Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 2003-2005 Approved Nissan Frontier 2005 MT
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C TRANSMISSION/TRANSAXLE
A
SECTION
MANUAL TRANSMISSION
MT B
MT
D
E
CONTENTS
FS5R30A INSTALLATION .................................................. 16 . F
Overhaul ................................................................ 17
.
PRECAUTIONS ......................................................... 3 . CASE COMPONENTS ....................................... 17 .
Service Notice or Precautions ................................. 3 . GEAR COMPONENTS ...................................... 19 . G
PREPARATION .......................................................... 4 . SHIFT CONTROL COMPONENTS .................... 23 .
Special Service Tools .............................................. 4 . CASE COMPONENTS ............................................. 25 .
Commercial Service Tool ........................................ 6 . Disassembly .......................................................... 25
.
NOISE, VIBRATION, AND HARSHNESS (NVH) H
Assembly ............................................................... 27
.
TROUBLESHOOTING ............................................... 7 . SHIFT CONTROL COMPONENTS .......................... 30 .
NVH Troubleshooting Chart .................................... 7 . Disassembly .......................................................... 30
.
DESCRIPTION ........................................................... 8. Inspection .............................................................. 30
. I
Description .............................................................. 8
. Assembly ............................................................... 31
.
CROSS-SECTIONAL VIEW ................................. 8 . GEAR COMPONENTS ............................................ 32 .
M/T OIL ...................................................................... 9
. Disassembly .......................................................... 32
. J
Changing ................................................................. 9
. Inspection .............................................................. 36
.
DRAINING ............................................................ 9
. GEARS AND SHAFTS ....................................... 36 .
FILLING ................................................................ 9
. SYNCHRONIZERS ............................................ 36 .
Checking ................................................................. 9
. K
BEARINGS ......................................................... 37
.
OIL LEAKAGE AND OIL LEVEL .......................... 9 . Assembly ............................................................... 37
.
REAR OIL SEAL ..................................................... 10 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 47 .
Removal and Installation ....................................... 10 . General Specifications ........................................... 47 . L
REMOVAL .......................................................... 10 . Gear End Play ....................................................... 47
.
INSTALLATION .................................................. 10 . Baulk Ring Clearance ............................................ 48 .
POSITION SWITCH ..................................................11 . Available Snap Rings ............................................ 48 . M
Checking ................................................................11
. MAIN DRIVE GEAR SNAP RING ...................... 48 .
BACK-UP LAMP SWITCH ..................................11 . MAINSHAFT FRONT SNAP RING ..................... 48 .
PARK/NEUTRAL POSITION SWITCH ...............11 . COUNTER GEAR REAR SNAP RING ............... 48 .
SHIFT CONTROL .................................................... 12 . Available C-Rings .................................................. 49
.
Removal and Installation ....................................... 12 . MAINSHAFT C-RING ......................................... 49 .
COMPONENTS ................................................. 12 . Available Thrust Washer ........................................ 49 .
REMOVAL .......................................................... 12 . REVERSE IDLER THRUST WASHER .............. 49 .
INSTALLATION .................................................. 12 . Available Shims ..................................................... 49
.
AIR BREATHER HOSE ........................................... 14 . TABLE FOR SELECTING PROPER COUNTER
Removal and Installation ....................................... 14 . GEAR FRONT BEARING SHIM ......................... 49 .
TRANSMISSION ASSEMBLY ................................. 15 .
Removal and Installation from Vehicle .................. 15 .
COMPONENTS ................................................. 15 .
FS6R31A
REMOVAL .......................................................... 16 . PRECAUTIONS ....................................................... 50
.
Service Notice or Precautions ............................... 50
.
Revision: November 2005 MT-1 2005 Frontier
PREPARATION ........................................................ 51 . SHIFT CONTROL .....................................................61 .
Special Service Tools ............................................ 51 . Removal and Installation ........................................61 .
Commercial Service Tools ..................................... 54 . COMPONENTS ..................................................61 .
NOISE, VIBRATION AND HARSHNESS (NVH) REMOVAL ...........................................................61.
TROUBLESHOOTING ............................................. 55 . INSTALLATION ...................................................61 .
NVH Troubleshooting Chart ................................... 55 . AIR BREATHER HOSE ............................................63 .
DESCRIPTION ......................................................... 56 . Removal and Installation ........................................63 .
Cross-Sectional View ............................................. 56 . TRANSMISSION ASSEMBLY ..................................64 .
DOUBLE-CONE SYNCHRONIZER ................... 57 . Removal and Installation from Vehicle (For 2WD
TRIPLE-CONE SYNCHRONIZER ...................... 57 . models) ..................................................................64
.
M/T OIL ..................................................................... 58
. COMPONENTS ..................................................64 .
Changing ............................................................... 58
. REMOVAL ...........................................................65.
DRAINING .......................................................... 58 . INSTALLATION ...................................................65 .
FILLING .............................................................. 58
. Removal and Installation from Vehicle (For 4WD
Checking ................................................................ 58
. models) ..................................................................66
.
OIL LEAKAGE AND OIL LEVEL ........................ 58 . COMPONENTS ..................................................66 .
REAR OIL SEAL ...................................................... 59 . REMOVAL ...........................................................67.
Removal and Installation (For 2WD models) ......... 59 . INSTALLATION ...................................................67 .
REMOVAL .......................................................... 59 . Disassembly and Assembly ...................................69 .
INSTALLATION ................................................... 59 . COMPONENTS ..................................................69 .
POSITION SWITCH ................................................. 60 . DISASSEMBLY ...................................................75 .
Checking ................................................................ 60
. INSPECTION AFTER DISASSEMBLY ...............89 .
BACK-UP LAMP SWITCH .................................. 60 . ASSEMBLY .........................................................93 .
PARK/NEUTRAL POSITION SWITCH ............... 60 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 116 .
General Specifications ......................................... 116 .
Gear End Play ...................................................... 117
.
Snap Rings .......................................................... 117
.
Baulk Ring Clearance .......................................... 118 .
Revision: November 2005 MT-2 2005 Frontier
PRECAUTIONS
[FS5R30A]
PRECAUTIONS PFP:00001
A
Service Notice or Precautions UCS0040T
G Do not reuse transmission oil once it has been drained.
G Check oil level or replace oil with vehicle on level surface. B
G During removal or installation, keep inside of transmission clear of dust or dirt.
G Check for the correct installation status prior to removal or disassembly. If matching marks are required,
be certain they do not interfere with the function of the parts they are applied to. MT
G In principle, tighten nuts and bolts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.
G Be careful not to damage sliding surfaces and mating surfaces. D
E
F
G
H
I
J
K
L
M
Revision: November 2005 MT-3 2005 Frontier
PREPARATION
[FS5R30A]
PREPARATION PFP:00002
Special Service Tools UCS003ZF
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name
ST23540000 Removing and installing retaining pin
(J-25689-A) a: 2.3 mm (0.091 in) dia.
Pin punch b: 4 mm (0.16 in) dia.
NT442
ST30031000 G Removing 1st and 2nd synchronizer as-
(J-22912-01) sembly
Puller G Removing counter gear rear thrust bearing
G Removing main drive bearing
G Inspecting baulk ring wear
a: 90 mm (3.54 in) dia.
NT411 b: 50 mm (1.97 in) dia.
ST33290001 Removing rear oil seal
(J-34286)
Puller
WMT066
ST33230000 Removing counter gear
( -- ) a: 51 mm (2.01 in) dia.
Drift b: 28.5 mm (1.122 in) dia.
NT084
ST22350000 Removing counter gear front bearing (Use
(J-25678-01) with KV38100300)
Drift a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
NT065
KV38100300 G Removing counter gear front bearing (Use
(J-25523) with ST22350000)
Drift G Installing counter gear rear bearing
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.
NT084
ST30720000 1. Removing and installing mainshaft front
1. ( -- ) bearing
2. (J-25405) 2. Installing rear oil seal
Drift a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
NT115
Revision: November 2005 MT-4 2005 Frontier
PREPARATION
[FS5R30A]
Tool number
(Kent-Moore No.) Description A
Tool name
ST33210000 1. Installing counter gear front bearing
1. (J-25523) 2. Installing front cover oil seal B
2. (J-25803-01) a: 44 mm (1.73 in) dia.
Drift b: 24.5 mm (0.965 in) dia.
MT
NT084
ST30613000 Installing main drive gear bearing
D
(J-25742-3) a: 72 mm (2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.
E
NT073
ST37750000 1. Removing counter gear rear bearing F
1. (J-25863-01) 2. Installing OD gear bushing
2. (J-34332) 2. Installing reverse cone
3. (J-34334) 3. Installing reverse counter gear G
4. (J-25679-01) 4. Installing counter gear rear end bearing
Drift a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
NT065 H
ST22452000 Installing reverse synchronizer hub
(J-34337) a: 45 mm (1.77 in) dia.
Drift b: 36 mm (1.42 in) dia.
I
J
NT065
-- Installing mainshaft and counter gear (Use
(J-26349-3) with J-34328)
Puller leg K
L
NT078
-- Installing mainshaft and counter gear (Use
(J-34328) with J-26349-3) M
Puller
NT079
-- G Installing OD main gear
(J-34342) G Installing reverse gear bushing
Drift
a: 44.5 mm (1.752 in) dia.
b: 40.5 mm (1.594 in) dia.
NT065
Revision: November 2005 MT-5 2005 Frontier
PREPARATION
[FS5R30A]
Tool number
(Kent-Moore No.) Description
Tool name
-- Removing and installing mainshaft rear bear-
(J-26349-A) ing (Use with J-25726-B)
Bearing Remover and Installer Set
WMT065
-- Removing and installing mainshaft rear bear-
(J-25726-B) ing (Use with J-26349-A)
Puller
ZZA0010D
Commercial Service Tool UCS003ZG
Tool name Description
Puller G Removing counter gear rear end bearing
G Removing reverse synchronizer hub
G Removing reverse cone
G Removing reverse gear bushing
G Removing reverse counter gear
NT077
Power tool Loosening bolts and nuts
PBIC0190E
Revision: November 2005 MT-6 2005 Frontier
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[FS5R30A]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
A
NVH Troubleshooting Chart UCS003ZH
Use the chart below to help you find the cause of the problem. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts. B
MT-17
MT-23
MT-19
MT-9
Reference page
MT
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
D
E
F
SUSPECTED PARTS
(Possible cause)
BAULK RING (Worn or damaged)
G
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
INSERT SPRING (Damaged)
O-RING (Worn or damaged)
GEAR (Worn or damaged)
GASKET (Damaged) H
SHIFT FORK (Worn)
OIL (Level too high)
OIL (Level low)
I
OIL (Wrong)
J
Noise 1 2 3 3
Oil leakage 3 1 2 2 2
Symptom K
Hard to shift or will not shift 1 1 2 2
Jumps out of gear 1 2 2
L
M
Revision: November 2005 MT-7 2005 Frontier
DESCRIPTION
[FS5R30A]
DESCRIPTION PFP:00000
Description UCS003ZI
CROSS-SECTIONAL VIEW
PCIB1296E
1. Release bearing sleeve 2. Front cover 3. Main drive gear
4. 3rd and 4th shift fork 5. Transmission case 6. 3rd and 4th coupling sleeve
7. Striking interlock 8. 3rd main gear 9. 2nd main gear
10. 1st main gear 11. OD main gear 12. Striking rod
13. Reverse shift fork 14. Shift lever 15. Mainshaft
16. Mainshaft rear bearing 17. Counter gear rear end bearing 18. Reverse main gear
19. Rear extension 20. OD counter gear 21. Adapter plate
22. Mainshaft front bearing 23. Drain plug 24. 1st and 2nd coupling sleeve
25. Counter gear 26. Sub-gear bracket 27. Counter gear front bearing
28. Main drive gear bearing 29. Main drive gear
Revision: November 2005 MT-8 2005 Frontier
M/T OIL
[FS5R30A]
M/T OIL PFP:KLD20
A
Changing UCS0040V
DRAINING
1. Start the engine and let it run to warm up the transmission.
B
2. Stop the engine. Remove the transmission drain plug and drain the oil.
3. Set a gasket on the drain plug and install it to the transmission. Tighten the drain plug to the specified
torque. Refer to MT-17, "CASE COMPONENTS" . MT
CAUTION:
Do no reuse gasket.
FILLING D
1. Remove the filler plug. Fill with new oil until oil level reaches the
specified limit near the filler plug hole.
Oil grade and Viscosity: E
Refer to MA-11, "Fluids and Lubricants" .
Oil capacity:
F
Refer to MA-11, "Fluids and Lubricants" .
2. After refilling the oil, check oil level. Set a gasket to the filler
plug, then install it to the transmission. Tighten the filler plug to G
the specified torque. Refer to MT-17, "CASE COMPONENTS" . PCIB0268E
CAUTION:
Do not reuse gasket. H
Checking UCS0040W
OIL LEAKAGE AND OIL LEVEL
G Make sure that oil is not leaking from the transmission or around it. I
G Check oil level from the filler plug hole as shown.
CAUTION:
J
Do not start engine while checking oil level.
G Set a gasket on the filler plug and install it to the transmission.
Tighten the filler plug to the specified torque. Refer to MT-17,
"CASE COMPONENTS" . K
CAUTION:
Do not reuse gasket.
L
PCIB0268E
M
Revision: November 2005 MT-9 2005 Frontier
REAR OIL SEAL
[FS5R30A]
REAR OIL SEAL PFP:33140
Removal and Installation UCS0040U
REMOVAL
1. Remove the rear propeller shaft. Refer to PR-10, "Removal and
Installation" .
2. Remove the rear oil seal using Tool.
Tool number : ST33290001 (J-34286)
CAUTION:
Do not reuse rear oil seal.
WCIA0176E
INSTALLATION
Installation is the reverse order of removal.
G Drive the new oil seal straight until it stops using Tool.
Tool number : ST30720000 (J-25405)
CAUTION:
G Do not reuse rear oil seal.
G Apply multi-purpose grease to oil seal lips before install-
ing.
G Do not incline rear oil seal during installation.
G Check the transmission oil level after installation. Refer to MT-9,
WCIA0493E
"Checking" .
Revision: November 2005 MT-10 2005 Frontier
POSITION SWITCH
[FS5R30A]
POSITION SWITCH PFP:32005
A
Checking UCS0040X
BACK-UP LAMP SWITCH
G Check continuity. B
Gear position Continuity
Reverse Yes
MT
Except reverse No
D
E
F
G
H
SMT981D
PARK/NEUTRAL POSITION SWITCH
I
G Check continuity.
Gear position Continuity
Neutral Yes
J
Except neutral No
K
L
M
Revision: November 2005 MT-11 2005 Frontier
SHIFT CONTROL
[FS5R30A]
SHIFT CONTROL PFP:32982
Removal and Installation UCS0040Z
COMPONENTS
LCIA0382E
1. Retaining plate 2. Dust boot cover (upper) 3. Dust boot cover (lower)
4. Shift knob 5. Shift lever assembly 6. Clip (A)
7. Boot 8. Clip (B) 9. Snap ring
REMOVAL
1. Remove the shift knob.
2. Remove the cup holder finisher and shift bezel. Refer to IP-10, "Removal and Installation" .
3. Remove the retaining plate and dust boot covers.
4. Remove the clip (B) and then separate the boot from the control housing.
5. Remove the snap ring.
6. Remove the shift lever assembly from the transmission.
INSTALLATION
Installation is the reverse order of removal.
Revision: November 2005 MT-12 2005 Frontier
SHIFT CONTROL
[FS5R30A]
CAUTION:
G Do not reuse the clip and snap ring. A
G Apply cement to threads of the shift lever assembly.
G When shift lever assembly is shifted to each position, make sure there is no binding or disconnection in
either boot. B
MT
D
E
F
G
H
I
J
K
L
M
Revision: November 2005 MT-13 2005 Frontier
AIR BREATHER HOSE
[FS5R30A]
AIR BREATHER HOSE PFP:31098
Removal and Installation UCS0040Y
Refer to the figure below for air breather hose removal and installation information.
LCIA0380E
1. Air breather hose 2. Harness 3. Breather tube
4. Clip
CAUTION:
G Make sure there are no pinched or blocked areas on the air breather hose after installation.
G When inserting the air breather hose, be sure to insert it fully until its end reaches the end of the
tube radius.
G Install the air breather hose with the paint mark side up.
G Install the air breather hose and harness to the clip to prevent separation.
G Push the harness so that it contacts with the interlocking bolt.
Revision: November 2005 MT-14 2005 Frontier
TRANSMISSION ASSEMBLY
[FS5R30A]
TRANSMISSION ASSEMBLY PFP:32010
A
Removal and Installation from Vehicle UCS00410
COMPONENTS
B
MT
D
E
F
G
H
I
J
K
L
M
LCIA0377E
1. Breather hose 2. Transmission assembly 3. Dust cover
4. Crossmember 5. Insulator
Revision: November 2005 MT-15 2005 Frontier
TRANSMISSION ASSEMBLY
[FS5R30A]
REMOVAL
1. Drain the transmission fluid. Refer to MT-9, "DRAINING" .
2. Disconnect the battery cable from the negative terminal.
3. Remove the shift lever assembly. Refer to MT-12, "Removal and Installation" .
4. Remove the rear propeller shaft. Refer to PR-10, "Removal and Installation" .
5. Remove the gusset.
6. Disconnect the heated oxygen sensor connector and remove wire harness from transmission.
7. Disconnect the back-up lamp switch and park/neutral position (PNP) switch connectors.
8. Remove the clutch operating cylinder from the transmission. Refer to CL-11, "Removal and Installation" .
9. Remove the starter motor. Refer to SC-23, "Removal and Installation" .
10. Support the transmission using a suitable jack.
11. Remove the transmission dust cover.
12. Remove the transmission to engine bolts.
13. Remove the nuts securing the insulator to the crossmember.
14. Remove the transmission crossmember using power tool.
WARNING:
Support the transmission using suitable jack.
15. Remove the air breather hose and breather tube. Refer to MT-14, "Removal and Installation" .
16. Separate the transmission from the engine and remove it from the vehicle.
WARNING:
Support manual transmission while removing it using suitable jack.
INSTALLATION
Installation is the reverse order of removal.
G When installing the transmission to the engine, install the bolts in
accordance with the standard below.
Bolt No. 1 2 3
Quantity 4 1 6
Bolt length " "
60 (2.36) 65 (2.56)
mm (in)
Tightening torque
34.3 (3.5, 25) 75 (7.7, 55)
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