Service Manual2005 UNIT REPAIR

Nubira-Lacetti

UNIT REPAIR

Torque Converter

Disassembly and Assembly Procedure

Remove the transaxle assembly. Refer to "Transaxle Assembly" in this section.
Remove the torque converter assembly.
Installation should follow the removal procedure in the reverse order.

Transaxle Holding Fixture Assembly

Tools Required

DW260-020 Transaxle Support Fixture

Caution : To reduce the possibility of personal injury or transaxle damage, make sure, when doing the next step, that all of the bolts for the support fixture are installed as shown, and that the bolts are tightened to 11 N•m (98 lb-in).

Disassembly and Assembly Procedure

Install the transaxle support fixture DW260-020 onto the transaxle.
Torque the support fixture bolts to 11 N•m (98 lb-in).
Position the transaxle with the rear cover facing up.

Valve Body

Disassembly and Assembly Procedure

Remove the oil pan bolts and oil pan.
Remove the oil pan gasket.

Installation Notice

Tighten the oil pan bolts to 6 N•m (53 lb-in).

Remove valve body fixing bolts and transaxle input speed sensor bolt on the valve body.
Remove the holder for the transaxle input speed sensor.

Installation Notice

Tighten the bolts to 8 N•m (71 lb-in).

Tilt the valve body.
Remove the fastening screw for the output speed sensor under the valve body assembly.
Lever the cable out of the retaining clip and pull out the output speed sensor.
Installation should follow the removal procedure in the reverse order.

Installation Notice

Tighten the screw to 6 N•m (53 lb-in).

Rear Cover

Disassembly and Assembly Procedure

Removal the valve body assembly. Refer to "Valve Body Removal" in this section.
Pull out sealing sleeve (brake C) with a kind of nail.
Turn transaxle by 90°.

Remove the rear cover bolts.
Hit the rear cover rightly.
Remove the cover.
Installation should follow the removal procedure in the reverse order.

Installation Notice

Tighten the rear cover bolts to 23 N•m (17 lb-ft).

Clutch B/E

Tools Required

DW260-140 Clutch B Stop Ring Remover/Installer

DW260-150 Clutch B Stop Ring Remover/Installer

Disassembly and Assembly Procedure

Remove the rear cover. Refer to "Rear Cover Removal" in this section.
Remove the two sealing rings(clutch B/E).

Take out input shaft with clutch B/E.

Remove needle bearing and thrust washer.
Remove shim.

Take out the retaining snap ring.

Take out the piston B.

Remove disc set B.

Take out the piston rings.

Removal Notice

Remove the rectangular-section ring for the input shaft and the retaining ring.

Remove inner disc carrier E and needle roller thrust bearing.

Take out the snap ring.

Remove disc set E.

Press down cup spring(clutch E) with cup spring press fixture.
Remove the split stop ring.

Remove the oil dam and cup spring.
Pull the o-ring off the oil dam.

Press down cup spring(clutch B)with cup spring press fixture.
Remove the split stop ring.

Remove the cup spring.
Installation should follow the removal procedure in the reverse order.

Adjustment Notice

Before assembling clutch B/E, setting discs(clutch B/E) have to measured by below measurement procedure.

Clutch B/E Measurement Procedure

Tools Required

DW260-090 Clutch B/E(snap ring play, installation space) Measuring Fixture

Determine Snap Ring Play

Put the dial gauge sensor on the clutch B adjusting ring.
Feed compressed air to clutch B via control valves.
Set dial gauge to zero.
Pressurize clutch E via the control valve and read measurement value.
Repeat measurement twice with disc set turned by 120°.
Average measurement values M1, M2, M3.(measurement value is S)

CALCULATION

S = (M1+M2+M3)/3

EXAMPLE

- M1 = 0.27mm, M2 = 0.23mm, M3 = 0.25mm

- S = 0.25mm

Tools Required

DW260-090 Clutch B/E (snap ring play, installation space) Measuring Fixture

Measuring Installation Space, Clutch B (EB)

Put the dial gauge's sensor on the clutch B adjusting ring.
Feed compressed air to clutch E via control valves.
Set dial gauge to zero.
Lift measurement ring B by hand until it touches the cup and read the measurement value.
Repeat measurement twice with the set turned by 120°.
Average measurement values M4, M5, M6. (measurement value is MB)

The minimum installation space EB is equal to the height of the ring RB (specification value ; 11.99mm) plus measurement value MB
CALCULATION

MB = (M4+M5+M6)/3

EB = RB + MB

EXAMPLE

M4 = 2.36mm

M5 = 2.40mm

M6 = 2.38mm

So,MB = (2.36+2.40+2.38)/3 = 2.38mm

EB = 11.99+2.38 =14.37mm

Tools Required

DW260-090 Clutch B/E(snap ring play, installation space) Measuring Fixture

Measuring Installation Space, Clutch E(EE)

Put the dial gauge's sensor on the clutch E adjusting ring.
Set dial gauge to zero.
Feed compressed air to clutch E via control valves.
Read off the measured value.
Repeat measurement twice with the set turned by 120°.
Average measurement values M7, M8, M9. (measurement value is ME)

The minimum installation space BE is equals ring height RE (specification value : 20.98mm) plus ME - minus snap ring play S.
CALCULATION

ME = (M7+M8+M9)/3

EE = RE + ME-S

EXAMPLE

M7 = 2.6mm

M8 = 2.55mm

M9 = 2.54mm

So,ME = (2.6+2.55+2.54)/3 = 2.56mm

EE = 20.98+2.56-0.25 = 23.29mm

Tools Required

DW260-100 Brake B/E Disc Thickness Measuring Fixture

Determining Adjusting Disc B(PB)

Using disc thickness gauge, determine thickness ME for the disc set for clutch B(without adjusting disc, which located in second highest plate).
Calculate the test dimension PB(PB = EB - MB)

EB = installation space

MB = disc set thickness

EXAMPLE

EB = 14.37mm

MB = 11.3mm

PB = 3.07mm

Find the disc set's thickness. Refer to the below table.

P B	Disc set's Thickness
2.83~3.39mm	1.8mm
3.40~3.68mm	2.1mm
3.69~4.08mm	2.5mm
4.09~4.54mm	3.0mm

PB is 3.08mm so, the disc set's thickness is 1.8mm.

Replace clutch B's setting disc. (1.8mm)

Tools Required

DW 260-100 Brake B/E Disc Thickness Measuring Fixture

Determining Adjusting Disc E(PE)

Using disc thickness gauge, determine thickness MB for the disc set for clutch E(without adjusting disc, which located in the lowest plate).
Calculate the test dimension PE(PE = EE - ME)

EE = installation space

MB = disc set thickness

EXAMPLE

EE = 23.29mm

ME = 16.70mm

PE = 6.59mm

Find the disc set's thickness. Refer to the below table.

PE	Disc set's Thickness
5.41~6.00mm	3.9mm
6.01~6.48mm	4.4mm
6.49~6.98mm	5.0mm

PB is 3.08mm so, the disc set's thickness is 5.0mm.

Replace clutch B's setting disc. (5.0mm)

Planetary Gear set

Disassembly and Assembly Procedure

Remove the clutch B/E. Refer to "Clutch B/E" in this section.
Remove the rear sun gear.

Remove the planetary gear set.

Remove snap ring from front ring gear.

Take out rear planetary gear set.

Remove the axial needle bearing.

Take out front gear set with rear ring gear, front sun gear and oil trays.

Take oil trays and front sun gear off the planetary gear set.
Installation should follow the removal procedure in the reverse order.

Brake C/D

Tools Required

DW260-160 Brake C/D Snap Ring Remover/Installer

Disassembly and Assembly Procedure

Take snap ring out of transaxle housing.

Release cylinder with piston C by applying compressed air to the feed bore .

Remove cylinder with piston C.

Take disc carrier C/D and spring disc out of transaxle housing.

Release cylinder with piston D by applying compressed air to the feed bore.

Remove cylinder with piston C.

Separate between piston C and cylinder C.

Take snap ring out of brake C.

Remove the disc set C.

Installation Notice

Transaxle has two lined clutch discs and one steel clutch disc. The lined discs must be installed in such a way that the lining faces the steel disc.
Insert the fitting keys into the appropriate grooves.

Turn the disc carrier C/D by 180°.
Turn the disc carrier C/D by 180°.
Using assembly bracket Press down cup spring and take out the snap ring.
Using assembly bracket Press down cup spring and take out the snap ring.

Remove the disc set D.
Remove the disc set D.
Installation should follow the removal procedure in the reverse order.

Differential

Disassembly and Assembly Procedure

Remove the torque converter housing. Refer to "Torque Converter" in this section.
Lift out the differential.
Installation should follow the removal procedure in the reverse order.

Removal Notice

Don't disassemble the differential to avoid incorrect operation.

Side Shaft

Disassembly and Assembly Procedure

Remove the differential. Refer to "Differential" in this section.
Tilt and remove the side shaft.
Installation should follow the removal procedure in the reverse order.

Removal Notice

Don't disassemble the differential to avoid incorrect operation.

Brake F, Slotted Nut

Tools Required

DW260-060 Brake F Split Stop Ring Remover

Disassembly and Assembly Procedure

Remove the side shaft. Refer to "Side Shaft" in this section.
Take OFF the disc set and the brake F inner disc carrier.

Mount fixture and remove the brake F split stop ring.

Remove the fixture and take off the cup spring.

Release the piston F by applying compressed air to the bore.

Remove piston F and bearing plate with spur gear.
Installation should follow the removal procedure in the reverse order.

Removal Notice

Since the bearing set is tight, press the bearing plate upward from underneath to remove it.

Tools Required

DW 260-110 Brake F Disc Clearance Measuring Bar

Measuring Installation Space F

Using a depth gauge, measuring from the transaxle housing sealing surfaces to the piston’s disc support surface at two opposing points = M1, M2
Average the measurement values M1, M2 = BF

CALCULATION

BF = (M1+M2)/2

CALCULATION

M1 = 18.6mm

M2 = 18.8mm

BF = 18.7mm

Determining Adjusting Disc F

Calculate the test dimension PF (PF = BF - MF)

BF = installation space

MF = disc set thickness (assume 14.50mm)

EXAMPLE

BF = 18.70mm

MF = 14.50mm

PE = 4.2mm

Find the disc set's thickness. Refer to the below table.

PF	Disc set's Thickness
3.01~3.19mm	1.8mm
3.20~3.48mm	2.1mm
3.49~3.88mm	2.5mm
3.89~4.08mm	2.7mm
4.09~4.30mm	3.0mm

PE is 4.20mm so, the disc set's thickness is 3.0mm.

Replace clutch B's setting disc. (3.0mm)

Torque Converter Housing

Disassembly and Assembly Procedure

Remove the torque converter bolts.
Hit the torque converter housing lightly.
Remove the torque converter housing.

Installation Notice

First pre-tighten the bolts in the following order.(7,20)→(12,23)→(16,4)

Tighten

Tighten the bolts to 15 N•m (11 lb-ft).

Then, tighten the bolts in the following order. (15,3) →(16,4) →(14,5) →(13,23) →(12,22)→(11,21) →(10,20) →(9,19) →(8,18) →(7,17) →(6) →(1,2)
Last, in numerical order, tighten the bolts all the way.(1→23)

Tighten

Tighten the bolts to 23 N•m (17 lb-ft).

Take out the metal gasket.
Take out the paper gasket.
Remove the oil filter bolt and oil filter.

Installation Notice

Tighten

Tighten the oil filter bolt to 10 N•m (89 lb-in).

Remove the baffle plate bolts and baffle plate.

Installation Notice

Tighten

Tighten the baffle plate bolts to 10 N•m (89 lb-in).

Remove the line pressure measurement plug.
Installation should follow the removal procedure in the reverse order.

Installation Notice

Tighten

Tighten the line pressure measurement plug to 20 N•m (15 lb-ft).

Shift Mechanism

Disassembly and Assembly Procedure

Take out the select shaft clamping sleeve.

Remove the shift mechanism.

Shift mechanism is consist of select shaft, detent disc, connecting bar, stop bush.

Installation should follow the removal procedure in the reverse order.

Parking Lock System

Disassembly and Assembly Procedure

Remove the parking lock assembly.

Parking lock system is consist of parking pawl, leg spring, support bolt.

Installation should follow the removal procedure in the reverse order.

Bearing Plate(With Spur Gear) Assembly

Disassembly and Assembly Procedure

Remove the piston F. Refer to "Brake F" in this section.
Remove the bearing plate bolts and bearing plate.
Installation should follow the removal procedure in the reverse order.

Installation Notice

Tighten

Tighten the bearing plate bolts to 27 N•m (17 lb-ft).

Oil Pump Assembly

Disassembly and Assembly Procedure

Remove the oil pump housing bolts.
Using the plastic hammer. Take out the oil pump housing.

Installation Notice

Tighten

Tighten the oil pump housing bolts 10 N•m (89 lb-in).

Remove the stator shaft bolts.

Dismantle the oil pump gear, ring gear
Installation should follow the removal procedure in the reverse order.

Differential/Side Shaft Outer Race, Bearing Shim

Disassembly and Assembly Procedure

Take out the outer race of the transaxle housing side.
Remove the bearing shim.
Take out the outer race of the torque converter housing side.

Installation Notice

Heat the bearing seats well and insert bearing outer rings with shim for differential and side shaft into the transaxle housing.

Important Measurement/Adjustment

Tools Required

DW260-080 Clutch B/E Shim Setting Gauge

Adjusting Axial Play, Input Shaft

Important : After assembling the rear cover. You must measure the axial play specification, if the measured data is not satisfied the specification. Replace the clutch B/E's shim.

Incorrect axial play may cause the vibration or noise. The specification of the axial play is 0.18 to 0.42mm.

Clamp fixture on the input shaft so that the measuring base rests on the stator shaft.
Set dial gauge to zero.
Measure axial play by pulling and pressing on the handle.(repeat measurement)

Calculate the measurement values.(average)

EXAMPLE

M1 = 0.51mm

M2 = 0.49mm

M = (0.51+0.49)/2 = 0.5mm

S (specification) = 0.18~0.42mm

D (adjustment value) = 0.5mm - (0.18~0.42)mm

So, D is 0.08 to 0.32mm

Calculate the average, so D is 0.2mm

Replace shim.

Disc thickness must be between 0.08 and 0.32mm thicker. It is sensible to select one with a disc that average 0.2mm thicker than the one that was installed.