NISSAN NAVARA 2005 Repair Workshop Manual

MT-54
TRANSMISSION ASSEMBLY
lBe careful with the shape of 1st-2nd, 3rd-4th and 5th-6th
shifting insert to avoid misassembly.
c. Install snap ring to reverse synchronizer hub.
CAUTION:
lDo not reuse snap ring.
lDo not align the snap ring notch with synchronizer hub
groove when assembling.
d. Press in reverse synchronizer hub assembly, reverse baulk ring,
reverse main gear and reverse main needle bearing using the
drift and press plate.
CAUTION:
Apply gear oil to reverse baulk ring and reverse main nee-
dle bearing.
PCIB0608E
PCIB1237E
PCIB1422E

TRANSMISSION ASSEMBLY
MT-55
D
E
F
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H
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MA
B
MT
NOTE:
Reverse baulk ring has three spaces that two gear teeth are
missing, and each space has small ditch for identification as
showninthefigure.
26. Select and install a snap ring so that the end play comes within
the standard value. Refer toMT-68, "
Snap Rings".
CAUTION:
Do not reuse snap ring.
27. Press in reverse counter gear using the drift.
CAUTION:
Be careful with the orientation counter gear.
28. Select and install a snap ring so that the end play comes within
the standard value. Refer toMT-68, "
Snap Rings".
CAUTION:
Do not reuse snap ring.
29. Install reverse idler shaft assembly according to the following.
a. Install reverse idler needle bearing, reverse idler gear and reverse idler thrust washer to reverse idler
shaft.
CAUTION:
Apply gear oil to reverse idler needle bearing.
PCIB0168E
End play: 0 - 0.10 mm (0 - 0.004 in)
PCIB0225E
PCIB1423E
End play: 0 - 0.10 mm (0 - 0.004 in)
PCIB0226E

MT-56
TRANSMISSION ASSEMBLY
b. Install reverse idler shaft assembly to adapter plate.
Shift Control Components
1. Install main drive gear assembly, mainshaft assembly, counter gear assembly and reverse idler shaft
assembly. Refer toMT-44, "
Gear Components".
2. Install striking rod assembly according to the following.
a. Install striking rod assembly to adapter plate.
b. Install stopper ring to striking rod assembly.
c. Install retaining pin onto stopper ring using a pin punch.
CAUTION:
Do not reuse retaining pin.
3. Install 5th-6th fork rod (reversal side) according to the following.
a. Install 5th-6th shift fork to 5th-6th coupling sleeve.
b. Install 5th-6th fork rod (reversal side) to 5th-6th shift fork.
c. Install retaining pin onto 5th-6th shift fork using a pin punch.
CAUTION:
Do not reuse retaining pin.
PCIB1326E
PCIB1235E
PCIB1234E
PCIB0412E

TRANSMISSION ASSEMBLY
MT-57
D
E
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B
MT
4. Install 5th-6th control lever to adapter plate, and then tighten
mounting bolts to the specified torque. Refer toMT-23, "
Shift
Control Components".
CAUTION:
Install 5th-6th control lever with projection side at upward.
5. Install 5th-6th fork rod according to the following.
a. Install 5th-6th fork bracket and 5th-6th fork rod to adapter plate.
b. Install retaining pin onto 5th-6th fork bracket using a pin punch.
CAUTION:
Do not reuse retaining pin.
6. Install check balls to adapter plate.
CAUTION:
Apply gear oil to check ball.
7. Install reverse fork rod according to the following.
a. Install reverse shift fork to reverse coupling sleeve.
b. Install reverse fork rod to reverse shift fork.
c. Install retaining pin onto reverse shift fork using a pin punch.
CAUTION:
Do not reuse retaining pin.
PCIB1233E
PCIB0239E
PCIB0148E
SCIA1447E

MT-58
TRANSMISSION ASSEMBLY
8. Install interlock pin and interlock plunger to adapter plate.
CAUTION:
Apply gear oil to interlock pin and interlock plunger.
9. Install 1st-2nd fork rod according to the following.
a. Install 1st-2nd shift fork to 1st-2nd coupling sleeve.
b. Install 1st-2nd fork rod to 1st-2nd shift fork.
c. Install retaining pin onto 1st-2nd shift fork using a pin punch.
CAUTION:
Do not reuse retaining pin.
10. Install interlock pin and check balls to adapter plate.
CAUTION:
Apply gear oil to interlock pin and check ball.
11. Install 3rd-4th fork rod (reversal side) according to the following.
a. Install 3rd-4th shift fork to 3rd-4th coupling sleeve.
b. Install 3rd-4th fork rod (reversal side) to 3rd-4th shift fork.
c. Install retaining pin onto 3rd-4th shift fork using a pin punch.
CAUTION:
Do not reuse retaining pin.
12. Install 3rd-4th fork rod according to the following.
PCIB0147E
PCIB0602E
PCIB0146E
PCIB0601E

TRANSMISSION ASSEMBLY
MT-59
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a. Install 3rd-4th fork rod to adapter plate.
b. Install 3rd-4th fork rod bracket to 3rd-4th fork rod.
c. Install retaining pin onto 3rd-4th fork rod bracket using a pin
punch.
CAUTION:
Do not reuse retaining pin.
13. Install 3rd-4th control lever according to the following.
a. Install shifter cap to 3rd-4th control lever.
b. Install 3rd-4th control lever to adapter plate, and then tighten
mounting bolts to the specified torque. Refer toMT-23, "
Shift
Control Components".
CAUTION:
Be careful with the orientation 3rd-4th control lever.
14. Install check ball plugs according to the following.
a. Install check balls and check ball springs to adapter plate.
b. Apply recommended sealant to threads of check ball plugs, and
tighten check ball plugs to the specified torque. Refer toMT-23,
"Shift Control Components".
15. Install baffle plate to adapter plate, and then tighten mounting
bolt to the specified torque. Refer toMT-19, "
Case Components"
.
Case Components
1. Install main drive gear assembly, mainshaft assembly, counter gear assembly and reverse idler shaft
assembly. Refer toMT-44, "
Gear Components".
2. Install fork rods and shift forks. Refer toMT-56, "
Shift Control Components".
PCIB0145E
PCIB1232E
PCIB1231E
PCIB1325E

MT-60
TRANSMISSION ASSEMBLY
3. Install oil gutter to transmission case.
4. Install counter front bearing to transmission case.
CAUTION:
Apply multi-purpose grease to counter front bearing.
5. Apply recommended sealant to mating surface of transmission
case as shown in the figure.
CAUTION:
Remove old sealant adhering to the mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
both mating surfaces.
6. Install transmission case to adapter plate assembly.
7. Install snap ring to main drive gear bearing using a snap ring pli-
ers.
CAUTION:
Do not reuse snap ring.
PCIB1228E
PCIB0436E
PCIB1270E
PCIB1227E
SCIA1532E

TRANSMISSION ASSEMBLY
MT-61
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MT
8. Tighten baffle plate mounting nut to the specified torque. Refer
toMT-19, "
Case Components".
9. Tighten baffle plate mounting bolt to the specified torque. Refer
toMT-19, "
Case Components".
10. Install front cover oil seal to front cover using the drift.
CAUTION:
When installing, do not incline front cover oil seal.
11. Install front cover according to the following.
SCIA1443E
PCIB1271E
Dimension “A”: 8.55 - 9.55 (0.336 - 0.376 in)
PCIB1424E

MT-62
TRANSMISSION ASSEMBLY
a. Install front cover gasket and front cover to transmission case.
CAUTION:
lDo not reuse front cover gasket.
lRemove any moisture, oil, or foreign material adhering to
both mating surfaces.
lDo not damage front cover oil seal.
b. Temporary tightening 2 bolts in the positions shown in the fig-
ure.
c. Temporary tightening remaining 9 bolts.
d. Tighten bolts to the specified torque in order as shown on the
figure. Refer toMT-19, "
Case Components".
CAUTION:
Do not reuse bolts indicated as A in the figure.
12. Install washer to withdrawal lever ball pin, and then install it to
front cover. Tighten withdrawal lever ball pin to the specified
torque. Refer toMT-19, "
Case Components".
13. Install counter end bearing to rear extension (or OD gear case)
using a suitable drift [32 mm (1.26 in) dia.].
CAUTION:
Install counter end bearing with maker stamp at upper side.
PCIB1273E
PCIB1274E
PCIB1224E
Dimension “A”: 0.5 - 1.5 (0.020 - 0.059 in)
PCIB1636E

TRANSMISSION ASSEMBLY
MT-63
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MT
14. Install rear oil seal (1) to rear extension (or OD gear case) using
the drift.
CAUTION:
When installing, do not incline rear oil seal.
(B): Seal lip
15. Install dust seal (1) to rear extension using the drift (for 2WD
models).
CAUTION:
When installing, do not incline dust seal.
(B): Seal lip
16. Install rear extension oil gutter according to the following (for 2WD models).
a. Install cap to rear extension oil gutter.
b. Install rear extension oil gutter to rear extension, and then
tighten mounting bolt to specified torque. Refer toMT-19, "
Case
Components". Tool number A: ST33200000
Dimension “H
1”:
2WD models : 1.2 - 2.2 mm (0.047 - 0.087 in)
4WD models : -0.5 - 0.5 mm (-0.020 - 0.020 in)
SCIA7341E
Tool number A: KV38100500
Dimension “H
2”: 0.5 - 1.5 mm (0.020 - 0.059 in)
SCIA7342E
PCIB1221E