Time to say goodbye?

[Flying Torquewrench]

Rick, if I understand you correctly then the reason there is no clearance between the ring and 1st motion shaft is because the insert has jammed the ring all the way over. With the insert in its usual position there is normal clearance.

At the moment I am not sure what to do. Either I need to rebuild most of the gearbox or reseat the insert and leave it be. There are two inserts available for this gearbox, depending on the time it was built. One insert is still available but the other one is no longer available according to the dealer. However, I can not find out if they are interchangeable. I am hoping that the dealer can provide this information.

Via Amayama I can get both inserts, the synchro rings and springs for about £100 delivered.

The synchro rings are actually not in too bad a shape. I will try to get a better photo tomorrow.

 

[solarman216]

If you have the info on the box it will tell you how to check the wear tolerance etc, but clearly there is something going on there that is not correct, I have never seen those slippers jump out even on worn rings, perhaps the discontinued ones are the bad ones and the new ones modified to sort the problem? Rick

 

[Flying Torquewrench]

Normally the various websites that I check tell you if there is an upgraded/replacement part. For these inserts it only has time periods so it really depends on when the gearbox was made.

The Nissan dealer can only supply 1 set of inserts and according to them the other part number is not available anymore. However, Amayama can supply both inserts for £1.57 each (need 3 of each). I have ordered bearings, inserts (both p/n’s), springs and synchro rings. It should be delivered by 6th September.

I have taken some photos this morning of the synchro rings. Whilst they show some wear, they aren’t in too bad a shape. As everything needs to be taken apart anyway, they will be changed.

 

[Flying Torquewrench]

More

 

[Flying Torquewrench]

And a close up.

 

[solarman216]

Once you have it apart, you need to check the distance between synchro and gear to check if within tolerance, this is where they wear, Rick

 

[Flying Torquewrench]

These are the measurements to check.

 

[Flying Torquewrench]

Typical, yesterday the Nissan dealer told me that only one set of insert was available. So today I ordered from Amayama with a delivery date of 6th September. Only to get an email from the dealer a few hours later to let me know that both inserts are available. :doh With the dealer they have a lead time of 4/5 days.

The cost of 6 inserts is £55 whilst at Amayama they cost me £100 but this includes shipping, a bearing, 2 synchro rings and new synchro rings springs. All in all, not too bad a prt from the long lead time.

This is the second page of measurements.

 

[solarman216]

So overall not too bad, be interesting to see the difference between the old and new parts, shame I cannot read the two pages, just too blurred, Rick

 

[Flying Torquewrench]

Sorry Rick, they are clear on my ipad but not when posted on the forum.

https://www.nicoclub.com/service-manual?fsm_download=Frontier/2004/mt.pdf

That is the link to the manual for my gearbox. Pages 81 & 82 have the measurements.

P.s. what did you used to do as a job before retirement? If I may ask? I know you mentioned it before but I can’t remember. :doh

 

[Flying Torquewrench]

Found a video on youtube of a Russian rebuilding a Nissan Terrano gearbox. They used the same gearbox in the Terrano and the 2.8td Patrol.

Whilst I can’t understand what he says, it is good to see.

 

[Flying Torquewrench]

It appears that the spring behind the synchro ring has either failed or has not been installed during the previous overhaul. (Item 11 on the drawing)

 

[Flying Torquewrench]

Shaft 1 (red arrow) is held in place by the gear on shaft 2 (blue arrow). Hence a little bit of play when the housing is not installed as it runs in a bearing in the housing. This is then held in place with a snap ring.

With the bit of play available in the shaft I may just be able to change the inserts. However, the springs need changing as they obviously are not working as designed.

 

[Flying Torquewrench]

This is the synchro ring pushed against the gear. The spring should push it out but it doesn’t.

 

[Flying Torquewrench]

With the shaft moved to the left as much as the clearance allows, one should just be able to remove the inserts. The spring on the other synchro ring seems to work fine.

 

[solarman216]

As said you are going to need to remove the lay shaft in order to do the job properly and inspect all items carefully, that 4th gear synchro will have suffered damage although slight it will most likely just jamb up again so needs to be changed, prior to retirement I was a general builder come solar engineer, prior to that long distance continental trucker and before that a diesel engineer so yes stripped and rebuilt many truck boxes, engines and diffs, Rick

 

[solarman216]

The box in the link does not correspond to yours, only given it a quick look but layshaft is different, Rick

 

[Flying Torquewrench]

Rick, I wasn’t questioning your knowledge! Not my intention if it came across that way. I thought that you had been a plumber and had a question about that.

The shafts are coming out as the synchro’s and springs need to be changed anyway.

Would you be able to enlighten me where you see a difference in the layshaft?

 

[solarman216]

Having looked at it more closely it looks as though I am wrong, what threw me was the bearing is shown on the layshaft being pulled with a puller (MT24)and your bearing is I assume still in the casing, if so it looks like you can pull the gear and and the 1st motion shaft together, in my defence looking at line drawings is never easy when it has never been seen in the flesh, and yes plumbing was one of my many trades so ask away, Rick

 

[Flying Torquewrench]

You had me worried for a second, Rick. When you mentioned that they were not the same gearboxes I thought that I ordered parts for the wrong gearbox!

When I search by using my VIN number it comes up with two possible gearboxes. One has the cover on top that you can open and the other one is the one I have.

Currently trying to work out how I can remove the synchro rings without having to dismantle the whole gearbox. Ideally I find a way to remove the first gear of the layshaft (circled in blue). Once that is removed part of the main shaft can be taken off. If I can’t remove that gear than I end up having to dismantle nearly the whole backside of the gearbox so that the layshaft can come out in 1 piece.