Nissan 2011 Versa Owners Manual SM1E 1C11U0(MT)

: Nissan Nissan-2011-Nissan-Versa-Owners-Manual-818457 nissan-2011-nissan-versa-owners-manual-818457 nissan pdf

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TRANSMISSION/TRANSAXLE

SECTION

MT

MANUAL TRANSAXLE

A

B

MT

D

E

CONTENTS
RS5F91R

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

SERVICE INFORMATION ............................ 3

TRANSAXLE ASSEMBLY ................................ 17
Exploded View .........................................................17
Removal and Installation .........................................17
Disassembly and Assembly .....................................18

PRECAUTIONS ................................................... 3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................... 3
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect ..................................... 3
Precaution for Procedure without Cowl Top Cover...... 4
Service Notice or Precaution ..................................... 4

PREPARATION ................................................... 5
Special Service Tools .............................................. 5
Commercial Service Tools ....................................... 7

NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 8
NVH Troubleshooting Chart ...................................... 8

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

M/T OIL ...............................................................11
Draining ................................................................... 11
Refilling ................................................................... 11
Inspection ................................................................ 11

MAINSHAFT AND GEAR ................................. 37
Disassembly and Assembly .....................................37
Disassembly and Assembly .....................................41
Inspection ................................................................42

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

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

RS6F94R
SERVICE INFORMATION ........................... 44

K

L

M

PRECAUTIONS ................................................. 44
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" .................................................................44
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect ...................................44
Precaution for Procedure without Cowl Top Cover....45
Precaution ...............................................................45

PREPARATION ................................................. 46
Special Service Tool ................................................46
Commercial Service Tool ........................................48

NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ........................... 51

Exploded View ........................................................ 16
Revision: May 2010

J

SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 43

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

Exploded View ........................................................ 14
Removal and Installation ......................................... 14
Inspection ................................................................ 15

I

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

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

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

H

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

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

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

G

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

DESCRIPTION .................................................... 9
System Diagram ........................................................ 9
System Description ................................................... 9

F

MT-1

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

2011 Versa

N

O

P

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

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

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

Component ............................................................. 61
Removal and Installation ......................................... 61
Disassembly and Assembly .................................... 62

M/T OIL .............................................................. 54
Changing M/T Oil .................................................... 54
Checking M/T Oil .................................................... 54

VEHICLE SPEED SENSOR .............................. 55
Removal and Installation ........................................ 55

SIDE OIL SEAL ................................................. 56
Removal and Installation ........................................ 56

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

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

INPUT SHAFT AND GEARS ............................. 80
Disassembly and Assembly .................................... 80

MAINSHAFT AND GEARS ............................... 85
Disassembly and Assembly .................................... 85

REVERSE IDLER SHAFT AND GEARS ........... 90
Disassembly and Assembly .................................... 90

FINAL DRIVE ..................................................... 92
Disassembly and Assembly .................................... 92

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

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

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

SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 95

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

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

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

Revision: May 2010

MT-2

2011 Versa

PRECAUTIONS
[RS5F91R]

< SERVICE INFORMATION >

SERVICE INFORMATION

A

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

B

INFOID:0000000005929653

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along MT
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
D
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Manual.
WARNING:
E
• 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.
F
• 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 G
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.
H
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.

I

J

Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000005929654

NOTE:
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYSTEM).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mechanism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.

K

L

M

N

O

OPERATION PROCEDURE
1.
2.
3.
4.

Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
Perform the necessary repair operation.

Revision: May 2010

MT-3

2011 Versa

P

PRECAUTIONS
[RS5F91R]
< SERVICE INFORMATION >
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-III.

Precaution for Procedure without Cowl Top Cover

INFOID:0000000005929655

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

PIIB3706J

Service Notice or Precaution

INFOID:0000000005929656

•
•
•
•
•

Use recommended brake fluid when adding fluid to the clutch reservoir tank. Refer to MA-14.
Never reuse fluid drained from clutch system.
Be careful not to splash brake fluid on painted areas.
Use new brake fluid to clean or wash all parts of master cylinder and operating cylinder.
Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic system.
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric slave cylinder).
Return CSC to original position to remove transaxle assembly. Dust on clutch disc sliding parts may
damage CSC seal and may cause clutch fluid leakage.
• Do not disassemble clutch master cylinder and CSC.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not use compressed air.

Revision: May 2010

MT-4

2011 Versa

PREPARATION
[RS5F91R]

< SERVICE INFORMATION >

PREPARATION

A

Special Service Tools

INFOID:0000000005929657

The actual shapes of tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name

B

Description

—
( J-46534 )
Trim tool set

MT

For removing trim

D

E
AWJIA0483ZZ

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

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

JPDIC0730ZZ

KV32300QAC
( — )
Puller

F

G

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

H

I

Removing 5th main gear

J

K
SCIA1781J

KV32300QAD
( — )
Puller

L

Removing 5th main gear

M

N

SCIA1782J

ST35300000
( — )
Drift

• Removing and installing input shaft rear
bearing
• Removing and installing mainshaft rear
bearing
a: 45 mm (1.77 in) dia.
b: 59 mm (2.23 in) dia.

O

P
ZZA0969D

Revision: May 2010

MT-5

2011 Versa

PREPARATION
[RS5F91R]

< SERVICE INFORMATION >
Tool number
(Kent-Moore No.)
Tool name

Description

KV111011S0
( — )
Valve seat remover

Removing mainshaft front bearing

ZZA0872D

ST33400001
(J-26082)
Drift

Installing mainshaft front bearing
a: 60 mm (2.36 in) dia.
a: 47 mm (1.85 in) dia.

ZZA0814D

KV40100900
( — )
Drift

Installing input shaft front bearing
a: 52 mm (2.05 in) dia.
a: 39.5 mm (1.55 in) dia.

NT084

KV32300QAE
( — )
Drift

Installing differential side bearing outer race
a: 65 mm (2.56 in) dia.
a: 63 mm (2.48 in) dia.

SCIA1783J

ST33052000
( — )
Drift

Removing differential side bearing
a: 22 mm (0.87 in) dia.
a: 28 mm (1.10 in) dia.

ZZA0969D

KV40104920
( — )
Drift

Installing differential side bearing
a: 21.7 mm (0.85 in) dia.
a: 44.7 mm (1.76 in) dia.

ZZA0969D

Revision: May 2010

MT-6

2011 Versa

PREPARATION
[RS5F91R]

< SERVICE INFORMATION >

Commercial Service Tools

INFOID:0000000005929658

A

Tool name

Description

Drift

Removing input shaft front bearing
a: 38 mm (1.50 in) dia.

B

MT

D

S-NT063

Drift

Installing bushing
a: 14.5 mm (0.571 in) dia.

E

F
S-NT063

Socket

Removing and installing drain plug
a: 8 mm (0.31 in)
b: 5 mm (0.20 in)

G

H
PCIB1776E

Puller

• Removing 5th-reverse synchronizer hub
• Removing differential side bearing

I

J

K
NT077

Bearing remover

Removing bushing

L

M
S-NT134

N

O

P

Revision: May 2010

MT-7

2011 Versa

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[RS5F91R]

< SERVICE INFORMATION >

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

INFOID:0000000005929659

3

1

Hard to shift or will not shift

1

1

Jumps out of gear

Revision: May 2010

2

2

MT-18
BEARING (Worn or damaged)

MT-18
SHIFT FORK (Worn)

GEAR (Worn or damaged)

MT-14
SHIFT CONTROL LINKAGE (Worn)

3

3

3

2
2
1

MT-8

3

INSERT SPRING (Damaged)

Oil leakage

GASKET (Damaged)

2

OIL (Oil level is high.)

1

BAULK RING (Worn or damaged)

Symptoms

OIL (Wrong oil.)

Noise

OIL (Oil level is low.)

SUSPECTED PARTS
(Possible cause)

O-RING (Worn or damaged)

MT-18

Reference page

OIL SEAL (Worn or damaged)

MT-18

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

2

2

2011 Versa

DESCRIPTION
[RS5F91R]

< SERVICE INFORMATION >

DESCRIPTION

A

System Diagram

INFOID:0000000005929660

CROSS-SECTIONAL VIEW

B

MT

D

E

F

G

H

I

J

K

L

M

JPDIC0580ZZ

1.

Clutch housing

2.

1st-2nd synchronizer hub assembly

3.

4.

5th input gear

5.

5th-reverse synchronizer hub assembly 6.

5th-reverse baulk ring

7.

5th main gear

8.

4th main gear

3rd main gear

9.

3rd-4th synchronizer hub assembly

10. 2nd main gear

11. 2nd double cone synchronizer

12. 1st double cone synchronizer

13. 1st main gear

14. Differential side bearing

15. Differential

16.

17. Mainshaft

18. Input shaft

Final gear

System Description

O

P

INFOID:0000000005929661

DOUBLE-CONE SYNCHRONIZER

Revision: May 2010

MT-9

N

2011 Versa

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

[RS5F91R]

SCIA7117E

REVERSE GEAR NOISE PREVENTION FUNCTION (SYNCHRONIZING METHOD)
Description
Soon after the clutch is disengaged, the input shaft is still rotating due to inertia. This may cause a gear noise
when the gear is shifted to reverse position. The reverse gear noise prevention function stops the rotation of
the input shaft and enables smooth gear shifting when the reverse gear is selected.
Operation Principle
1. When the gear is shifted to reverse position, 5th-reverse coupling sleeve (1) slides in the reverse direction( )
5: 5th input gear
2. Synchronizer levers (2) with support point (A) at 5th-reverse
synchronizer hub (3) presses 5th-reverse baulk ring (4).( )
3. Friction that is generated at 5-reverse baulk ring presses synchronizer lever on 5th-reverse coupling sleeve. ( )
4. 5th-reverse coupling sleeve that is presses by synchronizer
lever stops the rotation of input shaft.
JPDIC0415ZZ

Revision: May 2010

MT-10

2011 Versa

M/T OIL
[RS5F91R]

< SERVICE INFORMATION >

M/T OIL

A

Draining
1.
2.
3.

INFOID:0000000005929662

Start engine and let it run to warm up transaxle.
Stop engine. Remove drain plug (1) and drain oil.
Set a new gasket on drain plug (1) and install it to transaxle and
tighten drain plug to the specified torque. Refer to MT-18, "Disassembly and Assembly".
CAUTION:
Do not reuse gasket.

B

MT

D

E
PCIB1504E

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

2.
3.

INFOID:0000000005929663

G

: Refer to MA-14, "Fluids and
Lubricants".

After refilling oil, check oil level.
Set a new gasket on filler plug (1), then install it to transaxle and
tighten to the specified torque. Refer to MT-18, "Disassembly
and Assembly".
CAUTION:
Do not reuse gasket.

Inspection

F

H

I
SCIA7119E

J
INFOID:0000000005929664

LEAKAGE

K

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

LEVEL
1.

2.

3.

L

Remove filler plug (1) and check oil level at filler plug hole as
shown.
CAUTION:
Do not start engine while checking oil level.
Set a new gasket on filler plug (1) and install it to the transaxle
case.
CAUTION:
Do not reuse gasket.
Tighten filler plug to the specified torque. Refer to MT-18, "Disassembly and Assembly".

M

N

SCIA7119E

O

P

Revision: May 2010

MT-11

2011 Versa

SIDE OIL SEAL
[RS5F91R]

< SERVICE INFORMATION >

SIDE OIL SEAL
Removal and Installation

INFOID:0000000005929665

REMOVAL
1.
2.

Remove front drive shafts from transaxle assembly. Refer to FAX-9, "Removal and Installation (Left Side)"
and FAX-10, "Removal and Installation (Right Side)".
Remove differential side oil seal (1) using suitable tool.
CAUTION:
Do not damage transaxle case or clutch housing.

PCIB1505E

INSTALLATION
Installation is in the reverse order of removal.
Tool number

KV32500QAA ( – ) B.vi 1666-B

Dimension
L1 : 5.7 – 6.3 mm (0.224 – 0.248 in)
L2 : 2.4 – 3.0 mm (0.094 – 0.118 in)
• B: Transaxle case side
• C: Clutch housing side
CAUTION:
• Do not reuse differential side oil seal
• Never incline differential side oil seal.
• Never damage clutch housing and transaxle case.

Revision: May 2010

MT-12

JPDIC0401ZZ

2011 Versa

POSITION SWITCH
[RS5F91R]

< SERVICE INFORMATION >

POSITION SWITCH

A

Checking

INFOID:0000000005929666

NOTE:
For removal and installation of the switches, refer to MT-18, "Disassembly and Assembly"

B

BACK-UP LAMP SWITCH
• Check continuity between terminals 1 and 2.
Gear position

MT
Continuity

Reverse

Yes

Except reverse

No

D

E

MCIA0157E

F

PARK/NEUTRAL POSITION SWITCH
• Check continuity between terminals 2 and 3.
Gear position

G
Continuity

Neutral

Yes

Except neutral

No

H

I

JPDIC0092ZZ

J

K

L

M

N

O

P

Revision: May 2010

MT-13

2011 Versa

CONTROL LINKAGE
[RS5F91R]

< SERVICE INFORMATION >

CONTROL LINKAGE
Exploded View

INFOID:0000000005929667

PCIB1508E

1.

Shift selector handle

2.

Shift selector lever

3.

M/T shift selector assembly

6.

Clutch housing

4.

Select cable

5.

Shift selector cable

7.

Cable mounting bracket

8.

Bracket

A:

Black color

B:

White color

Removal and Installation

INFOID:0000000005929668

REMOVAL
1.
2.
3.

Remove the battery. Refer to SC-7, "Removal and Installation".
Remove the air duct and air cleaner case. Refer to EM-25, "Removal and Installation" .
Press the release button (1) of select cable and shift selector
cable, and then remove select cable and shift selector cable
from select lever of control shaft (2).
4. Move shift selector to neutral position.
5. Remove shift selector handle.
6. Remove center console assembly. Refer to IP-12, "Removal and
Installation".
7. Remove M/T shift selector assembly bolts.
8. Remove exhaust front tube, center muffler and heat plate. Refer
to EX-5, "Removal and Installation".
9. Remove cable support bracket.
10. Remove select cable and shift selector cable from cable mounting bracket.
11. Remove M/T shift selector assembly from the vehicle.

SCIA7077E

INSTALLATION
Installation is in the reverse order of removal.
Revision: May 2010

MT-14

2011 Versa

CONTROL LINKAGE
[RS5F91R]
< SERVICE INFORMATION >
• Move the shift selector to the neutral position.
• Securely assemble each of the cables to each select lever of control shaft, mounting bracket, and the M/T
shift selector assembly.
• Be careful about the installation direction, and push shift selector
handle onto shift selector.
CAUTION:
Do not reuse shift selector handle.

A

B

MT

D
PCIB1509E

E

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

F

G

H
PCIB1510E

Inspection

INFOID:0000000005929669

Inspect the following items:
• When shift selector is moved to 1st-2nd side and 5th-reverse side, confirm shift selector returns to neutral
position smoothly.
• When the shift selector is shifted to each position, make sure there is no binding or disconnection in each
boot.

I

J

K

L

M

N

O

P

Revision: May 2010

MT-15

2011 Versa

AIR BREATHER HOSE
[RS5F91R]

< SERVICE INFORMATION >

AIR BREATHER HOSE
Exploded View

INFOID:0000000005929670

PCIB1511E

1.

Air cleaner case

2.

Air breather hose

3.

Air duct

4.

Clip

5.

Transaxle assembly

6.

Two way connector

Removal and Installation

INFOID:0000000005929671

REMOVAL
1.
2.
3.

Remove the battery. Refer to SC-7, "Removal and Installation".
Remove the air duct and air cleaner case. Refer to EM-16, "Removal and Installation".
Remove air breather hose.
CAUTION:
When air breather hose is removed, be sure to hold two way connector securely.

INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Make sure air breather hose is not collapsed or blocked due to folding or bending when installed.
• When installing air breather hose on two way connector, aim paint mark toward the vehicle rear.
• When installing air breather hose on two way connector, push it until it hits the transaxle case.
• When installing air breather hose to air duct and air cleaner case, make sure that clips are fully inserted.

Revision: May 2010

MT-16

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

A

Exploded View

INFOID:0000000005929672

B

MT

D

E

F

G

H

I

J
PCIB1514E

1.

LH engine mount bracket (transaxle
side)

2.

Transaxle assembly

4.

Washer

5.

Rear torque rod

3.

Rear engine mount bracket
Front

L

: Refer to installation.

Removal and Installation

INFOID:0000000005929673

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

REMOVAL
1.
2.
3.
4.

Drain clutch fluid and remove clutch tube from CSC. Refer to CL-13, "Removal and Installation".
CAUTION:
Do not depress clutch pedal during removal procedure.
Remove the engine and transaxle as an assembly from the vehicle. Refer to EM-82, "Removal and Installation".
Remove the transaxle to engine and engine to transaxle bolts.
Separate the transaxle assembly from the engine.

INSTALLATION
Installation is in the reverse order of removal.
Revision: May 2010

K

MT-17

2011 Versa

M

N

O

P

TRANSAXLE ASSEMBLY
[RS5F91R]
< SERVICE INFORMATION >
CAUTION:
• Make sure the transaxle assembly does not interfere with the wire harnesses and clutch tube.
• When installing transaxle assembly, do not bring input shaft into contact with clutch cover.
• If transaxle is removed from the vehicle, always replace CSC. Refer to CL-13, "Removal and Installation".
• When installing the transaxle assembly to the engine, install the
bolts according to the following:
(A): Transaxle to engine
(B): Engine to transaxle
Bolt No.

1

2

3

4

Quantity

2

2

1

3

55
(2.17)

49
(1.93)

69
(2.72)

55
(2.17)

Bolt length “ ”
mm (in)
Tightening torque
N·m (kg-m, ft-lb)

•
-

48.0
(4.9, 35)

PCIB1517E

After installation perform the following:
Bleed the air from the clutch hydraulic system. Refer to CL-9, "Air Bleeding Procedure".
Check for oil leakage and oil level. Refer to MT-11, "Inspection".
Check the control linkage. Refer to MT-15, "Inspection".

Disassembly and Assembly

INFOID:0000000005929674

COMPONENTS
Case and Housing Component

Revision: May 2010

MT-18

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >

A

B

MT

D

E

F

G

H

I

J

K

L
AWDIA0791GB

M

1.

Differential side oil seal

2.

Clutch housing

3.

Dowel pin

4.

Magnet

5.

Drain plug

6.

Gasket

7.

Oil channel

8.

Plug (with ABS models)

9.

Vehicle speed sensor (w/o ABS models)

10. Two way connector

11. Oil gutter

12. Air breather inner tube

13. Filler plug

14. Transaxle case

15. O-ring

16. Rear housing

17. Position switch

N

Replace parts as a set

O
Gear Component
P

Revision: May 2010

MT-19

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >

JPDIC0480GB

1.

Input shaft front bearing

2.

Input shaft

3.

Snap ring

4.

Input shaft rear bearing

5.

Adapter plate

6.

Bushing

7.

5th input gear

8.

5th-reverse baulk ring

9.

Synchronizer lever

10. 5th-reverse synchronizer hub
13. Reverse gear assembly

11. 5th-reverse coupling sleeve

12. Retaining pin

Replace parts as a set

JPDIC0531GB

Revision: May 2010

MT-20

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >
1.

Mainshaft front bearing

2.

Mainshaft

3.

1st main gear

4.

1st inner baulk ring

5.

1st synchronizer cone

6.

1st outer baulk ring

7.

1st-2nd synchronizer hub

8.

1st-2nd coupling sleeve

9.

Spring

A

10. Insert key

11. 2nd outer baulk ring

12. 2nd synchronizer cone

13. 2nd inner baulk ring

14. Snap ring

15. Thrust washer

16. 2nd main gear

17. 3rd main gear

18. 3rd baulk ring

19. 3rd-4th synchronizer hub

20. 3rd-4th coupling sleeve

21. 4th baulk ring

22. 4th main gear

23. Spacer

24. Mainshaft rear bearing

25. 5th main gear

B

MT

Replace parts as a set

D

Shift Control Component

E

F

G

H

I

J

K

L

JPDIC0485GB

1.

Retaining pin

4.

1st-2nd fork rod

7.

5th-reverse shift fork

2.

1st-2nd shift fork

3.

Bushing

5.

Lock pin

6.

5th-reverse fork rod

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

N

O

Replace parts as a set

Final Drive Component

Revision: May 2010

M

P

MT-21

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >

JPDIC0602ZZ

1.
4.

Differential side bearing outer race

2.

Differential side bearing

3.

Speedometer drive gear

Pinion gear

5.

Pinion shaft

6.

Final drive assembly

Replace parts as a set

DISASSEMBLY
1.
2.
3.

Remove drain plug and gasket from clutch housing using a suitable tool and drain gear oil.
Remove filler plug and gasket from transaxle case.
Remove rear housing and O-ring.
CAUTION:
Remove to axial direction of input shaft ( ) because rear
housing oil channel is inserted to input shaft center hole.

SCIA1709J

4.

Shift control shaft shift lever (1) to the 3rd gear position.
NOTE:
• If it is not shifted to the 3rd gear position, transaxle case cannot be removed from clutch housing.
• The 3rd gear position means that control shaft select lever is
fully rotated clockwise and it is returned approximately 10
degrees.

PCIB1524E

Revision: May 2010

MT-22

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]
< SERVICE INFORMATION >
5. Remove 5th-reverse shift fork (1) and 5th-reverse coupling
sleeve according to the following procedures.
A
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
B
3rd gear.
c. Remove bolt (B).
MT
d. Remove nut (C) and washer.
CAUTION:
Never use an impact wrench for removal, or otherwise each
JPDIC0532ZZ
gear may be damaged.
D
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.
E
CAUTION:
Set claw of the puller to the wider side of the hub when setting the puller in 5th-reverse synchronizer hub.
F
7. Remove synchronizer levers, 5th-reverse baulk ring, 5th input
gear, bushing, and adapter plate from input shaft.
G
PCIB1526E

8.

H

Remove 5th main gear from mainshaft using the pullers.
Tool number

A: KV32300QAC (
B: KV32300QAD (

—
—

)
)

I

J

K
PCIB1527E

9.

Remove position switch from transaxle case.

L

M

N
PCIB1627E

O

P

Revision: May 2010

MT-23

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >
10. Remove transaxle case bolts ( ).
11. Remove transaxle case from clutch housing.

JPDIC0610ZZ

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

PCIB1529E

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

Pull 5th-reverse fork rod up until it contacts claw ( ) of reverse
gear assembly (2).
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 procedures.
a. Remove 4th baulk ring, insert keys, and springs from mainshaft.
b. Pull gear of reverse gear assembly (4) up.
c. Pull 1st-2nd fork rod (5) up, and then maintain the neutral position.
d. Remove 3rd-4th fork rod assembly, 3rd-4th coupling sleeve, and
input shaft assembly from clutch housing at the same time.
15. Remove retaining pin from 3rd-4th shift fork using a suitable tool.
16. Remove 3rd-4th shift fork from 3rd-4th shift fork rod.
17. Remove lock pins (

PCIB1531E

) from clutch housing.

JPDIC0534ZZ

Revision: May 2010

MT-24

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >
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.

A

B

MT

PCIB1532E

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

D

E

F

G
MCIB0033E

23.
24.
25.
26.
27.

Remove final drive assembly (1) from clutch housing.
Remove plug from the clutch housing (with ABS models).
Remove the vehicle speed sensor (without ABS models).
Remove pinion shaft and pinion gear from clutch housing.
Remove magnet and dowel pins (2) from clutch housing.

H

I

J

PCIB1533E

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

K

L

M

N
MCIB0044E

O

29. Cut oil channel tube at the root.
30. Remove mainshaft front bearing and oil channel from clutch
housing using Tool (A).
Tool number

A: KV111011S0 (

—

P

)

PCIB1536E

Revision: May 2010

MT-25

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >
31. Remove bushings (1) from clutch housing using a suitable tool.

PCIB1537E

32. Remove differential side oil seals (1) from clutch housing and
transaxle case using a suitable tool.
CAUTION:
Never damage transaxle case and clutch housing.

PCIB1534E

33. Remove differential side bearing outer races (1) from clutch
housing and transaxle case using a suitable tool.
CAUTION:
Never damage transaxle case and clutch housing.

JPDIC0484ZZ

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

PCIB1541E

36. Remove bushings (1) from transaxle case using a suitable tool.
37. Remove retaining pin ( ) from selector using a suitable tool.
38. Remove selector from control shaft.
39. Remove oil gutter from transaxle case.

PCIB1538E

Revision: May 2010

MT-26

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >
40. Remove bolt ( ), and then remove bushing, spring, and gear
catch from transaxle case.
41. Remove check ball plug from transaxle case.

A

B

MT

JPDIC0533ZZ

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

D

E

F

G
PCIB1540E

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

A: ST35300000 (

—

H

)

I

45. Remove snap rings from transaxle case.
46. Remove check balls (2) from transaxle case.

J

PCIB1535E

K

ASSEMBLY
1.

L

Install snap rings (1) along transaxle case groove so that notch
mates with housing as shown.
CAUTION:
Check snap ring installing direction. Never misassemble.

M

N

PCIB1547E

O

P

Revision: May 2010

MT-27

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
2. Expand snap rings (1) and install input shaft rear bearing and
mainshaft rear bearing to transaxle case using Tool (A).
Tool number

3.

A: ST35300000 (

—

[RS5F91R]

)

CAUTION:
Check that snap ring is correctly installed within bearing
groove.
Install check balls (2) to transaxle case.
PCIB1548E

4.
5.

Install bushings (1) until they reach transaxle case using a suitable tool (A).
Apply gear oil to O-ring, and then install it to control shaft.

JPDIC0636ZZ

6.

Install control shaft (1) to transaxle case, and tighten bolts (
to the specified torque. Refer to MT-17, "Exploded View".
CAUTION:
Replace control shaft and selector as a set.

)

PCIB1540E

7.

Install selector to control shaft, and then install retaining pin (
to selector using a suitable tool.
CAUTION:
• Be careful with the orientation of selector.
• Replace control shaft and selector as a set.
• Never reuse retaining pin.

)

SCIA1726J

8.

9.

Install gear catch, spring, and bushing to transaxle case, and
then tighten bolt ( ) to the specified torque. Refer to MT-17,
"Exploded View".
CAUTION:
Replace gear catch, spring, and bushing as a set.
Install oil gutter to transaxle case.

JPDIC0533ZZ

Revision: May 2010

MT-28

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >
10. Install air breather inner tube (2) to transaxle case.
CAUTION:
Never damage air breather inner tube.
NOTE:
It is easier to install when air breather inner tube end is wrapped
and narrowed by tape. Remove tape after installation.
11. Insert two way connector (1) straight, and then install it to air
breather inner tube.
CAUTION:
Check air breather inner tube for twists after installing.

A

B

MT

PCIB1541E

D

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

E

KV32500QAA ( – ) B.vi 1666-B

Dimension
L1 : 5.7 – 6.3 mm (0.224 – 0.248 in)
L2 : 2.4 – 3.0 mm (0.094 – 0.118 in)

F

• B: Transaxle case side
• C: Clutch housing side
CAUTION:
• Never incline differential side oil seal.
• Never damage clutch housing and transaxle case.

G
JPDIC0401ZZ

H

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

A: KV32300QAE (

—

I

)

J

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

K

PCIB1549E

14. Install bushings (1) until they reach clutch housing using a suitable tool (A).
15. Install oil channel to clutch housing.
CAUTION:
Never reuse oil channel.

L

M

N

O
JPDIC0637ZZ

P

Revision: May 2010

MT-29

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
16. Install mainshaft front bearing so that it becomes even to clutch
housing surface using Tool (A).
Tool number

[RS5F91R]

A: ST33400001 (J-26082)

PCIB1544E

17. Install input shaft front bearing so that it becomes even to clutch
housing surface using Tool (A).
Tool number

A: KV40100900 (

—

)

18. Install pinion gear and pinion shaft to clutch housing.

PCIB1545E

19. Install plug to clutch housing (with ABS models).
20. Install vehicle speed sensor to clutch housing (without ABS models).
NOTE:
Apply specific M/T fluid to the vehicle speed sensor O-ring prior to installation.
21. Install final drive assembly (1) to clutch housing.
22. Install dowel pins (2) and magnet to clutch housing.

PCIB1533E

23. Install reverse gear assembly to clutch housing, and then install
retaining pin to clutch housing using a suitable tool.
CAUTION:
Never reuse retaining pin.
24. 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

Revision: May 2010

MT-30

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
25. Set 1st-2nd fork rod assembly (1) onto mainshaft assembly (2),
and then install them to clutch housing.

[RS5F91R]
A

B

MT
PCIB1532E

D

26. Install lock pins ( ) to clutch housing.
27. 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.

E

F

G
JPDIC0534ZZ

28. 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 position.
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:
• Set lock pin (3rd-4th fork rod side) onto 1st-2nd fork rod
groove and then install 3rd-4th fork rod assembly.

H

I

J

PCIB1628E

•
•

Be careful with the orientation of 3rd-4th coupling sleeve.
A: 4th main gear side
B: 3rd main gear side
Install 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.

K

L

M

N
PCIB1551E

c.
d.
e.

O

Install springs and insert keys to 3rd-4th synchronizer hub.
Apply gear oil to 4th baulk ring.
Install 4th baulk ring.

P

MCIB0061E

Revision: May 2010

MT-31

2011 Versa

TRANSAXLE ASSEMBLY
[RS5F91R]

< SERVICE INFORMATION >
29. 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

c.

Press gear of reverse gear assembly (1) down and then install
5th-reverse fork rod (2) to clutch housing.
CAUTION:
Set levers of 5th-reverse fork rod so as to align with reverse
gear assembly groove ( ).

PCIB1552E

30. Install 4th main gear (2) and spacer (1) to mainshaft.
CAUTION:
Install spacer so that spacer protrusion faces to transaxle
rear side.
31. Press 3rd-4th shift fork down and then shift 3rd-4th coupling
sleeve to 3rd gear side.

PCIB1529E

32. Shift control shaft shift lever (1) to the 3rd gear position.
NOTE:
• If it is not shifted to the 3rd gear position, transaxle case cannot be installed to clutch housing.
• The 3rd gear position means that control shaft select lever is
fully rotated clockwise and it is returned approximately 10
degrees.
33. Apply recommended sealant to transaxle case mounting surface
of clutch housing.
• Use Genuine Silicone RTV or an equivalent. GI-42, "Recommended Chemical Product and Sealant".
PCIB1524E
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.

Revision: May 2010

MT-32

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
34. Install transaxle case to clutch housing. If it is difficult to install,
slightly rotate control shaft shift lever counterclockwise, and then
install.
• 1: Selector
• 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.

[RS5F91R]
A

B

MT
PCIB1553E

D

35. Rotate input shaft so that bearing and shaft fit each other, and
then tighten transaxle bolts ( ) to the specified torque. Refer to
MT-17, "Exploded View".

E

F

G
JPDIC0610ZZ

36. Apply recommended sealant to the position switch thread and check ball plug thread. tighten them to transaxle case to specified torque.
• Use Genuine Silicon RTV or an equivalent. Refer to GI-42, "Recommended Chemical Product and
Sealant".
CAUTION:
Never allow old liquid gasket, moisture, oil, or foreign matter to remain on thread.
37. Apply gear oil to mainshaft spline.
38. Install 5th main gear (1) to mainshaft using a suitable bolt (A)
[M10 x 1.0] and a suitable nut (B).

H

I

J

K

L

M
PCIB1554E

39. Install adapter plate (1), bushing (2), and 5th input gear (3) to
input shaft.
CAUTION:
Be careful with the orientation of adapter plate.
•
: Transaxle case side

N

O

P

PCIB1555E

40. Install 5th-reverse synchronizer hub, 5th-reverse coupling sleeve, and 5th-reverse shift fork according to
the following procedures.
a. Apply gear oil to 5th-reverse baulk ring.
Revision: May 2010

MT-33

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
b. Install 5th-reverse baulk ring (1) to 5th input gear.
CAUTION:
Be careful with the orientation of 5th-reverse baulk ring.
c. 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.
•
: 5th-reverse synchronizer hub side
d. Install 5th-reverse synchronizer hub assembly and washer to
input shaft.
CAUTION:
• Be careful with the orientation of 5th-reverse synchronizer hub.
: 5th input gear side

[RS5F91R]

JPDIC0421ZZ

PCIB1556E

• Never allow synchronizer lever (1) to mount on to 5threverse baulk ring (2) protrusion (A).
•
: 5th-reverse sychronizer hub

JPDIC0408ZZ

e.

Set 5th-reverse shift fork (1) to 5th-reverse coupling sleeve, and
then install them to 5th-reverse fork rod and input shaft.
• A: Pin punch
• B: Bolt
• C: Nut

JPDIC0532ZZ

CAUTION:

Revision: May 2010

MT-34

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
• 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 5threverse shift fork and shift to 5th gear.
g. Tighten bolt to the specified torque. Refer to MT-17, "Exploded
View".
h. Tighten nut to the specified torque. Refer to MT-17, "Exploded View".
CAUTION:
Never reuse nut.
i. Install retaining pin to 5th-reverse shift fork using a suitable tool.
CAUTION:
Never reuse retaining pin.
41. Shift control shaft shift lever (1) to the neutral position.
42. Install O-ring to rear housing.

[RS5F91R]
A

B

MT
JPDIC0409ZZ

D

E

F

G

H

SCIA7130E

43. Install rear housing to transaxle case, and tighten bolts ( ) to
the specified torque. Refer to MT-17, "Exploded View".
CAUTION:
Never pinch O-ring when installing rear housing.
44. Install drain plug according to the following procedures.
a. Install gasket to drain plug.
CAUTION:
Never reuse gasket.
b. Install drain plug to clutch housing using a suitable tool.
c. Tighten drain plug to the specified torque. Refer to MT-17,
"Exploded View".
45. 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-17, "Exploded View".
CAUTION:
Fill with gear oil before tightening filler plug to the specified torque.

I

J

K

L
PCIB1558E

M

N

O

P

Revision: May 2010

MT-35

2011 Versa

INPUT SHAFT AND GEAR
[RS5F91R]

< SERVICE INFORMATION >

INPUT SHAFT AND GEAR
Disassembly and Assembly

INFOID:0000000005929675

INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
Check the following items and replace if necessary.
• Damage, peeling, bend, uneven wear, and distortion of shaft
• Excessive wear, damage, and peeling of gear

PCIB0987J

Synchronizer
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.

SCIA0608J

Bearing
Check bearing for damage and unsmooth rotation. Replace if necessary.

MTF0041D

Revision: May 2010

MT-36

2011 Versa

MAINSHAFT AND GEAR
[RS5F91R]

< SERVICE INFORMATION >

MAINSHAFT AND GEAR

A

Disassembly and Assembly

INFOID:0000000005929676

GENERAL PRECAUTIONS

B

• Never reuse snap ring.
• 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.

MT

D

E

SCIA1755J

F

DISASSEMBLY
1.
2.

Remove 3rd-4th synchronizer hub and 3rd baulk ring.
Remove snap ring (1) and thrust washer (2) using suitable tools.

G

H

I

J
PCIB1559E

3.

Remove 3rd main gear (1) and thrust washer (2).

K

L

M
PCIB1560E

4.

N

Remove snap ring (1) and thrust washer (2) using suitable tools.
O

P

PCIB1561E

Revision: May 2010

MT-37

2011 Versa

MAINSHAFT AND GEAR
< SERVICE INFORMATION >
5. Remove 2nd main gear (1) and thrust washer (2).

[RS5F91R]

PCIB1562E

6.
7.
8.

Remove snap ring (1), and then remove 2nd inner baulk ring,
2nd synchronizer cone, and 2nd outer baulk ring.
Remove 1st-2nd coupling sleeve, insert keys, springs, and 1st2nd synchronizer hub.
Remove 1st outer baulk ring, 1st synchronizer cone, 1st inner
baulk ring, and 1st main gear (2).

JPDIC0541ZZ

INSPECTION AFTER DISASSEMBLY
Mainshaft and Gear
Check the following items and replace if necessary.
• Damage, peeling, bend, uneven wear, and distortion of shaft
• Excessive wear, damage, and peeling of gear

SCIA1762J

Synchronizer
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: May 2010

MT-38

2011 Versa

MAINSHAFT AND GEAR
< SERVICE INFORMATION >
• Breakage, damage, and excessive wear of baulk ring cam surface
and insert contact surface

[RS5F91R]
A

B

MT
SCIA0608J

D

Bearing
Check bearing for damage and unsmooth rotation. Replace if necessary.

E

F

G
MTF0041D

ASSEMBLY
Note the following items, and assemble in the reverse order of disassembly. Refer to MT-17, "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 baulk ring as a set.
•
•

H

I

J

K

Be careful with the orientation of 1st-2nd synchronizer hub.
A: 1st main gear side
B: 2nd main gear side
Replace 1st-2nd synchronizer hub and 1st-2nd coupling
sleeve as a set.

L

M

N
PCIB1566E

• Be careful with the orientation of 1st-2nd coupling sleeve.
- A: 2nd main gear side
- B: 1st main gear side

O

P

PCIB1567E

Revision: May 2010

MT-39

2011 Versa

MAINSHAFT AND GEAR
< SERVICE INFORMATION >
• Be careful with the orientation of 3rd-4th synchronizer hub.
- A: 4th main gear side
- B: 3rd main gear side

[RS5F91R]

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).

PCIB1564E

Revision: May 2010

MT-40

2011 Versa

FINAL DRIVE
[RS5F91R]

< SERVICE INFORMATION >

FINAL DRIVE

A

Disassembly and Assembly

INFOID:0000000005929677

DISASSEMBLY
1.

B

Remove differential side bearings using Tool (A) and a suitable
tool.
MT

Tool number
2.

A: ST33052000 (

—

)

Remove speedometer drive gear.

D

E
PCIB1568E

INSPECTION AFTER DISASSEMBLY

F

Case
Check differential case and replace if necessary.
G

Bearing
Check bearing for damage and unsmooth rotation. Replace if necessary.
CAUTION:
Replace differential side bearing outer race and differential side
bearing as a set.

H

I

J
SPD715

ASSEMBLY
1.
2.

K

Install speedometer drive gear.
Install differential side bearings using Tool (A).
Tool number

A: KV40104920 (

—

L

)

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

M

N
PCIB1570E

O

P

Revision: May 2010

MT-41

2011 Versa

SHIFT CONTROL
[RS5F91R]

< SERVICE INFORMATION >

SHIFT CONTROL
Inspection

INFOID:0000000005929678

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: May 2010

MT-42

2011 Versa

SERVICE DATA AND SPECIFICATIONS (SDS)
[RS5F91R]

< SERVICE INFORMATION >

SERVICE DATA AND SPECIFICATIONS (SDS)

A

General Specification

INFOID:0000000005929679

TRANSAXLE

B

Transaxle type

RS5F91R

Engine type

HR16DE

Number of speed

MT

5

Synchromesh type

Warner

D

Shift pattern

E

F
SCIA0821E

Gear ratio

Number of teeth

1st

3.7272

2nd

2.0476

3rd

1.3928

4th

1.0294

5th

0.8205

Reverse

3.5454

Final gear

4.0666

Input gear

Main gear

1st

11

2nd

21

3rd

28

4th

34

5th

39

Reverse

11

1st

41

2nd

43

3rd

39

4th

35

5th

32

Reverse

39

Reverse idler gear
Final gear

61/15

Side gear/Pinion
mate gear

13/9

(US pt, Imp pt)

Reverse synchronizer

I

J

K

L

M

N

O

Approx. 2.6 (5-1/2, 4-5/8)
Installed

Double-cone synchronizer

Revision: May 2010

H

26
Final gear/Pinion

Oil capacity (Reference)
Remarks

G

P

1st and 2nd

MT-43

2011 Versa

PRECAUTIONS
[RS6F94R]

< SERVICE INFORMATION >

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

INFOID:0000000005929680

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.

Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000005929681

NOTE:
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYSTEM).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mechanism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.

OPERATION PROCEDURE
1.
2.
3.
4.

Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
Perform the necessary repair operation.

Revision: May 2010

MT-44

2011 Versa

PRECAUTIONS
[RS6F94R]
< SERVICE INFORMATION >
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-III.

Precaution for Procedure without Cowl Top Cover

INFOID:0000000005929682

A

B

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

D

E
PIIB3706J

Precaution

INFOID:0000000005929683

• 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 tightening sequence is specified, follow it.
• Be careful not to damage the sliding surfaces and mating surfaces of parts.

F

G

H

I

J

K

L

M

N

O

P

Revision: May 2010

MT-45

2011 Versa

PREPARATION
[RS6F94R]

< SERVICE INFORMATION >

PREPARATION
Special Service Tool

INFOID:0000000005929684

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

Tool number
(Kent-Moore No.)
Tool name

Description

—
( J-46534 )
Trim tool set

For removing trim

AWJIA0483ZZ

KV381054S0
(J-34286)
Puller

Removing mainshaft front bearing outer race

ZZA0601D

KV38100200
(
—
)
Drift

• Installing mainshaft front bearing outer race
• Installing mainshaft rear bearing outer race
• Installing differential side bearing outer race
(clutch housing side)
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
ZZA1143D

ST33220000
(
—
)
Drift

Installing input shaft oil seal
a: 37 mm (1.46 in) dia.
b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia.

ZZA1046D

ST33400001
(J-26082)
Drift

Installing differential side bearing outer race
(transaxle case side)
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.

ZZA0814D

Revision: May 2010

MT-46

2011 Versa

PREPARATION
[RS6F94R]

< SERVICE INFORMATION >
Tool number
(Kent-Moore No.)
Tool name

Description

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

Installing differential side oil seal
1.
—
(Stamping number: B.vi 1666-A)
Drift
a: 54.3 mm (2.138 in) dia.
b: 45 mm (1.77 in) dia.
c: 26.6 mm (1.047 in) dia.
2.
—
(Stamping number: B.vi 1666-B)
Drift
a: 54.3 mm (2.138 in) dia.
b: 45 mm (1.77 in) dia.
c: 26.6 mm (1.047 in) dia.

JPDIC0730ZZ

ST36720030
(
—
)
Drift

A

• Installing input shaft rear bearing
• Installing mainshaft front bearing inner race
a: 70 mm (2.76 in) dia.
b: 40 mm (1.57 in) dia.
c: 29 mm (1.14 in) dia.

B

MT

D

E

F

G
ZZA0978D

ST33052000
(
—
)
Drift

•
•
•
•
•
•
•
•
•
•
ZZA0969D

KV32102700
(
—
)
Drift

S-NT065

ST30901000
(J-26010-01)
Drift

Removing mainshaft rear bearing inner race
Removing 6th main gear
Removing 5th main gear
Removing 4th main gear
Removing 1st main gear
Removing 1st-2nd synchronizer assembly
Removing 2nd main gear
Removing bushing
Removing 3rd main gear
Removing mainshaft front bearing inner
race
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
• Installing bushing
• Installing 2nd main gear
• Installing 3rd main gear
• Installing 4th main gear
• Installing 5th main gear
• Installing 6th main gear
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.

H

I

J

K

L

M

Installing mainshaft rear bearing inner race
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.

N

O
ZZA0978D

P

Revision: May 2010

MT-47

2011 Versa

PREPARATION
[RS6F94R]

< SERVICE INFORMATION >
Tool number
(Kent-Moore No.)
Tool name

Description

ST33061000
(J-8107-2)
Drift

Removing differential side bearing inner race
(clutch housing side)
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.

ZZA0969D

KV32300QAM
(Renault SST: B.vi 1823)
Drift

Removing and installing input shaft rear bearing bolt

PCIB2078J

Commercial Service Tool

INFOID:0000000005929685

Tool name

Description

Socket

Removing and installing drain plug
a: 8 mm (0.31 in)
b: 5 mm (0.20 in)

PCIB1776E

Spacer

Removing mainshaft front bearing outer race
a: 25 mm (0.98 in) dia.
b: 25 mm (0.98 in)

PCIB1780E

Drift

Installing bushing
a: 17 mm (0.67 in) dia.

S-NT063

Drift

Installing input shaft front bearing
a: 35 mm (1.38 in) dia.
b: 25 mm (0.98 in) dia.

S-NT065

Revision: May 2010

MT-48

2011 Versa

PREPARATION
[RS6F94R]

< SERVICE INFORMATION >
Tool name

Description

Drift

Removing input shaft rear bearing
a: 24 mm (0.94 in) dia.

A

B

MT

PCIB1779E

Drift

• Removing differential side bearing inner
race (transaxle case side)
• Installing input shaft rear bearing
a: 43 mm (1.69 in) dia.

D

E
NT109

Drift

Installing differential side bearing inner race
(clutch housing side)
a: 45 mm (1.77 in) dia.
b: 39 mm (1.54 in) dia.

F

G

H

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.

I

J
S-NT474

Puller

Removing differential side bearing inner race
(clutch housing side)
Removing differential side bearing inner race
(transaxle case side)

K

L
NT077

Puller

ZZB0823D

Revision: May 2010

MT-49

• Removing differential side bearing inner
race (clutch housing side)
• Removing differential side bearing inner
race (transaxle case side)
• Removing input shaft rear bearing
• Removing input shaft front bearing
• Removing mainshaft rear bearing inner race
• Removing 6th main gear
• Removing 4th main gear
• Removing 5th main gear
• Removing 1st main gear
• Removing 1st - 2nd synchronizer hub assembly
• Removing 2nd main gear
• Removing 3rd main gear
• Removing mainshaft front bearing outer
race

2011 Versa

M

N

O

P

PREPARATION
[RS6F94R]

< SERVICE INFORMATION >
Tool name

Description

Remover

• Removing bushing
• Removing mainshaft rear bearing outer
race

S-NT134

Power tool

• Loosening bolts and nuts

PBIC0190E

Revision: May 2010

MT-50

2011 Versa

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
[RS6F94R]

< SERVICE INFORMATION >

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart

A

INFOID:0000000005929686

MT-61

MT-94

MT-58

MT-61

Reference page

MT-61

MT-54

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

B

MT

D

Symptoms

Oil leakage

3

1

Hard to shift or will not shift

1

1

Jumps out of gear

2

2

3

INSERT SPRING (Damaged)

BEARING (Worn or damaged)

3

BAULK RING (Worn or damaged)

GEAR (Worn or damaged)

F

SHIFT FORK (Worn)

SHIFT CONTROL LINKAGE (Worn)

O-RING (Worn or damaged)

2

GASKET (Damaged)

1

OIL (Oil level is high.)

OIL (Wrong oil.)

Noise

OIL (Oil level is low.)

SUSPECTED PARTS
(Possible cause)

OIL SEAL (Worn or damaged)

E

G

H

I

J

2
2
1

3
3

3

3

K

L

M

N

O

P

Revision: May 2010

MT-51

2011 Versa

DESCRIPTION
[RS6F94R]

< SERVICE INFORMATION >

DESCRIPTION
Cross-Sectional View

INFOID:0000000005929687

JPDIC0631ZZ

1.

3rd input gear

2.

3rd-4th synchronizer assembly 3.

4th input gear

4.

5th input gear

5.

5th-6th synchronizer assembly 6.

6th input gear

7.

Transaxle case

8.

6th main gear

5th main gear

9.

10. 4th main gear

11. 3rd main gear

12. 2nd main gear

13. 1st-2nd synchronizer assembly

14. 1st 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: May 2010

MT-52

2011 Versa

DESCRIPTION
< SERVICE INFORMATION >
Triple-cone synchronizer is used for the 1st and the 2nd gears to
reduce operating force of the shift lever.
• 1st main gear (1)
• 1st-2nd coupling sleeve (2)
• Insert key (3)
• Outer baulk ring (4)
• 2nd main gear (5)
• Synchronizer cone (6)
• Inner baulk ring (7)
• 1st-2nd synchronizer hub (8)

[RS6F94R]
A

B

MT
SCIA7636E

D

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)
• Return spring (3)
• Reverse baulk ring (4)
• Reverse input gear (5)

E

F

G
SCIA7621E

H

I

J

K

L

M

N

O

P

Revision: May 2010

MT-53

2011 Versa

M/T OIL
[RS6F94R]

< SERVICE INFORMATION >

M/T OIL
Changing M/T Oil

INFOID:0000000005929688

DRAINING
1.
2.
3.

Start engine and let it run to warm up transaxle.
Stop engine. Remove drain plug (1) and drain oil.
Install a new gasket onto drain plug (1) and install it into transaxle. Tighten drain plug to specification. Refer to MT-61, "Component".
CAUTION:
Do not reuse gasket.

SCIA7622E

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 specification. Refer to MT-61, "Component".
CAUTION:
Do not reuse gasket.

Checking M/T Oil

SCIA7623E

INFOID:0000000005929689

OIL LEAKAGE AND OIL LEVEL
1.
2.

3.

Make sure that oil is not leaking from transaxle or around it.
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 transaxle. Tighten filler plug to specification. Refer to MT-61, "Component".
CAUTION:
Do not reuse gasket.
SCIA7623E

Revision: May 2010

MT-54

2011 Versa

VEHICLE SPEED SENSOR
[RS6F94R]

< SERVICE INFORMATION >

VEHICLE SPEED SENSOR

A

Removal and Installation

INFOID:0000000005929690

REMOVAL
1.
2.

B

Disconnect vehicle speed sensor.
Remove vehicle speed sensor.

MT

INSTALLATION
Installation is in the reverse order of removal.

D

E

F

G

H

I

J

K

L

M

N

O

P

Revision: May 2010

MT-55

2011 Versa

SIDE OIL SEAL
[RS6F94R]

< SERVICE INFORMATION >

SIDE OIL SEAL
Removal and Installation

INFOID:0000000005929691

REMOVAL
1.
2.

Remove front drive shafts from transaxle assembly. Refer to FAX-9, "Removal and Installation (Left Side)"
and FAX-10, "Removal and Installation (Right Side)".
Remove differential side oil seal (1) using a suitable tool.
CAUTION:
Be careful not to damage transaxle case and clutch housing.

SCIA7625E

INSTALLATION
Installation is in the reverse order of removal.
• Install differential side oil seal (1) to clutch housing and transaxle
case using Tool.
CAUTION:
Do not reuse oil seal.
Tool number

: KV32500QAA (B.vi 1666-B)

- A: Transaxle case side
- B: Clutch housing side
Dimension (L1)
Dimension (L2)

: 1.2 - 1.8 mm (0.047 - 0.071 in)
: 2.7 - 3.3 mm (0.106 - 0.130 in)

JPDIC0454ZZ

CAUTION:
• Never reuse differential oil seal
• Never incline differential oil seal.
• Never damage clutch housing and transaxle case.
• Check oil level after installation. Refer to MT-54, "Checking M/T Oil".

Revision: May 2010

MT-56

2011 Versa

POSITION SWITCH
[RS6F94R]

< SERVICE INFORMATION >

POSITION SWITCH

A

Checking

INFOID:0000000005929692

NOTE:
For removal and installation of the switches, refer to MT-62, "Disassembly and Assembly"

B

BACK-UP LAMP SWITCH
• Check continuity between terminals 1 and 2.
Gear position

MT
Continuity

Reverse

Yes

Except reverse

No

D

E

PCIB1781E

F

PARK/NEUTRAL POSITION SWITCH
• Check continuity between terminals 2 and 3.
Gear position

G
Continuity

Neutral

Yes

Except neutral

No

H

I

J

K

L

M

N

O

P

Revision: May 2010

MT-57

2011 Versa

CONTROL LINKAGE
[RS6F94R]

< SERVICE INFORMATION >

CONTROL LINKAGE
Component of Control Device and Cable

INFOID:0000000005929693

WCIA0626E

1.

Shift selector handle

2.

Shift selector

3.

M/T shift selector assembly

4.

Select cable

5.

Shift selector cable

6.

Lock plate

7.

Clutch housing

8.

Cable bracket

9.

Tapping bolt

10. Cable support bracket

11. Adapter plate

Removal and Installation

INFOID:0000000005929694

REMOVAL
1.
2.
3.
4.
a.

Remove battery. Refer to SC-7, "Removal and Installation".
Remove air duct (front), air duct (Inlet) and air cleaner case. Refer to EM-135, "Removal and Installation".
Remove shift selector cable from control shaft shift lever.
Remove select cable according to the following.
Move stopper (1) to the unlocked position.

SCIA7842E

Revision: May 2010

MT-58

2011 Versa

CONTROL LINKAGE
< SERVICE INFORMATION >
b. Pull the release button (1) of select cable (2) and then remove it
from control shaft select lever (3).
5. Move shift selector to neutral position.
6. Remove shift selector handle.
7. Remove center console assembly. Refer to IP-12, "Removal and
Installation".
8. Remove M/T shift selector assembly bolts.
9. Remove exhaust front tube, center muffler and heat plate. Refer
to EX-10, "Removal and Installation".
10. Remove cable support bracket.
11. Remove select cable and shift selector cable from cable bracket.
12. Remove M/T shift selector assembly from the vehicle.

[RS6F94R]
A

B

MT
WCIA0606E

D

INSTALLATION

E

Installation is in the reverse order of removal.
NOTE:
Self tapping bolts are used to attach cables to the clutch housing.
• Securely assemble each cable and lever of control shaft.
• Be careful about the installation direction, and push shift selector
handle onto shift selector.
CAUTION:
Do not reuse shift selector handle.

F

G

H

I
SCIA7630E

J

• Make sure that the front/rear claws (1) of M/T shift selector assembly are in contact with flange of the floor (2).
• When shift selector is selected to 1st-2nd side and 5th-6th side,
confirm shift lever returns to neutral position smoothly.
• When shift selector is shifted to each position, make sure there is
no binding or disconnection in each boot.

K

L

PCIB1510E

• Move stopper (1) to lock position when installing the shift cable
onto the control shaft shift lever.

M

N

O

P

SCIA7846E

Revision: May 2010

MT-59

2011 Versa

AIR BREATHER HOSE
[RS6F94R]

< SERVICE INFORMATION >

AIR BREATHER HOSE
Removal and Installation

INFOID:0000000005929695

COMPONENTS

SCIA7629E

1.

Air cleaner case

2.

Air breather hose

3.

Air duct (inlet)

4.

Clip

5.

Transaxle assembly

6.

Two way connector

REMOVAL
1.
2.
3.

Remove battery. Refer to SC-7, "Removal and Installation".
Remove air duct (front), air duct (inlet) and air cleaner case. Refer to EM-135, "Removal and Installation".
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.
• When installing air breather hose on two way connector, aim paint mark face toward the vehicle front.
• When installing air breather hose on two way connector, push it until it hits transaxle case.
• 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: May 2010

MT-60

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >

TRANSAXLE ASSEMBLY

A

Component

INFOID:0000000005929696

B

MT

D

E

F

G

H

I

J
SCIA7631E

1.

LH engine mount bracket (transaxle side)

2.

Transaxle assembly 3.

Rear engine mount bracket

4.

Washer

5.

Rear torque rod

Front

K

: Refer to MT-61, "Removal and Installation".

L

Removal and Installation

INFOID:0000000005929697

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.

M

N

REMOVAL
1.
2.
3.
4.
5.

Drain clutch fluid and remove clutch tube from CSC. Refer to CL-13, "Removal and Installation".
CAUTION:
Do not depress clutch pedal during removal procedure.
Remove engine and transaxle assembly. Refer to EM-197, "Removal and Installation".
Remove starter motor. Refer to SC-20, "Removal and Installation MR18DE".
Remove transaxle assembly to engine bolts.
Separate transaxle assembly from engine.

INSTALLATION
Installation is in the reverse order of removal.
• If transaxle is removed from the vehicle, always replace CSC. Refer to CL-13, "Removal and Installation" .
Revision: May 2010

MT-61

2011 Versa

O

P

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
• When installing the transaxle assembly to the engine, install the
bolts as shown.
CAUTION:
When installing transaxle assembly, be careful not to bring
transaxle input shaft into contact with clutch cover.
Bolt No.

1

2

Quantity

3

6

60 (2.36)

50 (1.97)

Bolt length “ ” mm (in)
Tightening torque
N·m (kg-m, ft-lb)

62.0 (6.3, 46)

[RS6F94R]

PCIB1786E

A: M/T to engine
B: Engine to M/T
• Bleed the air from the clutch hydraulic system. Refer to CL-9, "Air Bleeding Procedure".
• After installation, check oil level, and check for leaks and loose mechanisms. Refer to MT-54, "Checking M/T
Oil".

Disassembly and Assembly

INFOID:0000000005929698

COMPONENTS
Case and Housing Components

Revision: May 2010

MT-62

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >

A

B

MT

D

E

F

G

H

I

J

K

L
AWDIA0715ZZ

1.

Filler plug

2.

Gasket

3.

Transaxle case

4.

Bushing

5.

Snap ring

6.

Oil channel

7.

Oil gutter

8.

Position switch

9.

Bracket

10. Differential side oil seal

11. Magnet

12. Drain plug

13. Input shaft oil seal

14. Clutch housing

15. Two way connector

16. Plug (With ABS models)

17. Vehicle speed sensor (Without
ABS models)

18. Pinion shaft

19. Pinion gear

M

N

O

Use specified transaxle fluid. Refer to MA-14, "Fluids and Lubricants"

: Apply Genuine Liquid Gasket, Three Bond 1215 or an equivalent.

P

Gear Components

Revision: May 2010

MT-63

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >

JPDIC0407GB

1.

Input shaft front bearing

2.

Input shaft

3.

3rd input gear

4.

Spacer

5.

Snap ring

6.

3rd baulk ring

7.

3rd-4th coupling sleeve

8.

3rd-4th synchronizer hub

9.

Insert key

10. 4th baulk ring

11. 4th input gear

12. 5th input gear

13. 5th baulk ring

14. 5th-6th coupling sleeve

15. 5th-6th synchronizer hub

16. 6th baulk ring

17. Needle bearing

18. 6th input gear

19. Input shaft rear bearing
A:

First step

B:

Final step

: Apply gear oil.
: Replace the parts as a set.

Revision: May 2010

MT-64

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >

A

B

MT

D

E

F

G

H

I

J

K

SFIA3293E

1.

Mainshaft front bearing outer
race

2.

Mainshaft front bearing inner race

3.

Mainshaft

4.

1st main gear

5.

1st inner baulk ring

6.

1st synchronizer cone

7.

1st outer baulk ring

8.

1st-2nd coupling sleeve

9.

Insert key

L

10. 1st-2nd synchronizer hub

11. 2nd outer baulk ring

12. 2nd synchronizer cone

13. 2nd inner baulk ring

14. 2nd main gear

15. Bushing

M

16. 3rd main gear

17. Mainshaft adjusting shim

18. 4th main gear

19. 5th main gear

20. 6th main gear

21. Mainshaft rear bearing inner
race

22. Mainshaft rear bearing outer
race

23. Snap ring

24. Mainshaft rear bearing adjusting shim

N

O

: Apply gear oil.
: Replace the parts as a set.

Revision: May 2010

P

MT-65

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >

JPDIC0425GB

1.

Reverse output gear

2.

Snap ring

3.

Reverse baulk ring

4.

Return spring

5.

Needle bearing

6.

Seal washer

7.

Reverse idler shaft

8.

Spacer

9.

Reverse input gear

10. Lock washer

11. Spring washer

: Replace the parts as a set.

Shift Control Components

Revision: May 2010

MT-66

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >

A

B

MT

D

E

F

G

H

I
AWDIA0716ZZ

1.

Shifter lever A

2.

Shifter lever B

3.

Retaining pin

4.

Selector

5.

Selector lever

6.

Reverse fork rod

7.

1st-2nd fork rod

8.

Fork rod

J

: Replace the parts as a set.

K

Final Drive Components
L

M

N

O

P

Revision: May 2010

MT-67

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >

JPDIC0604GB

1.

Shim

2.

Differential side bearing outer
race (transaxle case side)

3.

Differential side bearing inner race
(transaxle case side)

4.

Final gear

5.

Differential case

6.

Speedometer drive gear

7.

Differential side bearing inner
race (clutch housing side)

8.

Differential side bearing outer
race (clutch housing side)

: Replace the parts as a set.

DISASSEMBLY
1.
2.
3.
4.

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

PCIB1693E

Revision: May 2010

MT-68

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >
5.

Remove transaxle case bolts (

).

A

B

MT
PCIB1694E

D

6.

Remove reverse idler shaft bolt (

) and seal washer.
E

F

G
PCIB1695E

7.

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

H

I

J

JPDIC0444ZZ

8.

K

Remove selector spring (1) from return bushing (A).
L

M

N
JPDIC0445ZZ

O

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.

P

PCIB1698E

Revision: May 2010

MT-69

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >
11. Remove reverse idler shaft assembly (1) according to the following 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.

JPDIC0606ZZ

13. Pull up and remove input shaft assembly (1), mainshaft assembly (2), fork rod (3), and 1st-2nd fork rod (4) from clutch housing.
NOTE:
It is easier to pull up when shifting each fork rod to each shaft
side.

JPDIC0607ZZ

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 housing, using a brass rod.
CAUTION:
Never damage clutch housing.

PCIB1716E

Revision: May 2010

MT-70

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >
18. Remove differential side bearing outer race (1) from transaxle
case, using a brass rod.
CAUTION:
Never damage transaxle case.
19. Remove shim (2) from transaxle case.

A

B

MT

PCIB1705E

20. Remove shifter lever A (1) retaining pin, using a suitable tool.
21. Remove shifter lever A from transaxle case.

D

E

F

G
JPDIC0106ZZ

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

H

I

J

PCIB1712E

K

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

M

N
PCIB1707E

O

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

P

PCIB1710E

Revision: May 2010

MT-71

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

< SERVICE INFORMATION >
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

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

PCIB1708E

28. Remove input shaft oil seal (1) from clutch housing, using a suitable tool.
CAUTION:
Never damage clutch housing.

PCIB1714E

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

: KV381054S0 (J-34286)

JPDIC0107ZZ

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

Revision: May 2010

MT-72

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
31. Remove bushing (1) from clutch housing, using suitable tool.

[RS6F94R]
A

B

MT
PCIB1717E

D

32. Remove two way connector (1) from clutch housing.
33. Remove plug from clutch housing. (With ABS models)
34. Remove vehicle speed sensor from clutch housing. (Without
ABS models)

E

F

G
PCIB1720E

35. Remove pinion gear (1) and pinion shaft (2) from clutch housing.

H

I

J

PCIB1719E

K

ASSEMBLY
1.

2.
3.

Install pinion gear (1) and pinion shaft (2) to clutch housing.
CAUTION:
Replace transaxle assembly when replacing clutch housing.
Install plug to clutch housing. (With ABS models)
Install vehicle speed sensor to clutch housing. (Without ABS
models)
NOTE:
Apply specified transaxle fluid to O-rings prior to installation.
Refer to MA-14, "Fluids and Lubricants".

L

M

N

PCIB1719E

O

P

Revision: May 2010

MT-73

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
4. Install two way connector (1) to clutch housing.

[RS6F94R]

PCIB1720E

5.
6.

Install bushings (1) so that they becomes even to clutch housing
edge surface, using a suitable tool (A).
Install oil channel to clutch housing.
CAUTION:
Never reuse oil channel.

JPDIC0108ZZ

7.

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.

PCIB1724E

8.

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

: ST33220000 (

—

)

PCIB1721E

9.

Install snap ring (1) and oil channel (2) to transaxle case.
CAUTION:
• Select and install snap ring that has the same thickness
as previous one.
• Replace transaxle assembly when replacing transaxle
case.
10. Install mainshaft rear bearing adjusting shim to transaxle case.
CAUTION:
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.
Revision: May 2010

MT-74

PCIB1729E

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]
< SERVICE INFORMATION >
- If new mainshaft adjusting shim is thinner than previous one, offset the thickness difference by
selecting thicker mainshaft rear bearing adjusting shim.
A
- 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.
B
- 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 MT
than 0.025 mm (0.0010 in).
11. Install mainshaft rear bearing outer race to transaxle case, using
Tool (A).
Tool number

: KV38100200 (

—

D

)

E

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

F

PCIB1728E

G

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

I

J
JPDIC0109ZZ

K

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

L

M

PCIB1730E

14. Install shifter lever B (1) to transaxle case.
CAUTION:
Replace shifter lever A and shifter lever B as a set.
15. Install shifter lever A to transaxle case.
CAUTION:
Replace shifter lever A and shifter lever B as a set.

O

P

PCIB1712E

Revision: May 2010

MT-75

N

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
16. Install retaining pin to shifter lever A (1), using a pin punch.
CAUTION:
Never reuse retaining pin.
17. Install shim to transaxle case.

[RS6F94R]

BCIA0047E

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

: ST33400001 (J-26082)

CAUTION:
Replace differential side bearing outer race (transaxle case
side) and differential side bearing inner race (transaxle case
side) as a set.
PCIB1726E

19. 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 housing side) as a set.
PCIB1722E

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

: KV32500QAA (B.vi 1666-B)

A

: Transaxle case side

B

: Clutch housing side

Dimension L1
Dimension L2

: 1.2 – —1.8 mm (0.047– 0.071 in)
: 2.7 – 3.3 mm (0.106 – 0.130 in)

JPDIC0454ZZ

CAUTION:
• Do not reuse differential side oil seal.
• Never incline differential side oil seal.
• Never damage clutch housing and transaxle case.
21. Install magnet to clutch housing.
22. Install final drive assembly to clutch housing.

Revision: May 2010

MT-76

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
23. Set fork rod (1) to input shaft assembly (2), and then install them
to clutch housing.

[RS6F94R]
A

B

MT
JPDIC0608ZZ

D

24. Install mainshaft assembly (1) according to the following procedures.
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.

E

F

G
JPDIC0609ZZ

25. 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
rod (4), and 1st-2nd fork rod (5).
NOTE:
It is easier to pull up when shifting each fork rod to each shaft
side.
c. Set reverse fork rod (6) to reverse idler shaft assembly, and then
install them to clutch housing.

H

I

J

JPDIC0606ZZ

26. Shift 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to
the neutral position.
27. Install selector (4) to clutch housing.
CAUTION:
Replace selector lever and selector as a set.

K

L

M

N
SCIA7782E

O

28. Install selector spring (1) to return bushing (A).
29. Apply recommended sealant to transaxle case mounting surface.
• Use Genuine Liquid Gasket, Three Bond 1215 or an equivalent.
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.

P

JPDIC0445ZZ

Revision: May 2010

MT-77

2011 Versa

TRANSAXLE ASSEMBLY
[RS6F94R]

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

JPDIC0110ZZ

31. Install reverse idler shaft bolt ( ) according to the following procedures.
a. Install seal washer to reverse idler shaft mounting 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
MT-62, "Disassembly and Assembly".
PCIB1695E

32. Tighten transaxle case bolts ( ) to the specified torque. Refer
to MT-62, "Disassembly and Assembly".

PCIB1694E

33. Install position switch (1) according to the following procedures.
a. Apply recommended sealant to position switch thread.
• Use Genuine Liquid Gasket, Three Bond 1215 or an equivalent.
CAUTION:
Never allow old liquid gasket, moisture, oil, or foreign matter to remain on thread.
b. Install position switch to transaxle case, and tighten it to the
specified torque. Refer to MT-62, "Disassembly and Assembly".
34. Install bracket (2) to transaxle case, and tighten mounting bolt to
the specified torque. Refer to MT-62, "Disassembly and Assembly".
35. Install selector lever (3) according to following the procedures.
a. Install selector lever to transaxle case.
CAUTION:
Replace selector lever and selector as a set.
b. Install retaining pin to selector lever, using a suitable tool.
CAUTION:
Never reuse retaining pin.
36. Install drain plug according to the following procedures.
a. Install gasket to drain plug.
CAUTION:
Revision: May 2010

MT-78

SCIA7784E

2011 Versa

TRANSAXLE ASSEMBLY
< SERVICE INFORMATION >
Never reuse gasket.
b. Install drain plug to clutch housing, using a suitable tool.
c. Tighten drain plug to the specified torque. Refer to MT-62, "Disassembly and Assembly".
37. 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-62, "Disassembly and Assembly".
CAUTION:
Fill with gear oil before tighten filler plug to the specified torque.

[RS6F94R]
A

B

MT

D

E

F

G

H

I

J

K

L

M

N

O

P

Revision: May 2010

MT-79

2011 Versa

INPUT SHAFT AND GEARS
[RS6F94R]

< SERVICE INFORMATION >

INPUT SHAFT AND GEARS
Disassembly and Assembly

INFOID:0000000005929699

GENERAL PRECAUTIONS
• Never reuse snap ring.
• Secure input shaft 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 do not affect any functions.

SCIA1755J

DISASSEMBLY
1.

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

A: KV32300QAM (

—

)

JPDIC0449ZZ

2.
a.
b.

Remove input shaft rear bearing (1) according to the following
procedures.
Set a suitable puller to input shaft rear bearing.
Remove input shaft rear bearing using a suitable drift (A).

JPDIC0111ZZ

3.
4.

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

PCIB1750E

Revision: May 2010

MT-80

2011 Versa

INPUT SHAFT AND GEARS
< SERVICE INFORMATION >
5. Remove snap ring (1) using suitable tool.
6. Remove spacer, 5th baulk ring, 5th input gear (2), and spacer.

[RS6F94R]
A

B

MT
PCIB1754E

7.
8.
9.

D

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

E

F

G
PCIB1753E

10. Remove snap ring (1).
11. Remove spacer, 3rd baulk ring, 3rd input gear (2).

H

I

J

PCIB1752E

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

K

L

M

N
PCIB1751E

INSPECTION AFTER DISASSEMBLY

O

Input shaft and gear
Check the following items and replace if necessary.
P

Revision: May 2010

MT-81

2011 Versa

INPUT SHAFT AND GEARS
< SERVICE INFORMATION >
• Damage, peeling, bend, uneven wear, and distortion of shaft.
• Excessive wear, damage, and peeling of gear.

[RS6F94R]

SCIA7736E

Synchronizer
• Synchronizer hub and coupling sleeve
Check the following items and replace if necessary.
- Breakage, damage, and unusual wear on contact surface of coupling sleeve, synchronizer hub, and insert key.
- Coupling sleeve and synchronizer hub move smoothly.

SCIA1753J

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

SCIA0608J

Bearing
Check bearing for damage and unsmooth rotation. Replace if necessary.

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: May 2010

MT-82

2011 Versa

INPUT SHAFT AND GEARS
< SERVICE INFORMATION >
• Replace 5th-6th coupling sleeve and 5th-6th synchronizer hub as a set.
• Be careful to install 3rd-4th synchronizer hub according to the
specified direction.

[RS6F94R]
A

A : 3rd input gear side

B

B : 4th input gear side

MT

PCIB1748E

• Be careful to install 5th-6th synchronizer hub according to the
specified direction.

D

E

A : 5th input gear side
B : 6th input gear side

F

G
PCIB1749E

H

• Install input shaft front bearing (1) using a suitable drift (A).

I

J

K
JPDIC0112ZZ

• Install input shaft rear bearing (1) using a suitable drift (A) and the
Tool (B).
Tool number

B: ST36720030 (

—

L

)

M

• Apply gear oil to 3rd baulk ring, 4th baulk ring, 5th baulk ring, and
6th baulk ring.
N

JPDIC0113ZZ

O

P

Revision: May 2010

MT-83

2011 Versa

INPUT SHAFT AND GEARS
< SERVICE INFORMATION >
• 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
2.
3.
4.

A: KV32300QAM (

—

[RS6F94R]

)

Install input shaft rear bearing bolt, and then tighten it to the
specified torque of the 1st step. Refer to MT-62, "Disassembly
JPDIC0449ZZ
and Assembly".
Loosen input shaft rear bearing bolt by a half turn.
Tighten input shaft rear bearing bolt to the specified torque of the 2nd step. Refer to MT-62, "Disassembly
and Assembly".

Revision: May 2010

MT-84

2011 Versa

MAINSHAFT AND GEARS
[RS6F94R]

< SERVICE INFORMATION >

MAINSHAFT AND GEARS

A

Disassembly and Assembly

INFOID:0000000005929700

GENERAL PRECAUTIONS

B

• Never reuse snap ring.
• 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.

MT

D

E

SCIA1755J

F

DISASSEMBLY
1.

Remove snap ring (1) using suitable tool.

G

H

I

PCIB1745E

2.
a.
b.

Remove 6th main gear (1) and mainshaft rear bearing inner race
(2) according to the following procedures.
Set a suitable puller to 6th main gear.
Remove mainshaft rear bearing inner race and 6th main gear
using the Tool (A).

J

K

L

Tool number

A: ST33052000 (

—

)
M
PCIB1744E

3.
a.
b.

Remove 4th main gear (1) and 5th main gear (2) according to
the following procedures.
Set a suitable tool to 4th main gear.
Remove 5th main gear and 4th main gear using Tool (A).
Tool number

4.

A: ST33052000 (

—

N

O

)
P

Remove mainshaft adjusting shim.

PCIB1743E

Revision: May 2010

MT-85

2011 Versa

MAINSHAFT AND GEARS
< SERVICE INFORMATION >
5. Remove 1st main gear (1), 1st-2nd synchronizer hub assembly
(2) , 2nd main gear (3), and 3rd main gear (4) according to the
following procedures.
a. Set a 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 synchronizer hub assembly, 1st outer baulk ring, 1st synchronizer
cone, 1st inner baulk ring, and 1st main gear using the Tool (A).
Tool number
c.
6.
a.
b.

A: ST33052000 (

—

)

[RS6F94R]

PCIB1742E

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

A: ST33052000 (

—

)

PCIB1741E

INSPECTION AFTER DISASSEMBLY
Mainshaft and Gear
Check the following items and replace if necessary.
• Damage, peeling, bend, uneven wear, and distortion of shaft.
• Excessive wear, damage, and peeling of gear.

PCIB1775E

Synchronizer
• Synchronizer hub and coupling sleeve
Check the following items and replace if necessary.
- Breakage, damage, and unusual wear on contact surface of coupling sleeve, synchronizer hub, and insert key.
- Coupling sleeve and synchronizer hub move smoothly.

SCIA1753J

• Baulk ring

Revision: May 2010

MT-86

2011 Versa

MAINSHAFT AND GEARS
< SERVICE INFORMATION >
Check contact surface of baulk ring cam and insert key for excessive wear, uneven wear, bend, and damage. Replace if necessary.

[RS6F94R]
A

B

MT
SCIA0608J

D

Bearing
Check bearing for damage and unsmooth rotation. Replace if necessary.
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.

E

F

G
SPD715

ASSEMBLY
CAUTION:
• 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.

3.

I

J

K

L

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

2.

H

A: ST36720030 (

—

M

)

CAUTION:
Replace mainshaft front bearing outer race and mainshaft
front bearing inner race as a set.
Apply gear oil to 1st inner baulk ring, 1st synchronizer cone, 1st
outer baulk ring, 2nd inner baulk ring, 2nd synchronizer cone,
and 2nd outer baulk ring.
CAUTION:
PCIB1733E
• 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.
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.

Revision: May 2010

MT-87

2011 Versa

N

O

P

MAINSHAFT AND GEARS
< SERVICE INFORMATION >
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 (A).
Tool number

A: KV32102700 (

—

[RS6F94R]

)

PCIB1734E

6.

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

A: ST32102700 (

—

)

PCIB1735E

7.

Measure dimension (L) as shown. Select mainshaft adjusting
shim (1) according to the following list, and then install it to mainshaft.
2

: Mainshaft

3

: 3rd main gear
Unit: mm (in)

Dimension (L)

Mainshaft adjusting shim thickness

147.690 – 147.666 (5.8146 – 5.8136)

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 (5.8106 – 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.

PCIB1736E

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

A: KV32102700 (

—

)

PCIB1737E

Revision: May 2010

MT-88

2011 Versa

MAINSHAFT AND GEARS
[RS6F94R]

< SERVICE INFORMATION >
9.

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

A: KV32102700 (

A

—

)
B

MT

PCIB1738E

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

A: KV32102700 (

—

)

D

E

F

G
PCIB1739E

11. Install mainshaft rear bearing inner race (1) usingTool (A).
Tool number

H

A: ST30901000 (J-2601001)

CAUTION:
Replace mainshaft rear bearing inner race and mainshaft
rear bearing outer race as a set.
12. Install snap ring.
CAUTION:
Never reuse snap ring.

I

J

PCIB1740E

K

L

M

N

O

P

Revision: May 2010

MT-89

2011 Versa

REVERSE IDLER SHAFT AND GEARS
[RS6F94R]

< SERVICE INFORMATION >

REVERSE IDLER SHAFT AND GEARS
Disassembly and Assembly

INFOID:0000000005929701

DISASSEMBLY
1.

Remove reverse output 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: May 2010

MT-90

2011 Versa

REVERSE IDLER SHAFT AND GEARS
[RS6F94R]

< SERVICE INFORMATION >
5. Remove needle bearings (1) and spacer.

A

B

MT
PCIB1761E

D

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.
• 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.

E

F

G

H

I

J

K

L

M

N

O

P

Revision: May 2010

MT-91

2011 Versa

FINAL DRIVE
[RS6F94R]

< SERVICE INFORMATION >

FINAL DRIVE
Disassembly and Assembly

INFOID:0000000005929702

DISASSEMBLY
1.
a.
b.

Remove differential side bearing inner race (clutch housing side)
(1) according to the following procedures.
Set a suitable toolto differential side bearing inner race (clutch
housing side).
Remove differential side bearing inner race (clutch housing side)
using Tool (A).
Tool number

2.

A: ST33061000 (J-8107-2)

Remove speedometer drive gear.
PCIB1767E

3.

Remove final gear bolts, and then remove final gear (1).

JPDIC0446ZZ

4.
a.
b.

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

JPDIC0114ZZ

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 necessary.
CAUTION:
• Replace differential side bearing outer race (clutch housing
side) and differential side bearing inner race (clutch housing
side) as a set.
• Replace differential side bearing inner race (transaxle case
side) and differential side bearing outer race (transaxle case
side) as a set.
SPD715

ASSEMBLY
Revision: May 2010

MT-92

2011 Versa

FINAL DRIVE
[RS6F94R]
< SERVICE INFORMATION >
1. Install final gear, and then tighten final gear bolts to the specified torque. Refer to MT-92, "Disassembly
and Assembly".
A
CAUTION:
Replace final gear and differential case as a set.
2. Install speedometer drive gear.
B
3. Install differential side bearing inner race (clutch housing side)
using a suitable tool (A).
CAUTION:
MT
Replace differential side bearing inner race (clutch housing
side) and differential side bearing outer race (clutch housing side) as a set.
D

E
JPDIC0115ZZ

4.

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.

F

G

H

JPDIC0116ZZ

I

J

K

L

M

N

O

P

Revision: May 2010

MT-93

2011 Versa

SHIFT CONTROL
[RS6F94R]

< SERVICE INFORMATION >

SHIFT CONTROL
Inspection

INFOID:0000000005929703

FORK ROD AND SHIFT FORK
Check contact surface and sliding surface for excessive wear,
uneven wear, bend, and damage. Replace if necessary.

SCIA7785E

Revision: May 2010

MT-94

2011 Versa

SERVICE DATA AND SPECIFICATIONS (SDS)
[RS6F94R]

< SERVICE INFORMATION >

SERVICE DATA AND SPECIFICATIONS (SDS)

A

General Specification

INFOID:0000000005929704

Transaxle type

RS6F94R

Engine type

MR18DE

Number of speed

B

MT

6

Synchromesh type

Warner

Shift pattern

D

E
PCIB1769E

Gear ratio

Number of teeth

1st

3.727

2nd

2.105

3rd

1.452

4th

1.171

5th

0.971

6th

0.811

Reverse

3.687

Final gear

3.933

Input gear

Main gear

1st

11

2nd

19

3rd

31

4th

35

5th

35

6th

37

Reverse

11

1st

41

2nd

40

3rd

45

4th

41

5th

34

6th

30

Reverse

42

Reverse idler gear

Input/Output

28/29

Final gear

Final gear/Pinion

59/15

Side gear/Pinion
mate gear

21/18

Oil capacity (Reference)
Remarks

(US pt, Imp pt)

Reverse synchronizer

G

H

I

J

K

L

M

N

O

P

Approx. 2.0 (4-1/4, 3-1/2)
Installed

Triple-cone synchronizer

Revision: May 2010

F

1st and 2nd

MT-95

2011 Versa



---

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