Gear Components

WARNING: This page is about a different car, the 2005 Nissan Xterra. However, it is still accessible from the selected car via links, so may be relevant.

Install 5th-6th synchronizer hub assembly according to the following.
1. Install 5th-6th coupling sleeve to 5th-6th synchronizer hub.
  CAUTION:
  - Do not reuse 5th-6th synchronizer hub and 5th-6th coupling sleeve.
  - Replace 5th-6th synchronizer hub and 5th-6th coupling sleeve as a set.
  - Be careful with the orientation 5th-6th coupling sleeve.
    
    Fig 1: Inspecting 5Th-6Th Coupling Sleeve
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the orientation 5th-6th synchronizer hub.
    
    Fig 2: Inspecting 5Th-6Th Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install shifting inserts and spread springs to 5th-6th synchronizer hub.
  CAUTION:
  - Do not install spread spring hook onto the same shifting insert.
    
    Fig 3: Installing Shifting Inserts And Spread Springs To 5Th-6Th Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the shape of reserve shifting insert to avoid misemploy.
    
    Fig 4: Inspecting Shifting Insert
    Courtesy of NISSAN MOTOR CO., U.S.A.
3. Press in 5th-6th synchronizer hub assembly, 6th baulk ring, 6th main gear and 6th needle bearing using Tool.
  CAUTION:
  - Apply gear oil to 6th baulk ring and 6th needle bearing.
  - Be careful with the orientation 5th-6th coupling sleeve.
    
    Fig 5: Installing 5Th-6Th Synchronizer Hub Assembly
    Courtesy of NISSAN MOTOR CO., U.S.A.
  NOTE: 5th and 6th baulk rings have three spaces that four gear teeth are missing as shown.
  
  Fig 6: Inspecting 5Th And 6Th Baulk Rings
  Courtesy of NISSAN MOTOR CO., U.S.A.
Select and install a snap ring so that the end play comes within the standard value. Refer to "SNAP RINGS ".
End play: 0 - 0.10 mm (0 - 0.004 in)

CAUTION: Do not reuse snap ring.

Fig 7: Checking End Play
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 1st-2nd synchronizer hub assembly according to the following.
1. Install 1st-2nd coupling sleeve to 1st-2nd synchronizer hub.
  CAUTION:
  - Do not reuse 1st-2nd coupling sleeve and 1st-2nd synchronizer hub.
  - Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.
  - Be careful with the orientation 1st-2nd coupling sleeve.
    
    Fig 8: Installing 1St-2Nd Coupling Sleeve
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the orientation 1st-2nd synchronizer hub.
    
    Fig 9: Inspecting 1St-2Nd Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install spread springs and shifting inserts to 1st-2nd synchronizer hub.
  CAUTION:
  - Do not install spread spring hook onto the same shifting insert.
    
    Fig 10: Installing Spread Springs And Shifting Inserts To 1St-2Nd Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the shape of reverse shifting insert to avoid mis-assembly.
    
    Fig 11: Inspecting Shifting Insert
    Courtesy of NISSAN MOTOR CO., U.S.A.
3. Press in 1st-2nd synchronizer hub assembly, 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring, 2nd main gear and 2nd needle bearing using Tool.
  CAUTION:
  - Apply gear oil to 2nd needle bearing, 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring, 1st-2nd synchronizer hub spline of mainshaft.
  - Replace 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring as a set.
  - Be careful with the orientation 1st-2nd coupling sleeve.
    
    Fig 12: Installing 1St-2Nd Synchronizer Hub Assembly
    Courtesy of NISSAN MOTOR CO., U.S.A.
  NOTE: 1st outer baulk ring has three spaces that three gear tooth is missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.
  
  Fig 13: Inspecting 1St Outer Baulk Ring
  Courtesy of NISSAN MOTOR CO., U.S.A.
Press in 1st gear bushing using Tool.
Install 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 1st needle bearing and 1st main gear to mainshaft.
CAUTION:
- Apply gear oil to 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring and 1st needle bearing.
- Replace 1st outer baulk ring, 1st synchronizer cone and 1st inner baulk ring as a set.
  
  Fig 14: Installing 1St Gear Bushing
  Courtesy of NISSAN MOTOR CO., U.S.A.
NOTE: 1st outer baulk ring has three spaces that three gear tooth is missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.

Fig 15: Inspecting 1St Outer Baulk Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in 3rd main gear using Tool.
CAUTION:
- Do not reuse 3rd main gear.
- Be careful with the orientation 3rd main gear.
  
  Fig 16: Installing 3Rd Main Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install 3rd-4th main spacer to mainshaft.
Press in 4th main gear using Tool.
CAUTION:
- Do not reuse 4th main gear.
- Be careful with the orientation 4th main gear.
  
  Fig 17: Installing 3Rd-4Th Main Spacer To Mainshaft
  Courtesy of NISSAN MOTOR CO., U.S.A.
Press in mainshaft bearing using Tool.
CAUTION: Be careful with the orientation mainshaft bearing.

Fig 18: Installing Mainshaft Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in reverse main gear bushing using Tool.

Fig 19: Installing Reverse Main Gear Bushing
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in 3rd gear bushing using Tool.
Install 3rd-4th synchronizer hub assembly according to the following.
1. Install 3rd-4th coupling sleeve to 3rd-4th synchronizer hub.
  CAUTION:
  - Do not reuse 3rd-4th synchronizer hub and 3rd-4th coupling sleeve.
  - Replace 3rd-4th synchronizer hub and 3rd-4th coupling sleeve as a set.
    
    Fig 20: Installing 3Rd Gear Bushing
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the orientation 3rd-4th coupling sleeve.
    
    Fig 21: Inspecting 3Rd-4Th Coupling Sleeve
    Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install spread springs and shifting inserts to 3rd-4th synchronizer hub.
  CAUTION:
  - Do not install spread spring hook onto the same shifting insert.
    
    Fig 22: Installing Spread Springs And Shifting Inserts To 3Rd-4Th Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the shape of reverse shifting insert to avoid mis-assembly.
    
    Fig 23: Inspecting Reverse Shifting Insert
    Courtesy of NISSAN MOTOR CO., U.S.A.
3. Press in 3rd-4th synchronizer hub assembly, 3rd inner baulk ring, 3rd synchronizer cone, 3rd outer baulk ring, 3rd counter gear and 3rd needle bearing using Tool.
  CAUTION:
  - Apply gear oil to 3rd inner baulk ring, 3rd synchronizer cone, 3rd outer baulk ring and 3rd needle bearing, hole spline of 3rd-4th synchronizer hub.
  - Replace 3rd inner baulk ring, 3rd synchronizer cone and 3rd outer baulk ring as a set.
  - Be careful with the orientation 3rd-4th coupling sleeve.
    
    Fig 24: Installing 3Rd-4Th Synchronizer Hub Assembly
    Courtesy of NISSAN MOTOR CO., U.S.A.
  NOTE: 4th baulk ring has three spaces that one gear tooth is missing but 3rd baulk ring doesn't.
  
  Fig 25: Inspecting 4Th Baulk Ring
  Courtesy of NISSAN MOTOR CO., U.S.A.
Press in 4th counter gear thrust washer, 4th gear bushing, 4th needle bearing, 4th counter gear, 4th outer baulk ring,4th synchronizer cone and 4th inner baulk ring using Tool.
CAUTION:
- Apply gear oil to 4th needle bearing, 4th outer baulk ring, 4th synchronizer cone and 4th inner baulk ring.
- Replace 4th outer baulk ring, 4th synchronizer cone and 4th inner baulk ring as a set.
- Be careful with the orientation 4th counter gear thrust washer.
  
  Fig 26: Installing 4Th Counter Gear Thrust Washer
  Courtesy of NISSAN MOTOR CO., U.S.A.
NOTE: 4th baulk ring has three spaces that one gear tooth is missing but 3rd baulk ring doesn't.

Fig 27: Inspecting 4Th Baulk Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in counter rear bearing inner race using Tool.
CAUTION: Be careful with the orientation counter rear bearing inner race.

Fig 28: Installing Counter Rear Bearing Inner Race
Courtesy of NISSAN MOTOR CO., U.S.A.
Install main drive gear bearing according to the following.
1. Press in main drive gear bearing using Tool.
  CAUTION: Be careful with the orientation main drive gear bearing.
  
  Fig 29: Installing Main Drive Gear Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Select and install a snap ring to main drive gear bearing so that the end play comes within the standard value. Refer to "SNAP RINGS ".
  End play: 0 - 0.10 mm (0 - 0.004 in)
  
  CAUTION: Do not reuse snap ring.
  
  Fig 30: Measuring End Play
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install breather to adapter plate.
CAUTION:
- Do not reuse breather.
- Be careful with the orientation breather.
  
  Fig 31: Installing Breather To Adapter Plate
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install magnet to adapter plate.
CAUTION: Be careful with the orientation magnet.

Fig 32: Installing Magnet To Adapter Plate
Courtesy of NISSAN MOTOR CO., U.S.A.
Install baffle plate to adapter plate, and then tighten bolt to the specified torque. Refer to "CASE COMPONENTS ".

Fig 33: Installing Baffle Plate To Adapter Plate
Courtesy of NISSAN MOTOR CO., U.S.A.
Install main drive gear assembly, mainshaft assembly and counter gear assembly according to the following.
1. Install main pilot bearing, pilot bearing spacer and 5th baulk ring to main drive gear.
2. Install main drive gear assembly, mainshaft assembly and counter gear assembly combined in one unit to adapter plate using brass bar.
  
  Fig 34: Installing Main Drive Gear Assembly
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install Tool to adapter plate, and then position in a vise.
CAUTION: Do not directly secure mating surface of adapter plate in a vise.
Install snap ring to mainshaft bearing.
CAUTION: Do not reuse snap ring.

Fig 35: Installing Tool To Adapter Plate
Courtesy of NISSAN MOTOR CO., U.S.A.
Install counter rear bearing to adapter plate using Tool.
Install counter rear bearing spacer to counter gear.
CAUTION: When installing counter rear bearing spacer, groove should face to the rear side.

Fig 36: Installing Snap Ring To Mainshaft Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install bearing retainer according to the following.
1. Instal bearing retainer to adapter plate.
2. Apply recommended thread locking sealant to threads of bolts, and then tighten bolts to the specified torque. Refer to "CASE COMPONENTS ".
  - Use Genuine Medium Strength Thread Locking Sealant or the equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
    
    Fig 37: Installing Counter Rear Bearing
    Courtesy of NISSAN MOTOR CO., U.S.A.
Install reverse synchronizer hub assembly according to the following.
1. Install reverse coupling sleeve to reverse synchronizer hub.
  CAUTION:
  - Do not reuse reverse coupling sleeve and reverse synchronizer hub.
  - Replace reuse reverse coupling sleeve and reverse synchronizer hub as a set.
  - Be careful with the orientation reverse coupling sleeve.
    
    Fig 39: Inspecting Reverse Coupling Sleeve
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the orientation reverse synchronizer hub.
    
    Fig 40: Inspecting Reverse Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install spread springs to shifting inserts to reverse synchronizer hub.
  CAUTION:
  - Do not install spread spring hook onto the same shifting insert.
    
    Fig 41: Installing Spread Springs To Shifting Inserts To Reverse Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the shape of 1st-2nd, 3rd-4th and 5th-6th shifting insert to avoid mis-assembly.
    
    Fig 42: Inspecting Shifting Insert
    Courtesy of NISSAN MOTOR CO., U.S.A.
3. Install snap ring to reverse synchronizer hub.
  CAUTION:
  - Do not reuse snap ring.
  - Do not align the snap ring notch with synchronizer hub groove when assembling.
    
    Fig 43: Installing Snap Ring To Reverse Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
4. Press in reverse synchronizer hub assembly, reverse baulk ring, reverse main gear and reverse main needle bearing using Tools.
  CAUTION: Apply gear oil to reverse baulk ring and reverse main needle bearing.
  
  Fig 44: Installing Reverse Synchronizer Hub Assembly
  Courtesy of NISSAN MOTOR CO., U.S.A.
  
  NOTE: Reverse baulk ring has three spaces that two gear teeth are missing, and each space has small ditch for identification as shown.
  
  Fig 45: Inspecting Reverse Baulk Ring
  Courtesy of NISSAN MOTOR CO., U.S.A.
Select and install a snap ring so that the end play comes within the standard value. Refer to "SNAP RINGS ".
End play: 0 - 0.10 mm (0 - 0.004 in)

CAUTION: Do not reuse snap ring.

Fig 46: Measuring End Play
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in reverse counter gear using Tool.
CAUTION:
- Do not reverse counter gear.
- Be careful with the orientation counter gear.
Select and install a snap ring so that the end play comes within the standard value. Refer to "SNAP RINGS ".
End play: 0 - 0.10 mm (0 - 0.004 in)

Fig 47: Installing Reverse Counter Gear
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Do not reuse snap ring.

Fig 48: Measuring End Play
Courtesy of NISSAN MOTOR CO., U.S.A.
Install reverse idler shaft assembly according to the following.
1. Install reverse idler needle bearing, reverse idler gear and reverse idler thrust washer to reverse idler shaft.
  CAUTION: Apply gear oil to reverse idler needle bearing.
2. Install reverse idler shaft assembly to adapter plate.
  
  Fig 49: Installing Reverse Idler Shaft Assembly
  Courtesy of NISSAN MOTOR CO., U.S.A.