G35M-R MTX - CAUTION WHEN SERVICING 4TH GEAR

Applicable Models

Related Category/Subcategory/Symptoms

TRANSMISSION-TRANSAXLE / MANUAL TRANS. / SERVICEABILITY
TRANSMISSION-TRANSAXLE / MANUAL TRANS. / HARD SHIFTING/NO SHIFTING/IMPROPER SYNCHRO./GEAR NOISE(M/T)
TRANSMISSION-TRANSAXLE / MANUAL TRANS. / IMPROPER OPERATION
TRANSMISSION-TRANSAXLE / MANUAL TRANS. / OTHERS

MTOL - 5739 Dealer Repair Information

Symptom and Conditions

*** SEE MAY/JUNE 2008 M-TIPS FOR FULL DETAILS ***                       
                                                                        
On vehicles equipped with the G35M-R manual transmission, the 4th gear primary and secondary gears have been superseded and some cut angles on the gears have changed.  When replacing, these gears must be installed as a set. 

Repair Procedure

If a primary 4th gear is mated to a non-corresponding secondary 4th gear, the gears will not mesh properly. The result will be difficulty during reassembly of the transmission case. If the transmission case halves do not fit flush easily during assembly, double check the parts used according to the chart below to ensure the gears are a matched set.
                                                                        
CAUTION: FORCING THE CASE HALVES TOGETHER WILL CAUSE CATASTROPHIC FAILURE OF THE TRANSMISSION THAT IS NOT COVERED BY THE VEHICLE WARRANTY.
                                                                        
PART NUMBER     DESCRIPTION                                             
Vehicles Built before 7/1/2007*                                         
G502-17-210C    4TH GEAR PRIMARY                                        
G502-17-303C    4TH GEAR SECONDARY                                      

Vehicles Built on/after 7/1/2007*                                       
G512-17-210     4TH GEAR PRIMARY                                        
G611-17-303     4TH GEAR SECONDARY                                      
                                                                        
* The gears may be interchanged between production dates, however the   
  gears MUST be installed as a set in order to install and operate      
  properly. 
              
To verify if the gears are corresponding, place both primary and secondary gears down on a hard, flat surface. Mesh and firmly press the gears together and press against the surface. If the gears mesh properly, there will be NO GAP between the surface and either gear. If a gap is present, one of the gears should be replaced with the corresponding gear to mesh properly.
           
NO GAP = Corresponding Gear Set **See May/June 08 M-Tips for Diagram** 
 
GAP = Non-Corresponding Gear Set **See May/June 08 M-Tips for Diagram**