Nissan Silvia. Manual — part 297

MANUAL TRANSMISSION

SECTION

MT

CONTENTS

PREPARATION . . . . . . . . . . . . . . . ...3

Special Service Tools . . . . . . . . . . . . ..3
Commercial Service Tools . . . . . . . . . . ...5

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . . . .6

NVH Troubleshooting Chart. . . . . . . . . . .6

MANUAL TRANSMISSION

. . . . . . . . . . ..6

M/T OIL . . . . . . . . . . . . . . . . . . . 7

Checking M/T Oil . . . . . . . . . . . . . . .7
Changing M/T Oil. . . . . . . . . . . . . . .7

ON-VEHICLE SERVICE . . . . . . . . . . . . ..8

Replacing Rear Oil Seal . . . . . . . . . . . ..8

REMOVAL

. . . . . . . . . . . . . . . . .8

INSTALLATION

. . . . . . . . . . . . . . ..8

Position Switch Check . . . . . . . . . . . . .8

DESCRIPTION . . . . . . . . . . . . . . . . .9

Cross-sectional View . . . . . . . . . . . . ...9
Triple Cone Synchronizer . . . . . . . . . . ..10

SHIFT CONTROL . . . . . . . . . . . . . . .. 11

Components. . . . . . . . . . . . . . . ... 11

REMOVAL AND INSTALLATION . . . . . . . . .12

Removal. . . . . . . . . . . . . . . . . .12
Installation. . . . . . . . . . . . . . . . ..13
Air Breather Hose . . . . . . . . . . . . . ..14

OVERHAUL . . . . . . . . . . . . . . . . ...15

Transmission Components . . . . . . . . . . 15

REPAIR FOR COMPONENT PARTS . . . . . . ...16

Rear Extension . . . . . . . . . . . . . . ..16

COMPONENTS

. . . . . . . . . . . . . ...16

REMOVAL

. . . . . . . . . . . . . . . ...16

INSTALLATION

. . . . . . . . . . . . . . 16

DISASSEMBLY

. . . . . . . . . . . . . . 17

ASSEMBLY

. . . . . . . . . . . . . . . .17

Transmission Case . . . . . . . . . . . . . 18

COMPONENTS

. . . . . . . . . . . . . ...18

REMOVAL

. . . . . . . . . . . . . . . ...19

INSTALLATION

. . . . . . . . . . . . . . 20

Counter Gear Bearing . . . . . . . . . . . ...23

DISASSEMBLY AND ASSEMBLY

. . . . . . . ..23

6th Coupling Sleeve and Synchronizer Hub . . . .24

DISASSEMBLY AND ASSEMBLY

. . . . . . . ..24

INSPECTION

. . . . . . . . . . . . . . ...24

Mainshaft Bearing Retainer . . . . . . . . . ...24

DISASSEMBLY AND ASSEMBLY

. . . . . . . ..24

6th Counter Gear and Baulk Ring. . . . . . . .25

INSPECTION

. . . . . . . . . . . . . . ...25

Clutch Housing . . . . . . . . . . . . . . ..25

COMPONENTS

. . . . . . . . . . . . . ...25

REMOVAL

. . . . . . . . . . . . . . . ...25

INSTALLATION

. . . . . . . . . . . . . . 27

Front Cover. . . . . . . . . . . . . . . . 28

REMOVAL AND INSTALLATION

. . . . . . . ...28

DISASSEMBLY

. . . . . . . . . . . . . . 28

ASSEMBLY

. . . . . . . . . . . . . . . .29

Reverse Idler Gear . . . . . . . . . . . . . 29

INSPECTION

. . . . . . . . . . . . . . ...29

Main Drive Gear . . . . . . . . . . . . . . 29

REMOVAL AND INSTALLATION

. . . . . . . ...29

DISASSEMBLY

. . . . . . . . . . . . . . 29

INSPECTION

. . . . . . . . . . . . . . ...30

ASSEMBLY

. . . . . . . . . . . . . . . .30

Mainshaft . . . . . . . . . . . . . . . . ...31

REMOVAL AND INSTALLATION

. . . . . . . ...31

INSPECTION BEFORE DISASSEMBLY

. . . . . .31

DISASSEMBLY

. . . . . . . . . . . . . . 32

INSPECTION

. . . . . . . . . . . . . . ...32

ASSEMBLY

. . . . . . . . . . . . . . . .34

Counter Gear . . . . . . . . . . . . . . . .36

REMOVAL AND INSTALLATION

. . . . . . . ...36

INSPECTION BEFORE DISASSEMBLY

. . . . . .36

DISASSEMBLY

. . . . . . . . . . . . . . 37

INSPECTION

. . . . . . . . . . . . . . ...38

ASSEMBLY

. . . . . . . . . . . . . . . .39

Shift Fork and Fork Rod . . . . . . . . . . . 40

REMOVAL AND INSTALLATION

. . . . . . . ...40

DISASSEMBLY AND ASSEMBLY

. . . . . . . ..41

INSPECTION

. . . . . . . . . . . . . . ...41

SERVICE DATA AND SPECIFICATIONS (SDS) . . .42

General Specifications. . . . . . . . . . . ...42
Gear End Play and Oil Clearance. . . . . . . .42
Clearance Between Baulk Ring and Gear . . . . 43

GI

MA

EM

LC

EC

FE

CL

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

Available Snap Ring . . . . . . . . . . . . ..43

MAIN DRIVE GEAR SNAP RING

. . . . . . . ..43

COUNTER FRONT BEARING SNAP RING

. . . . 43

4TH COUNTER GEAR FRONT SNAP RING

. . . ..43

COUNTER DRIVE GEAR SNAP RING

. . . . . ..43

5TH & REVERSE SYNCHRONIZER HUB SNAP
RING

. . . . . . . . . . . . . . . . . ..44

6TH MAIN GEAR REAR SNAP RING

. . . . . . 44

6TH SYNCHRONIZER HUB SNAP RING

. . . . ...44

CONTENTS

(Cont’d)

MT-2

Special Service Tools

NMMT0001

Tool number
Tool name

Description

ST23540000
Pin punch

NT442

Removing and installing retaining pin
a: 2.3 mm (0.091 in) dia.
b: 4 mm (0.16 in) dia.

KV32103100
Spring pressure

SMT066E

Removing and installing bearing retainer spring

KV381054S0
Puller

NT414

Removing rear extension oil seal
a: 250 mm (9.84 in)
b: 160 mm (6.30 in)

ST33230000
Drift

NT084

Removing and installing counter gear bearing
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.

ST23860000
Drift

NT065

Installing 6th clutch hub
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.

KV32102700
Drift

SMT067E

Installing the following:

I

Main drive gear bearing

I

5th & reverse coupling sleeve, synchronizer hub,

or reverse main gear

I

Mainshaft bearing

I

6th main gear

a: 54 mm (2.13 in) dia.
b: 32 mm (1.26 in) dia.
c: 410 mm (16.14 in)

ST30032000
Drift

SMT068E

Installing the following:

I

Main drive gear bearing

I

5th & reverse coupling sleeve, synchronizer hub,

or reverse main gear

I

Mainshaft bearing

I

6th main gear

a: 38 mm (1.50 in) dia.
b: 80 mm (3.15 in) dia.

GI

MA

EM

LC

EC

FE

CL

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

PREPARATION

Special Service Tools

MT-3

Tool number
Tool name

Description

ST37830000
Drift

NT084

Installing rear extension oil seal
a: 62 mm (2.44 in) dia.
b: 39 mm (1.54 in) dia.

ST30621000
Drift

NT073

Installing main drive gear bearing
(Use with ST35325000)
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.

ST35325000
Drift handle

NT416

Use with ST30621000
a: 15 mm (0.59 in)
b: 215 mm (8.46 in)
c: 25 mm (0.98 in) dia.
d: M12

×

1.5P

ST33061000
Drift

NT073

Front cover oil seal
a: 38 mm (1.496 in) dia.
b: 28.5 mm (1.122 in) dia.

KV40100621
Drift

NT086

Installing counter gear
a: 76 mm (2.99 in) dia.
b: 69 mm (2.72 in) dia.

ST20630000
Drift

NT405

Removing counter gear bearing
Removing counter gear
a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45 mm (1.77 in)

KV38102510
Drift

NT476

Installing reverse coupling sleeve and synchro-
nizer hub
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
c: 55 mm (2.17 in) dia.
d: 45 mm (1.77 in) dia.

ST22360002
Drift

NT065

Removing reverse coupling sleeve, synchronizer
hub and reverse main gear
a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.

PREPARATION

Special Service Tools (Cont’d)

MT-4