Infiniti G20 (P11). Manual — part 483

MANUAL TRANSAXLE

SECTION

MT

CONTENTS

PREPARATION . . . . . . . . . . . . . . . ...2

Special Service Tools . . . . . . . . . . . . ..2
Commercial Service Tools . . . . . . . . . . ...4

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

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

DESCRIPTION . . . . . . . . . . . . . . . . .7

Cross-sectional View . . . . . . . . . . . . ...7

DOUBLE-CONE SYNCHRONIZER

. . . . . . . ..8

ON-VEHICLE SERVICE . . . . . . . . . . . . ..9

Replacing Oil Seal . . . . . . . . . . . . . ...9

DIFFERENTIAL OIL SEAL

. . . . . . . . . . ..9

STRIKING ROD OIL SEAL

. . . . . . . . . . .9

Position Switch Check . . . . . . . . . . . ...10

BACK-UP LAMP SWITCH

. . . . . . . . . . 10

PNP SWITCH

. . . . . . . . . . . . . . ..10

Viscous Coupling Check. . . . . . . . . . . 11

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

Removal. . . . . . . . . . . . . . . . . .12
Installation. . . . . . . . . . . . . . . . ..14

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

Transaxle Gear Control . . . . . . . . . . . .15
Case Components . . . . . . . . . . . . . .16
Gear Components . . . . . . . . . . . . . .17
Shift Control Components . . . . . . . . . . .18
Final Drive Components . . . . . . . . . . . 19

DISASSEMBLY. . . . . . . . . . . . . . . ..20

Transaxle Case. . . . . . . . . . . . . . ..20
Clutch Housing . . . . . . . . . . . . . . ..22

REPAIR FOR COMPONENT PARTS . . . . . . ...26

Input Shaft and Gears . . . . . . . . . . . ...26

DISASSEMBLY

. . . . . . . . . . . . . . 26

INSPECTION

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

ASSEMBLY

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

Mainshaft and Gears . . . . . . . . . . . . .31

DISASSEMBLY

. . . . . . . . . . . . . . 31

INSPECTION

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

ASSEMBLY

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

Final Drive. . . . . . . . . . . . . . . . ..39

PRE-INSPECTION

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

DISASSEMBLY

. . . . . . . . . . . . . . 40

INSPECTION

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

ASSEMBLY

. . . . . . . . . . . . . . . .42

Shift Control Components . . . . . . . . . . .45

INSPECTION

. . . . . . . . . . . . . . ...45

ASSEMBLY. . . . . . . . . . . . . . . . . 46

Clutch Housing . . . . . . . . . . . . . . ..46
Transaxle Case. . . . . . . . . . . . . . ..50

SERVICE DATA AND SPECIFICATIONS (SDS) . . .56

General Specifications. . . . . . . . . . . ...56

TRANSAXLE

. . . . . . . . . . . . . . ...56

FINAL GEAR

. . . . . . . . . . . . . . ...56

Gear End Play . . . . . . . . . . . . . . ...57
Clearance Between Baulk Ring and Gear . . . . 57

3RD, 4TH, 5TH, REVERSE BAULK RING

. . . . ..57

1ST AND 2ND BAULK RING

. . . . . . . . . 57

Available Snap Rings . . . . . . . . . . . . 57

SNAP RING

. . . . . . . . . . . . . . . .57

Available C-rings. . . . . . . . . . . . . . 58

4TH INPUT GEAR C-RING

. . . . . . . . . ...58

5TH INPUT GEAR REAR C-RING

. . . . . . . .58

MAINSHAFT C-RING

. . . . . . . . . . . ...58

Available Adjusting Shims . . . . . . . . . . .59

INPUT SHAFT REAR BEARING ADJUSTING
SHIM

. . . . . . . . . . . . . . . . . ..59

MAINSHAFT ADJUSTING SHIM

. . . . . . . . 60

MAINSHAFT REAR BEARING ADJUSTING SHIM

. ..60

Available Thrust Washer. . . . . . . . . . . 61

MAINSHAFT THRUST WASHER

. . . . . . . ...61

Available Washers . . . . . . . . . . . . . .61

DIFFERENTIAL SIDE GEAR THRUST WASHER

. . 61

Available Shims - Differential Side Bearing
Preload and Adjusting Shim . . . . . . . . . ..62

BEARING PRELOAD

. . . . . . . . . . . ...62

DIFFERENTIAL SIDE BEARING ADJUSTING
SHIMS

. . . . . . . . . . . . . . . . . 62

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

Special Service Tools

NCMT0001

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.)
Tool name

Description

KV38107700
(J39027)
Preload adapter

NT087

Measuring turning torque of final drive assembly
Measuring total turning torque
Measuring clearance between side gear and differ-
ential case with washer
Selecting differential side bearing adjusting shim
[Use with KV38106000 (J34291-A).]

KV38106000
(J34291-A)
Height gauge adapter
(differential side bearing)

NT418

Selecting differential side bearing adjusting shim
[Use with KV38107700 (J39027).]
a: 140 mm (5.51 in)
b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
d: M8

×

1.25P

KV32101000
(J25689-A)
Pin punch

NT410

Removing and installing retaining pin
Removing and installing lock pin
Removing selector shaft
Removing welch plug
a: 4 mm (0.16 in) dia.

KV31100300
(J25689-A)
Pin punch

NT410

Removing and installing retaining pin
a: 4.5 mm (0.177 in) dia.

ST30031000
(J22912-01)
Puller

NT411

Removing 3rd, 5th input gear
Removing 3rd & 4th and 5th & Rev synchronizer
hub
Removing mainshaft rear bearing
Removing 2nd gear, 5th gear bush
Removing 1st & 2nd synchronizer hub, 1st and
4th main gear
Removing and installing differential side bearing
a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.

ST30021000
(J22912-01)
Puller

NT411

Removing input shaft front and rear bearing
Installing input shaft front and rear bearing
Installing 5th input gear, 3rd main gear and 4th
main gear
Installing 1st & 2nd, 3rd & 4th and 5th & Rev syn-
chronizer hub
Installing 2nd gear bush, 5th gear bush, Rev gear
bush
Installing mainshaft rear bearing
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.

PREPARATION

Special Service Tools

MT-2

Tool number
(Kent-Moore No.)
Tool name

Description

ST33061000
(J8107-2)
Drift

NT073

Removing differential side bearing
a: 39 mm (1.54 in) dia.
b: 29.5 mm (1.16 in) dia.

ST33290001
(J34286)
Puller

NT414

I

Removing idler gear bearing outer race

a: 250 mm (9.84 in)
b: 160 mm (6.30 in)

ST33230000
(J25805-01)
Drift

NT084

Removing differential oil seal
Installing differential side bearing
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia.

ST30720000
(J25405)
Drift

NT115

Installing differential side bearing outer race
(F70A and clutch housing side of F70V)
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.

ST22350000
(J25678-01)
Drift

NT065

Installing input shaft front and rear bearing
a: 34 mm (1.34 in) dia.
b: 28 mm (1.10 in) dia.

ST22452000
(J34335)
Drift

NT065

Installing 3rd and 4th main gear
Installing 5th gear bush
Installing 5th & Rev synchronizer hub
Installing Rev gear bush
Installing mainshft rear bearing
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.

ST37750000
(J34335)
Drift

NT065

Installing input shaft oil seal
Installing 5th synchronizer
Installing mainshaft rear bearing
Installing 5th main gear
Installing 3rd & 4th synchronizer hub
Installing striking rod oil seal
Installing clutch housing dust seal
a: 40 mm (1.57 in) dia.
b: 31 mm (1.22 in) dia.

GI

MA

EM

LC

EC

FE

CL

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

PREPARATION

Special Service Tools (Cont’d)

MT-3

Tool number
(Kent-Moore No.)
Tool name

Description

ST30621000
(J35869)
Drift

NT073

Installing differential side bearing outer race
[Use with ST30611000 (J25742-1).]
(F70A and clutch housing side of F70V)
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.

ST30611000
(J25742-1)
Drift handle

NT419

Installing differential side bearing outer race
[Use with ST30621000 (J35869).]
a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 in) dia.
d: M12

×

1.5P

Commercial Service Tools

NCMT0002

Tool name

Description

Drift

NT065

Installing differential side bearing inner race
(F70A and except viscos coupling side of F70V)
a: 56 mm (2.20 in) dia.
b: 50.5 mm (1.988 in) dia.

Drift

NT065

Installing differential oil seal
(F70V transaxle case side)
a: 94 mm (3.70 in) dia.
b: 72 mm (2.83 in) dia.

Drift

NT065

Installing differential side bearing outer race
(F70V viscous coupling side)
a: 104 mm (4.09 in) dia.
b: 98 mm (3.86 in) dia.

Drift

NT065

Installing differential side bearing inner race
(F70V viscous coupling side)
a: 91 mm (3.58 in) dia.
b: 81 mm (3.19 in) dia.

Drift

NT065

Removing input shaft rear bearing
Removing mainshaft rear bearing
a: 22 mm (0.87 in) dia.
b: 16 mm (0.63 in) dia.

Drift

NT065

Installing differential oil seal
(Transaxle case side of F70A and clutch housing
side of F70V)
a: 58 mm (2.28 in) dia.
b: 50 mm (1.97 in) dia.

PREPARATION

Special Service Tools (Cont’d)

MT-4