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MANUAL TRANSMISSION

C TRANSMISSION/TRANSAXLE

SECTION
MANUAL TRANSMISSION
MT B

E
CONTENTS
PRECAUTIONS ......................................................... 2 . SHIFT CONTROL .................................................... 13 . F
Caution .................................................................... 2
. Removal and Installation ....................................... 13 .
PREPARATION .......................................................... 3 . REMOVAL .......................................................... 13
.
Special Service Tools .............................................. 3 . INSTALLATION .................................................. 15 . G
Commercial Service Tools ....................................... 6 . INSPECTION AFTER INSTALLATION ............... 17 .
NOISE, VIBRATION AND HARSHNESS (NVH) AIR BREATHER HOSE ........................................... 18 .
TROUBLESHOOTING ............................................... 7 . Removal and Installation ....................................... 18 .
H
NVH Troubleshooting Chart .................................... 7 . TRANSMISSION ASSEMBLY ................................. 19 .
MANUAL TRANSMISSION .................................. 7 . Removal and Installation from Vehicle .................. 19 .
DESCRIPTION ........................................................... 8. REMOVAL .......................................................... 19
.
Cross-Sectional View .............................................. 8 . INSTALLATION .................................................. 21 . I
DOUBLE-CONE SYNCHRONIZER ..................... 8 . Component Parts Drawing .................................... 22 .
TRIPLE-CONE SYNCHRONIZER ....................... 9 . CASE COMPONENTS ....................................... 22 .
M/T OIL .................................................................... 10
. GEAR COMPONENTS ...................................... 23 . J
Replacement ......................................................... 10. SHIFT CONTROL COMPONENTS .................... 25 .
DRAINING .......................................................... 10. Disassembly and Assembly ................................... 27 .
FILLING .............................................................. 10
. DISASSEMBLY .................................................. 27 .
K
Checking ............................................................... 10
. INSPECTION AFTER DISASSEMBLY ............... 38 .
OIL LEAKAGE AND OIL LEVEL ........................ 10 . ASSEMBLY ........................................................ 43.
REAR OIL SEAL ......................................................11 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 61 .
Removal and Installation ........................................11 . General Specifications ........................................... 61 . L
REMOVAL ...........................................................11 . End Play ................................................................ 61
.
INSTALLATION ...................................................11 . Snap Rings ............................................................ 62
.
POSITION SWITCH ................................................. 12 . Baulk Ring Clearance ............................................ 63 . M
Checking ............................................................... 12
.
COMPONENT LOCATION ................................. 12 .
BACK-UP LAMP SWITCH ................................. 12 .
NEUTRAL POSITION SWITCH ......................... 12 .

Edition; 2004 September MT-1 2005 G35 Sedan
PRECAUTIONS

PRECAUTIONS PFP:00001

Caution ACS003SV

q Do not reuse transmission oil, once it has been drained.
q Check oil level or replace oil with vehicle on level ground.
q During removal or installation, keep inside of transmission clear of dust or dirt.
q Check for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
q In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
q Be careful not to damage sliding surfaces and mating surfaces.

Edition; 2004 September MT-2 2005 G35 Sedan
PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ACS003L6

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name

ST30911000 q Main shaft bearing installation MT
( -- ) q 5th-6th synchronizer assembly installation
a: 98 mm (3.86 in) dia.
b: 40 mm (1.57 in) dia. q Reverse main gear bushing installation
D
Inserter q 3rd gear bushing installation
q 3rd-4th synchronizer assembly installation

ZZA0920D
E
ST30022000 q 3rd main gear installation
( -- ) q 4th main gear installation
a: 110 mm (4.33 in) dia.
b: 46 mm (1.81 in) dia. F
Inserter

G
ZZA0920D

ST27861000 q 1st-2nd synchronizer assembly installation
( -- ) q 1st gear bushing installation
a: 62 mm (2.44 in) dia. H
b: 52 mm (2.05 in) dia.
Support ring
I
ZZA0832D

ST33400001 Rear oil seal installation
(J-26082) J
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
Drift
K

ZZA0814D

KV381054S0 Remove rear oil seal L
( -- )
Oil seal puller

ZZA0601D

ST30032000 Counter rear bearing inner race installation
(J-26010-01)
a: 80 mm (3.15 in) dia.
b: 31 mm (1.22 in) dia.
Inserter

ZZA0920D

Edition; 2004 September MT-3 2005 G35 Sedan
PREPARATION

Tool number
(Kent-Moore No.) Description
Tool name

KV32102700 Main drive gear bearing installation
( -- )
a: 48 mm (1.89 in) dia.
b: 41 mm (1.61 in) dia.
Drift

ZZA0534D

ST23860000 Reverse counter gear installation
( -- )
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
Drift

ZZA0534D

ST01530000 Reverse synchronizer assembly installation
( -- )
a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
Drift

ZZA0534D

ST35291000 Striking rod oil seal installation
( -- )
a: 40 mm (1.57 in) dia.
b: 29.5 mm (1.161 in) dia.
c: 22.5 mm (0.886 in) dia.
Drift

SCIA1575E

KV40100630 4th counter gear thrust washer installation
(J-26092)
a: 67 mm (2.64 in) dia.
b: 38 mm (1.50 in) dia.
Inserter

ZZA0920D

KV38102100 Front cover oil seal installation
(J-25803-01)
a: 44 mm (2.36 in) dia.
b: 28 mm (1.10 in) dia.
Drift

NT084

KV32103300 Reverse synchronizer assembly installation
(J-46529)
Press plate

PCIB0165J

Edition; 2004 September MT-4 2005 G35 Sedan
PREPARATION

Tool number
(Kent-Moore No.) Description A
Tool name

ST30031000 Inner baulk ring support
(J-22912-01) B
Puller

ZZC0499D

ST224490000 Hold adapter plate D
( -- )
Adapter setting plate

ZZC0465D
F

Edition; 2004 September MT-5 2005 G35 Sedan
PREPARATION

Commercial Service Tools ACS003L7

Tool name Description

Puller Each bearing, gear and bushing removal

ZZB0823D

Pin punch Each retaining pin removal and installation
Tip diameter: 6.0 mm (0.24 in) dia.

ZZA0815D

Power tool Loosening bolts and nuts

PBIC0190E

Puller q Reverse synchronizer assembly removal
q Reverse counter gear removal
q Reverse main gear removal

NT077

Edition; 2004 September MT-6 2005 G35 Sedan
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
A
NVH Troubleshooting Chart ACS003L8

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts. B
MANUAL TRANSMISSION

MT-10

MT-22

MT-13

MT-25

MT-23

MT-23
Reference page MT

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
D

SUSPECTED PARTS G
(Possible cause)

SHIFT CONTROL LINKAGE (Worn)

BAULK RING (Worn or damaged)
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)

INSERT SPRING (Damaged)
H

GEAR (Worn or damaged)
OIL (Oil level is high.)

GASKET (Damaged)

SHIFT FORK (Worn)
OIL (Oil level is low.)

I
OIL (Wrong oil.)

Noise 1 2 3 3
K
Oil leakage 3 1 2 2
Symptoms
Hard to shift or will not shift 1 1 2 2 2
Jumps out of gear 1 1 2 2 L

Edition; 2004 September MT-7 2005 G35 Sedan
DESCRIPTION

DESCRIPTION PFP:00000

Cross-Sectional View ACS003L9

PCIB0672E

1. Front cover 2. Main drive gear 3. 5th-6th synchronizer hub
4. 5th-6th coupling sleeve 5. Transmission case 6. 6th main gear
7. 2nd main gear 8. 1st-2nd synchronizer hub 9. 1st-2nd coupling sleeve
10. 1st main gear 11. 3rd main gear 12. 4th main gear
13. Reverse main gear 14. Reverse coupling sleeve 15. Reverse synchronizer hub
16. Striking rod 17. Counter shaft 18. Filler plug
19. 6th counter gear 20. 2nd counter gear 21. 1st counter gear
22. 3rd counter gear 23. 3rd-4th synchronizer hub 24. 3rd-4th coupling sleeve
25. Drain plug 26. 4th counter gear 27. Reverse idler gear
28. Reverse idler shaft 29. Reverse counter gear 30. Main shaft
31. Rear extension

DOUBLE-CONE SYNCHRONIZER
The 1st, 3rd and 4th gears are equipped with a double-cone synchronizer to reduce the operating force of the
shift lever as shown.

Edition; 2004 September MT-8 2005 G35 Sedan
DESCRIPTION

TRIPLE-CONE SYNCHRONIZER
The 2nd gear is equipped with a triple-cone synchronizer to reduce the operating force of the shift lever as A
shown.

PCIB0594E

Edition; 2004 September MT-9 2005 G35 Sedan
M/T OIL

M/T OIL PFP:KLD20

Replacement ACS003LA

DRAINING
1. Start the engine and warm up the transmission unit sufficiently.
2. After stopping engine, remove filler plug and drain plug to drain oil.
3. Replace gasket on drain plug with new one. Screw drain plug into transmission case, and tighten to the
specified torque. Refer to MT-22, "CASE COMPONENTS" .
CAUTION:
Do not reuse gasket.
FILLING
1. Fill new oil into the transmission to the level of the filler plug mounting hole.
Oil grade and Viscosity
: Refer to MA-11, "RECOMMENDED FLUIDS AND LUBRICANTS"
Oil capacity
: Approx. 2.9 (3-1/8 US qt, 2-1/2 lmp qt)
2. Replace gasket on filler plug with new one. Screw filler plug into transmission case, and tighten to the
specified torque. Refer to MT-22, "CASE COMPONENTS" .
CAUTION:
Do not reuse gasket.
Checking ACS003LB

OIL LEAKAGE AND OIL LEVEL
q Check if oil is leaking from transmission or around it.
q Check oil level from filler hole as shown in the figure.
CAUTION:
Never start engine while checking oil level.
q When screwing in filler plug with a new gasket, first screw into
the transmission by hand, then tighten to the specified torque.
Refer to MT-22, "CASE COMPONENTS" .
CAUTION:
Do not reuse gasket.

PCIB0268E

Edition; 2004 September MT-10 2005 G35 Sedan
REAR OIL SEAL

REAR OIL SEAL PFP:33140
A
Removal and Installation ACS003LC

REMOVAL
1. Remove propeller shaft. Refer to PR-5, "Removal and Installation" .
B
2. Remove rear oil seal using oil seal puller.
Tool number : KV381054S0 ( -- )
MT

E
PCIB0194E

INSTALLATION
1. Apply multi-purpose grease to rear oil seal lip. Drive in rear oil F
seal until the edge is approximately 1.2 - 2.2 mm (0.047 - 0.087
in) above the boss edge using drift.
Tool number : ST33400001 (J-26082) G
CAUTION:
q Do not reuse rear oil seal.

q When installing, do not tilt oil seal.
H

PCIB0267E

M
2. Install propeller shaft. Refer to PR-5, "Removal and Installation" .
CAUTION:
q If lubricant leak has occurred during the repair work, check oil level after finishing work. Refer
to MT-10, "Checking" .

Edition; 2004 September MT-11 2005 G35 Sedan
POSITION SWITCH

POSITION SWITCH PFP:32005

Checking ACS003LD

COMPONENT LOCATION

PCIB0622E

BACK-UP LAMP SWITCH
q Check continuity.
Gear position Continuity
Reverse Yes
Except reverse No

SCIA0645E

NEUTRAL POSITION SWITCH
q Check continuity.
Gear position Continuity
Neutral Yes
Except neutral No

SCIA0645E

Edition; 2004 September MT-12 2005 G35 Sedan
SHIFT CONTROL

SHIFT CONTROL PFP:34103
A
Removal and Installation ACS003LE

PCIB0689E

1. Insulator 2. Seat 3. Control lever J
4. Control lever spring 5. Guide plate 6. Control lever boot
7. Hole cover 8. Shift knob
K
REMOVAL
1. Remove shift knob with the following procedure.
a. Release metal clips on console boots from center console. Refer L
to IP-10, "Component Parts Drawing" .

PCIB0435E

Edition; 2004 September MT-13 2005 G35 Sedan
SHIFT CONTROL

b. Lift console boot, and push down hole cover. Set water pump
plier or a suitable tool to control lever.
CAUTION:
Put waste cloth between water pump plier and control lever
assembly to avoid damaging control lever.

SCIA2607E

c. Set monkey wrench to shift knob.
CAUTION:
Put waste cloth between shift knob and monkey wrench to
avoid damaging shift knob.

SCIA2608E

d. Keeping control lever in place with water pump plier, turn mon-
key wrench counterclockwise to loosen shift knob.
NOTE:
Remove shift knob from control lever keeping water pump plier
in place because a certain power to turn shift knob is still neces-
sary even after adhesive is peeled.
2. Remove insulator and seat from control lever.
3. Remove console boot. Refer to IP-10, "Component Parts Draw-
ing" .
SCIA2609J

4. Release the boot, remove control rod mounting bolt, and sepa-
rate control lever and control rod.

SCIA1671E

5. Remove the mounting bolts to remove hole cover.
6. Remove the control lever boot.

SCIA1511E

Edition; 2004 September MT-14 2005 G35 Sedan
SHIFT CONTROL

7. Remove guide plate mounting bolts, and then remove control A
lever and control lever spring from shift lever housing.

SCIA1365E
D
INSTALLATION
1. Set control lever and control lever spring in the vehicle and loosely mount guide plate.
2. After installing control lever in control rod, tighten bolts to the E
specified torque. Refer to MT-13, "Removal and Installation" .

SCIA2561J
H

3. After shifting control lever into 6th gear, push it toward reverse
gear (to the right) until it comes to a stop. I
4. At the point where the control lever assembly stops, bring the
guide plate closer until guide plate stopper contacts control lever
assembly claw, and then loosely tighten mounting bolt A. J

SCIA1665E

Edition; 2004 September MT-15 2005 G35 Sedan
SHIFT CONTROL

5. After shifting control lever into 5th gear, push it toward reverse
gear (to the right) until it comes to a stop.
6. At the point where control lever assembly stops, bring guide
plate closer until the guide plate stopper contacts control lever
assembly claw, and then tighten mounting bolt C to the specified
torque. Refer to MT-13, "Removal and Installation" .
7. Tighten guide plate bolts A and B to the specified torque. Refer
to MT-13, "Removal and Installation" .
8. Install control lever boot.
9. Install hole cover and tighten bolts to the specified torque. Refer
to MT-13, "Removal and Installation" .
10. Install console boot to the center console. Refer to IP-10, "Com-
ponent Parts Drawing" .

SCIA1666E

11. As shown in the figure, assemble seat and insulator to control
lever assembly.
CAUTION:
Do not reuse the insulator.
12. Apply locking sealant to control lever threads, install shift knob.
CAUTION:
Remove the remaining adhesive on control lever and shift
knob threads.

SCIA1771E

13. Put the shift knob in the correct position as the following indicates.

Edition; 2004 September MT-16 2005 G35 Sedan
SHIFT CONTROL

a. When tightening shift knob, if shift knob comes to the proper
position within 1/2 turn from the position at which resistance A
begins to be felt, tighten it 1 more turn to set it in the proper posi-
tion.
b. If it takes more than 1/2 turn from the position at which resis- B
tance begins to be felt tighten it to set it in the proper position.
CAUTION:
q Do not adjust the knob with loosing.
MT
q After adjusting to the regular position, until 30 minutes
pass, do not operate the shift intensely such as screwing or
turning the shift knob to opposite direction since a locking
sealant because stiff. D

G
SCIA1774E

INSPECTION AFTER INSTALLATION
After installing, confirm the following items: H
q When control lever assembly is shifted to each position, make sure there is no binding or disconnection in
each boot.
q When shifted to each position, make sure there is no noise, binding, and backlash. Especially when con- I
trol lever assembly is shifted to 5th, 6th without pressing downward, check for binding.
q When control lever assembly is shifted to 1st, 2nd side and 5th, 6th side, confirm control lever assembly
returns to neutral position smoothly. J
q In any position other than reverse, confirm that control lever assembly can be pressed downward.
q With control lever assembly pressed downward, confirm that it can be shifted to reverse.
q When shifted from reverse to neutral position, confirm control lever assembly returns to neutral position K
smoothly with spring power.
q Without control lever assembly pressed downward, confirm that it cannot be shifted to reverse.
L

Edition; 2004 September MT-17 2005 G35 Sedan
AIR BREATHER HOSE

AIR BREATHER HOSE PFP:31098

Removal and Installation ACS003LF

Refer to the figure for air breather hose removal and installation information.

PCIB0690E

1. Air breather hose

CAUTION:
q Make sure there are no pinched or blocked areas on the air breather hose caused by bending
when installing it.
q Insert overlap width of air breather hose as far as it will go.

Edition; 2004 September MT-18 2005 G35 Sedan
TRANSMISSION ASSEMBLY

TRANSMISSION ASSEMBLY PFP:32010
A
Removal and Installation from Vehicle ACS003LG

G
PCIB0691E

1. Transmission case 2. Rear engine mounting member 3. Insulator

REMOVAL H
1. Disconnect battery negative cable.
2. Remove catalytic converter stay mounting nuts and bolts, and
then remove exhaust mounting bracket. Refer to EX-3, I
"Removal and Installation" .

SCIA1471E
L
3. Remove nut connecting catalytic converter to exhaust manifold, and then remove catalytic converter and
exhaust front tube as one unit.
4. Remove propeller shaft. Refer to PR-5, "Removal and Installation" . M
5. Remove control rod mounting bolts and then separate shift lever
assembly from the control rod assembly.

SCIA1364E

Edition; 2004 September MT-19 2005 G35 Sedan
TRANSMISSION ASSEMBLY

6. Using a suitable tool, release claws and separate console boot
from center console. Refer to IP-10, "Component Parts Draw-
ing" .

PCIB0063E

7. Remove hole cover mounting bolts and then separate hole
cover from the floor panel.
8. Separate control lever boot from guide plate.

PCIB0064E

9. Remove guide plate mounting bolts and then separate shift lever
assembly from the shift lever housing.

SCIA1591E

10. Remove clutch operating cylinder mounting bolts and then separate heat insulator and clutch operating
cylinder from the transmission case. Refer to CL-11, "Removal and Installation" .

11. Remove crankshaft position sensor (POS).
CAUTION:
q Do not subject it to impact by dropping or hitting.

q Do not disassemble.

q Do not allow iron dust, etc., to get on the sensor's front
edge magnetic area.
q Do not place in an area affected by magnetism.

12. Disconnect neutral position switch and back-up lamp switch.
13. Separate heated oxygen sensor 2 wire harness, crankshaft
position sensor (POS) wire harness, back-up lamp switch wire SCIA1476E

harness and PNP switch wire harness from the transmission.
14. Remove starter motor. Refer to SC-18, "Removal and Installation" .
15. Set transmission jack to the transmission.
CAUTION:
When setting transmission jack, be careful so that it does not contact with the switch.

Edition; 2004 September MT-20 2005 G35 Sedan
TRANSMISSION ASSEMBLY

16. Remove rear engine mounting member. Refer to EM-113,
"Removal and Installation (2WD Model)" . A
17. Remove engine and transmission mounting bolts with power
tool.
18. Remove transmission from the vehicle. B

SCIA1531E

D
INSTALLATION
Install in the reverse order of removal procedure, following the cautions below:
q When installing transmission to the engine, install mounting bolts in accordance with the standards below. E
LHD Model
Bolt No. 1 2 3 4 5
F
Quantity 1 5 2 2 2
55 65 50 35 65
" " mm (in)
(2.17) (2.56) (1.97) (1.38) (2.56)
G
Tightening
75 55.4 46.6 55.4
torque
(7.7, 55) (5.7, 41) (4.8, 34) (5.7,41)
N

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