Nissan Z - ZX 1970-1988 Repair Guide

Transmission

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IDENTIFICATION



The transmission equipped on the Datsun/Nissan Z and ZX is dependant on year and whether or not the vehicle is equipped with a turbo.



1970-71 models use a F4W71A, 4-speed transmission.
 
1972-79 models use the F4W71B, 4-speed transmission.
 
1977-83 models use the FS5W71B 5-speed transmission.
 
1984-88 models use the Nissan FS5W71C 5-speed (non-turbo) or a Borg Warner BWT-5 (FS5R90A) 5-speed (turbo) models (1984-86) or a Borg Warner BWT-5 (FS5R30A) 5-speed (turbo) models (1987-88).
 

All models use a single to rail shifter with internal linkage. No shift linkage adjustments are necessary or possible.

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4 and 5

  1. Disconnect the battery negative cable and the accelerator linkage. Drain the transmission oil.
  2.  
  3. Remove the console screws. Disconnect the wiring harness and remove the console. Remove the shift lever boot.
  4.  

If equipped with a carburetor, remove the choke control wire from the console.

  1. Place the transmission in the NEUTRAL position.
  2.  



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Fig. Fig. 1: Underside view of 1970-83 transmission and components



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Fig. Fig. 2: To disconnect the gearshift lever, remove the E-clip-1970-83 models



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Fig. Fig. 3: To disconnect the shift lever on 1984-88 models, remove either the circlip or remove the retainer bolts



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Fig. Fig. 4: Transmission torque sequence-1970-83 models



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Fig. Fig. 5: Transmission torque sequence-1984-88 models

On the 1970-83 models, remove the E-ring from the gearshift lever pin, then the pin and the gearshift lever. On the 1984 and later models, remove the gearshift lever internal snapring (FS5W71C) or the gearshift lever plate BW T-5 (FS5R90A).

  1. Raise and support the vehicle on jackstands.
  2.  
  3. Disconnect the exhaust pipe from the exhaust manifold. Remove the exhaust pipe bracket from the extension housing. Support the pipe with a length of wire.
  4.  

On the 1984 and later models, remove the exhaust front tube, the catalytic converter and the exhaust manifold crossover tube.

  1. Disconnect the back-up light and neutral safety switch wires.
  2.  
  3. Remove the clutch operating cylinder from the transmission.
  4.  
  5. Disconnect the speedometer cable at the rear of the extension housing.
  6.  
  7. Remove the resonator and/or muffler insulator bolts and place the insulator on the exhaust pipe.
  8.  
  9. Using a awl, scribe matchmarks on the rear of the driveshaft and companion flanges.
  10.  
  11. Remove driveshaft flange bolts, then pull the rear down and draw the driveshaft sleeve yoke from the transmission. Withdraw the driveshaft carefully so as not to damage the oil seal, then plug the transmission opening with a clean rag.
  12.  
  13. Using a block of wood (between the jack and the oil pan) and a floor jack, support the engine under the oil pan.
  14.  
  15. Place a transmission jack under the transmission and support it; DO NOT place the jack under the drain plug.
  16.  
  17. Remove the nut attaching the transmission to the rear crossmember. Remove the crossmember-to-frame bolts and the crossmember.
  18.  
  19. Disconnect the starter wiring and remove the starter motor.
  20.  
  21. Remove the transmission-to-engine bolts, then slide the transmission rearward, downward and remove it from the vehicle.
  22.  
  23. To install, perform the following:
    1. Clean the mating surfaces of the engine and transmission case.
    2.  
    3. Lightly grease the clutch disc and mainshaft splines.
    4.  
    5. To complete the installation, reverse removal procedures. Tighten the engine-to-transmission bolts to 32-43 ft. lbs. (1970-83) or 29-36 ft. lbs. (1984 and later) for the upper bolts and 6.5-8.7 ft. lbs. (1970-83) or 22-29 ft. lbs. (1984 and later) for the bottom bolts. Refill the transmission to the level of the filler plug with the recommended oil.
    6.  

  24.  

TRANSMISSION OVERHAUL



4-Speed Transmission

See Figures 6, 7 and 8



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Fig. Fig. 6: Interlock and detent plunger-4-speed models



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Fig. Fig. 7: Mainshaft assembly- 4-speed models



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Fig. Fig. 8: Countershaft assembly-4-speed models

DISASSEMBLY

This transmission is constructed in three sections, the clutch housing, transmission housing and extension housing. There are no case cover plates. There is a cast iron adapter plate between the transmission and extension housing.

  1. Remove the clutch housing dust cover. Remove the retaining spring, release bearing sleeve, and throw-out lever.
  2.  
  3. Remove the back-up light/neutral safety switch.
  4.  
  5. Unbolt and remove the clutch housing, rapping with a soft hammer if necessary. Remove the gasket, mainshaft bearing shim, and countershaft bearing shim.
  6.  
  7. Remove the speedometer pinion sleeve.
  8.  
  9. Remove the striker rod pin from the rod. Separate the striker rod from the shift lever bracket.
  10.  
  11. Unbolt and remove the rear extension. It may be necessary to rap the housing with a soft hammer.
  12.  
  13. Remove the mainshaft bearing assembly.
  14.  
  15. Remove the adapter plate and gear assembly from the transmission case.
  16.  
  17. Punch out the shift fork retaining pins. Remove the shift rod snaprings. Remove the detent plugs, springs and balls from the adapter plate. Remove the shift rods, being careful not to lose the interlock balls.
  18.  
  19. Remove the snapring speedometer drive gear and locating ball.
  20.  
  21. Remove the nut, lockwasher, thrust washer, reverse hub and reverse gear.
  22.  
  23. Remove the snapring and countershaft reverse gear. Remove the snapring, reverse idler gear, thrust washer and needle bearing.
  24.  
  25. Support the gear assembly while rapping on the rear of the mainshaft with a soft hammer.
  26.  
  27. Remove the setscrew from the adapter plate. Remove the shaft nut, spring washer, plain washer and reverse idler shaft.
  28.  
  29. Remove the bearing retainer and the mainshaft rear bushing.
  30.  
  31. To disassemble the mainshaft (rear section), remove the front snapring, 3rd/4th synchronizer assembly, third gear and needle bearing. From the rear, remove the thrust washer, locating ball, 1st gear, needle bearings, 1st gear bushing, 1st/2nd synchronizer assembly, 2nd gear, and needle bearing.
  32.  
  33. To disassemble the clutch shaft, remove the snapring and bearing spacer and press off the bearing.
  34.  
  35. To disassemble the countershaft, press off the front bearing. Press off the rear bearing, press off the gears and remove the keys.
  36.  
  37. Remove the retaining pin, control arm pin and shift control arm from the rear of the extension housing.
  38.  

ASSEMBLY
  1. Place the O-ring in the front cover. Install the front cover to the clutch housing with a press. Put in the front cover oil seal.
  2.  
  3. Install the rear extension oil seal.
  4.  
  5. Assemble the 1st/2nd and 3rd/4th synchronizer assemblies. Make sure that the ring gaps are not both on the same side of the unit.
  6.  
  7. On the rear end of the mainshaft, install the needle bearing, 2nd gear, baulk ring, 1st/2nd synchronizer assembly, baulk ring, 1st gear bushing, needle bearing, 1st gear, locating ball and thrust washer.
  8.  
  9. Drive or press on the mainshaft rear bearing.
  10.  
  11. Install the countershaft rear bearing to the adapter plate. Drive or press the mainshaft rear bearing into the adapter plate until the bearing snapring groove comes through the rear side of the plate. Install the snapring. If it is not tight against the plate, press the bearing back in slightly.
  12.  
  13. Insert the countershaft bearing ring between the countershaft rear bearing and bearing retainer. Install the bearing retainer to the adapter plate. Stake both ends of the screws.
  14.  
  15. Insert the reverse idler shaft from the rear of the adapter plate. Install the spring washer and plain washer to the idler shaft.
  16.  
  17. Place the two keys on the countershaft and oil the shaft lightly. Press on 3rd gear and install a snapring.
  18.  
  19. Install the countershaft into its rear bearing.
  20.  
  21. From the front of the mainshaft, install the needle bearing, 3rd gear, baulk ring, 3rd/4th synchronizer assembly and snapring. snaprings are available in thicknesses from 0.05-0.06 in. (1.4-1.6mm) to adjust gear end-play.
  22.  
  23. Press the main drive bearing onto the clutch shaft. Install the main drive gear spacer and snapring. snaprings are available in thicknesses from 0.07-0.08 in. (1.8-2.1mm) to adjust gear end-play.
  24.  
  25. Insert a key into the countershaft drive gear with 4th gear and drive on the countershaft 4th gear with a drift. The rear end of the countershaft should be held steady while driving on the gear, to prevent rear bearing damage.
  26.  
  27. Install the reverse hub, reverse gear, thrust washer, and lock tab on the rear of the mainshaft. Install the shaft nut temporarily.
  28.  
  29. Install the needle bearing, reverse idler gear, thrust washer, and snapring.
  30.  
  31. Place the countershaft reverse gear and snapring on the rear of the countershaft. snaprings are available in thicknesses from 0.042-0.054 in. (1.1-1.5mm) to adjust gear end-play.
  32.  
  33. Engage both 1st and 2nd gears to lock the shaft.
  34.  
  35. On the rear of the mainshaft, install the snapring, locating ball, speedometer drive gear, and snapring. snaprings are available in thicknesses from 0.04-0.06 in. (1.1-1.5mm).
  36.  
  37. Recheck end-play and backlash of all gears.
  38.  
  39. Place the reverse shift fork on the reverse gear and install the reverse shift rod. Install the detent ball, spring and plug. Install the fork retaining pin. Place two interlock balls between the reverse shift rod and the 3rd/4th shift rod location. Install the 3rd/4th shift fork and rod. Install the detent ball, spring and plug. This plug is shorter than the other two. Install the fork retaining pin. Place two interlock balls between the 1st/2nd shift rod location and the 3rd/4th shift rod. Install the 1st/2nd shift fork and rod. Install the detent ball, spring and plug.
  40.  
  41. Install the shift rod snaprings.
  42.  
  43. Apply sealant sparingly to the adapter plate and transmission housing. Install the transmission housing to the adapter plate and bolt it down temporarily.
  44.  
  45. Drive in the countershaft front bearing with a drift. Place the snapring in the mainshaft front bearing.
  46.  
  47. Apply sealant sparingly to the adapter plate and extension housing. Align the shift rods in the neutral positions. Position the striker rod to the shift rods and bolt down the extension housing.
  48.  
  49. Insert the striker rod pinion, connect the rod to the shift lever bracket and install the striker rod pin retaining ring. Replace the shift control arm.
  50.  
  51. To select the proper mainshaft bearing shim, first measure the amount the bearing protrudes from the front of the transmission case. This is measurement (B). Then measure the depth of the bearing recess in the rear of the clutch housing. This is measurement (A). Required shim thickness is found by subtracting (B) from (A). Shims are available in thicknesses of 0.05-0.06 in. (1.4-1.6mm).
  52.  
  53. To select the proper countershaft front bearing shim, measure the amount that the bearing is recessed into the transmission case. Shim thickness should equal this measurement. Shims are available in thicknesses from 0.016-0.039 in. (0.4-1.0mm).
  54.  
  55. Apply sealant sparingly to the clutch and transmission housing mating surfaces.
  56.  
  57. Replace the clutch operating mechanism.
  58.  
  59. Install the shift lever temporarily and check shifting action.
  60.  

FSW71B FSW71C Model 5-Speed Transmission

See Figures 9, 10 and 11

These transmissions are similar to the 4-speed transmission, model F4W71B and the overhaul can be accomplished by following the outline for the disassembly and assembly of the model F4W71B transmission.



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Fig. Fig. 9: Case component parts-5-speed FSW71B model



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Fig. Fig. 10: Case component parts-5-speed FSW71C model



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Fig. Fig. 11: Exploded view of 5-speed gear train

Servo type synchromesh is used, instead of the Borg Warner type in the 4-speed units. Shift linkage and interlock arrangements are the same, except the reverse shift rod also operates 5th gear. Most service procedures are identical to those for the 4-speed unit. Those unique to the 5-speed follow.

DISASSEMBLY
  1. Remove the clutch housing dust cover. Remove the retaining spring, release bearing sleeve, and throw-out lever.
  2.  
  3. Remove the back-up light/neutral safety switch.
  4.  
  5. Unbolt and remove the clutch housing, rapping with a soft hammer if necessary. Remove the gasket, mainshaft bearing shim, and countershaft bearing shim.
  6.  
  7. Remove the speedometer pinion sleeve.
  8.  
  9. Remove the striker rod pin from the rod. Separate the striker rod from the shift lever bracket.
  10.  
  11. Unbolt and remove the rear extension. It may be necessary to rap the housing with a soft hammer.
  12.  
  13. Remove the mainshaft bearing assembly.
  14.  
  15. Remove the adapter plate and gear assembly from the transmission case.
  16.  
  17. Punch out the shift fork retaining pins. Remove the shift rod snaprings. Remove the detent plugs, springs and balls from the adapter plate. Remove the shift rods, being careful not to lose the interlock balls.
  18.  
  19. Remove the snapring speedometer drive gear and locating ball.
  20.  
  21. Remove the nut, lockwasher, thrust washer, reverse hub and reverse gear.
  22.  
  23. Remove the snapring and countershaft reverse gear. Remove the snapring, reverse idler gear, thrust washer and needle bearing.
  24.  
  25. Support the gear assembly while rapping on the rear of the mainshaft with a soft hammer.
  26.  
  27. Remove the setscrew from the adapter plate. Remove the shaft nut, spring washer, plain washer and reverse idler shaft.
  28.  
  29. Remove the bearing retainer and the mainshaft rear bushing.
  30.  
  31. To disassemble the mainshaft (rear section), remove the front snapring, 3rd/4th synchronizer assembly, third gear and needle bearing. From the rear, remove the thrust washer, locating ball, 1st gear, needle bearings, 1st gear bushing, 1st/2nd synchronizer assembly, 2nd gear, and needle bearing.
  32.  
  33. To disassemble the clutch shaft, remove the snapring and bearing spacer and press off the bearing.
  34.  
  35. To disassemble the countershaft, press off the front bearing. Press off the rear bearing, press off the gears and remove the keys.
  36.  
  37. To disassemble the synchronizers, remove the circlip, synchronizer ring, thrust block, brake band and anchor block. Be careful not to mix parts of the different synchronizer assemblies.
  38.  
  39. Remove the retaining pin, control arm pin and shift control arm from the rear of the extension housing.
  40.  

ASSEMBLY

When assembling the transmission, keep the following notes in mind:

  1. The synchronizer assemblies for 2nd, 3rd and 4th are identical. When assembling the 1st gear synchronizer, be sure to install the 0.086 in. (2.2mm) thick brake band at the bottom.
  2.  
  3. When assembling the mainshaft, select a 3rd gear synchronizer hub snapring to minimize hub end-play. snaprings are available in thicknesses of 0.060-0.062 in. (1.55-1.60mm), 0.59-0.060 in. (1.50-1.55mm), and 0.056-0.59 in. (1.45-1.50mm). The synchronizer hub must be installed with the longer boss to the rear.
  4.  
  5. When reassembling the gear train, install the mainshaft, countershaft and gears to the adapter plate. Hold the rear nut and force the front nut against it to a torque of 217 ft. lbs. (282 Nm). Select a snapring to minimize end-play of the 5th gear bearing at the rear of the mainshaft. snaprings are available in thicknesses from 0.04-0.05 in. (1.1-1.4mm).
  6.  

To assembly the transmission, proceed as follows:

  1. Place the O-ring in the front cover. Install the front cover to the clutch housing with a press. Put in the front cover oil seal.
  2.  
  3. Install the rear extension oil seal.
  4.  
  5. Assemble the 1st/2nd and 3rd/4th synchronizer assemblies. Make sure that the ring gaps are not both on the same side of the unit.
  6.  
  7. On the rear end of the mainshaft, install the needle bearing, 2nd gear, baulk ring, 1st/2nd synchronizer assembly, baulk ring, 1st gear bushing, needle bearing, 1st gear, locating ball and thrust washer.
  8.  
  9. Drive or press on the mainshaft rear bearing.
  10.  
  11. Install the countershaft rear bearing to the adapter plate. Drive or press the mainshaft rear bearing into the adapter plate until the bearing snapring groove comes through the rear side of the plate. Install the snapring. If it is not tight against the plate, press the bearing back in slightly.
  12.  
  13. Insert the countershaft bearing ring between the countershaft rear bearing and bearing retainer. Install the bearing retainer to the adapter plate. Stake both ends of the screws.
  14.  
  15. Insert the reverse idler shaft from the rear of the adapter plate. Install the spring washer and plain washer to the idler shaft.
  16.  
  17. Place the two keys on the countershaft and oil the shaft lightly. Press on 3rd gear and install a snapring.
  18.  
  19. Install the countershaft into its rear bearing.
  20.  
  21. From the front of the mainshaft, install the needle bearing, 3rd gear, baulk ring, 3rd/4th synchronizer assembly and snapring. snaprings are available in thicknesses from 0.05-0.06 in. (1.4-1.6mm) to adjust gear end-play.
  22.  
  23. Press the main drive bearing onto the clutch shaft. Install the main drive gear spacer and snapring. snaprings are available in thicknesses from 0.07-0.08 in. (1.8-2.1mm) to adjust gear end-play.
  24.  
  25. Insert a key into the countershaft drive gear with 4th gear and drive on the countershaft 4th gear with a drift. The rear end of the countershaft should be held steady while driving on the gear, to prevent rear bearing damage.
  26.  
  27. Install the reverse hub, reverse gear, thrust washer, and lock tab on the rear of the mainshaft. Install the shaft nut temporarily.
  28.  
  29. Install the needle bearing, reverse idler gear, thrust washer, and snapring.
  30.  
  31. Place the countershaft reverse gear and snapring on the rear of the countershaft. snaprings are available in thicknesses from 0.042-0.054 in. (1.1-1.5mm) to adjust gear end-play.
  32.  
  33. Engage both 1st and 2nd gears to lock the shaft.
  34.  
  35. On the rear of the mainshaft, install the snapring, locating ball, speedometer drive gear, and snapring. snaprings are available in thicknesses from 0.04-0.06 in. (1.1-1.5mm).
  36.  
  37. Recheck the end-play and backlash of all gears.
  38.  
  39. Place the reverse shift fork on the reverse gear and install the reverse shift rod. Install the detent ball, spring and plug. Install the fork retaining pin. Place two interlock balls between the reverse shift rod and the 3rd/4th shift rod location. Install the 3rd/4th shift fork and rod. Install the detent ball, spring and plug. This plug is shorter than the other two. Install the fork retaining pin. Place two interlock balls between the 1st/2nd shift rod location and the 3rd/4th shift rod. Install the 1st/2nd shift fork and rod. Install the detent ball, spring and plug.
  40.  
  41. Install the shift rod snaprings.
  42.  
  43. Apply sealant sparingly to the adapter plate and transmission housing. Install the transmission housing to the adapter plate and bolt it down temporarily.
  44.  
  45. Drive in the countershaft front bearing with a drift. Place the snapring in the mainshaft front bearing.
  46.  
  47. Apply sealant sparingly to the adapter plate and extension housing. Align the shift rods in the neutral positions. Position the striker rod to the shift rods and bolt down the extension housing.
  48.  
  49. Insert the striker rod pinion, connect the rod to the shift lever bracket and install the striker rod pin retaining ring. Replace the shift control arm.
  50.  
  51. To select the proper mainshaft bearing shim, first measure the amount the bearing protrudes from the front of the transmission case. This is measurement (B). Then measure the depth of the bearing recess in the rear of the clutch housing. This is measurement (A). Required shim thickness is found by subtracting (B) from (A). Shims are available in thicknesses of 0.05-0.06 in. (1.4-1.6mm).
  52.  
  53. To select the proper countershaft front bearing shim, measure the amount that the bearing is recessed into the transmission case. Shim thickness should equal this measurement. Shims are available in thicknesses from 0.016-0.039 in. (0.4-1.0mm).
  54.  
  55. Apply sealant sparingly to the clutch and transmission housing mating surfaces.
  56.  
  57. Replace the clutch operating mechanism.
  58.  
  59. Install the shift lever temporarily and check shifting action.
  60.  

Model FS5R90A 5-Speed Transmission

See Figures 12 and 13



Click image to see an enlarged view

Fig. Fig. 12: Exploded view of FSR90A 5-speed transmission



Click image to see an enlarged view

Fig. Fig. 13: Gear components of FSR90A 5-speed transmission

DISASSEMBLY
  1. Remove the transmission from the vehicle and attach it to a stand.
  2.  
  3. Drain the oil and then remove the shift lever assembly and damper sleeve.
  4.  
  5. Remove the pin from the offset lever.
  6.  
  7. Unscrew the mounting bolts and separate the extension housing from the transmission case. The offset lever, detent spring and ball will be removed with it.
  8.  

When removing the extension housing, be careful not to lose the thrust race and funnel.

  1. Unscrew the transmission case cover bolts and then tap the cover lightly with a rubber mallet. Slide the cover toward the right-side of the case and remove it.
  2.  
  3. Pull the shifter shaft to the rear and remove the striking lever-to-shifter shaft roll pin. Remove the shaft through the rear of the cover.
  4.  
  5. Remove the selector plates from the shift fork assemblies.
  6.  
  7. Remove the back-up light switch.
  8.  
  9. Remove the retainer ring and pivot pin.
  10.  
  11. Remove the funnel, thrust race and the needle thrust bearing.
  12.  
  13. Remove the snapring and thrust race from the back of the 5th gear synchronizer hub.
  14.  
  15. Remove the pin from the 5th gear shift fork. Remove the fork, synchronizer and counter gear.
  16.  
  17. Remove the front bearing retainer.
  18.  
  19. Remove the input shaft and main drive gear assembly. Position the flat area of the main drive gear toward the counter gear and remove it through the front of the case.
  20.  
  21. Remove the rear bearing race from the front of the mainshaft and then lift the mainshaft assembly out through the top of the case.
  22.  
  23. Remove the 5th gear shift rail, the reverse fork with 5th and the reverse relay lever and spring.
  24.  
  25. Remove the pin from the reverse idler shaft and then remove the shaft and gear.
  26.  
  27. Remove the snapring and spacer from the rear of the counter gear bearing. Press the gear toward the rear of the case until the bearing is free and then remove it.
  28.  


WARNING
When pressing out the bearing, do not let it drop into the case.

  1. Remove the counter gear and the front thrust washer. Press the bearing from the case.
  2.  

This bearing should not be removed unless replacement is absolutely necessary.

  1. Remove the speedometer gear and drive ball from the main shaft.
  2.  
  3. Press the 3rd/4th gear synchronizer from the mainshaft. Remove 3rd gear.
  4.  
  5. Press 5th gear from the mainshaft.
  6.  
  7. Slip the bearing off of the shaft and then remove the thrust washer.
  8.  
  9. Remove the pin and then press 1st gear from the mainshaft.
  10.  
  11. Remove the snapring, thrust washer and 2nd gear.
  12.  
  13. Remove the 1st/2nd gear synchronizer sleeve, inserts and springs.
  14.  

ASSEMBLY
  1. Install the 1st/2nd gear synchronizer sleeve, inserts and springs on the synchronizer hub.
  2.  
  3. Install 2nd gear, its thrust washer and snapring. Install 1st gear.
  4.  
  5. Position the thrust washer positioning pin so that it projects 0.11 in. (3mm) above the bearing surface.
  6.  
  7. Install the thrust washer against 1st gear so that the slot in the washer aligns with the pin.
  8.  
  9. Install the rear bearing and then press 5th gear onto the mainshaft.
  10.  
  11. Install 3rd gear and then press the 3rd/4th gear synchronizer onto the front of the mainshaft.
  12.  

Be sure that the portion of the hub with the extended hose faces forward.

  1. Install the speedometer drive, ball, gear and snapring.
  2.  
  3. Install the front counter gear bearing:
    1. Apply a small bead of adhesive to the outside diameter of the bearing.
    2.  
    3. Press the bearing into the case until the edge is flush with the case.
    4.  

  4.  
  5. Position the counter gear thrust washer into the case so that the tang is aligned with the notch in the case.
  6.  

The washer may be held in position with a light coating of petroleum jelly.

  1. Install the counter gear into the case and engage its front journal with the front bearing.
  2.  
  3. Install the rear counter gear bearing as follows:
    1. Position the spacer at the rear of the counter gear.
    2.  
    3. Install a bearing protector on the counter gear.
    4.  
    5. Install the bearing over the protector and then press it into the case. When properly installed, the bearing race should protrude from the case 0.11-0.12 in. (3.0-3.2mm).
    6.  
    7. Install a spacer and snapring behind the bearing.
    8.  

  4.  
  5. Position the reverse idler gear into the case with the shift fork groove facing the rear. Install the reverse idler shaft, O-ring and retaining pin.
  6.  
  7. Install the reverse fork with 5th gear and reverse relay lever, 5th gear shift rail and the spring.
  8.  
  9. Install the back-up light switch.
  10.  
  11. Place the mainshaft assembly into the case and install the mainshaft rear bearing race.
  12.  
  13. Position the roller bearing into the main drive gear and hold them in position with a light coating of petroleum jelly.
  14.  
  15. Install the input shaft and main drive gear assembly, needle thrust bearing, thrust bearing race and locking ring into the case.
  16.  

Be sure that the flat area of the main drive gear is aligned with the counter gear. Be careful not to dislodge the roller bearings during installation.

  1. Remove at least 0.006 in. (0.15mm) from under the front bearing race in the retainer. Install the remaining shims and race into the retainer.
  2.  
  3. Install the front bearing retainer to the case so that the oil collector groove is facing up. Tighten the bolts to 11-20 ft. lbs. (14-26 Nm).
  4.  
  5. Install the 4th gear shift fork, counter gear and synchronizer as a unit. Install the retaining pin with the pin holes in the shift fork and rail in alignment.
  6.  
  7. Install the thrust race and snapring to the rear of the 5th gear synchronizer hub.
  8.  
  9. Locate the selector plates on the fork assemblies.
  10.  
  11. Slide the shifter shaft through the hole in the rear of the case cover and then assemble the 1st/2nd gear shift fork, interlock plate, striking lever and the 3rd/4th gear shift fork. Install the shifter shaft roll pin in the striking lever.
  12.  
  13. Apply a continuous bead of sealant to the cover-to-case mating surface and then install the cover.
  14.  
  15. Apply sealant to the threads of the 2 cover alignment dowels and install them. Apply sealant to the remaining bolt threads and tighten them to 6-13 ft. lbs. (8-17 Nm)
  16.  
  17. Clean the mating surfaces of the case-to-rear extension housing and apply sealant to the mating surface of the case.
  18.  
  19. Using a light coating of petroleum jelly to retain them, locate the needle thrust bearing, race and funnel on the rear of the counter shaft.
  20.  
  21. Place the detent ball, spring and offset lever into position on the guide plate and then connect the extension housing to the case.
  22.  
  23. Align the holes in the shifter shaft and offset lever and then install the retaining pin.
  24.  
  25. Insert the mounting bolts and tighten them to 20-46 ft. lbs. (26-60 Nm).
  26.  
  27. Apply sealant to the shift cover hole in the extension housing. Assemble the damper sleeve into the offset lever and then install the shift lever. Tighten the mounting bolts to 11-20 ft. lbs. (14-26 Nm)
  28.  
  29. Install the drain plug and fill with lubricant.
  30.  
  31. Push the input shaft to the rear and mount a dial indicator so the stem rests against the front end of the shaft. Zero the indicator.
  32.  
  33. Push the output shaft forward and note the indicator reading. Remove the indicator.
  34.  
  35. Remove the bearing retainer and race. Select the proper thickness shim to provide 0.005-0.010 in. (0.13-0.25mm) preload.
  36.  

To get the desired shim thickness, add the dial indicator reading from Step 34 to the desired preload. The resulting total is the proper shim thickness.

  1. Apply sealant to the bearing retainer mating surface and the bolt threads. Install the shims and race into the retainer as in Steps 18 and 19.
  2.  
  3. Install the transmission into the vehicle.
  4.  

Model FS5R30A 5-Speed Transmission

See Figures 14, 15 and 16



Click image to see an enlarged view

Fig. Fig. 14: Case components of FS5R30 A 5-speed transmission



Click image to see an enlarged view

Fig. Fig. 15: Gear components-FS5R30A 5-speed transmission



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Fig. Fig. 16: Gear components (continued)-FS5R30A 5-speed transmission

DISASSEMBLY
  1. Remove the transmission from the vehicle and attach it to a stand. Drain all remaining fluid out.
  2.  
  3. Remove the check ball plug, check spring and ball. Then remove the interlock stopper.
  4.  

If interlock assembly is removed as a unit, the check ball can fall into the transmission case.

  1. Remove the control housing, return spring and check ball. Drive out the retaining pin from the striking arm.
  2.  
  3. Remove the rear extension together with the striking arm.
  4.  
  5. Remove the front cover and gasket.
  6.  
  7. Remove the stopper ring and main drive bearing snapring.
  8.  
  9. Remove the transmission case by tapping lightly with a soft hammer.
  10.  
  11. Remove the front cover oil seal.
  12.  
  13. Mount the adapter plate in a vise and remove the overdrive and reverse fork rods.
  14.  
  15. Remove the check ball plug, check ball and return spring. Drive out the striking lever retaining pin.
  16.  
  17. While pulling out the striking rod, remove the striking lever and striking interlock. Then remove the 1st and 2nd, 3rd and 4th and reverse shift fork.
  18.  
  19. Drive out the retaining pin, pull out the fork rod then remove the overdrive shift fork.
  20.  
  21. Before removing gears and shafts, measure each gear end-play. If not within specification, check the contact surface of gear to hub, washer, bushing, needle bearing and shaft.
  22.  
  23. Remove the rear side components on the mainshaft and counter gear.
    1. Remove the snapring, speedometer drive gear and steel ball.
    2.  
    3. Remove the reverse coupling sleeve.
    4.  
    5. Remove the mainshaft and counter gear rear snaprings.
    6.  
    7. Using a punch and hammer, remove the C-ring holder and the C-rings from the mainshaft.
    8.  
    9. Pull out the counter gear rear end bearing.
    10.  
    11. Remove the reverse idler gear and thrust washers.
    12.  
    13. Remove the sub gear from the reverse idler gear. Pull out the mainshaft rear bearing.
    14.  
    15. Pull out the reverse main gear together with the mainshaft spacer and reverse synchronizer hub. Then remove the reverse gear needle bearings.
    16.  
    17. Pull out the reverse counter gear.
    18.  
    19. Remove the overdrive coupling sleeve together with the baulk ring, reverse baulk ring and spring inserts.
    20.  
    21. Pull out the reverse gear bushing.
    22.  
    23. Pull out the overdrive counter gear together with the reverse cone.
    24.  

  24.  
  25. Remove the front side components on the mainshaft.
    1. Remove the 1st gear washer, steel ball and needle bearing. Remove the 1st main gear.
    2.  
    3. Press out the 2nd main gear together with the 1st gear bushing and 1st and 2nd synchronizer assembly.
    4.  
    5. Remove the mainshaft front snapring.
    6.  
    7. Press out the 3rd main gear together with the 3rd and 4th synchronizer assembly and the 3rd gear needle bearing.
    8.  

  26.  
  27. Remove the front side components on the counter gear.
    1. Remove the counter gear rear thrust bearing.
    2.  
    3. Remove the sub gear components.
    4.  

  28.  
  29. Press out the main drive gear bearing.
  30.  
  31. Remove the bearings from the case components.
  32.  

ASSEMBLY
  1. Install the bearings into the case components.
  2.  
  3. Press in the main drive gear bearing and install the spacer.
  4.  
  5. Select the proper main drive gear snapring to minimize the clearance of the groove.
  6.  

Allowable clearance of the groove is 0.0-0.004 in. (0.0-0.1mm).

  1. Install the counter gear rear thrust bearing and the sub gear snapring.
  2.  
  3. Assemble the 1st and 2nd synchronizer and the 3rd and 4th synchronizer.
  4.  
  5. Press on the 3rd and 4th synchronizer assembly together with the 3rd main gear and the 3rd gear needle bearing.
  6.  
  7. Select the proper snapring to minimize the clearance of the groove.
  8.  

Allowable clearance of the groove is 0.0-0.004 in. (0.0-0.1mm).

  1. Press on the 1st and 2nd synchronizer assembly together with the 2nd main gear and 2nd gear needle bearing.
  2.  
  3. Press on the 1st gear bushing and install the 1st main gear needle bearing.
  4.  
  5. Apply multi-purpose grease and install the steel ball and the 1st gear washer.
  6.  
  7. Install the counter gear with the sub gear components, counter gear front and rear thrust bearing on the adapter plate.
  8.  
  9. Remove the counter gear front bearing shim from the transmission case.
  10.  
  11. Place the adapter plate and counter gear assembly in the transmission case and tighten with 2 bolts.
  12.  
  13. Using a dial indicator on the rear end of the counter gear, move the counter gear up and down to measure deflection. Counter gear end-play is 0.004-0.010 in. (0.10-0.25mm).
  14.  
  15. Install the reverse idler gear, needle bearings, thrust washers and shaft into the rear extension.
  16.  
  17. Place a dial indicator on the front end of the reverse idler shaft. Use a straight-edge on the front surface of the rear extension as a stopper of the reverse idler shaft. Move the shaft up and down to measure the end-play. Reverse idler gear end-play is 0.01-0.02 in. (0.30-0.53mm). If not within specification replace the rear thrust washer.
  18.  
  19. Install the mainshaft and counter gear on the adapter plate and the main drive gear on the mainshaft.
  20.  

When installing the counter gear into the rear bearing, push up on upper roller of rear bearing with a screwdriver.

  1. Install the overdrive gear bushing while pushing on the front of the counter gear and install the overdrive main gear.
  2.  
  3. Install the adapter plate with the gear assembly into the transmission case. Install the overdrive gear needle bearing, counter gear and then the reverse idler shaft.
  4.  
  5. Install the reverse gear bushing and cone. Install the insert springs and reverse baulk ring on the overdrive coupling sleeve. Then install them and the overdrive baulk ring on the overdrive counter gear.
  6.  
  7. Install the reverse counter gear. Install the sub gear on the reverse idler gear.
  8.  
  9. Install the reverse gear needle bearing, main gear and thrust washers. Install the reverse hub.
  10.  
  11. Install the mainshaft spacer and rear bearing. Install the speedometer drive gear. Install the counter gear rear end bearing.
  12.  
  13. Separate the adapter plate from the transmission case and mount it in a vise. Select the proper mainshaft C-ring and counter gear rear snapring to minimize the clearance of the grooves.
  14.  
  15. Install the reverse coupling sleeve.
  16.  
  17. Install the overdrive shift fork rod and fork and retaining pin.
  18.  
  19. Install the 1st and 2nd, 3rd and 4th and reverse shift fork onto coupling sleeve.
  20.  
  21. Put the striking rod through the hole of the shift forks, striking lever and interlock. Make sure the striking rod moves smoothly.
  22.  
  23. Apply sealant to the thread of the check ball plug and install it and the return spring in the adapter plate.
  24.  
  25. Apply multi-purpose grease to the oil seal lip and install it in the front cover.
  26.  
  27. Install the selected counter gear front bearing shim onto the transmission case then the gear assembly.
  28.  
  29. Put the check spring and ball into the interlock stopper. Apply multi-purpose grease to the check ball. Install the stopper assembly and then tighten the check ball plug.
  30.  
  31. Install the stopper ring and the main drive bearing snapring.
  32.  
  33. Install the front cover and gasket. Apply sealant to the thread of the bottom 3 bolts.
  34.  
  35. Install the rear extension together with the striking arm. Install the return spring and check ball and then install the control housing. Tighten the control housing bolts to specifications.
  36.  

 
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