Nissan 2004 350Z Owners Manual MT

: Nissan Nissan-2004-Nissan-350Z-Owners-Manual-818422 nissan-2004-nissan-350z-owners-manual-818422 nissan pdf

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MT-1

MANUAL TRANSMISSION

C TRANSMISSION/TRANSAXLE

CONTENTS

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SECTION MT A

B

MT

Revision: 2004 December 2004 350Z

MANUAL TRANSMISSION

PRECAUTIONS .......................................................... 2

Caution ..................................................................... 2

Precautions for Battery Service ................................ 2

PREPARATION ........................................................... 3

Special Service Tools ............................................... 3

Commercial Service Tools ........................................ 6

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING ................................................ 7

NVH Troubleshooting Chart ..................................... 7

MANUAL TRANSMISSION ................................... 7

DESCRIPTION ............................................................ 8

Cross-Sectional View ............................................... 8

DOUBLE-CONE SYNCHRONIZER ...................... 8

TRIPLE-CONE SYNCHRONIZER ........................ 9

M/T OIL ..................................................................... 10

Replacement .......................................................... 10

DRAINING ........................................................... 10

FILLING ............................................................... 10

Checking ................................................................ 10

OIL LEAKAGE AND OIL LEVEL ......................... 10

REAR OIL SEAL .......................................................11

Removal and Installation .........................................11

REMOVAL ............................................................11

INSTALLATION ....................................................11

POSITION SWITCH .................................................. 12

Checking ................................................................ 12

COMPONENT LOCATION .................................. 12

BACK-UP LAMP SWITCH .................................. 12

NEUTRAL POSITION SWITCH .......................... 12

SHIFT CONTROL ..................................................... 13

Removal and Installation ........................................ 13

REMOVAL ........................................................... 13

INSTALLATION ................................................... 15

INSPECTION AFTER INSTALLATION ................ 17

AIR BREATHER HOSE ............................................ 18

Removal and Installation ........................................ 18

TRANSMISSION ASSEMBLY .................................. 19

Removal and Installation from Vehicle ................... 19

REMOVAL ........................................................... 19

INSTALLATION ................................................... 21

Component Parts Drawing ..................................... 22

CASE COMPONENTS ........................................ 22

GEAR COMPONENTS ....................................... 23

SHIFT CONTROL COMPONENTS ..................... 25

Disassembly and Assembly .................................... 27

DISASSEMBLY ................................................... 27

INSPECTION AFTER DISASSEMBLY ................ 37

ASSEMBLY ......................................................... 41

SERVICE DATA AND SPECIFICATIONS (SDS) ...... 58

General Specifications ............................................ 58

End Play ................................................................. 58

Snap Rings ............................................................. 59

Baulk Ring Clearance ............................................. 60

MT-2

PRECAUTIONS

Revision: 2004 December 2004 350Z

PRECAUTIONS PFP:00001

Caution ACS004NF

●Do not reuse transmission oil, once it has been drained.

●Check oil level or replace oil with vehicle on level ground.

●During removal or installation, keep inside of transmission clear of dust or dirt.

●Check for the correct installation status prior to removal or disassembly. If mating marks are required, be

certain they do not interfere with the function of the parts they are applied to.

●In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If

tightening sequence is specified, observe it.

●Be careful not to damage sliding surfaces and mating surfaces.

Precautions for Battery Service ACS004NG

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-

ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the

window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic

window function will not work with the battery disconnected.

PREPARATION

MT-3

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PREPARATION PFP:00002

Special Service Tools ACS004NH

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number

(Kent-Moore No.)

Tool name

Description

ST30911000

(—)

a: 98 mm (3.86 in) dia.

b: 40 mm (1.57 in) dia.

Inserter

●Main shaft bearing installation

●5th-6th synchronizer assembly installation

●Reverse main gear bushing installation

●3rd gear bushing installation

●3rd-4th synchronizer assembly installation

ST30022000

(—)

a: 110 mm (4.33 in) dia.

b: 46 mm (1.81 in) dia.

Inserter

●3rd main gear installation

●4th main gear installation

ST27861000

(—)

a: 62 mm (2.44 in) dia.

b: 52 mm (2.05 in) dia.

Support ring

●1st-2nd synchronizer assembly installation

●1st gear bushing installation

ST33400001

(J26082)

a: 60 mm (2.36 in) dia.

b: 47 mm (1.85 in) dia.

Drift

Rear oil seal installation

KV381054S0

(—)

Oil seal puller

Remove rear oil seal

ST30032000

(J26010-01)

a: 80 mm (3.15 in) dia.

b: 31 mm (1.22 in) dia.

Inserter

Counter rear bearing inner race installation

ZZA0920D

ZZA0920D

ZZA0832D

ZZA0814D

ZZA0601D

ZZA0920D

MT-4

PREPARATION

Revision: 2004 December 2004 350Z

KV32102700

(—)

a: 48 mm (1.89 in) dia.

b: 41 mm (1.61 in) dia.

Drift

Main drive gear bearing installation

ST23860000

(—)

a: 38 mm (1.50 in) dia.

b: 33 mm (1.30 in) dia.

Drift

Reverse counter gear installation

ST01530000

(—)

a: 50 mm (1.97 in) dia.

b: 41 mm (1.61 in) dia.

Drift

Reverse synchronizer assembly installation

ST35291000

(—)

a: 40 mm (1.57 in) dia.

b: 29.5 mm (1.161 in) dia.

c: 22.5 mm (0.886 in) dia.

Drift

Striking rod oil seal installation

KV40100630

(J26092)

a: 67 mm (2.64 in) dia.

b: 38 mm (1.50 in) dia.

Inserter

4th counter gear thrust washer installation

KV38102100

(J25803-01)

a: 44 mm (2.36 in) dia.

b: 28 mm (1.10 in) dia.

Drift

Front cover oil seal installation

KV32103300

(J46529)

Press plate

a: 73 mm (2.87 in)

Reverse synchronizer assembly installation

Tool number

(Kent-Moore No.)

Tool name

Description

ZZA0534D

ZZA0534D

ZZA0534D

SCIA1575E

ZZA0920D

NT084

PCIB0165J

PREPARATION

MT-5

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Revision: 2004 December 2004 350Z

ST30031000

(J22912-01)

Puller

Inner baulk ring support

ST22490000

(—)

Adapter setting plate

Hold a adapter plate

Tool number

(Kent-Moore No.)

Tool name

Description

ZZC0499D

ZZC0465D

MT-6

PREPARATION

Revision: 2004 December 2004 350Z

Commercial Service Tools ACS004NI

Tool name Description

Puller Each bearing, gear and bushing removal

Pin punch

Tip diameter: 6.0 mm (0.24 in) dia.

Each retaining pin removal and installation

Power tool Loosening bolts and nuts

Puller Reverse synchronizer assembly removal

Reverse counter gear removal

Reverse main gear removal

ZZB0823D

ZZA0815D

PBIC0190E

NT077

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

MT-7

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Revision: 2004 December 2004 350Z

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart ACS004NJ

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-

tion. If necessary, repair or replace these parts.

MANUAL TRANSMISSION

Reference page

MT-10

MT-10

MT-10

MT-22

MT-22

MT-13

MT-25

MT-25

MT-25

MT-25

MT-25

MT-25

SUSPECTED PARTS

(Possible cause)

OIL (Oil level is low.)

OIL (Wrong oil.)

OIL (Oil level is high.)

GASKET (Damaged)

OIL SEAL (Worn or damaged)

SHIFT CONTROL LINKAGE (Worn)

CHECK PLUG RETURN SPRING AND CHECK BALL (Worn or damaged)

SHIFT FORK (Worn)

GEAR (Worn or damaged)

BEARING (Worn or damaged)

BAULK RING (Worn or damaged)

INSERT SPRING (Damaged)

Symptoms

Noise 1 2 3 3

Oil leakage 3122

Hard to shift or will not shift 1 1 2 2 2

Jumps out of gear 1122

MT-8

DESCRIPTION

Revision: 2004 December 2004 350Z

DESCRIPTION PFP:00000

Cross-Sectional View ACS004NK

DOUBLE-CONE SYNCHRONIZER

The 1st and 3rd, 4th gears is equipped with a double-cone synchronizer to reduce the operating force of the

shift lever as shown.

1. Front cover 2. Main drive gear 3. 5th-6th synchronizer hub

4. 5th-6th coupling sleeve 5. Transmission case 6. 6th main gear

7. 2nd main gear 8. 1st-2nd synchronizer hub 9. 1st-2nd coupling sleeve

10. 1st main gear 11. 3rd main gear 12. 4th main gear

13. Reverse main gear 14. Reverse coupling sleeve 15. Reverse synchronizer hub

16. Striking rod 17. Counter shaft 18. Filler plug

19. 6th counter gear 20. 2nd counter gear 21. 1st counter gear

22. 3rd counter gear 23. 3rd-4th synchronizer hub 24. 3rd-4th coupling sleeve

25. Drain plug 26. 4th counter gear 27. Reverse idler gear

28. Reverse idler shaft 29. Reverse counter gear 30. Main shaft

31. Rear extension

PCIB0672E

DESCRIPTION

MT-9

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Revision: 2004 December 2004 350Z

TRIPLE-CONE SYNCHRONIZER

The 2nd gear is equipped with a triple-cone synchronizer to reduce the operating force of the shift lever as

shown.

PCIB0594E

MT-10

M/T OIL

Revision: 2004 December 2004 350Z

M/T OIL PFP:KLD20

Replacement ACS004NL

DRAINING

1. Start the engine and warm up the transmission unit sufficiently.

2. After stopping engine, remove filler plug and drain plug and then drain fluid.

3. After replace a new gasket on drain plug, screw drain plug into transmission body and tighten to the spec-

ified torque. Refer to MT-22, "CASE COMPONENTS" .

CAUTION:

Gaskets are not reusable. Never reuse them.

FILLING

1. Remove filler plug. Fill new oil into the transmission to the level of the filler plug mounting hole.

2. After filling, check fluid level, replace a new gasket on filler plug, screw filler plug into transmission body,

and tighten to the specified torque. Refer to MT-22, "CASE COMPONENTS" .

CAUTION:

Gaskets are not reusable. Never reuse them.

Checking ACS004NM

OIL LEAKAGE AND OIL LEVEL

●Check if oil is leaking from transmission or around it.

●Check oil level from filler plug mounting hole as shown in the fig-

ure.

CAUTION:

Never start engine while checking oil level.

●When screwing in filler plug with a new gasket, first screw into

the transmission by hand, then tighten to the specified torque.

Refer to MT-22, "CASE COMPONENTS" .

CAUTION:

Gaskets are not reusable. Never reuse them.

Oil grade: API GL-4

Viscosity: Refer to MA-12, "Fluids and Lubricants" .

Oil capacity: Approx. 2.9 ( 3-1/8 US qt, 2-1/2 lmp qt)

PCIB0268E

REAR OIL SEAL

MT-11

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Revision: 2004 December 2004 350Z

REAR OIL SEAL PFP:33140

Removal and Installation ACS004NN

REMOVAL

1. Remove propeller shaft. Refer to PR-7, "REMOVAL" .

CAUTION:

Do not impact or damage propeller shaft tube.

2. Using oil seal puller, remove rear oil seal.

INSTALLATION

1. Apply multi-purpose grease to rear oil seal lip. Using a drift,

drive in rear oil seal until the edge is approximately 1.2 - 2.2 mm

(0.047 - 0.087 in) above the boss edge.

CAUTION:

●Rear oil seals are not reusable. Never reuse them.

●When installing, do not incline the rear oil seal.

2. Install propeller shaft. Refer to PR-8, "INSTALLATION" .

CAUTION:

●Do not impact or damage propeller shaft tube.

●If lubricant leak has occurred, after finishing work, check oil level. Refer to MT-10, "Checking" .

Tool number : KV381054S0 ( — )

PCIB0194E

Tool number : ST33400001 (J26082)

PCIB0595E

MT-12

POSITION SWITCH

Revision: 2004 December 2004 350Z

POSITION SWITCH PFP:32005

Checking ACS004NO

COMPONENT LOCATION

BACK-UP LAMP SWITCH

●Check continuity.

NEUTRAL POSITION SWITCH

●Check continuity.

PCIB0622E

Gear position Continuity

Reverse Yes

Except reverse No

SCIA0645E

Gear position Continuity

Neutral Yes

Except neutral No

SCIA0645E

SHIFT CONTROL

MT-13

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SHIFT CONTROL PFP:34103

Removal and Installation ACS004NP

REMOVAL

1. Remove the shift knob with the following procedure.

a. Disconnect console boot from center console. Refer to IP-11,

"Removal and Installation" .

1. Insulator 2. Seat 3. Control lever

4. Control lever spring 5. Guide plate 6. Control lever boot

7. Hole cover 8. Shift knob

PCIB0689E

PCIB0596E

MT-14

SHIFT CONTROL

Revision: 2004 December 2004 350Z

b. Lift console boot, and push down hole cover. Set water pump

plier and others to control lever assembly.

CAUTION:

Put waste cloth between water pump plier and control lever

assembly to avoid damaging control lever assembly.

c. Set monkey wrench to shift knob.

CAUTION:

Put waste cloth between shift knob and suitable plier to

avoid damaging shift knob.

d. Turn monkey wrench with water pump plier and others fixed.

Loosen shift knob, and remove shift knob from control lever

assembly.

NOTE:

Remove shift knob from control assembly with water pump plier

and others fixed. Because a certain power to turn shift knob is

necessary even after adhesive is peeled.

2. Loosen the shift knob to remove the control lever.

3. Remove console boot. Refer to IP-11, "Removal and Installa-

tion" .

4. Push back the boot, remove control lever assembly mounting

bolt, and separate control lever and control rod assembly.

PCIB0222E

PCIB0246E

PCIB0247E

SCIA1671E

SHIFT CONTROL

MT-15

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Revision: 2004 December 2004 350Z

5. Remove the mounting bolts to remove the hole cover.

6. Remove the control lever boot.

7. Remove guide plate mounting bolts, and then remove control

lever assembly and control lever spring.

INSTALLATION

1. Set control lever assembly and control lever spring in the control lever housing assembly and loosely

mount the guide plate.

2. After installing control lever assembly in the control rod assem-

bly, tighten bolts to the specified torque. Refer to MT-13,

"Removal and Installation" .

SCIA1511E

SCIA1365E

SCIA1671E

MT-16

SHIFT CONTROL

Revision: 2004 December 2004 350Z

3. Shifting control lever assembly to 6th gear, the control lever

assembly is light pressed to the reverse side.

4. At the point where the control lever assembly stops, bring the

guide plate closer until guide plate stopper contacts control lever

assembly claw, and then loosely tighten mounting bolt A.

5. Shifting control lever assembly to 5th gear, the control lever

assembly light pressed to the reverse side.

6. At the point where control lever assembly stops, bring guide

plate closer until the guide plate stopper contacts control lever

assembly claw, and then loosely tighten mounting bolt C. Refer

to MT-13, "Removal and Installation" .

7. Tighten guide plate bolts A and B to the specified torque. Refer

to MT-13, "Removal and Installation" .

8. Install control lever boot.

9. Install hole cover and tighten bolt to the specified torque. Refer

to MT-13, "Removal and Installation" .

10. Install console boot. Refer to IP-11, "Removal and Installation" .

11. As shown in the figure, assemble seat and insulator to control

lever assembly.

CAUTION:

Do not reuse the insulator.

12. Apply locking sealant to control lever threads, install shift knob.

CAUTION:

Remove the remaining adhesive on control lever and shift

knob threads.

SCIA1665E

SCIA1666E

SCIA1771E

SHIFT CONTROL

MT-17

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13. Put the shift knob in the correct position as the following indicates.

a. When tightening shift knob, if shift knob position is the correct

position a less than 1/2 rotation from starting resistance, tighten

1 more rotation and set the correct position again.

b. If shift knob position is the correct position more than 1/2 rotation

from starting resistance, tighten and set the correct position.

CAUTION:

●Do not adjust the knob with loosing.

●After adjusting to regular position, until 30 minute passes

since a locking sealant because stiff. Do not operate the

shift intensely such as screwing or turning the shift knob

to opposite direction.

INSPECTION AFTER INSTALLATION

After installing, confirm the following items:

●When control lever assembly is shifted to each position, make sure there is no binding or disconnection in

each boot.

●When shifted to each position, make sure there is no noise, bending, and backlash. Especially when con-

trol lever assembly is shifted to 5th, 6th without pressing downward, check for bending.

●When control lever assembly is shifted to 1st, 2nd side and 5th, 6th side, confirm control lever assembly

returns to neutral position smoothly.

●In any position other than reverse, confirm that control lever assembly can be pressed downward.

●With control lever assembly pressed downward, confirm that it can be shifted to reverse.

●When shifted from reverse to neutral position, confirm control lever assembly returns to neutral position

smoothly with spring power.

●Without control lever assembly pressed downward, confirm that it cannot be shifted to reverse.

SCIA1774E

MT-18

AIR BREATHER HOSE

Revision: 2004 December 2004 350Z

AIR BREATHER HOSE PFP:31098

Removal and Installation ACS004NQ

Refer to the figure for air breather hose removal and installation information.

CAUTION:

●Make sure there are no pinched or blocked areas on the air breather hose caused by bending or

winding when installing it.

●Insert overlap width of air breather hose as far as it will go.

1. Air breather hose

PCIB0690E

TRANSMISSION ASSEMBLY

MT-19

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TRANSMISSION ASSEMBLY PFP:32010

Removal and Installation from Vehicle ACS004NR

REMOVAL

1. Disconnect battery negative cable.

2. Remove front cross bar with power tool. Refer to FSU-9, "REMOVAL" .

3. Remove catalytic converter stay mounting nuts and bolts, and

then remove catalytic converter bracket. Refer to EX-3,

"Removal and Installation" .

4. Remove nut connecting catalytic converter to exhaust manifold, and then remove catalytic converter and

exhaust front tube as one unit.

5. Remove propeller shaft. Refer to PR-7, "Removal and Installation" .

CAUTION:

Do not impact or damage propeller shaft tube.

6. Remove control rod mounting bolts and then separate shift lever

assembly from the control rod assembly.

1. Transmission case 2. Rear engine mounting member 3. Insulator

PCIB0691E

SCIA1471E

SCIA1364E

MT-20

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

7. Using a screwdriver wrapped in tape to remove claw and then

separate console boot from the center console. Refer to IP-11,

"Removal and Installation" .

8. Remove hole cover mounting bolts and then separate hole

cover from the floor panel.

9. Separate control lever boot from the guide plate.

10. Remove guide plate mounting bolts and then separate shift lever

assembly from the shift lever housing assembly.

11. Remove clutch operating cylinder mounting bolts and then separate heat insulator and clutch operating

cylinder from the transmission case. Refer to CL-11, "Removal and Installation" .

12. Remove crankshaft position sensor (POS).

CAUTION:

●Do not subject it to impact by dropping or hitting.

●Do not disassemble.

●Do not allow metal filings, etc., to get on the sensor's

front edge magnetic area.

●Do not place in an area affected by magnetism.

13. Disconnect neutral position switch and back-up lamp switch.

14. Separate heated oxygen sensor 2 wire harness, crankshaft

position sensor (POS), wire harness, back-up lamp switch wire

harness and PNP switch wire harness from the transmission.

15. Remove starter motor. Refer to SC-19, "Removal and Installation" .

16. Remove rear cover plate. Refer to EM-27, "Removal and Installation" .

17. Set transmission jack to the transmission.

CAUTION:

When setting transmission jack, be careful not to contact with the switch.

SCIA1473E

SCIA1590E

SCIA1591E

SCIA1476E

TRANSMISSION ASSEMBLY

MT-21

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18. Remove rear engine mounting member. Refer to EM-103,

"Removal and Installation" .

19. Remove engine and transmission mounting bolts with power

tool.

20. Remove transmission from the vehicle.

INSTALLATION

Install in the revers order of removal procedure, following the cautions below:

●When installing transmission to the engine, install mounting bolts in accordance with the standards below.

LHD Model

CAUTION:

●When installing, be careful to avoid interference between transmission main drive shaft and clutch

cover.

●If flywheel is removed, align dowel pin with the smallest hole of flywheel. Refer to EM-115,

"ASSEMBLY" .

●Do not impact or damage propeller shaft tube.

●Refer to MT-15, "INSTALLATION"MT-17, "INSPECTION AFTER INSTALLATION" for control lever

installation information.

●After installation, check oil level, and oil leaks and loose mechanisms.

SCIA1531E

Bolt No. 1 2 3 4 5

Quantity 15222

“ ” mm (in) 55

(2.17)

65

(2.56)

50

(1.97)

35

(1.38)

65

(2.56)

Tightening torque

N·m (kg-m, ft-lb)

75

(7.7, 55)

55.4

(5.7, 41)

46.6

(4.8, 34)

55.4

(5.7,41)

PCIB0700E

MT-22

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

Component Parts Drawing ACS004NS

CASE COMPONENTS

1. Front cover gasket 2. Front cover 3. Withdrawal lever ball pin

4. Washer 5. Front cover oil seal 6. Oil gutter

7. Bushing 8. Bushing 9. Dowel pin

10. Bushing 11. Breather 12. Filler plug

13. Bracket 14. Gasket 15. Transmission case

16. Drain plug 17. Sliding ball bearing 18. Bushing

19. Magnet 20. Baffle plate 21. Adapter plate

22. Main shaft bearing retainer 23. Main shaft bearing retainer 24. Bushing

25. Rear extension oil gutter 26. Bracket 27. Rear extension

28. Back-up lamp switch 29. Rear oil seal 30. Rear extension dust cover

31. Striking rod oil seal 32. Sliding ball bearing 33. Check ball

PCIB0900E

TRANSMISSION ASSEMBLY

MT-23

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GEAR COMPONENTS

34. Check select spring 35. Rear extension upper cover 36. Rear extension upper cover gasket

37. Plunger 38. Bracket 39. Sliding ball bearing

40. Neutral position switch 41. Sliding ball bearing 42. Sliding ball bearing

1. Snap ring 2. Main drive gear bearing 3. Snap ring

4. Main drive gear 5. Main pilot bearing 6. Pilot bearing spacer

7. Snap ring 8. 5th baulk ring 9. 5th - 6th spread spring

10. 5th-6th shifting insert 11. 5th-6th synchronizer hub 12. 5th - 6th coupling sleeve

13. 6th baulk ring 14. 6th main gear 15. 6th needle bearing

16. Main shaft 17. 2nd main gear 18. 2nd needle bearing

19. 2nd inner baulk ring 20. 2nd synchronizer cone 21. 2nd outer baulk ring

22. 1st-2nd spread spring 23. 1st - 2nd synchronizer hub 24. 1st - 2nd shifting insert

25. 1st - 2nd coupling sleeve 26. 1st outer baulk ring 27. 1st synchronizer cone

28. 1st inner baulk ring 29. 1st main gear 30. 1st needle bearing

31. 1st gear bushing 32. 3rd main gear 33. 3rd - 4th main spacer

34. 4th main gear 35. Main shaft bearing 36. Snap ring

37. Reverse main gear 38. Reverse main needle bearing 39. Reverse main gear bushing

40. Reverse baulk ring 41. Reverse spread spring 42. Reverse synchronizer hub

43. Reverse shifting insert 44. Reverse coupling sleeve 45. Snap ring

46. Snap ring

PCIB0693E

MT-24

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

1. Snap ring 2. Reverse counter gear 3. Counter rear bearing spacer

4. Counter rear bearing 5. Counter rear bearing inner race 6. 4th counter gear thrust washer

7. 4th gear bushing 8. 4th needle bearing 9. Counter front bearing

10. Counter shaft 11. 3rd gear bushing 12. 3rd needle bearing

13. 3rd counter gear 14. 3rd inner baulk ring 15. 3rd synchronizer cone

16. 3rd outer baulk ring 17. 3rd - 4th spread spring 18. 3rd - 4th synchronizer hub

19. 3rd - 4th shifting insert 20. 3rd - 4th coupling sleeve 21. 4th outer baulk ring

22. 4th synchronizer cone 23. 4th inner baulk ring 24. Reverse idler shaft

25. Reverse idler needle bearing 26. Reverse idler gear 27. Reverse idler thrust washer

28. 4th counter gear 29. Counter end bearing

PCIB0597E

TRANSMISSION ASSEMBLY

MT-25

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Revision: 2004 December 2004 350Z

SHIFT CONTROL COMPONENTS

1. Check ball plug 2. Check ball spring 3. Check ball

4. Interlock pin 5. Retaining pin 6. Striking lever

7. 3rd-4th fork rod bracket 8. 3rd-4th fork rod 9. 3rd - 4th fork rod (reversal side)

10. 1st-2nd fork rod 11. 1st-2nd shift fork 12. 3rd-4th shift fork

13. 5th-6th shift fork 14. 5th-6th fork rod (reversal side) 15. 5th-6th fork rod

16. Shifter cap 17. 3rd-4th control lever 18. 5th-6th fork rod bracket

19. 5th-6th control lever 20. Adapter plate 21. Reverse fork rod

22. Reverse shift fork 23. Striking rod 24. Low/high control lever

25. Stopper ring 26. Interlock plunger

PCIB0902E

MT-26

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

1. Control lever spring 2. Control lever housing 3. Control lever

4. Check shift pin 5. Control bracket 6. Return spring plug

7. Return spring plunger 8. Return spring 9. Rear extension

10. Return spring 11. Return spring plunger 12. Boot

13. Boot 14. Control rod 15. Retaining pin

16. Check ball 17. Check select spring 18. Dynamic damper bracket

19. Dynamic damper

PCIB0901E

TRANSMISSION ASSEMBLY

MT-27

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Revision: 2004 December 2004 350Z

Disassembly and Assembly ACS004NT

DISASSEMBLY

Case Components

1. Remove rear extension upper cover mounting bolts.

2. Remove rear extension upper cover and rear extension upper

cover gasket from the rear extension.

3. Remove check select spring and check ball from the rear exten-

sion.

4. Remove retaining pin using a pin punch [6 mm (0.24 in) dia.],

and remove control rod.

5. Remove neutral position switch, plunger and back-up lamp

switch from the rear extension.

6. Remove control bracket mounting bolts. Then remove check

shift pin and control bracket as one unit from the rear extension.

SCIA1393E

PCIB0599E

SCIA1437E

SCIA1440E

MT-28

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

7. Remove right and left return spring plug. Then remove return

spring and return spring plunger from the rear extension.

CAUTION:

Return spring and return spring plunger have different

lengths for right and left sides. Identify right and left side

and then store.

8. Remove rear oil seal from the rear extension using an oil seal

puller.

9. Remove rear extension mounting bolts. Using a soft hammer,

tap rear extension assembly to remove.

10. Remove control lever housing mounting bolts, and remove con-

trol lever housing from the rear extension.

11. Remove striking rod oil seal from the rear extension. Refer to

MT-22, "CASE COMPONENTS" .

12. Remove rear extension oil gutter from the rear extension. Refer

to MT-22, "CASE COMPONENTS" .

13. Remove reverse idler thrust washer, revers idler gear, and

reverse idler needle bearing from the reverse idler shaft.

14. Remove reverse idler shaft from the adapter plate.

15. Remove withdrawal lever ball pin and washer from the front

cover.

16. Remove front cover mounting bolts, then remove front cover

assembly and front cover gasket from the transmission case.

SCIA1441E

Tool number : KV381054S0 ( — )

PCIB0196E

PCIB0141E

PCIB0152E

PCIB0600E

TRANSMISSION ASSEMBLY

MT-29

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Revision: 2004 December 2004 350Z

17. Remove front cover oil seal from the front cover assembly, using

a flat-bladed screwdriver.

CAUTION:

Be careful not to damage front cover mating surface.

18. Remove baffle plate mounting nut from the transmission case.

19. Remove snap ring from the main drive gear bearing, using snap

ring pliers.

20. Using a soft hammer to carefully tap main shaft and counter

shaft from the transmission case side, and then separate

adapter plate and transmission case.

21. Remove counter front bearing from the transmission case.

22. Remove oil gutter from the transmission case.

SCIA1399E

SCIA1443E

SCIA1532E

SCIA1687E

PCIB0436E

MT-30

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

Shift Control Components

1. Install adapter setting plate to the adapter plate and then fixing

in adapter setting plate using a vise.

CAUTION:

Do not directly secure the surface in a vise.

2. Remove baffle plate mounting bolts, and remove baffle plate

from the adapter plate.

3. Remove magnet from the adapter plate.

4. Remove retaining pin using a pin punch [6 mm (0.24 in) dia.],

and remove striking lever and striking rod.

5. Remove check ball plug and then remove check ball spring and

check ball from the adapter plate.

Tool number : ST224490000 ( — )

PCIB0254E

PCIB0154E

PCIB0414E

PCIB0143E

TRANSMISSION ASSEMBLY

MT-31

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Revision: 2004 December 2004 350Z

6. Remove 3rd - 4th control lever mounting bolts and then remove

3rd - 4th control lever and shifter cap.

7. Remove check ball plug and then remove check ball spring and

check ball from the adapter plate.

8. Using a pin punch [6 mm (0.24 in) dia.] to knock out retaining

pin, and then remove 3rd - 4th fork rod bracket and 3rd - 4th fork

rod.

9. Using a pin punch [6 mm (0.24 in) dia.] to knock out retaining

pin, and then remove 3rd - 4th shift fork and 3rd - 4th fork rod

(reversal side).

10. Remove check ball and interlock pin from the adapter plate.

PCIB0235E

PCIB0144E

PCIB0145E

PCIB0601E

PCIB0146E

MT-32

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

11. Using a pin punch [6 mm (0.24 in) dia.] to knock out retaining

pin, and then remove 1st - 2nd shift fork and 1st - 2nd fork rod.

12. Remove interlock plunger and interlock pin from the adapter

plate.

13. Using a pin punch [6 mm (0.24 in) dia.] to knock out retaining

pin, and then remove reverse shift fork and reverse fork rod.

14. Remove check ball from the adapter plate.

15. Remove 5th - 6th control lever mounting bolts and then remove

5th - 6th control lever from the adapter plate.

PCIB0602E

PCIB0147E

SCIA1447E

PCIB0148E

PCIB0238E

TRANSMISSION ASSEMBLY

MT-33

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Revision: 2004 December 2004 350Z

16. Using a pin punch [6 mm (0.24 in) dia.] to knock out retaining

pin, and then remove 5th - 6th fork rod bracket and 5th - 6th fork

rod.

17. Using a pin punch [6 mm (0.24 in) dia.] to knock out retaining

pin, and then remove 5th - 6th fork rod (reversal side) and 5th -

6th shift fork.

Gear Components

●Before disassembly, measure end play for each position. If the end play is outside the standards, disas-

semble and inspect.

–Main drive gear

–Main shaft

PCIB0239E

PCIB0412E

End play : 0 - 0.10mm (0 - 0.004in)

PCIB0484E

End play : 0 - 0.10mm (0 - 0.004in)

PCIB0225E

MT-34

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

–Counter shaft

1. After removing snap ring and reverse coupling snap ring, using

puller to remove reverse main gear and reverse synchronizer

assembly.

2. Remove reverse main needle bearing.

3. Remove main shaft bearing retainer mounting bolts and then

remove main shaft bearing retainer.

4. After removing snap ring, using the puller to remove reverse

counter gear and counter rear bearing spacer.

5. Remove snap ring from the main shaft bearing.

End play : 0 - 0.10mm (0 - 0.004in)

PCIB0226E

SCIA1683E

SCIA1452E

SCIA1682E

SCIA1691E

TRANSMISSION ASSEMBLY

MT-35

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Revision: 2004 December 2004 350Z

6. Carefully tap main shaft with a plastic hammer and then remove

main shaft, main drive gear, and counter shaft from adapter

plate.

7. Remove pilot bearing spacer and main pilot bearing.

8. Remove counter rear bearing from the adapter plate.

9. Remove snap ring from the main drive gear using snap ring pli-

ers.

10. Set the suitable puller on the main drive gear and then using a

press to remove main drive gear bearing from the main drive

gear.

11. Using a press to remove the reverse main gear bushing, main

shaft bearing and 4th main gear.

SCIA1456E

PCIB0244E

SCIA1461E

SCIA1533E

SCIA1386E

MT-36

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

12. Remove 3rd - 4th main spacer.

13. Using a press to remove 1st main gear and 3rd main gear.

CAUTION:

Be careful not to damage the baulk ring.

14. Remove 1st needle bearing.

15. Using a press to remove 1st gear bushing, 1st - 2nd synchro-

nizer assembly, and 2nd main gear.

CAUTION:

Be aware that when using the press, if the main shaft gear

positioner catches on the V-block, etc., the main shaft

could be damaged.

16. Remove 2nd needle bearing.

17. After removing snap ring, using a press to remove 6th main gear

and 5th - 6th synchronizer assembly.

18. Remove 6th needle bearing.

19. Using a press to remove the 3rd counter gear, 3rd - 4th synchro-

nizer assembly, 4th counter gear, 4th needle bearing, 4th gear

bushing, 4th counter gear thrust washer, and counter rear bear-

ing inner race.

20. Remove 3rd needle bearing.

SCIA1458E

SCIA1459E

SCIA1460E

SCIA1389E

TRANSMISSION ASSEMBLY

MT-37

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Revision: 2004 December 2004 350Z

21. Using a press to remove the 3rd gear bushing.

INSPECTION AFTER DISASSEMBLY

Shift Control

If the contact surface on striking lever, fork rod, shift fork, etc. has

excessive wear, abrasion, bend, or any other damage, replace the

components.

Gear and Shaft

If the contact surface on each gear, main shaft, main drive gear, and

counter shaft, etc. has damage, peeling, abrasion, dent, bent, or any

other damage, replace the components.

SCIA1534E

SCIA1681E

PCIB0437E

MT-38

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

Synchronizer

●If the contact surface on coupling sleeve, synchronizer hub, and

shifting insert has damage or abrasion, replace the components.

●Coupling sleeve and synchronizer hub shall move smoothly.

●If the cam surface on baulk ring or contact surface on insert has

damage or excessive wear, replace with a new one.

●If spread spring damaged, replace with a new one.

Baulk Ring Clearance

●Single Cone Synchronizer (5th & 6th)

Push baulk ring on the cone and measure baulk ring back sur-

face clearance at two locations or more on opposite sides, find

the average value, and replace it if it is outside the limit value.

●Double Cone Synchronizer (1st & 3rd & 4th)

PCIB0438E

SMT387A

SCIA0608J

Clearance

Standard : 0.70 - 1.25 mm (0.028 - 0.049 in)

Limit value : 0.5 mm (0.020 in) or less

SMT140

TRANSMISSION ASSEMBLY

MT-39

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Revision: 2004 December 2004 350Z

Follow the instructions below and inspect the clearance of the

outer baulk ring, synchronizer cone, inner baulk ring.

CAUTION:

Clearances “A” and “B” of the outer baulk ring, synchro-

nizer cone, and inner baulk ring are controlled as a set, so if

the clearance is outside the limit value, replace the syn-

chronizer assembly.

1. Using a dial gauge, measure clearance A at 2 or more points

diagonally opposite, and calculate mean value.

2. Using a feeler gauge, measure clearance B at 2 or more points

diagonally opposite, and calculate mean value.

●Triple cone synchronizer (2nd)

Check clearance for 2nd outer baulk ring, 2nd synchronizer

cone, and 2nd inner baulk ring of triple cone synchronizer follow-

ing the direction.

NOTE:

2nd outer baulk ring, 2nd synchronize cone, and 2nd inner baulk

ring, three control“clearance A, B and C” as a three-piece suite.If

the value exceeds the limit value, replace them as a three-piece

suite.

1. Using feeler gauge put and press baulk ring on 2nd main gear

taper cone, and then measure “clearance A” at more then 2

diagonal points, and calculate the average.

SCIA1679E

Clearance A

Standard : 0.5 - 0.7 mm (0.020 - 0.028 in)

Limit value : 0.3 mm (0.012 in) or less

Tool number : ST30031000 (J22912-01)

PCIB0673E

Clearance B

Standard(1st) : 1.0 - 1.5mm(0.039 - 0.059 in)

Standard(3rd,4th) : 0.85 - 1.35mm (0.033 - 0.053 in)

Limit value : 0.7mm(0.028 in) or less

SCIA1084E

PCIB0603E

Clearance A

Reference value : 0.6-1.3 mm (0.024 - 0.051in)

Limit value : 0.3mm (0.012 in) or less

PCIB0887E

MT-40

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

2. Using feeler gauge measure “clearance B” at more than 2 diago-

nal positions, and calculate the average.

3. Using filler gauge put and press baulk ring on 2nd main gear

taper cone, and then measure “clearance C” at more then 2

diagonal points, and calculate the average.

●Reverse Synchronizer

Push baulk ring on the cone and measure baulk ring back sur-

face clearance at two locations or more on opposite sides, find

the average value, and replace if it is outside the limit value.

Bearing

If the bearing does not rotate smoothly or the contact surface on ball

or race is damaged or peeled, replace with new ones.

Clearance B

Reference value : 0.85 - 1.35 mm (0.033 - 0.053in)

Limit value : 0.7mm (0.028 in) or less

PCIB0605E

Clearance C

Reference value : 0.7-1.25 mm (0.028 - 0.049in)

Limit value : 0.3mm (0.012 in) or less

PCIB0888E

Clearance

Standard : 0.75-1.2 mm (0.030 - 0.047 in)

Limit value : 0.5 mm (0.020 in) or less

SMT140

SMT418A

TRANSMISSION ASSEMBLY

MT-41

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Revision: 2004 December 2004 350Z

ASSEMBLY

Gear Components

1. Install 5th - 6th coupling sleeve and 5th - 6th shifting insert in the

5th - 6th synchronizer hub.

CAUTION:

Install 5th - 6th coupling sleeve with the larger chamfer on

the rear side.

2. Install 5th - 6th spread spring in the 5th - 6th shifting insert.

CAUTION:

●Do not install 5th - 6th spread spring hook onto the same

5th - 6th shifting insert.

●Be careful with the shape of reserve shifting insert to

avoid misassembly.

3. Install 6th needle bearing, 6th main gear and 6th baulk ring on

the main shaft and then using an inserter and a press to press fit

the 5th - 6th synchronizer assembly.

SCIA1597E

PCIB0607E

PCIB0608E

Tool number : ST30911000 ( — )

PCIB0219E

MT-42

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

CAUTION:

●The 5th - 6th synchronizer hub is not reusable. Never

reuse it.

●When press fitting, install with the side having the three

boss edge oil grooves facing the rear side.

NOTE:

5th and 6th baulk rings have three spaces that two gear teeth

are missing as shown in the figure.

4. Select and install a snap ring so that the end play comes within

the standard value. Refer to MT-59, "Snap Rings" .

CAUTION:

Snap rings are not reusable. Never reuse them.

5. Install 1st - 2nd coupling sleeve and 1st - 2nd shifting insert into

the 1st - 2nd synchronizer hub.

CAUTION:

Install 1st - 2nd coupling sleeve with the thicker flange

faced the front side.

SCIA2699E

PCIB0398E

End play : 0 - 0.10 mm (0 - 0.004 in)

PCIB0609E

PCIB0610E

TRANSMISSION ASSEMBLY

MT-43

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6. Install 1st - 2nd spread spring in the 1st - 2nd shifting insert.

CAUTION:

●Do not install 1st - 2nd spread spring hook onto the same

1st - 2nd shifting insert.

●Be careful with the shape of reverse shifting insert to

avoid misassembly.

7. Install 2nd main gear, 2nd needle bearing, 2nd inner baulk ring,

2nd synchronizer cone, 2nd outer baulk ring on the main shaft

and then using a support ring and a press to press fit the 1st -

2nd synchronizer assembly.

CAUTION:

●The 1st - 2nd synchronizer hub is not reusable. Never

reuse it.

●When press fitting, install with the side having the three

boss edge oil grooves facing the front side.

PCIB0611E

PCIB0608E

Tool number : ST27861000 ( — )

PCIB0202E

SCIA2700E

MT-44

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

NOTE:

1st baulk ring has three spaces that one gear tooth is missing

and 2nd baulk ring has three spaces that two gear teeth are

missing.

8. Using a support ring and a press to press fit the 1st gear bush-

ing.

9. Install 1st outer baulk ring, 1st synchronizer cone, 1st inner

baulk ring, 1st needle bearing, and 1st main gear on the main

shaft and then using the inserter and a press to press fit the 3rd

main gear.

CAUTION:

3rd main gear is not reusable. Never reuse it.

10. Install 3rd - 4th main spacer on the main shaft and then using

the inserter and a press to press fit the 4th main gear.

CAUTION:

●4th main gear is not reusable. Never reuse it.

●When installing, set boss to rear side.

11. Using the inserter and a press to press fit the main shaft bearing

onto the main shaft.

PCIB0450E

Tool number : ST27861000 ( — )

PCIB0203E

Tool number : ST30022000 ( — )

PCIB0745E

Tool number : ST30022000 ( — )

PCIB0612E

Tool number : ST30911000 ( — )

PCIB0405E

TRANSMISSION ASSEMBLY

MT-45

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Revision: 2004 December 2004 350Z

12. Using the inserter and a press to press fit the reverse main gear

bushing onto the main shaft.

13. Using the inserter and a press to press fit the 3rd gear bushing

onto the counter shaft.

14. Install 3rd - 4th coupling sleeve and 3rd - 4th shifting insert into

the 3rd - 4th synchronizer hub.

CAUTION:

Install 3rd - 4th coupling sleeve with the thicker flange

faced the front side.

15. Install 3rd - 4th spread spring in the 3rd - 4th shifting insert.

Tool number : ST30911000 ( — )

PCIB0206E

Tool number : ST30911000 ( — )

PCIB0406E

PCIB0613E

PCIB0614E

MT-46

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

CAUTION:

●Do not install 3rd- 4th spread spring hook onto the same

3rd- 4th shifting insert.

●Be careful with the shape of reverse shifting insert to

avoid misassembly.

16. Install 3rd needle bearing,3rd counter gear,3rd inner baulk

ring,3rd synchronizer cone, and 3rd outer baulk ring on the

counter shaft and then using the inserter and a press to press fit

the 3rd - 4th synchronizer assembly.

CAUTION:

●The 3rd - 4th synchronizer hub is not reusable. Never

reuse it.

NOTE:

4th baulk ring has three spaces that one gear tooth is missing

but 3rd baulk ring doesn't.

17. Install 4th outer baulk ring,4th synchronizer cone,4th inner baulk

ring,4th needle bearing, and 4th counter gear onto the counter

shaft and then using the inserter and a press to press fit the 4th

gear bushing and 4th counter gear thrust washer.

PCIB0608E

Tool number : ST30911000 ( — )

PCIB0615E

PCIB0451E

Tool number : KV40100630 (J26092)

PCIB0209E

TRANSMISSION ASSEMBLY

MT-47

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Revision: 2004 December 2004 350Z

18. Using the inserter and a press to press fit the counter rear bear-

ing inner race onto the counter shaft.

19. Using the drift and a press to press fit the main drive gear bear-

ing onto the main drive gear.

20. Select and install a snap ring to the main drive gear bearing so

that the end play comes within the standard value. Refer to MT-

59, "Snap Rings" .

CAUTION:

Snap rings are not reusable. Never reuse them.

21. Install main shaft and counter shaft combined in one unit to

adapter plate, and fix bearing with snap ring.

CAUTION:

Snap rings are not reusable. Never reuse them.

22. Install counter rear bearing onto the adapter plate using soft

hammer or the equivalent.

Tool number : ST30032000 (J26010-01)

PCIB0210E

Tool number : KV32102700 ( — )

PCIB0215E

End play : 0 - 0.10 mm (0 - 0.004 in)

PCIB0484E

PCIB0151E

PCIB0616E

MT-48

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

23. Apply genuine medium strength locking sealant or equivalent

refer to GI section to the end of the bolt (first 3 to 4 threads),

screw the bolt into the main shaft bearing retainer, and tighten it

to the specified torque. Refer to MT-22, "CASE COMPONENTS"

.

24. Install reverse coupling sleeve and reverse shifting insert into

the reverse synchronizer hub.

CAUTION:

Install reverse coupling sleeve with the flat flange on the

rear side.

25. Install reverse spread spring in the reverse shifting insert.

CAUTION:

Do not install reverse spread spring hook onto the same

reverse shifting insert.

26. After installing reverse main gear bushing, reverse main needle

bearing, reverse main gear, and reverse baulk ring onto the

main shaft, using the drift and press plate and a press to press

fit the reverse synchronizer assembly.

SCIA1452E

PCIB0617E

PCIB0618E

Tool number (A) : KV32103300 (J46529)

Tool number (B) : ST01530000 ( — )

PCIB0242E

TRANSMISSION ASSEMBLY

MT-49

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CAUTION:

●The reverse synchronizer hub is not reusable. Never

reuse it.

●When installing, face the side with three ditches to the

front side.

27. Install reverse coupling snap ring.

NOTE:

Reverse baulk ring has three spaces that two gear teeth are

missing, and each space has small ditch for identification as

shown in the figure.

28. Select and install a snap ring so that the end play comes within

the standard value. Refer to MT-59, "Snap Rings" .

CAUTION:

Snap rings are not reusable. Never reuse them.

29. After installing counter rear bearing spacer, press and fit reverse

counter gear onto counter shaft with drift and press.

CAUTION:

●Reverse counter gear is not reusable. Never reuse it.

●When installing counter rear bearing spacer, maker's

stamp should face to the rear

PCIB0221E

PCIB0168E

End play : 0 - 0.10 mm (0 - 0.004 in)

PCIB0225E

Tool number : ST23860000 ( — )

PCIB0411E

MT-50

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

30. Select and install a snap ring so that the end play comes within

the standard value. Refer to MT-59, "Snap Rings" .

CAUTION:

Snap rings are not reusable. Never reuse them.

Shift Control Components

1. Install 5th-6th shift fork to the 5th - 6th coupling sleeve.

2. Install 5th-6th fork rod (reversal side) to the 5th - 6th shift fork.

3. Using a pin punch [6 mm (0.24in) dia.] to tap the retaining pin

into the 5th - 6th shift fork.

CAUTION:

Retaining pins are not reusable. Never reuse them.

4. Install 5th - 6th fork rod to the adapter plate.

5. Install 5th - 6th fork rod bracket to the 5th - 6th fork rod.

6. Using a pin punch [6 mm (0.24in) dia.] to tap the retaining pin

into the 5th - 6th fork rod bracket.

CAUTION:

Retaining pins are not reusable. Never reuse them.

7. Install 5th - 6th control lever to the adapter plate and then tighten

mounting bolts to the specified torque. Refer to MT-25, "SHIFT

CONTROL COMPONENTS" .

CAUTION:

Set the projection upward.

End play : 0 - 0.10 mm (0 - 0.004 in)

PCIB0226E

PCIB0412E

PCIB0238E

PCIB0172E

TRANSMISSION ASSEMBLY

MT-51

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Revision: 2004 December 2004 350Z

8. Install check ball to the adapter plate.

9. Install reverse shift fork to the reverse coupling sleeve.

10. Install reverse fork rod to the reverse shift fork.

11. Using a pin punch [6 mm (0.24 in) dia.] to tap the retaining pin

into the reverse shift fork.

CAUTION:

Retaining pins are not reusable. Never reuse them.

12. Install interlock pin and interlock plunger to the adapter plate.

13. Install 1st-2nd shift fork to the 1st - 2nd coupling sleeve.

14. Install 1st-2nd fork rod to the 1st - 2nd shift fork.

15. Using a pin punch [6 mm (0.24 in) dia.] to tap the retaining pin

into the 1st - 2nd shift fork.

CAUTION:

Retaining pins are not reusable. Never reuse them.

16. Install 3rd-4th shift fork to the 3rd - 4th coupling sleeve.

17. Install 3rd-4th fork rod (reversal side) to the 3rd - 4th shift fork.

18. Using a pin punch [6 mm (0.24 in) dia.] to tap the retaining pin

into the 3rd - 4th shift fork (reversal side).

CAUTION:

Retaining pins are not reusable. Never reuse them.

PCIB0148E

SCIA1447E

PCIB0147E

PCIB0602E

PCIB0601E

MT-52

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

19. Install interlock pin and check ball to the adapter plate.

20. Install 3rd-4th fork rod to the adapter plate.

21. Install 3rd-4th fork rod bracket to the 3rd - 4th fork rod.

22. Using a pin punch [6 mm (0.24 in) dia.] to tap the retaining pin

into the 3rd - 4th fork rod bracket.

CAUTION:

Retaining pins are not reusable. Never reuse them.

23. Install check ball, check ball spring into the adapter plate, apply

genuine silicone RTV or equivalent refer to GI section to the

check ball plug threads, and tighten check ball plug to the speci-

fied torque. Refer to MT-25, "SHIFT CONTROL COMPO-

NENTS" .

24. Install 3rd - 4th control lever to the adapter plate, and then

tighten mounting bolts to the specified torque. Refer to MT-25,

"SHIFT CONTROL COMPONENTS" .

CAUTION:

Make sure the top and bottom are oriented correctly.

25. Install check ball, check ball spring into the adapter plate, apply

genuine silicone RTV or equivalent refer to GI section to the

check ball plug threads, and tighten check ball plug to the speci-

fied torque. Refer to MT-25, "SHIFT CONTROL COMPO-

NENTS" .

PCIB0146E

PCIB0145E

PCIB0144E

PCIB0173E

PCIB0143E

TRANSMISSION ASSEMBLY

MT-53

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MT

Revision: 2004 December 2004 350Z

26. Install striking rod to the adapter plate.

27. Install striking lever to the striking rod.

28. Using a pin punch [6 mm (0.24 in) dia.] to tap the retaining pin

into the striking lever.

CAUTION:

Retaining pins are not reusable. Never reuse them.

29. Install magnet to the adapter plate.

30. Install baffle plate to the adapter plate, and then tighten mount-

ing bolts to the specified torque.

Case Components

1. Install counter front bearing to the transmission case.

2. Install oil gutter to transmission case.

3. Apply genuine silicone RTV or equivalent refer to GI section to

the transmission case adapter plate mounting surface as shown

in the figure.

CAUTION:

Complete remove all moisture and oil, etc., from the trans-

mission case and adapter plate mounting surfaces.

PCIB0414E

PCIB0154E

PCIB0436E

PCIB1373E

MT-54

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

4. Place the adapter plate in the transmission case, using soft

hammer to tap the adapter plate to install it into the transmission

case.

5. Install snap ring to main drive gear bearing, using snap ring pli-

ers.

CAUTION:

Snap rings are not reusable. Never reuse them.

6. Tighten baffle plate mounting nut to the specified torque. Refer

to MT-22, "CASE COMPONENTS" .

7. Apply multi-purpose grease to the lip of the front cover oil seal.

Using a drift, to install oil seal approx. 8.55-9.55 mm (0.336-

0.376 in) above from the front cover edge surface.

CAUTION:

●Front cover oil seals are not reusable. Never reuse them.

●When installing, do not incline the front cover oil seal.

SCIA1436E

SCIA1532E

SCIA1443E

Tool number : KV38102100 (J25803-01)

PCIB0415E

TRANSMISSION ASSEMBLY

MT-55

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MT

Revision: 2004 December 2004 350Z

8. Install front cover gasket and front cover to the transmission

case.

CAUTION:

Gasket is not reusable, Never reuse them.

9. Temporary tightening 2 bolts in the positions shown in the fig-

ure.

10. Temporary tightening remaining 9 bolts, tighten bolts to the

specified torque. Refer to MT-22, "CASE COMPONENTS" .

CAUTION:

Four bolts pointed by arrows in the figure are not reusable.

11. Tighten bolts to the specified torque in order as shown on the

figure.

12. Install washer to the withdrawal lever ball pin and then install it

to front cover. Tighten withdrawal lever ball pin to the specified

torque. Refer to MT-22, "CASE COMPONENTS" .

13. Install rear extension oil gutter to rear extension, and then tighten bolt to specified torque. Refer to MT-22,

"CASE COMPONENTS" .

14. Install reverse idler shaft, reverse idler needle bearing, reverse idler gear, and reverse idler thrust washer

to the adapter plate.

PCIB0454J

PCIB0455J

PCIB0258E

PCIB0456E

MT-56

TRANSMISSION ASSEMBLY

Revision: 2004 December 2004 350Z

15. Apply multi -purpose grease to the striking rod oil seal lip, and

then using the drift to install striking rod oil seal.

CAUTION:

●Striking rod oil seal are not reusable. Never reuse them.

●When installing, do not incline the striking rod oil seal.

16. Apply multi - purpose grease to the lip of the rear oil seal. Using

a drift to install rear oil seal. 1.2-2.2 mm (0.047-0.87 in) above

from the rear extension edge surface.

CAUTION:

●Rear oil seal are not reusable. Never reuse them.

●When installing, do not incline the rear oil seal.

17. Apply genuine silicone RTV or equivalent refer to GI section to

the adapter plate rear extension mounting surface as shown in

the figure.

CAUTION:

Completely remove all moisture, oil, etc., from the adapter

plate and rear extension mounting surfaces.

18. Install rear extension to the adapter plate and then tighten

mounting bolts to the specified torque in order as shown on the

figure. Refer to MT-22, "CASE COMPONENTS" .

19. Install control lever housing to the rear extension and then

tighten mounting bolts to the specified torque. Refer to MT-25,

"SHIFT CONTROL COMPONENTS" .

20. Install return spring plunger and return spring into the rear

extension, apply genuine silicone RTV gasket or equivalent refer

to GI section to the return spring plug threads, and then tighten

return spring plug to the specified torque. Refer to MT-25,

"SHIFT CONTROL COMPONENTS" .

Tool number : ST35291000 ( — )

PCIB0213E

Tool number : ST33400001 (J26082)

PCIB0619E

PCIB1374E

PCIB0256E

Return spring identification mark Plunger notch

RH Brown No

LH Blue Yes

SCIA1607E

TRANSMISSION ASSEMBLY

MT-57

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CAUTION:

The right and left return springs and return spring plungers are different, so make sure they are

installed correctly.

21. Install shift check pin as a one unit with the control bracket to

rear extension and then tighten mounting bolts to the specified

torque. Refer to MT-25, "SHIFT CONTROL COMPONENTS" .

22. Install plunger to the rear extension, and then screwing neutral

position switch and back-up lamp switch to the rear extension

with 1-2 pitches. Apply genuine silicone RTV or equivalent refer

to GI section to the switch threads, and tighten switch to the

specified torque. Refer to MT-22, "CASE COMPONENTS" .

23. Install retaining pin into the control rod, using a pin punch [6 mm

(0.24 in) dia.].

CAUTION:

Retaining pins are not reusable. Never reuse them.

24. Install check ball and check select spring into the rear extension.

25. Install rear extension upper cover gasket and rear extension

upper cover to rear extension.

CAUTION:

●Rear extension upper cover gaskets are not reusable.

Never reuse them.

●Avoid tangling check select spring.

26. Tighten rear extension upper cover bolts to the specified torque

in order as shown on the figure. Refer to MT-22, "CASE COM-

PONENTS" .

SCIA1440E

SCIA1437E

PCIB0599E

PCIB0257E

MT-58

SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: 2004 December 2004 350Z

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications ACS004NU

End Play ACS004NV

Unit: mm (in)

Applied model VQ35DE

Transmission FS6R31A

Number of speed 6

Shift pattern

Synchromesh type Warner

Gear ratio

1st 3.794

2nd 2.324

3rd 1.624

4th 1.271

5th 1.000

6th 0.794

Reverse 3.446

Main gear

(Number of teeth)

Drive 26

1st 37

2nd 34

3rd 33

4th 31

6th 31

Reverse 42

Counter gear

(Number of teeth)

Drive 32

1st 12

2nd 18

3rd 25

4th 30

6th 48

Reverse 15

Reverse idler gear (Number of teeth) 26

Oil capacity

( US qt, Imp qt ) Approx. 2.9 ( 3-1/8, 2-1/2)

Remarks

Reverse synchronizer Installed

Double cone synchronizer 1st & 3rd & 4th

Triple cone synchronizer 2nd

SCIA0955E

Item Standard

Counter gear 0 - 0.10 (0 - 0.004)

Main drive gear 0 - 0.10 (0 - 0.004)

Main shaft 0 - 0.10 (0 - 0.004)

SERVICE DATA AND SPECIFICATIONS (SDS)

MT-59

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Snap Rings ACS004NW

Unit: mm (in)

Selective parts Thickness Part No.

Main drive gear

1.89 (0.0744)

1.95 (0.0768)

1.99 (0.0783)

2.03 (0.0799)

2.07 (0.0815)

2.11 (0.0831)

32204 01G60

32204 01G61

32204 01G62

32204 01G63

32204 01G64

32204 01G65

Counter shaft

1.96 (0.0772)

2.02 (0.0795)

2.08 (0.0819)

2.14 (0.0843)

2.20 (0.0866)

2.26 (0.0890)

2.32 (0.0913)

2.38 (0.0937)

2.44 (0.0961)

2.50 (0.0984)

2.56 (0.1008)

2.62 (0.1031)

32236 CD000

32236 CD001

32236 CD002

32236 CD003

32236 CD004

32236 CD005

32236 CD006

32236 CD007

32236 CD008

32236 CD009

32236 CD010

32236 CD011

Main shaft

Front side

2.08 (0.0819)

2.14 (0.0843)

2.20 (0.0866)

2.26 (0.0890)

32204 CD000

32204 CD001

32204 CD002

32204 CD003

Shaft rear end

2.08 (0.0819)

2.14 (0.0843)

2.20 (0.0866)

2.26 (0.0890)

2.32 (0.0913)

2.38 (0.0937)

2.44 (0.0961)

2.50 (0.0984)

2.56 (0.1008)

2.62 (0.1031)

2.68 (0.1055)

2.74 (0.1079)

2.80 (0.1102)

2.86 (0.1126)

2.92 (0.1150)

2.98 (0.1173)

32204 CD000

32204 CD001

32204 CD002

32204 CD003

32204 CD004

32204 CD005

32204 CD006

32204 CD007

32204 CD008

32204 CD009

32204 CD010

32204 CD011

32204 CD012

32204 CD013

32204 CD014

32204 CD015

MT-60

SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: 2004 December 2004 350Z

Baulk Ring Clearance ACS004NX

Unit: mm (in)

Measurement point Standard Limit value

1st & 3rd & 4th

(Double - cone synchronizer)

Inner baulk ring clearance “A”

Outer baulk ring clearance “B”

A: 0.50 - 0.70(0.020 - 0.028)

B(1st): 1.00 - 1.50(0.039 - 0.059)

B(3rd,4th):0.85 - 1.35(0.033 - 0.053)

0.3(0.012)

0.7(0.028)

0.7(0.028)

2nd

(Triple - cone sychronizer)

Main gear taper corn clearance “ A”

Outer baulk ring clearance “B”

Inner baulk ring clearance “C”

A: 0.60 - 1.30 (0.024 - 0.051)

B: 0.85 - 1.35 (0.033 - 0.053)

C: 0.70 - 1.25 (0.028 - 0.049)

0.3 (0.012)

0.7 (0.028)

0.3 (0.012)

5th & 6th 0.70 - 1.25 (0.028 - 0.049) 0.5 (0.020)

Reverse 0.75 - 1.20 (0.030 - 0.047) 0.5 (0.020)

PCIB0249E

PCIB0261E