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Transaxle Assembly: Assembly

  1. Install 2 way connector (1) to clutch housing.
    Fig 1: Identifying Clutch Housing Way Connector
    G04926415Courtesy of NISSAN NORTH AMERICA, INC.
  2. Install bushings (1) so that they becomes even with clutch housing surface, using suitable tool (A).
  3. Install oil channel to clutch housing.
    CAUTION: Do not reuse oil channel.
    Fig 2: Installing Clutch Housing Bushings Using Drift
    G09458681Courtesy of NISSAN NORTH AMERICA, INC.
  4. Install mainshaft front bearing outer race to clutch housing using Tool (A).
    CAUTION: Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set.
    Do not reuse mainshaft front bearing inner or outer race.

    Tool number (A): KV38100200 (-) 

    Fig 3: Installing Mainshaft Front Bearing Outer Race To Clutch Housing Using Drift
    G04926420Courtesy of NISSAN NORTH AMERICA, INC.
  5. Install input shaft oil seal (1) to clutch housing using the Tool (A).

    Tool number (A): ST33220000 (-) 

    Fig 4: Installing Input Shaft Oil Seal To Clutch Housing Using Drift
    G09458683Courtesy of NISSAN NORTH AMERICA, INC.
  6. 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.
    Fig 5: Identifying Transaxle Case Snap Ring And Oil Channel
    G09458684Courtesy of NISSAN NORTH AMERICA, INC.
  7. Install mainshaft rear bearing adjusting shim to transaxle case.
    CAUTION: Select mainshaft rear bearing adjusting shim, with the following procedure 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).
  8. Install mainshaft rear bearing outer race to transaxle case using suitable tool (A).
    CAUTION: Replace mainshaft rear bearing outer race and mainshaft rear bearing inner race as a set.

    Tool number: KV38100200 (-) 

    Fig 6: Installing Mainshaft Rear Bearing Outer Race To Transaxle Case Using Drift
    G04926423Courtesy of NISSAN NORTH AMERICA, INC.
  9. Install bushings (1) to transaxle case, using suitable tool (A).
    Fig 7: Installing Bushings To Transaxle Case Using Drift
    G09458686Courtesy of NISSAN NORTH AMERICA, INC.
  10. Install oil gutter (1) to transaxle case.
    Fig 8: Identifying Transaxle Case Oil Gutter
    G04926425Courtesy of NISSAN NORTH AMERICA, INC.
  11. Install shifter lever B (1) to transaxle case.
    CAUTION: Replace shifter lever A and shifter lever B as a set.
  12. Install shifter lever A to transaxle case.
    CAUTION: Replace shifter lever A and shifter lever B as a set.
    Fig 9: Identifying Transaxle Case Shifter Lever B
    G04926405Courtesy of NISSAN NORTH AMERICA, INC.
  13. Install retaining pin to shifter lever A (1) using a suitable tool.
    CAUTION: Do not reuse retaining pin.
  14. Install shim to transaxle case.
    Fig 10: Installing Retaining Pin To Shifter Lever Using Pin Punch
    G04926404Courtesy of NISSAN NORTH AMERICA, INC.
  15. Install differential side bearing outer race (transaxle case side) to transaxle case, using Tool (A).
    CAUTION: Replace differential side bearing outer race (transaxle case side) and differential side bearing inner race (transaxle case side) as a set.
    Do not reuse differential side bearing inner or outer race.

    Tool number: ST33400001 (J-26082) 

    Fig 11: Installing Differential Side Bearing Outer Race Using Drift (Transaxle Case Side)
    G04926429Courtesy of NISSAN NORTH AMERICA, INC.
  16. Install differential side bearing outer race (clutch housing side) to clutch housing, using Tool (A).
    CAUTION: Replace differential side bearing outer race (clutch housing side) and differential side bearing inner race (clutch housing side) as a set.
    Do not reuse differential side bearing inner or outer race.

    Tool number: KV38100200 (-)

    Fig 12: Installing Differential Side Bearing Outer Race Using Drift (Clutch Housing Side)
    G04926430Courtesy of NISSAN NORTH AMERICA, INC.
  17. Install differential side oil seals (1) to clutch housing and transaxle case, using Tools.

    Tool number: KV32500QAA 

    Tool number: B.vi 1666-B 

    Fig 13: Identifying Transaxle Case Side/Clutch Housing Side And Clutch Housing Differential Side Oil Seals
    G09458692Courtesy 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) 

    CAUTION:
    • Do not incline differential side oil seal.
    • Do not damage clutch housing and transaxle case.
  18. Install magnet to clutch housing.
  19. Install final drive assembly to clutch housing.
  20. Set fork rod (1) to input shaft assembly (2), and then install them to clutch housing.
    Fig 14: Installing Input Shaft Assembly And Fork Rod
    G05914946Courtesy of NISSAN NORTH AMERICA, INC.
  21. Install mainshaft assembly (1), with the following procedure.
    1. Pull up input shaft assembly (2) and fork rod (3).
    2. Set 1st-2nd fork rod (4) to mainshaft assembly and install them to clutch housing.
      Fig 15: Pulling Up Input Shaft Assembly And Fork Rod
      G05914947Courtesy of NISSAN NORTH AMERICA, INC.
  22. Install reverse idler shaft assembly (1) with the following procedure.
    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 install them to clutch housing.
      Fig 16: Pulling Up Input Shaft Assembly, Mainshaft Assembly And Fork Rod
      G05914915Courtesy of NISSAN NORTH AMERICA, INC.
  23. Move 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to the neutral position.
  24. Install selector (4) to clutch housing.
    CAUTION: Replace selector lever and selector as a set.
    Fig 17: Installing Selector Clutch Housing
    G04926436Courtesy of NISSAN NORTH AMERICA, INC.
  25. Install selector spring (1) to return bushing (A).
  26. Apply recommended sealant to the gasket surface of transaxle case.
    CAUTION:
    • Do not allow old liquid gasket, moisture, oil, or foreign matter to remain on gasket surface.
    • Check that the gasket surface is not damaged.
    • Apply sealant bead continuously.
    Fig 18: Installing Selector Spring To Return Bushing
    G05914913Courtesy of NISSAN NORTH AMERICA, INC.
  27. Install transaxle case to clutch housing while rotating shifter lever A (1) in the direction as shown below.
    Fig 19: Installing Transaxle Case To Clutch Housing
    G05914951Courtesy of NISSAN NORTH AMERICA, INC.
  28. Install reverse idler shaft bolt (<==), as per the following procedure.
    1. Install sealing washer to reverse idler shaft bolt, and install reverse idler shaft bolt to transaxle case.
      CAUTION: Do not reuse sealing washer.
    2. Tighten reverse idler shaft bolt to the specified torque.
      Fig 20: Locating Reverse Idler Shaft Mounting Bolt
      G04926392Courtesy of NISSAN NORTH AMERICA, INC.
  29. Tighten transaxle case bolts (<==) to the specified torque.
    Fig 21: Locating Transaxle Case Mounting Bolts
    G04926391Courtesy of NISSAN NORTH AMERICA, INC.
  30. Install position switch (1), with the following procedure.
    1. Apply recommended sealant to threads of position switch.
      CAUTION: Do not allow old liquid gasket, moisture, oil, or foreign matter to remain on thread.
      Fig 22: Identifying Selector Lever, Bracket And Position Switch
      G04926440Courtesy of NISSAN NORTH AMERICA, INC.
    2. Install position switch to transaxle case and tighten it to the specified torque.
  31. Install bracket (2) to transaxle case and tighten bolt to the specified torque.
  32. Install selector lever (3) with the following procedure.
    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 suitable tool.
      CAUTION: Do not reuse retaining pin.
  33. Install drain plug with the following procedure.
    1. Install gasket to drain plug.
      CAUTION: Do not reuse gasket.
    2. Install drain plug to clutch housing using a suitable tool.
    3. Tighten drain plug to the specified torque.
      CAUTION: Do not overtighten drain plug as this could cause the transaxle case to crack.
  34. Install filler plug with the following procedure.
    1. Install gasket to filler plug and install it to the transaxle case.
      CAUTION: Do not reuse gasket.
    2. Tighten filler plug to the specified torque.
      CAUTION: Fill with gear oil before tighten filler plug to the specified torque.
      Do not overtighten the filler plug as this could cause the transaxle case to crack.
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