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Input Shaft And Gears: Assembly

WARNING: This page is about a different car, the 2004 Nissan Sentra. However, it is still accessible from the selected car via links, so may be relevant.
  1. Press on input shaft front bearing using Tool.
    Fig 1: Installing Input Shaft Front Bearing
    G00777330Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring bearing to input shaft.
  3. Install spread spring, shifting insert, and 3rd & 4th synchronizer hub onto 3rd & 4th coupling sleeve.
    • Pay attention to the shape of spread spring and shifting insert for correct assembly.

      Do not install spread spring hook onto the same shifting insert.

      CAUTION: Do not reuse 3rd & 4th synchronizer hub.
      Fig 2: Identifying Shape Of Spread Spring And Shifting Insert
      G00777331Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install synchronizer hub with its three grooves facing the front side (3rd input gear side).
      Fig 3: Installing Synchronizer Hub
      G00777332Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install 3rd & 4th coupling sleeve with its chamfered surface facing the 4th input gear side.
      Fig 4: Installing 3rd & 4th Coupling Sleeve
      G00777333Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Position bearing replacer to the front side of input shaft front bearing.
    • Align grooves of shifting insert and 3rd gear baulk ring. Then, press it onto 3rd & 4th synchronizer hub assembly using a drift.
      Fig 5: Pressing On 3rd & 4th Synchronizer Hub Assembly
      G00777334Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install 4th gear C-ring onto input shaft using Tool.
  6. Measure the end play of 3rd & 4th synchronizer hub with a suitable tool, and check if it is within allowable specification.

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

  7. If not within specification, adjust the end play by changing thickness of 4th (input) gear C-ring. Refer to . "AVAILABLE C-RINGS ".
    Fig 6: Measuring End Play Of 3rd & 4th Synchronizer Hub
    G00777335Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install 4th gear needle bearing, 4th gear baulk ring, and 5th gear front C-ring.
    Fig 7: Installing 4th Gear Needle Bearing, 4th Gear Baulk Ring, And 5th Gear Front C-Ring
    G00777336Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install 4th input gear using Tool.
  10. Position 5th input gear as shown, to install it on input shaft.
    Fig 8: Installing 4th Input Gear
    G00777337Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install 5th input gear using Tool as shown.
    CAUTION: Do not reuse 5th input gear.
    Fig 9: Installing 5th Input Gear
    G00777338Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install 5th gear rear C-ring onto input shaft using Tool.
  13. Measure the end play of 5th input gear with a suitable tool, and check if it is within the allowable specification below.

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

    Fig 10: Measuring End Play Of 5th Input Gear
    G00777339Courtesy of NISSAN MOTOR CO., U.S.A.
  14. If not within specification, adjust the end play by changing thickness of the 5th (input gear) rear C-ring. Refer to . "AVAILABLE C-RINGS ".
  15. Install C-ring holder onto 5th gear rear C-ring using Tool.
    CAUTION: Do not reuse C-ring holder.
  16. Install input shaft rear bearing using Tool.
    CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.
    Fig 11: Installing C-Ring Holder Onto 5th Gear Rear C-Ring
    G00777340Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install oil channel onto input shaft.
    Fig 12: Installing Oil Channel Onto Input Shaft
    G00777341Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Measure gear end play as a final check. Refer to . "GEAR END PLAY ".
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