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Home >> Nissan-Datsun >> 2004 >> Frontier Base, Standard >> Repair and Diagnosis >> Transmission >> Manual Transmission - FS5W71C >> Gear Components >> Disassembly

Gear Components: Disassembly

  1. Before disassembly, measure the end play of each gear.
    • If end play is not within the specified limit, disassemble and inspect the parts.
    • Replace any part which is worn or damaged. Refer to GEAR END PLAY .
    Fig 1: Inspecting End Play
    G00771199Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Mesh 2nd and reverse gear, then remove counter gear front bearing using a suitable puller.
  3. Remove counter gear snap ring, then remove sub-gear bracket, sub-gear spring and sub-gear.
    Fig 2: Removing Sub-Gear Bracket, Sub-Gear Spring And Sub-Gear
    G00771200Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Remove counter drive gear together with main drive gear assembly using a suitable puller. Remove woodruff keys and pilot bearing.
    • When removing main drive gear assembly, be careful not to drop pilot bearing or baulk ring.
  5. Remove mainshaft front snap ring, then remove 3rd and 4th synchronizer assembly, 3rd main gear and needle bearing using suitable puller.
    Fig 3: Removing Drive Gear Assembly
    G00771201Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Disassemble parts at rear of adapter plate as follows:
    1. Release staking on both counter gear and mainshaft lock nuts, then loosen both nuts.
      1. Mainshaft lock nut: Left-hand thread 
      Fig 4: Releasing Staking On Both Counter Gear And Mainshaft Lock Nuts
      G00771202Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Remove over drive counter gear together with counter gear rear end bearing using a suitable puller.
    3. Remove reverse counter gear and reverse counter gear spacer.
    4. Remove snap rings from reverse idler shaft, then remove reverse idler gear, sub-gear, sub-gear spring, sub-gear bracket, steel ball, reverse idler thrust washer and reverse idler gear bearing.
      Fig 5: Removing Overdrive Mainshaft Bearing Snap Ring
      G00771203Courtesy of NISSAN MOTOR CO., U.S.A.
    5. Remove overdrive mainshaft bearing snap ring and pull out overdirve mainshaft bearing using Tool, then remove snap ring.
      1. Tool number: (J-26349-A), (J-25726-B) 
    6. Remove mainshaft lock nut.
    7. Remove speedometer drive gear and steel ball.
    8. Remove thrust washer, steel roller, roller bearing and washer.
    9. Remove overdrive main gear, needle bearing and overdrive baulk ring.
    10. Remove counter gear by tapping on rear end of counter gear.
    11. Press out overdrive gear bushing and overdrive & reverse synchronizer assembly.
    12. Remove reverse main gear and needle bearing.
    13. Press out reverse main gear bushing.
      Fig 6: Pressing Out Reverse Main Gear Bushing
      G00771204Courtesy of NISSAN MOTOR CO., U.S.A.
    14. Remove mainshaft by tapping on rear end of mainshaft.
  7. Remove 1st gear thrust washer, steel ball, 1st main gear and needle bearing and 1st and 2nd synchronizer assembly.
    • Be careful not to lose steel ball.
    Fig 7: Removing 1st Gear Thrust Washer, Steel Ball
    G00771205Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Press out 1st gear bushing together with 2nd main gear using Tool.
    1. Tool number: ST30031000 (J22912-01) 
    Fig 8: Pressing Out 1st Gear Bushing Together With 2nd Main Gear Using Tool
    G00771206Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Remove 2nd gear needle bearing.
  10. Remove main drive gear ball bearing.
    1. Remove main drive gear ball bearing snap ring.
    2. Remove main drive gear ball bearing using Tool.
      1. Tool number: ST30031000 (J22912-01) 
    Fig 9: Removing Main Drive Gear Ball Bearing Using Tool
    G00771207Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Disassemble adapter plate components.
    1. Remove bearing retainer.
    2. Remove oil gutter
    3. Remove reverse idler shaft.
    4. Remove mainshaft ball bearing and counter rear bearing using suitable tool.
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