Transmission Assembly: Assembly

1. As shown in the figure below, use a drift [22 mm (0.87 in) dia. commercial service tool] to drive manual shaft oil seals into the transmission case until it is flush.
   CAUTION:

   • Never reuse manual shaft oil seals.
   • Apply ATF to manual shaft oil seals.
   Fig 1: Driving Manual Shaft Oil Seals Into Transmission Case

   Courtesy of NISSAN NORTH AMERICA, INC.
2. Install detent spring to transmission case and tighten detent spring mounting bolt (<==) to the specified torque.
   Fig 2: Locating Detent Spring Mounting Bolt

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3. Install manual shaft to transmission case.
   Fig 3: Installing Manual Shaft

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4. Install parking rod (1) to manual plate (2).
   Fig 4: Installing Parking Rod To Manual Plate

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5. Install manual plate (with parking rod) to manual shaft.
   Fig 5: Installing Manual Plate With Parking Rod To Manual Shaft

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6. Install retaining pin (1) into the manual plate and manual shaft.
   1. Fit pinhole of the manual plate to pinhole of the manual shaft with a pin punch.
   2. Use a hammer to tap the retaining pin into the manual plate.

      A: Approx. 2 mm (0.08in) 

      CAUTION: Drive retaining pin to 2±0.5 mm (0.08±0.020 in) over the manual plate.
      Fig 6: Identifying Retaining Pin Installation Dimensions

      Courtesy of NISSAN NORTH AMERICA, INC.
7. Install retaining pin into the transmission case and manual shaft.
   1. Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.
   2. Use a hammer to tap the retaining pin into the transmission case.
      CAUTION: Drive retaining pin to 5±1 mm (0.20±0.04 in) over the transmission case.
      Fig 7: Identifying Retaining Pin Installation Dimensions

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8. Install D-rings in reverse brake piston.
   Fig 8: Identifying D-Rings And Reverse Brake Piston

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9. Install reverse brake piston in transmission case.
   Fig 9: Identifying Reverse Brake Piston

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10. Install needle bearing to drum support edge surface.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 10: Identifying Needle Bearing

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11. Install seal rings to drum support.
    Fig 11: Identifying Seal Rings

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12. Install reverse brake spring retainer and reverse brake return spring in transmission case.
    Fig 12: Identifying Spring Retainer

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13. Set the clutch spring compressor on reverse brake spring retainer and install snap ring (fixing spring retainer) in transmission case while compressing return spring.
    CAUTION:

    • Securely assemble them using a flat-bladed screwdriver so that snap ring tension is slightly weak.
    • Be careful not to damage snap ring.
    Fig 13: Identifying Clutch Spring Compressor And Snap Ring

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14. Install reverse brake component part (drive plates, driven plates, and dish plates) in transmission case.
    Fig 14: Identifying Reverse Brake Component Part (Drive Plates, Driven Plates And Dish Plates)

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    CAUTION: Check order of plates.
15. Assemble N-spring.
16. Install reverse brake retaining plate in transmission case.
    Fig 15: Identifying N-Spring, Plates, Driven Plates And Transmission Case

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17. Install snap ring in transmission case.
    CAUTION: Be careful not to damage snap ring.
    Fig 16: Identifying Snap Ring

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18. Measure clearance between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.

    Specified clearance "A" 

    Standard: Refer to  "REVERSE BRAKE CLEARANCE ".

    Retaining plate: Refer to  "REVERSE BRAKE CLEARANCE "

    Fig 17: Identifying Clearance Between Retaining Plate And Snap Ring

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19. Install needle bearing to transmission case.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 18: Identifying Needle Bearing

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20. Install output speed sensor (1) to transmission case and tighten output speed sensor mounting bolt (<==) to the specified torque.
    CAUTION:

    • Never subject it to impact by dropping or hitting it.
    • Never disassemble.
    • Never allow metal filings, etc. to get on the sensor's front edge magnetic area.
    • Never place in an area affected by magnetism.
    Fig 19: Identifying Output Speed Sensor

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21. As shown in the figure below, use the drift to drive rear oil seal into the rear extension (2WD) (A) or adapter case (AWD) (B) until it is flush.
    Fig 20: Installing Rear Oil Seal

    Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:

    • Never reuse rear oil seal.
    • Apply ATF to rear oil seal.
22. Install return spring (1) to parking pawl (2).
    Fig 21: Identifying Return Spring And Parking Pawl

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23. Install parking pawl (with return spring) and pawl shaft to rear extension (2WD) or adapter case (AWD).
    Fig 22: Removing/Installing Rear Extension Parking Pawl And Pawl Shaft

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24. Install parking actuator support to rear extension (2WD) or adapter case (AWD).
    Fig 23: Removing/Installing Rear Extension Parking Actuator Support

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25. Install needle bearing (1) to rear extension (2WD) or adapter case (AWD).
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 24: Identifying Needle Bearing

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26. Install rear extension assembly (2WD) or adapter case assembly (AWD) according to the following procedures.
    1. 2WD 
       1. Install seal rings (1) to output shaft.
          Fig 25: Identifying Output Shaft Seal Rings

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       2. Install parking gear (1) to output shaft (2).
          Fig 26: Removing/Installing Output Shaft Parking Gear

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       3. Install output shaft in transmission case.
          CAUTION: Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)
          Fig 27: Removing/Installing Transmission Case Output Shaft

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       4. Install bearing race to output shaft.
          Fig 28: Removing/Installing Output Shaft Bearing Race

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       5. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".) to rear extension assembly as shown in the figure below.

          Sealant starting point and end point (A): Start and finish point shall be in the center of two bolts. 

          Overlap width of sealant starting point and end point (B): 3 - 5 mm (0.12 - 0.20 in) 

          Sealant width (C): 1.0 - 2.0 mm (0.04 - 0.08 in) 

          Sealant height (C): 0.4 - 1.0 mm (0.016 - 0.04 in) 

          CAUTION: Completely remove all moisture, oil and old sealant, etc. from the transmission case and rear extension assembly mounting surfaces.
          Fig 29: Identifying Anaerobic Liquid Gasket

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       6. Install rear extension assembly to transmission case.
          CAUTION: Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the rear extension assembly.
          Fig 30: Installing Rear Extension Assembly

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       7. Tighten rear extension assembly bolts to the specified torque.
          Fig 31: Identifying Rear Extension Assembly Bolts

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    2. AWD 
       1. Install seal rings (1) to output shaft.
          Fig 32: Identifying Output Shaft Seal Rings

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       2. Install parking gear (1) to output shaft (2).
          Fig 33: Removing/Installing Output Shaft Parking Gear

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       3. Install output shaft in transmission case.
          CAUTION: Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)
          Fig 34: Removing/Installing Transmission Case Output Shaft

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       4. Install bearing race to output shaft.
          Fig 35: Removing/Installing Output Shaft Bearing Race

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       5. Install gasket onto transmission case.
          CAUTION:

          • Completely remove all moisture, oil and old gasket, etc. from the transmission case and adapter case assembly mounting surfaces.
          • Never reuse gasket.
          Fig 36: Removing/Installing Transmission Case Gasket

          Courtesy of NISSAN NORTH AMERICA, INC.
       6. Install adapter case assembly to transmission case.
          CAUTION: Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the adapter case assembly.
          Fig 37: Removing/Installing Adapter Case Assembly

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       7. Tighten adapter case assembly bolts to the specified torque.
          Fig 38: Identifying Adapter Case Assembly Bolts

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27. Install needle bearing in drum support.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 39: Identifying Needle Bearing

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28. Install direct clutch assembly in reverse brake.
    CAUTION: Make sure that drum support edge surface and direct clutch inner boss edge surface come to almost same place.
    Fig 40: Identifying Direct Clutch Assembly

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29. Install high and low reverse clutch assembly in direct clutch.
    Fig 41: Identifying High And Low Reverse Clutch Assembly

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30. Align the drive plate using a flat-bladed screwdriver.
    Fig 42: Aligning Drive Plate Using Flat-Bladed Screwdriver

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31. Install high and low reverse clutch hub, mid sun gear assembly, and rear sun gear assembly as a unit.
    Fig 43: Identifying Mid Sun Gear Assembly & Rear Sun Gear Assembly

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    CAUTION: Make sure that portion "A" of high and low reverse clutch drum protrudes approximately 2 mm (0.08 in) beyond portion "B" of rear sun gear.
    Fig 44: Identifying Proper Installation Of High & Low Reverse Clutch Drum

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32. Install needle bearing in rear carrier assembly.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 45: Removing/Installing Rear Carrier Assembly Needle Bearing

    Courtesy of NISSAN NORTH AMERICA, INC.
33. Install bearing race in rear carrier assembly.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 46: Removing/Installing Rear Carrier Assembly Bearing Race

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34. Install rear carrier assembly in direct clutch drum.
    Fig 47: Identifying Rear Carrier Assembly

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35. Install needle bearing (rear side) to mid carrier assembly.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 48: Removing/Installing Mid Carrier Assembly Needle Bearing (Rear Side)

    Courtesy of NISSAN NORTH AMERICA, INC.
36. Install needle bearing (front side) to mid carrier assembly.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 49: Removing/Installing Mid Carrier Assembly Needle Bearing (Front Side)

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37. Install mid carrier assembly in rear carrier assembly.
    Fig 50: Identifying Mid Carrier Assembly

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38. Install seal rings (1) to input clutch assembly.
    Fig 51: Identifying Input Clutch Assembly Seal Rings

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39. Install needle bearing (1) to front carrier assembly.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 52: Identifying Front Carrier Assembly Needle Bearing

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40. Install input clutch assembly (with front carrier assembly and rear internal gear) (1) to transmission case.
    CAUTION: Check that the needle bearing (2) is securely positioned. If the needle bearing position is misaligned, adjust it to the specified position.
    Fig 53: Installing Input Clutch Assembly To Transmission Case

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41. Install 1st one-way clutch (1) to front brake hub (with under drive carrier) (2).
42. Check operation of 1st one-way clutch.
    1. Hold 1st one-way clutch.
    2. Check front brake hub for correct locking and unlocking directions.
       Fig 54: Checking 1st One-Way Clutch Operation

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       CAUTION: If not shown in figure below, check installation direction of 1st one-way clutch.
43. Install under drive carrier (with 1st one-way clutch) (1) to transmission case.
    Fig 55: Identifying Under Drive Carrier (With 1st One-Way Clutch)

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44. Install snap ring (1) to transmission case.
    CAUTION: Be careful not to damage snap ring.
    Fig 56: Identifying Snap Ring

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45. Install front brake component part (retaining plates, drive plates and driven plate) to transmission case.
    Fig 57: Identifying Front Brake Components (Retaining Plates, Drive Plates And Driven Plate)

    Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Check order of plates.
46. Install needle bearing (1) to under drive carrier assembly.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 58: Identifying Drive Carrier Assembly Needle Bearing

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47. Install under drive sun gear (1) to under drive carrier assembly.
    Fig 59: Identifying Drive Carrier Assembly Drive Sun Gear

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48. Adjustment of total end play "T".
    • Measure clearance between bearing race (1) and oil pump cover (2).
    • Select proper thickness of bearing race so that end play is within specifications.
      Fig 60: Identifying Bearing Race And Oil Pump Cover Total End Play

      Courtesy of NISSAN NORTH AMERICA, INC.
    1. Measure dimensions "K" and "L", and calculate dimension "J".
       Fig 61: Identifying Dimensions "K", "L" & "J"

       Courtesy of NISSAN NORTH AMERICA, INC.

       "J": Distance between the oil pump fitting surface of transmission case and the needle bearing mating surface of under drive sun gear. 

       J = K - L 

       1. Measure dimension "K" between the converter housing fitting surface of transmission case (1) and the needle bearing mating surface of under drive sun gear (2).
          CAUTION:

          • Never change the straightedge (A) installation position before the completion of "L" measurement.
          • Measure dimension "K" in at least three places, and take the average.
          Fig 62: Identifying Dimension Between Converter Housing Fitting Surface Of Transmission Case And Needle Bearing Mating Surface

          Courtesy of NISSAN NORTH AMERICA, INC.
       2. Measure dimension "L" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
          Fig 63: Identifying Dimension Between Converter Housing Fitting Surface Of Transmission Case And Oil Pump Fitting Surface

          Courtesy of NISSAN NORTH AMERICA, INC.
          CAUTION: Measure dimension "L" in at least three places, and take the average.
       3. Calculate dimension "J".

       J = K - L 

    2. Measure dimensions "M1" and "M2", and calculate dimension "M".
       Fig 64: Identifying Dimensions "M1", "M2" & "M"

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       "M": Distance between the transmission case fitting surface of oil pump and the needle bearing on oil pump. 

       M = M1-M2 

       1. Place bearing race (1) and needle bearing (2) on oil pump assembly (3).
          Fig 65: Identifying Bearing Race, Needle Bearing And Oil Pump Assembly

          Courtesy of NISSAN NORTH AMERICA, INC.
       2. Measure dimension "M1" between the transmission case fitting surface of oil pump and the end of oil pump.
          Fig 66: Identifying Dimension Between Transmission Case Fitting Surface Of Oil Pump And End Of Oil Pump

          Courtesy of NISSAN NORTH AMERICA, INC.
          CAUTION: Measure dimension "M1" in at least three places, and take the average.
       3. Measure dimension "M2" between the needle bearing on oil pump and the end of oil pump.
          Fig 67: Identifying Dimension Between Needle Bearing On Oil Pump And End Of Oil Pump

          Courtesy of NISSAN NORTH AMERICA, INC.
          CAUTION: Measure dimension "M2" in at least three places, and take the average.
       4. Calculate dimension "M".

       M = M1-M2 

    3. Adjust total end play "T".
       Fig 68: Identifying Bearing Race And Oil Pump Assembly Total End Play

       Courtesy of NISSAN NORTH AMERICA, INC.

       T = J - M 

       Total end play "T": Refer to  "TOTAL END PLAY ".

       • Select proper thickness of bearing race so that total end play is within specifications.

       Bearing races: Refer to  "TOTAL END PLAY ".

49. Adjustment of front brake clearance "C".
    • Measure clearance between front brake piston (1) and front brake retaining plate (2).
    • Select proper thickness of front brake retaining plat so that clearance is within specifications.
      Fig 69: Identifying Clearance Between Front Brake Piston And Front Brake Retaining Plate

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    1. Measure dimensions "O" and "P", and calculate dimension "N".
       Fig 70: Identifying Dimensions "O" And "P" And "N"

       Courtesy of NISSAN NORTH AMERICA, INC.

       "N": Distance between the oil pump fitting surface of transmission case and the front brake retaining plate. 

       N = O - P 

       1. Measure dimension "O" between the converter housing fitting surface of transmission case (1) and the front brake retaining plate (2).
          CAUTION:

          • Never change the straightedge (A) installation position before the completion of "P" measurement.
          • Measure dimension "O" in at least three places, and take the average.
          Fig 71: Identifying Dimension Between Converter Housing Fitting Surface Of Transmission Case And Front Brake Retaining Plate

          Courtesy of NISSAN NORTH AMERICA, INC.
       2. Measure dimension "P" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
          Fig 72: Identifying Dimension Between Converter Housing Fitting Surface Of Transmission Case And Oil Pump Fitting Surface

          Courtesy of NISSAN NORTH AMERICA, INC.
          CAUTION: Measure dimension "P" in at least three places, and take the average.
       3. Calculate dimension "N".

          N = O - P 

    2. Measure dimensions "Q1" and "Q2", and calculate dimension "Q".
       Fig 73: Identifying Dimensions "Q1" And "Q2" And "Q"

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       "Q": Distance between the transmission case fitting surface of oil pump and the front brake piston. 

       Q = Q1-Q2 

       1. Measure dimension "Q1" between the transmission case fitting surface of oil pump and the straightedge on front brake piston.
          Fig 74: Identifying Dimension Between Transmission Case Fitting Surface Of Oil Pump And Straightedge On Front Brake Piston

          Courtesy of NISSAN NORTH AMERICA, INC.
          CAUTION: Measure dimension "Q1" in at least three places, and take the average.
       2. Measure dimension "Q2" of the straightedge.
          Fig 75: Identifying Dimension "Q2" Of Straightedge

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       3. Calculate dimension "Q".

          Q = Q1-Q2 

    3. Adjust front brake clearance "C".
       Fig 76: Identifying Front Brake Clearance "C"

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       C = N - Q 

       Front brake clearance "C": Refer to  "FRONT BRAKE CLEARANCE ".

       • Select proper thickness of retaining plate so that front brake clearance is within specifications.

       Retaining plate: Refer to  "FRONT BRAKE CLEARANCE ".

50. Remove under drive sun gear (1) from under drive carrier assembly.
    Fig 77: Identifying Drive Carrier Assembly Drive Sun Gear

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51. Install needle bearing (1) to under drive sun gear.
    CAUTION: Check the direction of needle bearing. Refer to "LOCATION OF NEEDLE BEARINGS AND BEARING RACES ".
    Fig 78: Removing/Installing Under Drive Sun Gear Needle Bearing

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52. Install O-ring (1) to oil pump assembly.
    Fig 79: Identifying Oil Pump Assembly O-Ring

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53. Install seal ring (1) to oil pump assembly.
    Fig 80: Identifying Oil Pump Assembly Seal Ring

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54. Install bearing race (1) to oil pump assembly.
    Fig 81: Identifying Oil Pump Assembly Bearing Race

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55. Install under drive sun gear (with needle bearing) (1) to oil pump assembly (2).
    Fig 82: Identifying Under Drive Sun Gear And Oil Pump Assembly

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56. Install oil pump assembly (with under drive sun gear) to transmission case.
    CAUTION: Apply ATF to oil pump bearing.
    Fig 83: Installing Oil Pump Assembly (With Under Drive Sun Gear) To Transmission Case

    Courtesy of NISSAN NORTH AMERICA, INC.
57. Apply recommended sealant to oil pump assembly as shown in the figure below.

    Use genuine RTV silicone sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

    CAUTION: Completely remove all moisture, oil and old sealant, etc. from the oil pump mounting bolts and oil pump mounting bolt mounting surfaces.
    Fig 84: Identifying Sealant Application Area

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58. Tighten oil pump bolts (<==) to the specified torque.
    Fig 85: Identifying Oil Pump Bolts

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59. Install O-ring to input clutch assembly.
    Fig 86: Identifying Input Clutch Assembly O-Ring

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60. Install converter housing to transmission case, and tighten converter housing bolts (<==) to the specified torque.
    Fig 87: Locating Converter Housing Bolts

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61. Connect TCM connector (A) to joint connector.
    Fig 88: Identifying TCM Connector

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62. Install joint connector (1) to the control valve & TCM.
    CAUTION: Apply ATF to O-ring of joint connector.
    Fig 89: Installing Joint Connector To Control Valve

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63. Install the control valve & TCM (1) to transmission case.
    Fig 90: Removing/Installing Transmission Case Control Valve & TCM

    Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:

    • Make sure that input speed sensor securely installs input speed sensor holes (A).
    • Hang down output speed sensor harness toward outside so as not to disturb installation of the control valve & TCM.
    • Adjust joint connector of the control valve & TCM to terminal hole of transmission case.
      Fig 91: Identifying Input Speed Sensor Holes

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    • Assemble it so that manual valve cutout is engaged with manual plate projection.
    Fig 92: Identifying Manual Valve Manual Plate

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64. Install bolts and clip (1) to the control valve & TCM. Tighten bolt (E) to the specified torque before tightening the other than bolts.
    Fig 93: Identifying Control Valve & TCM Bolts And Clip

    Courtesy of NISSAN NORTH AMERICA, INC.

    Bolt symbol	Length mm (in)	Number of bolts
    A	43 (1.69)	3
    B	40 (1.57)	2
    C	54 (2.13)	6
    D	50 (1.97)	2
    E(1)	50 (1.97)	1
    (1) Reamer bolt

65. Connect output speed sensor connector (A).
66. Engage output speed sensor harness with terminal clips (<==).
    Fig 94: Identifying Output Speed Sensor Connector And Clips

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67. Pull down joint connector (1).
    CAUTION: Be careful not to damage connector.
    Fig 95: Pulling Down Joint Connector

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68. Install snap ring (1) to joint connector (2).
    Fig 96: Installing Snap Ring To Joint Connector

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69. Install magnets (1) in oil pan.
70. Install oil pan gasket to transmission case.
    CAUTION:

    • Never reuse oil pan gasket.
    • Install it in the direction to align hole positions.
    • Completely remove all moisture, oil and old gasket, etc. from oil pan gasket mounting surface.
    Fig 97: Identifying Oil Pan Magnets

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71. Install oil pan (2) and clips (1) to transmission case.
    Fig 98: Locating Oil Pan Mounting Bolts

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    CAUTION:

    • Be careful not to pinch harnesses.
    • Completely remove all moisture, oil and old gasket, etc. from oil pan mounting surface.
72. Tighten oil pan mounting bolts to the specified torque in numerical order shown in the figure below after temporarily tightening them. Tighten oil pan mounting bolts to the specified torque.
    Fig 99: Identifying Oil Pan Mounting Bolt Tightening Sequence

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    CAUTION: Never reuse oil pan mounting bolts.
73. Install drain plug to oil pan. Tighten drain plug to the specified torque.
    CAUTION: Never reuse drain plug gasket.
74. Pour ATF into torque converter.
    • Approximately 2 liter (2-1/8 US qt, 1-3/4 Imp qt) of ATF is required for a new torque converter. 
    • When reusing old torque converter, add the same amount of ATF as was drained. 
      Fig 100: Pouring ATF Into Torque Converter

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75. Install torque converter while aligning notches of torque converter with notches of oil pump.
    CAUTION: Install torque converter while rotating it.
    Fig 101: Removing/Installing Torque Converter

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76. Measure dimension "A" to make sure that torque converter is in proper position.
    Fig 102: Measuring Dimension "A" Using Straightedge And Scale

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Dimension "A": Refer to  "TORQUE CONVERTER ".