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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 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 Tool
    G04888892Courtesy of NISSAN NORTH AMERICA, INC.
  2. 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 (-) 

    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 Tool
    G04888893Courtesy of NISSAN NORTH AMERICA, INC.
  3. 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 To Clutch Housing Using Tool
    G04888894Courtesy of NISSAN NORTH AMERICA, INC.
  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: Identifying Oil Channel Installing Position On Mainshaft Side
    G04888895Courtesy of NISSAN NORTH AMERICA, INC.
  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
    G04888896Courtesy of NISSAN NORTH AMERICA, INC.
  6. Install mainshaft bearing retainer (1) to clutch housing and tighten bolt to the specified torque.
    Fig 6: Locating Mainshaft Bearing Retainer Bolt
    G06996528Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Install with punched surface facing up.
  7. Install magnet to clutch housing.
    Fig 7: Locating Clutch Housing Magnet
    G04888887Courtesy of NISSAN NORTH AMERICA, INC.
  8. Install final drive assembly into clutch housing.
    Fig 8: Identifying Clutch Housing Final Drive Assembly
    G04888899Courtesy of NISSAN NORTH AMERICA, INC.
  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: Identifying Input Shaft Assembly, Reverse Idler Gear Assembly, Mainshaft And Input Shaft Assembly
    G04888886Courtesy of NISSAN NORTH AMERICA, INC.
  10. Install striking rod assembly (1) into clutch housing.
    Fig 10: Identifying Striking Rod Assembly
    G04888885Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Check that return spring is securely seated in the groove on return pin.
    Fig 11: Locating Return Pin
    G04888902Courtesy of NISSAN NORTH AMERICA, INC.
  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 by the arrow until it becomes flush with the end surface of 1st-2nd shift fork.
    Fig 12: Locating 1st-2nd Shift Fork Retaining Pin
    G04888884Courtesy of NISSAN NORTH AMERICA, INC.
  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: Identifying 3rd-4th Shift Fork
    G04888883Courtesy of NISSAN NORTH AMERICA, INC.
  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 until it becomes flush with the end surface of 5th-6th shift fork.
    Fig 14: Locating 5th-6th Shift Fork Retaining Pin
    G04888880Courtesy of NISSAN NORTH AMERICA, INC.
  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 until it becomes flush with the end surface of 3rd-4th shift fork.
    Fig 15: Locating 3rd-4th Shift Fork Retaining Pin
    G04888881Courtesy of NISSAN NORTH AMERICA, INC.
  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: Identifying Reverse Shift Fork And Reverse Fork Rod
    G04888907Courtesy of NISSAN NORTH AMERICA, INC.
  16. Rotate striking lever of striking rod assembly as shown. 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 Rod Assembly Striking Lever
    G04888879Courtesy of NISSAN NORTH AMERICA, INC.
  17. Install retaining pin to reverse shift fork (1).
    CAUTION:
    • Do not reuse retaining pin.
    • Assemble retaining pin from the direction shown by the arrow until it becomes flush with the end surface of reverse shift fork.
    Fig 18: Identifying Reverse Shift Fork Retaining Pin
    G06549360Courtesy of NISSAN NORTH AMERICA, INC.
  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 and striking rod oil seal.
    • Do not damage transaxle case.
    Fig 19: Identifying Shifter Lever Oil Seal And Striking Rod Oil Seal Installing Dimension
    G04888910Courtesy of NISSAN NORTH AMERICA, INC.
  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
    G04888911Courtesy of NISSAN NORTH AMERICA, INC.
  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: Identifying Shifter Lever A And B
    G04888912Courtesy of NISSAN NORTH AMERICA, INC.
  25. Install retaining pin to shifter lever A.
    CAUTION:
    • Do not reuse retaining pin.
    • Assemble retaining pin from the direction shown by the arrow until it becomes flush with the end surface of shifter lever A.
    Fig 22: Locating Retaining Pin
    G04888873Courtesy of NISSAN NORTH AMERICA, INC.
  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: Identifying Oil Gutter Tab And Oil Gutter A And B
      G04888871Courtesy of NISSAN NORTH AMERICA, INC.
    3. Temporarily install snap ring of mainshaft rear bearing into transaxle case.
      CAUTION: Do not reuse snap ring.
      Fig 24: Identifying Mainshaft Rear Bearing Snap Ring
      G04888872Courtesy of NISSAN NORTH AMERICA, INC.
    4. Apply recommended sealant to mating surface of clutch housing as shown.
      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 Clutch Housing Mating Surface Sealant Applying Areas
      G04888916Courtesy of NISSAN NORTH AMERICA, INC.
    5. With shifter lever A (1) held in the position shown, 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. Otherwise transaxle case cannot be installed to clutch housing.
      Fig 26: Identifying Shifter Lever A Position
      G04888870Courtesy of NISSAN NORTH AMERICA, INC.
    6. While rotating shifter lever A (1) in the direction of the arrow shown, assemble transaxle case to clutch housing.
      Fig 27: Rotating Shifter Lever A
      G06996549Courtesy of NISSAN NORTH AMERICA, INC.
    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 And Clutch Housing Snap Ring
      G04888869Courtesy of NISSAN NORTH AMERICA, INC.
    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.
        Fig 29: Shifting Shifter Lever A To 2nd Gear Position
        G04888920Courtesy of NISSAN NORTH AMERICA, INC.
      • 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 Mainshaft Rear Bearing Groove
      G04888921Courtesy of NISSAN NORTH AMERICA, INC.
    11. Tighten transaxle case bolts to the specified torque.
      Fig 31: Locating Transaxle Case Bolts
      G04888867Courtesy of NISSAN NORTH AMERICA, INC.
    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.
    Fig 32: Shifting Shifter Lever A To Neutral Position
    G04888923Courtesy of NISSAN NORTH AMERICA, INC.
  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
    G04888924Courtesy of NISSAN NORTH AMERICA, INC.
  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 by the arrow until it becomes flush with the end surface of selector lever.
    Fig 34: Locating Retaining Pin
    G04888866Courtesy of NISSAN NORTH AMERICA, INC.
  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: Identifying Guide Bolt
      G06549142Courtesy of NISSAN NORTH AMERICA, INC.
      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
    G04888865Courtesy of NISSAN NORTH AMERICA, INC.
  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.
  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.
    Fig 37: Identifying Park/Neutral Position Switch, Back-Up Lamp Switch And Air Breather Tube
    G04888864Courtesy of NISSAN NORTH AMERICA, INC.
  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: Locating Transaxle Case Plug
    G04888863Courtesy of NISSAN NORTH AMERICA, INC.
  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: Locating Transaxle Drain Plug
    G04888862Courtesy of NISSAN NORTH AMERICA, INC.
  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: Locating Clutch Housing O-Ring
G04926538Courtesy of NISSAN NORTH AMERICA, INC.
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