Nissan Qashqai (2007-2010). Manual — part 527

MAINSHAFT AND GEAR

TM-43

< DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

MAINSHAFT AND GEAR

Exploded View

INFOID:0000000001070453

Refer to

TM-25, "Exploded View"

Disassembly

INFOID:0000000001070454

CAUTION:

• Set mainshaft on the vise with back plate and remove gears.
• Disassemble gear components putting matching marks on the parts that do not affect any functions.

NOTE:
The the parts below underneath the 2nd, 3rd, and 4th main gears are fitted tightened. They will be systemati-
cally replaced during assemble.
• 1st inner baulk ring
• 1st synchronizer cone
• 1st outer baulk ring
• 2nd inner baulk ring
• 2nd synchronizer cone
• 2nd outer baulk ring

Remove the 3rd main gear and 3rd-4th synchronizer hub with
the press, resting underneath the 3rd main gear claw teeth.

Remove needle bearing and thrust washer.

Remove the 1st and 2nd main gears and 1st-2nd synchronizer
assembly with the press, resting underneath the 1st main gear.

Remove mainshaft front bearing inner race from mainshaft using
a suitable puller.

Assembly

INFOID:0000000001070455

CAUTION:

• When replacing the parts below, adjust mainshaft rear bearing preload. Refer to

TM-39, "Adjust-

ment"

- Mainshaft front bearing outer race
- Mainshaft front bearing inner race
- Mainshaft rear bearing inner race
- Mainshaft rear bearing outer race
- Clutch housing
- Transaxle case
- Mainshaft

MCIB0072E

MCIB0073E

TM-44

< DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

MAINSHAFT AND GEAR

• Place the new parts below on the hot plate. Heat them for 15

minutes with a thermostat setting of 150

C (302

F). The hot

plate with a setting of 150

C (302

F) should be used for

assemble.

- 1st inner baulk ring
- 1st synchronizer cone
- 1st outer baulk ring
- 2nd inner baulk ring
- 2nd synchronizer cone
- 2nd outer baulk ring

• Remove the parts below from the hot plate, using pliers. And

use a suitable tube with an internal diameter of 33 mm (1.30
in) to fit it on the mainshaft until it is resting on the synchro-
nizer hub.

- 1st inner baulk ring
- 1st synchronizer cone
- 1st outer baulk ring
- 2nd inner baulk ring
- 2nd synchronizer cone
- 2nd outer baulk ring

Install mainshaft front bearing inner race to mainshaft using a suitable drift.

CAUTION:

Replace mainshaft front bearing inner race and mainshaft front bearing outer race as a set.

Install 1st main gear to mainshaft using a suitable drift.

Apply gear oil to 1st inner baulk ring, 1st synchronizer cone, 1st outer baulk ring, 2nd inner baulk ring, 2nd
synchronizer cone, and 2nd outer baulk ring.

CAUTION:

• Replace 1st inner baulk ring, 1st synchronizer cone, and 1st outer baulk ring as a set.
• Replace 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring as a set.

Install 1st-2nd synchronizer hub assembly to mainshaft using a suitable drift.

CAUTION:

Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.

Install needle bearing, 2nd main gear, and thrust washer to mainshaft.

Install needle bearing and 3rd main gear to mainshaft.

Apply gear oil to 3rd baulk ring and then install it to mainshaft.

Install 3rd-4th synchronizer hub to mainshaft using a suitable drift.

Inspection

INFOID:0000000001070456

MAINSHAFT AND GEAR

Check items below. If necessary, replace them with new ones.
• Damage, peeling, dent, uneven wear, bending, and other non-

standard conditions of the shaft.

• Excessive wear, damage, peeling, and other non-standard condi-

tions of the gears.

NOTE:

MCIB0074E

MCIB0075E

SCIA1762J

MAINSHAFT AND GEAR

TM-45

< DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

The inspection focuses mainly on the appearance of the teeth,
especially in terms of claw chamfers.

- Check that the teeth (A) are not broken or chipped.
- Check that the claws (B) are not broken, chipped or worn.
- Check that the cone (C) shows no scratches or blueness.

SYNCHRONIZER

Synchronizer Hub and Coupling Sleeve

• Make sure the coupling sleeve turns smoothly in the synchronizer

hub.

• Check that the springs or insert keys are in good condition.
• The synchronizer hub teeth and the claws should not be chipped

or excessively worn.

• Also ensure that there are no signs of grating or abnormal wear on

the surfaces of the coupling sleeves or the inner walls of the syn-
chronizer hubs.

• It is advisable to mark the position of the coupling sleeves in rela-

tion to the hub.

Baulk Ring

Check that the grooves and ridges on the ring are not worn or dam-
aged. Otherwise, replace the baulk ring.
• Check that put the baulk ring onto the gear cone.
• Check that rotate the baulk ring while applying force in the direc-

tion of the cone (1).

• Check that the baulk ring should lock against the cone.

BEARING

If the bearings does not rotate smoothly of the contact surface on
ball or race is damaged or peeled, replace with new ones.

JPDIC0099ZZ

MCIB0020E

JPDIC0100ZZ

MCIB0017E

TM-46

< DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F92R]

REVERSE IDLER SHAFT AND GEAR