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Disassembly and Assembly: Assembly

  1. Install a new input shaft oil seal from the clutch housing end of the side, to the depth of 1.8 - 2.8 mm (0.071 - 0.110 in) using Tool as shown.

    Tool number: ST35321000 (-) 

    CAUTION: Oil seals are not reusable.
    Fig 1: Installing Input Shaft Oil Seal
    G04167956Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install a new differential oil seal using Tool as shown.

    Tool number: ST30720000 (J-25405) 

    CAUTION: Oil seals are not reusable.
    Fig 2: Installing Differential Oil Seal Using Tool
    G04167957Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install the oil channel on the mainshaft side as shown.
    CAUTION: Position the oil channel with the orientation as shown, for installation.
    Fig 3: Installing Oil Channel On Mainshaft Side
    G04167958Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install the mainshaft front bearing using Tool as shown.

    Tool number: ST33200000 (J-26082) 

    CAUTION: Position the mainshaft front bearing with the orientation as shown, for installation.
    Fig 4: Installing Mainshaft Front Bearing Using Tool
    G04167959Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install the mainshaft front bearing retainer.
    CAUTION: Install the bearing retainer with the punched surface facing up.

    Retainer bolt: 6.27 - 8.33 N.m (0.64 - 0.84 kg-m, 56 - 73 in-lb) 

    Fig 5: Installing Mainshaft Front Bearing Retainer
    G04167960Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install the differential side bearing outer race using Tool as shown.

    Tool number: ST30720000 (J-25405) 

    Fig 6: Installing Differential Side Bearing Outer Race Using Tool
    G04167961Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install the final drive assembly into the clutch housing.
    Fig 7: Installing Final Drive Assembly Into Clutch Housing
    G04167962Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install the input shaft assembly, mainshaft assembly, and reverse idler gear assembly into the clutch housing.
    CAUTION: Do not damage the input shaft oil seal.
    Fig 8: Installing Input Shaft Assembly, Mainshaft Assembly, And Reverse Idler Gear Assembly Into Clutch Housing
    G04167963Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install the 1st-2nd fork rod bracket onto the 1st-2nd fork rod, and then install a new retaining pin as shown.
    CAUTION: Retaining pins are not reusable.
    Fig 9: Installing 1st-2nd Fork Rod Bracket Onto 1st-2nd Fork Rod
    G04167964Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install the 1st-2nd fork rod and the 1st-2nd shift fork, and then install a new retaining pin.
    CAUTION: Retaining pins are not reusable.
    Fig 10: Installing 1st-2nd Fork rod And 1st-2nd Shift Fork
    G04167965Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install the shift check sleeve.
  12. Install the 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with the interlock pin.
  13. Install the new stopper rings onto the 3rd-4th shift fork.
    CAUTION: Stopper rings are not reusable.
    Fig 11: Installing Stopper Rings Onto 3rd-4th Shift Fork
    G04167966Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install a new retaining pin onto the 3rd-4th bracket.
    CAUTION: Retaining pins are not reusable.
  15. Install the 2 check balls.
  16. Install the 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod.
  17. Install new stopper rings onto the 5th-6th bracket with interlock pin.
    CAUTION: Stopper rings are not reusable.
    Fig 12: Installing Stopper Rings Onto 5th-6th Bracket With Interlock Pin
    G04167967Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install a new retaining pin onto the 5th-6th shift fork.
    CAUTION: Retaining pins are not reusable.
    Fig 13: Installing Retaining Pin Onto 5th-6th Shift Fork
    G04167968Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Install the two check balls.
  20. Install the 5th-6th check ball, 5th-6th shift check sleeve, 5th-6th check spring, and the 5th-6th check ball plug.
    CAUTION:
    • Do not reuse the check ball plug.
    • Do not drop the check ball.
  21. Install the reverse bracket fork rod and reverse lever bracket.
  22. Install a new retaining pin onto the reverse bracket.
    CAUTION: Retaining pins are not reusable.
    Fig 14: Installing Retaining Pin Onto Reverse Bracket
    G04167969Courtesy of NISSAN MOTOR CO., U.S.A.
  23. Install the reverse shift fork and reverse fork rod.
  24. Install the reverse lever assembly using the following steps:
    1. Install the shifter cap onto the reverse lever assembly cam, and then install them onto the reverse shift fork.
      CAUTION: Do not drop the shifter cap.
    2. While lifting the reverse shift fork, align the cam with the reverse bracket.
      Fig 15: Aligning Cam With Reverse Bracket
      G04167970Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Tighten the bracket bolts to specification, and install the reverse lever assembly.

      Bracket bolts: 13.7 N.m (1.4 kg-m, 10 ft-lb) 

      Fig 16: Tightening Bracket Bolts
      G04167971Courtesy of NISSAN MOTOR CO., U.S.A.
  25. Install the check ball, reverse shift check sleeve, reverse check spring, and the reverse check ball plug.
    CAUTION:
    • Do not reuse the check ball plug.
    • Do not drop the check ball.
  26. Install the magnet onto the clutch housing.
  27. Install the selected input shaft adjusting shim onto the input shaft. Refer to , "INPUT SHAFT END PLAY ".
  28. Install selected differential side bearing adjusting shim and differential side bearing outer race. Refer to , "DIFFERENTIAL SIDE BEARING PRELOAD ".
  29. Install the baffle plate and oil gutter.
  30. Install the transaxle case using the following steps:
    1. Install the selected mainshaft rear bearing adjusting shim into the transaxle case. Refer to , "MAINSHAFT END PLAY ".
    2. Temporarily install the snap ring of the mainshaft rear bearing into the transaxle case.
      CAUTION: Do not reuse the snap ring.
    3. Apply sealant to the mating surfaces of the transaxle case and clutch housing as shown. Use Genuine Silicone RTV or equivalent. Refer to , "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Remove any old sealant adhering to the mounting surfaces. Also remove any moisture, oil, or foreign material adhering to the sealant application and mounting surfaces.
      Fig 17: Applying Sealant To Mating Surface Of Transaxle Case And Clutch Housing
      G04167972Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Using a snap ring of the mainshaft rear bearing temporarily, install the transaxle case over the clutch housing as shown.
      Fig 18: Identifying Mainshaft Rear Bearing And Snap Ring
      G04167973Courtesy of NISSAN MOTOR CO., U.S.A.
    5. Through the bore plug mounting hole, with the snap ring stretched, lift up the mainshaft assembly from the control assembly mounting hole.
      Fig 19: Installing Transaxle Case Over Clutch Housing
      G04167974Courtesy of NISSAN MOTOR CO., U.S.A.
    6. Securely install the snap ring onto the mainshaft rear bearing as shown.
    7. Tighten the "A" bolts (gold) and new "B" bolts (black) to specification.

      "A" Bolt: 52.0 N-m (5.3 kg-m, 38 ft-lb) 

      "B" Bolt: 65.0 N-m (6.6 kg-m, 48 ft-lb) 

      CAUTION: Always replace the "B" bolts as they are self-sealing bolts.
      Fig 20: Tightening Transaxle Case Bolts
      G04167975Courtesy of NISSAN MOTOR CO., U.S.A.
    8. Apply gear oil to the O-ring and install it to the control assembly. Then install control assembly to transaxle case. Tighten bolts to the specified torque. Refer to , "SHIFT CONTROL COMPONENTS ".
      CAUTION: Do not reuse the O-ring.
    9. Install a new shift check and a new stopper bolt.
      CAUTION: Shift check and stopper bolt are not reusable.
  31. Install a new bore plug using Tool as shown.

    Tool number: ST33061000 (J-8107-2) 

    CAUTION: Bore plugs are not reusable.
    Fig 21: Installing Bore Plug Using Tool
    G04167976Courtesy of NISSAN MOTOR CO., U.S.A.
  32. Install the new welch plug using Tool as shown.

    Tool number: ST33052000 (-) 

    CAUTION: Do not reuse the welch plug.
    Fig 22: Installing Welch Plug Using Tool
    G04167977Courtesy of NISSAN MOTOR CO., U.S.A.
  33. Install the 2 check balls, 2 check springs, and the 2 new check ball plugs.
    CAUTION: Check ball plugs are not reusable.
    Fig 23: Identifying Check Balls, Check Springs, And Check Ball Plugs
    G04167978Courtesy of NISSAN MOTOR CO., U.S.A.
  34. Apply sealant to the threads of the park/neutral position switch and back-up lamp switch. Then install them into the transaxle case. Refer to , "CASE AND HOUSING COMPONENTS ". Use Genuine Silicone RTV or equivalent. Refer to , "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
    Fig 24: Identifying Back-Up Lamp Switch And Park/Neutral Position Switch
    G04167979Courtesy of NISSAN MOTOR CO., U.S.A.
  35. Install new gaskets onto the drain plug and filler plug, and then install them into the transaxle case.
    CAUTION:
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