NISSAN PATROL 1998 Y61 / 5.G Manual Transmission Workshop Manual

MANUAL TRANSMISSION
SECTION
MT
CONTENTS
PREPARATION................................................................1
Special Service Tools ..................................................1
Commercial Service Tools ...........................................2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................3
NVH Troubleshooting Chart.........................................3
ON-VEHICLE SERVICE..................................................4
Replacing Rear Oil Seal ..............................................4
Position Switch Check .................................................4
REMOVAL AND INSTALLATION....................................5
Removal .......................................................................5
Installation ....................................................................6
DESCRIPTION.................................................................7
Cross-sectional View ...................................................7
AIR BREATHER..............................................................8
Air Breather Piping ......................................................8
MAJOR OVERHAUL.......................................................9Case Components .......................................................9
Gear Components .....................................................10
Shift Control Components .........................................12
DISASSEMBLY..............................................................13
Case Components .....................................................13
Shift Control Components .........................................14
Gear Components .....................................................15
INSPECTION..................................................................19
Shift Control Components .........................................19
Gear Components .....................................................19
ASSEMBLY....................................................................21
Gear Components .....................................................21
Shift Control Components .........................................29
Case Components .....................................................29
SERVICE DATA AND SPECIFICATIONS (SDS)..........32
General Speci®cations ...............................................32
Inspection and Adjustment ........................................33
MT

Special Service Tools
Tool number
Tool nameDescription
ST23540000
Pin punch
NT442
Removing and installing retaining pin
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.
ST30031000
Puller
NT411
Removing 1st & 2nd synchronizer assembly
Removing counter gear rear thrust bearing
Removing main drive gear bearing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.
ST33230000
Drift
NT084
Removing mainshaft and counter gear
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.
ST22350000
Drift
NT065
Removing and installing mainshaft rear bear-
ing
Removing counter gear front bearing
(Use with KV38100300)
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.
KV38100300
Drift
NT065
Removing counter gear front bearing
(Use with ST22350000)
Installing counter gear rear bearing
a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.
ST30720000
Drift
NT115
Removing mainshaft front bearing
Installing mainshaft front bearing
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST33210000
Drift
NT084
Installing counter gear front bearing
Installing front cover oil seal
a: 44 mm (1.73 in) dia.
b: 24.5 mm (0.965 in) dia.
ST30613000
Drift
NT073
Installing main drive gear bearing
a: 71.5 mm (2.815 in) dia.
b: 47.5 mm (1.870 in) dia.
PREPARATION
MT-1

Tool number
Tool nameDescription
ST37750000
Drift
NT065
Removing and installing mainshaft
rear bearing
Removing counter gear rear bearing
Installing OD gear bushing
Installing reverse cone
Installing reverse counter gear
Installing counter gear rear end bearing
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.
ST22452000
Drift
NT065
Installing reverse hub
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
Commercial Service Tools
Tool name Description
Puller
NT077
Removing counter gear rear end bearing
Removing reverse synchronizer hub
Removing reverse counter gear
Drift
NT065
V1Installing sub-gear snap ring
V2Installing OD main gear
V1a: 44.5 mm (1.752 in) dia.
b: 38.5 mm (1.516 in) dia.
V2a: 44.5 mm (1.752 in) dia.
b: 40.5 mm (1.594 in) dia.
PREPARATION
Special Service Tools (Cont'd)
MT-2

NVH Troubleshooting Chart
Use the chart below to help you ®nd the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference page
FS5R30A
Refer to MA section (``Checking M/T Oil'',
``CHASSIS AND BODY MAINTENANCE'').
MT-9
MT-9
MT-12
MT-12
MT-10
MT-10
MT-10
MT-10
SUSPECTED PARTS (Possible cause)
Transmission model
OIL (Level low)
OIL (Wrong)
OIL (Level too high)
LIQUID GASKET (Damaged)
OIL SEAL (Worn or damaged)
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)
SymptomNoise 1 2 3 3
Oil leakage3122
Hard to shift or will not shift 1 1 2 2
Jumps out of gear 1 2 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING
MT-3

Replacing Rear Oil Seal
REMOVAL
1. Remove transfer assembly. Ð Refer to TF section.
2. Pull out rear oil seal.
INSTALLATION
1. Install rear oil seal.
+Before installing apply multi-purpose grease to seal lip.
2. Install transfer assembly. Ð Refer to TF section.
Position Switch Check
Switch Gear position Continuity
Reverse position switchReverse Yes
Except reverse No
Neutral position switchNeutral Yes
Except neutral No
SMT321B
SMT322B
SMT274D
ON-VEHICLE SERVICE
MT-4

Removal
1. Remove front and rear propeller shafts. Refer to PD section
(``Removal and Installation'', ``PROPELLER SHAFT'').
2. Remove clutch operating cylinder.
3. Remove exhaust front and rear tubes. Refer to FE section
(``EXHAUST SYSTEM'').
4. Disconnect vehicle speed sensor, back-up lamp switch, 4WD
switch and neutral position switch harness connector.
5. Remove center brake cable. Refer to BR section.
6. Remove shift lever of transmission. Refer to MT-12 (RS5R30A).
7. Remove transfer control lever. Refer to TF section (``Removal'',
``REMOVAL AND INSTALLATION'').
8. Support engine by placing a jack under oil pan.
+Do not place jack under the oil pan drain plug.
9. Remove transmission with transfer from engine.
WARNING:
Support Manual Transmission with transfer, while removing it.
SMT321D
REMOVAL AND INSTALLATION
MT-5

Installation
+Apply sealant as below:
+Tighten bolts securing transmission.
Bolt No. Tightening torque Nzm (kg-m, ft-lb)!mm (in)
V139 - 49 (4.0 - 5.0, 29 - 36) 79 (3.11)
V239 - 49 (4.0 - 5.0, 29 - 36) 85 (3.35)
V329 - 39 (3.0 - 4.0, 22 - 29) 79 (3.11)
V429 - 39 (3.0 - 4.0, 22 - 29) 57 (2.24)
V529 - 39 (3.0 - 4.0, 22 - 29) 50 (1.97)
Gusset to engine 29 - 39 (3.0 - 4.0, 22 - 29) 35 (1.38)
SMT550D
SMT322D
REMOVAL AND INSTALLATION
MT-6

Cross-sectional View
SMT320D
DESCRIPTION
MT-7

Air Breather Piping
SMT546D
AIR BREATHER
MT-8

Case Components
SMT544D
MAJOR OVERHAUL
MT-9