Nissan Frontier D40. Manual - part 1034

TM-34

< DISASSEMBLY AND ASSEMBLY >

[FS5R30A]

SHIFT CONTROL COMPONENTS

Assembly

INFOID:0000000005273947

1.

Install OD fork rod and OD shift fork. Then install new retaining
pin into OD shift fork.

CAUTION:

Do not reuse retaining pin.

2.

Install 1st and 2nd, 3rd and 4th, and reverse shift forks onto coupling sleeve.

3.

Install striking rod into hole of shift forks, striking lever and inter-
lock and then install new retaining pin into striking lever using
Tool.

CAUTION:

• Make sure that striking rod moves smoothly.
• Do not reuse retaining pin.

4.

Apply sealant to thread of OD and reverse fork rod bolt, and
then install OD and reverse fork rod.

• Use Genuine Medium Strength Thread Locking Sealant or the equivalent. Refer to 

GI-22, "Rec-

ommended Chemical Products and Sealants"

.

SMT457A

Tool number

: ST23540000 (J-25689-A)

OD and reverse fork rod bolt

Refer to 

TM-21, "Overhaul"

SMT374A

GEAR COMPONENTS

TM-35

< DISASSEMBLY AND ASSEMBLY >

[FS5R30A]

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GEAR COMPONENTS

Disassembly

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1.

Before removing gears and shafts, measure each gear end play.
Refer to 

TM-52, "Gear End Play"

.

• If not within specification, disassemble and check contact sur-

face of gear to hub, washer, bushing, needle bearing and
shaft.

2.

Remove rear side components on mainshaft and counter gear.

a.

Remove reverse coupling sleeve.

b.

Remove mainshaft rear snap ring and counter gear rear snap
ring using suitable tool.

c.

Remove C-ring holder and mainshaft C-rings from mainshaft
using suitable tool. 

d.

Remove counter gear rear end bearing using suitable tool.

e.

Remove reverse idler thrust washer, reverse idler gear and
reverse idler needle bearings.

f.

Remove mainshaft rear bearing using Tools.

SMT376A

SMT463A

SMT377A

Tool number

: 

—

 (J-26349-A)

: —

 

(J-25726-B)

SMT378A

TM-36

< DISASSEMBLY AND ASSEMBLY >

[FS5R30A]

GEAR COMPONENTS

g.

Remove reverse main gear together with mainshaft spacer and
reverse synchronizer hub using suitable tool. Then remove
reverse gear needle bearings.

h.

Remove reverse counter gear using suitable tool.

i.

Remove OD coupling sleeve together with OD baulk ring,
reverse baulk ring and spring inserts.

j.

Remove reverse gear bushing using suitable tool.

k.

Remove OD counter gear and reverse cone using suitable tool.

l.

Remove OD gear needle bearing.

m. Remove reverse idler shaft.

3.

Press out mainshaft, OD main gear, OD gear bushing and counter gear alternately using Tool.

SMT380A

SMT773A

SMT770A

SMT771A

Tool number

: ST33230000 (

—

)

GEAR COMPONENTS

TM-37

< DISASSEMBLY AND ASSEMBLY >

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4.

Remove front side components on mainshaft.

a.

Remove 1st gear washer and steel ball using suitable tool.

CAUTION:

Be careful not to lose steel ball.

b.

Remove 1st main gear and 1st gear needle bearing.

c.

Press out 2nd main gear together with 1st gear bushing and 1st
and 2nd synchronizer assembly using Tool.

d.

Remove 2nd gear needle bearing.

e.

Remove mainshaft front snap ring.

f.

Press out 3rd main gear together with 3rd and 4th synchronizer
assembly.

g.

Remove 3rd gear needle bearing.

AMT174A

SMT383A

Tool number

: ST30031000 (J-22912-01)

SMT482C

SMT385A