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MAINSHAFT And Gears: Assembly

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  1. Install 1st gear needle bearing and 1st main gear onto mainshaft.
    Fig 1: Installing 1st Gear Needle Bearing And 1st Main Gear Onto Mainshaft
    G00777359Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install 1st double cone assembly onto mainshaft.
  3. Install 1st & 2nd synchronizer hub with its three grooves facing the front side (1st main gear side) onto mainshaft.
    CAUTION: Do not reuse 1st & 2nd synchronizer hub.
    Fig 2: Identifying Synchronizer Hub
    G00777360Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install 1st & 2nd synchronizer hub using Tool.
    Fig 3: Installing 1st & 2nd Synchronizer Hub
    G00777361Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install insert spring onto 1st & 2nd coupling sleeve.
    Fig 4: Installing Insert Spring Onto 1st & 2nd Coupling Sleeve
    G00777362Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install 1st & 2nd coupling sleeve with its chamfered surface facing the 1st main gear side onto 1st & 2nd synchronizer hub.
    Fig 5: Installing 1st & 2nd Coupling Sleeve
    G00777363Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install 2nd gear bushing with its flange surface facing 1st & 2nd synchronizer hub side using Tool.
    Fig 6: Installing 2nd Gear Bushing
    G00777364Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install 2nd needle bearing, 2nd double cone assembly, and 2nd main gear onto mainshaft using Tool.
  9. Position 3rd main gear as shown, and install it using Tool.
    CAUTION: Do not reuse 3rd main gear.
    Fig 7: Positioning 3rd Main Gear
    G00777365Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install spacer and mainshaft adjusting shim onto mainshaft.
  11. Select a mainshaft adjusting shim suitable to satisfy the following specification of dimension "L" and install it onto mainshaft.

    Dimension "L": 151.35 - 151.45 mm (5.9586 - 5.9626 in) 

    Mainshaft adjusting shims: Refer to  . "AVAILABLE ADJUSTING SHIMS ".

    Fig 8: Installing Main Adjusting Shim
    G00777366Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Position 4th main gear as shown, and install it onto mainshaft.
    Fig 9: Positioning 4th Main Gear
    G00777367Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install 4th main gear onto mainshaft using Tool.
    CAUTION: Do not reuse 4th main gear.
    Fig 10: Installing 4th Main Gear Onto Mainshaft
    G00777368Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install 5th gear bushing with its flange surface facing the 4th main gear side using Tool.
    Fig 11: Installing 5th Gear Bushing
    G00777369Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install 5th needle bearing, 5th main gear, and 5th gear baulk ring onto mainshaft.
    Fig 12: Installing 5th Needle Bearing, 5th Main Gear, And 5th Gear Baulk Ring Onto Mainshaft
    G00777370Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Being careful of the following points, install spread spring, shifting insert, and 5th & reverse synchronizer hub onto 5th & reverse coupling sleeve.
    Fig 13: Installing Spread Spring, Shifting Insert, And 5th & Reverse Synchronizer Hub Onto 5th & Reverse Coupling Sleeve
    G00777371Courtesy of NISSAN MOTOR CO., U.S.A.
    • 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.

    • Install synchronizer hub with its three grooves facing the front side (5th main gear side).
      CAUTION: Do not reuse 5th & reverse synchronizer hub.
      Fig 14: Identifying Installation Direction Of Synchronizer Hub
      G00777372Courtesy of NISSAN MOTOR CO., U.S.A.
    • Install 5th & reverse coupling sleeve with its chamfered surface facing the reverse main gear side.
      Fig 15: Installing 5th & Reverse Coupling Sleeve
      G00777373Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install 5th & reverse synchronizer hub assembly using Tool.
    Fig 16: Installing 5th & Reverse Synchronizer Hub Assembly
    G00777374Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install reverse gear baulk ring using Tool.
    19. Fig 17: Installing Reverse Gear Baulk Ring & Bushing
    G00777375Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Install reverse gear bushing using Tool.
  20. Install reverse gear needle bearing using Tool.
  21. Install sub-gear, sub-gear washer, and snap ring onto reverse main gear.
    CAUTION:
    • Pay attention to direction of sub-gear washer.
    • Do not reuse snap ring.
    Fig 18: Installing Sub-Gear, Sub-Gear Washer, And Snap Ring Onto Reverse Main Gear
    G00777376Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Install reverse main gear assembly onto mainshaft.
  23. Select a thrust washer suitable to satisfy the following specification of dimension "M" as shown, and install it onto mainshaft.

    Dimension "M": 244.20 - 244.30 mm 

    (9.6142-9.6181 in) 

    Available thrust:   Refer to Figure.

    Fig 19: Installing Thrust Washer To Mainshaft
    G00777377Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Install mainshaft rear bearing using Tool.
    Fig 20: Installing Mainshaft Rear Bearing
    G00777378Courtesy of NISSAN MOTOR CO., U.S.A.
  25. Install mainshaft C-ring.
  26. Using feeler gauge, measure the end play of mainshaft rear bearing with a suitable tool, and check if it satisfies the following specification.

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

    Mainshaft C-rings:   Refer to . "AVAILABLE C-RINGS ".

    Fig 21: Measuring End Play Of Mainshaft Rear Bearing
    G00777379Courtesy of NISSAN MOTOR CO., U.S.A.
  27. Install C-ring holder.
    Fig 22: Installing C-Ring Holder
    G00777380Courtesy of NISSAN MOTOR CO., U.S.A.
  28. Install snap ring with a suitable tool.
    Fig 23: Installing Snap Ring
    G00777381Courtesy of NISSAN MOTOR CO., U.S.A.
  29. Measure gear end play as a final check. Refer to . "GEAR END PLAY ".
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