Tips for Rebuilding the FS5R30A

I rebuilt a broken 30A transmission this weekend, thought I would share a few things.

First of all, here are some helpful links:

*http://beergarage.com/PathTransmission2Prep.aspx

*http://www.google.com/url?sa=t&rct=j…ed6lQeHItBfgOA

^IDK how to link that. Search "Manual Transmission service B15u.com" and download the .pdf. This is an amazing resource for rebuilding this transmission. I believe its the training modules provided to Nissan service Techs.

*The FSM is actually pretty good also, so be sure to have all three of these references at hand during rebuild.

Special tools needed:
*Snap ring pliers for external rings
*Snap ring pliers for "C-rings"
*Several sizes of bearing splitters. Get the kinds with threaded holes so you can attach a puller to them
*long threaded rod to go between bearing splitter and puller
*A wide assortment of pullers. 1 small 3 jaw, medium and large 2 jaw, large 3 jaw. You also need a really long 2 jaw, like 18" or so. I ended up making some "extensions" for a two jaw puller.
*Piece of ~1" steel round stock. Can't remember exact length (~12"), but this helps you press both shafts out at once. Get like 18" and then cut it down.
*Hydraulic press

Here are some examples of the stuff were talking about:

http://image.turbomagazine.com/f/168572 … puller.jpg




Anyways after getting it out of the case, you clamp it in the vice and start working from the back end. Follow the instructions and using a wide assortment of pullers (you really need a wide variety of crazy ones, long and such), you just pull it all apart. Label the stuff in bags because its easy to get disorganized. Don't lose the steel balls, easy ones to misplace are on speedo drive, reverse idler, and first gear washer. I think they are 5/32" if you lose em (check mcmaster-carr.com).
Check out the space shuttle puller extenders left of the vice:


Once you finish pulling the rear components off, its time to press the shafts out. This is where you need a press and a length of steel bar, or tube. Make sure you put something under the press to catch the shafts when they press out. They are heavy. I used a cardboard box and it punched straight through and smacked the floor.


Now replace whatever needs replacing. Synchros, bearings, broken gears, etc. In my case, the input and counter shaft had broken gears. The bearings all looked good. I cleaned everything really well in a mineral spirits parts washer before re-assembly.

For re-assembly, press the counter, main, and input shafts back into the midplate. Now your ready to press all the rear components back on. This is tricky because the FSM instructs you to use a pipe and hammer. There are like 8 different things you need to press on, so you will need all kinds of different sized pipes, plus its a ton of work, hammering it all together and trying not to break it. For a few of them you would need to get creative with your pullers, using them as "extenders". Reading the tech service manual above I found a pretty handy tip. Heat all the press fit components to 425F on a hotplate or oven. I did this and it was awesome. Instead of 20mins of hammering to press one thing on, everything literally just slips on. Hold it for a minute and it cools rock solid. I highly recommend doing this. You will save hours.



Thats all I have for now. I'm waiting on some gaskets, then its back into the case.