tow NISSAN 300ZX 1984 Z31 Manual Transmission Workshop Manual

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
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