Nissan Patrol, Ford Maverick

1988-1997 of release

Repair and car operation



Nissan Patrol and Ford Maverik
+ Cars of the Nissan Patrol and Ford Maverick series
+ Diagnostics of malfunctions
+ Settings and routine maintenance
+ Engine
+ Systems of cooling, heating and air conditioning
+ the Power supply system and production of the fulfilled gases
+ Systems of decrease in toxicity of the fulfilled gases
+ Systems of electric equipment of the engine
- Transmission
   - Manual box of gear shifting (RKPP)
      Removal and installation
      Dismantling
      Check of a condition of components
      Assembly
   + Automatic transmission
   + Transfer case
   + Driveshafts
+ Coupling
+ Brake system
+ Forward and back bridges, running gear and steering
+ Body
+ Onboard electric equipment




Dismantling

During dismantle try to remember the adjusting provision of all removed components. It should simplify the subsequent assembly.

Carburetor models of 4.2 l

 PERFORMANCE ORDER

  1. Remove transmission from the car. Clear external surfaces of assembly, watching that solvent did not get in vyzhimny the coupling bearing.
  2. Give fixing bolts and remove from transmission a coupling dome, the lever of switching off and vyzhimny the bearing assembled.
  3. Give fixing bolts and remove from a transmission case the top cover with laying (see an accompanying illustration).
1 — the synchronizer coupling
2 — - a gear wheel of the 1st transfer
3 — - a gear wheel of the 3rd transfer
4 — - the synchronizer coupling
5 — - a coupling dome
6 — - a lengthening casing
7 — - a gear wheel of a reverse gear
8 — - the synchronizer coupling
9 — - a gear wheel of the 2nd transfer
  1. Give fixing screws and by means of a hammer with soft brisk remove from a transmission case a lengthening casing (see an accompanying illustration). Take from a casing an epiploon and will throw out it.
1 — the remote plug
2 — the bearing
3 — the holder
4 — a conducted shaft
5 — a lock ring
6 — a switching fork
7 — a synchronizer cone
8 — a gear wheel of the fifth transfer of an intermediate shaft
  1. Remove a lock ring, the holder and With-shaped from the end of a conducted shaft.
  2. By Shchup of lezviyny type measure a gap behind a gear wheel of the fifth transfer of an intermediate shaft. If the size axial люфта leaves out of admissible limits (see size tables and adjustments at the end of the Management), attentively check components of the fifth transfer (after transmission dismantling) on existence of signs of wear.

Components of an intermediate shaft are shown on an accompanying illustration.
1 — - the holder
2 — - a tarelchaty spring
3 — - a gear ring
4 — - an intermediate shaft
5 — - an internal holder
6 — - an internal holder
7 — - a lock ring
8 — - a ball
9 — - a persistent washer
10 — - the coupling
11 — - a blocking ring of the synchronizer
12 — - a washer
13 — - an external holder
14 — - the bearing
15 — - a gear wheel of the 5th transfer
16 — - a synchronizer cone
17 — - a lock ring

  1. Remove a lock ring and a washer from an intermediate shaft.
  2. Remove a lock plate of an intermediate shaft of a reverse gear.
  3. Include at the same time two transfers to avoidance of a provorachivaniye of an intermediate shaft and establish a dvukhzakhvatny stripper, having got his legs for a gear wheel of the fifth transfer. Remove a synchronizer cone, a gear wheel of the fifth transfer, synchronizer assembly, a fork of switching and a rod assembled. Take from the coupling of a gear wheel of the fifth transfer the roller bearing.

In order to avoid damage of a teeth of a gear wheel of the fifth transfer use a stripper with wide captures.

  1. Give bolts and remove from transmission the holder of the bearing.
  2. By means of a stripper remove from a conducted shaft the back bearing of a conducted shaft, a gear wheel of the fifth transfer and the remote plug. In case of need delay a conducted shaft back a hand for simplification of installation of a stripper.
  3. Establish a separator of bearings behind the coupling of the roller bearing of a gear wheel of the fifth transfer, strongly tighten bolts. By means of a stripper remove the bearing coupling from an intermediate shaft (see an accompanying illustration) and take a persistent washer, remembering adjusting situation of the last.
1 — a separator of bearings
2 — the coupling
3 — a stripper
  1. Establish a lock plate of an intermediate shaft of a reverse gear and a fixing bolt.
  2. By means of a stripper remove the bearing of a conducted shaft.
    to be strongly fixed behind a lock ring of an external holder of the bearing. At removal of the bearing use as an emphasis the wooden block.
  3. Give fixing bolts and remove from transmission a forward cover with laying. Remove from a cover an epiploon and will throw out it together with laying.
  4. Slightly knock on a back end face of an intermediate shaft with a hammer with soft brisk and rotary progress take from a transmission case an external holder of the forward bearing of an intermediate shaft.
  5. Slightly knock with a hammer with soft brisk on a forward end face of an intermediate shaft, remove an external holder of the back bearing and lower an intermediate shaft on a bottom of a case of transmission.

For extraction of an external holder of the back bearing of an intermediate shaft the stripper probably is required.

  1. Turn primary shaft so that one of лысок gear wheels of its synchronizer turned to an opening of the top cover Take primary shaft with the bearing from a transmission case.
  2. Remove from the forward end of a conducted shaft directing bearing and blocking ring of the synchronizer.
  3. Take assembly of a conducted shaft and an intermediate shaft from a transmission case through an opening of the top cover.

Appearance of assembly of a conducted shaft
1 — - a gear wheel of the 3rd transfer
2 — - a gear wheel of the 2nd transfer
3 — - a gear wheel of a reverse gear
4 — - a conducted shaft
5 — - couplings of synchronizers
6 — - a gear wheel of the 1st transfer
7 — - the synchronizer coupling

  1. Give a fixing bolt and remove a lock plate of an intermediate shaft of a reverse gear. Remember the adjusting direction intermediate gear wheels of a reverse gear and take a shaft, a gear wheel, persistent washers and roller bearings from a transmission case.
  2. Remove a lock ring and a remote ring of fastening of the bearing on primary to a shaft (see an accompanying illustration), by means of a press equipped with basic plates, remove the bearing.
1 — a remote ring
2 — a lock ring
3 — the bearing
4 — primary shaft
5 — a blocking ring of the synchronizer
6 — the directing bearing
  1. By Shchup of lezviyny type measure size axial люфтов gear wheels of the first, second and back transfers on conducted to a shaft. Results of measurements write down.
  2. For measurement axial люфта gear wheels of the third transfer clamp on it a separator of bearings and strongly fix on a separator a tsiferblatny measuring instrument so that its plunzher rested against a shaft end face (see an accompanying illustration). Move a gear wheel forward-back and write down instrument reading. If axial люфт gear wheels leaves out of admissible limits (see size tables and adjustments at the end of the Management), disassemble a conducted shaft on components and carefully check the corresponding gear wheel and components accompanying it Replace defective details.
1 — a tsiferblatny measuring instrument
2 — a separator of bearings
  1. Disassemble a conducted shaft on components (see an accompanying illustration):
1 — - a lock ring
2 — - a blocking ring of the synchronizer
3 — - the bearing
4 — - a gear wheel of the 2nd transfer
5 — - the bearing
6 — - blocking rings
7 — - the bearing
8 — - synchronizer assembly
9 — - a gear wheel of the 3rd transfer
10 — - the coupling
11 — - a lock ring
12 — - synchronizer assembly
13 — - a gear wheel of the 1st transfer
14 — - the bearing
15 — - a blocking ring
16 — - a conducted shaft
17 — - a gear wheel of a reverse gear
18 — - synchronizer assembly
    1. Remove a lock ring from the forward end of a conducted shaft.
    2. Establish a separator of bearings behind a gear wheel of the third transfer and remove it by means of a press with basic plates, then remove from a shaft assembly of the synchronizer of 3/4 transfers and the roller bearing. Remember the adjusting direction of a nave of the synchronizer.
    3. Establish a separator behind a gear wheel of the second transfer and by means of a press remove from a shaft a gear wheel, the roller bearing and the bearing coupling.
    4. Remove a lock ring of fastening on a shaft of a nave of the synchronizer of 1/2 transfers.
    5. Establish a conducted shaft in a press with basic plates, having propped up the last a gear wheel of the first transfer and remove from a shaft assembly of the synchronizer of 1/2 transfers, a gear wheel of the first transfer and the roller bearing.
    6. Overturn a conducted shaft and обоприте on basic plates a gear wheel of a reverse gear. Remembering the adjusting provision of components, remove from a shaft a gear wheel of a reverse gear, assembly of the synchronizer and the roller bearing.
  1. Disassemble on components assembly of an intermediate shaft (see an illustration):
    1. By means of a press with basic plates remove from an intermediate shaft internal holders of forward and back bearings.
    2. Remove from the forward end of a shaft a lock ring, the holder, a tarelchaty spring, a gear ring and a ball.
  1. In case of need disassemble on components the top cover (see an accompanying illustration):
1 — a cap
2 — a spring
3 — a plunzher
4 — a casing
5 — a stopper
6 — a ball
7 — a rod of a choice of transfers
8 — a pin
9 — a plate
10 — bolts
11 — the lever of a rod of a choice
12 — an arm of a rod of a choice
    1. Give fixing bolts and disconnect a casing of the selector of transfers from the top cover. Components of a casing of the selector are shown on an accompanying illustration.
    2. Turn out a restrictive stopper from the top part of a casing of the selector, take a spring and a ball. Turn out the remained caps and take springs and plunzher, remembering the adjusting provision of each of components.
    3. By means of a drift take a pin of fastening of an arm of the selector on a rod of a choice of transfers.
    4. Overturn a selector casing, give fixing bolts and remove directing plate. Remember adjusting provisions of bolts.
    5. Drift beat out a pin of fastening of the lever on a rod of a choice of transfers, at the same time taking from a casing a spherical cap. Beat out a rod of a choice of transfers from a selector casing forward. Pick up an arm of the selector and a forward cap.
    6. Turn out a cap and take from the top cover the fixing spring directing and a ball.
    7. Remove the sensor switch of fires of a backing.
    8. By means of a hammer and a screw-driver remove and will throw out jams of a rod of a choice of transfers.
    9. Remove fixing pins of a fork of inclusion of a reverse gear and the lever of a choice of a reverse gear. Take a rod of a choice of a reverse gear, then remove a fork and the lever, remembering their adjusting situation. The top cover with the removed casing of the selector is shown on an accompanying illustration.
1 — control assembly of a reverse gear
2 — the shock lever
3 — a shock clamp
4 — the lever of a choice of a reverse gear
5 — a fork of inclusion of a reverse gear
6 — rods of a choice of transfers
7 — a fork of switching of 3/4 transfers
    1. Take a fixing pin of the shock lever, take a choice rod, then, remembering the adjusting provision of components, take from the top cover the shock lever, a shock clamp and switching forks. Internal components of the top cover are shown on an accompanying illustration.
1 — a shock clamp
2 — - the shock lever
3 — - a pin
4 — - a cap
5 — - directing
6 — - a spring
7 — - a ball
8 — - control assembly of a reverse gear
9 — - a stopper
10 — - jams
11 — - a rod
12 — - a fork of switching of 3/4 transfers
13 — - a fork of switching of 1/2 transfers
14 — - a cover
15 — - the sensor switch of fires of a backing
16 — - a fork of inclusion of a reverse gear
17 — - a rod
18 — - the lever of inclusion of a reverse gear
19 — - pins
    1. Take a fixing pin and remove control assembly of a reverse gear.
  1. In case of need disassemble a casing of management of the lever of gear shifting:
    1. Remove collars and shift up on the lever a rubber protective cover.
    2. Remove a big lock ring and take from a casing the gear shifting lever with a spring.
    3. Remove a lock ring, take the switching lever from a nest and remove from it a rubber saddle (see an accompanying illustration).
1 — laying
2 — a casing
3 — a spring
4 — a lock ring
5 — a nest
6 — a saddle
7 — the plug
8 — a washer
9 — a protective cover
10 — the gear shifting lever
11 — the handle

Models of 4.2 l of EFI

Dismantling of a transmission is made in the same order, as on carburetor models of 4.2 l taking into account listed below changes. Components of a conducted shaft are presented on an accompanying illustration - on inserts blocking rings of synchronizers of models of late years of release are shown.
1 — blocking rings of the synchronizer (model of late years of release)
2 — synchronizer assembly
3 — a lock ring
4 — blocking rings of the synchronizer (model of early years of release)
5 — a gear wheel of the 3rd transfer
6 — the bearing
7 — the bearing coupling
8 — a gear wheel of the 2nd transfer
9 — a blocking ring of the synchronizer
10 — a gear wheel of the 1st transfer
11 — a conducted shaft
12 — a gear wheel of a reverse gear

 PERFORMANCE ORDER

  1. At performance of points b) and e) procedures of dismantling of a conducted shaft it is necessary to remember adjusting provisions of assemblies of blocking rings of the synchronizer of 2/3 transfers.
  1. For check of serviceability of assemblies of blocking rings of synchronizers of the 2nd and 3rd transfers measure gaps between an external ring and a cone (see an accompanying illustration), - its size should not exceed 0.2 mm and between an internal ring and a cone (see an accompanying illustration), - the difference of heights should not exceed 0.2 mm.
  1. At assembly of components of a conducted shaft establish rings of synchronizers of the 2nd and 3rd transfers according to the instruction made in the course of dismantle.

On release models since October, 1994 the remote plug of the forward bearing of primary shaft and a washer of a cone of the synchronizer of an intermediate shaft are cleaned.

Models of 3.0 l

 PERFORMANCE ORDER

  1. Remove transmission assembly from the car and clear it outside, watching that solvent did not get in vyzhimny the coupling bearing.
  2. Take the lever of switching off of coupling and vyzhimny the bearing from a case (dome) of coupling.
  3. Turn out a cap and take a control spring and a ball from the coupling of a clamp located on a wall of a dome of coupling (components of a drive of gear shifting are shown on an accompanying illustration).
1 — a switching rod
2 — a washer
3 — a lock ring
4 — a ball
5 — a bolt
6 — a cap
7 — the clamp coupling
8 — a sealing ring
9 — a spring
10 — a clamp
11 — a cylindrical pin
12 — a rod of switching of the back / 5th transfer
13 — a plunzher
14 — a fork of switching of 3/4 transfers
15 — the shock lever
16 — a fork of switching of 1/2 transfers
17 — a fork of inclusion of a reverse gear
18 — a selector arm
19 — a fork of inclusion of the 5th transfer
20 — a nut
21 — the coupling

Give a fixing bolt and remove the clamp coupling. Remove a sealing ring and will throw out it.

If a control spring and a ball not to take out earlier, at coupling removal they can drop out in transmission.

  1. If did not remove earlier, take a spring and a ball from an opening in a surface of interface of a casing of lengthening with a casing of management of the lever of gear shifting.
  2. By means of a drift beat out a cylindrical pin of fastening of an arm of the selector on a switching rod.
  3. Give fixing bolts and by means of a hammer with soft brisk remove a casing of lengthening and a selector arm from transmission. Take from a lengthening casing an epiploon, will throw out it.
  4. Give fixing bolts and remove the top cover with laying for what pass the lever in an opening under installation of the lever of switching off in a coupling dome. Take from a cover an epiploon and will throw out it.
  5. Remove lock rings from an external holder of the bearing of primary shaft and from a switching rod. Remove from a rod a washer.
  6. Having propped up a back part of a conducted shaft, separate a coupling dome from a bearing plate by means of a hammer with soft the brisk. Remove the persistent bearing and an adjusting washer from the forward end of an intermediate shaft.
  7. Clamp bearing plate in a vice with soft sponges and give a bolt of fastening of a rod of switching of the back/fifth transfers to a fork of inclusion of a reverse gear. Take a rod from a bearing plate.
  8. Drift beat out a cylindrical pin of fastening of the shock lever and a clamp on a switching rod. Take a switching rod from a bearing plate and remove the shock lever and a clamp, and also forks of switching 1/2, 3/4 and back transfers, remembering the adjusting provision of components.
  9. By means of a drift take a cylindrical pin of fastening of a fork of the fifth transfer on a switching rod. Take a rod and remove a fork.
  10. By Shchup of lezviyny type measure axial люфт gear wheels of the first, second, third and back transfers on conducted to a shaft. Also measure axial люфт gear wheels of the fifth transfer on intermediate to a shaft. If axial люфт any gear wheels leaves out of admissible limits (see size tables and adjustments at the end of the Management), attentively check the corresponding components on existence of signs of wear, replace defective details.
  11. Take the connecting coupling of a reverse gear from a nave, having remembered the adjusting direction of its landing. Remove from the end of a conducted shaft a lock ring, then by means of a hammer remove With-shaped half rings (see an illustration).
1 — a bearing plate
2 — a lock ring
3 — a conducted gear wheel of the 5th transfer
4 — the coupling
5 — bearings
6 — a nave
7 — the holder
8 — a conducted gear wheel of a reverse gear
9 — the synchronizer coupling
10 — the remote plug
11 — With-shaped half rings
12 — a lengthening casing
13 — a leading gear wheel of the 5th transfer
14 — a sliding key
15 — a blocking ring
16 — a leading gear wheel of a reverse gear
17 — a cone of the synchronizer of a reverse gear
18 — a blocking ring of the synchronizer
19 — a washer
20 — an intermediate shaft of a reverse gear
21 — a pin
22 — a persistent washer
23 — an intermediate gear wheel of a reverse gear
  1. Remove a lock ring and a washer from the back end of an intermediate shaft, then by means of a stripper remove the bearing and a gear wheel of a reverse gear.
  2. Remove from an intermediate shaft of a reverse gear a gear wheel, bearings and persistent washers, remembering adjusting position of the last.
  3. Establish a stripper captures behind a gear wheel of a reverse gear and remove from a conducted shaft the bearing, the remote plug, a nave of a reverse gear, a gear wheel of a reverse gear and roller bearings. Try to remember the adjusting provision of components.
  4. Remove the coupling of the synchronizer of the fifth transfer with blocking rings and sliding keys of the fifth and back transfers. Try to remember adjusting positions of the coupling and sliding keys.
  5. By means of a stripper remove the coupling of the roller bearing of a gear wheel of a reverse gear from a conducted shaft.
  6. Establish a stripper captures behind a gear wheel of the fifth transfer and remove at the same time a cone of a reverse gear, a gear wheel of the fifth transfer and an intermediate shaft of a reverse gear.
  7. Establish bearing plate in a press, having propped up it basic plates and serially squeeze out of a plate a conducted and intermediate shaft. Remember the provision of a gear wheel of the fifth transfer of a conducted shaft. After removal of an intermediate shaft take primary shaft and remove with conducted a shaft roller bearings and the remote plug.
  8. Give bolts and remove from a bearing plate the holder of the bearing.
  9. Remove from a conducted shaft a washer, a ball, a gear wheel of the first transfer and the roller bearing.
  10. Establish a conducted shaft in a press, having propped up basic plates a gear wheel of the second transfer and remove the coupling of the roller bearing of a gear wheel of the first transfer, assembly of the synchronizer of 1/2 transfers and a gear wheel of the second transfer with the roller bearing.
  11. Remove a lock ring from the forward end of a conducted shaft, then establish a shaft in a press, having propped up basic plates a gear wheel of the third transfer. Remove assembly of the synchronizer of 3/4 transfers, a gear wheel of the third transfer and the roller bearing.
  12. Establish in a press an intermediate shaft and remove the back persistent bearing, having remembered the adjusting direction of its landing. Remove a lock ring from the forward end of an intermediate shaft, then remove the plug, a conic spring, a gear ring and a ball.
  13. Remove a lock ring and a washer from primary shaft. Establish primary shaft in a press, having propped up basic plates the bearing and remove the last.
  14. By means of a suitable opravka remove bearings from a bearing plate, a casing of lengthening and a coupling case.

Components of assembly of the lever of gear shifting
1 — a spring
2 — bolts
3 — the bottom saddle
4 — a lock ring
5 — washers
6 — the gear shifting lever
7 — the top saddle
8 — a collar
9 — a protective cover







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