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Transaxle Assembly: Assembly

  1. Install pinion gear (1) and pinion shaft (2) to clutch housing.
    CAUTION: Replace transaxle assembly when replacing clutch housing.
  2. Install plug to clutch housing.
    Fig 1: Identifying Pinion Gear And Pinion Shaft
    G04926416Courtesy of NISSAN NORTH AMERICA, INC.
  3. Install 2 way connector (1) to clutch housing.
    Fig 2: Identifying Two Way Connector
    G04926415Courtesy of NISSAN NORTH AMERICA, INC.
  4. Install bushings (1) so that they becomes even to clutch housing edge surface, using a drift (A) [Commercial service tool].
  5. Install oil channel to clutch housing.
    CAUTION: Never reuse oil channel.
    Fig 3: Installing Bushings Using Drift
    G05914934Courtesy of NISSAN NORTH AMERICA, INC.
  6. Install mainshaft front bearing outer race to clutch housing, using the drift (A) [SST: KV38100200 (-)].
    CAUTION: Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set.
    Fig 4: Installing Mainshaft Front Bearing Outer Race
    G04926420Courtesy of NISSAN NORTH AMERICA, INC.
  7. Install input shaft oil seal (1) to clutch housing, using the drift (A) [SST: ST33220000 (-)].
    Fig 5: Installing Input Shaft Oil Seal
    G04926421Courtesy of NISSAN NORTH AMERICA, INC.
  8. Install snap ring (1) and oil channel (2) to transaxle case.
    CAUTION:
    • Select and install snap ring that has the same thickness as previous one.
    • Replace transaxle assembly when replacing transaxle case.
  9. Install mainshaft rear bearing adjusting shim to transaxle case.
    Fig 6: Identifying Snap Ring And Oil Channel
    G04926422Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Select mainshaft rear bearing adjusting shim according to the following procedures when replacing mainshaft adjusting shim, 6th main gear, 5th main gear, or 4th main gear.
    • Replace mainshaft adjusting shim.
      • If new mainshaft adjusting shim is thinner than previous one, offset the thickness difference by selecting thicker mainshaft rear bearing adjusting shim.
      • If new mainshaft adjusting shim is thicker than previous one, offset the thickness difference by selecting thinner mainshaft rear bearing adjusting shim.
    • Replace 6th main gear, 5th main gear, or 4th main gear.
      • Measure the thickness of the main gear used before and the new main gear
      • Increase the thickness of the mainshaft rear bearing adjusting shim, if the difference is smaller than 0.025 mm (0.0010 in).
      • Decrease the thickness of the mainshaft rear bearing adjusting shim, if the difference is greater than 0.025 mm (0.0010 in).
  10. Install mainshaft rear bearing outer race to transaxle case, using the drift (A) [SST: KV38100200 (-)].
    CAUTION: Replace mainshaft rear bearing outer race and mainshaft rear bearing inner race as a set.
    Fig 7: Installing Mainshaft Rear Bearing Outer Race
    G04926423Courtesy of NISSAN NORTH AMERICA, INC.
  11. Install bushings (1) to transaxle case, using a drift (A) [Commercial service tool].
    Fig 8: Installing Bushings To Transaxle Case
    G05914939Courtesy of NISSAN NORTH AMERICA, INC.
  12. Install oil gutter (1) to transaxle case.
    Fig 9: Identifying Oil Gutter
    G04926425Courtesy of NISSAN NORTH AMERICA, INC.
  13. Install shifter lever B (1) to transaxle case.
    CAUTION: Replace shifter lever A and shifter lever B as a set.
  14. Install shifter lever A to transaxle case.
    CAUTION: Replace shifter lever A and shifter lever B as a set.
    Fig 10: Identifying Shifter Lever
    G04926405Courtesy of NISSAN NORTH AMERICA, INC.
  15. Install retaining pin to shifter lever A (1), using a pin punch.
    CAUTION: Never reuse retaining pin.
  16. Install shim to transaxle case.
    Fig 11: Installing Retaining Pin To Shifter Lever
    G04926404Courtesy of NISSAN NORTH AMERICA, INC.
  17. Install differential side bearing outer race (transaxle case side) to transaxle case, using the drift (A) [SST: ST33400001 (J-26082)].
    CAUTION: Replace differential side bearing outer race (transaxle case side) and differential side bearing inner race (transaxle case side) as a set.
    Fig 12: Installing Differential Side Bearing Outer Race (Transaxle Case Side)
    G04926429Courtesy of NISSAN NORTH AMERICA, INC.
  18. Install differential side bearing outer race (clutch housing side) to clutch housing, using the drift (A) [SST: KV38100200 (-)].
    CAUTION: Replace differential side bearing outer race (clutch housing side) and differential side bearing inner race (clutch housing side) as a set.
    Fig 13: Installing Differential Side Bearing Outer Race (Clutch Housing Side)
    G04926430Courtesy of NISSAN NORTH AMERICA, INC.
  19. Install differential side oil seals (1) to clutch housing and transaxle case, using the drift [Stamping number: B.vi 1666-B] of the drift set [SST: KV32500QAA (-)].
    Fig 14: Identifying Differential Side Oil Seals
    G08136212Courtesy of NISSAN NORTH AMERICA, INC.

    Dimension "L1": 1.2 - 1.8 mm (0.047 - 0.071 in) 

    Dimension "L2": 2.7 - 3.3 mm (0.106 - 0.130 in) 

  20. Install magnet to clutch housing.
  21. Install final drive assembly to clutch housing.
  22. Set fork rod (1) to input shaft assembly (2), and then install them to clutch housing.
    Fig 15: Identifying Fork Rod And Shaft Assembly
    G05914946Courtesy of NISSAN NORTH AMERICA, INC.
  23. Install mainshaft assembly (1) according to the following procedures.
    1. Pull up input shaft assembly (2) and fork rod (3).
    2. Set 1st-2nd fork rod (4) to mainshaft assembly, and then install them to clutch housing.
      Fig 16: Installing Mainshaft Assembly
      G05914947Courtesy of NISSAN NORTH AMERICA, INC.
  24. Install reverse idler shaft assembly (1) according to the following procedures.
    1. Install spring washer to clutch housing.
    2. Pull up input shaft assembly (2), mainshaft assembly (3), fork rod (4), and 1st-2nd fork rod (5).
      NOTE: It is easier to pull up when shifting each fork rod to each shaft side.
    3. Set reverse fork rod (6) to reverse idler shaft assembly, and then install them to clutch housing.
      Fig 17: Installing Reverse Idler Shaft Assembly
      G05914915Courtesy of NISSAN NORTH AMERICA, INC.
  25. Shift 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to the neutral position.
  26. Install selector (4) to clutch housing.
    CAUTION: Replace selector lever and selector as a set.
    Fig 18: Installing Selector To Clutch Housing
    G04926436Courtesy of NISSAN NORTH AMERICA, INC.
  27. Install selector spring (1) to return bushing (A).
  28. Apply recommended sealant to mounting surface of transaxle case.
    CAUTION:
    • Remove old sealant contacting the mounting surfaces. Also remove any moisture, oil, or foreign material contacting to both mounting surfaces.
    • Check that mounting surface is not damaged.
    • Apply sealant bead continuously.
  29. Install transaxle case to clutch housing while rotating shifter lever A (1) in the direction as shown in the figure.
    Fig 20: Installing Transaxle Case To Clutch Housing
    G05914951Courtesy of NISSAN NORTH AMERICA, INC.
  30. Install reverse idler shaft mounting bolt (<==) according to the following procedures.
    1. Install seal washer to reverse idler shaft mounting bolt, and install reverse idler shaft mounting bolt to transaxle case.
      CAUTION: Never reuse seal washer.
    2. Tighten reverse idler shaft mounting bolt to the specified torque.
      Fig 21: Locating Reverse Idler Shaft Bolt
      G04926392Courtesy of NISSAN NORTH AMERICA, INC.
  31. Tighten transaxle case mounting bolts (<==) to the specified torque.
    Fig 22: Locating Transaxle Bolts
    G04926391Courtesy of NISSAN NORTH AMERICA, INC.
  32. Install position switch (1) according to the following procedures.
    1. Apply recommended sealant to threads of position switch.
      CAUTION: Remove old sealant and oil contacting to threads.
      Fig 23: Identifying Shift Lever, Bracket And Switch
      G04926440Courtesy of NISSAN NORTH AMERICA, INC.
    2. Install position switch to transaxle case, and tighten it to the specified torque.
  33. Install bracket (2) to transaxle case, and tighten mounting bolt to the specified torque.
  34. Install selector lever (3) according to following the procedures.
    1. Install selector lever to transaxle case.
      CAUTION: Replace selector lever and selector as a set.
    2. Install retaining pin to selector lever, using a pin punch.
    CAUTION: Never reuse retaining pin.
  35. Install drain plug according to the following procedures.
    1. Install gasket to drain plug.
      CAUTION: Never reuse gasket.
    2. Install drain plug to clutch housing, using a socket [Commercial service tool].
    3. Tighten drain plug to the specified torque.
  36. Install filler plug according to the following procedures.
    1. Install gasket to filler plug, and then install them to transaxle case.
      CAUTION: Never reuse gasket.
    2. Tighten filler plug to the specified torque.
    CAUTION: Fill with gear oil before tighten filler plug to the specified torque.
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