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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 a new input shaft oil seal from the clutch housing end of the side, to the depth of 1.8 - 2.8 mm (0.071 - 0.110 in) using Tool as shown.
    CAUTION: Oil seals are not reusable.
    Fig 1: Install A New Input Shaft Oil Seal
    G00778947Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install a new differential oil seal using Tool (drift) as shown.
    CAUTION: Oil seals are not reusable.
    Fig 2: Install A New Differential Oil Seal
    G00778948Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install the oil channel on the mainshaft side as shown.
    CAUTION: Position the oil channel with the orientation as shown, for installation.
    Fig 3: Install The Oil Channel
    G00778949Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install the mainshaft front bearing using Tool (drift) as shown.
    CAUTION: Position the mainshaft front bearing with the orientation as shown, for installation.
    Fig 4: Install The Mainshaft Front Bearing
    G00778950Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install the mainshaft front bearing retainer.
    CAUTION: Install the bearing retainer with the punched surface facing up.

    Retainer bolt : 6.27 - 8.33 N.m (0.64 - 0.84 kg-m, 56 - 73 in-lb) 

    Fig 5: Install The Mainshaft Front Bearing Retainer
    G00778951Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install the differential side bearing outer race using Tool as shown.
    Fig 6: Install The Differential Side Bearing Outer Race
    G00778952Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install the final drive assembly into the clutch housing.
    Fig 7: Install The Final Drive Assembly
    G00778953Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install the input shaft assembly, mainshaft assembly, and reverse idler gear assembly into the clutch housing.
    CAUTION: Do not damage the input shaft oil seal.
    Fig 8: Install Gear Assembly Into The Clutch Housing
    G00778954Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install the 1st-2nd fork rod bracket onto the 1st-2nd fork rod, and then install a new retaining pin as shown.
    CAUTION: Retaining pins are not reusable.
    Fig 9: Install The 1st-2nd Fork Rod Bracket Onto The 1st-2nd Fork Rod
    G00778955Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install the 1st-2nd fork rod and the 1st-2nd shift fork, and then install a new retaining pin.
    CAUTION: Retaining pins are not reusable.
    Fig 10: Install The 1st-2nd Fork Rod And The 1st-2nd Shift Fork
    G00778956Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install the shift check sleeve.
  12. Install the 3rd-4th bracket, 3rd-4th shift fork, and 3rd-4th fork rod with the interlock pin.
  13. Install the new stopper rings onto the 3rd-4th shift fork.
    CAUTION: Stopper rings are not reusable.
  14. Install a new retaining pin onto the 3rd-4th bracket.
    CAUTION: Retaining pins are not reusable.
    Fig 11: Install The New Stopper Rings Onto The 3rd-4th Shift Fork & New Retaining Pin Onto The 3rd-4th Bracket
    G00778957Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install the 2 check balls.
  16. Install the 5th-6th bracket, 5th-6th shift fork, and 5th-6th fork rod.
  17. Install new stopper rings onto the 5th-6th bracket with interlock pin.
    CAUTION: Stopper rings are not reusable.
    Fig 12: Install New Stopper Rings Onto The 5th-6th Bracket With Interlock Pin
    G00778958Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install a new retaining pin onto the 5th-6th shift fork.
    CAUTION: Retaining pins are not reusable.
    Fig 13: Install A New Retaining Pin Onto The 5th-6th Shift Fork
    G00778959Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Install the two check balls.
  20. Install the 5th-6th check ball, 5th-6th shift check sleeve, 5th-6th check spring, and the 5th-6th check ball plug.
    CAUTION:
    • Do not reuse the check ball plug. 
    • Do not drop the check ball. 
  21. Install the reverse bracket fork rod and reverse lever bracket.
  22. Install a new retaining pin onto the reverse bracket.
    CAUTION: Retaining pins are not reusable.
    Fig 14: Install A New Retaining Pin Onto The Reverse Bracket
    G00778960Courtesy of NISSAN MOTOR CO., U.S.A.
  23. Install the reverse shift fork and reverse fork rod.
  24. Install the reverse lever assembly using the following steps:
    1. Install the shifter cap onto the reverse lever assembly cam, and then install them onto the reverse shift fork.
      CAUTION: Do not drop the shifter cap.
    2. While lifting the reverse shift fork, align the cam with the reverse bracket.
      Fig 15: While Lifting The Reverse Shift Fork, Align The Cam With The Reverse Bracket
      G00778961Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Tighten the bracket bolts to specification, and install the reverse lever assembly.

      Bracket bolts : 11.8 -15.6 N.m (1.2 - 1.5 kg-m, 9 - 11 ft-lb) 

      Fig 16: Tighten The Bracket Bolts To Specification, And Install The Reverse Lever Assembly
      G00778962Courtesy of NISSAN MOTOR CO., U.S.A.
  25. Install the check ball, reverse shift check sleeve, reverse check spring, and the reverse check ball plug.
    CAUTION:
    • Do not reuse the check ball plug. 
    • Do not drop the check ball. 
  26. Install the magnet onto the clutch housing.
  27. Install the selected input shaft adjusting shim onto the input shaft.
  28. Install the baffle plate and oil gutter.
  29. Install the transaxle case using the following steps:
    1. Install the selected mainshaft rear bearing adjusting shim into the transaxle case.
    2. Temporarily install the snap ring of the mainshaft rear bearing into the transaxle case.
      CAUTION: Do not reuse the snap ring.
    3. Apply sealant to the mating surfaces of the transaxle case and clutch housing as shown. Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Remove any old sealant adhering to the mounting surfaces. Also remove any moisture, oil, or foreign material adhering to the sealant application and mounting surfaces.
      Fig 17: Apply Sealant To The Mating Surfaces Of The Transaxle Case And Clutch Housing As Shown
      G00778963Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Using a snap ring of the mainshaft rear bearing temporarily, install the transaxle case over the clutch housing as shown.
      Fig 18: Install The Transaxle Case Over The Clutch Housing As Shown
      G00778964Courtesy of NISSAN MOTOR CO., U.S.A.
    5. Through the bore plug mounting hole, with the snap ring stretched, lift up the mainshaft assembly from the control assembly mounting hole.
    6. Securely install the snap ring onto the mainshaft rear bearing as shown.
      Fig 19: Securely Install The Snap Ring Onto The Mainshaft Rear Bearing As Shown
      G00778965Courtesy of NISSAN MOTOR CO., U.S.A.
    7. Tighten the "A" bolts (gold) and new "B" bolts (black) to specification.

      "A" Bolt : 50.0 - 53.9 N-m (5.1 - 5.4 kg-m, 37 - 39 ft-lb) 

      "B" Bolt : 63.0 - 66.9 N-m (6.5 - 6.8 kg-m, 47 - 49 ft-lb) 

      CAUTION: Always replace the "B" bolts as they are self-sealing bolts.
      Fig 20: Tighten The "A" Bolts (Gold) And New "B" Bolts (Black) To Specification
      G00778966Courtesy of NISSAN MOTOR CO., U.S.A.
    8. Install the control assembly using new O-rings.
      CAUTION: Do not reuse the O-ring.
    9. Install a new shift check and a new stopper bolt.
      CAUTION: Shift check and stopper bolt are not reusable.
  30. Install a new bore plug using Tool (drift) as shown.
    CAUTION: Bore plugs are not reusable.
    Fig 21: Install A New Bore Plug Using Tool (Drift) As Shown
    G00778967Courtesy of NISSAN MOTOR CO., U.S.A.
  31. Install the new welch plug using Tool (drift).
    CAUTION: Do not reuse the welch plug
    Fig 22: Install The New Welch Plug Using Tool (Drift)
    G00778968Courtesy of NISSAN MOTOR CO., U.S.A.
  32. Install the 2 check balls, 2 check springs, and the 2 new check ball plugs.
    CAUTION: Check ball plugs are not reusable.
    Fig 23: Install The 2 Check Balls, 2 Check Springs, And The 2 New Check Ball Plugs
    G00778969Courtesy of NISSAN MOTOR CO., U.S.A.
  33. Apply sealant to the threads of the neutral switch and reverse lamp switch. Then install them into the transaxle case. Refer to "CASE AND HOUSING COMPONENTS  ". Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
    Fig 24: Apply Sealant To The Threads Of The Neutral Switch And Reverse Lamp Switch
    G00778970Courtesy of NISSAN MOTOR CO., U.S.A.
  34. Install new gaskets onto the drain plug and filler plug, and then install them into the transaxle case.
    CAUTION:
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