Nissan Almera Classic (also known as Nissan Sunny or Samsung SM3 in some countries) is a popular sedan whose manual transmission JR5 famous for its reliability. However, even she has a weak point: 5th gear. Owners often face the problem of its wear and tear on runs over 150,000 km, which is manifested by a crunching sound, loss of speed or difficulty starting. In this article we will look at why this happens, how to diagnose the malfunction and replace the part with your own hands - taking into account the nuances specifically for Almera Classic (body B10/N16).
The design feature of this gearbox is that fifth gear is not synchronized (unlike later versions Almera G15). This means that its gears experience increased loads when shifting, especially if the driver is used to “pressing” the lever or turning on the speed at high speeds. As a result, the gear teeth and synchronizer clutch wear out, which leads to characteristic symptoms. Below is a detailed description of each of them.
Signs of 5th gear malfunction
The first warning signs are often ignored until the problem becomes critical. Pay attention to the following symptoms:
- 🔊 Crunching or grinding noise when engaging 5th gear - especially while driving (for example, when accelerating on the highway). The sound may be barely audible at first.
- 🚗 Spontaneous knocking out speed: the lever “flies” into neutral when releasing the gas or loading.
- ⚙️ Difficulty turning on - you have to apply force or “press” the lever with a second movement.
- 🔥 Burning smell from the gearbox after a long drive at high speed (indicates oil overheating due to friction of damaged gears).
It is important to distinguish gear wear from problems with gearbox rocker or clutch. For example, if 5th gear engages only slowly when standing still, but when moving it is normal, the synchronizer or fork is most likely to blame. If you hear a crunching noise even when shifting into gears 1-4, check the oil level in the gearbox (it may be critically low).
⚠️ Attention: If the gear has already “licked” the teeth, further operation will lead to damage to the secondary shaft of the gearbox. In this case, repairs will cost 2–3 times more!
Causes of failure: why does the 5th gear break?
The main reason is design feature of the JR5 gearbox, where fifth gear does not have a synchronizer (or it is extremely weak). This is done to reduce production costs, but leads to accelerated wear when:
- 🏁 Aggressive driving style — sharp shifts at high speeds.
- 🛣️ Long driving at high speed (e.g. 120+ km/h) when the maximum load is applied to the gear.
- 🛢️ Untimely oil change in the gearbox (recommended interval is every 60,000 km).
- 🔧 Unqualified repairswhen, after replacing the clutch, the gearbox is assembled with a shaft misalignment.
The second common reason is secondary shaft bearing wear. When it is loose, the 5th gear gear shifts and the teeth begin to “eat” each other. This can be diagnosed by vibration on the gearshift lever when driving in 5th gear.
- Every 10,000 km
- Every 30,000 km
- Only when problems arise
- Never checked
Articles and prices: what to buy for replacement
For Nissan Almera Classic (1.6, 16V, JR5 gearbox) the original 5th gear gear has the article number 32510-4M000. However, its cost (from 8,000 rubles) often forces owners to look for analogues. The table below shows the tested options:
| Manufacturer | Article | Price (RUB) | Notes |
|---|---|---|---|
| Nissan (original) | 32510-4M000 | 7 500–9 000 | Best quality, but often counterfeited |
| Sachs | 3000 951 005 | 4 200–5 500 | A good analogue, but it can crunch the first 500 km |
| Koyo | 32510-4M00A | 3 800–4 500 | Budget option, resource ~100,000 km |
| Febi | 22710 | 3 500–4 000 | Suitable for gearbox JR5 And RS5F31A |
When purchasing, pay attention to completeness: often the gear is sold together with a synchronizer (article number 32505-4M000), coupling (32506-4M000) and retaining ring (30506-4M00A). If you are replacing only the gear, check the condition of these parts - their wear will speed up the failure of the new part.
⚠️ Attention: There are many fake brands on the market Nissan. The original part has a laser engraving of the article number on the end and comes in branded packaging with a hologram.
Step-by-step instructions for replacing gears
Replacing the 5th gear with Almera Classic requires removal of the gearbox, but if you have tools and an inspection hole, you can do it yourself. Below are the key steps:
Drain the gearbox oil (you will need ~2.5 liters of new one)
Disconnect the battery and remove the starter
Remove the wheel drives and gearshift lever
Remove the transmission from the engine (you will need an assistant)
Disassemble the gearbox on the table, after washing it outside-->
- Removing the gearbox:
Unscrew the bolts securing the box to the engine (there are 6 of them, the head is on
14 mm). First disconnect the clutch cables, speed sensor and reverse wires. Hang the gearbox on hoists or carefully lower it to the floor. - Disassembling the box:
Remove the gearbox cover (8 bolts per
10 mm) and remove the secondary shaft. The 5th gear gear is located at its end - it is fixed with a retaining ring, which must be removed with special pliers. - Gear replacement:
Carefully remove the old gear (a puller may be needed) and install the new one. Please note: there is a groove on the shaft for a key - if it is not aligned, the gear will play! After installation, check the axial clearance (should be no more than 0.3 mm).
- Assembly:
Reinstall the synchronizer, clutch and retaining ring. Before assembling the gearbox, apply a thin layer of gear oil to the gears (
GL-4 75W-90).
After installing the gearbox in place be sure to adjust the linkage - to do this, loosen the nut on the rod (the key is on 10 mm) and set the lever to the neutral position, aligning the marks on the shaft and gearbox housing.
Before assembly, take photographs of the location of all gears and bearings on the shaft - this will help to avoid mistakes during reinstallation.
What oil to fill after changing
For gearbox JR5 Nissan Almera Classic manufacturer recommends oil Nissan MT-XZ 75W-85 (article KE916-99931). However, analogues are also suitable:
- 🛢️ Mobil Mobilube 1 SHC 75W-90 — synthetics, improves switching in the cold.
- 🛢️ Castrol Syntrans Transaxle 75W-90 — reduces gearbox noise.
- 🛢️ Liqui Moly Hochleistungs-Getriebeoil 75W-90 — contains additives to protect synchronizers.
Oil volume for a complete change - 2.7 liters. After filling, check the level through the inspection hole (it is located on the side of the gearbox, under the plug on 24 mm). The oil should begin to flow out when the car is in a horizontal position.
⚠️ Attention: Never use oilGL-5instead ofGL-4! It contains aggressive additives that destroy gearbox synchronizers Almera Classic.
Common replacement mistakes and how to avoid them
Even experienced craftsmen make mistakes that lead to repeated repairs. Here are the most common:
- 🔧 Incorrect installation of the retaining ring - if it is not fully latched, the gear will play and wear out quickly.
- 🛠️ Transmission bolt retightening - this deforms the housing and leads to oil leakage. Tightening torque:
25–30 Nm. - 🔄 Ignoring bearing wear — if you do not replace the worn secondary shaft bearing, the new gear will last no more than 20,000 km.
- 🧲 Chips getting into the gearbox — before assembly, be sure to wash the case and magnets (they are located in the tray).
Another typical problem is incompatibility of spare parts. For example, a gear from Nissan Primera P11 (article 32510-4M010) is similar in appearance, but has a different tooth angle. Installing it will lead to constant crunching.
What to do if after replacing the 5th gear still crunches?
If the crunch remains, check:
1. **Synchronizer** - its ring may be worn or installed incorrectly.
2. **Shift fork** - it may be bent or have play.
3. **Clutch** - if it “drives”, the gearbox gears experience increased load.
4. **Oil level** - if the oil level is underfilled, the gears are not properly lubricated.
Cost of repairs in the service vs independent replacement
Prices for replacing the 5th gear gear in services vary depending on the region and level of the service station:
| Service type | Cost of work (rub.) | Cost of spare parts (RUB) | Total (RUB) |
|---|---|---|---|
| Official dealer Nissan | 12 000–15 000 | 8 000–10 000 | 20 000–25 000 |
| Independent service (specializing in checkpoints) | 6 000–9 000 | 4 000–6 000 | 10 000–15 000 |
| Garage foreman | 3 000–5 000 | 3 500–5 000 | 6 500–10 000 |
| DIY repair | 0 | 3 500–8 000 | 3 500–8 000 |
When replacing it yourself, the main costs are spare parts and oil. However, keep in mind that for work you will need:
- 🔧 Set of sockets and keys (
10 mm, 12 mm, 14 mm, 24 mm). - 🛠️ Retaining ring remover.
- 🧲 Powerful magnet for collecting shavings.
- 🛢️ Syringe for pouring oil into the gearbox.
If you do not have experience in disassembling a gearbox, it is better to entrust the work to professionals - an error during assembly can result in complete failure of the box.
Saving on high-quality spare parts is more expensive: a cheap gear will last 2-3 times less than the original, and replacing it will require re-disassembling the gearbox.
FAQ: Frequently asked questions about the 5th gear Nissan Almera Classic
Is it possible to drive if 5th gear crunches?
Short-term - yes, but the longer you delay repairs, the higher the risk of damage to the transmission output shaft. If the crunch is accompanied by a loss of speed, driving is dangerous: this can lead to jamming of the box.
How long does the 5th gear gear last after replacement?
When using original spare parts and high-quality oil, the service life is 150,000–200,000 km. If you install an analogue (for example, Koyo), service life is reduced to 80,000–120,000 km.
Is it possible to repair the gear without removing the gearbox?
No. The 5th gear gear is located inside the gearbox housing, and replacing it requires complete disassembly of the gearbox. Any promises to “repair without removal” are a scam.
What should I do if, after replacing the gear, 5th gear is difficult to engage?
The reasons may be:
- Incorrect adjustment of the gearbox linkage.
- Worn shift fork.
- Incorrect installation of the synchronizer.
It is necessary to disassemble the gearbox again and check the assembly.
What kind of oil is better to fill in the gearbox? Almera Classic to extend the life of the gear?
Optimal choice - Nissan MT-XZ 75W-85 or its analogues with approval GL-4. Oils with viscosity 75W-90 Suitable for hot climates, but may impair shifting in winter.