Nissan Frontier D40. Manual - part 1036

 

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Nissan Frontier D40. Manual - part 1036

 

 

TM-42

< DISASSEMBLY AND ASSEMBLY >

[FS5R30A]

GEAR COMPONENTS

b.

Select proper main drive gear snap ring to minimize clearance of
groove. Refer to 

TM-52, "Available Snap Rings"

.

CAUTION:

Do not reuse main drive gear snap ring.

c.

Install selected new main drive gear snap ring on main drive
gear.

5.

Install front side components on mainshaft.

a.

Assemble 1st and 2nd synchronizer.

CAUTION:

Do not reuse 1st and 2nd synchronizer hub.

b.

Assemble 3rd and 4th synchronizer.

CAUTION:

Do not reuse 3rd and 4th synchronizer hub.

c.

Press on 3rd and 4th synchronizer assembly together with 3rd
main gear and 3rd gear needle bearing.

CAUTION:

Pay attention to direction of synchronizer assembly.

d.

Select proper mainshaft front snap ring to minimize clearance of
groove. Refer to 

TM-52, "Available Snap Rings"

.

CAUTION:

Do not reuse mainshaft front snap ring.

e.

Install selected new mainshaft front snap ring on mainshaft.

End play

Refer to 

TM-52, "Gear 

End Play"

SMT426A

SMT614B

SMT615B

SMT399A

End play 

: 0 - 0.1 mm (0 - 0.004 in)

SMT400A

GEAR COMPONENTS

TM-43

< DISASSEMBLY AND ASSEMBLY >

[FS5R30A]

C

E

F

G

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A

B

TM

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f.

Press on 1st and 2nd synchronizer assembly together with 2nd
main gear and 2nd gear needle bearing.

CAUTION:

Pay attention to direction of synchronizer assembly.

g.

Press on 1st gear bushing using 1st gear washer.

h.

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

i.

Install steel ball and 1st gear washer.

CAUTION:

Apply multi-purpose grease to steel ball and 1st gear
washer before installing.

6.

Install components on counter gear.

a.

Install steel ball, sub-gear bracket and new sub-gear snap ring.

CAUTION:

• Apply multi-purpose grease to steel ball.
• Do not reuse sub-gear snap ring.

b.

Install counter gear rear thrust bearing using a brass drift.

CAUTION:

Be careful not to damage counter gear rear thrust bearing.

SMT401A

SMT402A

SMT403A

SMT405A

TM-44

< DISASSEMBLY AND ASSEMBLY >

[FS5R30A]

GEAR COMPONENTS

7.

Select proper counter gear front bearing shim when replacing
transmission case, counter gear, counter gear rear thrust bear-
ing or sub-gear bracket.

a.

Install counter gear, counter gear front thrust bearing and
counter gear rear thrust bearing on adapter plate.

b.

Place adapter plate and counter gear assembly in transmission
case (case inverted).

c.

Tighten adapter plate to transmission case using 2 bolts.

d.

Place dial indicator on rear end of counter gear.

e.

Move counter gear up and down and measure dial indicator
deflection.

f.

Select proper counter gear front bearing shim using the table as
a guide. Refer to 

TM-53, "Available Shims"

.

g.

Separate adapter plate and transmission case.

h.

Remove counter gear assembly.

PCIB1290E

End play

: 0.10 - 0.26 mm (0.0039 - 0.0102 in)

SMT578A

GEAR COMPONENTS

TM-45

< DISASSEMBLY AND ASSEMBLY >

[FS5R30A]

C

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A

B

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8.

Select proper reverse idler thrust washer when replacing rear
extension, reverse idler gear or reverse idler shaft.

a.

Install reverse idler thrust washer, reverse idler gear, reverse
idler needle bearings and reverse idler shaft into rear extension.
• When replacing reverse idler thrust washer, install either

A or B. Refer to 

TM-53, "Available Thrust Washer"

.

b.

Place dial indicator on front end of reverse idler shaft.

c.

Put straightedge on front surface of rear extension as a stopper
of reverse idler shaft.

d.

Move reverse idler shaft up and down and measure end play.

e.

If not within specification, replace reverse idler thrust washer
with the other (A or B) and check again.

9.

Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.

a.

Mount adapter plate on vise and apply multi-purpose grease to
counter gear rear bearing.

PCIB1291E

End play

Refer to 

TM-53, "Available Thrust Washer"

SMT433A

SMT438A

 

 

 

 

 

 

 

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