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Nissan Note E12. Manual - part 620

TM-38

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F91R]

TRANSAXLE ASSEMBLY

19. Install final drive (1) to clutch housing.
20. Install dowel pins (2) and magnet to clutch housing.

CAUTION:

Do not reuse dowel pins.

21. Install reverse gear to clutch housing, and then install retaining

pin to clutch housing, using suitable tool.

CAUTION:

Do not reuse retaining pin.

22. Install 1st-2nd shift fork to 1st-2nd fork rod, and then install

retaining pin to 1st-2nd shift fork.

CAUTION:

• Do not reuse retaining pin.

• Replace 1st-2nd fork rod and 1st-2nd shift fork as a set.

23. Set 1st-2nd fork rod assembly (1) onto mainshaft assembly (2),

and then install them to clutch housing.

24. Install lock pins (

) to clutch housing.

25. Install 3rd-4th shift fork to 3rd-4th fork rod, and then install

retaining pin to 3rd-4th shift fork.

CAUTION:

• Do not reuse retaining pin.

• Replace 3rd-4th fork rod and 3rd-4th shift fork as a set.

26. Install 3rd-4th fork rod assembly (1), 3rd-4th coupling sleeve (2),

and input shaft assembly (3) to clutch housing.

a. Pull 1st-2nd fork rod (4) up, and then maintain the neutral posi-

tion.

b. Set 3rd-4th fork rod assembly onto 3rd-4th coupling sleeve, and

then install them together with input shaft assembly to clutch

housing.

CAUTION:

• Set lock pin (3rd-4th fork rod side) onto 1st-2nd fork rod

groove and then install 3rd-4th fork rod assembly.

PCIB1533E

MCIB0033E

PCIB1532E

JPDIC0534ZZ

PCIB1628E

TRANSAXLE ASSEMBLY

TM-39

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F91R]

• Be careful with the orientation of 3rd-4th coupling sleeve.

• Install 3rd input gear of input shaft assembly so that it is

set under reverse main gear of 3rd-4th coupling sleeve.

• Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer

hub as a set.

c. Install springs and insert keys to 3rd-4th synchronizer hub.
d. Apply gear oil to 4th baulk ring.
e. Install 4th baulk ring.

27. Install 5th-reverse fork rod (1) to clutch housing.

CAUTION:

Replace 5th-reverse fork rod and 5th-reverse shift fork as a

set.

a. Pull gear of reverse gear (2) up.
b. Temporarily install 5th-reverse fork rod to clutch housing.

c. Press gear of reverse gear (1) down and then install 5th-reverse

fork rod (2) to clutch housing.

CAUTION:

Set levers of 5th-reverse fork rod so as to align with reverse
gear groove ( ).

28. Install 4th main gear (2) and spacer (1) to mainshaft.

CAUTION:

Install spacer so that spacer protrusion faces rear side of

transaxle.

29. Press 3rd-4th shift fork down and then shift 3rd-4th coupling

sleeve to 3rd gear side.

(A)

: 4th main gear side

(B)

: 3rd main gear side

PCIB1551E

MCIB0061E

PCIB1629E

PCIB1552E

PCIB1529E

TM-40

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F91R]

TRANSAXLE ASSEMBLY

30. Move the shifter lever A (1) to the 3rd gear position.

NOTE:

• If it is not moved to the 3rd gear position, transaxle case can-

not be installed to clutch housing.

• The 3rd gear position means that shifter lever A is fully rotated

clockwise and it is returned approximately 10 degrees.

31. Apply recommended sealant to transaxle case mating surface of

clutch housing.

CAUTION:

• Use Genuine Silicone RTV or equivalent. Refer to

GI-22,

• Do not allow old Silicone RTV, moisture, oil, or foreign

matter to remain on mating surface.

• Check that mating surface is not damaged.

• Apply a continuous bead of Silicone RTV to the mating surface.

32. Install transaxle case to clutch housing. If it is difficult to install,

slightly rotate shifter lever A counterclockwise, and then install.

CAUTION:

• Do not damage Silicone RTV bead with transaxle case or

other objects during installation.

• Be careful to align the lever of 5th-reverse fork rod with

reverse gear groove.

33. Rotate input shaft so that bearing and shaft fit each other, and

then tighten transaxle bolts (

) to the specified torque.

34. Apply recommended sealant to position switch thread and check

ball plug thread. Install to transaxle case and tighten to specified

torque.

CAUTION:

• Use Genuine Silicone RTV or equivalent. Refer to

GI-22,

• Do not allow old Silicone RTV, moisture, oil, or foreign

matter to remain on thread.

35. Apply gear oil to mainshaft spline.
36. Install 5th main gear (1) to mainshaft, using a suitable bolt (A)

[M10 x 1.0] and a suitable nut (B).

PCIB1524E

(1)

: Selector

(2)

: Shift fork

PCIB1553E

JPDIC0610ZZ

PCIB1554E

TRANSAXLE ASSEMBLY

TM-41

< UNIT DISASSEMBLY AND ASSEMBLY >

[5MT: RS5F91R]

37. Install adapter plate (1), bushing (2), and 5th input gear (3) to

input shaft.

CAUTION:

Be careful with the orientation of adapter plate.

38. Install 5th-reverse synchronizer hub, 5th-reverse coupling sleeve, and 5th-reverse shift fork.
a. Apply gear oil to 5th-reverse baulk ring.
b. Install 5th-reverse baulk ring (1) to 5th input gear.

CAUTION:

Be careful with the orientation of 5th-reverse baulk ring.

c. Install synchronizer levers (2) to 5th-reverse synchronizer hub

(3).

CAUTION:

• Replace 5th-reverse synchronizer hub and 5th-reverse

coupling sleeve as a set.

• Be careful with the orientation of synchronizer lever.

d. Install 5th-reverse synchronizer hub assembly and lock washer to input shaft.

CAUTION:

• Be careful with the orientation of 5th-reverse synchro-

nizer hub.

• Do not allow synchronizer lever (1) to overlap 5th-reverse

baulk ring protrusion (A).

: Transaxle case side

PCIB1555E

: 5th-reverse synchronizer hub side

: 5th input gear side

JPDIC0421ZZ

PCIB1556E

(2)

: 5th-reverse baulk ring

(3)

: 5th-reverse synchronizer hub

JPDIC0408ZZ

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