2000 NISSAN PATROL Electronic Repair Manual

lMeasure clearance between baulk ring and gear.
Clearance between baulk rings and main gears:
Unit: mm (in)
Gears Standard Wear limit
Main drive gear 1.00 - 1.45 (0.0394 - 0.0571)
0.7 (0.028) OD counter gear 1.00 - 1.45 (0.0394 - 0.0571)
Reverse main gear 1.00 - 1.45 (0.0394 - 0.0571)
lMeasure wear of 1st, 2nd and 3rd baulk rings.
a. Place inner baulk ring in position on synchronizer cone.
b. Hold baulk ring evenly against synchronizer cone and mea-
sure distance ``A''.
c. Place outer baulk ring in position on synchronizer cone.
d. Hold baulk ring evenly against synchronizer cone and mea-
sure distance ``B''.
Standard:
Inner-A 0.7 - 0.9 mm (0.028 - 0.035 in)
Outer-B 1.4 - 1.6 mm (0.055 - 0.063 in)
Wear Limit:
0.2 mm (0.008 in)
e. If distance ``A'' or ``B'' is smaller than the wear limit, replace
outer baulk ring, inner baulk ring and synchronizer cone as
a set.
BEARING
lMake sure bearings roll freely and are free from noise,
cracks, pitting or wear.
SMT140 Baulk ring to gear
clearance
SMT041BA Inner baulk ring
Inner baulk ring
Synchronizer cone
Dial indicator
SMT330D Outer baulk ring
Outer baulk ring
Synchronizer cone
SMT552D
INSPECTIONFS5R50B
Gear Components (Cont'd)
MT-1025

Shift Control Components
CONTROL HOUSING
1. Install select check plunger, select check spring and select
check plug.
2. Install reverse check parts.
a. Install cam pin.
b. Install check plunger, spacer, reverse check spring and
thrust washer.
c. Install E-ring.
3. Assemble control housing parts as shown on left.
GEAR SHIFT HOUSING
1. Assemble gear shift housing.
2. Install slide ball bearing into gear shift housing using SST.
SMT548D Select check spring
(Color: white)
Select check
plug
Select check
plunger
Air breather
Check plunger
Reverse check spring
E-ringThrust washerSpacerSelect check spring
(Color: black)Select check
plug Select check plungerControl housing Cam pin
Plug
SMT299D Reverse check assembly
SMT300D Reverse check assemblyE-ring
SMT304D
SMT329D Slide ball bearing
Press in 4 mm (0.16 in)Press in 35 mm (1.38 in)
ASSEMBLYFS5R50B
MT-1026

3. Install striking rod through striking lever and shift lever
bracket.
lPay attention to direction of each part.
lPay attention to direction of each part.
lAlign cutout portion of striking lever, 1st & 2nd rod
bracket, 3rd & 4th rod bracket and reverse shift fork.
4. Install 1st & 2nd shift fork, 1st & 2nd rod bracket and 1st &
2nd fork rod.
5. Install 3rd & 4th rod bracket, 1st & 2nd and 3rd & 4th shift
forks and 3rd & 4th fork rod.
6. Insert interlock plunger and check ball for interlock part, then
install reverse shift fork and reverse fork rod.
7. Drive in retaining pins into striking lever, each shift fork and
bracket.
8. Install retaining pin into shift lever bracket.
SMT296D 1st & 2nd fork rod1st & 2nd shift fork3rd & 4th rod bracket
1st & 2nd rod bracket
Alignment portion
Front
Gear shift housing
Reverse shift fork
Striking lever
Striking rod
Reverse fork rod 3rd & 4th shift fork3rd & 4th fork
rod
SMT545D Interlock plungerPlug
Interlock pinCheck ballCheck ball spring
SMT302D Striking leverReverse fork
rod
SMT292D Shift lever bracket
ASSEMBLYFS5R50B
Shift Control Components (Cont'd)
MT-1027

9. Install fork rod caps by tapping lightly.
10. Install reverse and neutral position switches.
Gear Components
MAIN DRIVE GEAR
1. Press main drive gear bearing.
2. Select proper main drive gear snap ring to minimize clear-
ance of groove, then install it.
Allowable clearance of groove:
0 - 0.15 mm (0 - 0.0059 in)
Main drive gear snap ring:
Refer to SDS, MT-1038.
MAIN SHAFT
1. Assemble synchronizers.
1st & 2nd synchronizer
lOpening of shifting insert springs must not be aligned
with each other.
SMT303D Striking rod cap
Fork rod cap
Striking
lever cap
Fork rod cap
Gear shift housing
Shift rod cap
SMT295D Interlock plunger
Plug
Interlock pin
Check ballNeutral position switch Reverse position switch
SMT425AA
SMT426A
SMT914A Synchronizer
hubCoupling sleeve
Shifting insert
Shifting insert
Shifting insert spring
ASSEMBLYFS5R50B
Shift Control Components (Cont'd)
MT-1028

3rd & 4th synchronizer
Reverse synchronizer
lPay attention to direction of synchronizer hub, shifting
inserts and coupling sleeve.
lOpenings of shift insert springs must not be aligned with
each other.
2. Press reverse synchronizer assembly together with reverse
main gear and reverse gear needle bearing.
lPay attention to direction of reverse synchronizer hub
assembly.
3. Install 1st main gear and 1st gear needle bearing.
SMT288D Shifting insert spring
Shifting insert
spring
Coupling
sleeve
Shifting insert
SMT331D Synchronizer hub
Stopper
Shifting insert
Coupling sleeve
Front
SMT278B Drift
ASSEMBLYFS5R50B
Gear Components (Cont'd)
MT-1029

4. Press 1st & 2nd synchronizer assembly.
l1st baulk ring and 2nd baulk ring are different.
5. Select proper 1st & 2nd hub snap ring to minimize clearance
of groove, then install it.
Allowable clearance of groove:
0 - 0.13 mm (0 - 0.0051 in)
1st & 2nd hub snap ring:
Refer to SDS, MT-1038.
6. Install 2nd main gear and 2nd gear needle bearing.
7. Press 3rd gear bushing.
8. Install 3rd main gear and 3rd gear needle bearing.
9. Press 3rd & 4th synchronizer assembly.
lPay attention to direction of synchronizer assembly.
SMT289D Drift
This groove is only
on front side.
SMT280B 1st & 2nd hub snap
ring
SMT281B
SMT282B Front
ASSEMBLYFS5R50B
Gear Components (Cont'd)
MT-1030

10. Select proper 3rd & 4th hub snap ring to minimize clearance
of groove, then install it.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
3rd & 4th hub snap ring:
Refer to SDS, MT-1038.
11. Measure 1st, 2nd, 3rd and reverse main gear end plays as
the final check. Ð Refer to ``Disassembly''.
COUNTER GEAR
1. Press on counter gear front and rear bearing inner race.
2. Install sub-gear, sub-gear spring, sub-gear washer, and snap
ring, while compressing sub-gear spring.
lPay attention to direction of sub-gear spring.
TRANSMISSION CASE
1. Install reverse idler shaft, thrust washers, needle bearings
and gear.
lPay attention to direction of reverse idler gear and wash-
ers.
2. Install lock plate of reverse idler shaft.
3. Settle counter gear assembly on bottom of transmission
case.
SMT332D
SMT924A Counter gear front
bearing inner raceCounter gear rear
bearing outer race
SMT334D Front
Sub-gear
spring
SMT306D Reverse idler gear
Front
Transmission
case
SMT307D Counter gear
Front
ASSEMBLYFS5R50B
Gear Components (Cont'd)
MT-1031

4. Place mainshaft assembly on top of counter gear assembly
and then support it with hoist.
lAlign matching portion of counter gear and sub-gear
tooth to upper side.
5. Install main drive gear assembly by tapping front end of it
lightly.
lSet cutting portion of clutch gear on main drive gear to
the upper side.
6. Install counter gear front bearing outer race by tapping it
lightly while holding counter gear assembly.
lPay attention to direction.
7. Install counter gear rear bearing outer race by tapping it
lightly while holding counter gear assembly.
lPay attention to direction.
8. Take off hoist from mainshaft.
SMT308D Mainshaft
assembly
Front
SMT309D
SMT310D Upper
Rear view
Soft hammer
SMT311D Front
Soft hammer
SMT312D Front
Tool
ASSEMBLYFS5R50B
Gear Components (Cont'd)
MT-1032