main NISSAN PATROL 2006 Service Manual

Shift Control Components
+Check contact surface and sliding surface for wear, scratches,
projections or other damage.
Gear Components
GEARS AND SHAFTS
+Check shafts for cracks, wear or bending.
+Check gears for excessive wear, chips or cracks.
SYNCHRONIZERS
+Check spline portion of coupling sleeves, hubs, and gears for
wear or cracks.
+Check baulk rings for cracks or deformation.
+Check shifting inserts for wear or deformation.
+Check insert springs for deformation.
+Measure wear of main drive, 1st and OD baulk rings.
Clearance between baulk ring and gear:
Refer to SDS, MT-33.
+If the clearance is smaller than the wear limit, replace baulk
ring.
SMT398A
SMT386A
SMT423A
SMT427C
SMT140
INSPECTION
MT-19

Gear Components
1. Install bearings into case components.
2. Install main drive gear bearing.
a. Press main drive gear bearing.
b. Select proper main drive gear snap ring to minimize clearance
of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Main drive gear snap ring:
Refer to SDS, MT-33.
c. Install selected snap ring on main drive gear.
3. Install components on counter gear.
a. Install sub-gear components.
+When installing sub-gear snap ring, tap sub-gear snap ring
into position on counter gear.
SMT484CB
SMT425AA
SMT426A
SMT577AA
ASSEMBLY
MT-21

b. Install counter gear rear thrust bearing.
4. Install front side components on mainshaft.
a. Assemble 1st & 2nd synchronizer.
b. Assemble 3rd & 4th synchronizer.
c. Press on 3rd & 4th synchronizer assembly together with 3rd
main gear and 3rd gear needle bearing.
+Pay attention to direction of synchronizer assembly.
d. Select proper snap ring to minimize clearance of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Mainshaft front snap ring:
Refer to SDS, MT-33.
e. Install selected snap ring on mainshaft.
SMT405A
SMT614B
SMT615B
SMT399A
SMT400A
ASSEMBLY
Gear Components (Cont'd)
MT-22

f. Press on 1st & 2nd synchronizer assembly together with 2nd
main gear and 2nd gear needle bearing.
g. Press on 1st gear bushing using 1st gear washer.
h. Install 1st main gear and needle bearing.
i. Install steel ball and 1st gear washer.
+Apply multi-purpose grease to steel ball and 1st gear
washer before installing.
5. Select proper counter gear front bearing thrust washer when
replacing transmission case, counter gear, counter gear rear
thrust bearing or sub-gear components.
a. Install counter gear with sub-gear components, counter gear
front and rear bearing thrust washer on adapter plate.
b. Remove counter gear front bearing thrust washer from trans-
mission case.
c. Place adapter plate and counter gear assembly in transmission
case (case inverted).
SMT401A
SMT402A
SMT403A
SMT427AA
ASSEMBLY
Gear Components (Cont'd)
MT-23

b. Place dial indicator on front end of reverse idler shaft.
c. Put straightedge on front surface of OD gear case as a stop-
per of reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse
idler gear end play.
Reverse idler gear end play:
0.30 - 0.53 mm (0.0118 - 0.0209 in)
e. If not within speci®cation, replace reverse idler rear thrust
washer with the other (A or B) and check again.
7. Install mainshaft and counter gear on adapter plate and main
drive gear on mainshaft.
a. Mount adapter plate on vise and apply multi-purpose grease to
counter gear rear bearing.
b. Install mainshaft a little on mainshaft front bearing.
+To allow for installation of counter gear, do not install
mainshaft completely.
c. Install counter gear on counter gear rear bearing and install
main drive gear, pilot bearing and spacer on mainshaft.
SMT433A
SMT438A
SMT440A
SMT441A
ASSEMBLY
Gear Components (Cont'd)
MT-25

+When installing counter gear into counter gear rear
bearing, push up on upper roller of counter gear rear bear-
ing with screwdriver.
d. Install mainshaft and counter gear completely by tapping rear
side of adapter plate and pulling mainshaft.
8. Install rear side components on mainshaft and counter gear.
a. Install OD gear bushing while pushing on the front of counter
gear.
b. Install OD main gear.
+Pay attention to direction of OD main gear. (B is wider than
A as shown at left.)
c. Install adapter plate with gear assembly onto transmission
case.
d. Install OD gear needle bearing and then install OD counter gear
and reverse idler shaft.
e. Install reverse cone.
SMT442A
SMT443A
SMT444AA
SMT580AB
SMT582AA
ASSEMBLY
Gear Components (Cont'd)
MT-26

f. Install insert springs and reverse baulk ring on OD coupling
sleeve. Then install them and OD baulk ring on OD counter
gear.
+Pay attention to direction of OD coupling sleeve.
g. Install reverse counter gear.
h. Install reverse gear needle bearing and then install reverse
main gear, reverse idler gear and reverse idler thrust washers.
i. Install reverse hub and mainshaft spacer.
+Pay attention to direction of reverse hub.
j. Install counter gear rear end bearing.
k. Separate adapter plate from transmission case and mount
adapter plate on vice again.
SMT571AA
SMT583A
SMT584AA
SMT585AA
SMT828C
ASSEMBLY
Gear Components (Cont'd)
MT-27

l. Select proper mainshaft C-ring to minimize clearance of
groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Mainshaft C-ring:
Refer to SDS, MT-34.
m. Install selected C-ring, C-ring holder and mainshaft rear snap
ring.
n. Select proper counter gear rear snap ring to minimize clear-
ance of groove.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Counter gear rear snap ring:
Refer to SDS, MT-34.
o. Install selected counter gear rear snap ring.
p. Install reverse coupling sleeve.
+Pay attention to its direction.
q. Measure each gear end play as a ®nal check. Refer to
``DISASSEMBLY'', MT-15.
SMT829C
SMT830C
SMT831C
SMT832C
SMT833C
ASSEMBLY
Gear Components (Cont'd)
MT-28

7. Install stopper ring and main drive bearing snap ring.
8. Install front cover and gasket.
+Apply sealant to thread of 3 bolts shown left.
9. Apply sealant to mating surface of adapter plate.
10. Install OD gear case together with striking arm.
11. Install retaining pin into striking arm.
12. Install return spring and check ball and then install control hous-
ing.
+Apply sealant to mating surface of OD gear case.
SMT371A
SMT459A
SMT444B
SMT439B
SMT445B
ASSEMBLY
Case Components (Cont'd)
MT-30

General Speci®cations
Applied modelRD28ETi
4WD
Transmission FS5R30A
Number of speed 5
Transmission control Floor direct
Shift pattern
Synchromesh type Warner
Gear ratio
1st 4.061
2nd 2.357
3rd 1.490
4th 1.000
OD 0.862
Reverse 4.125
Number of teeth
Mainshaft
Drive 20
1st 32
2nd 30
3rd 28
OD 23
Reverse 30
Countershaft
Drive 33
1st 13
2nd 21
3rd 31
OD 44
Reverse 12
Reverse idler gear 22
Oil capacity!(Imp pt) 5.1 (9)
Remarks2nd & 3rd double baulk ring
type synchronizer
Reverse breaking mechanism type
SERVICE DATA AND SPECIFICATIONS (SDS)
MT-32