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 3rd needle bearing.
Install 3rd input gear and 3rd baulk ring.
Install spread spring, shifting insert and 3rd-4th synchronizer hub onto 3rd-4th coupling sleeve.
CAUTION:
- Be careful with orientation of synchronizer hub.
  
  Fig 1: Identifying Front & Rear Side Of Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Be careful with orientation of coupling sleeve.
  
  Fig 2: Locating 3rd & 4th Input Gear To Coupling Sleeve Orientation
  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 3: Latching Spread Springs To Insert
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Align grooves of shifting insert and 3rd baulk ring.

Fig 4: Installing 3rd-4th Synchronizer Hub Assembly

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

Install 3rd-4th synchronizer hub assembly.
Install 4th bushing.

Fig 5: Installing 4th Bushing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 4th baulk ring.
Install 4th input gear and 4th needle bearing.
Select thrust washer so that dimension "C2" satisfies standard below. Then install it onto input shaft.

Fig 6: Identifying Dimension C2
Courtesy of NISSAN MOTOR CO., U.S.A.
1. Standard for : 154.7 - 154.8 mm (6.091 - 6.094 in)
2. dimension C2
Thrust Washer

Fig 7: Identifying Adjusting Shims & Thicknesses For Adjusting Dimension C2
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 5th bushing.

Fig 8: Installing 5th Bushing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 5th needle bearing and 5th input gear.
Install 5th baulk ring.

CAUTION:

Be careful with orientation of synchronizer hub.

Fig 9: Identifying Front & Rear Side Of Synchronizer Hub

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

Install synchronizer assembly onto 5th-6th synchronizer hub.
- Be sure not to hook ends of 2 spread springs (front and back: 2 each) on same shifting insert.
  
  Fig 10: Latching Spread Springs
  Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Align grooves of 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 5th-6th synchronizer hub assembly.
Install needle bearing, 6th input gear and then 6th bushing.

Fig 12: Installing 6th Components
Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring onto input shaft, and check that end play (gap between snap ring and groove) of 6th bushing meets specification.

Fig 13: Checking End Play
Courtesy of NISSAN MOTOR CO., U.S.A.
1. End play standard value : 0 - 0.1 mm (0 - 0.004 in)
  - If measurement is outside the standard range, select snap ring.
Snap Rings

Fig 14: Snap Ring Thickness Chart
Courtesy of NISSAN MOTOR CO., U.S.A.

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 input shaft rear bearing.
Install input shaft front bearing.

Fig 16: Installing Input Shaft Front Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install oil channel onto input shaft.
Check end play of 3rd, 4th, 5th and 6th input gears.

Fig 17: Checking End Play
Courtesy of NISSAN MOTOR CO., U.S.A.
1. End play standard value
  1. 3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
  2. 4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
  3. 5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
  4. 6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)