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Nissan 240sx Manual Transmission Overhaul: mainshaft,input shaft, hub assembly and more

Nissan 240sx S13 1991-1994 Tranny model FS5W71C

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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.
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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. See image.
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. See image.
4. Measure thrust clearance of each gear.
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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)

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. See image.

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.
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COMPONENT DISASSEMBLY AND REASSEMBLY




INPUT SHAFT

Disassembly
Inspect input shaft, synchronizer ring and input shaft bearing for wear or damage. Rotate bearing by hand. If any roughness or binding is felt, replace input shaft bearing. Support bearing in blocks and press input shaft out of bearing.

Reassembly
Reverse procedure to install bearing. Select and install bearing retaining snap ring that will allow minimum snap ring groove clearance. Groove clearance should be 0-.005" (0-.13 mm). Refer to the following table:

INPUT SHAFT SNAP RING SPECIFICATION

MAINSHAFT

Disassembly
Remove 1st gear washer, steel ball and 1st gear with bearing. Support 2nd gear and press mainshaft out of 1st/2nd synchro assembly, bushing and 2nd gear. Support 3rd gear in blocks and press mainshaft out of 3rd/4th synchro assembly and 3rd gear with bearing.

Inspection
Thoroughly clean all bearings in solvent and dry with compressed air. DO NOT spin bearings with air pressure. Check all bearings for wear, scratches, pitting or flaking. Ensure bearings turn smoothly and do not bind. Inspect gears for excessive wear, chips, cracks or other damage. Replace as necessary. Check bearing journal surface of mainshaft for wear.

FYI: Coat all components with gear oil before reassembly.

Reassembly
Install 3rd gear with bearing. Press on 3rd/4th synchro assembly. Install 2nd gear with bearing on mainshaft. Press on 1st/2nd synchronizer assembly. Press on 1st gear bushing. Install 1st gear with bearing. Install steel ball and 1st gear washer.

SYNCHRO HUB ASSEMBLY

Disassembly
1. Slide synchro sleeve off of synchro hub. Remove springs and/or keys from synchro assembly. Note component positions and locations for reassembly reference. Wash all parts in solvent and blow dry with compressed air.
2. Check synchro sleeve for damage, cracking or excessive wear. Inspect synchro key or insert key for wear at shoulders. Check synchro hub and sleeve for smooth operation. Inspect remaining parts for damage or wear. Replace components as necessary.

Reassembly
To reassemble, reverse disassembly procedure. Fit synchro springs in 3 grooves of synchro hub. Ensure synchro key spring openings are offset.

Inspection (1-Piece Synchro Ring)
Check synchronizer rings for wear or damage. Turn and push ring to check braking action. Measure clearance between synchronizer ring back and gear spline end.

Clearance should be .047-.063" (1.20-1.60 mm). Service limit is .031" (.80 mm).
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Inspection (2-Piece Synchro Ring)
The 3rd/4th hub assembly uses a 2-piece synchro ring assembly. Apply pressure on inner and outer synchro ring against synchro cone. Measure clearance "A" between inner synchro ring and synchro cone. See figure. Clearance should be .024-.043" (.60-1.10 mm). Measure clearance "B" between outer synchro ring and synchro cone. Clearance should be .028-.035" (.70-.90 mm). Service limit for both measurements is .008" (.20 mm).
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TRANSMISSION REASSEMBLY


FYI: Overdrive gear and overdrive counter gear should only be replaced as a matched set.

1. If mainshaft and countershaft bearings have been replaced in intermediate plate, ensure rear bearing retainer screws have been staked in 2 locations after tightening.
2. Install mainshaft and countershaft in intermediate plate. Reverse disassembly procedure. Alternate press between mainshaft and countershaft when installing shafts. Support intermediate plate on Press Stand (KV31100401). Install 3rd gear with bearing. Press on 3rd/4th synchro assembly on mainshaft. See figure.
3. Install front thrust washer and snap ring. Select and install snap ring that will obtain minimum groove clearance. Groove clearance should be 0-.007" (0-.18 mm). Thickness of snap rings available are .094" (2.4 mm), .098" (2.5 mm) and .102" (2.6 mm). Part numbers are 32263-V5200, 32263-V52001 and 32263-V52002.
4. Press on counter drive gear while installing input shaft with bearing. Ensure small groove side of counter drive gear faces forward. Install sub-gear, spring and collar onto countershaft. Select and install snap ring that will obtain minimum snap ring groove clearance.
5. Groove clearance should be .000-.007" (.00-.18 mm). Thickness of snap rings available are .055" (1.4 mm), .059" (1.5 mm) and .063" (1.6 mm). Part numbers are 32215-E9000, 32215-E90001 and 32215- E90002. Using driver, press on countershaft front bearing. Install reverse idler gear assembly with shaft.
6. Install insert retainer and overdrive/5th synchro hub assembly onto mainshaft. Install overdrive gear bushing with Driver (ST22350000). Install overdrive gear with bearing. Install spacer, reverse counter gear and overdrive counter gear on countershaft. Install NEW lock nut. See figure
7. Install washer, thrust bearing, thrust washer and NEW lock nut on mainshaft. Install countershaft rear bearing. Mesh (shift) 2nd and reverse gears. Using Socket (ST22520000) and torque wrench, tighten mainshaft lock nut to specifications. See figure. Stake mainshaft and countershaft lock nuts.
8. Install snap ring and mainshaft rear bearing. Select and install rear bearing snap ring that will obtain minimum snap ring groove clearance. Groove clearance should be .000-.006" (.00-.14 mm). Thickness of snap rings available are .043" (1.1 mm), .047" (1.2 mm), .051" (1.3 mm) and .055" (1.4 mm). Part numbers are 32228-20100, 32228-201001, 32228-201002 and 32228-201003. Recheck thrust clearance of each gear. Also, See figure.
9. Install shift rods. Install interlock plunger, interlock balls and check balls.
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Install retaining roll pins in 1st/2nd shift fork, 3rd/4th shift fork and overdrive/reverse shift fork. Install overdrive and
everse fork shaft by rotating overdrive and reverse bracket clockwise.
10. Install "E" ring on overdrive and reverse fork rod. Install lever bracket securing bolt (if equipped). Apply sealant to transmission case and install gear assembly. Install input shaft front bearing snap ring.
11. Set all shift forks in Neutral position. Install shift rod into intermediate plate while aligning shift lever with shift brackets. Apply sealant to intermediate plate and install extension housing (2WD) or transfer case adapter (4WD). Install shift arm onto shift rod when installing housing or case.
12. Install shift arm retaining roll pin. Measure distance ("A") from front of transmission case to front of countershaft bearing.
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Clearance should be .178" (4.52 mm) to .185" (4.71 mm). If clearance is less than specifications, select and install correct shim. To determine correct shim, subtract mmeasurement ("A") from specification. Match difference to shims available.
13. Install front bearing retainer. Install shifter restrict pin assemblies. Install reverse check ball and spring. Install shifter control housing.

COUNTERSHAFT ADJUSTING SHIM SPECIFICATION


TORQUE SPECIFICATIONS Ft. Lbs. (N.m)



TORQUE SPECIFICATIONS INCH Lbs. (N.m)




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Nissan 240sx S13 1991-1994 Tranny model FS5W71C

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