Nissan:: Patrol:: Assembly

9.1.4. Assembly

Models of 4.2 l

Assembly is made as it should be, skim milk to a dismantle order.

For greasing of components use universal lubricant on a lithium basis if other grade of lubricant is not stipulated especially in the description of an order of implementation of the procedure.

PERFORMANCE ORDER

Before assembly grease all components with lubricant of the recommended grade.

Collect knot of the synchronizer 1/2 of transfers according to the tags put in the course of dismantle. Track that the sliding keys correctly were combined with three V-shaped flutes in coupling vents. Locks of springs should not appear opposite (see an accompanying illustration).

Collect knot of the synchronizer 3/4 of transfers (taking into account tags). Track combination of keys with flutes. Establish springs (locks in different directions). Hooks on the ends of springs have to get to the corresponding opening in a synchronizer nave.
Taking into account tags collect knot of the synchronizer of the reverse gear. Track that the coupling was turned by the narrow end to the back party of a nave, and locks of springs were turned in different directions. By means of a mandrel to a napressuyta the holder's plate on a nave aflush with a face surface of the last.
Establish the blocking ring, a gear wheel of the reverse gear and the roller bearing on assembly of the synchronizer of the reverse gear (observe the adjusting direction of details). Place assembly in a press, having propped up basic plates a nave of the synchronizer and establish the conducted shaft.
Establish the conducted shaft in a press, having propped up basic plates a gear wheel of the reverse gear, and put on a gear wheel of the first transfer, the bearing and the blocking synchronizer ring a shaft.

The blocking rings of the first and second transfers are not interchangeable. The ring of the first transfer differs in existence of three admissions in teeth (see an accompanying illustration).

1 — the blocking ring of the synchronizer of the 1st transfer
2 — the blocking ring of the synchronizer of the 2nd transfer
3 — the admission

Put on a nave of the synchronizer 1/2 of transfers the conducted shaft (use a press and a suitable mandrel). Track that flutes were turned into surfaces of a nave from a gear wheel of the first transfer aside (see an accompanying illustration).

1 — a nave
2 — a flute

Measure a side gap between a lock ring and a nave of the synchronizer. Compare result of measurement to standard requirements (see size tables and adjustments at the end of the Management). Pick up a new lock ring of the required thickness.
Put on the blocking ring of the synchronizer of the second transfer and a gear wheel of the second transfer the conducted shaft. Install the coupling of the bearing of a gear wheel of the third transfer (use a press and a suitable mandrel). Track that the flange of the coupling was turned towards a gear wheel of the second transfer.
Put on the bearing, a gear wheel of the third transfer and the blocking synchronizer ring the conducted shaft. Establish a shaft in a press, having propped up basic plates its end face.
Napressuyte on a shaft assembly of the synchronizer 3/4 of transfers. Track that oil flutes in a nave were turned towards a gear wheel of the third transfer.

Check axial loofahs

Measure a side gap between a lock ring and a nave of the synchronizer (see an accompanying illustration). Compare result to data of size tables and adjustments and pick up a new ring of the required thickness.

by t of gear wheels of the first, second, third and back transfers as it is described above.

Put on the bearing a main shaft, having tracked that the flute under a lock ring in an external holder was turned from a gear wheel of a main shaft aside, then, having propped up basic plates the bearing, press in it a shaft.
Put on the remote plug a main shaft and measure a side gap between a lock ring and the plug. Compare result of measurement to standard requirements (see size tables and adjustments at the end of the Management), pick up a new lock ring of the required thickness.
Establish on an intermediate shaft the holder of a gear ring and measure a side gap between a lock ring and the holder. Pick up a new ring of the required thickness. Remove the holder from an intermediate shaft.
Grease with dense lubricant a steel ball and establish a ball, a gear ring, a dish-shaped spring and the holder on a forward part of an intermediate shaft. Track that the concave party of a spring was turned towards a gear ring.
Establish a new lock ring of the required thickness on an intermediate shaft so that it nestled on the holder. Use a suitable mandrel and a napressuyta a lock ring on intermediate before its landing in a flute. Remove a mandrel and check correctness of landing of a ring.
Napressuyte internal holders of forward and back bearings on an intermediate shaft (use a suitable mandrel). Establish a narrow holder back.
Establish in a transmission case an intermediate gear wheel of the reverse gear with persistent washers. Track that uvulas of washers got to flutes, and the step party of a gear wheel was turned forward (as well as before dismantling). Establish an intermediate shaft of the reverse gear and a lock uvula. Tighten a fixing bolt with the required effort. Components of an intermediate shaft of the reverse gear are shown on an accompanying illustration.

1 — a bolt
2 — a lock plate
3 — a shaft
4 — a persistent washer
5 — bearings
6 — a gear wheel

Establish the intermediate and conducted shaft in a transmission case. Turn an intermediate shaft so that its combined segment and teeth of a ring appeared opposite to the conducted shaft.
Establish the blocking ring of the synchronizer and the directing bearing of the conducted shaft (use dense lubricant), then, holding a shaft, combine a flat segment of a gear wheel of the synchronizer of a main shaft with an opening of the top cover, then establish a main shaft by means of the hammer with soft brisk.
Center an intermediate shaft and by means of the hammer with soft brisk establish an external holder of the forward bearing. Track that bearing it was turned by a razvaltsovanny part of a separator of rollers towards an intermediate shaft.
Prop up an intermediate shaft and establish an external holder of the back bearing (again use the hammer with soft brisk).
Press a piece of a firm board in a forward part of an intermediate shaft and turn transmission so that the board rested against a firm support. Put on dense lubricant a persistent washer (a facet on a shaft back), then put on the coupling of the bearing of a gear wheel of the reverse gear an intermediate shaft by means of a suitable mandrel. Track that the persistent washer on was clamped between the coupling and a separator of the bearing.
Grease sponges of a new epiploon and establish it in a forward cover. Using new laying, establish a forward cover on transmission and tighten bolts of its fastening with the required effort.

Manufacturers insist that in the points shown on an accompanying illustration (A) new bolts with a kontryashchy covering were established, however it is possible to use also old bolts, having greased their carving with Loctite 242 sealant (or equivalent to it).

Establish a coupling dome, the lever of switching off and the release bearing. Tighten fixing bolts with the required effort.
Slightly extend the conducted shaft from a back part of transmission and fill a suitable piece of a board ahead of a gear wheel of the second transfer (see an accompanying illustration) to prevent transfer of load of a main shaft when clothing on conducted bearings and a gear wheel of the fifth transfer.

1 — a gear wheel of the 2nd transfer
2 — the conducted shaft
3 — a case

Install transmission vertically, оперев a coupling dome on wooden blocks.
Remove a lock ring from the bearing of the conducted shaft and by means of a suitable mandrel put the bearing and a gear wheel of the fifth transfer on a shaft (components of a back part of the conducted shaft are shown on an accompanying illustration). Track that the bearing was installed by a flute under installation of a lock ring back. The acting part of a gear wheel has to rest against the bearing. Install a lock ring on the bearing.

1 — the bearing
2 — a lock ring
3 — a gear wheel of the 5th transfer
4 — the remote plug
5 — With-shaped lock half rings
6 — the holder

Having used a suitable mandrel, install the remote plug and the back bearing on the conducted shaft. Track that the plug was turned by grooves to a gear wheel of the fifth transfer, take a board piece from transmission.
Measure a side gap between one of With-shaped half rings and the bearing. Compare result to standard requirements. Pick up two half rings of the required thickness and establish on the conducted shaft the holder and a new lock ring.
Establish the holder of the bearing and previously tighten bolts with secret heads, having temporarily recorded the holder. Tighten all fixing bolts with the required effort. A center punch fuller a secret head of each of bolts in two points.
Dress the synchronizer coupling on a gear wheel of the fifth transfer of an intermediate shaft (the flat party to a gear wheel). The narrow risks drawn from the inside of the coupling have to are combined with grooves of the sliding keys.
Establish the sliding keys and springs. The long ends of keys and hooks of springs have to be turned to a gear wheel, and springs - it is correct to enter gearing with keys. In order to avoid a vyskakivaniye of the sliding keys and their springs establish the blocking synchronizer ring on assembly of a gear wheel of the fifth transfer.
Establish a gear wheel of the fifth transfer of an intermediate shaft and a fork of switching with a rod, having tracked that the end of a rod equipped with a lock ring was turned towards a transmission case. By means of a suitable mandrel put a synchronizer cone on an intermediate shaft.
Establish a washer on an intermediate shaft and measure a side gap between a lock ring and a washer. Compare result to standard requirements (see size tables and adjustments at the end of the Management) and pick up a new ring of the required thickness.
Check an axial side play of a gear wheel of the fifth transfer of an intermediate shaft.
Grease sponges of a new epiploon and by means of a suitable mandrel put an epiploon in a casing of lengthening of transmission.
Having replaced laying, establish a lengthening casing on transmission and tighten fixing bolts with the required effort.

Make assembly of the top cover (see an accompanying illustration):

1 — rods
2 — - the shock lever
3 — - a shock clamp
4 — - a fork of turning on of the reverse gear
5 — - a fork of switching of 1/2 transfers
6 — - the lever of turning on of the reverse gear
7 — - a fork of switching of 3/4 transfers

Establish control assembly of the reverse gear and put a fixing pin in a casing, having used the hammer and a drift.
Establish a fork of switching of 1/2 transfers, the shock lever and a fork of switching of 3/4 transfers to the top cover (observe the order of installation of components remembered in the course of dismantle). Insert a switching rod.
Establish a fork of turning on of the reverse gear and the lever of inclusion in the top cover (observe the correct order of installation of components).
Achieve combination of selections in forks of switching, the lever of turning on of the reverse gear, a shock clamp and the shock lever. Make sure that the shock clamp is located between edges in a casing (see an accompanying illustration), then establish new fixing pins.

1 — a shock clamp
2 — edges

Grease face traffic jams of rods of switching with Loctite 587 sealant (or equivalent to it) and establish traffic jams in a casing.
Grease the fixing ball and a guide and establish the last on the place, insert a ball and a spring into a casing of the top cover. Grease with sealant a cap and a carving of the sensor switch of fires of a backing and strongly screw them in a casing.
Establish an arm of the selector and the lever in a selector casing, insert a choice rod. Put new cylindrical pins in an arm of the selector and the lever. Grease with Loctite 587 sealant (or equivalent to it) new traffic jams and establish them in a selector casing.
Establish the directing plate, having tracked that it was turned by a circular flute on a selector casing forward (as it was noted during dismantle). Strongly tighten fixing bolts.
Grease the fixing plungers and balls and establish them together with springs in a selector casing according to the instruction made in the course of dismantle). Grease with Loctite 587 sealant (or equivalent to it) caps and strongly tighten them.
Establish a selector casing on the top cover (do not forget to replace laying) and tighten fixing bolts with the required effort.

Having replaced laying, establish assembly of the top cover on transmission, tighten fixing bolts with the required effort.

Collect a casing of management of the lever of gear shifting:
1. Install a rubber saddle on the lever;
2. Fill lubricant a nest and the plug on the end of the lever of switching and insert the lever into a nest, having recorded it a new lock ring.
3. Establish a spring and the lever in a casing, record a new lock ring.
4. Shift on a casing a protective rubber cover (F tag on a casing forward). Establish fixing collars.
Temporarily install the gear shifting lever on transmission and, turning a main shaft, make sure of freedom of rotation of transmission at any provisions of the lever.
At assembly of transmission of models 4.2 consider the differences which are available in it (see the Sections Dismantling and General Information ).

Models of 3.0 l

PERFORMANCE ORDER

Install bearings in casings (cases). Track that the back bearing of an intermediate shaft appeared aflush with a lengthening casing, and the lock ring in an external holder of the conducted shaft was turned towards a back part of the bearing plate.

If the bearing of the conducted shaft was also not replaced, it has to be all the same completed with a new lock ring.

Establish the holder of the bearing on the bearing plate and tighten bolts with the required effort.
By means of a press dress the bearing on a main shaft (the external holder has to be turned by a flute under installation of a lock ring from a gear wheel aside. Do not establish a ring in an external holder at this stage. Components of a forward part of transmission are presented on an accompanying illustration.


1 — a lock ring 2 — a coupling dome 3 — the bearing 4 — a washer 5 — a main shaft 6 — a remote ring 7 — the blocking synchronizer ring 8 — a spring 9 — the sliding keys 10 — the synchronizer coupling 11 — the conducted gear wheel of the 3rd transfer 12 — a ball	13 — the conducted shaft 14 — an adjusting washer 15 — the persistent bearing 16 — the plug 17 — a conic spring 18 — a gear ring 19 — an intermediate shaft 20 — the conducted gear wheel of the 2nd transfer 21 — a synchronizer nave 22 — the conducted gear wheel of the 1st transfer 23 — the bearing coupling

Establish a washer on a main shaft and measure a side gap between a lock ring and a flute. Compare result of measurement to standard requirements (see size tables and adjustments at the end of the Management) and pick up a new lock ring of the required thickness.
Grease with universal lubricant on a lithium basis a ball and establish it in an intermediate shaft. Establish a gear ring, a conic spring and the plug on an intermediate shaft. Track that the conic spring was developed by the concave party to a gear wheel.
Establish a lock ring on an intermediate shaft and begin to knock it on the seat by means of the mandrel of the suitable size which is put on the end of a shaft.
By means of a brass drift and the hammer install the persistent bearing on an intermediate shaft. Observe the direction of landing of the bearing noted dismantle process.
In a former order collect knots of synchronizers 1/2 and 3/4 of transfers. Track that the ends of springs on were hooked for the same sliding keys.
Grease the roller bearing of a gear wheel of the third transfer and put on it the conducted shaft.
Establish on a gear wheel of the third transfer knot of the synchronizer 3/4 of transfers with the blocking ring. Put on assembly the conducted shaft by means of a press. Track that the nave and the coupling of the synchronizer were turned by the conical party forward.
Measure a side gap between a lock ring and a flute. Compare result of measurement to standard data (see size tables and adjustments at the end of the Management) and pick up a new lock ring of the required thickness.
Grease the roller bearing of a gear wheel of the second transfer and install it from the opposite side of the conducted shaft.
Establish knot of the synchronizer 1/2 of transfers with the blocking ring on a gear wheel of the second transfer and put on assembly the conducted shaft by means of a press, propping up basic plates of the last a gear wheel of the second transfer.
Put on the coupling of the roller bearing of a gear wheel of the first transfer and a washer the conducted shaft and put the coupling by means of a press, having propped up plates of the last a washer. Remove a washer from the conducted shaft.
Grease the roller bearing of a gear wheel of the first transfer and establish assembly of the bearing with a gear wheel on the conducted shaft.
Grease with universal lubricant on a lithium basis a steel ball with a washer and establish them in the conducted shaft.
If replacement of components of a case of transmission, intermediate shaft, the persistent bearing, a gear ring was made, or actually intermediate shaft is replaced, check an axial side play of the last:
1. Establish an intermediate shaft in the bearing plate and dress the persistent bearing on its forward end.
2. Turn a dome of coupling and establish in it the bearing plate with an intermediate shaft, having achieved dense contact of the interfaced surfaces. Do not establish adjusting washers of the forward bearing of an intermediate shaft at this stage.
3. Screw and tighten two fixing bolts.
4. Fix the dial measuring instrument on the bearing plate so that its plunger nestled on an end face of an intermediate shaft. Move a shaft up-down and consider instrument reading.
5. Compare result of measurement to standard values of an axial side play (see the table below) for determination of the required thickness of an adjusting washer:

Size of an axial side play, mm	The required thickness of a washer, mm
0.93 ÷ 1.02	0.88
1.03 ÷ 1.12	0.96
1.13 ÷ 1.22	1.04
1.23 ÷ 1.32	1.12
1.33 ÷ 1.42	1.28
1.43 ÷ 1.52	1.36
1.53 ÷ 1.62	1.44

If replacement of a casing of lengthening, an intermediate gear wheel of the reverse gear, a shaft or persistent washer is made, check an axial side play of an intermediate gear wheel of the reverse gear:

Establish a persistent washer of an intermediate gear wheel of the reverse gear in a lengthening casing (as it was noted in the course of dismantle).
Put on a forward persistent washer of a gear wheel, roller bearings and a gear wheel an intermediate shaft of the reverse gear and establish assembly in a lengthening casing, having tracked correctness of the direction of landing of a washer.
Fix the dial measuring instrument on a lengthening casing, having pressed its plunger to an end face of an intermediate shaft of the reverse gear.
Lay the planeness measuring instrument (an edge of a steel ruler) across the interfaced surface of a casing of lengthening and press it to an end face of an intermediate shaft of the reverse gear. Lift a shaft against the stop in an edge of the measuring instrument of planeness and consider the indication of the indicator. If the size of an axial side play goes beyond admissible limits, it is necessary to pick up a new back persistent washer of a shaft of the required thickness.

Back persistent washers of two sizes - 1.97 mm and 2.07 mm are issued.

Clamp the bearing plate in a vice with soft sponges and grease bearings of the intermediate and conducted shaft with universal lubricant on a lithium basis.
Fill the back end of the conducted shaft in the bearing plate, tapping on the holder of the bearing with the hammer with soft brisk. That it was possible then to establish an intermediate shaft, do not put the conducted shaft up to the end.
On dense lubricant put the blocking ring of the synchronizer of the fourth transfer on a nave of the synchronizer 3/4 of transfers and put on assembly the conducted shaft. Track that flutes of the blocking ring were combined with the sliding keys.
Grease the roller bearing and dress it together with a remote ring in a main shaft. Dress a main shaft for conducted. Holding a main shaft, arrange intermediate so that teeth of the sprung ring were combined with its teeth. It is necessary for the purpose of introduction to gearings of gear wheels of both shaft. Establish an intermediate shaft in the bearing plate, holding for this purpose the top roller of the bearing with the screw-driver.
Finally put the intermediate and conducted shaft in the bearing plate for what press the conducted shaft, at the same time tapping with the hammer with soft brisk on the back party of a plate.
Prop up the forward end of an intermediate shaft and by means of a suitable mandrel put the coupling of the roller bearing of the fifth transfer on its back end.
By means of a mandrel put on a gear wheel of the fifth transfer the conducted shaft (also as it was established before dismantling).
Establish assembly of the bearing plate with shaft in a coupling dome.
Grease the roller bearing of a gear wheel of the fifth transfer and dress it on an intermediate shaft.
At the same time establish an intermediate shaft of the reverse gear and a gear wheel of the fifth transfer. Track that the fixing pin of a shaft got to deepening.
Put a cone of the synchronizer of the reverse gear on an intermediate shaft, and the coupling of the roller bearing of a gear wheel of the reverse gear - on conducted (use a suitable mandrel).
Install knot of the blocking ring of the synchronizer of the reverse gear with the sliding keys on the coupling of the synchronizer of the fifth transfer (as they were established before dismantling). Establish assembly on an intermediate shaft, having tracked that the coupling was turned by the slanted party from the bearing plate. Establish the blocking ring of the synchronizer of the fifth transfer.
By means of a suitable mandrel dress a gear wheel of the reverse gear on an intermediate shaft.
Establish a forward persistent washer of an intermediate gear wheel of the reverse gear on a gear wheel shaft in the same direction what it had before dismantling.
Grease a gear wheel of the reverse gear of the conducted shaft and roller bearings of an intermediate shaft of the reverse gear and dress components on the shaft.
Dress a persistent plate of an intermediate gear wheel of the reverse gear on the shaft (as it stood before dismantling).
By means of a suitable mandrel put a nave of the synchronizer of the reverse gear and a remote ring on the conducted shaft. Track that the nave was turned by dredging to the bearing plate.
Put on back bearings an intermediate shaft (use a mandrel).
Take assembly of the bearing plate with shaft from a dome of coupling and clamp a plate in a vice with soft sponges.
By means of the probe of lezviyny type measure a side gap between With figurative lock half rings and a flute in the conducted shaft. If the size of a gap exceeds 0.1 mm, establish new half rings of the required thickness.
By means of a brass drift establish half rings and the holder, then put a lock ring.
Establish a remote ring on the back end of an intermediate shaft and measure a side gap between a lock ring and a flute. Compare result of measurement to standard requirements (see size tables and adjustments at the end of the Management) and pick up a new lock ring of the required thickness.
Install the connecting coupling of the reverse gear on a nave of the reverse gear, having tracked that the coupling was turned by the slanted party to a nave.
Measure by the probe of lezviyny type an axial side play of gear wheels of the first, second, third and back transfers of the conducted shaft and a gear wheel of the fifth transfer of an intermediate shaft. If the size of a side play goes beyond admissible limits (see size tables and adjustments at the end of the Management), sort transmission and carefully check the corresponding gear wheels and the accompanying components for wear. Replace defective parts.
Install a fork of inclusion of the fifth transfer on the coupling of the synchronizer of the fifth transfer. Pass a switching rod through a fork throughout the bearing plate. Insert a new roller pin.
Install a fork of turning on of the reverse gear on the connecting coupling of the reverse gear, pass a switching rod through a fork throughout the bearing plate.
Establish a fork of switching of 1/2 transfers, the shock lever with a clamp and a fork of switching of 3/4 transfers as they were established before dismantling and insert a switching rod.
Install a new cylindrical pin in the shock lever and check smoothness of functioning of a rod of switching.
Establish a rod of switching of transfers by the back/fifth, grease with the fixing sealant a carving of a fixing bolt and tighten the last with the required effort.
Grease with universal lubricant on a lithium basis an adjusting washer of the forward bearing of an intermediate shaft and establish a washer in a coupling dome.
Grease with sealant 587 (or equivalent to it) the interfaced surface of a dome of coupling and establish the bearing plate with shaft, having tracked density of a prileganiye of the interfaced surfaces.
Install a new sealing ring and a control spring and a ball in the clamp coupling (grease components with universal lubricant on a lithium basis). Install the coupling and tighten a fixing bolt with the required effort.
Grease with sealant a carving of a cap of a clamp and tighten a cap with the required effort.
Dress a washer on the forward end of a rod of switching and establish new lock rings on a rod of switching and an external holder of the bearing of a main shaft.
Grease with universal lubricant on a lithium basis of a sponge of a new epiploon and establish an epiploon in a forward cover.
Having taken new laying, establish a forward cover on a dome of coupling and screw fixing bolts (the carving lower three, close to a coupling switching off lever opening, has to be greased with sealant).
Grease with universal lubricant on a lithium basis of a sponge of a new epiploon and establish an epiploon in a lengthening casing.
Grease with Loctite 587 sealant (or equivalent to it) the interfaced surface of the bearing plate. Press a lengthening casing, directing a selector arm to a switching rod. Make sure of density of a prileganiye of the interfaced surfaces. Tighten fixing screws with the required effort.
By means of a drift put a new cylindrical pin in a selector arm.
Install the lever of switching off and the release bearing of coupling.
Install transmission on the car.