Disassembly and Assembly: 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.

Install the 3rd needle bearing.
Install the 3rd input gear and 3rd baulk ring.
Install the spread spring, shifting insert, and a new 3rd-4th synchronizer hub onto the 3rd-4th coupling sleeve.
CAUTION: Do not reuse the 3rd-4th synchronizer hub.
- Install with orientation of the synchronizer hub as shown.
  
  Fig 1: Identifying Orientation Of Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Install with orientation of coupling sleeve as shown.
  
  Fig 2: Identifying Orientation Of Coupling Sleeve
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Be sure not to hook the ends of the 2 spread springs (front and back have two each) on the same shifting insert.
  
  Fig 3: Identifying Center Projection Of Spread Spring
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install 3rd-4th coupling sleeve assembly using Tool as shown.
CAUTION: Align the grooves of the shifting insert and the 3rd baulk ring.

Fig 4: Installing 3rd-4th Coupling Sleeve Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the 4th bushing using Tool as shown.
Install the 4th baulk ring.
Install the 4th input gear and 4th needle bearing.

Fig 5: Installing 4th Bushing
Courtesy of NISSAN MOTOR CO., U.S.A.
Measure the dimension "C2" as shown. Select a thrust washer so that dimension "C2" satisfies standard dimension specification. Then install the thrust washer onto the input shaft.
Standard for dimension "C2": 154.7 - 154.8 mm (6.091 - 6.094 in)

CAUTION: Only 1 thrust washer can be selected.

Fig 6: Measuring Dimension Of Input Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.

thrust Washer

Fig 7: Thrust Washer Specifications
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the 5th bushing using Tool as shown.
Install the 5th needle bearing and 5th input gear.
Install the 5th baulk ring.

Fig 8: Installing 5th Bushing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the synchronizer assembly onto a new 5th-6th synchronizer hub.
CAUTION: Do not reuse the 5th-6th synchronizer hub.
- Install with the orientation of the synchronizer hub as shown.
  
  Fig 9: Identifying Orientation Of Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Be sure not to hook the ends of the 2 spread springs (front and back have two each) on the same shifting insert.
  
  Fig 10: Identifying Center Projection Of Spread Spring
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install the 5th-6th synchronizer hub assembly using Tool as shown.
CAUTION: Align the grooves of the 5th-6th shifting insert and 5th-6th baulk ring.

Fig 11: Installing 5th-6th Synchronizer Hub Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the needle bearing, 6th input gear and then 6th bushing using Tool as shown.

Fig 12: Installing Needle Bearing, 6th Input Gear And 6th Bushing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the snap ring onto the input shaft, and measure to check that end play (gap between snap ring and groove) of the 6th bushing is within specification.
End play standard value: 0 - 0.1 mm (0 - 0.004 in)
- If the measurement is outside the standard value, select the appropriate size snap ring.
  
  Fig 13: Checking Gap Between Snap Ring And Groove
  Courtesy of NISSAN MOTOR CO., U.S.A.
Snap Rings

Fig 14: Snap Rings Specifications
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the input shaft rear bearing using Tool as shown.
CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.

Fig 15: Installing Input Shaft Rear Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the input shaft front bearing using Tool as shown.
Install the oil channel onto the input shaft.

Fig 16: Installing Input Shaft Front Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Check the end play of the 3rd, 4th, 5th and 6th input gears as shown.
End play standard value

3rd gear: 0.18 - 0.31 mm (0.0071 - 0.0122 in)

4th gear: 0.20 - 0.30 mm (0.0079 - 0.0118 in)

5th gear: 0.06 - 0.16 mm (0.0024 - 0.0063 in)

6th gear: 0.06 - 0.16 mm (0.0024 - 0.0063 in)

Fig 17: Checking End Play Of 3rd, 4th, 5th And 6th Input Gears
Courtesy of NISSAN MOTOR CO., U.S.A.