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Nissan VG30E and KA24E engine factory workshop and repair manual download

1) Core theory (what the planetary gearset is and how it fails)
- A planetary gearset consists of a sun gear, multiple planet gears riding on a carrier, and a ring (annulus) gear. Different output ratios are produced by holding or driving one of those three members with clutches/brakes while input torque is applied to another member. Automatic transmissions use combinations of clutch packs and one-way clutches to selectively lock members and produce forward gears, reverse and park.
- Failure modes: chipped/worn teeth, excessive bearing/bushing wear, broken carrier or sun gear, collapsed thrust washers, and excessive axial (endplay) or radial play. Cause: metal fatigue from overload, poor lubrication (burnt fluid, plugged filter), contaminated fluid (metal particles), or worn hydraulic control (slips lead to overheating and gear damage).
- Symptoms tied to theory: grinding/metallic noise under load = damaged gear teeth or bearings; clunk on engage = excessive endplay/loose carrier or degraded snap rings; slipping/flat shifts = worn clutch surfaces but metal debris from a failing planetary can damage clutches; burnt fluid/overheating = internal friction from misalignment/worn bearings.

2) Preparatory theory and purpose of steps
- You must remove the transmission and separate the torque converter/input path to access the planetary assembly in the maincase or intermediate drum. Every removed hydraulic/rotational component either blocks access or secures the gearset; remove in order to avoid damaging sealing faces or losing small parts (snap rings, thrusts).
- Inspection and measurement are critical: replacing only the visibly damaged gear without checking bushings, bearings, thrust clearances, and endplay will leave the root cause; correct replacement restores geometry and preload so clutches and hydraulic circuits work normally.

3) High-level ordered procedure with theory at each step (concise)
1. Safety & preparation
- Disconnect battery, lift car safely, drain ATF. Purpose: prevent electrical hazards and reduce mess; draining reduces weight and spillage when separating.
2. Remove transmission from vehicle
- Unbolt driveshafts/axles, disconnect linkages, cooler lines, electrical connectors, support transmission and drop it. Purpose: to provide full access; planetary gearset sits inside transmission case.
3. Remove torque converter and transmission bellhousing components
- Remove torque converter from input shaft (after loosening trans from engine) and separate bellhousing. Theory: torque converter engages the input to the planetary; it must be removed to access input drum/sun gear.
4. Disassemble valve body/pumps/drums blocking access
- Remove valve body and oil pump cover as required, then the direct/reverse clutch drums and intermediate plates. Purpose: these components are stacked and must come off in sequence to get to the planetary carrier or ring gear.
5. Expose planetary assembly
- Remove snap rings, retaining plates, and bearing caps to free the carrier, sun gear and ring. Theory: planet carrier is typically held by circlips and thrust washers; removing retaining hardware allows extraction.
6. Remove sun gear, planet gears and carrier
- Lift carrier with planet gears, inspect cage and planets, then remove sun gear and ring gear (ring gear may be part of case or removable). Purpose: separate components so each can be examined/replaced; bearing and bushing wear are often internal and hidden until disassembled.
7. Clean and assess
- Thoroughly clean every part and the case. Magnetic drain plugs/filters often show metal debris — note particle sizes. Theory: cleanliness is essential for accurate inspection and prevents re-abrasion of new parts.
8. Inspect and measure tolerances
- Check gear teeth for pitting/chipping, measure bearing play, bushing clearances (use a bore gauge or feeler), check thrust washer thickness and endplay with a dial indicator. Purpose: determine what exactly failed and whether case or shafts are damaged. Excessive endplay requires shims or new thrusts; radial clearances require new bushings or bearings.
9. Replace worn components
- Replace planet gears, sun gear, ring gear, carrier bearings/bushings, thrust washers, snap rings and any related clutch packs/seals/soft parts contaminated by metal. Theory: replacing only the visibly damaged teeth without bearings/bushings allows residual play and misalignment to persist; replacing the support hardware restores correct gear alignment and load distribution.
10. Set clearances and endplay during reassembly
- Reassemble planet carrier and gearset with new thrusts/shims as required. Measure ring/sun clearance and carrier endplay; adjust by adding/removing shims or selecting correct bushings. Theory: proper axial and radial clearances keep planet meshes centered on tooth (correct contact pattern) and maintain preload on bearings so loads are taken by intended surfaces, preventing chatter, clunk, and accelerated wear.
11. Reassemble drums, valve body, pump and external parts in reverse order
- Replace all seals and gaskets; torque bolts to factory specs. Theory: hydraulic integrity and torque specs ensure clutches engage reliably and that no leaks or distortions change clearances.
12. Reinstall torque converter and transmission
- Ensure torque converter fully engages input splines and pump drives; refill with correct ATF. Theory: incomplete seating means the pump won’t prime or causes early wear; correct fluid fills hydraulic circuits and cools/lubricates.
13. Initial filling, bleeding and test
- Start engine, cycle through gears, check for leaks, verify fluid level at operating temperature. Road test to confirm shifts and absence of noise.

4) How the repair fixes the fault — component-by-component theory
- Gear tooth replacement: restores proper mesh geometry so torque transfers without impact loads. Damaged teeth concentrate stress and can nick mating gear surfaces, creating noise and progressive failure.
- Carrier/planet bearings and bushings: restore concentric support so planets rotate true on the carrier. Worn bushings allow radial runout -> mis-mesh -> heat and accelerated tooth wear. New bearings re-establish intended clearances and load paths.
- Thrust washers and shims (endplay): restore axial position. Excessive endplay causes clunking on engagement and disengagement because a member shifts before the next one is engaged; too little endplay can bind and cause overheating. Correct setting ensures clutches and brakes engage with predictable travel and hydraulic timing.
- Snap rings and retaining hardware: secure the position under load. Broken or deformed rings let carriers shift causing noise and catastrophic failure.
- Replacing contaminated clutches/filters/fluid: removes abrasive particles and restores friction characteristics. Metal contamination wears down new gears if not cleaned/replaced.
- Rebuilding seals and valve body components: ensures hydraulic pressures for clutch application are correct. Many planetary faults appear as poor shift quality; even with new gearset, weak hydraulics will cause slip and overheating which damages gears again.

5) Key measurements and their meaning (what to check and why)
- Gear tooth contact pattern: shows whether mesh is centered — incorrect pattern indicates misalignment.
- Bearing preload and radial play: prevents fretting and oscillation.
- Carrier/sun/ring axial endplay: controls free movement and engagement timing.
- Oil passages and pump pressure: low pressure causes slip and overheating, which killed the gearset initially.

6) Final notes (concise)
- Use factory service manual for exact disassembly order, torque values, shim selection method and clearances — those are specific to the transmission model.
- Replacing the planetary gearset without addressing contaminated fluid, damaged clutches, or worn hydraulic components risks repeat failure; a complete rebuild mindset (gears + supports + seals + fluid) is required to fix the root cause.
- Proper diagnosis (identify metal debris, burnt fluid, failure pattern) guides whether a partial or full rebuild is necessary.
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