Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 1998-2002 Approved Nissan Frontier 2001 mt
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MANUAL TRANSMISSION GI
SECTION MT MA
EM
LC
EC
CONTENTS FE
FS5W71C Case Components .....................................................27
CL
ASSEMBLY .............................................................27
PREPARATION ...............................................................3
SERVICE DATA AND SPECIFICATIONS (SDS) .........30
Special Service Tools ..................................................3
General Specifications...............................................30
Commercial Service Tools ...........................................5
Gear End Play ...........................................................30
NOISE, VIBRATION AND HARSHNESS (NVH)
Clearance Between Baulk Ring and Gear ................31 AT
TROUBLESHOOTING .....................................................6
Available Snap Rings ................................................31
NVH Troubleshooting Chart.........................................6 MAIN DRIVE GEAR BEARING ..................................31
MANUAL TRANSMISSION..........................................6 MAINSHAFT FRONT ................................................31 TF
DESCRIPTION .................................................................7 COUNTER DRIVE GEAR .........................................31
Cross-sectional View ...................................................7 OD MAINSHAFT BEARING ......................................32
ON-VEHICLE SERVICE ..................................................8 Available Shims .........................................................32 PD
Replacing Rear Oil Seal ..............................................8 COUNTERSHAFT FRONT BEARING ........................32
REMOVAL .................................................................8
INSTALLATION..........................................................8 AX
FS5R30A
Position Switch Check .................................................8
REMOVAL AND INSTALLATION ...................................9 PREPARATION .............................................................33
Special Service Tools ................................................33
SU
Removal.......................................................................9
Installation..................................................................10 Commercial Service Tool...........................................35
OVERHAUL ...................................................................11 NOISE, VIBRATION AND HARSHNESS (NVH) BR
Case Components .....................................................11 TROUBLESHOOTING ...................................................36
Gear Components .....................................................12 NVH Troubleshooting Chart.......................................36
Shift Control Components .........................................13 MANUAL TRANSMISSION........................................36 ST
DISASSEMBLY..............................................................14 DESCRIPTION ...............................................................37
Case Components .....................................................14 Cross-sectional View - 2WD Model...........................37
DISASSEMBLY ........................................................14 Cross-sectional View - 4WD Model...........................38 RS
Shift Control Components .........................................14 ON-VEHICLE SERVICE ................................................39
DISASSEMBLY ........................................................14 Replacing Rear Oil Seal - 2WD Model .....................39
REMOVAL ...............................................................39
BT
Gear Components .....................................................15
DISASSEMBLY ........................................................15 INSTALLATION........................................................39
INSPECTION..................................................................18 Position Switch Check ...............................................40 HA
Shift Control Components .........................................18 REMOVAL AND INSTALLATION .................................41
INSPECTION ...........................................................18 Removal.....................................................................41
Gear Components .....................................................18 2WD MODEL ...........................................................41 SC
INSPECTION ...........................................................18 4WD MODEL ...........................................................42
ASSEMBLY....................................................................20 Installation..................................................................43
Gear Components .....................................................20 OVERHAUL ...................................................................44 EL
ASSEMBLY .............................................................20 Case Components .....................................................44
Shift Control Components .........................................26 Gear Components .....................................................45
ASSEMBLY .............................................................26 Shift Control Components (2/4WD models) ..............47
IDX
CONTENTS (Cont'd)
DISASSEMBLY..............................................................48 ASSEMBLY .............................................................65
Case Components .....................................................48 SERVICE DATA AND SPECIFICATIONS (SDS) .........67
DISASSEMBLY ........................................................48 General Specifications...............................................67
Shift Control Components .........................................49 Gear End Play ...........................................................67
DISASSEMBLY ........................................................49 Clearance Between Single Baulk Ring and Gear .....67
Gear Components .....................................................50 DOUBLE BAULK RING ............................................68
DISASSEMBLY ........................................................50 Distance Between Rear Surface of Reverse
INSPECTION..................................................................54 Cone and Reverse Baulk Ring..................................68
Shift Control Components .........................................54 Available Snap Ring ..................................................68
INSPECTION ...........................................................54 MAIN DRIVE GEAR SNAP RING ..............................68
Gear Components .....................................................54 MAINSHAFT FRONT SNAP RING .............................68
INSPECTION ...........................................................54 COUNTER GEAR REAR SNAP RING .......................69
ASSEMBLY....................................................................56 Available C-ring .........................................................69
Gear Components .....................................................56 MAINSHAFT C-RING ...............................................69
ASSEMBLY .............................................................56 Available Shim and Washer ......................................69
Shift Control Components .........................................64 TABLE FOR SELECTING PROPER COUNTER
ASSEMBLY .............................................................64 GEAR FRONT BEARING THRUST WASHER ............69
Case Components .....................................................65 REVERSE IDLER REAR THRUST WASHER .............70
MT-2
PREPARATION FS5W71C
Special Service Tools
Special Service Tools NEMT0050
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
GI
Tool number (Kent-Moore Description
No.) Tool name
ST23810001 Fixing adapter plate with gear assembly MA
( -- ) a: 166 mm (6.54 in)
Adapter setting plate b: 270 mm (10.63 in)
EM
LC
NT407
KV32101330 Removing overdrive mainshaft bearing
(See J34286) a: 447 mm (17.60 in)
EC
Puller b: 100 mm (3.94 in)
FE
NT408 CL
KV31100401 Pressing counter gear and mainshaft
( -- )
Transmission press stand
NT068 AT
ST22520000 Tightening mainshaft lock nut
(J26348) a: 100 mm (3.94 in)
Wrench b: 41 mm (1.61 in) TF
PD
NT409
ST23540000 Removing and installing fork rod retaining pin
(J25689-A) a: 2.3 mm (0.091 in) dia. AX
Pin punch b: 4 mm (0.16 in) dia.
SU
NT442
ST30031000 Removing and installing 1st gear bushing
(J22912-01) Removing main drive gear bearing BR
Puller a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST
NT411 RS
ST23860000 Installing counter drive gear
( -- ) a: 38 mm (1.50 in) dia.
Drift b: 33 mm (1.30 in) dia. BT
NT065 HA
ST22360002 Installing counter gear front and rear end bear-
(J25679-01) ings
Drift a: 29 mm (1.14 in) dia. SC
b: 23 mm (0.91 in) dia.
NT065 EL
IDX
MT-3
PREPARATION FS5W71C
Special Service Tools (Cont'd)
Tool number (Kent-Moore Description
No.) Tool name
ST22350000 Installing OD gear bushing
(J25678-01) a: 34 mm (1.34 in) dia.
Drift b: 28 mm (1.10 in) dia.
NT065
ST23800000 Installing front cover oil seal
(J25691-01) a: 44 mm (1.73 in) dia.
Drift b: 31 mm (1.22 in) dia.
NT065
ST33400001 Installing rear oil seal
(J26082) a: 60 mm (2.36 in) dia.
Drift b: 47 mm (1.85 in) dia.
NT086
ST33290001 Removing rear oil seal
(J34286) a: 250 mm (9.84 in)
Puller b: 160 mm (6.30 in)
NT414
ST30720000 Installing mainshaft ball bearing
(J25405) a: 77 mm (3.03 in) dia.
Drift b: 55.5 mm (2.185 in) dia.
NT115
ST30613000 Installing main drive gear bearing
(J25742-3) a: 71.5 mm (2.815 in) dia.
Drift b: 47.5 mm (1.870 in) dia.
NT073
ST33200000 Installing counter rear bearing
(J26082) a: 60 mm (2.36 in) dia.
Drift b: 44.5 mm (1.752 in) dia.
NT091
MT-4
PREPARATION FS5W71C
Commercial Service Tools
Commercial Service Tools NEMT0051
Tool name Description GI
Puller Removing counter bearings, counter drive and OD
gears
MA
EM
NT077
Drift Installing countershaft rear end bearing
a: 40 mm (1.57 in) dia. LC
b: 30 mm (1.18 in) dia.
NT074 EC
FE
CL
AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
MT-5
NOISE, VIBRATION AND HARSHNESS (NVH) NEMT0052
TROUBLESHOOTING FS5W71C
NVH Troubleshooting Chart
NVH Troubleshooting Chart NEMT0052S01
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.
MANUAL TRANSMISSION NEMT0052S0101
"Checking M/T Oil".
Refer to MA-37,
MT-13
MT-13
MT-12
MT-12
MT-12
MT-12
MT-11
MT-11
Reference page
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SUSPECTED PARTS
(Possible cause)
BAULK RING (Worn or damaged)
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
INSERT SPRING (Damaged)
GEAR (Worn or damaged)
OIL (Oil level is high.)
GASKET (Damaged)
SHIFT FORK (Worn)
OIL (Oil level is low.)
OIL (Wrong oil.)
Noise 1 2 3 3
Oil leakage 3 1 2 2
Symptom
Hard to shift or will not shift 1 1 2 2
Jumps out of gear 1 2 2
MT-6
NEMT0053
DESCRIPTION FS5W71C
Cross-sectional View
Cross-sectional View NEMT0053S01
GI
MA
EM
LC
EC
FE
CL
AT
TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
SMT153D EL
IDX
MT-7
ON-VEHICLE SERVICE FS5W71C
Replacing Rear Oil Seal
Replacing Rear Oil Seal NEMT0054
REMOVAL NEMT0054S01
1. Remove the propeller shaft. Refer to PD-9, " Removal and
Installation".
2. Remove rear oil seal using Tool.
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