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Disassembly and Assembly: Assembly

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    CAUTION: Be careful with orientation of reverse main gear.
    Fig 1: Identifying Rear Side Reverse Main Bearing
    G02023275Courtesy of NISSAN MOTOR CO., U.S.A.
    Fig 2: Installing Reverse Main Gear
    G02023274Courtesy of NISSAN MOTOR CO., U.S.A.
  1. Install reverse main gear.
  2. Install 1st bushing.
  3. Install needle bearing, and then 1st main gear.
    Fig 3: Installing Needle Bearing, & 1st Main Gear
    G02023276Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install spread spring, shifting insert and 1st-2nd synchronizer hub onto 1st-2nd coupling sleeve.
    CAUTION:
    • Be careful with orientation of synchronizer hub.
      Fig 4: Front & Rear Side Of Synchronizer Hub
      G02023277Courtesy of NISSAN MOTOR CO., U.S.A.
    • Be careful with orientation of coupling sleeve.
      Fig 5: Identifying 1st & 2nd Main Gear To Coupling Sleeve Orientation
      G02023278Courtesy 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: Latching Spread Springs
      G02023279Courtesy of NISSAN MOTOR CO., U.S.A.
    5. 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.
    Fig 7: Installing 1st Gear Synchronizer Assembly Onto Mainshaft
    G02023280Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install 1st gear synchronizer assembly onto mainshaft, and synchronizer hub assembly onto mainshaft.
  6. Install 2nd bushing.
    Fig 8: Installing 2nd Bushing
    G02023281Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install outer baulk ring, synchronizer cone, and inner baulk ring on 2nd gear-side.
  8. Install 2nd needle bearing and 2nd gear.
    9. CAUTION: Be careful with orientation of 3rd main gear.
    Fig 9: Installing 3rd Main Gear
    G02023282Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install 3rd main gear.
  10. Install 3rd-4th mainshaft spacer.
  11. Select suitable adjusting shim so that dimension "C1" satisfies standard value below, and install it onto mainshaft.
    Fig 10: Identifying Dimension C1
    G02023283Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Standard for: 173.85 - 173.95 mm (6.844 - 6.848 in) dimension "C1" 

    Adjusting Shim 

    Fig 11: Identifying Adjusting Shims & Thicknesses For Adjusting Dimension C1
    G02023284Courtesy of NISSAN MOTOR CO., U.S.A.
    12. CAUTION: Be careful with orientation of 4th main gear.
    Fig 12: Installing 4th Main Gear
    G02023285Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install 4th main gear.
    13. CAUTION: Be careful with orientation of 5th main gear.
  13. Install 5th main gear.
  14. Install 5th-6th mainshaft spacer.
    Fig 13: Installing 5th Main Gear
    G02023286Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install 6th main gear.
    Fig 14: Installing 6th Main Gear
    G02023287Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Adjustment between 6th main gear and 6th main adjusting shim.
    • Calculate thickness "S" of 6th main adjusting shim so that end play dimension between 6th main gear and mainshaft rear bearing is the dimension shown below.
      Fig 15: Identifying & Determining Dimension S
      G02023288Courtesy of NISSAN MOTOR CO., U.S.A.
      1. End play: 0 - 0.1 mm (0 - 0.004 in) 
        1. Dimension "S" = (S1 - S2) + End play 
          1. S: Thickness of adjusting shim 
          2. S1: Dimension from mainshaft reference face to mainshaft rear bearing press-fit end face 
          3. S2: Dimension from mainshaft reference face to 6th main gear end face 

    Adjusting Shim 

    Fig 16: Identifying Adjusting Shims & Thicknesses For Adjusting Dimension M
    G02023289Courtesy of NISSAN MOTOR CO., U.S.A.
    1. Using height gauge, measure dimension "S1" and "S2".
    2. Install selected 6th main adjusting shim to mainshaft.
  17. Install mainshaft rear bearing.
    Fig 17: Installing Mainshaft Rear Bearing
    G02023290Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install C-ring onto mainshaft, and check that end play of main-shaft rear bearing meets specifications.
    Fig 18: Installing C-Ring Onto Mainshaft, & Checking End Play
    G02023291Courtesy 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-ring 

    Fig 19: Available Mainshaft C-Rings & Specifications
    G02023292Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Fit C-ring holder, and install snap ring.
    Fig 20: Installing C-Ring Holder & Snap Ring
    G02023293Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Check end play of 1st and 2nd main gears.
    Fig 21: Checking End Play
    G02023294Courtesy 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) 
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