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Disassembly and Assembly: Assembly

  1. Using a drift, install a new input shaft oil seal from the clutch housing end of side to the depth of 1.8 - 2.8 mm (0.071 - 0.110 in).
    CAUTION: Oil seals are not reusable.
    Fig 1: Input Shaft Oil Seal At Clutch Housing
    G02886245Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Using a drift, install a new differential oil seal.
    CAUTION: Oil seals are not reusable.
    Fig 2: Installing Differential Oil Seal
    G02886246Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install oil channel on mainshaft side as shown.
    CAUTION: Use the correct orientation for installation as shown.
    Fig 3: Installing Oil Channel On Mainshaft Side
    G02886247Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Using a drift, install mainshaft front bearing.
    CAUTION: Use the correct orientation for installation as shown.
    Fig 4: Installing Mainshaft Front Bearing
    G02886248Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install bearing retainer.
    CAUTION: Install with the punched surface facing up.
    Fig 5: Installing Bearing Retainer
    G02886249Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install differential side bearing outer race.
    Fig 6: Installing Differential Side Bearing Outer Race
    G02886250Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install final drive assembly into clutch housing.
    Fig 7: Installing Final Drive Assembly Into Clutch Housing
    G02886251Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing.
    CAUTION: Be sure not to damage input shaft oil seal.
    Fig 8: Installing Input Shaft Assembly
    G02886252Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install 1st-2nd fork rod bracket onto 1st-2nd fork rod, and then install retaining pin.
    CAUTION: Retaining pins are not reusable. Never reuse them.
    Fig 9: Installing 1st-2nd Fork Rod Bracket Onto 1st-2nd Fork Rod
    G02886253Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install 1st-2nd fork rod and 1st-2nd shift fork, and then install retaining pin.
    CAUTION: Retaining pins are not reusable. Never reuse them.
    Fig 10: Installing 1st-2nd Fork Rod & 1st-2nd Shift Fork
    G02886254Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install shift check sleeve.
  12. Install 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with inter lock pin.
    Fig 11: Installing 3rd-4th Bracket, 3rd-4th Shift Fork, & 3rd-4th Fork Rod With Inter Lock Pin
    G02886255Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install stopper ring onto 3rd-4th shift fork.
    CAUTION: Stopper rings are not reusable. Never reuse them.
  14. Install retaining pin onto 3rd-4th bracket.
    CAUTION: Retaining pins are not reusable. Never reuse them.
  15. Install 2 check balls.
  16. Install 5th-reverse bracket, 5th shift fork, and 5th-reverse fork rod.
    Fig 12: Installing 5th-Reverse Bracket, 5th Shift Fork, And 5th-Reverse Fork Rod
    G02886256Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install stopper ring onto 5th-reverse bracket.
    CAUTION: Stopper rings are not reusable. Never reuse them.
  18. Install retaining pin onto 5th shift fork.
    CAUTION: Retaining pins are not reusable. Never reuse them.
    Fig 13: Installing Retaining Pin Onto 5th Shift Fork
    G02886257Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Install reverse shift fork and reverse fork rod.
  20. Install reverse lever assembly following procedures below.
    1. Install shifter cap onto reverse lever assembly cam, and then install them onto reverse shift fork.
      CAUTION: Do not drop shifter cap.
    2. While lifting reverse shift fork, align cam with 5th-reverse bracket.
      Fig 14: Installing Shifter Cap Onto Reverse Lever Assembly Cam
      G02886258Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Tighten mounting bolts to specified torque, and then install reverse lever assembly.
      Fig 15: Tightening Mounting Bolts
      G02886259Courtesy of NISSAN MOTOR CO., U.S.A.
  21. Install the magnet onto clutch housing.
  22. Install the selected input shaft adjusting shim onto the input shaft.
  23. Install baffle plate and oil gutter.
  24. Install transaxle case using the following procedure:
    1. Install selected mainshaft rear bearing adjusting shim into transaxle case.
    2. Temporarily install a new snap ring of mainshaft rear bearing into transaxle case.
      CAUTION: Do not reuse the snap ring.
    3. Apply Anaerobic Liquid Gasket or equivalent to mating surfaces of transaxle case and clutch housing. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
      Fig 16: Removing Sealant Adhering To Mounting Surfaces
      G02886260Courtesy of NISSAN MOTOR CO., U.S.A.
    4. With snap ring of mainshaft rear bearing temporarily installed, place transaxle case over clutch housing.
      Fig 17: Placing Transaxle Case Over Clutch Housing
      G02886261Courtesy of NISSAN MOTOR CO., U.S.A.
    5. Through bore plug mounting hole, with snap ring stretched, and lift up mainshaft assembly from the control assembly mounting hole.
      Fig 18: Identifying Snap Ring
      G02886262Courtesy of NISSAN MOTOR CO., U.S.A.
    6. Securely install snap ring onto mainshaft rear bearing.
    7. Tighten the mounting bolts "A" and the new bolts "B".

      Bolt "A" 50.0 - 53.9 N.m (5.1 - 5.4 kg-m, 37 - 39 ft-lb) 

      Bolt "B" : 63.0 - 66.9 N.m (6.5 - 6.8 kg-m, 47 - 49 ft-lb) 

      CAUTION: Always replace bolts "B" because they are self-sealing bolts.
      Fig 19: Tightening Mounting Bolts
      G02886263Courtesy of NISSAN MOTOR CO., U.S.A.
    8. Install control assembly.
      CAUTION: Do not reuse the O-ring.
    9. Install shift check and a new stopper bolt.
      CAUTION: Shift check and stopper bolt are not reusable.
  25. Using a drift, install a new bore plug as shown.
    CAUTION: Bore plugs are not reusable.
    Fig 20: Installing Bore Plug
    G02886264Courtesy of NISSAN MOTOR CO., U.S.A.
  26. Install a welch plug using a drift.
    Fig 21: Installing A Welch Plug Using A Drift
    G02886265Courtesy of NISSAN MOTOR CO., U.S.A.
  27. Install 1 shift check sleeve, 3 check balls, 3 check springs, and 3 check ball plugs.
    CAUTION: Check ball plugs are not reusable. Never reuse them.
    Fig 22: Installing 1 Shift Check Sleeve, 3 Check Balls, 3 Check Springs
    G02886266Courtesy of NISSAN MOTOR CO., U.S.A.
  28. Apply Anaerobic Liquid Gasket or equivalent to threads of neutral switch and reverse lamp switch. Then install them into transaxle case. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
    Fig 23: Identifying Neutral Switch And Reverse Lamp Switch
    G02886267Courtesy of NISSAN MOTOR CO., U.S.A.
  29. Install gaskets onto drain plug and filler plug, and then install them into transaxle case.
    CAUTION:
    • Gaskets are not reusable. Never reuse them.
    • After oil is filled, tighten filler plug to specified torque.
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