Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 1998-2002 Approved Nissan Frontier 2002 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 2ND & 3RD BAULK RING ........................................31
NVH Troubleshooting Chart.........................................6 Available Snap Rings ................................................31
MANUAL TRANSMISSION..........................................6 MAIN DRIVE GEAR BEARING ..................................31 TF
DESCRIPTION .................................................................7 MAINSHAFT FRONT ................................................31
Cross-sectional View ...................................................7 COUNTER DRIVE GEAR .........................................31
ON-VEHICLE SERVICE ..................................................8 OD MAINSHAFT BEARING ......................................32 PD
Replacing Rear Oil Seal ..............................................8 Available Shims .........................................................32
REMOVAL .................................................................8 COUNTERSHAFT FRONT BEARING ........................32
INSTALLATION..........................................................8 AX
Position Switch Check .................................................8 FS5R30A
REMOVAL AND INSTALLATION ...................................9
PREPARATION .............................................................33 SU
Removal.......................................................................9
Installation..................................................................10 Special Service Tools ................................................33
OVERHAUL ...................................................................11 Commercial Service Tool...........................................35 BR
Case Components .....................................................11 NOISE, VIBRATION AND HARSHNESS (NVH)
Gear Components .....................................................12 TROUBLESHOOTING ...................................................36
Shift Control Components .........................................13 NVH Troubleshooting Chart.......................................36 ST
DISASSEMBLY..............................................................14 MANUAL TRANSMISSION........................................36
Case Components .....................................................14 DESCRIPTION ...............................................................37
DISASSEMBLY ........................................................14 Cross-sectional View - 2WD Model...........................37 RS
Shift Control Components .........................................14 Cross-sectional View - 4WD Model...........................38
DISASSEMBLY ........................................................14 ON-VEHICLE SERVICE ................................................39
Replacing Rear Oil Seal - 2WD Model .....................39
BT
Gear Components .....................................................15
DISASSEMBLY ........................................................15 REMOVAL ...............................................................39
INSPECTION..................................................................18 INSTALLATION........................................................39
HA
Shift Control Components .........................................18 Position Switch Check ...............................................40
INSPECTION ...........................................................18 REMOVAL AND INSTALLATION .................................41
Gear Components .....................................................18 Removal.....................................................................41 SC
INSPECTION ...........................................................18 2WD MODEL ...........................................................41
ASSEMBLY....................................................................20 4WD MODEL ...........................................................42
Gear Components .....................................................20 Installation..................................................................43 EL
ASSEMBLY .............................................................20 OVERHAUL ...................................................................44
Shift Control Components .........................................26 Case Components .....................................................44
ASSEMBLY .............................................................26 Gear Components .....................................................45 IDX
CONTENTS (Cont'd)
Shift Control Components (2/4WD models) ..............47 ASSEMBLY .............................................................65
DISASSEMBLY..............................................................48 SERVICE DATA AND SPECIFICATIONS (SDS) .........67
Case Components .....................................................48 General Specifications...............................................67
DISASSEMBLY ........................................................48 Gear End Play ...........................................................67
Shift Control Components .........................................49 Clearance Between Single Baulk Ring and Gear .....67
DISASSEMBLY ........................................................49 DOUBLE BAULK RING ............................................68
Gear Components .....................................................50 Distance Between Rear Surface of Reverse
DISASSEMBLY ........................................................50 Cone and Reverse Baulk Ring..................................68
INSPECTION..................................................................54 Available Snap Ring ..................................................68
Shift Control Components .........................................54 MAIN DRIVE GEAR SNAP RING ..............................68
INSPECTION ...........................................................54 MAINSHAFT FRONT SNAP RING .............................68
Gear Components .....................................................54 COUNTER GEAR REAR SNAP RING .......................69
INSPECTION ...........................................................54 Available C-ring .........................................................69
ASSEMBLY....................................................................56 MAINSHAFT C-RING ...............................................69
Gear Components .....................................................56 Available Shim and Washer ......................................69
ASSEMBLY .............................................................56 TABLE FOR SELECTING PROPER COUNTER
Shift Control Components .........................................64 GEAR FRONT BEARING THRUST WASHER ............69
ASSEMBLY .............................................................64 REVERSE IDLER REAR THRUST WASHER .............70
Case Components .....................................................65
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
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