Nissan Stanza/200SX/240SX 1982-1992 Repair Guide

Transaxle

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REMOVAL & INSTALLATION



1982-86 Stanza with RS5F31A Type Transaxle
  1. Disconnect the battery. Removing the battery may allow greater ease of access.
  2.  
  3. Raise and safely support the vehicle and drain the gear oil.
  4.  
  5. Remove the wheel bearing lock-nut while depressing the brake pad.
  6.  
  7. Remove the brake caliper assembly. The brake hose does not need to be disconnected from the caliper. Support the caliper.
  8.  
  9. Remove the tie rod and lower ball joint securing nuts.
  10.  
  11. Loosen but do not remove the upper strut mounting nuts.
  12.  
  13. Separate the halfshafts from the knuckle by lightly tapping.
  14.  
  15. Separate the ball joint from steering knuckle and move assembly aside to allow room to remove halfshafts.
  16.  
  17. Remove halfshafts by prying against the reinforcement locations on halfshaft. Do not pull halfshafts, this will damage the sliding boots and oil seals.
  18.  
  19. After removing halfshafts, insert a suitable bar to prevent the side gears from rotating and falling into the differential case.
  20.  
  21. Remove the wheel protector and undercover.
  22.  
  23. Separate the control rod and support rod from the transaxle.
  24.  
  25. Remove the exhaust tube securing nut and bolt.
  26.  
  27. Remove the engine gusset bolt and engine mounting.
  28.  
  29. Remove the clutch control cable from the withdrawal lever.
  30.  
  31. Disconnect the speedometer cable.
  32.  
  33. Disconnect the wire connectors from the backup light and neutral safety switches.
  34.  
  35. Support the engine.
  36.  
  37. Support the transaxle with an suitable transmission jack.
  38.  
  39. Remove the starter.
  40.  
  41. Remove the engine mounting bolts.
  42.  
  43. Remove the transaxle-to-engine bolts.
  44.  
  45. Carefully lower transaxle down and away from engine. Take care not to damage halfshafts or other components in the area.
  46.  

To install:
  1. Clean all mating surfaces.
  2.  
  3. Apply a light coat of lithium based grease to the input shaft splines.
  4.  
  5. Carefully raise the transaxle to the engine.
  6.  
  7. Tighten transaxle to engine bolts to proper torque 22-30 ft. lbs.
  8.  
  9. Install the starter.
  10.  
  11. Connect cables and electrical connectors.
  12.  
  13. Install the exhaust tube securing bolts.
  14.  
  15. Check wheel bearing by installing halfshaft to hub and torqueing nut to 145-203 ft. lbs. (196-275 Nm). Spin wheel in both directions several times and measure the bearing pre-load. If pre-load is not 3.1-10.8 lb. (13.9-48.1 N) pull, as measured by pulling on a lug stud, the wheel bearing should be replaced.
  16.  
  17. If bearing pre-load was checked, remove halfshaft for hub.
  18.  
  19. Set the seal protector KV38105500 on the transaxle and install the halfshafts. Make certain to properly align serrations and then withdraw tool.
  20.  
  21. Push the halfshaft, then press-fit the circular clip on the halfshaft into the clip groove of the side gear.
  22.  
  23. Pull back on the halfshaft to make certain it is fully locked in place.
  24.  
  25. Tighten wheel bearing lock-nut to 145-203 ft. lbs. (196-275 Nm).
  26.  
  27. Install ball joint bolt and tie rod.
  28.  
  29. Install brake caliper assembly.
  30.  
  31. Tighten strut bolts and install wheels.
  32.  
  33. Fill transaxle axle to proper level (5.9 pints API gear oil) with gear lubricant.
  34.  
  35. Install the undercover and wheel house protector.
  36.  
  37. Lower the vehicle.
  38.  
  39. Install and connect the battery.
  40.  

1987 and later Stanza 1986-88 Stanza Wagon 2WD/4WDRS5F50A Type Transaxle
  1. Disconnect the battery. Remove the battery and its bracket.
  2.  
  3. Raise and safely support vehicle. Drain gear oil.
  4.  
  5. Remove the wheel bearing lock-nut while depressing the brake pedal.
  6.  
  7. Remove the brake caliper assembly. The brake hose does not need to be disconnected from the caliper. Support the caliper.
  8.  
  9. Remove the tie rod end and lower ball joint securing nuts.
  10.  
  11. Loosen but do not remove the upper strut mounting nuts.
  12.  
  13. Separate the halfshafts from the knuckle by lightly tapping.
  14.  
  15. Separate the ball joint from steering knuckle and move assembly aside to allow room to remove halfshafts.
  16.  
  17. Remove halfshafts by prying against the reinforcement locations on halfshaft.
  18.  
  19. Remove bolts securing exhaust to front tube.
  20.  
  21. If equipped with 4WD, disconnect (matchmark for correct installation) driveshaft and remove transfer case.
  22.  
  23. Lower vehicle and remove the air cleaner and airflow meter assembly.
  24.  
  25. Disconnect cables and electrical connections from transaxle.
  26.  
  27. Remove transaxle to engine bolts and mount bolts.
  28.  
  29. Carefully lower transaxle from engine.
  30.  

To install:
  1. Carefully raise the transaxle to the engine.
  2.  
  3. Tighten transaxle to engine bolts to proper torque 29-40 ft. lbs.
  4.  
  5. If equipped with 4WD, install the transfer case and driveshaft.
  6.  
  7. Connect cables and electrical connectors.
  8.  
  9. Install the exhaust pipe.
  10.  
  11. Install the air cleaner and airflow meter assemblies.
  12.  
  13. Check wheel bearing by installing halfshaft to hub and torqueing nut to 174-231 ft. lbs. (235-314 Nm). Spin wheel in both directions several times and measure the bearing pre-load. If pre-load is not 1.1-10.1 lb. (4.9-45.1N) pull, as measured by pulling on a lug stud, the wheel bearing should be replaced.
  14.  
  15. If bearing pre-load was checked, remove halfshaft for hub.
  16.  
  17. Set the installation KV381060700 and KV381060800 tools on the transaxle and install the halfshafts. Make certain to properly align serrations and then withdraw tool.
  18.  
  19. Push the halfshaft, then press-fit the circular clip on the halfshaft into the clip groove of the side gear.
  20.  
  21. Pull back on the halfshaft to make certain it is fully locked in place.
  22.  
  23. Tighten wheel bearing lock-nut to 174-231 ft. lbs. (235-314 Nm).
  24.  
  25. Install ball joint bolt and tie rod end.
  26.  
  27. Install brake caliper assembly.
  28.  
  29. Tighten strut bolts and install wheels.
  30.  
  31. Lower vehicle and fill transaxle axle to proper level (10 pints API GL-4 gear oil) with gear lubricant.
  32.  
  33. Install and connect the battery.
  34.  

CHECKING FLUID LEVEL



See Figures 1 and 2

With the vehicle on a level surface, place a drain pan under the vehicle and remove the oil filler plug. The transaxle is correctly filled if the oil just begins to run out of the hole or is level with the bottom of the fill hole.

On vehicles without a filler plug, remove the speedometer cable from the transaxle case. Check that the fluid level is within 0.35 in. of the inside case lip. On the 4WD Stanza remove filler plug and using a straight wire check that the level is 3.82-4.13 in. (97-105mm) from the top of the housing.



Click image to see an enlarged view

Fig. Fig. 1: Check transaxle fluid level - Stanza 2WD



Click image to see an enlarged view

Fig. Fig. 2: Check transaxle fluid level - Stanza 4WD

 
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