Disassembly and Assembly: Assembly

Gear Components 

1. Install 5th-6th coupling sleeve and 5th-6th shifting inserts onto 5th-6th synchronizer hub.
   CAUTION:

   • Do not reuse 5th-6th synchronizer hub and 5th-6th coupling sleeve.
   • Install 5th-6th coupling sleeve with the larger chamfer on the rear side.
   Fig 1: Transmission Reassembly (1 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
   CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
   Fig 2: Transmission Reassembly (2 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install 5th-6th spread springs in 5th-6th shifting inserts.
   CAUTION: Install the hook of each spread spring onto separate shifting inserts.
   Fig 3: Transmission Reassembly (3 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
3. Install 6th needle bearing, 6th main gear, 6th baulk ring and 5th-6th synchronizer assembly onto main shaft using a press and the inserter.
   1. Tool number :ST30911000 (-) 
   Fig 4: Transmission Reassembly (4 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
   CAUTION: The rear side of synchronizer hub has three oil grooves. When press fitting, install the rear side to the rearward.
   Fig 5: Transmission Reassembly (5 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
4. Select and install snap ring onto the front side of main shaft so that the end play comes within the specifications. Refer to "Snap Rings ".
   1. End play :0 - 0.1 mm (0 - 0.004 in) 
   CAUTION: Do not reuse snap ring.
   Fig 6: Transmission Reassembly (6 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
5. Install 1st-2nd coupling sleeve and 1st-2nd shifting inserts onto 1st-2nd synchronizer hub.
   CAUTION:

   • Do not reuse 1st-2nd synchronizer hub and 1st-2nd coupling sleeve.
   • Install 1st-2nd coupling sleeve with the thicker flange faced the front side.
   Fig 7: Transmission Reassembly (7 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
   CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
   Fig 8: Transmission Reassembly (8 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
6. Install 1st-2nd spread spring in 1st-2nd shifting inserts onto 1st-2nd synchronizer hub.
   CAUTION: Install hook of each spread spring onto separate shifting inserts.
   Fig 9: Transmission Reassembly (9 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
7. Install 2nd needle bearing, 2nd main gear, 2nd inner baulk ring, 2nd synchronizer cone, 2nd outer baulk ring and 1st-2nd synchronizer assembly onto main shaft using a press and the support ring.
   1. Tool number :ST27861000 (-) 
   Fig 10: Transmission Reassembly (10 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
   CAUTION: Install with the side, which has identification mark on one of four oil grooves on the boss edge surface, facing rearward.
   Fig 11: Transmission Reassembly (11 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
8. Install 1st gear bushing onto main shaft using a press and the support ring.
   1. Tool number :ST27861000 (-) 
   Fig 12: Transmission Reassembly (12 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
9. Install 1st needle bearing, 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 3rd main gear and 1st main gear onto main shaft using a press and the inserter.
   1. Tool number :ST30022000 (-) 
   CAUTION: Do not reuse 3rd main gear.
   Fig 13: Transmission Reassembly (13 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
10. Install 3rd-4th main spacer and 4th main gear onto main shaft using a press and the inserter.
    1. Tool number :ST30022000 (-) 
    CAUTION:

    • Do not reuse 4th main gear.
    • Install with the side on which the boss protrudes out of gear edge surface facing rearward.
    Fig 14: Transmission Reassembly (14 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
11. Install main shaft bearing onto main shaft using a press and the inserter.
    1. Tool number :ST30911000 (-) 
    Fig 15: Transmission Reassembly (15 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
12. Install reverse main gear bushing onto main shaft using a press and the inserter.
    1. Tool number :ST30911000 (-) 
    Fig 16: Transmission Reassembly (16 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
13. Install 3rd gear bushing onto counter shaft using a press and the inserter.
    1. Tool number :ST30911000 (-) 
    Fig 17: Transmission Reassembly (17 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
14. Install 3rd-4th coupling sleeve and 3rd-4th shifting inserts onto 3rd-4th synchronizer hub.
    CAUTION:

    • Do not reuse 3rd-4th synchronizer hub and 3rd-4th coupling sleeve.
    • Install 3rd-4th coupling sleeve with the thicker flange faced the front side.
    Fig 18: Transmission Reassembly (18 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
    Fig 19: Transmission Reassembly (19 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
15. Install 3rd-4th spread springs into 3rd-4th shifting insert.
    CAUTION: Install the hook of each spread spring onto separate shifting inserts.
    Fig 20: Transmission Reassembly (20 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
16. Install 3rd needle bearing, 3rd counter gear, 3rd inner baulk ring, 3rd synchronizer cone, 3rd outer baulk ring and 3rd-4th synchronizer assembly onto counter shaft using a press and the drift.
    1. Tool number :ST30911000 (-) 
    Fig 21: Transmission Reassembly (21 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
17. Install 4th outer baulk ring, 4th synchronizer cone, 4th inner baulk ring, 4th gear bushing, 4th needle bearing, 4th counter gear and 4th counter shaft thrust washer onto counter shaft using a press and the drift.
    1. Tool number :KV40100630 (J26029) 
    Fig 22: Transmission Reassembly (22 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
18. Install counter rear bearing inner race onto counter shaft using a press and the drift.
    1. Tool number :ST30032000 (J26010-01) 
    Fig 23: Transmission Reassembly (23 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
19. Install main drive bearing onto main drive gear using a press and the drift.
    1. Tool number :KV32102700 (-) 
    Fig 24: Transmission Reassembly (24 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
20. Select and install snap ring on main drive gear so that comes within the specifications. Refer to "Snap Rings ".
    1. End play :0 - 0.1 mm (0 - 0.004 in) 
    CAUTION: Do not reuse snap ring.
    Fig 25: Transmission Reassembly (25 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
21. Install 5th baulk ring, pilot bearing spacer, main pilot bearing and main drive gear onto main shaft.
22. Install main shaft and counter shaft combined in one unit to adapter plate, and secure main shaft bearing with a snap ring.
    1. Tap main shaft bearing slightly via brass bar or the equivalent to install snap ring.
    2. After installing snap ring, hammer snap ring and adapter plate slightly in the reverse direction to make them in contact with each other.
       CAUTION: Do not reuse snap ring.
       Fig 26: Transmission Reassembly (26 Of 71)

       Courtesy of NISSAN MOTOR CO., U.S.A.
23. Install counter rear bearing outer race onto adapter plate using plastic hammer or equivalent.
    Fig 27: Transmission Reassembly (27 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
24. Apply genuine medium strength locking sealant or equivalent (refer to GI section) to the end of the bolt (first 3 to 4 threads). Install main shaft bearing retainer onto adapter plate, and tighten bolts to the specified torque. Refer to "CASE COMPONENTS ".
    Fig 28: Transmission Reassembly (28 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
25. Install reverse coupling sleeve and reverse shifting inserts onto reverse synchronizer hub.
    CAUTION:

    • Do not reuse reverse synchronizer hub and reverse coupling sleeve.
    • Install reverse coupling sleeve with the flat flange on the rear side.
    Fig 29: Transmission Reassembly (29 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
    Fig 30: Transmission Reassembly (30 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
26. Install spread springs into shifting insert.
    CAUTION: Install the hook of each spread spring onto separate shifting inserts.
    Fig 31: Transmission Reassembly (31 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
27. Install reverse main needle bearing, reverse main gear, reverse baulk ring and reverse synchronizer assembly onto main shaft using a press, the press plate and the drift.
    1. Tool number (A) :KV32103300 (J46529) 
    2. Tool number (B) :ST01530000 (-) 
    Fig 32: Transmission Reassembly (32 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: When installing, face the side with three grooves to the front side.
    Fig 33: Transmission Reassembly (33 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
28. Select and install a snap ring to the main shaft rear side so that the end play comes within the standard value. Refer to "Snap Rings ".
    1. End play :0 - 0.1 mm (0 - 0.004 in) 
    CAUTION: Do not reuse snap ring.
    Fig 34: Transmission Reassembly (34 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
29. Install counter rear bearing spacer and reverse counter gear using a press and the drift.
    1. Tool number :ST23860000 (-) 
    CAUTION:

    • Do not reuse reverse counter gear.
    • When installing counter rear bearing spacer, maker's stamp should face to the rear.
    Fig 35: Transmission Reassembly (35 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
30. Select and install a snap ring to the counter shaft so that the end play comes within the standard value. Refer to "Snap Rings ".
    1. End play :0 - 0.1 mm (0 - 0.004 in) 
    CAUTION: Do not reuse snap ring.
    Fig 36: Transmission Reassembly (36 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.

Shift Control Components 

1. Install 5th-6th shift fork to 5th-6th coupling sleeve.
2. Install 5th-6th fork rod (reversal side) to 5th-6th shift fork.
3. Drive retaining pin into 5th-6th shift fork using a pin punch [6 mm (0.24in) dia.].
   CAUTION: Do not reuse retaining pin.
   Fig 37: Transmission Reassembly (37 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
4. Install 5th-6th fork rod to adapter plate.
5. Install 5th-6th fork rod bracket to 5th-6th fork rod.
6. Drive retaining pin into 5th-6th fork rod bracket using a pin punch [6 mm (0.24in) dia.].
   CAUTION: Do not reuse retaining pin.
   Fig 38: Transmission Reassembly (38 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
7. Install 5th-6th control lever to adapter plate, and then tighten mounting bolts to the specified torque. Refer to "SHIFT CONTROL COMPONENTS ".
   CAUTION: Set the projection upward.
   Fig 39: Transmission Reassembly (39 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
8. Insert check balls into adapter plate.
   Fig 40: Transmission Reassembly (40 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
9. Install reverse shift fork onto reverse coupling sleeve.
10. Insert reverse fork rod to reverse shift fork.
11. Drive retaining pin into reverse shift fork using a pin punch [6 mm (0.24 in) dia.].
    CAUTION: Do not reuse retaining pin.
    Fig 41: Transmission Reassembly (41 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
12. Insert interlock pin and interlock plunger into adapter plate.
    Fig 42: Transmission Reassembly (42 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
13. Install 1st-2nd shift fork onto 1st-2nd coupling sleeve.
14. Insert 1st-2nd fork rod to 1st-2nd shift fork.
15. Drive retaining pin into 1st-2nd shift fork using a pin punch [6 mm (0.24 in) dia.].
    CAUTION: Do not reuse retaining pin.
    Fig 43: Transmission Reassembly (43 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
16. Install 3rd-4th shift fork onto 3rd-4th coupling sleeve.
17. Install 3rd-4th fork rod (reversal side) to 3rd-4th shift fork.
18. Drive retaining pin into 3rd-4th shift fork (reversal side) using a pin punch [6 mm (0.24 in) dia.].
    CAUTION: Do not reuse retaining pin.
    Fig 44: Transmission Reassembly (44 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
19. Insert interlock pin and check balls into adapter plate.
    Fig 45: Transmission Reassembly (45 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
20. Install 3rd-4th fork rod to adapter plate.
21. Install 3rd-4th fork rod bracket to 3rd-4th fork rod.
22. Drive retaining pin into 3rd-4th fork rod bracket using a pin punch [6 mm (0.24 in) dia.].
    CAUTION: Do not reuse retaining pin.
    Fig 46: Transmission Reassembly (46 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
23. Insert check ball, check ball spring into adapter plate, apply genuine anaerobic liquid gasket or equivalent (refer to GI section) to check ball plug threads, and tighten to the specified torque. Refer to "SHIFT CONTROL COMPONENTS ".
    Fig 47: Transmission Reassembly (47 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
24. Install shifter cap to 3rd-4th control lever.
25. Insert 3rd-4th control lever to adapter plate, and then tighten mounting bolts to the specified torque. Refer to "SHIFT CONTROL COMPONENTS ".
    CAUTION: Make sure the top and bottom are oriented correctly.
    Fig 48: Transmission Reassembly (48 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
26. Insert check ball spring and check ball into the adapter plate, apply genuine anaerobic liquid gasket or equivalent (refer to GI section) to the check ball plug threads, and tighten to the specified torque. Refer to "SHIFT CONTROL COMPONENTS ".
    Fig 49: Transmission Reassembly (49 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
27. Install striking rod to adapter plate.
28. Install striking lever to striking rod.
29. Drive retaining pin into striking lever using a pin punch [6 mm (0.24 in) dia.].
    CAUTION: Do not reuse retaining pin.
    Fig 50: Transmission Reassembly (50 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
30. Install baffle plate onto adapter plate, and tighten mounting bolts to the specified torque.
    Fig 51: Transmission Reassembly (51 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.

Case Components 

1. Install counter front bearing in transmission case.
2. Install oil gutter to transmission case.
   Fig 52: Transmission Reassembly (52 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
3. Apply genuine anaerobic liquid gasket or equivalent (refer to GI section) to adapter plate mounting surface of transmission case as shown in the figure.
   CAUTION: Completely remove all moisture and oil, etc., from the transmission case and adapter plate mounting surfaces.
4. Install magnet to adapter plate.
   Fig 53: Transmission Reassembly (53 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
5. Install adapter plate onto transmission case and then tap adapter plate with a soft hammer to seat it completely on transmission case.
   Fig 54: Transmission Reassembly (54 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
6. Install snap ring to main drive gear bearing using snap ring pliers.
   CAUTION: Do not reuse snap ring.
   Fig 55: Transmission Reassembly (55 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
7. Tighten baffle plate mounting nut to the specified torque. Refer to "CASE COMPONENTS ".
   Fig 56: Transmission Reassembly (56 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
8. Apply multi-purpose grease to the lip of front cover oil seal. Install front cover oil seal approx. 8.55-9.55 mm (0.336-0.376 in) above from the front cover edge surface using a drift.
   1. Tool number :KV38102100 (J25803-01) 
   CAUTION:

   • Do not reuse front cover oil seal.
   • When installing, do not tilt front cover oil seal.
   Fig 57: Transmission Reassembly (57 Of 71)

   Courtesy of NISSAN MOTOR CO., U.S.A.
9. Install front cover gasket and front cover to transmission case.
   CAUTION: Do not reuse gasket.
10. Temporarily tighten bolts in the positions shown in the figure.
    Fig 58: Transmission Reassembly (58 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
11. Install remaining bolts, and tighten them by hand.
    CAUTION: Four bolts pointed by arrows in the figure are not reusable.
    Fig 59: Transmission Reassembly (59 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
12. Tighten bolts to the specified torque in order as shown in the figure. Refer to "CASE COMPONENTS ".
    Fig 60: Transmission Reassembly (60 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
13. Install washer to withdrawal lever ball pin, and install it to front cover. Tighten withdrawal lever ball pin to the specified torque. Refer to "CASE COMPONENTS ".
    Fig 61: Transmission Reassembly (61 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
14. Install rear extension oil gutter to rear extension, and then tighten bolt to specified torque. Refer to "CASE COMPONENTS ".
15. Install reverse idler shaft, reverse idler needle bearing, reverse idler gear and reverse thrust washer to adapter plate.
16. Apply multi-purpose grease to the lip of control shaft oil seal. Install control shaft oil seal to rear extension using the drift.
    1. Tool number :ST35291000 (-) 
    CAUTION:

    • Do not reuse striking rod oil seal.
    • When installing, do not tilt striking rod seal.
    Fig 62: Transmission Reassembly (62 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
17. Apply multi - purpose grease to the lip of the rear oil seal. Using a drift, to install rear oil seal. 1.2-2.2 mm (0.047-0.087 in) above from the rear extension edge surface.
    1. Tool number :ST33400001 (J26082) 
    CAUTION:

    • Do not reuse rear oil seal.
    • When installing, do not tilt rear oil seal.
    Fig 63: Transmission Reassembly (63 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
18. Place shift forks in neutral position.
19. Apply genuine anaerobic liquid gasket or equivalent (refer to GI section) to rear extension mounting surface of adapter plate as shown in the figure.
    CAUTION: Completely remove all moisture, oil, etc., from the adapter plate and rear extension mating surfaces.
    Fig 64: Transmission Reassembly (64 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
20. Install rear extension to transmission case, and tighten mounting bolts to the specified torque in order as shown in the figure. Refer to "CASE COMPONENTS ".
21. Install control lever housing to rear extension, and then tighten mounting bolts to the specified torque. Refer to "SHIFT CONTROL COMPONENTS ".
    Fig 65: Transmission Reassembly (65 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
22. Insert return spring and plunger into the rear extension, apply genuine anaerobic liquid gasket or equivalent (refer to GI section) to the return spring plug threads, and then tighten to the specified torque. Refer to "SHIFT CONTROL COMPONENTS ".
    Fig 66: Transmission Reassembly (66 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
    Fig 67: Transmission Reassembly (67 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: The right and left return springs and plungers are different, so make sure they are installed correctly.
23. Install shift check pin and control bracket as a one unit to rear extension, and then tighten mounting bolts to specified torque. Refer to "SHIFT CONTROL COMPONENTS ".
24. After screwing plunger, neutral position switch and back-up lamp switch to rear extension with 1-2 pitches, apply genuine anaerobic liquid gasket or equivalent (refer to GI section) to the switch threads, and tighten them to the specified torque. Refer to "CASE COMPONENTS ".
    Fig 68: Transmission Reassembly (68 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
25. Drive retaining pin into control rod using a pin punch [6 mm (0.24 in) dia.].
    CAUTION: Do not reuse retaining pin.
    Fig 69: Transmission Reassembly (69 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
26. Insert check select spring and check ball into rear extension.
    Fig 70: Transmission Reassembly (70 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.
27. Install rear extension upper cover gasket and rear extension upper cover to rear extension.
    CAUTION:

    • Do not reuse rear extension upper cover gasket.
    • Avoid tangling check select spring.
28. Tighten rear extension upper cover bolts to specified torque in order as shown in the figure. Refer to "CASE COMPONENTS ".
    Fig 71: Transmission Reassembly (71 Of 71)

    Courtesy of NISSAN MOTOR CO., U.S.A.