# DRIVE TRAIN

## TRANSMISSION AND TRANSAXLE

### Manual Transmission Assembly

#### REMOVAL AND INSTALLATION

##### 240SX

1. Disconnect the negative battery cable.
2. Raise and support the vehicle safely.
3. Place the shift lever in the N position and disconnect the shifter lever from the transmission.
4. Remove the shifter lever with control housing from the transmission.
5. Remove the crankshaft position sensor from the upper side of the transmission housing.
6. Remove the clutch operating (slave cylinder) cylinder from the clutch housing.
7. Disconnect the electrical harness connections from the transmission and disconnect the rear heated oxygen sensor connection.
8. Matchmark then unbolt the driveshaft at the rear and remove. If equipped with a center bearing, unbolt it from the crossmember. Plug the end of the transmission extension to prevent leakage.
9. Support the engine with a large wood block and a jack under the oil pan. Do not place the jack under the oil pan drain plug.
10. Unbolt the transmission from the crossmember. Support the transmission with a jack and remove the crossmember.
11. Lower the rear of the engine to allow clearance.
12. Disconnect the wiring to the starter motor and remove the starter from the transaxle.
13. Remove the exhaust tube mounting bracket from the transmission.
14. Unbolt the transmission assembly from the engine. Lower and move it to the rear.

    NOTE: Tagging the different length transmission bolts upon removal is necessary to ensure that they are installed in their original position.

    To install:

15. Clean the engine and transmission mating surfaces. Lightly lubricate the clutch disc splines and main drive gear splines. Also lubricate the control lever sliding surfaces with grease.
16. Properly support the transmission and install the transmission to the rear of the engine.
17. Use the following torque specifications to bolt the transmission to the engine:
    1. Torque bolts No. 1 and 2 to 29–36 ft. lbs. (39–49 Nm).
    2. Torque bolts No. 3, 4 and 5 to 22–29 ft. lbs. (29–39 Nm).

       Fig. 1: Transmission bolt tightening specifications — 240SX

18. Install the exhaust tube mounting bracket to the transmission.
19. Install the starter assembly.
20. Raise the rear of the engine to its original position.
21. Bolt the crossmember in place and remove the jack.
22. Install the remaining components in the reverse order of removal.
23. Connect the negative battery cable and check the transmission fluid level.
24. Lower the vehicle and road test the vehicle for proper operation.

##### 300ZX

Fig. 2: Manual transmission mounting bolt identification and tightening torque — 300ZX without turbocharger

1. Disconnect the negative battery cable.
2. Raise and support the vehicle safely.
3. Remove the exhaust pipe section from the manifold and remove the support bracket from the transmission.
4. Matchmark the driveshaft and unbolt the shaft from the rear housing. Unbolt the driveshaft at the center bearing and remove the shaft from the rear of the transmission. Install a sealing plug in the end of the transmission extension housing to prevent leakage.
5. Disconnect the speedometer drive cable from the transmission.
6. Disconnect the shifter lever.
7. Without disconnecting the hydraulic line, remove the clutch operating cylinder from the clutch housing and position it aside.
8. Support the engine with a large wood block and a jack under the oil pan. Do not place the jack under the oil pan drain plug.
9. Unbolt the transmission from the crossmember. Support the transmission with a jack and remove the crossmember.
10. Lower the rear of the engine to allow clearance.
11. Unplug the backup light, neutral and overdrive switch connectors.
12. Unbolt the transmission. Lower and remove it to the rear.

    NOTE: The transmission bolts are different lengths. Tagging the transmission-to-engine bolts upon removal will facilitate proper positioning during installation.

    To install:

13. Lubricate the output shaft of the transmission with high temperature grease.
14. Raise the transmission onto the engine and install the mounting bolts. Tighten bolts to correct torque specification.

    NOTE: The bolts that secure the transmission to the engine are of different length and require different torque. Be sure to properly position all bolts.

    Fig. 3: Manual transmission mounting bolt identification and tightening torque — 300ZX with turbocharger

15. Connect the backup light, and the neutral and overdrive switch connectors.
16. Install the crossmember.
17. Install the clutch slave cylinder and tighten the mounting bolts to 22–30 ft. lbs. (30–40 Nm).
18. Install the shifter lever, shift knob and console boot finisher or control rod.
19. Connect the speedometer drive cable.
20. On 1993–94 models, install the driveshaft. Torque the flange bolts to 29–33 ft. lbs. (34–44 Nm). Torque the center bearing bracket nuts to 19–29 ft. lbs. (25–39 Nm).
21. On 1995–97 models, install the driveshaft. Torque the flange bolts to 41–48 ft. lbs. (55–65 Nm) for non-turbo models or 47–54 ft. lbs. (64–74 Nm) for turbo models. Torque the center bearing bracket mounting bolts to 43–58 ft. lbs. (59–78 Nm).
22. Connect the exhaust tube section to the manifolds and attach the support bracket to the transmission.
23. Remove the jack from underneath the engine.
24. Lower the vehicle and connect the negative battery cable. Road test the vehicle for proper operation.