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Disassembly and Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Install differential side oil seal (1) to clutch housing using a suitable tool and Tool (A).

    Dimension (H) : -0.5 - 0.5 mm (-0.020 - 0.020 in) 

    Tool number : ST33400001 (J-26082) 

    CAUTION:
    • Do not reuse differential side oil seal.
    • When installing, do not incline differential side oil seal.
    • Do not damage clutch housing.
      Fig 1: Installing Differential Side Oil Seal To Clutch Housing Using Suitable Tool
      G07138675Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install input shaft oil seal (1) to clutch housing using a suitable tool and Tool (A).

    Dimension (H) : 1.1 - 2.1 mm (0.043 - 0.083 in) 

    Tool number : ST35321000 (-) 

    CAUTION:
    • Do not reuse input shaft oil seal.
    • When installing, do not incline input shaft oil seal.
    • Do not damage clutch housing.
      Fig 2: Installing Input Shaft Oil Seal To Clutch Housing Using Suitable Tool
      G07138676Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install differential side bearing outer race (clutch housing side) to clutch housing using Tools.

    Tool number : ST30720000 (J-25405) 

    : KV40105320 (-) 

    CAUTION: Replace differential side bearing and differential side bearing outer race as a set.
    Fig 3: Installing Differential Side Bearing Outer Race (Clutch Housing Side) To Clutch Housing Using Tools
    G07138677Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install oil channel (1) on mainshaft side.
    CAUTION: When installing oil channel, fit the rib (A) of oil channel into the processed area of the spot facing (B).
    Fig 4: Installing Oil Channel On Mainshaft Side
    G07138678Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install mainshaft front bearing to clutch housing using Tool.

    Tool number : ST33200000 (J-26082) 

    CAUTION: Be careful with the orientation of mainshaft front bearing.
    Fig 5: Installing Mainshaft Front Bearing To Clutch Housing Using Tool
    G07138679Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install mainshaft bearing retainer (1) to clutch housing and tighten bolt to the specified torque.
    Fig 6: Installing Mainshaft Bearing Retainer To Clutch Housing
    G07138680Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Install with punched surface facing up.
  7. Install magnet to clutch housing.
    Fig 7: Installing Magnet To Clutch Housing
    G07138681Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install final drive assembly into clutch housing.
    Fig 8: Installing Final Drive Assembly Into Clutch Housing
    G07138682Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install input shaft assembly, mainshaft assembly, and reverse idler gear assembly into clutch housing.
    CAUTION:
    • Wrap a tape, etc. to the spline of input shaft so as not to damage the input shaft oil seal.
    • Be careful with the orientation of reverse idler shaft.
      Fig 9: Installing Input Shaft Assembly, Mainshaft Assembly, And Reverse Idler Gear Assembly Into Clutch Housing
      G07138683Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install striking rod assembly (1) into clutch housing.
    Fig 10: Installing Striking Rod Assembly Into Clutch Housing
    G07138684Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Check that return spring is securely seated in the groove on return pin.
      Fig 11: Location Of Return Spring
      G07138685Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install 1st-2nd shift fork (1) and 1st-2nd fork rod (2) and then install retaining pin to 1st-2nd shift fork.
    CAUTION:
    • Do not reuse retaining pin.
    • Be careful with the orientation of 1st-2nd shift fork and 1st-2nd fork rod.
    • Assemble retaining pin from the direction shown in the figure by the arrow until it becomes flush with the end surface of 1st-2nd shift fork.
      Fig 12: Installing 1st-2nd Shift Fork And 1st-2nd Fork Rod
      G07138686Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install 3rd-4th shift fork (1) to 3rd-4th coupling sleeve.
    CAUTION: Be careful with the orientation of 3rd-4th shift fork.
    Fig 13: Installing 3rd-4th Shift Fork To 3rd-4th Coupling Sleeve
    G07138687Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install 5th-6th shift fork (1) and 5th-6th fork rod (2) and then install retaining pin to 5th-6th shift fork.
    CAUTION:
    • Do not reuse retaining pin.
    • Be careful with the orientation of 5th-6th shift fork and 5th-6th fork rod.
    • Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of 5th-6th shift fork.
      Fig 14: Installing 5th-6th Shift Fork And 5th-6th Fork Rod
      G07138688Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install 3rd-4th fork rod (2) and then install retaining pin to 3rd-4th shift fork (1).
    CAUTION:
    • Do not reuse retaining pin.
    • Be careful with the orientation of 3rd-4th fork rod.
    • Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of 3rd-4th shift fork.
      Fig 15: Installing 3rd-4th Fork Rod
      G07138689Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install reverse shift fork (1) and reverse fork rod (2).
    CAUTION: Be careful with the orientation of reverse shift fork and reverse fork rod.
    Fig 16: Installing Reverse Shift Fork And Reverse Fork Rod
    G07138690Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Rotate striking lever of striking rod assembly as shown in the figure. Then rotate reverse fork rod to a position where bracket of reverse fork rod does not interfere with striking lever of striking rod assembly.
    Fig 17: Rotating Striking Lever
    G07138691Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install retaining pin to reverse shift fork (1).
    Fig 18: Installing Retaining Pin To Reverse Shift Fork
    G07138692Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse retaining pin.
    • Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of reverse shift fork.
  18. Install selected differential side bearing adjusting shim(s) and differential side bearing outer race (transaxle case side).
  19. Install selected reverse idler gear adjusting shim onto reverse idler gear assembly.
  20. Install selected input shaft rear bearing adjusting shim onto input shaft.
  21. Install selected striking rod adjusting shim and striking rod shim onto striking rod assembly.
  22. Install shifter lever oil seal (1) and striking rod oil seal (2) to transaxle case using suitable tool.

    Dimension (H) : 0 - 1.0 mm (0 - 0.039 in) 

    CAUTION:
    • Do not reuse shifter lever oil seal or striking rod oil seal.
    • When installing, do not incline shifter lever oil seal or striking rod oil seal.
    • Do not damage transaxle case.
      Fig 19: Installing Shifter Lever Oil Seal And Striking Rod Oil Seal To Transaxle Case Using Suitable Tool
      G07138693Courtesy of NISSAN MOTOR CO., U.S.A.
  23. Install differential side oil seal (1) to transaxle case using Tool (A).

    Dimension (H) : -0.5 - 0.5 mm (-0.020 - 0.020 in) 

    Tool number : ST30720000 (J-25405) 

    CAUTION:
    • Do not reuse differential side oil seal.
    • When installing, do not incline differential side oil seal.
    • Do not damage transaxle case.
      Fig 20: Installing Differential Side Oil Seal To Transaxle Case Using Tool
      G07138694Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Install shifter lever B (1) and shifter lever A (2) to transaxle case.
    CAUTION: Be careful with the orientation of shifter lever B and shifter lever A.
    Fig 21: Installing Shifter Lever B And Shifter Lever A To Transaxle Case
    G07138695Courtesy of NISSAN MOTOR CO., U.S.A.
  25. Install retaining pin to shifter lever A.
    CAUTION:
    • Do not reuse retaining pin.
    • Assemble retaining pin from the direction shown by the arrow in the figure until it becomes flush with the end surface of shifter lever A.
      Fig 22: Installing Retaining Pin To Shifter Lever
      G07138696Courtesy of NISSAN MOTOR CO., U.S.A.
  26. Install transaxle case following the procedures below.
    1. Install selected mainshaft rear bearing adjusting shim into transaxle case.
    2. Install oil gutter A (1) and oil gutter B (2) to transaxle case.
      CAUTION: Insert the tab (A) of oil gutter A and oil gutter B into transaxle case.
      Fig 23: Installing Oil Gutter A And Oil Gutter B To Transaxle Case
      G07138697Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
      CAUTION: Do not reuse snap ring.
      Fig 24: Installing Snap Ring Of Mainshaft Rear Bearing Into Transaxle Case
      G07138698Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Apply recommended sealant to mating surface of clutch housing as shown in the figure.
      CAUTION:
      • Remove old sealant adhering to the mounting surfaces. Also remove any moisture, oil, or foreign material adhering to both mounting surfaces.
      • Apply sealant so as not to break the bead.
      • The width of sealant bead is 1 - 2 mm (0.04 - 0.08 in).
      • The height of sealant bead is 0.4 - 1 mm (0.016 - 0.04 in).
      • The overlap length of both ends of sealant bead is 3 - 5 mm (0.12 - 0.20 in).
        Fig 25: Identifying Sealant Application Area
        G07138699Courtesy of NISSAN MOTOR CO., U.S.A.
    5. With shifter lever A (1) held in the position shown in the figure, temporarily assemble transaxle case to clutch housing.
      CAUTION: Do not damage striking rod oil seal.
      NOTE: Make sure to hold shifter lever A in the position shown in the figure. Otherwise transaxle case cannot be installed to clutch housing.
      Fig 26: Location Of Shifter Lever
      G07138700Courtesy of NISSAN MOTOR CO., U.S.A.
    6. While rotating shifter lever A (1) in the direction of the arrow shown in the figure, assemble transaxle case to clutch housing.
      Fig 27: Identifying Shifter Lever Position
      G07138701Courtesy of NISSAN MOTOR CO., U.S.A.
    7. Accessing from the bore plug hole, expand snap ring at mainshaft rear bearing so that the ring catches the periphery of mainshaft rear bearing.
    8. Temporarily tighten transaxle case bolts.
      Fig 28: View Of Snap Ring
      G07138702Courtesy of NISSAN MOTOR CO., U.S.A.
    9. Shift the shifter lever A (1) to 2nd gear position.
      NOTE:
      • The 2nd gear position is attained when shifter lever A is in the position shown in the figure.
        Fig 29: View Of Shifter Lever Position
        G07138703Courtesy of NISSAN MOTOR CO., U.S.A.
      • When transaxle is shifted to the 2nd gear position, mainshaft assembly is lifted.
    10. Seat snap ring in the groove on mainshaft rear bearing. If snap ring is not seated in the groove on mainshaft rear bearing, remove transaxle case and repeat the procedure from step  d.
      Fig 30: Seating Snap Ring In Groove On Mainshaft Rear Bearing
      G07138704Courtesy of NISSAN MOTOR CO., U.S.A.
    11. Tighten transaxle case bolts to the specified torque.
      Fig 31: Location Of Transaxle Case Bolts
      G07138705Courtesy of NISSAN MOTOR CO., U.S.A.
    12. Shift the shifter lever A (1) to neutral position.
      NOTE: The neutral position is attained when shifter lever A is in the position shown in the figure.
      Fig 32: View Of \Shifter Lever Neutral Position
      G07138706Courtesy of NISSAN MOTOR CO., U.S.A.
  27. Install bore plug to transaxle case using Tool.

    Tool number : ST33061000 (J-8107-2) 

    CAUTION: Do not reuse bore plug.
    Fig 33: Installing Bore Plug To Transaxle Case Using Tool
    G07138707Courtesy of NISSAN MOTOR CO., U.S.A.
  28. Install selector lever to transaxle case and then install retaining pin to selector lever.
    CAUTION:
    • Do not reuse retaining pin.
    • Assemble retaining pin from the direction shown in the figure by the arrow until it becomes flush with the end surface of selector lever.
      Fig 34: Installing Selector Lever To Transaxle Case
      G07138708Courtesy of NISSAN MOTOR CO., U.S.A.
  29. Install guide bolt following the procedures below.
    1. Shift the shifter lever A and selector lever to neutral position.
    2. Visually confirm from the guide bolt hole (C) that the lever is securely set to neutral position (A). If it is not in the neutral position, repeat the procedure from step  a.
      Fig 35: Installing Guide Bolt
      G07138709Courtesy of NISSAN MOTOR CO., U.S.A.
      CAUTION: The guide groove (D) of striking rod assembly will be damaged when assembling guide bolt with the lever is in except neutral position (B).
    3. Check continuity between terminals of park/neutral position (PNP) switch to confirm it in the neutral position. If it is not in the neutral position, remove park/neutral position (PNP) switch and repeat the procedure from step  a. Refer to "CHECKING ".
    4. Install guide bolt to transaxle case and then tighten guide bolt to the specified torque.
      CAUTION: Do not reuse guide bolt.
      Fig 36: Location Of Guide Groove
      G07138710Courtesy of NISSAN MOTOR CO., U.S.A.
  30. Apply recommended sealant to threads of park/neutral position (PNP) switch (1). Then install it to transaxle case and tighten to the specified torque.
    CAUTION: Remove old sealant and oil adhering to threads.
    Fig 37: Removing Old Sealant And Oil Adhering To Threads
    G07138711Courtesy of NISSAN MOTOR CO., U.S.A.
  31. Install plunger to transaxle case.
  32. Apply recommended sealant to threads of back-up lamp switch (2). Then install it to transaxle case and tighten to the specified torque.
    CAUTION: Remove old sealant and oil adhering to threads.
  33. Install air breather tube (3) to transaxle case.
    CAUTION:
    • Do not reuse air breather tube.
    • Assemble air breather tube until its collar element contacts with transaxle case.
  34. Install gasket onto plug and then install them into transaxle case. Tighten plug to the specified torque.
    CAUTION: Do not reuse gasket.
    Fig 38: Location Of Gasket Onto Plug
    G07138712Courtesy of NISSAN MOTOR CO., U.S.A.
  35. Install gasket onto drain plug and then install them into clutch housing. Tighten drain plug to the specified torque.
    CAUTION: Do not reuse gasket.
    Fig 39: Location Of Drain Plug
    G07138713Courtesy of NISSAN MOTOR CO., U.S.A.
  36. Install O-ring onto plug and then install it into clutch housing. Tighten bolt to the specified torque.
    CAUTION:
    • Do not reuse O-ring.
    • After oil is filled, tighten bolt to specified torque.
      Fig 40: Location Of O-Ring On Plug
      G07138714Courtesy of NISSAN MOTOR CO., U.S.A.
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