patrol 5th gear goes bang

Yes, unfortunately it was a common issue with a group of Patrols built from (I think) late 1999 to early 2001.

The problem arose from the way the main shaft was incorrectly machined......5th cog was only "supported" about half way through it's inner length by the spline......

So, it's not the teeth on the outside of 5th that cause the problem, it's the spline on the main shaft.

Solution requires removal of gearbox, new main shaft and new 5th cog. I doubt whether Nissan will cover you at this age, but it'd be worth a try under their "goodwill" policy.

If you do have to buy your own parts, it may be worth looking at using a different ratio 5th cog which you buy from Marks Adaptors. Fitting one of these will reduce your revs at highway speed.

Cheers and good luck

Roachie

The spline on the gear shaft is too short, it will need a new shaft, 5th gear, bearings seals etc etc. I believe that it is also wise to fit the GQ thrust washer in place of the GU one.
Cost will vary dramatically, depending on where you go, your first call tomorrow should be to Nissan Australia, as they have assisted many owners from total rebuild of the gearbox down to cash contributions for repairs.
Curiously, they have no hard & fast policy, so remember, "the squeaky wheel gets the oil"!

Joel, mine went about two weeks ago on way back from Qld, when the box was pulled apart, the main shaft had the case hardening worn off it, new shaft required from Japan, all the bearings needed replacing, my fault drove from Moree to Melb, new lay shaft, new 5th gear, Marks, will let you know the cost tomorrow, but figuring not much change out of $4k. New 5th gear from Marks is $1100 or so alone, but a Nissan one is about the same as that. Factor in a new clutch too if yours hasn't been changed out recently. Nissan refused to cover anything with the repairs too. Good luck with your repairs.

Found it! Reason it tokk me a while to reply above & virtually mimic Roachies replay was I was looking for this
GU 5th Gear Photos

Scroll down a little & all be revealed!

Hi Joel,
I know how u feel mine went two weeks ago in western QLD on they back from the Cape,total bugger of a spot as well. At First Nissan were not help full at all ,I stood my ground and mentioned a certain web site with lots of postings???And they came to the party with parts only,which is about all i was after any way, New 5 th gear cog & Main shaft!!It did take 3 phone calls to get that! Mines pulled down know and waiting parts from Nissan as well,I had alook at the 5th gear and main shaft that is the problem and can see clearly the problem, the new 5 th gear is 10 mm wider giving it more metal to metal on the spline. Good luck mate and stand your ground and u should be fine!! I had to drive 1600 kms after mine went?? Seems there no damage in the box either!! Cheers , Shakey!!

Hi Joel,
Just curious, did you do any towing? Mine had never done any towing, but failed anyway at about 120,000.
Mine went back in 2005, right out on the Nullarbor, just before the extended warranty ran out, so Nissan fixed it ok.
Dunno why they changed the original GQ-design box.
Good luck with Nissan!
Gerry

Hows it going Joel , not too good I guess.

The same thing happened to me in '04 near Perth. My vehicle was just over 100k and out of warranty '01 model.

I decided to go to a dealer cause they are nation wide and we were on the wrong side of Oz.

The dealer I went to made me pay for everything exept parts , main shaft and 5th gear, After I had problems with their exchange box went and saw another dealer to get it checked , The Mechanic at this place told me he had done heaps of these under warranty even if the vehicle was out . We had to go back to Perth cause the new box was cactus , The original guy pretended to contact Nissan and said they wouldnt help out.

After I got home I wrote a long letter to Nissan Aust. A couple of weeks later a lady rang me , appologised , told me a cheque for 90% of the cost was in the mail.

You should do a search on this site cause you will get heaps of ammo !

Hope you get sorted out ok .

Glenn.

Check out eBay item number 160158165084 this may be cheaper for you , good luck.