Disassembly and Assembly: 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.

Install reverse main gear.

Fig 1: Installing Reverse Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Be careful with orientation of reverse main gear.

Fig 2: Checking Orientation Of Reverse Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 1st bushing.
Install needle bearing, and then 1st main gear.

Fig 3: Installing 1st Bushing & 1st Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION:

Be careful with orientation of synchronizer hub.

Fig 4: Checking Orientation Of 1st & 2nd Gear Synchronizer Hub
Courtesy of NISSAN MOTOR CO., U.S.A.
Be careful with orientation of coupling sleeve.

Fig 5: Checking Orientation Of 1st & 2nd Gear Coupling Sleeve
Courtesy of NISSAN MOTOR CO., U.S.A.
Be sure not to hook ends of 2 spread springs (front and back: 2 each) on same shifting insert.

Fig 6: Installing Spread Springs
Courtesy of NISSAN MOTOR CO., U.S.A.

Install spread spring, shifting insert and 1st-2nd synchronizer hub onto 1st-2nd coupling sleeve.
Install 1st gear synchronizer assembly onto mainshaft, and synchronizer hub assembly onto mainshaft.

Fig 7: Installing 1st Gear Components To Mainshaft
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- Outer baulk ring, synchronizer cone, and inner baulk ring on 2nd gear-side must have been removed.
- Be careful with orientation of coupling sleeve.
Install 2nd bushing.

Fig 8: Installing 2nd Gear Components To Mainshaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Install outer baulk ring, synchronizer cone, and inner baulk ring on 2nd gear-side.
Install 2nd needle bearing and 2nd gear.
Install 3rd main gear.

Fig 9: Installing 3rd Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Be careful with orientation of 3rd main gear.
Install 3rd-4th mainshaft spacer.
Select suitable adjusting shim so that dimension "CI" satisfies standard value below, and install it onto mainshaft.
1. Standard for dimension C1:
2. 173.85 - 173.95 mm (6.844 - 6.848 in)
Fig 10: Identifying Dimension C1
Courtesy of NISSAN MOTOR CO., U.S.A.

Adjusting Shims

Fig 11: Dimension C1 Adjustment Shim Chart
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 4th main gear.

Fig 12: Installing 4th Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Be careful with orientation of 4th main gear.
Install 5th main gear.

Fig 13: Installing 5th Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Be careful with orientation of 5th main gear.
Install snap ring onto mainshaft, and check that end play of 5th main gear satisfies standard value.
1. End play standard value: 0 - 0.1 mm (0 - 0.004 in)
- If measurement is outside the standard range, reselect snap ring.
  
  Fig 14: Checking End Play
  Courtesy of NISSAN MOTOR CO., U.S.A.
Snap Rings

Fig 15: Snap Ring Thickness Chart
Courtesy of NISSAN MOTOR CO., U.S.A.
Install mainshaft rear bearing.

Fig 16: Installing Mainshaft Rear Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install C-ring onto mainshaft, and check that end play of mainshaft rear bearing meets specifications.

Fig 17: Measuring Mainshaft Rear Bearing End Play
Courtesy of NISSAN MOTOR CO., U.S.A.
1. End play standard value: 0 - 0.06 mm (0 - 0.0024 in)
- If measurement is outside the standard range, reselect C-ring.
C-rings

Fig 18: C-Ring Thickness & Part Number Chart
Courtesy of NISSAN MOTOR CO., U.S.A.
Fit C-ring holder, and install snap ring.
Check end play of 1st and 2nd main gears.

Fig 19: Identifying C-Ring, C-Ring Holder & Snap Ring Installation Order
Courtesy of NISSAN MOTOR CO., U.S.A.
1. End play standard value
  1. 1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
  2. 2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)