Nissan Frontier D40. Manual - part 1051

TM-102

< DISASSEMBLY AND ASSEMBLY >

[6MT: FS6R31A]

GEAR COMPONENTS

a.

Remove snap ring from main drive gear using suitable tool.

b.

Press out main drive gear bearing using suitable tool.

16. Before disassembling, measure the end play for mainshaft

(Front side). If the end play is outside the standards, disassem-
ble and inspect.

17. Press out reverse main gear bushing, mainshaft bearing and 4th

main gear using suitable tool.

18. Remove 3rd-4th main spacer from mainshaft.

19. Remove 3rd main gear and 1st main gear according to the following.

SCIA1461E

SCIA1533E

End play

Refer to 

TM-122, "Gear 

End Play"

PCIB1243E

SCIA1386E

GEAR COMPONENTS

TM-103

< DISASSEMBLY AND ASSEMBLY >

[6MT: FS6R31A]

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a.

Press out 3rd main gear and 1st main gear using suitable tool.

CAUTION:

Be careful not to damage 1st outer baulk ring.

b.

Remove 1st needle bearing from mainshaft.

20. Remove 1st-2nd synchronizer hub assembly and 2nd main gear according to the following.
a.

Press out 1st gear bushing, 1st-2nd synchronizer hub assembly
and 2nd main gear using suitable tool.

CAUTION:

Be aware that when using the press, if mainshaft gear posi-
tioner catches on the V-block, etc., mainshaft could be dam-
aged.

b.

Remove 2nd needle bearing from mainshaft.

21. Remove 1st-2nd coupling sleeve according to the following.

a.

Remove spread springs and shifting inserts from 1st-2nd syn-
chronizer hub.

b.

Remove 1st-2nd coupling sleeve from 1st-2nd synchronizer
hub.

22. Remove 6th main gear and 5th-6th synchronizer hub assembly according to the following.

a.

Remove snap ring from mainshaft using suitable tool.

b.

Press out 6th main gear and 5th-6th synchronizer hub assembly
using suitable tool.

c.

Remove 6th needle bearing from mainshaft.

23. Remove 5th-6th coupling sleeve according to the following.

a.

Remove spread springs and shifting inserts from 5th-6th syn-
chronizer hub.

b.

Remove 5th-6th coupling sleeve from 5th-6th synchronizer hub.

24. Remove 3rd counter gear, 3rd-4th synchronizer hub assembly, 4th counter gear according to the follow-

ing.

SCIA1458E

SCIA1459E

PCIB1244E

SCIA1460E

TM-104

< DISASSEMBLY AND ASSEMBLY >

[6MT: FS6R31A]

GEAR COMPONENTS

a.

Press out 3rd counter gear, 3rd-4th synchronizer hub assembly,
4th counter gear, 4th needle bearing, 4th gear bushing, 4th
counter gear thrust washer, and counter rear bearing inner race
using suitable tool.

b.

Remove 3rd needle bearing from counter gear.

25. Remove 3rd-4th coupling sleeve according to the following.

a.

Remove spread springs and shifting inserts from 3rd-4th syn-
chronizer hub.

b.

Remove 3rd-4th coupling sleeve from 3rd-4th synchronizer hub.

26. Press out 3rd gear bushing using suitable tool.

CAUTION:

Do not use oil hole of 3rd gear bushing when press out.

Inspection

INFOID:0000000005589603

GEAR AND SHAFT

If the contact surface on each gear, mainshaft, main drive gear, and
counter gear, etc., has damage, peeling, abrasion, dent, bent, or any
other damage, replace the components.

SYNCHRONIZERS

SCIA1389E

PCIB1327E

SCIA1680E

PCIB1246E

GEAR COMPONENTS

TM-105

< DISASSEMBLY AND ASSEMBLY >

[6MT: FS6R31A]

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• If the contact surface on coupling sleeve, synchronizer hub, and

shifting insert has damage or abrasion, replace the components.

• Coupling sleeve and synchronizer hub shall move smoothly.

• If the cam surface on baulk ring or contact surface on insert has

damage or excessive wear, replace with a new one.

• If spread spring damaged, replace with a new one.

• Reverse Synchronizer 

Push baulk ring on the cone, and measure the clearance between
baulk ring and cone. If the measurement is below limit, replace it
with a new one.

BAULK RING CLEARENCE

• Single Cone Synchronizer (5th and 6th)

Push baulk ring on the cone, and measure the clearance between
baulk ring and cone. If the measurement is below limit, replace it
with a new one.

• Double Cone Synchronizer (1st, 3rd and 4th) 

SMT387A

SCIA0608J

Clearance

Standard 
value

Refer to 

TM-122, "Baulk Ring 

Clearance"

Limit value

Refer to 

TM-122, "Baulk Ring 

Clearance"

PCIB1328E

Clearance

Standard value

Refer to 

TM-122, "Baulk Ring 

Clearance"

Limit value

Refer to 

TM-122, "Baulk Ring 

Clearance"

PCIB1328E