NISSAN 300ZX 1984 Z31 Manual Transmission Owner's Manual

5SPEED TRANSMISSION [Model: BW T-5 (FS5R90A)l -1
C aterrhaft assembly
1 Rollerbearmg
2 Thrustwasha
3 Countershaft gear
4 Spacer
5 Rollerbeanng
6 Spacer I snapnng
8 5th speed drlve gear
9 Blockrngrmg
10 Hub Notsmced
11 Sleeve 1 separately 12 lnmt
14 Insert retamer
16 Needle thrust bearmg
18 Funnel
13 SP~
IS Thrust race
17 Thrustrace
Reverse idler assembly
n
1 Reverse idler bushmg Not ~e~ced
2 Rwase idler gear
3 Rwersetdler shaft 1 separately
4 Spnngpm
UT850
MT-22

5SPEED TRANSMISSION [Model: BW T-5 (FS5R90A)l
REAR EXTENSION
DISASSEMBLY
1
2 Drain oil
3
damper sleeve
Wipe off drt and grease
Remove sluft lever assembly and
4 Remove pm from offset lever
-.. - ._
'.* .I El
-.. n
5 Remove rear extension, offset
lever, detent
spnng and ball by tappmg
it
7
When disassembling rear extension,
be careful not to lose thrust race
and funnel.
INSPECTION
1 Clean with solvent and check for
cracks
2 Check mating surface of rear
extension for small nicks, prolec-
tions or sealant
If the rear extension bushing or guide
plate are worn, cracked or broken,
replace them as an assembly of bush-
ing, guide plate and rear extension
housing.
ASSEMBLY
1 Clean matmg surfaces of case and
rear extension
2 Apply a contmuous bead of
sealant to the matmg surface of the
case
3 Retam the needle thrust bearmg,
race and funnel
to the rear of the
countershaft with Petroleum Jelly
4 Place detent ball, spnng and offset
lever mto position on guide plate and
install extension houslng to the
transmission case
5 Ahgn the hole ?n the shifter shaft
with the hole
m the offset lever and
mstall the retammg pm
MT-23
6 Install rear extenQon bolts to
transmission case
0 : 27 - 62 Nm
(2 8 -6 3 kg-m,
20 - 46 ft-lb)
7 Apply a contmuous bead of
sealant to shlft cover opening of
rear extension
8 Assemble damper sleeve mto
offset lever and install shlft lever
@ :20-34Nm
(2.0 - 3.5 kgm,
14 .25 ft-lb)
9 Make sure that gears operate
smoothly
10 Apply sealant to thread and
install dram plug
0.20 - 34 N m
(2 0 - 3.5 kg-m,
14
- 25 ft-lb)
CASE COVER
DISASSEMBLY
1 Remove rear extension Refer to
rear extension for disassembly
2 Remove cover bolts and cover
by tapping it with dnver Shde cover
to nght side of case and hft
3 Pull shifter shaft to rear and re-
move stnkmg lever to shlfter shaft
roll pm

5SPEED TRANSMISSION [Model: BW T-5 (FS5R90A)I
4 Remove shifter shaft through rear
of case cover
5 Slide selector plates from shift
fork assembhes
. __ - - . . I
INSPECTION
1 Clean with solvent and check for
wear, scratches, projections, damage,
breakage
or other faulty conditions
Replace any part whch is worn or
damaged
2 Inspect shft fork inserts for wear
or damage Replace if necessary
ASSEMBLY
I Assemble selector plates to sluft
fork assembhes
2 Install shifter shaft through open-
mg m rear of case cover and assemble
to
1-2 duft fork, mterlock plate,
strkmg lever and
3-4 sluft fork
Install shfter shaft roll pin
to stnkmg
lever
3 Apply a contmuous bead of
sealant to case cover matlng surface
4 Install cover to case
5 Apply sealant to threads and
install two ahgnment dowels into
cover
6 Apply sealant to threads and
install case cover bolts
@ : 8.1 - 14.7 N m
(0.83 - 1.5 kg-m,
6.0 - 10 8 ft-lb)
7 Install rear extension Refer to
rear extension for assembly
TRANSMISSION CASE
DISASSEMBLY
1 Remove rear extenson Refer to
rear extension for disassembly
2 Remove case cover Refer to case
cover for disassembly
3 Remove back-up hght swltch
4 Remove retamer rmg and pivot
Pm
5 Remove funnel, thrust race, and
needle thrust beanng
6 Remove snap nng and thrust
race from rear
of 5th speed synchro-
nuer hub
MT-24
7 Remove pin from 5th speed hft
fork
8 Remove 5th speed shift fork,
synchronizer and counter gear
9 Remove front bearmg retamer
10 Remove mput shaft and mam
drive gear assembly Position flat area
of mam drive gear toward the counter
gear and remove
through the front
of the case

SSPEED TRANSMISSION [Model: BW T-5 (FS5R90A)I
11 Remove mamshaft rear bearmg
race and remove mamshaft assembly
through top of case
I
12 Remove 5th speed shift rad,
reverse fork with 5th and reverse
relay lever, and spnng
13 Remove pm from reverse idler
shaft Remove reverse idler shaft
and gear
14 Rrmove snap nng and spacer
from rear of counter gear beanng
15. Remove counter gear rear beanng
by pressmg counter gear toward rear
of case untd bearmg is free Remove
bearing and spacer from rear of
counter gear
CAUTION:
When pressing out bearing, hold hand
under counter gear
so bearing does not
drop
16 Remove counter gear and front
thrust washer through top of case
11 Press front counter gear beanng
from case
This bearing should not be removed
unless replacement
is necessary.
INSPECTION
1 Clean with solvent and check for
cracks or pits
2 Check mating surfaces of trans-
mission case for small nicks, projec-
tions or sealant
The magnet at the bottom of the caSe
is held in place by a clip and a special
glue.
It should not be removed from
the case.
ASSEMBLY
1 Install front counter gear beanng
as follows
(1) Apply a
small bead of adheslve
agent to outside dlameter of bearmg
(2) Press bearmg into case untd the
front edge
is flush with the front edge
of the case
2 Install the counter gear thrust
washer into the case being sure
to abgn
the tang with the notch
m the case
Retam the washer
m the case with
a light coat of petroleum jelly
MT-25
3 Install the counter gear mto the
case and engage its front journal mto
the front bearmg
-' .".-:;-;' . -
.._. .." .
4 Install the rear counter gear bear-
ing as follows
(1) Install spacer to the rear of
counter gear
(2) Install beanng protector 5-33032
on the counter gear

SSPEED TRANSMISSION [Model: BW T-5 (FS5R90A)I
(3) Install beanng over protector and
press mto case uslng bearmg mstaller
J-29895 When properly mstalled,
the beanng race
WIU protrude from the
case
3 12 to 3 22 mm (0 1228 to
0 1268 in)
(4) Install spacer and snap nng at
rear of beanng
5 Install reverse idler gear mto case
with shft fork groove toward the
rear Install reverse idler shaft, 0-rmg
and retammg pm
6 Install reverse fork with 5th and
reverse relay lever, 5th speed sluft
rad and spnng Install backup hght
switch
7 Instal mamshaft assembly mto the
case and mstall mamshaft rear bear-
mg race.
8 Install roller bearmgs mto the
mam drive gear Retaxn with petro-
leum jelly
9 Install mput shaft and
mam drive
gear assembly, needle thrust bearing,
thrust bearmg race and bloclung ring
into case
Be sure to align the flat arm of the
main drwe gear wlth the countergear
and
install carefully IO as not to dis-
lodge the roller bearings.
10 Remove at least 0 15 mm shuns
(0 0059 in) from under front bearing
race
in bearing retainer Install reman-
ing
shuns and race into retainer
11 Install front bearing retamer to
case
Be sure to position it so that
the
oll collector groove is up
@ : 15 - 27 Nm
(1.5 - 2.8 kg-m,
11-20h-lb)
12 Install 5th speed shift fork, 5th
speed counter gear and synchronuer as
a umt Ahgn
pm holes m duft fork
and
sluft rad and mstall retmmg pm
13 Install thrust race and snap rmg
to rear of 5th speed synchronuer hub
14 Install case cover Refer to case
cover for assembly
15 Install rear extension Refer to
rear extension for assembly
16 Push mput shaft to rear and
mount dial mdicator
so that its stem
rests aganst the front end of the
input shaft Zero indicator
17 Push output shaft forward and
read mdicator Record readmg for
calculation Remove mdicator
.-. ,
18 Remove beanng retamer and bear-
ing race Select proper thckness
sium
to provlde 0 13 to 025 mm (00051
to 0 0098 m) preload
Calculation Example
A
+ B = Shim size
(A) Indicator reading 0.10 rnm
(B) Desired preload 0.20 mm
Additional shim 0.30 mm
required
(deaance)
19 Apply a contmuous bead of
sealant
to bearing retamer matmg
surface and threads of bolts.
20 Install shuns and bearmg race
mto beanng retamer and lnstall the
beanng retainer as in Step 11
MT-26

5SPEED TRANSMISSION [Model: BW T-5 (FS5R90A)I
GEARS & SHAFTS
DISASSEMBLY
1 Remove rear extension Refer to
rear extension for disassembly
2 Remove case cover Refer to case
cover for disassembly
3 Remove transmission case Refer
to transmission case for dsassembly
4 Remove speedometer gear and
drive ball from manshaft
.b ., . W"
5 Press 3rd and 4th synchronrzer
from front of mmshaft Remove
3rd speed gear
6 Press 5th speed gear from mam-
shaft
7 Shp rear beanng off shaft Re-
move thrust washer
8 Remove pm from mmshaft and
remove 1st speed gear
9
and second speed gear
Remove snap rmg, thrust washer,
10 Remove 1st and 2nd !,ynchronrzer
sleeve, inserts and spnngs
INSPECTION
Bearings
1
compressed au
CAUTION:
Do not allow bearing to spin as It will
damage the race and rollers.
Thoroughly clean and dry with
2
rough, replace bearing
3
damaged
Gean and shafts
1 Check all gears for excessive wear,
chips
or cracks, replace as requlred
2 Check shafts for bendmg, cracks,
wear and worn sphes, replace if
necessary
When race or rollers are worn or
Replace needle rollers if worn
or
3 Measure gear end play
rn It is necessary to measure end play
before disassembhng mmshaft and
also after reassembhg it
rn If end play is not withm specified
hits, disassemble and check parts
for condition
rn Replace any part whch is worn or
damaged
Standard end play
1st main gear
0.10.025 mm
(0.0039 - 0.0098 in)
0.10 - 025 mm
(0.0039
- 0.0098 in)
0.15 - 0.40 my
(0.0059 .0.0157
in)
0.10 .0.48 mm
(0.0039.0 0189
in)
025.050 mm
(0.0098
- 0.0197 in)
2nd main gear
3rd main gear
5th counter gear
Counter gear
bulk rings
1 Replace baulk nng if found to
be deformed, cracked or otherwise
damaged
2 Check teeth and msert notches
for wear
SMT026
MT-27

5SPEED TRANSMISSION [Model: BW T-5 (FS5R90A)I
3 Inspect cone surface for ex-
cessive wear
Shifting insert
Replace if worn excessively, worn
unevenly, or damaged
011 seals
1 Replace oll seal if seahng hp is
deformed or cracked Also discard
OII seal d spnng is out of position
Refer
to replacement of OII seals
2 Check contact between
od seal
lip and shaft, if necessary, replace
oil
seal and shaft as a set
ASSEMBLY
Synchronizers
1 Assemble couplmg sleeve to syn-
chronuer hub Make sure that the
sleeve &des freely on the hub
2 Posltion duftmg mserts mto 3
slots m synchroruzer hub with raised
portion facmg outward
3 hstd first msert SpMg wlth
hooked end engaged
to one of the
shft mserts
4 Install the second insert sprlng
on the opposlte side of the synchro-
nuer with the hooked end engaged
to the same msert but turned in the
opposite direction of the first sprmg
7 Install 3rd speed gear Press
3rd and
4th synchronuer onto front
of mainshaft using special
tool
J-25863-01 Be sure that the portion
of the hub with the extended hose
is toward the front
Mainshaft
1 Assemble the 1st and 2nd syn-
chronizer sleeve, mserts and springs
to the synchronuer hub
2 Install 2nd speed gear, thrust
washer and snap rmg
3 Install 1st speed gear
4 Install thrust washer positioning
pm into mmshaft
so that it projects
3 nun (0 12 in) from the bearmg
surface
5 Install thrust washer against 1st
speed gear, bemg certain that the
slot m the washer allgns mth the
Pm 6 Install rear beanng and press
5th speed gear onto mamshaft
usmg
special tool J-2.601041.
8 Install speedometer drive ball,
speedometer gear, and snap ring
9 Install transmission case Refer to
transmission case for assembly
10 Install case cover Refer to case
cover for assembly
11 Install rear extension Refer to
rear extension for assembly
REPLACEMENT OF
OIL SEALS
FRONT BEARING RETAINER
SEAL
It is necessary to remove transmission
unit from car Replace
all seal as
follows 1 Remove transmission Refer
to
removal
2
3 Dramall.
4 Remove front bearmg retamer
Wipe off dnt and grease
MT-28

SSPEED TRANSMISSION [Model: BW T-5 (FS5R90A)l
5 Remove oil seal
6 Clean bearing retainer and case
mating surface
7 Check beanng retainer and matmg
surface for cracks, nicks, projections
or sealant
8 Apply a coat of transmission fluid
to oil seal surface and install seal usmg
seal installer J-23096
- -.
REAR EXTENSION OIL SEAL
The rear extension oll seal can be
replaced without removing transmis-
sion from car
1 Remove propeller shaft Refer
to propeller shaft (section
PD) for
removal
2 Remove oll seal
3 Apply a coat of transmission
fluid
to oil seal surface and drive new
seal into place
usmg seal installer
J-28894
4 Install propeller shaft Refer to
propeller shaft (section
PD) for instal-
lation
REPLACEMENT OF
BEARINGS
9 Install front bearing retainer to
case Be sure to position
it so that
the
oil collector groove is up
@ 15.27N.m
(1.5 - 2 8 kg-m,
11 -20ft-lbl
10 Install transmission Refer to
installation
1 Remove rear extension Refer to
rear extension for disassembly
2 Remove case cover Refer
to case
cover for disassembly
3 Remove mput shaft, mmshaft,
counter gear
and counter gear front
beanng Refer to tranmission case
for disassembly
4 Press man drive bearmg from
input shaft
5 Press new mam drive bearmg
to mput shaft usmg special tool
J-26010-01 6 Replace rear bearmg Refer
to
gears and shafts for disassembly and
assembly
7 Install front and rear counter-
gear bearmgs Refer to transmission
case for assembly
8 Install transmission case Refer to
transmission case for assembly
9 Install case cover Refer to case
cover for assembly
10 Install rear extension Refer to
rear extension for assembly
MT-29

SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Synchromesh type
General I
Warner
Transmtrrion -ode1
Shnft pattern
I
Synchromesh type
Gear ratio 1st
2nd
3rd
4th
OD
Re"e,Se
Number of teeth
Maln drive gear
Main bear 1st 2nd
3rd
OD
Reverse
Counter drive gear
counter gear 1st 2nd
3rd
OD RWeW
Reverse idler gear
011 capacity 1,ter (US pt Imp Pt)
FS5W71C
135
24R
Warner
3 321
1902
1308
1000
0 759
3 382
22
33
21 26
21
36
31 14
20
28 39
15
21
1 9 l4,3-3/81
cifications ~~
Slitft pattern
I ll 35
24R
Gear
ratio
1st 2nd
3rd
4th
OD
Reverse
3 350
2 056 1376
1 000
0 779
3
153
Number of teeth Main drive gear
Main gear 1 It
2nd
3rd
OD Reverse
23
34
32
21
29
32
Counter drwe gear Counter gear 1st
2nd
3rd OD
Reverse Reverse idler gear
34
15 23
29 55 15
20
011 capactty liter IUS pt. Imp ptl 1 1 9 I4 3-3/81
MT-30