Nissan Pick-ups and Pathfinder 1989-1995

Transmission

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REMOVAL & INSTALLATION



See Figures 1 through 11

  1. Disconnect the negative battery cable.
  2.  
  3. If necessary, disconnect the accelerator linkage.
  4.  
  5. Raise the front of the truck and support it with jackstands.
  6.  
  7. Disconnect the exhaust pipe from the manifold and bracket, if necessary, to gain clearance for transmission removal.
  8.  
  9. Tag and disconnect any switches that are connected to the transmission case (back-up, neutral, top gear or overdrive).
  10.  
  11. Disconnect the speedometer cable where it attaches to the transmission.
  12.  
  13. Remove the driveshaft(s). Don't forget to plug the opening in the rear extension so that oil won't flow out.
  14.  
  15. Remove the clutch slave cylinder.
  16.  
  17. Remove the rubber boot and console box (if so equipped). Place the shift lever in neutral, remove the circlip and then remove the shifter. On 4wd models remove the transfer case shift lever also.
  18.  
  19. Support the engine by placing a jack under the oil pan with a wooden block used between the jack and the pan.
  20.  

Never position the jack directly under the oil pan drain plug.

  1. Support the transmission with a transmission jack.
  2.  
  3. Loosen the rear engine mount securing nuts temporarily and then remove the crossmember. On 4wd models, remove the torsion bar springs.
  4.  



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Fig. Fig. 1: Remove the torsion spring



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Fig. Fig. 2: Transmission-to-engine bolt locations-4-cylinder engines



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Fig. Fig. 3: Transmission-to-engine bolt locations-6-cylinder engines



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Fig. Fig. 4: Sealant application-4-cylinder engines



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Fig. Fig. 5: Sealant application-6-cylinder engines



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Fig. Fig. 6: Remove the bolts from the transmission gussets or brackets before removal of the assembly



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Fig. Fig. 7: View of engine-to-transmission supporting bracket-note location for proper installation



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Fig. Fig. 8: Remove the lower mounting bolt for the transfer case shifter lever



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Fig. Fig. 9: After removing the hold-down bolt remove, the transfer case lever



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Fig. Fig. 10: Remove the transmission retaining bolts with box-type wrench



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Fig. Fig. 11: Remove the clutch slave cylinder from the transmission assembly

  1. Lower the rear of the engine slightly to allow additional clearance.
  2.  
  3. Remove the starter electrical connections and the starter motor.
  4.  
  5. Remove the transmission-to-engine mounting bolts, lower the transmission (or transmission and transfer case assembly) and remove it toward the rear.
  6.  

To install:
  1. Install the transmission in the correct position. Tighten all the transmission-to-engine mounting bolts.
    1. On Z24i and KA24E engines, tighten the 4 longest bolts (65mm and 60mm) to 29-36 ft. lbs. (39-49 Nm); tighten the 2 shortest bolts (25mm and 16mm) to 14-18 ft. lbs. (19-25 Nm).
    2.  
    3. On VG30i and VG30E engines, tighten the 5 longest bolts (65mm and 60mm) to 29-36 ft. lbs. (39-49 Nm); tighten the 4 shortest bolts (55mm, 30mm and 16mm) to 22-29 ft. lbs. (29-39 Nm).
    4.  

  2.  
  3. Install the starter motor and electrical connections.
  4.  
  5. Install the crossmember assembly and tighten all retaining nuts to crossmember and rear engine mounts. Install the torsion bars on 4wd models.
  6.  
  7. Install the shifter(s). Install the rubber boot and console box if so equipped.
  8.  
  9. Install the clutch slave cylinder.
  10.  
  11. Install the driveshaft(s) and connect the speedometer cable.
  12.  
  13. Connect any switches that are connected to the transmission case (back-up, neutral, transfer switch).
  14.  
  15. Connect the exhaust pipe to the manifold and bracket if necessary.
  16.  
  17. Connect the accelerator linkage.
  18.  
  19. Connect the negative battery cable. Bleed the clutch hydraulic system if necessary. Road test the vehicle for proper operation.
  20.  

OVERHAUL



Model F4W71C (4-Speed) and Model FS5W71C (5-Speed)
DISASSEMBLY

See Figures 12 through 22

  1. Remove the control housing, check ball, return spring plug, select check plunger and return springs from the extension housing. Tap the housing lightly with a rubber mallet and remove it from the adapter plate (2wd) or overdrive case (4wd).
  2.  
  3. Remove the front cover, oil seal and gasket. Remove the countershaft front bearing shim and the main drive gear ball bearing snapring.
  4.  
  5. Tap the transmission case lightly with a rubber mallet and separate the case from the adapter plate.
  6.  
  7. Secure the adapter plate in a soft-jawed vise and then remove the check ball plugs, check springs and check balls.
  8.  
  9. Drive out the fork rod retaining pins. Lift out the fork rods and remove the interlock balls.
  10.  
  11. On 4wd models with a mainshaft braking mechanism, remove the lever bracket securing bolt.
  12.  
  13. On 4wd models, remove the 3-4 fork rod and then remove the overdrive-reverse fork rod. Rotate the OD-reverse bracket counterclockwise and then remove the fork shaft.
  14.  
  15. Measure the end-play at all gear assemblies:
    1. 1st gear: 0.31-0.41mm
    2.  
    3. 2nd and 3rd gears: 0.11-0.21mm
    4.  
    5. Overdrive (FS5W71C): 0.24-0.41mm
    6.  

  16.  
  17. Turn 2nd and reverse gears until they mesh and then remove the counter front bearing with a suitable puller.
  18.  
  19. Remove the sub-gear snapring and then slide the sub-gear bracket, spring and gear off the shaft.
  20.  
  21. Remove the counter drive gear along with the main drive gear assembly with a suitable puller. Be careful that the pilot bearing and baulk ring don't fall off.
  22.  
  23. Remove the snapring and then slide the 3-4 synchronizer (and 3rd gear) off the shaft.
  24.  
  25. For the FS5W71C, disassemble the rear of the adapter plate as follows:
    1. Release the staking and then loosen the countershaft and mainshaft nuts. The mainshaft nut is a left-hand thread.
    2.  
    3. Remove the OD counter gear and its bearing with a puller. Remove the reverse counter gear and spacer.
    4.  
    5. Remove the snaprings from the reverse idler shaft and then slide off the reverse idler gear, thrust washers and bearing.
    6.  
    7. On 2wd models, remove the snapring and slide the overdrive mainshaft bearing and snapring off the shaft.
    8.  
    9. Remove the mainshaft nut. Remember, it's a left-hand thread.
    10.  
    11. On 2wd models, remove the speedometer drive gear and and steel ball.
    12.  
    13. Remove the thrust washer, steel roller, roller bearing and washer.
    14.  
    15. Remove the OD main gear, needle bearing and baulk ring. Remove the OD coupling sleeve, shifting inserts and insert springs.
    16.  
    17. Tap the rear of the counter gear with a rubber mallet and remove it.
    18.  
    19. Press out the OD gear bushing, insert retainer and the OD synchronizer hub.

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      Fig. Fig. 12: Manual transmission case components-F4W71C and FS5W71C



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      Fig. Fig. 13: Manual transmission gear components-F4W71C



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      Fig. Fig. 14: Manual transmission gear components-FS5W71C



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      Fig. Fig. 15: Exploded view of a common manual transmission shift control assembly- 1989 FS5W71C shown



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      Fig. Fig. 16: Manual transmission shift control assembly- 1990 and later FS5W71C (2wd)



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      Fig. Fig. 17: Manual transmission shift control components- 1990 and later FS5W71C (4wd)



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      Fig. Fig. 18: Remove the E ring- FS5W71C (4wd)



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      Fig. Fig. 19: Measure the gear end-play-F4W71C and FS5W71C



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      Fig. Fig. 20: Install the oil gutter on the adapter plate-F4W71C and FS5W71C



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      Fig. Fig. 21: 3-4 synchronizer assembly-F4W71C and FS5W71C



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      Fig. Fig. 22: OD synchronizer assembly-FS5W71C

    20.  

  26.  
  27. For the F4W71C, disassemble the rear of the adapter plate as follows:
    1. Remove the snaprings, the speedometer drive gear and the steel ball.
    2.  
    3. Release the staking on the mainshaft nut and loosen it. Remove the mainshaft nut and slide it off the reverse main gear.
    4.  
    5. Remove the snapring at the rear of the countershaft and then remove the reverse counter gear.
    6.  
    7. Remove the reverse idler gear.
    8.  
    9. Tap the rear of the counter gear with a rubber mallet and slide it off the shaft.
    10.  
    11. Tap the rear of the mainshaft assembly with a rubber mallet and slide the assembly out of the adapter plate.
    12.  

  28.  
  29. Remove the thrust washer, steel ball and the 1st main gear with needle bearing.
  30.  
  31. Press the 1st mainshaft bushing together with the 2nd main gear with a suitable tool and then remove the 2nd gear needle bushing.
  32.  
  33. Remove the main drive gear bearing snapring and washer and then slide off the bearing.
  34.  

ASSEMBLY
  1. Install all bearings into the case components.
  2.  
  3. Install the oil gutter on the adapter plate so that it is expanded on the rear side. Insert the reverse shaft and then install the bearing retainer; tighten each screw and then stake at two points.
  4.  
  5. Press in the main drive gear bearing and install the spacer. Install a snapring so that the clearance of the groove is 0-0.14mm. Snaprings come in sizes from 1.73mm to 2.08mm.
  6.  
  7. Assemble the synchronizers.
  8.  
  9. Assemble the 2nd main gear, needle bearing and the 1-2 syncro assembly, then press the 1st gear bushing onto the mainshaft.
  10.  
  11. Coat the steel ball and thrust washer with grease and then install them and the 1st main gear to the mainshaft.
  12.  
  13. Install the counter rear bearing to the adapter plate.
  14.  
  15. Press the mainshaft assembly and the counter gear into the adapter plate.
  16.  
  17. Install the 3rd main gear and the 3-4 syncro assembly. Install the synchro assembly.
  18.  
  19. Install the mainshaft thrust washer and secure it with the proper size snapring. There should be minimal clearance in the groove.
  20.  
  21. Coat the pilot bearing with gear oil and install it on the mainshaft.
  22.  
  23. Press the counter drive gear (along with the main drive gear) onto the shaft.
  24.  
  25. Install the sub-gear and bracket on the counter drive gear and install a snapring that will minimize groove clearance. Snaprings come in 3 sizes; 1.4mm, 1.5mm and 1.6mm. Remove the snapring, sub-gear bracket and sub-gear from the counter gear and then reinstall them with the sub-gear spring between them.
  26.  
  27. Install the front bearing onto the counter gear.
  28.  
  29. Assemble the parts at the rear of the adapter plate.
  30.  
  31. Make sure that the 2nd and reverse gears are meshed and then tighten the locknut. On the FS5W71C, install a new countershaft locknut and tighten it. Stake both nuts with a punch.
  32.  
  33. Measure the gear end-play.
  34.  
  35. Install the shift rods, interlock plunger, interlock balls and check balls.
  36.  
  37. On 4wd models, rotate the OD-reverse bracket clockwise and install the fork shaft. Install the E-ring on the fork rod and then install the lever bracket bolt.
  38.  
  39. Coat the lip of a new oil seal with grease and install it in the front cover.
  40.  
  41. Apply sealant to the transmission case mating surface and then slide the gear assembly onto the adapter plate.
  42.  
  43. Apply sealant to the adapter plate mating surface and then install the extension housing. Install the main drive bearing snapring.
  44.  
  45. Install a counter front bearing shim. Install a new gasket and the front cover.
  46.  
  47. Install the return spring plugs, check ball, return springs and check plunger.
  48.  
  49. Install the control housing with a new gasket.
  50.  

Model FS5R30A (5-Speed)
DISASSEMBLY

See Figures 23 through 31

  1. Remove the check ball plug, check spring and check ball. Remove the interlock stopper. Don't let the check ball fall into the transmission case.
  2.  
  3. Remove the control housing, return spring and check ball.
  4.  
  5. Drive out the striking arm retaining pin with a punch.
  6.  
  7. Tap the extension housing (or OD case) lightly with a rubber mallet and remove it along with the striking arm.
  8.  
  9. Remove the front cover and its gasket.
  10.  
  11. Remove the stopper ring and the main drive bearing snapring.
  12.  
  13. Tap the transmission case lightly with a rubber mallet and remove it. Remove the front cover oil seal.
  14.  
  15. Mount the adapter plate in a soft-jawed vise and then remove the OD and reverse fork rod.
  16.  
  17. Drive the striking lever retaining pin out with a punch. While pulling out the striking rod, remove the lever and interlock. Then, remove 1-2 and 3-4 gears and the reverse shift fork.
  18.  
  19. Drive the OD shift fork retaining pin out with a punch, pull out the OD fork and then remove the OD shift fork.
  20.  
  21. Measure the end-play at each gear. It should be .0091-0.013 in. (0.23-0.33mm) at all gears except reverse, which should be 0.013-0.017 in. (0.33-0.43mm).
  22.  



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Fig. Fig. 23: Manual transmission case components-FS5R30A



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Fig. Fig. 24: Manual transmission gear components-FS5R30A



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Fig. Fig. 25: Manual transmission gear components-FS5R30A



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Fig. Fig. 26: Manual transmission shift control assembly-FS5R30A



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Fig. Fig. 27: Shim chart



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Fig. Fig. 28: 1-2 synchronizer assembly-FS5R30A



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Fig. Fig. 29: 3-4 synchronizer assembly-FS5R30A



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Fig. Fig. 30: Measure the countergear end-play-FS5R30A



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Fig. Fig. 31: Measure the reverse idler gear end-play-FS5R30A

  1. Remove the reverse coupling sleeve. Remove the snaprings from the rear of the mainshaft and counter gear.
  2.  
  3. Remove the C-ring holder and then the C-rings on the mainshaft. Use a hammer and punch.
  4.  
  5. Remove the mainshaft rear bearing on 2wd models.
  6.  
  7. Remove the reverse main gear along with the mainshaft spacer and the reverse synchronizer hub. Remove the reverse gear needle bearings.
  8.  
  9. Remove the reverse counter gear. Remove the OD coupling sleeve along with the OD and reverse baulk rings and the spring inserts.
  10.  
  11. Remove the reverse gear bushing. Remove the OD counter gear along with the reverse cone.
  12.  
  13. Press out the mainshaft and counter gear alternately.
  14.  
  15. From the mainshaft, remove the 1st gear washer and steel ball, 1st main gear and needle bearing. Remove the 2nd main gear along with the 1st gear bushing and the 1-2 syncro assembly. Remove the front snapring. Press out the 3rd main gear along with the 3-4 syncro assembly and the 3rd gear needle bearing.
  16.  
  17. From the counter gear, remove the rear thrust bearing and the sub-gear components.
  18.  
  19. Remove the main drive gear snapring and washer and the remove the bearing itself.
  20.  

ASSEMBLY
  1. Install all bearing into the case components. Install the main drive gear bearing and snapring so that the groove clearance is 0-0.1mm. Snaprings come in sizes ranging from 1.89mm to 2.19mm.
  2.  
  3. Install the components on the counter gear. Remember to tap the sub-gear snapring into place on the counter gear.
  4.  
  5. Assemble the 1-2 and 3-4 synchronizers. Install the 3-4 syncro assembly together with the 3rd main gear and needle bearing onto the mainshaft.
  6.  
  7. Press the 1-2 syncro assembly along with the 2nd main gear and needle bearing onto the mainshaft.
  8.  
  9. Press the 1st gear bushing and washer, the 1st main gear and needle bearing, the steel ball and the 1st gear washer onto the mainshaft.
  10.  
  11. Install the counter gear along with the sub-gear components and the thrust washers onto the adapter plate. Remove the counter gear front bearing shim from the transmission case and then position the counter gear assembly into the inverted transmission case.
  12.  
  13. Secure the adapter plate to the case with 2 bolts and install a dial indicator on the rear end of the counter gear. Move the gear up and down while measuring the deflection. End-play should be .004-.01 in. (0.10-0.25mm). Select the proper shim from the chart.
  14.  
  15. Install the reverse idler gear, reverse idler needle bearings, reverse idler thrust washers and the reverse idler shaft to the extension housing (or OD case). Install a dial indicator on the front end of the shaft. Install a straightedge across the extension housing (or OD case) flange as a stopper and then move the shaft up and down to measure end-play. It should be .012-.021 in. (0.30-0.53mm). Adjustment is made by changing the thrust washer; there are 2 sizes: .078-.08 in. (1.97mm and 2.07)mm.
  16.  
  17. Install the mainshaft and counter gear on the adapter plate and then install the main drive gear on the mainshaft.
  18.  
  19. Install the rear side components on the mainshaft and counter gear as removed during the disassembly procedures.
  20.  
  21. Install the OD fork rod and shift fork and then press the retaining pin into the shift fork with a punch.
  22.  
  23. Install the 1-2, 3-4 and reverse shift forks onto the coupling sleeve.
  24.  
  25. Install the striking rod into the shift fork, striking lever and interlock hole, then press the retaining pin into the striking lever. Check for smooth movement of the lever.
  26.  
  27. Coat the lip of a new oil seal with grease and install it in the front cover.
  28.  
  29. Coat the selected counter gear front bearing shim with grease and install it in the transmission case.
  30.  
  31. Apply sealant to the case mating surface and install the gear assembly.
  32.  
  33. Coat the check ball with grease and then install it along with the check spring into the interlock stopper.
  34.  
  35. Install the interlock stopper assembly and then tighten the check ball plug. Be sure to coat the threads of the plug with sealant.
  36.  
  37. Install the stopper ring and the main drive bearing snapring.
  38.  
  39. Install the front cover with a new gasket. Apply sealant to the threads of the 3 lower bolts.
  40.  
  41. Install the extension housing (or OD case) along with the striking arm. Install the striking arm retaining pin with a punch.
  42.  
  43. Install the return spring and check ball, then install the control housing.
  44.  
  45. Tighten the control housing bolts to 12-15 ft. lbs. (16-21 Nm).
  46.  

 
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