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gearbox change on 2001 d22

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Helen7441

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Discussion starter · #1 ·
Hi,
We need to change our 2001 d22 gearbox, it's the last chrome bumper style model of 2001 before they changed the engine. We've found a replacement lump but for a 2004 d22. Our is a YD25? Don't know how to check the 2004 will fit before we buy?? Any help greatly appreciated, thanks in advance
 
#2 ·
Hi Helen
Assuming we're talking about the 4WD gearbox the TD25DDTi and the YD25DDTi run the same transmissions so the gearbox/transfer assembly is the same being the FS5R30A.
It will be stamped on the gearbox casing somewhere, can't remember exactly where but seem to recall it's near the joint with the bell housing :|
 
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#5 ·
Helen7441 said:
Brilliant thanks for your help, yes it's the 4wd gearbox. Presumably my existing clutch and flywheel will be compatible? Thanks again
Click to expand...
Yup, all be 'good to go' but if mileage of your truck is high, like 100k plus, you'll be foolish to not examine the existing clutch for wear whilst the gearbox is out :!:
Only go genuine Exedy replacement please as you will regret it :!:
Nice looking truck BTW :thumbleft:
 
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#6 ·
:+1 with Woz when its all apart it would be wise to check/replace the clutch
nice look truck :thumbleft:
 
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Discussion starter · #8 ·
Thanks guys, yep did add the (?) after TD /YD as I can never remember! Thank you though. Mileage is at 89k but will check clutch when we've dropped the box etc. Thanks for all your help.. Didn't want to just buy it and hope for the best!!
Fingers crossed she's back to fighting form soon, having withdrawals from non tarmac driving ? I ?
:cry
 
Discussion starter · #9 ·
Hi,
Update with regards to box change. Have removed lump from truck ( after shed loads of welding underneath got to gearbox stage) Removed torsion bars and cross member to get box out, discovered our compatible box had a different bellhousing. Successful switched that over, now almost set to go back to rebuild truck. Did as suggested and replaced clutch whilst we were doing all this. Currently being held up by a sticky speedo sensor, have removed nut but can't get it to budge. Any ideas to uncease /remove, otherwise I have a feeling an angle grinder and brute force may come into play. Unfortunately our new box came without speedo so we have to remove our old one. Thanks Guys :)

Feeling like I know far too much about the ins and outs of my d22 currently, unfortunately still don't have enough knowledge to know what I'm doing lol
 
#10 ·
Heat the surrounding aluminium housing (Propane or oxy/acetylene), then soak the area in diesel, you may have to repeat a few times, after a few goes mix the diesel 50/50 with ATF (preferably) or oil if you don't have ATF, possibly leaving to soak for a period (e.g. overnight), then try rotating the sensor to free it off.
Be careful with it, they are WELL known for seizing up internally, hence good used ones are rare, Nissan will steal about £160 for a new one, although you can buy new pattern parts from the good 'ole USA for about £40 delivered.
When you refit it, clean it up well and cover the end joint (where the internals meet the external casing) with silicone to stop water ingress into it, the cause of them seizing up in the first place.
 
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Discussion starter · #12 ·
Having major issues getting the splines to line up and get tranny in. Anybody know if the flywheel would be different? We've a 2004 gearbox and swapped bellhousing over fine. All seem to have the same number teeth etc, just can't get her to go in. I'm buying everyone here a virtual pint!! Major thumbs up to everyone for all help received. Cheers guys
 
#13 ·
Helen7441 said:
Hi,
Update with regards to box change. Have removed lump from truck ( after shed loads of welding underneath got to gearbox stage) Removed torsion bars and cross member to get box out, discovered our compatible box had a different bellhousing. Successful switched that over, now almost set to go back to rebuild truck. Did as suggested and replaced clutch whilst we were doing all this. Currently being held up by a sticky speedo sensor, have removed nut but can't get it to budge. Any ideas to uncease /remove, otherwise I have a feeling an angle grinder and brute force may come into play. Unfortunately our new box came without speedo so we have to remove our old one. Thanks Guys :)

Feeling like I know far too much about the ins and outs of my d22 currently, unfortunately still don't have enough knowledge to know what I'm doing lol
Click to expand...
speedo sensor , not speedo drive ??
 
#14 ·
its much easier to remove then engine and then take the box out the front Helen7441 , you only need to remove front prop , drop the main gearbox mount cross member, remove it and unclip the wiring loom , slide it forward to remove prop and it can be lowered to the ground
 
#15 ·
Helen7441 said:
Having major issues getting the splines to line up and get tranny in. Anybody know if the flywheel would be different? We've a 2004 gearbox and swapped bellhousing over fine. All seem to have the same number teeth etc, just can't get her to go in. I'm buying everyone here a virtual pint!! Major thumbs up to everyone for all help received. Cheers guys
Click to expand...
i dint know there were 2 types of box fitted to the navara but i know my mates import model has the 2.7 engine but with a partially electronic fuel injector pump fitted , his bell housing was the same as the terrano / maverick gearbox , has the spline got the same shape teeth ??
 
Discussion starter · #16 ·
bembo449 said:
Helen7441 said:
Hi,
Update with regards to box change. Have removed lump from truck ( after shed loads of welding underneath got to gearbox stage) Removed torsion bars and cross member to get box out, discovered our compatible box had a different bellhousing. Successful switched that over, now almost set to go back to rebuild truck. Did as suggested and replaced clutch whilst we were doing all this. Currently being held up by a sticky speedo sensor, have removed nut but can't get it to budge. Any ideas to uncease /remove, otherwise I have a feeling an angle grinder and brute force may come into play. Unfortunately our new box came without speedo so we have to remove our old one. Thanks Guys :)

Feeling like I know far too much about the ins and outs of my d22 currently, unfortunately still don't have enough knowledge to know what I'm doing lol
Click to expand...
speedo sensor , not speedo drive ??
Click to expand...

Speedo 'something' - am learning as I go along, sorry for technical part slip ups!! Got it out now, and is fitted nicely with a waterproof seal in the new box. Thanks again for input :)
 
#17 ·
Difficulty getting the box back in is not uncommon, when I changed my clutch I centred the driven plate with a proper alignment tool, would it go back in, I swore, took it out put the tool straight back in easily, tried the box again after about 20 minutes and close to giving up, it just slide in without rhyme or reason.
I may well be wrong with this GUESS, but your spare part looks a little like it should be on the release bearing?
What are it's dimensions?
 
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Discussion starter · #18 ·
Thanks for letting me know that it's not uncommon, ironically swearing has been frequent today!!
Spare part dimensions, edge to edge across is 37mm, internal aperture is 21mm across, 22mm internally top to bottom. Thanks

Hi Jace, didn't originally but have since tested both new clutch and old clutch on both shafts and they fit fine.
Thanks

Thanks again for all help ?
 
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bembo449
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