NISSAN Pathfinder Manual Transmission Rebuild Part 6
Transmission Gear Re Freakin Grinding in my 1994 Nissan Pathfinder.

Reverse main gear dog teeth were ground up. So ground up that I often had trouble getting into reverse. The teeth are supposed to fit together like this:

 V V V
But mine were ground down to look like this:
 W W W
So they would lock together and not engage half the time.

reverse     dog     teeth

This is not in the manual.
In fact, the only reference to grinding these dog teeth that I could find explicitly stated: Don't do it. It is far too precise an operation for the home mechanic. Special precision tools are necessary.
So anyway, here is how I did it.
But first, lets pay some bills:

  1. Washed the gear and coupling sleeve.

  2. Got some cheap diamond bits
    diamond bits

  3. Started Grinding
    dog grinding

  4. Thought to myself: Man, I rock.

  5. First gear syncro measurement
    baulk ring measurement

  6. Second gear syncro measurement
    baulk ring measurement

  7. Third gear syncro measurement
    baulk ring measurement

  8. Counter gear front bearing thrust washer tolerance. I think this improvised method is fine.
    MT-47 5
    thrust washer measurement    thrust washer measurement

  9. All well within factory spec. Now why the hell is third grinding so freakin bad?

  10. Reassembled the "insert springs" on the OD and 3-4 syncro coupling sleeve. Not well documented in the manual.
    insert springs

  11. Next I sold out to make 02ยข so I can fulfill my lifelong dream of owning a 1986 944 with blown head gaskets.

    But no minivans!

  12. Then I finished my beer.

Reassebling the Manual Transmission in my 1994 Nissan Pathfinder 1.

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