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Hello 
Thank you .
Yes we are all well now but COVID-19 comes my town .are you and your family and dog well ?
Finally someones worried about the poor dogs haha. Stay safe mate, though seems ypu got a good project to help keep you self isolated without going crazy.

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Discussion Starter #203
Finally someones worried about the poor dogs haha. Stay safe mate, though seems ypu got a good project to help keep you self isolated without going crazy.

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Hello
Thank you Yes It is good for evacuate from COVID-19 .
 

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Discussion Starter #204
Remove the main shaft gear.
This time I'm not going smoothly and I'm having problems. First, remove the bearing retainer. can easily remove it by removing the 4 Torx and 2 bolts. The main shaft has a main shaft gear spacer and a main shaft gear, but the main shaft spacer cannot be removed without a special tool. So I tried using the bearing separator and puller together with the main shaft gear and the spacer to try out. The result is NG. Since there was no sign of movement and I felt that the gear teeth were likely to be damaged in the process of tightening the separator, I canceled it. The strategy needs to be changed.

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Discussion Starter #205
Removing the main shaft gear spacer.
Replacing the 5th gear is the most troublesome work. I tried to remove it with the gear last time, but I stopped because It didn't seem to move. not mention the removal of this spacer in the manual, and didn't specify SST, so I thought it would come off easily. However, it was actually quite tight and could not be easily removed. I wondered if I could process a puller or make an SST, but first I decided to give it a try with a simple method. The width of the notch is about 9 mm, and a M4 size soft iron spacer with a length of 15 mm was put in the notch and a bearing separator was applied to hook it. I pulled it with a puller, but there is no sign of movement yet, so I was able to remove it by pulling while heating the separator with a heat gun. I used a heat gun because heating it at too high a temperature may cause metal brittleness of the main shaft.


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Discussion Starter #207
Assemble the gear
In the manual, it is instructed to fix the 2th gear of the main shaft with SST and press-fit with SST. To do this, you need to remove the shift linkage and create an SST. This time, I will consider a strategy to work in this state. The situation is the same as they say the Marks kit can be replaced on the car. I think that it is necessary to reduce the load on the main shaft gears when press fitting as much as possible. I will use the method of heating with oil with the advice of a friend of a mechanic in Hino. Although the counter gear sync can be used with the Y60 one before, I actually checked it with a temporary assembly. No problem.
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Discussion Starter #208
Main shaft gear installation

With the advice of a friend of Hino's mechanic, I heat it up to 120 degrees with engine oil and install it. It is good to use engine oil as it also serves as a measure against rust after heating. I slowly overheated and when it reached 120 degrees, I left it for a while. I grabbed the gear with leather gloves and pushed it into the main shaft, and it easily set. When it gets cold to some extent, it contracts in the vertical direction, so lightly hammering is complete.



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Discussion Starter #209
Installing the main shaft gear spacer

It is this sparser that is most worrisome when incorporating. It also has a role of holding down the main shaft gear, and the tightness of the fitting is quite tight, so I think that I can reduce the load at the time of press fitting as much as possible. Polish the contact surfaces of the main shaft and spacers with paper. After cooling the main shaft sufficiently, slowly heat it to 120 degrees. Assembling does not go smoothly as expected. It was carefully hammered in.

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Discussion Starter #210
Bearing Retainer Installation

After installing the main gear and spacer, install the bearing retainer. Secure with 2 bolts and 4 Torx. After tightening with the specified torque, Torx is instructed to hit with two punches to lock.

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Discussion Starter #211
Counter gear installation
Install the synchronizer mechanism and then the shift fork together. For the synchronizer mechanism, pay attention to the direction of the spring and the position of the synchronization with the three shifting inserts. The sleeve is also directional. Assemble with the shift fork attached to the sleeve, but do not forget the guide pin of the shift fork. Instead of suddenly inserting the guide pin into the case, first shift the shift fork to the lower side, position the gear assembly on the counter shaft, push it in while taking care not to disassemble the sync assembly, and then push it to the Attach the guide pin to the mission after hooking the notch on the linkage of the mission body. After that, the counter gear assembly is press-fitted onto the shaft, but this individual could be attached by just pushing it by hand. In the manual, it is press-fitted by drift.

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Discussion Starter #212
Main shaft bearing installation

It's finally the end. The main shaft bearing was also heated to 120 degrees with an oil bath. It can be installed very smoothly. After cooling down, install the two-part spacer for the selected parts. Originally it was a running 15,000 km and the gear was new so it could be reused as it was. Since the C ring of the counter gear is a component that is selected and prohibited from reuse, I measured the thickness, but it seems that there is no problem with the same thickness. After confirming this, will order parts from Nissan.

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Discussion Starter #213
C ring attachment
Parts are delivered to Nissan, so I will assemble them. This time, I changed some parts of the synchro. This completes the gear replacement. After that, replace the oil seal on the case and assemble the case.
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Discussion Starter #214
Oil seal replacement and case installation

Replace the oil seal and install the case. The original oil seal had two lips, but the one we ordered was a wide lip. Clean the inside of the case and remove the gasket. Replace with a new gasket and attach the case. Since the three internal bolts are seal bolts, apply a seal and assemble. The tightening is completed with the specified torque.

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Discussion Starter #215
Time to replace the mission.
This time, the transfer was separated and replaced. Although the number of processes increases, I like this method considering the psychology, weight to be handled, and safety. When I turn the input shaft to mount the mission, it doesn't turn! I couldn't think of the cause and inspected the inside. The cause was that the large counter gear interfered with the case. After reassembling the case, there is no problem.

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Massive mission my friend, always good to see a 'man on a mission'. Your pics keep reminding me I've got to lift the centre console so I can check the gearstick rubber boot, I think it is dislodged, allowing fumes to come into cab under various circumstances when aircon is off.
 

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Discussion Starter #217
Massive mission my friend, always good to see a 'man on a mission'. Your pics keep reminding me I've got to lift the centre console so I can check the gearstick rubber boot, I think it is dislodged, allowing fumes to come into cab under various circumstances when aircon is off.
Hi gee
”Massive mission” will turn to be much more familiar mission if disconnect the transfer. haha
 
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