NISSAN NAVARA 2005 Repair Workshop Manual

MT-4
PREPARATION
KV381054S0
PullerRemoving rear oil seal
ST33200000
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
lInstalling counter rear bearing
lInstalling rear oil seal
KV38100500
Drift
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.Installing dust seal (for 2WD models)
KV40100630
Inserter
a: 67 mm (2.64 in) dia.
b: 38 mm (1.50 in) dia.Installing 4th counter gear thrust washer
KV38102100
Drift
a: 44 mm (1.73 in) dia.
b: 28 mm (1.10 in) dia.Installing front cover oil seal
KV32103300
Press plate
a: 73 mm (2.87 in)Installing reverse synchronizer hub assembly Tool number
Tool nameDescription
ZZA0601D
ZZA1002D
S-NT086
ZZA0920D
NT084
PCIB0165J

PREPARATION
MT-5
D
E
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H
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K
L
MA
B
MT
Commercial Service ToolsECS00ID0
ST30031000
PullerMeasuring wear of inner baulk ring
ST22490000
Adapter setting plateHolding a adapter plate Tool number
Tool nameDescription
ZZC0499D
ZZC0465D
Tool nameDescription
PullerRemoving each bearing, gear and bushing
Pin punch
Tipdiameter:6.0mm(0.236in)dia.Removing and installing each retaining pin
Puller
lRemoving reverse synchronizer hub
assembly
lRemoving reverse main gear
lRemoving reverse counter gear
Drift
a: 32 mm (1.26 in) dia.Installing counter end bearing
PullerRemoving counter end bearing
ZZB0823D
ZZA0815D
NT077
LCIA0362E
S-NT134

MT-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting ChartECS00ID1
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.
Reference pageMT-9MT-19MT-13MT-23MT-21
SUSPECTED PARTS
(Possible cause)
OIL (Oil level is low.)
OIL(Wrongoil.)
OIL (Oil level is high.)
GASKET (Damaged)
OIL SEAL (Worn or damaged)
SHIFT CONTROL LINKAGE (Worn)
CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)
SHIFT FORK (Worn)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
INSERT SPRING (Damaged)
SymptomsNoise 1 2 3 3
Oilleakage 3122
Hard to shift or will not shift 1 1 2 2 2
Jumpsoutofgear 1122

DESCRIPTION
MT-7
D
E
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B
MT
DESCRIPTIONPFP:00000
Cross-Sectional ViewECS00ID2
1. Mainshaft 2. Reverse synchronizer hub 3. Reverse coupling sleeve
4. Reverse main gear 5. 4th main gear 6. 3rd main gear
7. 1st main gear 8. 1st-2nd coupling sleeve 9. 1st-2nd synchronizer hub
10. 2nd main gear 11. 6th main gear 12. 5th-6th coupling sleeve
13. 5th-6th synchronizer hub 14. Main drive gear 15. Front cover
16. Transmission case 17. Counter gear 18. Filler plug
19. 3rd counter gear 20. 3rd-4th synchronizer hub 21. 3rd-4th coupling sleeve
22. Drain plug 23. Adapter plate 24. 4th counter gear
25. Reverse idler gear 26. Reverse idler shaft 27. Reverse counter gear
28. OD gear case 29. Rear extension
PCIB1297E

MT-8
DESCRIPTION
DOUBLE-CONE SYNCHRONIZER
The 1st, 3rd and 4th gears is equipped with a double-cone synchronizer to reduce the operating force of the
shift lever.
TRIPLE-CONE SYNCHRONIZER
The 2nd gear is equipped with a triple-cone synchronizer to reduce the operating force of the shift lever.
PCIB0594E

M/T OIL
MT-9
D
E
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B
MT
M/T OILPFP:KLD20
Changing M/T OilECS00ID3
DRAINING
1. Start engine and let it run to warm up transmission.
2. Stop engine. Remove drain plug and gasket and then drain oil.
3. Set a gasket on drain plug and install it to transmission case. Tighten drain plug to the specified torque.
Refer toMT-19, "
Case Components".
CAUTION:
Do no reuse gasket.
FILLING
1. Remove filler plug and gasket. Fill with new oil until oil level reaches the specified limit near filler plug
mounting hole.
2. After refilling oil, check oil level. Set a gasket to filler plug, then install it to transmission case. Tighten filler
plug to the specified torque. Refer toMT-19, "
Case Components".
CAUTION:
Do no reuse gasket.
Checking M/T OilECS00ID4
OIL LEAKAGE AND OIL LEVEL
lMake sure that oil is not leaking from transmission or around it.
lCheck oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Do not start engine while checking oil level.
lSet a gasket on filler plug and install it to transmission case.
Tighten filler plug to the specified torque. Refer toMT-19, "
Case
Components".
CAUTION:
Do not reuse gasket.Oil grade and viscosity: Refer toMA-14, "
Fluids and Lubricants".
Oil capacity
2WD models:
Approx. 3.99 (7 Imp pt)
4WD models:
Approx. 4.32 (7-5/8 Imp pt)
PCIB0268E

MT-10
REAR OIL SEAL
REAR OIL SEAL
PFP:33140
Removal and InstallationECS00ID5
REMOVAL
For 2WD Models
1. Remove rear propeller shaft. Refer toPR-8, "Removal and Installation".
2. Remove dust seal and rear oil seal using a suitable tool.
CAUTION:
Do not damage rear extension.
For 4WD Models
1. Remove front and rear propeller shafts. Refer toPR-4, "Removal and Installation"(front) andPR-8,
"Removal and Installation"(rear).
2. Remove transfer assembly. Refer toTF-111, "
Removal and Installation".
3. Remove rear oil seal using the drift.
CAUTION:
Do not damage OD gear case.
LCIA0383E
PCIB1631E

REAR OIL SEAL
MT-11
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MT
INSTALLATION
Note the following, and install in the reverse order of removal.
lFor 2WD models
Drive the rear oil seal (1) and dust seal (2) using the drift.
CAUTION:
Do not incline the dust seal and rear oil seal during installa-
tion.
(A): Seal lip
lFor 4WD models
Drive the rear oil seal using the drift.
CAUTION:
Do not incline the rear oil seal during installation.
lCheck the transmission oil level after installation. Refer toMT-9,
"Checking M/T Oil". Tool number
For oil seal : ST33200000
For dust seal : KV38100500
Dimension “H
1”: 1.2 - 2.2 mm (0.047 - 0.087 in)
Dimension “H
2”: 0.5 - 1.5 mm (0.020 - 0.059 in)
PCIB1660E
Tool number : ST33200000
Dimension “A”: -0.5 - 0.5 mm (-0.020 - 0.020 in)
PCIB1632E

MT-12
POSITION SWITCH
POSITION SWITCH
PFP:32005
CheckingECS00ID6
BACK-UP LAMP SWITCH
lCheck continuity.
PARK/NEUTRAL POSITION (PNP) SWITCH
lCheck continuity.
Gear position Continuity
Reverse Yes
Except reverse No
PCIB1633E
Gear position Continuity
Neutral Yes
Except neutral No

SHIFT CONTROL
MT-13
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SHIFT CONTROLPFP:34103
Removal and InstallationECS00ID7
COMPONENTS
REMOVAL
1. Remove console boot. Refer toIP-14, "CONSOLE BOOT M/T".
2. Remove shift knob.
3. Remove cover mounting bolts and then remove cover, control lever boot and insulator.
4. Remove clip (B) and then separate boot from control housing.
5. Remove guide plate mounting bolts and then separate guide plate.
6. Remove control lever assembly and spring from the transmission.
INSTALLATION
Note the following, and install in the reverse order of removal.
1. Cover 2. Control lever boot 3. Insulator
4. Shift knob 5. Control lever assembly 6. Clip (A)
7. Boot 8. Guide plate 9. Socket
10. Bushing 11. Clip (B) 12. Spring
PCIB1634E