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Transaxle Assembly: Assembly

  1. Install 2 way connector (1) to clutch housing.
    Fig 1: Two Way Connector From Clutch Housing
    G04812767Courtesy of NISSAN NORTH AMERICA, INC.
  2. Install bushings (1) so that they becomes even with clutch housing surface, using suitable tool (A).
    Fig 2: Installing Clutch Housing Bushings Using Drift
    G05914934Courtesy of NISSAN NORTH AMERICA, INC.
  3. Install oil channel to clutch housing.
    CAUTION:

    Do not reuse oil channel.

  4. Install mainshaft front bearing outer race to clutch housing using Tool (A).
    Fig 3: Installing Mainshaft Front Bearing Outer Race To Clutch Housing Using Drift
    G04812772Courtesy of NISSAN NORTH AMERICA, INC.
    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 (-)
  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
    G04812773Courtesy of NISSAN NORTH AMERICA, INC.
  6. Install snap ring (1) and oil channel (2) to transaxle case.
    Fig 5: Snap Ring And Oil Channel
    G04812774Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Select and install snap ring that has the same thickness as previous one.
    • Replace transaxle assembly when replacing transaxle case.
  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).
    Fig 6: Installing Mainshaft Rear Bearing Outer Race To Transaxle Case Using Drift
    G04812775Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:

    Replace mainshaft rear bearing outer race and mainshaft rear bearing inner race as a set.

    Tool number : KV38100200 (-)
  9. Install bushings (1) to transaxle case, using suitable tool (A).
    Fig 7: Installing Bushings To Transaxle Case Using Drift
    G05914939Courtesy of NISSAN NORTH AMERICA, INC.
  10. Install oil gutter (1) to transaxle case.
    Fig 8: Oil Gutter
    G04812777Courtesy of NISSAN NORTH AMERICA, INC.
  11. Install shifter lever B (1) to transaxle case.
    Fig 9: Transaxle Case Shifter Lever B
    G04812757Courtesy of NISSAN NORTH AMERICA, INC.
    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.

  13. Install retaining pin to shifter lever A (1) using a suitable tool.
    Fig 10: Installing Retaining Pin To Shifter Lever A Using Pin Punch
    G04926404Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:

    Do not reuse retaining pin.

  14. Install shim to transaxle case.
  15. Install differential side bearing outer race (transaxle case side) to transaxle case, using Tool (A).
    Fig 11: Shim And Differential Side Bearing
    G04812781Courtesy of NISSAN NORTH AMERICA, INC.
    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)
  16. Install differential side bearing outer race (clutch housing side) to clutch housing, using Tool (A).
    Fig 12: Installing Differential Side Bearing Outer Race To Clutch Housing Using Tool
    G04812782Courtesy of NISSAN NORTH AMERICA, INC.
    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 (-)
  17. Install differential side oil seals (1) to clutch housing and transaxle case, using Tools.
    Fig 13: Differential Side Oil Seal
    G06538170Courtesy of NISSAN NORTH AMERICA, INC.
    Tool number : KV32500QAA
    Tool number : B.vi 1666-B
    (A) : Transaxle case side
    (B) : Clutch housing side
    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: Fork Rod And Input Shaft Assembly
    G05914946Courtesy of NISSAN NORTH AMERICA, INC.
  21. Install mainshaft assembly (1), with the following procedure.
    Fig 15: Pulling Up Input Shaft Assembly And Fork Rod
    G05914947Courtesy of NISSAN NORTH AMERICA, INC.
    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.
  22. Install reverse idler shaft assembly (1) with the following procedure.
    Fig 16: Removing Reverse Idler Shaft Assembly
    G05914915Courtesy of NISSAN NORTH AMERICA, INC.
    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.
  23. Move 1st-2nd fork rod (1), fork rod (2), and reverse fork rod (3) to the neutral position.
    Fig 17: Installing Selector To Clutch Housing
    G04812788Courtesy of NISSAN NORTH AMERICA, INC.
  24. Install selector (4) to clutch housing.
    CAUTION:

    Replace selector lever and selector as a set.

  25. Install selector spring (1) to return bushing (A).
    Fig 18: Installing Selector Spring To Return Bushing
    G05914913Courtesy of NISSAN NORTH AMERICA, INC.
  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.
  27. Install transaxle case to clutch housing while rotating shifter lever A (1) in the direction as shown.
    Fig 19: Installing Transaxle Case To Clutch Housing
    G05914951Courtesy of NISSAN NORTH AMERICA, INC.
  28. Install reverse idler shaft bolt (ARROWF ), as per the following procedure.
    Fig 20: Reverse Idler Shaft Mounting Bolt
    G04812744Courtesy of NISSAN NORTH AMERICA, INC.
    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.
  29. Tighten transaxle case bolts (ARROWF ) to the specified torque.
    Fig 21: Transaxle Case Mounting Bolts
    G04812743Courtesy of NISSAN NORTH AMERICA, INC.
  30. Install position switch (1), with the following procedure.
    Fig 22: Shift Lever, Bracket And Switch
    G04812792Courtesy of NISSAN NORTH AMERICA, INC.
    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.

    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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