Nissan Frontier D40. Manual - part 1035

TM-38

< DISASSEMBLY AND ASSEMBLY >

[FS5R30A]

GEAR COMPONENTS

5.

Remove front side components on counter gear.

a.

Remove counter gear rear thrust bearing using Tool.

b.

Remove sub-gear snap ring, sub-gear bracket and steel ball
using suitable tool.

6.

Remove main drive gear bearing.

a.

Remove spacer and pilot bearing.

b.

Remove main drive gear snap ring.

c.

Press out main drive gear bearing using Tool.

7.

Remove bearing retainer.

8.

Remove bearings from case components using Tools.

Tool number

: ST30031000 (J-22912-01)

SMT404A

SMT470A

Tool number

: ST30031000 (J-22912-01)

SMT420A

Tool number

: ST22350000 (J-25678-01)

: KV38100300 (J-25523)

: ST30720000 (

—

)

: ST37750000 (J-5863-01)

GEAR COMPONENTS

TM-39

< DISASSEMBLY AND ASSEMBLY >

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9.

Remove mainshaft front bearing snap ring from mainshaft front bearing.

Inspection

INFOID:0000000005273949

GEARS AND SHAFTS

• Check shafts for cracks, wear or bending.

• Check gears for excessive wear, chips or cracks.

SYNCHRONIZERS

• Check spline portion of coupling sleeves, hubs, and gears for wear

or cracks.

• Check baulk rings for cracks or deformation.
• Check shifting inserts for wear or deformation.
• Check insert springs for deformation.

PCIB1286E

SMT386A

SMT423A

SMT427C

TM-40

< DISASSEMBLY AND ASSEMBLY >

[FS5R30A]

GEAR COMPONENTS

• Measure wear of main drive, 1st and OD baulk rings. Refer to 

TM-

52, "Baulk Ring Clearance"

.

• If the clearance is smaller than the wear limit, replace baulk ring.

• Measure wear of 2nd and 3rd double baulk rings using Tool.

- Place baulk rings in position on synchronizer cone.
- While holding baulk rings against synchronizer cone as far as it will

go, measure the dimensions (A) and (B).

• If the dimension (A) or (B) is smaller than the wear limit, replace

outer baulk ring, inner baulk ring and synchronizer cone as a set.

• Measure wear of reverse baulk ring.
- Place baulk ring in position on reverse cone.
- While holding baulk ring against reverse cone as far as it will go,

measure the dimension (A) with dial indicator.

- If the dimension (A) is larger than the wear limit, replace baulk ring.

BEARINGS

SMT140

Tool number

: ST30031000 (J-22912-01)

Standard

Dimension (A)

: 0.7 - 0.9 mm (0.028 - 0.035 in)

Dimension (B)

: 0.6 - 1.1 mm (0.024 - 0.043 in)

Wear limit

: 0.2 mm (0.008 in)

SCIA1046E

SCIA1084E

Standard

Dimension (A)

: 0.35 - 0.95 mm (0.0138 -0.0374 in)

Wear limit

: 1.1 mm (0.043 in)

SMT424A

GEAR COMPONENTS

TM-41

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• Make sure bearings roll freely and are free from noise, crack, pit-

ting or wear.

Assembly

INFOID:0000000005273950

1.

Install mainshaft front bearing snap ring to mainshaft front bearing.

2.

Install bearings into case components using Tools.

3.

Install bearing retainer. Tighten bearing retainer bolts to the specified torque.

4.

Install main drive gear bearing.

a.

Press main drive gear bearing using Tool.

SMT418A

Tool number

: ST33210000 (J-25523)

: ST30720000 (

—

)

: KV38100300 (J-25523)

PCIB1287E

Bearing retainer bolts

Refer to 

TM-21, "Overhaul"

Tool number

: ST30613000 (J-25742-3)

SMT425A