly SCIA1753J e Baulk ring Check contact surface of baulk ring cam and insert key for exces sive wear uneven wear bend and damage Replace if necessary SCIA0608J Bearing Check bearing for damage and unsmooth rotation Replace if neces sary MTF0041D ASSEMBLY Note the following procedures and assemble in the reverse order of disassembly CAUTION Replace transaxle assembly when replacing input shaft Never reuse snap ring Check that snap ring is securely installed in a groove Replace 3rd 4th coupling sleeve and 3rd 4th synchronizer hub as a set Revision October 2008 MT 78 2009 Versa INPUT SHAFT AND GEARS SERVICE INFORMATION RS6F94R Replace 5th 6th coupling sleeve and 5th 6th synchronizer hub as a set Be
30. ain gear oil 2 Remove filler plug and gasket from transaxle case 3 Remove select lever 1 retaining pin using a suitable tool and then remove select lever 4 Remove bracket 2 and position switch 3 from transaxle case PCIB1693E Revision October 2008 MT 65 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RS6F94R 5 Remove transaxle case bolts 6 Remove reverse idler shaft bolt and seal washer 7 Remove transaxle case 2 while rotating shift lever A 1 in the direction as shown JPDICO444ZZ 8 Remove selector spring 1 from return bushing 9 Shift 1st 2nd fork rod 1 fork rod 2 and reverse fork rod 3 to the neutral position 10 Remove selector 4 from clutch housing PCIB1698E Revision October 2008 MT 66 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R 11 Remove reverse idler shaft assembly 1 according to the follow ing procedures a 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 b Remove reverse idler shaft assembly and reverse fork rod 6 from clutch housing 12 Remove spring washer from clutch housing JPDICO606ZZ 13 Pull up and remove input shaft assembly 1 mainshaft assem bly 2 fork rod 3 and 1st 2nd fork rod 4 from clutch housing NOTE It is easier to pull up when shiftin
31. amage transaxle case or clutch housing INSTALLATION Installation is in the reverse order of removal e lt lt Front Install differential side oil seal 1 to clutch housing and transaxle case using Tool A as shown Tool number T27862000 Dimension H1 5 7 6 3 mm 0 224 0 248 in Dimension H2 2 4 3 0 mm 0 094 0 118 in CAUTION Do not reuse differential side oil seal When installing do not incline differential side oil seal Do not damage clutch housing or transaxle case Check oil level and oil leakage after installation Refer to MT 10 Inspection ZZ Hi IN 0505050 6050065 09050906 09090009 09090905 2609050609 6050065 HOO N N TT i SN N WACK AD T NSN SN J N SENSAS OON NE 1 Nu PCIB1506E Revision October 2008 MT 11 2009 Versa POSITION SWITCH lt SERVICE INFORMATION gt RSSF91R POSITION SWITCH C h e C kl n INFOID 0000000004786252 NOTE For removal and installation of the switches refer to MI 17 Disassembly and Assembly BACK UP LAMP SWITCH Check continuity between terminals 1 and 2 DISCONNECT Gear position Continuity Reverse Yes Except reverse PARK NEUTRAL POSITION SWITCH Check continuity between terminals 2 and 3 Gear position Continuity Neutral Yes Except neutral No JPDICOO092ZZ Revision October 2008 MT 12 2009 Versa CONTROL LINKAGE SERVI
32. ar e Removing 1st main gear a e Removing 1st 2nd synchronizer hub as sembly e Removing 2nd main gear e Removing bushing b e Removing 3rd main gear ee e Removing mainshaft front bearing inner race a 22 mm 0 87 in dia b 28 mm 1 10 in dia KV32102700 e Installing bushing Installing 2nd main gear Drift Installing 3rd main gear Installing 4th main gear Installing 5th main gear b Installing 6th main gear a a 54 mm 2 13 in dia b 32 mm 1 26 in dia S NTO065 5730901000 Installing mainshaft rear bearing inner race J 26010 01 a 79 mm 3 11 in dia Drift b 45 mm 1 77 in dia 35 2 mm 1 386 dia a b ZZA0978D 5733061000 Removing differential side bearing inner J 8107 2 clutch housing side Drift a 28 5 mm 1 122 in dia b 38 mm 1 50 in dia b ZZA0969D KV32300QAM Removing and installing input shaft rear bear ing bolt 2009 Versa PREPARATION lt SERVICE INFORMATION gt RS6F94R Commercial Service Tool T Tool name Description Socket Removing and installing drain plug a 8 mm 0 31 in b b 5 mm 0 20 in E PCIB1776E Spacer Removing mainshaft front bearing outer race a 25 mm 0 98 in dia b 25 mm 0 98 in mt Q PCIB1780E Drift Installing bushing a 17 mm 0 67 in dia wo S NT063 Drift Installing input shaft front bearing a 35 mm 1 38 in dia b 25 mm 0 98 in dia oo a S NTO065 Drift Removing input shaft
33. at ter to remain on thread b Install position switch to transaxle case and tighten it to the specified torque Refer to 59 Disassembly and Assembly 33 Install bracket 2 to transaxle case and tighten bolt to the spec ified torque Refer to MT 59 Disassembly and Assembly SE 34 Install select lever 3 according to following the procedures a Install select lever to transaxle case CAUTION Replace select lever and selector as a set b Install retaining pin to select lever using a suitable tool CAUTION Never reuse retaining pin 35 Install drain plug according to the following procedures a Install gasket to drain plug CAUTION Never reuse gasket Install drain plug to clutch housing Tighten drain plug to the specified torque Refer to MT 59 Disassembly and Assembly 36 Install filler plug according to the following procedures a Install gasket to filler plug and then install them to transaxle case CAUTION Never reuse gasket b Tighten filler plug to the specified torque Refer to MT 59 Disassembly and Assembly CAUTION Fill with gear oil before tighten filler plug to the specified torque Revision October 2008 MT 75 2009 Versa INPUT SHAFT AND GEARS SERVICE INFORMATION RS6F94R INPUT SHAFT AND GEARS Disassembly and Assembly INFOID 0000000004305280 GENERAL PRECAUTIONS Never reuse snap ring e Secure input shaft in a vise with backplate and then remove gears an
34. aulk ring 1st synchronizer cone 1st inner baulk ring and 1st main gear 2 INSPECTION AFTER DISASSEMBLY Mainshaft and Gear Check the following items and replace if necessary e Damage peeling bend uneven wear and distortion of shaft Excessive wear damage and peeling of gear SCIA1762J oynchronizer Check the following items and replace if necessary Contact surface breakage damage and unusual wear of coupling sleeve synchronizer hub insert key and spring Coupling sleeve and synchronizer hub move smoothly SCIA1753J Revision October 2008 MT 38 2009 Versa MAINSHAFT AND GEAR SERVICE INFORMATION RSSF91R Breakage damage and excessive wear of baulk ring cam surface and insert contact surface SCIA0608J Bearing Check bearing for damage and unsmooth rotation Replace if neces sary MTF0041D ASSEMBLY Note the following items and assemble in the reverse order of disassembly Refer to 16 Exploded View CAUTION Never reuse snap ring Check that snap ring is securely installed to the groove Apply gear oil to 3rd baulk ring Apply gear oil to 1st outer baulk ring 1st synchronizer cone and 1st inner baulk ring Apply gear oil to 2nd outer baulk ring 2nd synchronizer cone and 2nd inner baulk ring Replace 1st outer baulk ring 1st synchronizer cone and 1st inner baulk ring as a set Replace 2nd outer baulk ring 2nd synchronizer cone and 2nd outer b
35. aulk ring as a set Be careful with the orientation of 1st 2nd synchronizer hub A 1st main gear side B 2nd main gear side e Replace 1st 2nd synchronizer hub and 1st 2nd coupling sleeve as a set PCIB1566E Be careful with the orientation of 1st 2nd coupling sleeve A 2nd main gear side B 1st main gear side _ V PCIB1567E Revision October 2008 MT 39 2009 Versa RS5F91R MAINSHAFT AND GEAR lt SERVICE INFORMATION gt Be careful with the orientation of 3rd 4th synchronizer hub A 4th main gear side B 3rd main gear side PCIB1565E Replace 3rd 4th synchronizer hub and 3rd 4th coupling sleeve as a set Be careful with the orientation of insert key 1 and spring 2 LAY d 2 PCIB1564E MT 40 2009 Versa Revision October 2008 FINAL DRIVE lt SERVICE INFORMATION gt RSSF91R FINAL DRIVE Disassembly and Assembly INFOID 0000000004788552 DISASSEMBLY 1 Remove differential side bearings using Tool A and a suitable tool 0000000000 ES ES CU Tool number 5733052000 2 Remove speedometer drive gear GGG GG UI e PCIB1568E INSPECTION AFTER DISASSEMBLY Case Check differential case and replace if necessary Bearing Check bearing for damage and unsmooth rotation Replace if neces sary CAUTION Replace differential side bearing outer race and differential side bearing as a set
36. careful to install 3rd 4th synchronizer hub according to the specified direction A 3rd input gear side B 4th input gear side PCIB1748E Be careful to install 5th 6th synchronizer hub according to the specified direction A 5th input gear side lt B 6th e side CY PCIB1749E Install input shaft front bearing 1 using a suitable drift A JPDICO 1 12ZZ e Install input shaft rear bearing 1 using a suitable drift A and the Tool B Tool number ST36720030 Apply gear oil to 3rd baulk ring 4th baulk ring 5th baulk ring and 6th baulk ring JPDICO 1 1324 Revision October 2008 MT 79 2009 Versa INPUT SHAFT AND GEARS lt SERVICE INFORMATION gt RS6F94R Install input shaft rear bearing bolt 1 according to the following procedures CAUTION Follow the procedures Otherwise it may cause a transaxle malfunction 1 Secure the Tool A in a vise and then set input shaft assembly Tool number KV32300QAM 2 Install input shaft rear bearing bolt and then tighten it to the specified torque of the 1st step Refer to MT 59 Disassembly and Assembly JPDICO449ZZ 3 Loosen input shaft rear bearing bolt by a half turn 4 Tighten input shaft rear bearing bolt to the specified torque of the 2nd step Refer to 59 Disassembly and Assembly Revision October 2008 MT 80 2009 Versa MAINSHAFT AND GEARS SERVICE INFORMATION RS6F94R MAINSHAFT AND GEARS
37. ce if necessary SCIA0608J Bearing Check bearing for damage and unsmooth rotation Replace if neces sary CAUTION Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set Replace mainshaft rear bearing inner race and mainshaft rear bearing outer race as a set ASSEMBLY CAUTION e Select mainshaft rear bearing adjusting shim according to the following procedures when replacing mainshaft adjusting shim 6th main gear 5th main gear or 4th main gear Replace mainshaft adjusting shim If new mainshaft adjusting shim is thinner than previous one offset the thickness difference by selecting thicker mainshaft rear bearing adjusting shim If new mainshaft adjusting shim is thicker than previous one offset the thickness difference by selecting thinner mainshaft rear bearing adjusting shim Replace 6th main gear 5th main gear or 4th main gear Measure the thickness of the main gear used before and the new main gear Increase the thickness of the mainshaft rear bearing adjusting shim if the difference is smaller than 0 025 mm 0 0010 in Replace transaxle assembly when replacing mainshaft 1 Install mainshaft front bearing inner race 1 using the Tool A Tool number A S1T36720030 CAUTION Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set 2 Apply gear oil to 1st inner baulk ring 1st synchronizer cone 1st outer baulk ring 2nd
38. ce select lever and selector as a set SCIA7782bE 27 Install selector spring 1 to return bushing A 28 Apply recommended sealant to transaxle case mounting sur face Use Genuine Silicone RTV or an equivalent Refer to Gl 42 Recommended Chemical Product and Sealant CAUTION Never allow old liquid gasket moisture oil or foreign matter to remain on mounting surface Check that mounting surface is not damaged Apply liquid gasket bead continuously 29 Install transaxle case to clutch housing while rotating shift lever A 1 in the direction as shown JPDICO110ZZ Revision October 2008 74 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RS6F94R 30 Install reverse idler shaft bolt according to the following pro cedures a Install seal washer to reverse idler shaft bolt and install reverse idler shaft bolt to transaxle case CAUTION Never reuse seal washer b Tighten reverse idler shaft bolt to the specified torque Refer to 59 Disassembly and Assembly 31 Tighten transaxle case bolts to the specified torque Refer to MT 59 Disassembly and Assembly 32 Install position switch 1 according to the following procedures a Apply recommended sealant to position switch thread Use Genuine Silicone RTV or an equivalent Refer to Gl 42 Recommended Chemical Product and Sealant CAUTION Never allow old liquid gasket moisture oil or foreign m
39. d lever of control shaft Be careful about the installation direction and push control lever knob onto control lever CAUTION Do not reuse control lever knob Make sure that the front rear claws 1 of control device assembly are in contact with flange of the floor 2 When control lever is selected to 1st 2nd side and 5th 6th side confirm control lever returns to neutral position smoothly e When control lever is shifted to each position make sure there is no binding or disconnection in each boot Move stopper 1 to lock position when installing the shift cable onto the shift lever Revision October 2008 MT 56 RS6F94R WCIAO606E SCIA7630E PCIB1510E SCIA7846E 2009 Versa BREATHER HOSE lt SERVICE INFORMATION gt RS6F94R AIR BREATHER HOSE Removal and Installation COMPONENTS SEC 165 320 321 ay 7 IL Q aS SSS CANES SCIA7629E 1 cleaner case 2 Air breather hose 3 A Air duct inlet 4 Clip 5 Transaxle assembly 6 Two way connector REMOVAL 1 Remove battery Refer to SC 7 Removal and Installation 2 Remove air duct front air duct inlet and air cleaner case Refer to EM 139 Removal and Installation 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 e When installing air breather hose on two way connector aim
40. d snap rings For installation and removal of snap ring set snap ring pliers and flat pliers at both sides of snap ring While expanding snap ring with snap ring pliers move snap ring with flat pliers Disassemble gear components putting direction marks on the parts that do not affect any functions SCIA1755J DISASSEMBLY 1 Remove input shaft rear bearing bolt 1 using Tool A Tool number A KV32300QAM JPDICO449ZZ 2 Remove input shaft rear bearing 1 according to the following procedures a Seta suitable puller to input shaft rear bearing b Remove input shaft rear bearing using a suitable drift A 3 Remove spacer 1 6th input gear 2 needle bearing 6th baulk ring and 5th 6th synchronizer hub assembly 3 4 Remove insert keys and 5th 6th coupling sleeve from 5th 6th synchronizer hub PCIB1750E Revision October 2008 MT 76 2009 Versa INPUT SHAFT AND GEARS lt SERVICE INFORMATION gt RS6F94R 5 Remove snap ring 1 using suitable tool 6 Remove spacer 5th baulk ring 5th input gear 2 and spacer PCIB1754E 7 Remove snap ring 1 using suitable tool 8 Remove spacer 4th input gear 2 4th baulk ring and 3rd 4th synchronizer hub assembly 3 9 Remove insert keys and 3rd 4th coupling sleeve from 3rd 4th synchronizer hub PCIB1753E 10 Remove snap ring 1 11 Remove spacer 3rd baulk ring 3rd input gear 2 PCIB1752E 12 Set a suitable puller to input sh
41. d then install 3rd 4th fork rod assembly PCIB1628E Be careful with the orientation of 3rd 4th coupling sleeve 4th main gear side B 3rd main gear side nstall 3rd input gear of input shaft assembly so that it is set under reverse main gear of 3rd 4th coupling sleeve Replace 3rd 4th coupling sleeve and 3rd 4th synchronizer hub as a set PCIB1551E c Install springs and insert keys to 3rd 4th synchronizer hub d Apply gear oil to 4th baulk ring Install 4th baulk ring aAA ail MCIBO0061E 27 Install 5th reverse fork rod 1 to clutch housing according to the following procedures CAUTION Replace 5th reverse fork rod and 5th reverse shift fork as a set a Pull gear of reverse gear assembly 2 up b Temporarily install 5th reverse fork rod to clutch housing PCIB1629E Revision October 2008 MT 31 2009 Versa 28 29 30 31 32 TRANSAXLE ASSEMBLY SERVICE INFORMATION RSSF91R C Press gear of reverse gear assembly 1 down and then install oth reverse fork rod 2 to clutch housing CAUTION Set levers of 5th reverse fork rod so as to align with reverse gear assembly groove A Install 4th main gear 2 and spacer 1 to mainshaft CAUTION Install spacer so that spacer protrusion faces to transaxle rear side Press 3rd Ath shift fork down and then shift 3rd Ath coupling sleeve to 3rd gear side PCIB1529E
42. ft a 39 5 mm 1 55 in dia NT084 KV32300QAE Installing differential side bearing outer race a 65 mm 2 56 in dia Drift a 63 mm 2 48 in dia SCIA1783J 5733052000 Removing differential side bearing a 22 mm 0 87 in dia Drift 5 28 mm 1 10 dia b ZZA0969D KV40104920 Installing differential side bearing a 21 7 mm 0 85 in dia Drift 44 7 mm 1 76 in dia b ZZA0969D Commercial Service Tools INFOID 0000000004784218 Tool name Description Drift Removing input shaft front bearing a 38 mm 1 50 in dia wo S NT063 Drift Installing bushing 14 5 mm 0 571 in dia wo S NT063 Revision October 2008 MT 5 2009 Versa PREPARATION lt SERVICE INFORMATION gt RSSF91R Tool name Description Socket Removing and installing drain plug a 8 mm 0 31 in RI b b 5 mm 0 20 in PCIB1776E Puller e Removing 5th reverse synchronizer hub e Removing differential side bearing NTO77 Bearing remover Removing bushing S NT134 Revision October 2008 MT 6 2009 Versa NOISE VIBRATION AND HARSHNESS TROUBLESHOOTING SERVICE INFORMATION RSSF91R NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Chart Use the chart below to help you find the cause of the symptom The numbers indicate the order of the inspec tion If necessary repair or replace these parts INFOID 0000000004784215 N N N N Reference
43. g each fork rod to each shaft side 14 Remove final drive assembly 1 from clutch housing 15 Remove magnet from clutch housing PCIB1703E 16 Remove differential side oil seals 1 from clutch housing and transaxle case CAUTION Never damage clutch housing and transaxle case PCIB1704E 17 Remove differential side bearing outer race 1 from clutch hous ing using a suitable tool CAUTION Never damage clutch housing Revision October 2008 MT 67 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RS6F94R 18 Remove differential side bearing outer race 1 from transaxle case using a suitable tool CAUTION Never damage transaxle case 19 Remove shim 2 from transaxle case 20 Remove shift lever A 1 retaining pin using a suitable tool 21 Remove shift lever A from transaxle case JPDICO106ZZ 22 Remove shift lever B 1 from transaxle case 23 Remove oil gutter 1 from transaxle case PCIB1707E 24 Remove bushings 1 from transaxle case using a suitable tool Revision October 2008 MT 68 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R 25 Remove mainshaft rear bearing outer race from transaxle case using a suitable tool 26 Remove mainshaft rear bearing adjusting shim from transaxle case PCIB1706E 2 Remove snap ring 1 and oil channel 2 from transaxle case 28 Remove input shaft oil seal 1 from clutch housing using a suit able to
44. h housing PCIB1545E 19 Install final drive assembly 1 to clutch housing 20 Install dowel pins 2 and magnet to clutch housing PCIB1533E 21 Install reverse gear assembly to clutch housing and then install retaining pin to clutch housing using a suitable tool CAUTION Never reuse retaining pin 22 Install 1st 2nd shift fork to 1st 2nd fork rod and then install retaining pin to 1st 2nd shift fork CAUTION Never reuse retaining pin Replace 1st 2nd fork rod and 1st 2nd shift fork as a set MCIB0033E 23 Set 1st 2nd fork rod assembly 1 onto mainshaft assembly 2 and then install them to clutch housing PCIB1532E Revision October 2008 MT 30 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RSSF91R 24 Install lock pins to clutch housing 25 Install 3rd 4th shift fork to 3rd 4th fork rod and then install retaining pin to 3rd 4th shift fork CAUTION Never reuse retaining pin Replace 3rd 4th fork rod and 3rd 4th shift fork as a set 26 Install 3rd 4th fork rod assembly 1 3rd 4th coupling sleeve 2 and input shaft assembly 3 to clutch housing according to the following procedures a Pull 1st 2nd fork rod 4 up and then maintain the neutral posi tion b Set 3rd 4th fork rod assembly onto 3rd 4th coupling sleeve and then install them together with input shaft assembly to clutch housing CAUTION e Set lock pin 3rd 4th fork rod side onto 1st 2nd fork rod groove an
45. ice tools illustrated here Tool number Description Kent Moore No Tool name KV381054S0 Removing mainshaft front bearing outer race J 34286 Puller gt ZZA0601D KV38100200 e Installing mainshaft front bearing outer race Installing mainshaft rear bearing outer race Drift e Installing differential side bearing outer race Y clutch housing side jb a 65 mm 2 56 in dia b 49 mm 1 93 in dia ZZA1143D 571733220000 Installing input shaft oil seal a 37 mm 1 46 in dia Drift b 31 mm 1 22 in dia c 22 mm 0 87 in dia 5733400001 Installing differential side bearing outer race J 26082 transaxle case side Drift a 60 mm 2 36 in dia b 47 mm 1 85 in dia ZZA0814D KV38100300 Installing differential side oil seal J 25523 a 54 mm 2 13 in dia Drift b 46 mm 1 81 in dia c 32 mm 1 26 in dia ZZA1046D 5736720030 Installing input shaft rear bearing e Installing mainshaft front bearing inner race Drift a 70 mm 2 76 in dia b 40 mm 1 57 dia ae 29 1 14 dia ZZA0978D Revision October 2008 MT 45 2009 Versa PREPARATION Ce Renault SST 1 1823 Revision October 2008 f N PCIB2078J MT 46 SERVICE INFORMATION RS6F94R Tool number Description Kent Moore No Tool name ST33052000 e Removing mainshaft rear bearing inner race e Removing 6th main gear Drift e Removing 5th main gear e Removing 4th main ge
46. ing and O ring CAUTION Remove to axial direction of input shaft because rear housing oil channel is inserted to input shaft center hole SCIA1709J 4 Shift control shaft shift lever 1 to the 3rd gear position NOTE e f it is not shifted to the 3rd gear position transaxle case can not be removed from clutch housing e The 3rd gear position means that control shaft select lever is fully rotated clockwise and it is returned approximately 10 degrees PCIB1524E Revision October 2008 MT 22 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RSSF91R 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 set ting 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 PCIB1526E 8 Remove 5th main gea
47. it to transaxle and tighten drain plug to the specified torque Refer to MT 17 Dis assembly and Assembly CAUTION Do not reuse gasket Refilling 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 Seta new gasket on filler plug 1 then install it to transaxle and tighten to the specified torque Refer to MT 17 Disassembly and Assembly CAUTION Do not reuse gasket n S cti O n INFOID 0000000004784222 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 Seta 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 17 Dis assembly and Assembly Revision October 2008 MT 10 2009 Versa SIDE OIL SEAL SERVICE INFORMATION RSSF91R SIDE OIL SEAL m Ova n d sta ati n INFOID 0000000004784224 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 d
48. ly 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 e When installing air breather hose to air duct and air cleaner case make sure that clips are fully inserted Revision October 2008 MT 15 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RSSF91R TRANSAXLE ASSEMBLY Explod ed View INFOID 0000000004786260 SEC 112 320 0 64 5 6 6 48 5760 6 1 44 C 2 KSC 7 80 8 2 59 PCIB1514E 1 LH engine mount bracket transaxle 2 Transaxle assembly 3 Rear engine mount bracket side 4 Washer 5 Reartorque rod lt Front Referto installation Removal and Installation INFOID 0000000004786261 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 12 Removal and Installa tion REMOVAL 1 Drain gear oil Refer to MT 10 Draining RS5F91R MT 52 Changing M T Oil RS6F94R 2 Drain clutch fluid and remove clutch tube from CSC Refer t
49. main gear 9 5th main gear 10 4th main gear 11 3rd main gear 12 2nd main gear 13 1st 2nd synchronizer assembly 14 1 main gear 15 Differential 16 Final gear 17 Mainshaft 18 Input shaft 19 Clutch housing 20 Reverse idler shaft 21 Reverse input gear 22 Reverse output gear TRIPLE CONE SYNCHRONIZER Revision October 2008 MT 50 2009 Versa DESCRIPTION SERVICE INFORMATION RS6F94R Triple cone synchronizer is used for the 1st and the 2nd gears to reduce operating force of the shift lever e 1st main gear 1 1st 2nd coupling sleeve 2 Insert key 3 Outer baulk ring 4 e 2nd main gear 5 e Synchronizer cone 6 e Inner baulk ring 7 e 1st 2nd synchronizer hub 8 SCIA7636E REVERSE GEAR NOISE PREVENTION FUNCTION SYNCHRONIZING METHOD Reverse gear assembly consists of reverse input gear return spring reverse baulk ring and reverse output gear When the shift lever is shifted to the reverse position the construction allows smooth shift operation by stopping the reverse idler shaft rotation by frictional force of synchronizer Reverse fork rod 1 Reverse output gear 2 e Return spring 3 e Reverse baulk ring 4 Reverse input gear 5 SCIA7621E Revision October 2008 MT 51 2009 Versa M T OIL SERVICE INFORMATION RS6F94R M T OIL Changing M Oil INFOID 0000000004305271 DRAINING 1 Start engine and let it run to warm up transaxle 2 Stop engine Rem
50. n is in the reverse order of removal e Shift the control lever to the neutral position e Securely assemble each the cables to each lever mounting bracket and the control device assembly Be careful about the installation direction and push control lever knob into control lever lt Front PCIB1509E Make sure that the front rear claws 1 of control device assembly are in contact with flange of the floor 2 PCIB1510E S cti O n INFOID 0000000004784227 Inspect the following items When control lever is selected to 1st 2nd side and 5th reverse side confirm control lever returns to neutral position smoothly When the control lever is shifted to each position make sure there is no binding or disconnection in each boot Revision October 2008 MT 14 2009 Versa BREATHER HOSE SERVICE INFORMATION RSSF91R AIR BREATHER HOSE Exploded View INFOID 0000000004784228 SEC 165 320 321 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 0000000004784229 REMOVAL 1 the battery Refer to SC 7 Removal and Installation 2 Remove the air duct and air cleaner case Refer to EM 17 Removal and Installation HR16DE or EM 139 Removal and Installation MR18DE 3 Remove air breather hose CAUTION When air breather hose is removed be sure to hold two way connector secure
51. ntrol Component Revision October 2008 TRANSAXLE ASSEMBLY 11 14 3rd main gear 20 23 Mainshaft 1st synchronizer cone 1st 2nd coupling sleeve 2nd outer baulk ring Snap ring 3rd 4th coupling sleeve Spacer MT 20 12 15 18 21 24 RS5F91R 1st main gear 1st outer baulk ring Spring 2nd synchronizer cone Thrust washer 3rd baulk ring 4th baulk ring Mainshaft rear bearing 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RSSF91R SEC 328 23 2 3 17 1 Retaining pin 2 1st 2nd shift fork 3 Bushing 4 1st 2nd fork rod 5 Lock pin D 5th reverse fork rod 7 bth 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 Apply gear oil Apply Genuine Silicone RTV or an equivalent Refer to XX XX Replace the parts as a set Final Drive Component Revision October 2008 MT 21 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RSSF91R SEC 381 JPDICO602ZZ 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 the 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 hous
52. o CL 12 Removal and Installation CAUTION Do not depress clutch pedal during removal procedure 3 Remove the engine and transaxle as an assembly from the vehicle Refer to EM 88 Removal and Instal lation HR16DE EM 195 Removal and Installation MR18DE 4 Remove the transaxle to engine and engine to transaxle bolts 5 Separate the transaxle assembly from the engine INSTALLATION Revision October 2008 MT 16 2009 Versa lt TRANSAXLE ASSEMBLY SERVICE INFORMATION RSSF91R Installation is in the reverse order of removal 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 12 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 Disassembly and Assembly Bolt No 1 2 3 4 Quantity 2 2 1 3 Bolt length 7 55 49 69 55 mm in 2 17 1 93 2 72 2 17 Tightening torque 48 0 PCIB1517E N m kg m ft Ib 4 9 35 After installation perform the following Bleed the air from the clutch hydraulic system Refer to CL 8 Air Bleeding Procedure Check for oil leakage and oil level Refer to MT 10 Inspection Check the cont
53. ol CAUTION Never damage clutch housing 29 Remove mainshaft front bearing outer race 1 from clutch hous ing using Tool A and a spacer B Tool number A KV381054S0 J 34286 30 Remove oil channel 2 from clutch housing eg Gi 31 Remove bushing 1 from clutch housing using a suitable tool PCIB1717E Revision October 2008 MT 69 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RS6F94R 32 Remove two way connector 1 from clutch housing 33 Remove plug from clutch housing 34 Remove pinion gear 1 and pinion shaft 2 from clutch housing ASSEMBLY 1 Install pinion gear 1 and pinion shaft 2 to clutch housing CAUTION Replace transaxle assembly when replacing clutch hous ing 2 Install plug to clutch housing 3 Install two way connector 1 to clutch housing PCIB1720E Revision October 2008 MT 70 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R 4 Install bushings 1 so that they becomes even to clutch housing edge surface using a suitable tool A 5 Install oil channel to clutch housing CAUTION Never reuse oil channel 6 Install mainshaft front bearing outer race to clutch housing using Tool A Tool number KV38100200 CAUTION Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set 7 Install input shaft oil seal 1 to clutch housing using Tool A
54. osition switch thread and check ball plug thread Tighten them to transaxle case and them to the specified torque Refer to 16 Exploded View e Use Genuine Silicone RTV or an equivalent 1 42 Rec ommended Chemical Product and Sealant CAUTION Never allow old liquid gasket moisture oil or foreign mat ter to remain on thread Apply gear oil to mainshaft spline Install 5th main gear 1 to mainshaft using a suitable bolt A M10 x 1 0 and a suitable nut re e row uy we gt A Install adapter plate 1 bushing 2 and 5th input gear 3 to input shaft CAUTION Be careful with the orientation of adapter plate e Transaxle case side PCIB1555E Install 5th reverse synchronizer hub 5th reverse coupling sleeve and 5th reverse shift fork according to the following procedures Apply gear oil to 5th reverse baulk ring Install 5th reverse baulk ring 1 to 5th input gear CAUTION Be careful with the orientation of 5th reverse baulk ring Install synchronizer levers 2 to 5th reverse synchronizer hub 3 CAUTION Replace 5th reverse synchronizer hub and 5th reverse coupling sleeve as a set Be careful with the orientation of synchronizer lever e 1 Sth reverse synchronizer hub side Install 5th reverse synchronizer hub assembly and washer to 010042122 input shaft CAUTION Revision October 2008 MT 33 2009 Versa TRANSAXLE ASSE
55. ove drain plug 1 and drain oil 3 Install a new gasket onto drain plug 1 and install it into tran saxle Tighten drain plug to specification Refer to MT 59 Dis assembly and Assembly CAUTION Do not reuse gasket FILLING 1 Remove filler plug 1 Fill with new oil until oil level reaches the specified limit at filler plug hole as shown Oil grade and capacity Refer to MA 14 Fluids and Lubricants 2 After refilling oil check oil level Install a new gasket on filler plug 1 then install it into transaxle Tighten filler plug to specifica tion Refer to MT 59 Disassembly and Assembly CAUTION Do not reuse gasket SCIA7623E C h ki INFOID 0000000004305272 OIL LEAKAGE AND OIL LEVEL 1 Make sure that oil is not leaking from transaxle or around it 2 Remove filler plug 1 and check oil level at filler plug hole as shown CAUTION Do not start engine while checking oil level Install a new gasket onto filler plug 1 and install it into tran saxle Tighten filler plug to specification Refer to MT 59 Disas sembly and Assembly CAUTION Do not reuse gasket SCIA7623E Revision October 2008 52 2009 Versa SIDE OIL SEAL SERVICE INFORMATION RS6F94R SIDE OIL SEAL Removal and Installation hob REMOVAL 1 Remove front drive shafts from transaxle assembly Refer to FAX 9 Removal and Installation Left oide 2 Remove differential
56. paint mark face toward the vehicle front When installing air breather hose two way connector push it until it hits transaxle case e When installing air breather hose to air duct and air cleaner case make sure that clips are fully inserted CAUTION Make sure air breather hose is not collapsed or blocked due to folding or bending when installed Revision October 2008 MT 57 2009 Versa TRANSAXLE ASSEMBLY SERVICE INFORMATION RS6F94R TRANSAXLE ASSEMBLY Explod ed View INFOID 0000000004 786254 Removal and Installation CAUTION If transaxle assembly is removed from the vehicle always replace CSC Concentric Slave Cylinder Inserted CSC returns to the original position when removing transaxle assembly Dust on clutch disc sliding parts may damage CSC seal and may cause clutch fluid leakage COMPONENTS SEC 112 320 3 80 8 2 59 SCIA7631E 1 LH engine mount bracket transaxle 2 Transaxle assembly 3 Rear engine mount bracket side 4 Washer 5 Reartorque rod lt Front Refer to MT 58 Removal and Installation REMOVAL 1 Drain gear oil Refer to 52 Changing M T Oil 2 Drain clutch fluid and remove clutch tube from CSC Refer to CL 10 Removal and Installation CAUTION Do not depress clutch pedal during removal procedure Remove engine and transaxle assembly Refer to EM 195 Removal and Installation Remove starter motor Refer to SC 20 Removal and Installation MR18DE
57. procedures a Seta suitable tool to 1st main gear b Remove 3rd main gear busing 2nd main gear 2nd inner baulk ring 2nd synchronizer cone 2nd outer baulk ring 1st 2nd syn chronizer hub assembly 1st outer baulk ring 1st synchronizer cone 1st inner baulk ring and 1st main gear using the Tool Tool number A 5733052000 c Remove insert keys and 1st 2nd coupling sleeve from 1st 2nd synchronizer hub 6 Remove mainshaft front bearing inner race 1 according to the following procedures a Seta suitable puller to mainshaft front bearing inner race b Remove mainshaft front bearing inner race using the Tool A PCIB1742E Tool number A 1 33052000 PCIB1741E INSPECTION AFTER DISASSEMBLY Mainshaft and Gear Check the following items and replace if necessary e Damage peeling bend uneven wear and distortion of shaft Excessive wear damage and peeling of gear PCIB1775E oynchronizer e Synchronizer hub and coupling sleeve Check the following items and replace if necessary Breakage damage and unusual wear on contact surface of cou pling sleeve synchronizer hub and insert key Coupling sleeve and synchronizer hub move smoothly SCIA1753J e Baulk ring Revision October 2008 MT 82 2009 Versa MAINSHAFT AND GEARS SERVICE INFORMATION RS6F94R Check contact surface of baulk ring cam and insert key for exces sive wear uneven wear bend and damage Repla
58. r from mainshaft using the pullers Tool number KV32300QAC KV32300QAD 9 Remove position switch from transaxle case Sie E PCIB1627E Revision October 2008 MT 23 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RSSF91R 10 Remove transaxle case bolts 11 Remove transaxle case from clutch housing 12 Remove spacer 1 and 4th main gear 2 from mainshaft PCIB1529E 13 Remove 5th reverse fork rod 1 according to the following pro cedures 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 PCIB1530E 14 Remove 3rd 4th fork rod assembly 1 3rd 4th coupling sleeve 2 and input shaft assembly 3 according to the following pro cedures a Remove 4th baulk ring insert keys and springs from mainshaft Pull gear of reverse gear assembly 4 up 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 puse 16 Remove 3rd 4th shift fork from 3rd 4th shift fork rod 17 Remove lock pins __ from clutch housing JPDICO534ZZ Revision October 2008 24 2009 Versa TRANSAXLE ASSEMBLY lt SERVI
59. r tube CAUTION Check air breather inner tube for twists after installing Install differential side oil seals 1 to clutch housing and tran saxle case within the specified dimensions using Tool A Tool number A 5727862000 CAUTION Never incline differential side oil seal Never damage clutch housing and transaxle case Dimension H1 Transaxle case side 5 7 6 3mm 0 224 0 248 in H2 Clutch housing side 2 4 3 0 mm 0 094 0 118 in AM AA GOD 7 Install differential side bearing outer races until they reach clutch housing and transaxle case using the Tool A Tool number KV32300QAE CAUTION Replace differential side bearing outer race and differential side bearing as a set Install bushings 1 until they reach clutch housing using a suit able tool A Install oil channel to clutch housing CAUTION Never reuse oil channel Revision October 2008 MT 29 ws RS5F91R E NS PCIB1550E JPDICO637ZZ 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RSSF91R 16 Install mainshaft front bearing so that it becomes even to clutch housing surface using Tool Tool number 5733400001 J 26082 PCIB1544E 17 Install input shaft front bearing so that it becomes even to clutch housing surface using Tool A Tool number KV40100900 18 Install pinion gear and pinion shaft to clutc
60. rear bearing a 24 mm 0 94 in dia 10 PCIB1779E Drift e Removing differential side bearing inner race transaxle case side Installing input shaft rear bearing a 43 mm 1 69 in dia w NT109 Revision October 2008 47 2009 Versa lt SERVICE INFORMATION gt Tool name Drift PREPARATION RS6F94R Description Installing differential side bearing inner race clutch housing side a 45 mm 1 77 in dia b 39 mm 1 54 in dia S NT474 Drift Installing differential side bearing inner race transaxle case side a 52 mm 2 05 in dia b 45 mm 1 77 in dia S NT474 Puller Removing differential side bearing inner race clutch housing side Removing differential side bearing inner race transaxle case side NTO77 Puller e Removing differential side bearing inner race clutch housing side e Removing differential side bearing inner race transaxle case side e Removing input shaft rear bearing e Removing input shaft front bearing e Removing mainshaft rear bearing inner race e Removing 6th main gear e Removing 4th main gear e Removing 5th main gear e Removing 1st main gear e Removing 1st 2nd synchronizer hub as ZZB0823D sembly e Removing 2nd main gear e Removing 3rd main gear e Removing mainshaft front bearing outer race Remover e Removing bushing e Removing mainshaft rear bearing outer race S NT134 Power tool Revision Oc
61. remove it from air breather inner tube 2 33 Remove air breather inner tube from transaxle case PCIB1541E 34 Remove bushings 1 from transaxle case using a suitable tool 35 Remove retaining pin from selector using a suitable tool 36 Remove selector from control shaft 37 Remove oil gutter from transaxle case PCIB1538E Revision October 2008 MT 26 2009 Versa 39 40 41 42 43 44 ASSEMBLY 1 TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RS5F91R 38 Remove bolt 1 and then remove bushing spring and gear catch from transaxle case Remove check ball plug from transaxle case JPDIC0533ZZ Remove bolts JL and then remove control shaft 1 from tran saxle case Remove O ring from control shaft PCIB1540E Expand snap rings 1 and remove input shaft rear bearing and mainshaft rear bearing from transaxle case using Tool A Tool number ST35300000 Remove snap rings from transaxle case Remove check balls 2 from transaxle case Install snap rings 1 along transaxle case groove so that notch mates with housing as shown CAUTION Check snap ring installing direction Never misassemble PCIB1547E Revision October 2008 MT 27 2009 Versa 9 TRANSAXLE ASSEMBLY SERVICE INFORMATION RSSF91R 2 Expand snap rings 1 and install input shaft rear bearing and mainshaft rear bearing to transaxle case using Tool A Tool number
62. rol linkage Refer to MT 14 Inspection INFOID 0000000004784232 COMPONENTS Case and Housing Component Revision October 2008 MT 17 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt RSSF91R SEC 321 Dko 2 0 20 18 1 Differential side oil seal 2 Clutch housing 3 Dowel pin Magnet 5 Drain plug 6 Gasket 7 Oil channel 8 Two way connector 9 Oil gutter 10 Air breather inner tube 11 Filler plug 12 Transaxle case 13 O ring 14 Rear housing 15 Position switch Apply Genuine Silicone RTV or an equivalent Refer to XX XX Gear Component Revision October 2008 MT 18 2009 Versa TRANSAXLE ASSEMBLY lt SERVICE INFORMATION gt 1 Input shaft front bearing 2 Input shaft 4 Input shaft rear bearing 5 Adapter plate 7 input gear 8 5th reverse baulk ring 10 5th reverse synchronizer hub 11 5th reverse coupling sleeve 13 Reverse gear assembly Apply gear oil Replace the parts as a set Revision October 2008 MT 19 12 RS5F91R 9 186 19 137 JPDICO480GB Snap ring Bushing Synchronizer lever Retaining pin 2009 Versa lt SERVICE INFORMATION gt 322 10 13 16 19 22 25 Mainshaft front bearing 1st inner baulk ring 1st 2nd synchronizer hub Insert key 2nd inner baulk ring 2nd main gear 3rd 4th synchronizer hub 4th main gear oth main gear Apply gear oil Replace the parts as a set Shift Co
63. t of Control Device and Cable 55 Removal and Installation 55 AIR BREATHER HOSE 57 Removal and Installation 57 TRANSAXLE ASSEMBLY 58 Exploded Nd 58 Removal and Installation 58 Disassembly and Assembly 59 Revision October 2008 MT 2 INPUT SHAFT AND GEARS 76 Disassembly and Assembly 76 MAINSHAFT AND GEARS 81 Disassembly and Assembly 81 REVERSE IDLER SHAFT AND GEARS 86 Disassembly and Assembly 86 FINAL DRIVE 88 Disassembly and Assembly 88 SHIFI CONTROL zenne 90 INSPECCION meme 90 SERVICE DATA AND SPECIFICATIONS ODD msnnen nnen 91 General Specification 91 2009 Versa PRECAUTIONS SERVICE INFORMATION RSSF91R SERVICE INFORMATION PRECAUTIONS Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER INFOID 0000000004786253 The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along with a front seat belt helps to red
64. ted for 1st and 2nd gears to reduce operating force of the shift lever 1 Outer baulk ring 2 2nd main gear Synchronizer cone Inner baulk ring 1st main gear 1st 2nd coupling sleeve 3 4 5 6 SCIA7117E REVERSE GEAR NOISE PREVENTION FUNCTION SYNCHRONIZING METHOD Description ooon 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 cou pling sleeve 1 slides in the reverse direction 9 oth 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 syn chronizer lever on 5th reverse coupling sleeve 4 Sth reverse coupling sleeve that is presses by synchronizer lever stops the rotation of input shaft JPDICO415ZZ Revision October 2008 MT 9 2009 Versa M T OIL lt SERVICE INFORMATION gt RSSF91R M T OIL D n n INFOID 0000000004784220 1 Start engine and let it run to warm up transaxle 2 Stop engine Remove drain plug 1 and drain oil 3 Seta new gasket on drain plug 1 and install
65. tober 2008 Loosening bolts and nuts PBICO190E MT 48 2009 Versa NOISE VIBRATION AND HARSHNESS TROUBLESHOOTING SERVICE INFORMATION RS6F94R NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Chart Use the chart below to help you find the cause of the symptom The numbers indicate the order of the inspec tion If necessary repair or replace these parts INFOID 0000000004305269 N O O LO O O LO LO LO LO LO LO Reference page gt gt gt gt gt gt SUSPECTED PARTS m Possible cause 5 Sa 5 D ge LLI c e E e D D O D 5 2 H as O O c o he i C 5 1 S Sg el EECH ENGER ECG HI KE E Si 9 5 9 509 2 a 9 ii lt 5 LL c Z P i 2 2 2 O Se Se O m o lt Noise 1 2 3 3 Oil leakage 3 1 2 2 2 Symptoms Hard to shift or will not shift 1 2 3 3 Jumps out of gear 1 3 3 Revision October 2008 49 2009 Versa DESCRIPTION lt SERVICE INFORMATION gt RS6F94R DESCRIPTION Cross Sectional View INFOID 0000000004305270 JPDICO631ZZ 1 3rd input gear 2 3rd 4th synchronizer assembly 3 4th input gear 4 input gear 5 bth 6th synchronizer assembly 6 6th input gear 7 Transaxle case 8 6th
66. uce 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 Man ual 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 har ness connectors e When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni tion 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 deplo
67. y 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 Revision October 2008 MT 3 2009 Versa PREPARATION SERVICE INFORMATION RSSF91R PREPARATION Special Service Tools INFOID 0000000004784217 The actual shapes of tools may differ from those of special service tools illustrated here Tool number Kent Moore No Description Tool name 5727862000 Installing differential side seal 62 5 mm 2 461 in dia Drift S b 49 mm 1 93 in dia ZZA0194D KV32300QAC Removing 5th main gear Puller AC SCIA1781J KV32300QAD Removing 5th main gear s g Puller SCIA1782J ST35300000 e Removing and installing input shaft rear bearing Drift e Removing and installing mainshaft rear bearing a 45 mm 1 77 in dia b 59 mm 2 23 in dia b ZZA0969D KV111011S0 Removing mainshaft front bearing Cs 0 Valve seat remover ZZA0872D 51733400001 Installing mainshaft front bearing J 26082 a 60 mm 2 36 in dia Drift a 47 mm 1 85 in dia ZZA0814D Revision October 2008 MT 4 2009 Versa PREPARATION SERVICE INFORMATION RSSF91R Tool number Kent Moore No Description Tool name KV40100900 Installing input shaft front bearing a 52 mm 2 05 in dia Dri

MT - 4 8 15 16 23 42

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