Nissan Frontier 2006 Owner's Manual

C TRANSMISSION/TRANSAXLE

SECTION

CONTENTS

FS5R30A

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

Service Notice or Precautions .................................. 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/NEUTRA L PO SI TION 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 ............................................. 37

BEARINGS ..................... ..................................... 38

Assembly ..................... ...........................................38

SERVICE DATA AND SPECIFICATIONS (SDS) ......48

General Specifications . ...... ....... ...... ........................48

Gear End Play ........................................................ 48

Baulk Ring Clearance ..................... ....... ...... ....... .... 49

Available Snap Rings .............................................49

MAIN DRIVE GEAR SNAP RING ....................... 49

MAINSHAFT FRONT SNAP RING ......................49

COUNTER GEAR REAR SNAP RING ................49

Available C-Rings ...................................................50

MAINSHAFT C-RING ..........................................50

Available Thrust Washer .........................................50

REVERSE IDLER THRUST WASHER ............... 50

Available Shims ......................................................50

T ABLE FOR SELECTING PROPER COUNTER

GEAR FRONT BEARING SHIM ..........................50

FS6R31A

PRECAUTIONS ........................................................ 51

Service Notice or Precautions ................................ 51

Revision: September 2005 2006 Frontier

MT-1

PREPARATION .........................................................52

Special Service Tools .................. ....... ...... ..............52

Commercial Service Tools ......................................55

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING ..............................................56

NVH Troubleshooting Chart .................................... 56

DESCRIPTION .......................................................... 57

Cross-Sectional View ..............................................57

DOUBLE-CONE SYNCHRONIZER .................... 58

TRIPLE-CONE SYNCHRONIZER .......................58

M/T OIL ......................................................................59

Changing ................................................................59

DRAINING ........................................................... 59

FILLING ............................................................... 59

Checking ................... .......................... ....................59

OIL LEAKAGE AND OIL LEVEL .........................59

REAR OIL SEAL ......... ...... ....... ...... ....... ...... ....... ....... 60

Removal and Installation ........................................60

REMOVAL ...........................................................60

INSTALLATION ...................................... .............. 60

POSITION SWITCH ................. ...... ....... ...... ....... ....... 62

Checking ................... .......................... ....................62

BACK-UP LAMP SWITCH .. ...... ....... ...... ....... ....... 62

PA RK/NEUTRAL POSITION SWITCH ................62

SHIFT CONTROL ......................................................63

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

COMPONENTS ...................................................63

REMOVAL ........................................................ ....63

INSTALLATION ...................... ..............................64

REMOVAL ........................................................ ....63

AIR BREATHER HOSE .............................................65

Removal and Installation .........................................65

TRANSMISSION ASSEMBLY ...................................66

Removal and Installation from Vehicle (For 2WD

Models) ...................................................................66

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

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

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

Removal and Installation from Vehicle (For 4WD

Models) ...................................................................68

COMPONENTS ...................................................68

REMOVAL ........................................................ ....69

INSTALLATION ...................... ..............................69

Disassembly and Assembly ................... .................71

COMPONENTS ...................................................71

DISASSEMBLY ................................................ ....77

INSPECTION AFTER DISASSEMBLY ..... ....... ....91

ASSEMBLY ...................................................... ....95

SERVICE DATA AND SPECIFICATIONS (SDS) ....118

General Specifications ..........................................118

Gear End Play .......................................................119

Snap Rings ...........................................................119

Baulk Ring Clearance ...........................................120

Revision: September 2005 2006 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 remova l or installation, ke ep inside of transmission clear of dust or dirt.

● Check for the correc t installation status pri or to removal or dis assembly. If matching marks are require d,

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

● In principle, ti ghten nuts an d bolts grad ually in sev eral steps wo rking diag onally from inside to outside. If

tightening sequence is specified, use it.

● Be careful no t to damage sliding surfaces and mating surfaces.

Revision: September 2005 2006 Frontier

MT-3

PREPARATION

[FS5R30A]

PREPARATION PFP:00002 Special Service Tools UCS003ZF

The actual shapes of Kent-Moore tools may differ from those of spe ci al se rvice 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

● Removing and installing mainshaft front

bearing

● Installing rear oil seal

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

NT115

Revision: September 2005 2006 Frontier

MT-4

PREPARATION

[FS5R30A]

Tool number (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

● Installing counter gear front bearing

● 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.

● Removing counter gear rear bearing

● Installing OD gear bushing

● Installing reverse cone

● Installing reverse counter gear

● 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 bushing

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

Revision: September 2005 2006 Frontier

MT-5

PREPARATION

[FS5R30A]

Tool number

Description (Kent-Moore No.) Tool name

—

(J-26349-A)

Removing and installing mainsha ft rear bear -

ing (Use with J-25726-B) Bearing Remover and Installer Set

WMT065

—

(J-25726-B)

Removing and installing mainsha ft rear bear -

ing (Use with J-26349-A) Puller

ZZA0010D

Commercial Service Tool UCS003ZG

Tool name Description Puller

● Removing counter gear rear end bearing

● Removing reverse synchronizer hub

● Removing reverse c on e

● Removing reverse gear bushing

● Removing reverse counter gear

NT077

Power tool Loosening bolts and nuts

PBIC0190E

Revision: September 2005 2006 Frontier

MT-6

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

[FS5R30A]

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart UCS003ZH

Use the chart below to help you find the cause of the problem. The numbers indicate the order of the inspection. 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 PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

SHIFT FORK (Worn)

GEAR (Worn or damaged)

BEARING (Worn or damaged)

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

INSERT SPRING (Damaged)

Revision: September 2005 2006 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. Reverse shift fork 14. Shift lever 15. Mainshaft

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: September 2005 2006 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. Remove the transmission drain plug and drain the oil.

3. Set a ga sket on the drai n plug and install i t to the transmissi on. Tighten the drain pl ug to the specifie d torque. Refer to MT-17, "

CAUTION:

Do no reuse gasket.

CASE COMPONENTS" .

FILLING

1. Remove t he fi lle r p lug . F ill with new oil un til oil level reac he s the specified limit near the filler plug hole.

Oil grade and Viscosity:

Refer to MA-11, "

Oil capacity:

Refer to MA-11, "

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

CAUTION:

Do not reuse gasket.

Fluids and Lubricants" .

CASE COMPONENTS" .

PCIB0268E

Checking UCS0040W

OIL LEAKAGE AND OIL LEVEL

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

2. Check oil level from the filler plug hole as shown.

CAUTION:

Do not start engine while checking oil level.

3. Set a gasket on the filler plug and install it to the transmission. Tighten the filler plug to the specified torque. Refer to MT-17,

"CASE COMPONENTS" .

CAUTION:

Do not reuse gasket.

PCIB0268E

Revision: September 2005 2006 Frontier

MT-9

REAR OIL SEAL

[FS5R30A]

REAR OIL SEAL PFP:33140 Removal and Installation UCS0040U

REMOVAL

1. Remove the rear p rop eller sh aft. Re fer to PR-10, "Removal and

Installation" .

2. Remove the r ear oil seal using Tool.

Tool number : ST33290001 (J-34286)

CAUTION:

Do not reuse rear oil seal.

WCIA0176E

INSTALLATION

Installat ion 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 grease to oi l seal lips before install-

ing.

● Do not incline rear oil seal during installation.

● Check the transmis s io n o il lev el after installation . R ef er t o MT-9,

"Checking" .

WCIA0493E

Revision: September 2005 2006 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: September 2005 2006 Frontier

MT-11

SHIFT CONTROL

[FS5R30A]

SHIFT CONTROL PFP:32982 Removal and Installation UCS0040Z

COMPONENTS

LCIA0382E

1. Retaining plate 2. Dust bo ot co ver (uppe r) 3. Dust boot cove r (lower )

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

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

REMOVAL

1. Remove the shift knob.

2. Remove the cup holder finisher and shift bezel. Refer to IP-10, "

3. Remove the r etaining plate and dust boot covers.

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

5. Remove the snap ring.

6. Remove the shift lever assembly from the tr ansmission.

Removal and Installation" .

INSTALLATION

Installat ion is the reverse order of removal.

Revision: September 2005 2006 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 ea ch position, make su re there is no binding or dis connection in

either boot.

Revision: September 2005 2006 Frontier

MT-13

AIR BREATHER HOSE

[FS5R30A]

AIR BREATHER HOSE PFP:31098 Removal and Installation UCS0040Y

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

LCIA0380E

1. Air breather hose 2. H arness 3. Breather tube

4. Clip

CAUTION:

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

● When inserting the air brea ther hose, be sur e to insert it fully until its end reaches 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: September 2005 2006 Frontier

MT-14

TRANSMISSION ASSEMBLY

[FS5R30A]

TRANSMISSION ASSEMBLY PFP:32010

Removal and Installation from Vehicle UCS00410

COMPONENTS

LCIA0377E

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

4. Crossmember 5. Insulator

Revision: September 2005 2006 Frontier

MT-15

TRANSMISSION ASSEMBLY

REMOVAL

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

2. Disconnect the battery cable from the negative terminal.

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

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

5. Remove the gusset.

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

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

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

9. Remove 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 using suitable jack.

Removal and Installation" .

Removal and I nstallation" .

Removal and Installation" .

[FS5R30A]

INSTALLATION

Installat ion is the reverse order of removal.

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

accordance with the standard below.

Bolt No. 1 2 3 Quantity 4 1 6

Bolt length “ ” mm (in)

Tightening torque N·m (kg-m, ft-lb)

CAUTION:

● When installing be careful to avoid interference between

transmission main drive gear and clutch cover.

● When replacing an engine or transmission you must make sure the dowels are installed correctly

during re-assembly.

● Improper alignment caus ed by m issing dow els ma y cause v ibratio n oil lea ks or bre akage of driv-

etrain components.

● 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: September 2005 2006 Frontier

MT-16

TRANSMISSION ASSEMBLY

[FS5R30A]

Overhaul UCS00419

CASE COMPONENTS

PCIB1281E

Revision: September 2005 2006 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 plug 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. A i r breat her 23. Adapter plate 24. Bearing retainer

[FS5R30A]

Revision: September 2005 2006 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: September 2005 2006 Frontier

MT-19

TRANSMISSION ASSEMBLY

[FS5R30A]

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

10. Shifting insert 1 1. Spread spring 12. 3rd and 4th synchronizer hub

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

16. 3rd main gear 17. 3 rd gea r nee dle 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. 1 st mai n gear 36. 1st gear needle bearing

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

Revision: September 2005 2006 Frontier

MT-20

TRANSMISSION ASSEMBLY

[FS5R30A]

PCIB1283E

1. Mainshaft front bearing 2. Mainshaft front bearing snap ring 3. OD m ai n 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: September 2005 2006 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 gea r rear bea ring 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. Reverse counter gear 24. Counter gear rear end bearing

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

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

Revision: September 2005 2006 Frontier

MT-22

TRANSMISSION ASSEMBLY

SHIFT CONTROL COMPONENTS

[FS5R30A]

PCIB1284E

1. Snap ring 2. Socket 3. Spring

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

Revision: September 2005 2006 Frontier

MT-23

TRANSMISSION ASSEMBLY

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

10. Washer 11. Control housing 12. Bushing

13. Return spring 14. Check ball 15. Select check plunger

16. Select check spring (small) 17. Select check spring (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. Inter loc k st opper bolt 36. Clip

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

40. Reverse shift fork

[FS5R30A]

Revision: September 2005 2006 Frontier

MT-24

CASE COMPONENTS

[FS5R30A]

CASE COMPONENTS PFP:32100

Disassembly UCS003ZN

1. Remove interlo ck st oppe r bolt , wash er an d clip an d the n remov e interlock stopper using suitable tool.

PCIB1337E

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

CAUTION:

Do not lose check ball.

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

Tool number : ST23540000 (J-25689-A)

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

SMT367A

SMT368A

SMT135C

Revision: September 2005 2006 Frontier

MT-25

CASE COMPONENTS

5. Remove front cover and gasket using suitable tool.

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

[FS5R30A]

SMT370A

7. Remove transmission case by tapping lightly using suitable tool.

8. Remove counte r gear fron t bear ing shim a nd cou nter gear fron t bearing.

9. Remove front cover oil seal using suitable tool.

CAUTION:

Do not damage front cover.

SMT371A

SMT372A

SMT392A

Revision: September 2005 2006 Frontier

MT-26

CASE COMPONENTS

[FS5R30A]

Assembly UCS003ZO

1. Install new front cover oil seal using Tool.

Tool number : ST33210000 (J-25803-01)

CAUTION:

● Apply multi-purpose grease to seal lip.

● Do not reuse front cover oil seal.

2. Install select ed coun ter gear new fr ont bearing shim onto trans mission case.

CAUTION:

● Apply multi-purpose grease to counter 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 tran smission case.

● Use Genuine Silicone RTV or the equivalent. Refer to GI-48, "Recommended Chemic al Pr odu cts

and Sealants" .

4. Install ge ar assembly onto transmis sion case.

SMT393A

SMT588A

5. Install interlock stopper to trans mission case.

6. Install clip an d washer to interlock stop per bolt, and then ins tall 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, new snap ring and new main drive bearing snap ring using suitable tool.

CAUTION:

Do not reuse the snap rings.

PCIB1285E

SMT371A

Revision: September 2005 2006 Frontier

MT-27

CASE COMPONENTS

8. Install front cover and gasket.

CAUTION:

Do not reuse bolts indicated as A in the figure.

[FS5R30A]

Bolt symbol

A 35 (1.38)

C 50 (1.97)

Bolt len g th “ ”

mm (in)

Tightening torque

N·m (kg-m, ft-lb)

16-20 (1.6-2.1, 12-15)B 30 (1.18)

9. Apply sealant to mating surface of adapter plate.

● Use Genuine Silicone RTV or the e quivalent. Refe r to GI-

48, "Recommended Chemical Produ cts and Sealants" .

10. Install rear extension together with striking arm.

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

24 - 30 lb-ft)

11. Install new retaining pin into striking arm using Tool.

Tool number : ST23540000 (J-25689-A)

PCIB1288E

SMT461A

CAUTION:

Do not reuse retaining pin.

12. Install chec k ball an d retu rn sp ring.

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

● Use Genuine Silicone RTV or the e quivalent. Refe r to GI-

48, "Recommended Chemical Produ cts and Sealants" .

SMT368A

SMT462A

Revision: September 2005 2006 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: September 2005 2006 Frontier

MT-29

SHIFT CONTROL COMPONENTS

[FS5R30A]

SHIFT CONTROL COMPONENTS PFP:32982 Disassembly UCS003ZP

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

2. Remove OD and reverse fork rod.

SMT373A

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

Tool number : ST23540000 (J-25689-A)

4. While pulling out striking ro d, remove striking lever and strik ing interlock. Then remove 1st and 2nd, 3rd and 4th, and reverse shift forks.

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

Tool number : ST23540000 (J-25689-A)

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

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Inspection UCS003ZQ

● Check contact surfac e and sliding surfac e for wear, scratches,

projections or other dama ge .

SMT398A

Revision: September 2005 2006 Frontier

MT-30

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