Input Shaft And Gears: Assembly

WARNING: This page is about a different car, the 2002 Nissan Sentra. However, it is still accessible from the selected car via links, so may be relevant.

Press on input shaft front bearing using Tool.

Fig 1: Pressing Input Shaft Front Bearing On
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring bearing to input shaft.

CAUTION: Do not reuse 3rd and 4th synchronizer hub.

Fig 2: Installing Spread Springs & Shifting Inserts

Courtesy of NISSAN MOTOR CO., U.S.A.

Install spread spring, shifting insert, and 3rd and 4th synchronizer hub onto 3rd and 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.
- Install synchronizer hub with its three grooves facing the front side (3rd input gear side).
  
  Fig 3: Installing Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Install 3rd and 4th coupling sleeve with its chamfered surface facing the 4th input gear side.
  
  Fig 4: Installing 3rd & 4th Coupling Sleeve
  Courtesy of NISSAN MOTOR CO., U.S.A.
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 and 4th synchronizer hub assembly using a drift.
  
  Fig 5: Pressing 3rd & 4th Synchronizer Hub Assembly On
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install 4th gear C-ring onto input shaft using Tool.
Measure the end play of 3rd and 4th synchronizer hub with a suitable tool, and check if it is within allowable specification.

Fig 6: Measuring End Play Of 3rd & 4th Synchronizer Hub
Courtesy of NISSAN MOTOR CO., U.S.A.
1. End play: 0 - 0.06 mm (0 - 0.0024 in)
If not within specification, adjust the end play by changing thickness of 4th (input) gear C-ring.
1. 4th (input) gear C-ring: Refer to AVAILABLE C-RINGS .
Install 4th gear needle bearing, 4th gear baulk ring, and 5th gear front C-ring.

Fig 7: Installing 4th Gear Needle Bearing, Baulk Ring, & 5th Gear Front C-Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 4th input gear using Tool.
Position 5th input gear as shown in Fig 8, and install it on input shaft.

Fig 8: Installing 5th Input Gear On Input Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Do not reuse 5th input gear.

Install 5th input gear.
Install 5th gear rear C-ring onto input shaft using Tool.

Fig 9: Installing 5th Gear Rear C-Ring Onto Input Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Measure the end play of 5th input gear with a suitable tool, and check if it is within the allowable specification below.
1. End play: 0 - 0.06 mm (0 - 0.0024 in)
If not within specification, adjust the end play by changing thickness of the 5th (input gear) rear C-ring.

Fig 10: Measuring End Play Of 5th Input Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
1. 5th (input gear) rear C-ring: Refer to AVAILABLE C-RINGS .

CAUTION: Do not reuse C-ring holder.

Fig 11: Installing C-Ring Holder & Input Shaft Rear Bearing

Courtesy of NISSAN MOTOR CO., U.S.A.

Install C-ring holder onto 5th gear rear C-ring using Tool.

CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.

Install input shaft rear bearing using Tool.
Install Oil channel onto input shaft.

Fig 12: Installing Oil Channel Onto Input Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Measure gear end play as a final check. Refer to GEAR END PLAY .