spartanic

Click on the link to see the complete article with images check it out here: Nissan 240sx Manual Transmission Overhaul: mainshaft,input shaft, hub assembly and more. Garage411.com


This overhaul procedure applies to 1991-1994 240sx with FS5W71C trannys only.
Remove manual transmission from vehicle.


TRANSMISSION DISASSEMBLY

1. Remove control housing, reverse check ball and spring. Remove shift restrict spring plugs, springs and plungers. Use pin punch to remove shift arm retaining roll pin. Remove shift arm. Using plastic hammer, remove extension housing (2WD) or transfer case adapter (4WD). Remove front bearing retainer. Remove countershaft front bearing shim and mainshaft bearing snap ring.

2. Separate transmission case from intermediate plate. Install mounting Adapter Plate (ST23810001) to intermediate plate. Remove shift rod from intermediate plate. Remove all check ball plugs, springs and check balls from intermediate plate.
3. Drive out all retaining roll pins from shift forks. Remove fork rods and interlock balls. Remove lever bracket securing bolt (if equipped). Remove 3rd/4th fork rod. Remove "E" ring from overdrive fork rod. Remove overdrive fork shaft by rotating overdrive/reverse bracket counterclockwise.
4. Measure thrust clearance of each gear.

For specifications, see mainshaft gear thrust clearance table. If thrust clearances are not within specifications, check condition of gears, bushings, washers, shaft and/or synchro hub for wear or damage during disassembly.

MAINSHAFT GEAR THRUST CLEARANCES In. (mm)

• 1st Main Gear: .012-.016 (.31-.41)
• 2nd Main Gear: .004-.008 (.11-.21)
• 3rd Main Gear: .004-.008 (.11-.21)
• 5th Gear (OD Gear): .009-.016 (.24-.41)

5. Mesh (shift) 2nd and reverse gear. Using 2-Jaw Puller, remove countershaft front bearing. Remove countershaft front snap ring. Remove sub-gear collar, spring and gear. Using 2-Jaw Puller, remove counter drive gear with input shaft assembly. Unstake mainshaft and countershaft lock nuts and remove.

FYI: Main shaft lock nut has left-hand thread.

6. Using 2-Jaw Puller, remove overdrive counter gear with bearing. Remove reverse counter gear with spacer. Remove reverse idler gear assembly with shaft. Remove speedometer drive gear with steel ball. Using 2-Jaw Puller, remove mainshaft bearing. Remove mainshaft nut, steel roller and washer.
7. Remove overdrive gear with needle bearing and synchro ring. Remove intermediate mounting adapter plate. Mount intermediate plate in press. Alternate press between mainshaft and countershaft and remove shafts from intermediate plate. Ensure that mainshaft and countershaft gears do not apply pressure against each other when removing shafts.


Click on the link to see the complete article with images check it out here: Nissan 240sx Manual Transmission Overhaul: mainshaft,input shaft, hub assembly and more. Garage411.com

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tam85

hey thanks. nice article. looks helpful for everyone who need this overhaul procedure on their 1991-1994 nissan transmission. thanks for the link i will bookmart it.

rebornS14

Links no longer work =(

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