oil NISSAN 300ZX 1984 Z31 Manual Transmission Workshop Manual

MANUAL TRANSMISSION
I
CONTENTS
REMOVAL AND INSTALLATION ...... ...... .... MT-2
ON-VEHICLE SERVICE
. . .. .. _. MT- 3
MAJOR OVERHAUL - FS5W71C. ... ...... ........ Mi- 4
DISASSEMBLY - FS5W71C ....... .. MT- 7
REPAIR FOR COMPONENT PARTS-FS5W71C ..... MT- a
ASSEMBLY - FS5W71C ...... , . . MT-18
5-SPEED TRANSMISSION [Model BW T-5 (FS5R90AIl
... MT-20
Rear extension
.. ... ..... ...... MT-23
Case cover
. . ......... ......... MT-23
Transmission case
. . ... .... MT-24
Gearstkshafts
.... .. .. .. ... MT-27
Replacement of
oil seals .... ..... MT-28
Replacement
of bearings . .I. ....... . MT-29
SPECIAL SERVICE TOOLS .... MT-33
SERVICE DATA AND SPECIFICATIONS (S D S ) .. MT-30

REMOVAL AND INSTALLATION
Remove exhaust front tube, catalytic converter
and exhaust manifold connecting tube
Refer to
EM section.
a Remove propeller shaft.
Refer to
PD section
Insert plug into rear oil seal after removing pro-
peller shaft.
a Support engine by placing a jack under oil pan.
CAUTION:
a Be careful not to damage spline, sleeve yoke
and rear oil seal, when removing propeller
shaft.
Do not place lack under the oil pan drain plug.
a Remove shift lever
BW T-5 (FS5R90A)
SMTOlZA FS5W71C
WARNING:
Support Manual Transmission, while removing It.
Installation
a
These bolts have different lengths.
Tighten bolts securing transmission to engine
22.291
SMT978
Fill transmission with recommended gear oil
MT-2

ON-VEHICLE SERVICE
0 Rear extension oil seal.
I
MT-3

REPAIR FOR COMPONENT PARTS-FS5W71C
Gears and S
Shifting inserts and springs
If worn excessively, worn unevenly, deformed, or
damaged, replace
SMTO64
ASSEMBLY
Note:
Apply gear oil to each
part.
Needle bearings
Baulk rings
Shafts
Gears
Oil seals
1 Place inserts
1st & 2nd
ifts (Cont'd)
3rd &4th
OD
SMT994
0 D (5th) synchronizer SMT986 hub
2 Assemble 2nd gear and 1st & 2nd synchronizer
assembly, then press 1st gear bushing on main-
shaft
MT-11

REPAIR FOR COMPONENT PARTS-FS5W71C
Parts number
Gears and 5
Thickness mm (in)
3 Assemble 1st gear, steel ball, and thrust washer
on mainshaft
Before
installing steel ball and thrust washer apply
grease
to them.
32263-V5202
TM358
4 Install counter rear bearing to adapter plate
5 Press mainshaft assembly to adapter plate using
Tool.
2.6 (0.102)
KV31100401
TM439
6 Press counter gear into adapter plate.
Bfts (Cont'd)
7. Install 3rd main gear, and 3rd & 4th synchroni-
zer assembly
Pay attention to direction of synchronizer. ~
Front
SMT008A
8 Install
thrust washer on mainshaft and secure
it with mainshaft front snap ring
Select proper snap ring that will minimize clear-
ance
of groove in mainshaft.
TMMl
Mainshaft front snap ring'
2.5 (0.098) 32263-V5201 I
9. Apply gear oil to mainshaft pilot bearing and
install it on mainshaft
MT-12

REPAIR FOR COMPONENT PARTS-FS5W71C
Oil Seals
FRONT COVER OIL SEAL
Be careful not to damage lip of oil seal.
ST23800000
Adapter Plate
When replacing adapter plate parts, use the
following procedures.
DOWEL PIN
Adapter plate
oowel pm 12 placer)
7 5 IO 2951 1 Mainshaft bearing7
umt mrn I!") SMT027
OIL GUTTER
Install
oil gutter on adapter plate and expand on
rear side.
... TM356
MT-16

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
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