Nissan Frontier 2005 Owner's Manual

C TRANSMISSION/TRANSAXLE

SECTION MT

CONTENTS

FS5R30A

PRECAUTIONS .......................................................... 3

Service Noti ce or Pre ca u ti o ns ........... ....................... 3

PREPARATION ........................................................... 4

Special Service Tools ............................................... 4

Commercial Service Tool ......................................... 6

NOISE, VIBRATION, AND HARSHNESS (NVH)

TROUBLESHOOTING ................................................ 7

NVH Troubleshooting Chart ..................................... 7

DESCRIPTION ............................................................ 8

Description ............................................................... 8

CROSS-SECTIONAL VIEW .................................. 8

M/T OIL ....................................................................... 9

Changing .................................................................. 9

DRAINING ............................................................. 9

FILLING .................................................................9

Checking ..................................................................9

OIL LEAKAGE AND OIL LEVEL ........................... 9

REAR OIL SEAL ...................................................... 10

Removal and Installation ........................................ 10

REMOVAL ........................................................... 10

INSTALLATION ................................................... 10

POSITION SWITCH ...................................................11

Checking .................................................................11

BACK-UP LAMP SWITCH ...................................11

PARK/NEUTRAL POSITION SWITCH ................11

SHIFT CONTROL ........................................... .......... 12

Removal and Installation ........................................ 12

COMPONENTS .................................................. 12

REMOVAL ........................................................... 12

INSTALLATION ................................................... 12

AIR BREATHER HOSE ............................................ 14

Removal and Installation ........................................ 14

TRANSMISSION ASSEMBLY ... ............................... 15

Removal and Installation from Vehicle ................... 15

COMPONENTS .................................................. 15

REMOVAL ........................................................... 16

MANUAL TRANSMISSION

INSTALLATION ...................................................16

Overhaul .................................................................17

CASE COMPONENTS ........................................17

GEAR COMPONENTS ........... ............................19

SHIFT CONTROL COMPONENTS .....................23

CASE COMPONENTS ...... ........................................25

Disassembly ...........................................................25

Assembly ................................................................27

SHIFT CONTROL COMPONENTS ...........................30

Disassembly ...........................................................30

Inspection ...............................................................30

Assembly ................................................................31

GEAR COMPONENTS .............................................32

Disassembly ...........................................................32

Inspection ...............................................................36

GEARS AND SHAFTS ........................................36

SYNCHRONIZERS .............................................36

BEARINGS ..........................................................37

Assembly ................................................................37

SERVICE DATA AND SPECIFICATIONS (SDS) ...... 47

General Specifications ............................................47

Gear End Play ........................................................47

Baulk Ring Clearance ..... ........................................48

Available Snap Rings .......... ....... ....... ....... ..... .........48

MAIN DRIVE GEAR SNAP RING .......................48

MAINSHAFT FRONT SNAP RING ......................48

COUNTER GEAR REAR SNAP RING ....... .........48

Available C-Rings ...................................................49

MAINSHAFT C-RING ..........................................49

Available Thrust Washer .........................................49

REVERSE IDLER THRUST WASHER ...............49

Available Shims ............ ..................... .....................49

T ABLE FOR SELECTIN G PROPER COUNTER

GEAR FRONT BEARING SHIM ..........................4 9

FS6R31A

PRECAUTIONS ........................................................50

Service Notice or Precautions ................................50

Revision: November 2005 2005 Frontier

MT-1

PREPARATION .........................................................51

Special Service Tools .............................................51

Commercial Ser vice Tools ......................................54

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING .............................................. 55

NVH Troubleshooting Chart ....................................55

DESCRIPTION ..........................................................56

Cross-Sectional View ..............................................56

DOUBLE-CONE SYNCHRONIZER ....................57

TRIPLE-CONE SYNCHRONIZER .......................57

M/T OIL ........................................................ .............. 58

Changing ................................................................58

DRAINING ........................................................... 58

FILLING ...............................................................58

Checking .................................................................58

OIL LEAKAGE AND OIL LEVEL .........................58

REAR OIL SEAL .......................................................59

Removal and Installation (For 2WD models) ..... .....59

REMOVAL ...........................................................59

INSTALLATION ....................................................59

POSITION SWITCH ..................................................60

Checking .................................................................60

BACK-UP LAMP SWITCH ...................................60

PARK/NEUTRAL POSITION SWITCH ................ 60

SHIFT CONTROL ......................................................61

Removal and Installation ......................................... 61

COMPONENTS ...................................................61

REMOVAL ............................................................61

INSTALLATION ....................................................61

AIR BREATHER HOSE .............................................63

Removal and Installation ......................................... 63

TRANSMISSION ASSEMBLY ...................................64

Removal and Installation from Vehicle (For 2WD

models) ...................................................................64

COMPONENTS ...................................................64

REMOVAL ............................................................65

INSTALLATION ....................................................65

Removal and Installation from Vehicle (For 4WD

models) ...................................................................66

COMPONENTS ...................................................66

REMOVAL ............................................................67

INSTALLATION ....................................................67

Disassembly and Assembly .................................... 69

COMPONENTS ...................................................69

DISASSEMBLY ....................................................75

INSPECTION AFTER DISASSEMBLY ................89

ASSEMBLY ..........................................................93

SERVICE DATA AND SPECIFICA TI ONS (SDS) ....116

General Specifications ..........................................116

Gear End Play .................................. .....................117

Snap Rings ...........................................................117

Baulk Ring Clearance ...........................................118

Revision: November 2005 2005 Frontier

MT-2

PRECAUTIONS

[FS5R30A]

PRECAUTIONS PFP:00001

Service Notice or Precautions UCS0040T

● Do not reuse transmission oil once it has been drained.

● Check oil level or replace oil with vehicle on level surface.

● During removal or installation, keep inside of transmission clear of dust or dirt.

● Check for t he corr ect installation status p rior to re moval o r disassem bly. If matching marks are requ ired,

be certain they do not interfere with the function of the parts they are applied to.

● In principle, tighte n nuts and b olts gradually i n several ste ps working d iagonally fro m inside to ou tside. If

tightening sequence is specified, use it.

● Be careful not to damage sliding surfaces and mating surfaces.

Revision: November 2005 2005 Frontier

MT-3

PREPARATION

[FS5R30A]

PREPARATION PFP:00002 Special Serv ice Tools UCS003ZF

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

ST23540000 (J-25689-A) Pin punch

NT442

ST30031000 (J-22912-01) Puller

NT411

ST33290001 (J-34286) Puller

Description

Removing and installing retaining pin

a: 2.3 mm (0.091 in) dia. b: 4 mm (0.16 in) dia.

● Removing 1st and 2nd synchronizer as-

sembly

● Removing counter gear rear thrust bearing

● Removing main drive bearing

● Inspecting baulk ring wear

a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia.

Removing rear oil seal

ST33230000 (—) Drift

ST22350000 (J-25678-01) Drift

KV38100300 (J-25523) Drift

ST30720000

1. ( — )

2. (J-25405) Drift

WMT066

Removing counter gear

a: 51 mm (2.01 in) dia. b: 28.5 mm (1.122 in) dia.

NT084

Removing counter gear front bearing (Use with KV38100300)

a: 34 mm (1.34 in) dia. b: 28 mm (1.10 in) dia.

NT065

● Removing counter gear front bearing (Use

with ST22350000)

● Installing counter gear rear bearing

a: 54 mm (2.13 in) dia. b: 32 mm (1.26 in) dia.

NT084

1. Removing and installing mainshaft front bearing

2. Installing rear oil seal

a: 77 mm (3.03 in) dia. b: 55.5 mm (2.185 in) dia.

NT115

Revision: November 2005 2005 Frontier

MT-4

PREPARATION

[FS5R30A]

Tool numbe r (Kent-Moore No.) Tool name

ST33210000

1. (J-25523)

2. (J-25803-01) Drift

ST30613000 (J-25742-3) Drift

ST37750000

1. (J-25863-01)

2. (J-34332)

3. (J-34334)

4. (J-25679-01) Drift

ST22452000 (J-34337) Drift

NT084

NT073

NT065

Description

1. Installing counter gear front bearing

2. Installing front cover oil seal

a: 44 mm (1.73 in) dia. b: 24.5 mm (0.965 in) dia.

Installing main drive gear bearing

a: 72 mm (2.83 in) dia. b: 48 mm (1.89 in) dia.

1. Removing counter gear rear bearing

2. Installing OD gear bushing

2. Installing reverse cone

3. Installing reverse counter gear

4. Installing counter gear rear end bearing

a: 40 mm (1.57 in) dia. b: 31 mm (1.22 in) dia.

Installing reverse synchronizer hub

a: 45 mm (1.77 in) dia. b: 36 mm (1.42 in) dia.

— (J-26349-3) Puller leg

— (J-34328) Puller

— (J-34342) Drift

NT065

NT078

NT079

NT065

Installing mainshaft and counter gear (Use with J-34328)

Installing mainshaft and counter gear (Use with J-26349-3)

● Installing OD main gear

● Installing reverse gear bushin g

a: 44.5 mm (1.752 in) dia. b: 40.5 mm (1.594 in) dia.

Revision: November 2005 2005 Frontier

MT-5

PREPARATION

[FS5R30A]

Tool number (Kent-Moore No.) Tool name

— (J-26349-A) Bearing Remover and Installer Set

WMT065

— (J-25726-B) Puller

ZZA0010D

Description

Removing and installing mainshaft rear bearing (Use with J-25726-B)

Removing and installing mainshaft rear bearing (Use with J-26349-A)

Commercial Service Tool UCS003ZG

Tool name Description Puller

● Removing counter gear rear end bearing

● Removing revers e synchr onizer hub

● Removing reverse cone

● Removing reverse gear bushing

● Removing reverse counter gear

NT077

Power tool Loosening bolts and nuts

PBIC0190E

Revision: November 2005 2005 Frontier

MT-6

NOISE, VIBRATION , AND HARSHN ESS (NVH) TR OUBLESH OOT ING

[FS5R30A]

NOIS E, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart UCS003ZH

Use the char t below to hel p you find the c ause o f the pro blem. Th e numbers indicate the ord er of th e inspec tion. If necessary, repair or replace these parts.

Reference page

SUSPECTED PARTS (Possible cause)

MT-9

MT-17

MT-23

MT-19

Symptom

OIL (Level low )

OIL (Wrong)

OIL (Level too high)

GASKET (Damaged)

OIL SEAL (Worn or damaged)

O-RING (Worn or damaged)

CHECK PL UG RETURN SPRING AND CHECK BALL (Worn or damaged )

SHIFT FO RK (Worn)

GEAR (Worn or damaged)

BEARING (Worn or damaged)

BAULK RING (Worn or damaged) Noise 1 2 3 3 Oil leakage 31222 Hard to shift or will not shift 1 1 2 2 Jumps out of gear 1 2 2

INSERT SPRING (Damaged)

Revision: November 2005 2005 Frontier

MT-7

DESCRIPTION

[FS5R30A]

DESCRIPTION PFP:00000 Description UCS003ZI

CROSS-SECTIONAL VIEW

PCIB1296E

1. Release bearing sleeve 2. Front cover 3. Main drive gear

4. 3rd and 4th shift fork 5. Transmission case 6. 3rd and 4th coupling sleeve

7. Striking interlock 8. 3rd main gear 9. 2nd main gear

10. 1st main gear 11. OD main gear 12. Striking rod

13. Rever se shift fork 14. Shift lever 15. Main shaft

16. Mainshaft rear bearing 17. Counter gear rear end bearing 18. Reverse main gear

19. Rear extension 20. OD counter gear 21. Adapter plate

22. Mainshaft front bearing 23. Drain plug 24. 1st and 2nd coupling sleeve

25. Counter gear 26. Sub-gear bracket 27. Counter gear front bearing

28. Main drive gear bearing 29. Main drive gear

Revision: November 2005 2005 Frontier

MT-8

M/T OIL

[FS5R30A]

M/T OIL PFP:KLD20

Changing UCS0040V

DRAINING

1. Start the engine and let it run to warm up the transmission.

2. Stop the engine. Re move the transmission drain plug and drain the oil.

3. Set a gasket on the dra in plug and install it to th e transmission. Tighten th e drain plug to the spe cified torque. Refer to MT-17, "

CAUTION:

Do no reuse gasket.

CASE COMPONENTS" .

FILLING

1. Remove the filler plug. Fill with new oil until oil level reaches the specified limit near the filler plug hole.

Oil grade and Viscosity:

Refer to MA-11, "

Fluids and Lubricants" .

Oil capacity:

Refer to MA-11, "Fluids and Lubricants" .

2. After refilling the oil, check oil level. Set a gasket to the filler plug, then in stall it to the transmissi on. Tighten the filler plug t o the specified torque. Refer to MT-17, "

CASE COMPONENTS" .

PCIB0268E

CAUTION:

Do not reuse gasket.

Checking UCS0040W

OIL LEAKAGE AND OIL LEVEL

● Make sure that oil is not leaking from the transmission or around it.

● Check oil le vel from the filler plug hole as shown.

CAUTION:

Do not start engine while checking oil level.

● Set a gasket on the filler plug and install it to the transmission .

Tighten the filler plug to the specified torque. R efer to MT-17,

"CASE COMPONENTS" .

CAUTION:

Do not reuse gasket.

PCIB0268E

Revision: November 2005 2005 Frontier

MT-9

REAR OIL SEAL

[FS5R30A]

REAR OIL SEAL PFP:33140 Removal and Installation UCS0040U

REMOVAL

1. Re move th e r ear pr opeller shaft. Refe r t o PR -10, "R emoval and

Installation" .

2. Re move the rear oil seal using Tool.

Tool number : ST33290001 (J-34286)

CAUTION:

Do not reuse rear oil seal.

WCIA0176E

INSTALLATION

Installation is the reverse order of removal.

● Drive the new oil seal straight until it stops using Tool.

Tool number : ST30720000 (J-25405)

CAUTION:

● Do not reuse rear oil seal.

● Apply multi- purpose gre ase to oil se al lips before install-

ing.

● Do not incline rear oil se al during installation.

● Check the transmis sion oil le vel after in stallation. Re fer to MT-9,

"Checking" .

WCIA0493E

Revision: November 2005 2005 Frontier

MT-10

POSITION SWITCH

[FS5R30A]

POSITION SWITCH PFP:32005

Checking UCS0040X

BACK-UP LAMP SWITCH

● Check continuity.

Gear position Continuity Reverse Yes Except reverse No

PARK/NEUTRAL POSITION SWITCH

● Check continuity.

Gear position Continuity Neutral Yes Except neutral No

SMT981D

Revision: November 2005 2005 Frontier

MT-11

SHIFT CONTROL

[FS5R30A]

SHIFT CONTROL PFP:32982 Removal and Installation UCS0040Z

COMPONENTS

LCIA0382E

1. Retainin g plate 2. Dust boot cover (upper ) 3. Dust boot cove r (lower)

4. Sh ift knob 5. Shift lever assembly 6. Clip (A)

7. Boot 8. Clip (B) 9. Snap ring

REMOVAL

1. Re move the shift knob.

2. Re move the cup hol der finisher and shift bezel. Refer to IP-10, "

3. Re move the retaining plate and dust boot covers.

4. Re move the clip (B) and then separate the boot from the control housing.

5. Re move the snap ring.

6. Re move the shift lever assembly from the transmission.

Removal and Installation" .

INSTALLATION

Installation is the reverse order of removal.

Revision: November 2005 2005 Frontier

MT-12

SHIFT CONTROL

[FS5R30A]

CAUTION:

● Do not reuse the clip and snap ring.

● Apply cement to threads of the shift lever assembly.

● When shift lever as sembly is shifted to eac h position, make sure ther e is no binding or disconne ction in

either boot.

Revision: November 2005 2005 Frontier

MT-13

AIR BREATHER HOSE

[FS5R30A]

AIR BREATHER HO SE PFP:31098 Removal and Installation UCS0040Y

Refer to the figure below for air breather hose removal and instal lation information.

LCIA0380E

1. Air breather hos e 2. Harness 3. Breather tube

4. Clip

CAUTION:

● Make sure there are no pinched or blocked areas on the air breather hose after installation.

● When inse rting the air br eather hose, b e sure to inse rt it fully until its end rea ches the end of the

tube radius.

● Install the air breather hose with the paint mark side up.

● Install the air breather hose and harness to the clip to prevent separation.

● Push the harness so that it contacts with the interlocking bolt.

Revision: November 2005 2005 Frontier

MT-14

TRANSMISSION ASSEMBLY

[FS5R30A]

TRANSMISSION ASSEMBLY PFP:32010

Removal and Installation f rom Vehicle UCS00410

COMPONENTS

LCIA0377E

1. Breather hose 2. Transmission assembly 3. Dust cover

4. Crossmember 5. Insulator

Revision: November 2005 2005 Frontier

MT-15

TRANSMISSION ASSEMBLY

REMOVAL

1. Drai n the transmission fluid. Refer to MT-9, "DRAINING" .

2. Disconnect the battery cable from the negative terminal.

3. Re move the shift lever assembly. Refer to MT-12, "

4. Re move the rear propeller shaft. Refer to PR-10, "

5. Re move the gusset.

6. Disconnect the heated oxygen sensor connector and remove wire harness from transm ission.

7. Disconnect the back-up lamp switch and park/neutral pos ition (PNP) switch connectors.

8. Re move the clutch operating cylinder from the transmission. Refer to CL -11, "

9. Re move the starter motor. Refer to SC-23, "

Removal and Installation" .

10. Support the transmission using a suitable jack.

11. Remove the transmission dust cover.

12. Remove the transmission to engine bolts.

13. Remove the nuts securing the insulator to the crossmember.

14. Remove the transmission crossmember using power tool.

WARNING:

Support the transmission using suitable jack.

15. Remove the air breather hose and breather tube. Refer to MT-14, "

16. Separate the transmission from the engine and remove it from the vehicle.

WARNING:

Support manual transmission while removing it usin g suitable jack.

Removal and Installation" .

[FS5R30A]

INSTALLATION

Installation is the reverse order of removal.

● When installing the transmission to the engine, install the bolts in

accordance with the standard below.

Bolt No. 123 Quantity 416

Bolt length “ ” mm (in)

Tightening torque N·m (kg-m, f t-lb)

CAUTION:

● When installing be careful to avoid interference between

transmissio n main drive gear and clutch cover.

● When rep lacing an engine o r t ran smissio n yo u must m ake sure the do wels a r e installed co rrect ly

during re-assembly.

● Improp er alignment caused by missi ng dowels m ay cause vib ration oil le aks or breakag e of driv-

etrain compo nents.

● After installation, check for oil leakage and oil level. Refer to MT-9, "Checking" .

60 (2.36) 65 (2.56)

34.3 (3.5, 25) 75 (7.7, 55)

WCIA0505E

Revision: November 2005 2005 Frontier

MT-16

TRANSMISSION ASSEMBLY

[FS5R30A]

Overhaul UCS00419

CASE COMPONENTS

PCIB1281E

Revision: November 2005 2005 Frontier

MT-17

TRANSMISSION ASSEMBLY

1. Back-up lamp switch 2. Park/neutral position (PNP) switch 3. Clip

4. Plug 5. Dust cover 6. Rear oil seal

7. Rear extension 8. Rear extension bolt 9. Bearing retainer bolt

10. Slide ball bearing 11. Drain pl ug 12. Gasket

13. Front cover oil seal 14. Front cover bolt 15. Washer

16. Ball pin 17. Front cover 18. Gasket

19. Slide ball bearing 20. Transmission case 21. Filler plug

22. Air breather 23. Adapter plate 24. Bearing retainer

[FS5R30A]

Revision: November 2005 2005 Frontier

MT-18

GEAR COMPONENTS

TRANSMISSION ASSEMBLY

[FS5R30A]

PCIB1282E

1. Main drive gear bearing snap ring 2. Main drive gear snap ring 3. Main drive gear bearing

4. Main drive gear 5. Pilot bearing 6. Spacer

Revision: November 2005 2005 Frontier

MT-19

TRANSMISSION ASSEMBLY

[FS5R30A]

7. Mainshaft front snap ring 8. 4th baulk ring 9. 3rd and 4th coupling sleeve

10. Shifting insert 11. Spread spring 12. 3rd and 4th synchronizer hub

13. 3rd outer baulk ring 14. Synchronizer cone 15. 3 rd inner baulk ring

16. 3rd main gear 17. 3rd gear needle bearing 18. Steel ball (For 1st gear washer)

19. Mainshaft 20. Counter gear front bearing 21. Counter gear front bearing shim

22. Counter gear front thrust bearing 23. Sub-gear snap ring 24. Sub-gear bracket

25. Steel ball 26. Counter gear 27. Counter gear rear thrust bearing

28. 2nd main gear 29. 2nd gear needle bearing 30. 2nd inner baulk ring

31. 2nd outer baulk ring 32. 1st and 2nd synchronizer hub 33. 1st and 2nd coupling sleeve

34. 1st baulk ring 35. 1st main gear 36. 1st gear needle bearing

37. 1st gear bushing 38. 1st gear washer

Revision: November 2005 2005 Frontier

MT-20

TRANSMISSION ASSEMBLY

[FS5R30A]

PCIB1283E

1. Mainshaft front bearing 2. Mainshaft front bearing snap ring 3. OD main gear

4. Reverse gear bushing 5. Reverse main gear 6. Reverse gear needle bearings

7. Reverse synchronizer hub 8. Reverse coupling sleeve 9. Mainshaft spacer

Revision: November 2005 2005 Frontier

MT-21

TRANSMISSION ASSEMBLY

[FS5R30A]

10. Mainshaft rear bearing 11. Mainshaft C-ring 12. C-ring holder

13. Mainshaft rear snap ring 14. Counter gear rear bearing 15. OD gear bushing

16. OD gear needle bearing 17. OD counter gear 18. OD coupling sleeve

19. Spring insert 20. Reverse cone 21. Reverse baulk ring

22. OD baulk ring 23. Revers e count er gear 24. Counter gear rear end bear ing

25. Counter gear rear snap ring 26. Retaining pin 27. Reverse idler shaft

28. Reverse idler needle bearings 29. Reverse idler gear 30. R everse idler thrust washer

Revision: November 2005 2005 Frontier

MT-22

TRANSMISSION ASSEMBLY

SHIFT CONTROL COM PON ENTS

[FS5R30A]

PCIB1284E

1. Snap ring 2. Socket 3. Spring

4. Shift knob 5. Shift lever 6. Upper boot retainer

Revision: November 2005 2005 Frontier

MT-23

TRANSMISSION ASSEMBLY

7. Boot 8. Lower boot retainer 9. Control housing bolt

10. Washer 11. Control housin g 12. Bushing

13. Retur n spring 14. Check ball 15. Select che ck plun ger

16. Selec t check spring (small) 17. Select check spr ing (large) 18. Select check plug

19. Select check spring 20. Retaining pin 21. Guide plate bolt

22. Guide plate 23. Striking arm 24. O-ring

25. Reverse check sleeve 26. Reverse check sleeve bolt 27. OD rod bracket

28. OD shift fork 29. OD fork rod 30. 1st and 2nd shift fork

31. Striking interlock 32. Striking lever 33. 3rd and 4th shift fork

34. Stopper ring 35. Interlock stopper bolt 36. Clip

37. Interlock stopper 38. Striking rod 39. OD and reverse fork rod

40. Rever se shift fork

[FS5R30A]

Revision: November 2005 2005 Frontier

MT-24

CASE COMPONENTS

[FS5R30A]

CASE COMPONENTS PFP:32100

Disassembly UCS003ZN

1. Remove interlock stopper bolt, washer and clip and then remove interlock stopper using suitable tool.

PCIB1337E

2. Remove control housing, return spring and check ball.

CAUTION:

Be careful not to lose check ball.

3. Drive out retaining pin from striking arm using Tool.

4. Remove rear extension together with striking arm by tapping lightly.

SMT367A

SMT368A

SMT135C

Revision: November 2005 2005 Frontier

MT-25

CASE COMPONENTS

5. Re move front cover and gasket using suitable tool.

6. Remove stopper ring and main drive bearing snap ring using suitable tool.

[FS5R30A]

SMT370A

7. Re move transmission case by tapping li ghtly using suitable tool.

8. Re move counte r gear fron t b ear ing shi m an d cou nter g ear fr ont bearing.

9. Re move front cover oil seal using suitable tool.

CAUTION:

Be careful not to damage front cover.

SMT371A

SMT372A

SMT392A

Revision: November 2005 2005 Frontier

MT-26

CASE COMPONENTS

[FS5R30A]

Assembly UCS003ZO

1. Install front cover oil seal using Tool.

CAUTION:

● Apply multi-pu rpose grea se to seal lip.

● Do not reuse front cover oil seal.

2. Install select ed counter gear front bear ing shim onto transmission case.

CAUTION:

● Apply multi-purpose grease to coun ter gear front bearing

shim and counter gear front bearing.

● Do not reuse counter gear front bearing and counter gear

front bearing shim.

3. Apply sealant to mating surface of transmission case.

● Use Genuine Silicone RTV or the equivalent. Refer to GI-47, "Recommended Chemical Products

and Sealants" .

SMT393A

4. Install gear assembly onto transmission case.

5. Install interlock stopper to transmission case.

6. Install clip and washer to interlock stopper bolt, and then it to transmission case. Tighten to the specified torque.

Interlock stopper bolt : 30 - 39 N·m (3.1 - 3.9 kg-m,

23 - 28 lb-ft)

7. Install stopper ring, snap ring and m ain drive bearing snap ring using suitable tool.

CAUTION:

Do not reuse snap ring and main drive bearing snap ring.

SMT588A

PCIB1285E

SMT371A

Revision: November 2005 2005 Frontier

MT-27

CASE COMPONENTS

8. Install front cover and gasket.

CAUTION:

Do not reuse bolts indicated as A in the figure.

[FS5R30A]

Bolt symbo l

A 35 (1.38)

C 50 (1.97)

Bolt length “ ”

mm (in)

Tightening torque

N·m (kg-m, f t-lb)

16-20 (1.6- 2. 1, 12-1 5)B 30 (1.18)

9. Apply sealant to mating surface of adapter plate.

● Use Genu ine Silic one RT V or the equivalen t. Refer to GI-

47, "Recommended Chemical Prod ucts and Sealants" .

10. Install rear extension together with striking arm.

Rear extension bolts : 32 - 42 N·m (3.3 - 4.2 kg-m,

24 - 30 lb-ft)

11. Install retaining pin into striking arm using Tool.

CAUTION:

Do not reuse retaining pin.

PCIB1288E

SMT461A

SMT368A

12. Install check ball and return spring.

13. Apply sealant to mating surface of rear extension, and then install control housing.

● Use Genu ine Silic one RT V or the equivalen t. Refer to GI-

47, "Recommended Chemical Prod ucts and Sealants" .

SMT462A

Revision: November 2005 2005 Frontier

MT-28

CASE COMPONENTS

14. Tighten control housing bolts to the specified torque.

Bolt head size A bolts : 12 mm (0.47 in) B bolts : 13 mm (0.51 in)

[FS5R30A]

Control housing bolts

: 16 - 20 N·m (1. 7 - 2.0 kg- m, 12 - 14 lb-ft)

PCIB1289E

Revision: November 2005 2005 Frontier

MT-29

SHIFT CON TROL COMPONE NTS

[FS5R30A]

SHIFT CONTROL COMP ONENTS PFP:32982 Disassembly UCS003ZP

1. Mount adapter plate on vise using copper plates to protect adapter plate.

2. Re move OD and reverse fork rod.

SMT373A

3. Drive out retaining pin from striking lever using Tool.

4. Whil e pulling out str iking rod, remove s triking lever a nd striking interlock. Then r emove 1st and 2nd, 3rd and 4th, and reverse shift forks.

SMT374A

5. Drive out retaining pin from OD shift fork using Tool.

6. Pull out OD fork rod and then remove OD shift fork.

SMT375A

Inspection UCS003ZQ

● Check con tact surface and sliding surface for wear, scratches,

projections or other damage.

SMT398A

Revision: November 2005 2005 Frontier

MT-30

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