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Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2004 Nissan Maxima. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the reverse main gear using Tool as shown.
    Fig 1: Assembly (1 Of 21)
    G00779031Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Install with the orientation of reverse main gear as shown.
    Fig 2: Assembly (2 Of 21)
    G00779032Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install the 1st bushing using Tool as shown.
  3. Install the needle bearing, and then the 1st main gear.
    Fig 3: Assembly (3 Of 21)
    G00779033Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install the spread spring, shifting insert, and a new 1st-2nd synchronizer hub onto the 1st-2nd coupling sleeve.
    CAUTION:
    • Install with the orientation of the new synchronizer hub as shown. 
    • Do not reuse 1st-2nd synchronizer hub 
      Fig 4: Assembly (4 Of 21)
      G00779034Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install with the orientation of coupling sleeve as shown. 
      Fig 5: Assembly (5 Of 21)
      G00779035Courtesy of NISSAN MOTOR CO., U.S.A.
    • Do not hook the ends of the two spread springs (front and back have two each) on the same shifting insert. 
      Fig 6: Assembly (6 Of 21)
      G00779036Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install the 1st gear synchronizer assembly onto the mainshaft, and the synchronizer hub assembly onto the mainshaft using Tool as shown.
    CAUTION:
    • Outer baulk ring, synchronizer cone, and inner baulk ring on the 2nd gear-side must have been removed. 
    • Install the coupling sleeve with the proper orientation. 
      Fig 7: Assembly (7 Of 21)
      G00779037Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install the 2nd bushing using Tool as shown.
  7. Install the outer baulk ring, synchronizer cone, and inner baulk ring on 2nd gear-side.
  8. Install the 2nd needle bearing and 2nd gear.
    Fig 8: Assembly (8 Of 21)
    G00779038Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install the 3rd main gear.
    CAUTION: Install the 3rd main gear with the orientation as shown.
  10. Install the 3rd-4th mainshaft spacer.
    Fig 9: Assembly (9 Of 21)
    G00779039Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Measure the dimension "C1". Select a suitable adjusting shim so that the dimension "C1" satisfies the specified standard value, and install it onto the mainshaft.

    Standard for : 173.85 - 173.95 mm (6.844 - 6.848 in) dimension "C1" 

    CAUTION: Only 1 adjusting shim can be selected.
    Fig 10: Assembly (10 Of 21)
    G00779040Courtesy of NISSAN MOTOR CO., U.S.A.

    Adjusting Shim 

    Fig 11: Assembly (11 Of 21) Available Adjusting Shims
    G00779041Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install the 4th main gear with the specified orientation as shown, using Tool as shown.
    CAUTION: Install the 4th main gear with the orientation as shown.
    Fig 12: Assembly (12 Of 21)
    G00779042Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install the 5th main gear with the specified orientation as shown, using Tool as shown.
    CAUTION: Install the 5th main gear with the orientation as shown.
  14. Install the 5th-6th mainshaft spacer.
    Fig 13: Assembly (13 Of 21)
    G00779043Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install the 6th main gear using Tool as shown.
    Fig 14: Assembly (14 Of 21)
    G00779044Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Select the 6th main adjusting shim and then install it onto the mainshaft.
    • Calculate thickness "S" of 6th main adjusting shim by procedure below so that end play dimension between 6th main gear and mainshaft rear bearing becomes the dimension specified.

      End play : 0 - 0.1 mm (0 - 0.004 in) 

      Dimension "S" = ("S 1" - "S 2") + End play 

      "S" : Thickness of adjusting shim 

      "S 1: Dimension from mainshaft standard face to " mainshaft rear bearing press-fit end face 

      "S 2: Dimension from mainshaft standard face to " 6th main gear end face 

      CAUTION: Only 1 adjusting shim can be selected.
      Fig 15: Assembly (15 Of 21)
      G00779045Courtesy of NISSAN MOTOR CO., U.S.A.

    Adjusting Shim 

    Fig 16: Assembly (16 Of 21) Available Adjusting Shims
    G00779046Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Using a height gauge, measure the dimension "S1 " and "S2 " as shown.
    2. Install the selected 6th main adjusting shim to the mainshaft.
  17. Install the mainshaft rear bearing using Tool as shown.
    Fig 17: Assembly (17 Of 21)
    G00779047Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install the C-ring onto the mainshaft, and check that the end play of mainshaft rear bearing meets specifications.

    End play standard value : 0 - 0.06 mm (0 - 0.0024 in) 

    • If the measurement is outside the specified standard value, reselect a new C-ring.
      Fig 18: Assembly (18 Of 21)
      G00779048Courtesy of NISSAN MOTOR CO., U.S.A.

      C-Ring 

      Fig 19: Assembly (19 Of 21) Available C-Rings
      G00779049Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Fit the C-ring holder, and install the snap ring as shown.
    Fig 20: Assembly (20 Of 21)
    G00779050Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Check the end play of 1st and 2nd main gears as shown.

    End play standard value 

    1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in) 

    2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in) 

    Fig 21: Assembly (21 Of 21)
    G00779051Courtesy of NISSAN MOTOR CO., U.S.A.
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