Disassembly and Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.

Install differential side oil seal (1) to clutch housing using Tool (A).
Dimension (H) : -0.5 - 0.5 mm (-0.020 - 0.020 in)

Tool number : ST33400001 (J-26082)

Fig 1: Installing Differential Side Oil Seal To Clutch Housing Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- Do not reuse differential side oil seal.
- When installing, do not incline differential side oil seal.
- Do not damage clutch housing.
Install input shaft oil seal (1) to clutch housing using Tool (A).
Dimension (H) : 1.1 - 2.1 mm (0.043 - 0.083 in)

Tool number : ST35321000 (-)

Fig 2: Installing Input Shaft Oil Seal To Clutch Housing Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- Do not reuse input shaft oil seal.
- When installing, do not incline input shaft oil seal.
- Do not damage clutch housing.
Install differential side bearing outer race (clutch housing side) to clutch housing using Tools.
Tool number : KV40105320 (-)

: ST30720000 (J-25405)

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
Courtesy of NISSAN MOTOR CO., U.S.A.
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
Courtesy of NISSAN MOTOR CO., U.S.A.
Install mainshaft front bearing to clutch housing using Tool.
Tool number : ST33200000 (J-26082)

Fig 5: Installing Mainshaft Front Bearing To Clutch Housing Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Be careful with the orientation of mainshaft front bearing.
Install mainshaft bearing retainer (1) to clutch housing and tighten bolt to the specified torque.

Fig 6: Installing Mainshaft Bearing Retainer To Clutch Housing And Tighten Bolt
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Install with punched surface facing up.
Install magnet to clutch housing.

Fig 7: Installing Magnet To Clutch Housing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install final drive assembly into clutch housing.

Fig 8: Installing Final Drive Assembly Into Clutch Housing
Courtesy of NISSAN MOTOR CO., U.S.A.
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
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install striking rod assembly (1) into clutch housing.

Fig 10: Installing Striking Rod Assembly Into Clutch Housing
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- Check that return spring is securely seated in the groove on return pin.
  
  Fig 11: Locating Return Spring Seat
  Courtesy of NISSAN MOTOR CO., U.S.A.
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: Pulling Out 1st-2nd Shift Fork And 1st-2nd Fork Rod
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install 3rd-4th shift fork (1) to 3rd-4th coupling sleeve.
CAUTION: Be careful with the orientation of 3rd-4th shift fork.

Fig 13: Location Of 3rd-4th Shift Fork To 3rd-4th Coupling Sleeve
Courtesy of NISSAN MOTOR CO., U.S.A.
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: Locating 5th-6th Shift Fork And 5th-6th Fork Rod
  Courtesy of NISSAN MOTOR CO., U.S.A.
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: Pulling Out 3rd-4th Fork Rod
  Courtesy of NISSAN MOTOR CO., U.S.A.
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
Courtesy of NISSAN MOTOR CO., U.S.A.
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 Of Striking Rod Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Install retaining pin to reverse shift fork (1).

Fig 18: Installing Retaining Pin To Reverse Shift Fork
Courtesy 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.
Install selected differential side bearing adjusting shim(s) and differential side bearing outer race (transaxle case side).
Install selected reverse idler gear adjusting shim onto reverse idler gear assembly.
Install selected input shaft rear bearing adjusting shim onto input shaft.
Install selected striking rod adjusting shim and striking rod shim onto striking rod assembly.
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)

Fig 19: Locating Shifter Lever Oil Seal And Striking Rod Oil Seal
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- Do not reuse shifter lever oil seal or striking rod oil seal.
- When installing, do not incline shifter lever oil seal and striking rod oil seal.
- Do not damage transaxle case.
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)

Fig 20: Installing Differential Side Oil Seal To Transaxle Case
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- Do not reuse differential side oil seal.
- When installing, do not incline differential side oil seal.
- Do not damage transaxle case.
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
Courtesy of NISSAN MOTOR CO., U.S.A.
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: Locating Shifter Lever Retaining Pin
  Courtesy of NISSAN MOTOR CO., U.S.A.
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: Inserting Tab Of Oil Gutter A And Oil Gutter B Into Transaxle Case
  Courtesy 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
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Apply recommended sealant to mating surface of clutch housing as shown in the figure.
  - Use Genuine Silicone RTV or an equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCT AND SEALANT ".
    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
    Courtesy 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: Locating Shifter Lever A Held In Position
  Courtesy 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
  Courtesy 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: Identifying Transaxle Case Bolts
  Courtesy 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: Shifting Shifter Lever A To 2nd Gear Position
    Courtesy 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
  Courtesy of NISSAN MOTOR CO., U.S.A.
11. Tighten transaxle case bolts to the specified torque.
  
  Fig 31: Location Of Transaxle Case Mounting Bolts
  Courtesy 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: Identifying Shifter Lever Position
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install bore plug to transaxle case using Tool.
Tool number : ST33061000 (J-8107-2))

Fig 33: Installing Bore Plug To Transaxle Case Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Do not reuse bore plug.
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 by the arrow in the figure until it becomes flush with the end surface of selector lever.
  
  Fig 34: Locating Selector Lever Retaining Pin
  Courtesy of NISSAN MOTOR CO., U.S.A.
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
  Courtesy 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: Locating Transaxle Case Guide Bolt
  Courtesy of NISSAN MOTOR CO., U.S.A.
Apply recommended sealant to threads of park/neutral position (PNP) switch (1). Then install it to transaxle case and tighten to the specified torque.
- Use Genuine Silicone RTV or an equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCT AND SEALANT ".
  CAUTION: Remove old sealant and oil adhering to threads.
Install plunger to transaxle case.
Apply recommended sealant to threads of back-up lamp switch (2). Then install it to transaxle case and tighten to the specified torque.
- Use Genuine Silicone RTV or an equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCT AND SEALANT ".
  CAUTION: Remove old sealant and oil adhering to threads.
  
  Fig 37: Location Of Back-Up Lamp Switch And Plunger On Transaxle Case
  Courtesy of NISSAN MOTOR CO., U.S.A.
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.
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 Plug And Gasket On Transaxle Case
Courtesy of NISSAN MOTOR CO., U.S.A.
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 And Gasket On Clutch Housing
Courtesy of NISSAN MOTOR CO., U.S.A.
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 Plug Bolt, Plug And O-Ring On Clutch Housing
  Courtesy of NISSAN MOTOR CO., U.S.A.