MANUAL TRANSAXLE

C TRANSMISSION/TRANSAXLE

B
SECTION
MANUAL TRANSAXLE MT

E
CONTENTS
PRECAUTIONS .......................................................... 3 Gearing ................................................................... 19 F
Cautions ................................................................... 3 Synchronizer Ring .................................................. 19
PREPARATION ........................................................... 4 Sliding Gear Hub .................................................... 19
Special Service Tools ............................................... 4 SEPARATING THE HOUSINGS ............................... 20 G
Removal ................................................................. 20
JH3 REPAIRING THE GEARBOX ................................... 22
Removal ................................................................. 22
H
DESCRIPTION ............................................................ 6 MAINSHAFT ............................................................. 24
Cross-sectional View ................................................ 6 Removal ................................................................. 24
REMOVAL AND INSTALLATION ............................... 7 Refitting .................................................................. 25
Removal ................................................................... 7 TRANSAXLE CASE BEARING ................................ 26 I
Installation ................................................................ 7 Removal ................................................................. 26
TIGHTENING TORQUES ........................................... 8 Refitting .................................................................. 26
Description ............................................................... 8 CLUTCH HOUSING BEARING ................................ 27 J
COMPONENTS .......................................................... 9 Removal ................................................................. 27
Gear Components .................................................... 9 Refitting .................................................................. 27
Differential Gear ..................................................... 10 SELECTOR SHAFT RINGS ...................................... 28
K
Shift Control Components ...................................... 10 Removal ................................................................. 28
Case Components ..................................................11 Refitting .................................................................. 28
Clutch Housing ........................................................11 DIFFERENTIAL BEARINGS ..................................... 29
CONTROL LINKAGE ............................................... 12 Removal and Installation ........................................ 29 L
Removal and Installation of Control Device and SELECTOR SHAFT .................................................. 30
Cable ...................................................................... 12 Removal ................................................................. 30
REMOVAL ........................................................... 12 Refitting .................................................................. 30 M
INSTALLATION ................................................... 12 ASSEMBLY ............................................................... 31
RATIOS ..................................................................... 13 Refitting .................................................................. 31
NISSAN Gearbox ................................................... 13 HOUSING ASSEMBLY ............................................. 33
CONSUMABLES ...................................................... 14 Assembly ................................................................ 33
Description ............................................................. 14
CAPACITIES - LUBRICANTS .................................. 15 JR5
Description ............................................................. 15
TROUBLE DIAGNOSIS ............................................ 16 DESCRIPTION .......................................................... 36
Symptom Chart ...................................................... 16 Cross-sectional View .............................................. 36
Back-up Lamp Switch ............................................ 16 REMOVAL AND INSTALLATION ............................. 37
PRECAUTIONS ........................................................ 17 Removal ................................................................. 37
Precautions ............................................................ 17 Installation .............................................................. 37
PARTS TO BE REPLACED SYSTEMATICALLY ..... 18 TIGHTENING TORQUES .......................................... 38
Description ............................................................. 18 Description .............................................................. 38
CHECKING ............................................................... 19 COMPONENTS ......................................................... 39
Bearings ................................................................. 19 Gear Components .................................................. 39

MT-1
 Differential Gear ...................................................... 40 SEPARATING THE HOUSINGS ................................50
Shift Control Components ....................................... 40 Removal ..................................................................50
Case Components .................................................. 41 REPAIRING THE GEARBOX ....................................52
Clutch Housing ....................................................... 41 Removal ..................................................................52
CONTROL LINKAGE ................................................ 42 Removing the Gearing ............................................53
Removal and Installation of Control Device and Checking Parts ........................................................53
Cable ...................................................................... 42 Refitting the Gearing ...............................................54
REMOVAL ........................................................... 42 TRANSAXLE CASE BEARING ................................55
INSTALLATION .................................................... 42 Removing the Bearing, Input Shaft Side .................55
RATIOS ..................................................................... 43 Refitting ...................................................................55
NISSAN Gearbox ................................................... 43 CLUTCH HOUSING BEARING .................................56
CONSUMABLES ....................................................... 44 Removal and Installation .........................................56
Description .............................................................. 44 SELECTOR SHAFT RINGS ......................................57
CAPACITIES - LUBRICANTS ................................... 45 Removal ..................................................................57
Description .............................................................. 45 Refitting ...................................................................57
TROUBLE DIAGNOSIS ............................................ 46 DIFFERENTIAL BEARINGS .....................................58
Symptom Chart ....................................................... 46 Removal and Installation .........................................58
Back-up Lamp Switch ............................................. 46 SELECTOR SHAFT ...................................................59
PRECAUTIONS ......................................................... 47 Removal ..................................................................59
Precautions ............................................................. 47 Refitting ...................................................................59
PARTS TO BE REPLACED SYSTEMATICALLY ..... 48 REPAIRING THE GEARBOX ....................................60
Description .............................................................. 48 Setting the Pre-tensioning of the Output Shaft Bear-
CHECKING ................................................................ 49 ings .........................................................................60
Bearings ................................................................. 49 ASSEMBLY ...............................................................61
Gearing ................................................................... 49 Refitting ...................................................................61
Synchronizer Ring .................................................. 49 HOUSING ASSEMBLY ..............................................63
Sliding Gear Hub .................................................... 49 Assembly ................................................................63

MT-2
 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Cautions ECS00FE3

● Do not reuse transaxle oil, once it has been drained.

● Check oil level or replace oil with vehicle on level ground. B
● During removal or installation, keep inside of transaxle clear of dust or dirt.
● Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to. MT
● In principle, tighten nuts and bolts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
● Be careful not to damage sliding surfaces and mating surfaces. D

MT-3
 PREPARATION

PREPARATION PFP:00002

Special Service Tools ECS00FD1

Tool number
Description
Tool name
B. Vi. 1581 Disassembly and assembly for transmission or
Transmission stand transaxle

YMT029

B. Vi. 31-01 Removing and installing retaining pin

Pin punch

YMT030

B. Vi. 1170 Removing 5th synchronizer

Puller

YMT031

B. Vi. 22-01 Removing 5th gear

Puller
B. Vi. 1000-01 Removing 5th gear
Puller

MCIB0026E

B. Vi. 1576 Removing input shaft bearing

Mandrel

YMT032

B. Vi. 1601 Installing bearing guide of mainshaft

Mandrel

YMT033

MT-4
 PREPARATION

Tool number
Description
Tool name A
B. Vi. 1554 Installing bearing race
Drift kit
B

MT
MCIA0151E

B. Vi. 1175 Installing 5th gear

Installer D

E
YMT035

B. Vi. 1666 Installing differential oil seal

Drift
F

YMT036

B. Vi. 1165 Removing mainshaft bearing H

Extractor

MCIA0152E
J

MT-5
 DESCRIPTION
[JH3]
DESCRIPTION
[JH3] PFP:zzzzz

Cross-sectional View ECS00FF3

MCIA0153E

MT-6
 REMOVAL AND INSTALLATION
[JH3]
REMOVAL AND INSTALLATION PFP:00000
A
Removal ECS00FE4

CAUTION:
Remove the crankshaft position sensor (POS) from transaxle assembly before separating transaxle B
from engine. Be careful not to damage sensor edge.
1. Remove battery.
2. Remove the air cleaner. Refer to EM-16, "AIR CLEANER AND AIR DUCT" (CR engine) or EM-123, "AIR MT
CLEANER AND AIR DUCT" (K9K engine).
3. Disconnect the cable end ball of the select cable, and the cable end of the shift cable. Refer to MT-12,
"CONTROL LINKAGE" . D
4. Disconnect the clutch tube.
5. Remove the engine harness clamp.
6. Remove the starter. Refer to SC-45, "Removal and Installation (CR Engine Models)" , “STARTING SYS- E
TEM”.
7. Remove the engine mounting LH side installation bolt. Refer to EM-69, "ENGINE ASSEMBLY" (CR
engine) or EM-147, "ENGINE ASSEMBLY" (K9K engine). F
8. Set the engine hanger.

I
MBIB0585E

9. Lift up the vehicle and remove the front fender protectors (RH & LH). J
10. Remove the undercover.
11. Remove the front exhaust pipe. Refer to EX-3, "Removal and Installation" , “EXHAUST SYSTEM”.
12. Remove the turbocharger outlet tube bracket from the transaxle. K
13. Remove the RH and LH drive shafts. Refer to FAX-13, "Removal and Installation" , “FRONT DRIVE
SHAFT”.
L
14. Disconnect the ground cable from the transaxle.
15. Set the transmission jack.
16. Remove the rear engine mounting bracket. Then, remove the rear torque link from the transaxle. Refer to M
EM-69, "ENGINE ASSEMBLY" (CR engine) or EM-147, "ENGINE ASSEMBLY" (K9K engine).
CAUTION:
Do not remove the rear torque link from the suspension member.
17. Remove the engine mounting bracket LH.
18. Disconnect the position switch connector.
19. Remove the transaxle mounting nuts and bolts, and remove the transaxle.
Installation ECS00FE5

Install in the reverse order of removal.

MT-7
 TIGHTENING TORQUES
[JH3]
TIGHTENING TORQUES PFP:32010

Description ECS00FE6

Tightening portion N·m (kg-m, ft-lb)

Gearbox casing bolt 25 (2.6, 18)
Mainshaft bolt 70 (7.1, 52)
Input shaft nut 190 (19, 140)
Rear cover bolt 25 (2.6, 18)
Back-up lamp switch 25 (2.6, 18)
Concentric slave cylinder 21 (2.1, 15)
Selector shaft bolt 20 (2.0, 15)
Gear shift catch bolt 10 (1.0, 7)
Reverse gear fork support bolt 25 (2.6, 18)
Drain bolt 25 (2.6, 18)
Selector shaft balls 23 (2.3, 17)

MT-8
 COMPONENTS
[JH3]
COMPONENTS PFP:32010
A
Gear Components ECS00FE7

MT

MCIB0130E

1. Oil channel 2. Mainshaft front bearing 3. Mainshaft J

4. 1st main gear 5. Baulk ring 6. 1st & 2nd synchronizer hub
7. Spring 8. Roller 9. Stop ring
10. Adapter plate 11. 2nd main gear 12. 3rd main gear K
13. 3rd & 4th synchronizer hub 14. 4th main gear 15. Support washer
16. Retaining clip 17. Mainshaft rear bearing 18. 5th main gear
19. Bolt 20. Bearing guide 21. Input shaft L
22. Retaining clip 23. Input shaft rear bearing 24. Support washer
25. 2nd & 3rd gear bushing 26. 5th main gear 27. Baulk ring
28. Spread spring 29. 5th synchronizer hub 30. Spread spring M
31. Friction cone 32. Baulk ring 33. Washer
34. Nut

MT-9
 COMPONENTS
[JH3]
Differential Gear ECS00FE8

1 Oil seal
2 Differential side bearing
3 Differential case
4 Pinion mate gear
5 Bevel side gear
6 Pinion mate shaft
7 Shaft retaining spring
8 Side gear thrust washer

MCIA0170E

Shift Control Components ECS00FE9

1 Control assembly
2 Gear shift catch
3 Reverse gear brake fork and shaft
4 Fork rod (For 5th)
5 Lock pin
6 Reverse idler gear assembly
7 Fork rod (For 3rd and 4th)
8 Ring
9 Lock pin
10 Fork rod (For 1st and 2nd)
11 Check ball cartridge
12 Selector shaft bolt [20 N·m (2.0 kg-m, 15 ft-lb)]
13 Reverse gear fork shaft bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

MCIA0155E

MT-10
 COMPONENTS
[JH3]
Case Components ECS00FEA

A
1 Transaxle case
2 Filler plug
3 Dowel pin B
4 Oil gutter
5 Breather pipe
MT
6 Back-up lamp switch
7 O-ring
8 Transaxle case cover D
9 Gearbox edge bolt [25 N·m (2.6 kg-m, 18 ft-lb)]
10 Fifth gear housing bolt [25 N·m (2.6 kg-m, 18 ft-lb)]
E

MCIB0013E

Clutch Housing ECS00FEB

H

1 Clutch housing
2 Drain bolt [25 N·m (2.6 kg-m, 18 ft-lb)] I
3 Magnet
4 Concentric slave cylinder
J
5 Concentric slave cylinder bolt [21 N·m (2.1 kg-m, 15 ft-lb)]

MCIB0014E

MT-11
 CONTROL LINKAGE
[JH3]
CONTROL LINKAGE PFP:34103

Removal and Installation of Control Device and Cable ECS00FEC

MCIA0156E

REMOVAL
1. Remove center console and shift boot. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" .
2. Remove control device mounting bolts.
3. Pressing release bottom of cable end, remove cable from either manual transmission shift lever.
4. Lift up cable and remove it from cable bracket 1.
5. Remove center muffler and heat plate. Refer to EX-3, "Removal and Installation" , “EXHAUST SYSTEM”.
6. Separate cable bracket 2 from the vehicle.
7. Remove front and rear claws of control device. Remove control device and cable from the vehicle.
NOTE:
If shift knob needs to be removed, pull it up to remove.
INSTALLATION
Note the following, and install in the reverse order of removal.
● When installing, make sure to insert cable end into either manual transmission shift lever.
● After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or
Reverse.
● After installation, make sure that the shift to each position works well.
● When installing shift knob, press it onto selector lever.
CAUTION:
Do not reuse shift knob.

MT-12
 RATIOS
[JH3]
RATIOS PFP:32010
A
NISSAN Gearbox ECS00FED

Suffix First Second Third Fourth Fifth Reverse gear Final drive
JH3-102 11:41 21:43 28:39 34:35 39:32 11:39 15:61 B
JH3-103 11:41 21:43 28:39 34:35 39:32 11:39 15:61
JH3-110 11:41 21:43 28:39 34:35 39:32 11:39 15:61
MT
JH3-140 11:37 22:41 28:37 30:29 42:31 11:39 15:58
JH3-148 11:41 21:43 28:39 34:35 39:32 11:39 14:59
D

MT-13
 CONSUMABLES
[JH3]
CONSUMABLES PFP:32010

Description ECS00FEE

Types Packaging Parts Department No. Component

Gearbox oil Cover all parts
RHODORSEAL 100 g tubes 77 01 404 452 Housing assembly
LOCTITE 518 24 ml syringe 77 01 421 162 Back-up lamp switch threading

MT-14
 CAPACITIES - LUBRICANTS
[JH3]
CAPACITIES - LUBRICANTS PFP:32010
A
Description ECS00FEF

Capacity Grade
B
2.6 (4-5/8 Imp pt) SAE 75W-80, 75W-85

Fill to the level of the oil filler cap hole.

MT

MCIB0015E

MT-15
 TROUBLE DIAGNOSIS
[JH3]
TROUBLE DIAGNOSIS PFP:00004

Symptom Chart ECS00FEG

Symptoms (after checking

Possible causes
the clutch)

Engine
Oil level External Synchro- Sliding Fork and
Symptoms Gearing Bearings mounting
or grade control nizer gear hub balls
- housing
Gear grinding 1 2 3 4
One or more gears
1 2 3 4
cannot be selected
Gear disengagement 2 4 4 3 1
One or more gears
1 4 2 3
locked
Noisy 1 3 2

NOTE:
The numbers indicate the order of priority for diagnostics.
Back-up Lamp Switch ECS00FEH

Gear position Continuity

Reverse Yes
Except reverse No

MCIA0157E

MT-16
 PRECAUTIONS
[JH3]
PRECAUTIONS PFP:00001
A
Precautions ECS00FEI

Removing and handling the parts must be carried out on a workbench with a knockproof cover. (rubber or thick
plastic) B
Cover all turning and synchronizer points in oil.
Observe the tightening torques.
Carefully carry out the specific settings and adjustments.
Be sure to properly refit parts in the same order and position after removal. MT
Marking the position of the sliding rods in relation to the hubs before removal is recommended.
During refitting, make sure the inside of the box remains free of dust or impurities.
D

MT-17
 PARTS TO BE REPLACED SYSTEMATICALLY
[JH3]
PARTS TO BE REPLACED SYSTEMATICALLY PFP:32010

Description ECS00FEJ

If they have been removed:

● the lip seals,
● the O-rings,
● the gear supporting rings,
● the roll pins,
● the input shaft and mainshaft bearing circlips,
● the sliding gear hub springs.

MT-18
 CHECKING
[JH3]
CHECKING PFP:32010
A
Bearings ECS00FEK

Check that the bearings show no signs of damage and that they turn
evenly. Replace them if necessary. B

MT

MCIB0017E

E
Gearing ECS00FEL

NOTE:
The inspection focuses mainly on the appearance of the teeth, espe- F
cially in terms of claw chamfers.
1. Check that the teeth (A) are not broken or chipped.
2. Check that the claws (B) are not broken, chipped or worn. G
3. Check that the friction cone (C) shows no scratches or blueness.

MCIB0018E
I
Synchronizer Ring ECS00FEM

Check that the grooves and ridges on the ring are not worn or dam-
J
aged.
1. Check that put the ring onto the gear cone.
2. Check that rotate the ring while applying force in the direction of
K
the cone (D).
3. Check that the ring should lock against the cone.
Otherwise, replace the synchronizer ring. L

MCIB0019E
M
Sliding Gear Hub ECS00FEN

Make sure the sliding gear turns smoothly in the hub.

Check that the rollers or keys are in good condition.

MCIB0020E

MT-19
 SEPARATING THE HOUSINGS
[JH3]
SEPARATING THE HOUSINGS PFP:32010

Removal ECS00FEO

Fit the B. Vi. 1581 support plate on a Desvil stand.

Fit the gearbox on the B. Vi. 1581 support.

MCIB0021E

1. Remove the concentric slave cylinder.

2. Remove the bolts located inside the housing.

MCIB0022E

3. Remove the rear housing. This must be removed along the hori-
zontal axis of the gearbox because it has a lubrication spline
which is located in the input shaft bore.

MCIB0023E

Remove the two reverse gear fork support mounting bolts (A).
Drive in the 5th gear fork using B. Vi. 31-01.
Shift the 3rd gear on the gear selector lever and the 5th gear by slid-
ing the 5th gear fork on its shaft.
4. Remove the mainshaft bolt (B).
5. Remove the input shaft nut (C).
6. Remove the reverse gear synchronizer.
7. Remove the 5th gear fork and sliding gear.

MCIB0024E

MT-20
 SEPARATING THE HOUSINGS
[JH3]
Remove the 5th gear hub using B. Vi. 1170.
To do this, fit the sliding gear B. Vi. 1170 and rotate it so that the A
splines are opposite those of the input shaft hub.

MT

MCIB0025E

D
Remove the fixed 5th gear using B. Vi. 22-01 and B. Vi. 1000-01.
Remove the gearbox edge bolts.
E

G
MCIB0026E

Remove the back-up lamp switch (B). H

Engage 3rd gear.
Lift and remove the mechanism housing.
I

K
MCIB0027E

MT-21
 REPAIRING THE GEARBOX
[JH3]
REPAIRING THE GEARBOX PFP:32010

Removal ECS00FEP

1. Remove the 4th-gear pinion.

MCIB0028E

2. Remove the 3rd/4th gear shaft/fork and sliding gear assembly

while gently lifting the mainshaft assembly.

MCIB0029E

3. Remove input shaft assembly.

MCIB0030E

4. Remove mainshaft assembly.

MCIB0031E

MT-22
 REPAIRING THE GEARBOX
[JH3]
5. Remove the 1st/2nd shaft and fork and the 5th gear shaft.
A

MT

MCIB0032E

D
6. Remove the pin from the reverse gear and remove the reverse
gear.
E

G
MCIB0033E

MT-23
 MAINSHAFT
[JH3]
MAINSHAFT PFP:32241

Removal ECS00FEQ

1. Put the mainshaft in a vice with soft jaws.

2. Remove the 4th main gear and the 3rd/4th gear sliding gear
hub.

MCIA0158E

3. Remove the stop ring (systematically replace) and the grooved

washer.

MCIA0159E

4. Remove the 3rd main gear and the grooved washer.

MCIA0160E

5. Remove the stop ring (systematically replace) and the grooved

washer.

MCIA0161E

MT-24
 MAINSHAFT
[JH3]
6. Remove the 2nd main gear and the grooved washer.
A

MT

MCIA0162E

D
7. Remove the stop ring and the 1st/2nd gear sliding gear hub.

G
MCIA0163E

Refitting ECS00FER
H
Proceed in the reverse order of removal.
The retaining rings must be systematically replaced.
Oil the synchronizer rings. I
WARNING:
Make sure that the notches on the synchronizer double cones
are correctly positioned. J

K
MCIA0164E

MT-25
 TRANSAXLE CASE BEARING
[JH3]
TRANSAXLE CASE BEARING PFP:32010

Removal ECS00FES

Remove the circlips with circlip pliers and drive the bearing inside the
housing using tool B. Vi. 1576.

MCIA0165E

Refitting ECS00FET

Place the new circlips in their respective housings.

Fit the bearings using tool B. Vi. 1576.
Knock the tool with the bearing using a small hammer.

MT-26
 CLUTCH HOUSING BEARING
[JH3]
CLUTCH HOUSING BEARING PFP:32010
A
Removal ECS00FEU

Cut the base of the plastic hollow needle located at the centre of the
bearing. B
Fit tool B. Vi. 1165 and extract the bearing.

MT

MCIA0166E

E
Refitting ECS00FEV

1. Fit a new deflector, then the bearing on the press flush with the
inner surface of the housing.
F
2. Set the bearing with a mortise chisel.

MCIA0167E

I
3. Remove the input shaft bearing guide using the press and a 38
mm (1.50 in) diameter tube.
J

L
MCIB0044E

4. Refit the bearing guide using the press and tool B. Vi. 1601. M

MCIB0045E

MT-27
 SELECTOR SHAFT RINGS
[JH3]
SELECTOR SHAFT RINGS PFP:32010

Removal ECS00FEW

Remove the rings with an inertia puller.

MCIB0046E

Refitting ECS00FEX

Refit the rings using a 14.5 mm (0.57 in) tube down to the thrust
bearing.

MCIB0047E

MT-28
 DIFFERENTIAL BEARINGS
[JH3]
DIFFERENTIAL BEARINGS PFP:32010
A
Removal and Installation ECS00FEY

1. Remove the bearing using an antisticking pin.

B

MT

MCIB0048E

E
2. Refit the bearings using a 40 mm (1.57 in) tube.

H
MCIB0049E

3. Remove the bearing races using a roll pin punch. I

MCIB0050E
L

4. Refit the bearing races using tools C-F from the B. Vi. 1554 kit.
M

MCIB0051E

MT-29
 SELECTOR SHAFT
[JH3]
SELECTOR SHAFT PFP:32010

Removal ECS00FEZ

After removing the pin from the selector finger (B), remove the
mounting bolts (C) and remove the control shaft unit.

MCIB0052E

MCIB0053E

Refitting ECS00FF0

Proceed in the reverse order to removal.

NOTE:
Replace the O-ring (D).

MCIB0054E

MT-30
 ASSEMBLY
[JH3]
ASSEMBLY PFP:00000
A
Refitting ECS00FF1

1. Fit the mainshaft and 1st/2nd gear fork assembly.

B

MT

MCIB0055E

E
2. Fit the input shaft.

H
MCIB0056E

3. Fit the reverse gear assembly. I

MCIB0057E
L

4. Fit the two locking shafts.

M

MCIB0058E

MT-31
 ASSEMBLY
[JH3]
5. Fit the 5th gear shaft and the 3rd/4th gear shaft/fork and sliding
gear assembly while gently lifting the input shaft assembly.
Rotate the reverse gear assembly to position the 5th gear fork
(A).

MCIB0059E

6. Pin the reverse gear assembly.

MCIB0060E

7. Shift to 3rd gear and insert the rollers and clawing springs.

MCIB0061E

8. Refit the 4th main gear fitted with its synchronizer ring.

MCIB0028E

MT-32
 HOUSING ASSEMBLY
[JH3]
HOUSING ASSEMBLY PFP:32010
A
Assembly ECS00FF2

1. Fit the 1st/2nd, 3rd/4th, and 5th gear shaft ball cartridges into
the housing mechanism. B
2. Engage 3rd gear.

MT

MCIB0062E

E
3. Check the positioning of the centring dowels (A).
4. Check the positioning of magnet (B).
F

H
MCIB0063E

5. Apply a line of LOCTITE 518 to the gasket face. I

6. Offer up the housing while guiding the selector finger (C) into
fork (D) of the 3rd gear.
J

MCIB0064E
L

7. Pretighten the peripheral bolts and rotate the input shaft to

check that they make contact with the bearings. M
8. Tighten the bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
9. Put three drops of LOCTITE Frenbloc on the splines of the fixed
5th gear and fit it using tool B. Vi. 1175.

MCIB0065E

MT-33
 HOUSING ASSEMBLY
[JH3]
10. On the input shaft, fit the support washer (top side gear side).
11. On the input shaft, fit the sprocket bushing.
12. On the input shaft, fit the 5th main gear fitted with its synchro-
nizer ring.
13. On the input shaft, fit the 5th gear hub fitted with its spring.

MCIB0066E

14. Refit the 5th gear fork/sliding gear/reverse gear fork assembly.
15. Fit the reverse gear synchronizer.
16. Screw on the reverse gear fork support and tighten the bolts (A)
to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
17. Slide the 5th gear fork on its shaft to engage 5th gear.

MCIB0067E

18. Tighten the gear bolt and nut to torque of:

output shaft bolt (B) : [70 N·m (7.1 kg-m, 52 ft-lb)]
input shaft nut (C) : [190 N·m (19 kg-m, 140 ft-lb)]
19. Reset to neutral and pin the 5th gear fork.

MCIB0024E

20. Fit a new O-ring, position the 5th gear cover and tighten the
bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
21. Fit the back-up lamp switch (A) and tighten to a torque of [25
N·m (2.6 kg-m, 18 ft-lb)].

MCIB0068E

MT-34
 HOUSING ASSEMBLY
[JH3]
22. Refit the new differential output seals using B. Vi. 1666.
A

MT

MCIB0069E

D
23. Refit the concentric slave cylinder and tighten the bolts.
Tightening torque : 21 N·m (2.1 kg-m, 15 ft-lb) E

G
MCIB0022E

MT-35
 DESCRIPTION
[JR5]
DESCRIPTION
[JR5] PFP:00000

Cross-sectional View ECS00FD2

MCIA0168E

MT-36
 REMOVAL AND INSTALLATION
[JR5]
REMOVAL AND INSTALLATION PFP:00000
A
Removal ECS00FD3

CAUTION:
Remove the crankshaft position sensor (POS) from transaxle assembly before separating transaxle B
from engine. Be careful not to damage sensor edge.
1. Remove battery.
2. Remove the air cleaner. Refer to EM-123, "AIR CLEANER AND AIR DUCT" . MT
3. Disconnect the cable end ball of the select cable, and the cable end of the shift cable. Refer to MT-42,
"CONTROL LINKAGE" .
4. Disconnect the clutch tube. D
5. Remove the engine harness clamp.
6. Remove the starter. Refer to SC-45, "Removal and Installation (CR Engine Models)" , “STARTING SYS-
TEM”. E
7. Remove the engine mounting LH side installation bolt. Refer to .
8. Set the engine hanger.
F

MBIB0585E
I
9. Lift up the vehicle and remove the front fender protectors (RH & LH).
10. Remove the undercover.
J
11. Remove the front exhaust pipe. Refer to EX-3, "Removal and Installation" , “EXHAUST SYSTEM”.
12. Remove the turbocharger outlet tube bracket from the transaxle.
13. Remove the RH and LH drive shafts. Refer to FAX-13, "Removal and Installation" , “FRONT DRIVE K
SHAFT”.
14. Disconnect the ground cable from the transaxle.
15. Set the transmission jack. L
16. Remove the rear engine mounting bracket. Then, remove the rear torque link from the transaxle. Refer to
EM-147, "ENGINE ASSEMBLY" .
CAUTION: M
Do not remove the rear torque link from the suspension member.
17. Remove the engine mounting bracket LH.
18. Disconnect the position switch connector.
19. Remove the transaxle mounting nuts and bolts, and remove the transaxle.
Installation ECS00FD4

Install in the reverse order of removal.

MT-37
 TIGHTENING TORQUES
[JR5]
TIGHTENING TORQUES PFP:32010

Description ECS00FD5

Tightening portion N·m (kg-m, ft-lb)

Gearbox casing bolt 25 (2.6, 18)
Mainshaft bolt 70 (7.1, 52)
Input shaft nut 190 (19, 140)
Rear cover bolt 25 (2.6, 18)
Back-up lamp switch 25 (2.6, 18)
Concentric slave cylinder 21 (2.1, 15)
Selector shaft bolt 20 (2.0, 15)
Gear shift catch bolt 10 (1.0, 7)
Reverse gear fork support bolt 25 (2.6, 18)
Drain bolt 25 (2.6, 18)
Selector shaft balls 23 (2.3, 17)

MT-38
 COMPONENTS
[JR5]
COMPONENTS PFP:32010
A
Gear Components ECS00FD6

MT

MCIB0131E

1. Oil channel 2. Mainshaft front bearing 3. Mainshaft J

4. 1st main gear 5. Synchronizer ring 6. Spread spring
7. 1st & 2nd synchronizer hub 8. Synchronizer ring 9. Mainshaft bearing
10. 2nd main gear 11. Adapter plate 12. Mainshaft bearing K
13. 3rd main gear 14. Baulk ring 15. 3rd & 4th synchronizer hub and
reverse gear
16. Baulk ring 17. Mainshaft bearing 18. 4th main gear L
19. Adapter plate 20. Mainshaft rear bearing 21. 5th main gear
22. Bolt 23. Bearing guide 24. Input shaft
25. Retaining clip 26. Input shaft rear bearing 27. Adapter plate M
28. 2nd & 3rd gear bushing 29. 5th main gear 30. Baulk ring
31. Spread spring 32. 5th synchronizer hub 33. Spread spring
34. Friction cone 35. Baulk ring 36. Washer
37. Nut

MT-39
 COMPONENTS
[JR5]
Differential Gear ECS00FD7

1 Oil seal
2 Differential side bearing
3 Differential case
4 Pinion mate gear
5 Bevel side gear
6 Pinion mate shaft
7 Shaft retaining spring
8 Side gear thrust washer

MCIA0170E

Shift Control Components ECS00FD8

1 Control assembly
2 Gear shift catch
3 Reverse gear brake fork and shaft
4 Fork rod (For 5th)
5 Lock pin
6 Reverse idler gear assembly
7 Fork rod (For 3rd and 4th)
8 Ring
9 Lock pin
10 Fork rod (For 1st and 2nd)
11 Check ball cartridge
12 Selector shaft bolt [20 N·m (2.0 kg-m, 15 ft-lb)]
13 Reverse gear fork shaft bolt [25 N·m (2.6 kg-m, 18 ft-lb)]

MCIA0155E

MT-40
 COMPONENTS
[JR5]
Case Components ECS00FD9

A
1 Transaxle case
2 Filler plug
3 Dowel pin B
4 Oil gutter
5 Breather pipe
MT
6 Back-up lamp switch
7 O-ring
8 Transaxle case cover D
9 Gearbox edge bolt [25 N·m (2.6 kg-m, 18 ft-lb)]
10 Fifth gear housing bolt [25 N·m (2.6 kg-m, 18 ft-lb)]
E

MCIB0013E

Clutch Housing ECS00FDA

H

1 Clutch housing
2 Drain bolt [25 N·m (2.6 kg-m, 18 ft-lb)] I
3 Magnet
4 Concentric slave cylinder
J
5 Concentric slave cylinder bolt [21 N·m (2.1 kg-m, 15 ft-lb)]

MCIB0014E

MT-41
 CONTROL LINKAGE
[JR5]
CONTROL LINKAGE PFP:34103

Removal and Installation of Control Device and Cable ECS00FDB

MCIA0156E

REMOVAL
1. Remove center console and shift boot. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" .
2. Remove control device mounting bolts.
3. Pressing release bottom of cable end, remove cable from either manual transmission shift lever.
4. Lift up cable and remove it from cable bracket 1.
5. Remove center muffler and heat plate. Refer to EX-3, "Removal and Installation" , “EXHAUST SYSTEM”.
6. Separate cable bracket 2 from the vehicle.
7. Remove front and rear claws of control device. Remove control device and cable from the vehicle.
NOTE:
If shift knob needs to be removed, pull it up to remove.
INSTALLATION
Note the following, and install in the reverse order of removal.
● When installing, make sure to insert cable end into either manual transmission shift lever.
● After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or
Reverse.
● After installation, make sure that the shift to each position works well.
● When installing shift knob, press it onto selector lever.
CAUTION:
Do not reuse shift knob.

MT-42
 RATIOS
[JR5]
RATIOS PFP:32010
A
NISSAN Gearbox ECS00FDC

Suffix First Second Third Fourth Fifth Reverse gear Final drive
JR5-106 11:41 21:43 28:37 35:34 42:31 11:39 15:56 B
JR5-114 11:41 21:43 28:37 35:34 42:31 11:39 15:56

MT

MT-43
 CONSUMABLES
[JR5]
CONSUMABLES PFP:32010

Description ECS00FDD

Types Packaging Parts Department No. Component

Gearbox oil Cover all parts
RHODORSEAL 100 g tubes 77 01 404 452 Housing assembly
LOCTITE 518 24 ml syringe 77 01 421 162 Back-up lamp switch threading

MT-44
 CAPACITIES - LUBRICANTS
[JR5]
CAPACITIES - LUBRICANTS PFP:32010
A
Description ECS00FDE

Capacity Grade
B
2.5 (4-3/8 Imp pt) SAE 75W-80, 75W-85

Fill to the level of the oil filler cap hole.

MT

MCIB0015E

MT-45
 TROUBLE DIAGNOSIS
[JR5]
TROUBLE DIAGNOSIS PFP:00004

Symptom Chart ECS00FDF

Symptoms (after checking

Possible causes
the clutch)

Engine
Oil level External Synchro- Sliding Fork and
Symptoms Gearing Bearings mounting
or grade control nizer gear hub balls
- housing
Gear grinding 1 2 3 4
One or more gears
1 2 3 4
cannot be selected
Gear disengagement 2 4 4 3 1
One or more gears
1 4 2 3
locked
Noisy 1 3 2

NOTE:
The numbers indicate the order of priority for diagnostics.
Back-up Lamp Switch ECS00FDG

Gear position Continuity

Reverse Yes
Except reverse No

MCIA0157E

MT-46
 PRECAUTIONS
[JR5]
PRECAUTIONS PFP:00001
A
Precautions ECS00FDH

Removing and handling the parts must be carried out on a workbench with a knockproof cover. (rubber or thick
plastic) B
Cover all turning and synchronizer points in oil.
Observe the tightening torques.
Carefully carry out the specific settings and adjustments.
Be sure to properly refit parts in the same order and position after removal. MT
Marking the position of the sliding rods in relation to the hubs before removal is recommended.
During refitting, make sure the inside of the box remains free of dust or impurities.
D

MT-47
 PARTS TO BE REPLACED SYSTEMATICALLY
[JR5]
PARTS TO BE REPLACED SYSTEMATICALLY PFP:32010

Description ECS00FDI

If they have been removed:

● the lip seals,
● the O-rings,
● the gear supporting rings,
● the roll pins,
● the input shaft and mainshaft bearing circlips,
● the sliding gear hub springs.

MT-48
 CHECKING
[JR5]
CHECKING PFP:32010
A
Bearings ECS00FDJ

Check that the bearings show no signs of damage and that they turn
evenly. Replace them if necessary. B

MT

MCIB0017E

E
Gearing ECS00FDK

NOTE:
The inspection focuses mainly on the appearance of the teeth, espe- F
cially in terms of claw chamfers.
1. Check that the teeth (A) are not broken or chipped.
2. Check that the claws (B) are not broken, chipped or worn. G
3. Check that the friction cone (C) shows no scratches or blueness.

MCIB0018E
I
Synchronizer Ring ECS00FDL

Check that the grooves and ridges on the ring are not worn or dam-
J
aged.
1. Check that put the ring onto the gear cone.
2. Check that rotate the ring while applying force in the direction of
K
the cone (D).
3. Check that the ring should lock against the cone.
Otherwise, replace the synchronizer ring. L

MCIB0019E
M
Sliding Gear Hub ECS00FDM

Make sure the sliding gear turns smoothly in the hub.

Check that the rollers or keys are in good condition.

MCIB0020E

MT-49
 SEPARATING THE HOUSINGS
[JR5]
SEPARATING THE HOUSINGS PFP:32010

Removal ECS00FDN

Fit the B. Vi. 1581 support plate on a Desvil stand.

Fit the gearbox on the B. Vi. 1581 support.

MCIB0021E

1. Remove the concentric slave cylinder.

2. Remove the bolts located inside the housing.

MCIB0022E

3. Remove the rear housing. This must be removed along the hori-
zontal axis of the gearbox because it has a lubrication spline
which is located in the input shaft bore.

MCIB0023E

Remove the two reverse gear fork support mounting bolts (A).
Drive in the 5th gear fork using B. Vi. 31-01.
Shift the 3rd gear on the gear selector lever and the 5th gear by slid-
ing the 5th gear fork on its shaft.
4. Remove the mainshaft bolt (B).
5. Remove the input shaft nut (C).
6. Remove the reverse gear synchronizer.
7. Remove the 5th gear fork and sliding gear.

MCIB0024E

MT-50
 SEPARATING THE HOUSINGS
[JR5]
Remove the 5th gear hub using B. Vi. 1170.
To do this, fit the sliding gear B. Vi. 1170 and rotate it so that the A
splines are opposite those of the input shaft hub.

MT

MCIB0025E

D
Remove the fixed 5th gear using B. Vi. 22-01 and B. Vi. 1000-01.
Remove the gearbox edge bolts.
E

G
MCIB0026E

Remove the back-up lamp switch (B). H

Engage 3rd gear.
Lift and remove the mechanism housing.
I

K
MCIB0027E

MT-51
 REPAIRING THE GEARBOX
[JR5]
REPAIRING THE GEARBOX PFP:32010

Removal ECS00FDO

1. Remove the 4th-gear pinion.

MCIB0028E

2. Remove the 3rd/4th gear shaft/fork and sliding gear assembly

while gently lifting the mainshaft assembly.

MCIB0029E

3. Remove input shaft assembly.

MCIB0030E

4. Remove mainshaft assembly.

MCIB0031E

MT-52
 REPAIRING THE GEARBOX
[JR5]
5. Remove the 1st/2nd shaft and fork and the 5th gear shaft.
A

MT

MCIB0032E

D
6. Remove the pin from the reverse gear and remove the reverse
gear.
E

G
MCIB0033E

Removing the Gearing ECS00FDP

H
NOTE:
The rings underneath the 2nd, 3rd and 4th gears are fitted tightened.
They will be systematically replaced during refitting. I
1. Remove the ring/hub/3rd gear assembly with the press, resting
underneath the 3rd gear claw teeth.
J

MCIB0072E

L
2. Remove the rings/1st and 2nd gears/hub/sliding gear assembly
with the press, resting underneath the 1st gear.
M

MCIB0073E

Checking Parts ECS00FDQ

The sprocket teeth and the claws should not be chipped or excessively worn.
Also ensure that there are no signs of grating or abnormal wear on the surfaces of the shafts or the inner walls
of the sprockets.
It is advisable to mark the position of the sliding shafts in relation to the hub.

MT-53
 REPAIRING THE GEARBOX
[JR5]
Refitting the Gearing ECS00FDR

A hot plate with a setting of 150°C (302°F) should be used for refit-
ting.
Place the new rings on the cold hot plate. Heat them for 15 minutes
with a thermostat setting of 150°C (302°F).

MCIB0074E

Proceed in the reverse order to removal.

Refit the rings:
Remove a ring from the heating plate, using pliers, and use a tube
with an internal diameter of 33 mm (1.30 in) to fit it on the shaft until
it is resting on the hub.
NOTE:
The 1st/2nd gear has double-cone synchronizer, bring the notches
of the synchro rings together with those on the hubs and gears.

MCIB0075E

MT-54
 TRANSAXLE CASE BEARING
[JR5]
TRANSAXLE CASE BEARING PFP:32010
A
Removing the Bearing, Input Shaft Side ECS00FDS

Remove the circlips and drive the bearing inside the housing using
tool B. Vi. 1576. B

MT

MCIB0076E

E
Refitting ECS00FDT

1. Fit a new circlip.

2. Fit the bearing using tool B. Vi. 1576. F
3. Remove the bearing race, output shaft side using a tube with a
diameter of 55 mm (2.17 in).
G

MCIB0077E

I
4. Refit the race using a 60 mm (2.36 in) diameter tube.

L
MCIB0078E

MT-55
 CLUTCH HOUSING BEARING
[JR5]
CLUTCH HOUSING BEARING PFP:32010

Removal and Installation ECS00FDU

1. Cut the base of the deflector plastic hollow needle located at the
centre of the bearing.
Drive out the cup using a puller.

MCIB0079E

2. Fit a new deflector, then the bearing race using a 55 mm (2.17

in) diameter tube.

MCIB0080E

3. Remove the input shaft bearing guide using the press and a 38
mm (1.50 in) diameter tube.

MCIB0044E

4. Refit the bearing guide using the press and tool B. Vi. 1601.

MCIB0045E

MT-56
 SELECTOR SHAFT RINGS
[JR5]
SELECTOR SHAFT RINGS PFP:32010
A
Removal ECS00FDV

Remove the rings with an inertia puller.

B

MT

MCIB0046E

E
Refitting ECS00FDW

Refit the rings using a 14.5 mm (0.57 in) tube down to the thrust
bearing. F

MCIB0047E

MT-57
 DIFFERENTIAL BEARINGS
[JR5]
DIFFERENTIAL BEARINGS PFP:32010

Removal and Installation ECS00FDX

1. Remove the bearing using an antisticking pin.

MCIB0048E

2. Refit the bearings using a 40 mm (1.57 in) tube.

MCIB0049E

3. Remove the bearing races using a roll pin punch.

MCIB0050E

4. Refit the bearing races using tools C-F from the B. Vi. 1554 kit.

MCIB0051E

MT-58
 SELECTOR SHAFT
[JR5]
SELECTOR SHAFT PFP:32010
A
Removal ECS00FDY

After removing the pin from the selector finger (B), remove the
mounting bolts (C) and remove the control shaft unit. B

MT

MCIB0052E

MCIB0053E

Refitting ECS00FDZ I
Proceed in the reverse order to removal.
NOTE:
J
Replace the O-ring (D).

MCIB0054E

MT-59
 REPAIRING THE GEARBOX
[JR5]
REPAIRING THE GEARBOX PFP:32010

Setting the Pre-tensioning of the Output Shaft Bearings ECS00FE0

NOTE:
This operation is carried out in the event of replacing the bearings,
housings or mainshaft.
Clutch housing without differential and without input shaft.
Fit the mainshaft in the clutch housing with the bearings and the pre-
setting washer B. Vi. 1161, or equivalent, of 1.60 mm (0.06 in) (large
outer ý).
Fit the transaxle case assembly.
Fit and tighten to torque the box belt bolts.
Fit the dial gauge support plate B. Vi. 1161, or equivalent, on the tri-
pod basin mountings.
MCIB0081E

1. Fit the B. Vi. 1527 special spacer (A).

2. Fit the bolt (C).
3. Fit the dial gauge with its magnetic holder.
1 Rotate the mainshaft several times to fit the bearings.
2 Set the dial gauge to zero.
3 Pull the mainshaft upwards by making a lever out of two screwdrivers.
4 Take a reading from the dial gauge.
Repeat the operations several times (1 to 4).
Calculate the average of the readings. MCIB0082E

Calculation of the value of the pre-load washer.

Prescribed value + value of the pre-setting washer + average of the readings on the dial gauge = value of the
pre-tensioning dial gauge washer.
Example: [Value in mm (in)]
0.26 + 0.49 + 1.60 = 2.35
↓ ↓ ↓ ↓
Prescribed value Average reading Pre-setting washer value Pre-load washer value

NOTE:
A set of pre-load washers of 2.15 mm (0.08 in) to 2.43 mm (0.10 in) from 0.04 mm (0.002 in) to 0.04 mm
(0.002 in) thickness is supplied as replacement parts.

MT-60
 ASSEMBLY
[JR5]
ASSEMBLY PFP:00000
A
Refitting ECS00FE1

1. Fit the mainshaft and 1st/2nd gear fork assembly.

B

MT

MCIB0055E

E
2. Fit the input shaft.

H
MCIB0056E

3. Fit the reverse gear assembly. I

MCIB0057E
L

4. Fit the two locking shafts.

M

MCIB0058E

MT-61
 ASSEMBLY
[JR5]
5. Fit the 5th gear shaft and the 3rd/4th gear shaft/fork and sliding
gear assembly while gently lifting the input shaft assembly.
Rotate the reverse gear assembly to position the 5th gear fork
(A).

MCIB0059E

6. Pin the reverse gear assembly.

MCIB0060E

7. Shift to 3rd gear and insert the rollers and clawing springs.

MCIB0061E

8. Refit the 4th main gear fitted with its synchronizer ring.

MCIB0028E

MT-62
 HOUSING ASSEMBLY
[JR5]
HOUSING ASSEMBLY PFP:32010
A
Assembly ECS00FE2

1. Fit the 1st/2nd, 3rd/4th, and 5th gear locking balls into the
transaxle case. B
2. Engage 3rd gear.

MT

MCIB0062E

E
3. Check the positioning of the centring dowels (A).
4. Check the positioning of magnet (B).
F

H
MCIB0063E

5. Apply a line of LOCTITE 518 to the gasket face. I

6. Offer up the housing while guiding the selector finger (C) into
fork (D) of the 3rd gear.
J

MCIB0064E
L

7. Pretighten the peripheral bolts and rotate the input shaft to

check that they make contact with the bearings. M
8. Tighten the bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
9. Put three drops of LOCTITE Frenbloc on the splines of the fixed
5th gear and fit it using tool B. Vi. 1175.

MCIB0065E

MT-63
 HOUSING ASSEMBLY
[JR5]
10. On the input shaft, fit the support washer (top side gear side).
11. On the input shaft, fit the sprocket bushing.
12. On the input shaft, fit the 5th main gear fitted with its synchro-
nizer ring.
13. On the input shaft, fit the 5th gear hub fitted with its spring.

MCIB0066E

14. Refit the 5th gear fork/sliding gear/reverse gear fork assembly.
15. Fit the reverse gear synchronizer.
16. Screw on the reverse gear fork support and tighten the bolts (A)
to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
17. Slide the 5th gear fork on its shaft to engage 5th gear.

MCIB0067E

18. Tighten the gear bolt and nut to torque of:

output shaft bolt (B) : [70 N·m (7.1 kg-m, 52 ft-lb)]
input shaft nut (C) : [190 N·m (19 kg-m, 140 ft-lb)]
19. Reset to neutral and pin the 5th gear fork.

MCIB0024E

20. Fit a new O-ring, position the 5th gear cover and tighten the
bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)].
21. Fit the back-up lamp switch (A) and tighten to a torque of [25
N·m (2.6 kg-m, 18 ft-lb)].

MCIB0068E

MT-64
 HOUSING ASSEMBLY
[JR5]
22. Refit the new differential output seals using B. Vi. 1666.
A

MT

MCIB0069E

D
23. Refit the concentric slave cylinder and tighten the bolts.
Tightening torque : 21 N·m (2.1 kg-m, 15 ft-lb) E

G
MCIB0022E

MT-65
HOUSING ASSEMBLY
[JR5]

MT-66