Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2003 Nissan Altima and 2002 Nissan Altima. 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: Identifying Correct 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, Needle Bearing And 1st Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
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: Identifying Correct Orientation Of Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Be careful with orientation of coupling sleeve.
  
  Fig 5: Identifying Correct Orientation Of Coupling Sleeve
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Be sure not to hook ends of 2 spread springs (front and back have two each) on same shifting insert.
  
  Fig 6: Identifying Correct Installing Position Of 2 Spread Springs
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install 1st gear synchronizer assembly onto mainshaft, and synchronizer hub assembly onto mainshaft.
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
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 2nd bushing.
Install outer baulk ring, synchronizer cone, and inner baulk ring on 2nd gear-side.
Install 2nd needle bearing and 2nd gear.

Fig 8: Installing 2nd Needle Bearing And 2nd Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 3rd main gear.
CAUTION: Be careful with orientation of 3rd main gear.
Install 3rd-4th mainshaft spacer.

Fig 9: Installing 3rd-4th Mainshaft Spacer
Courtesy of NISSAN MOTOR CO., U.S.A.
Select suitable adjusting shim so that dimension "C₁ " satisfies standard value below, and install it onto mainshaft.
Standard for dimension "C ₁ " : 173.85 - 173.95 mm (6.844 - 6.848 in)

Fig 10: Identifying Dimension C1 For Selecting Adjusting Shim
Courtesy of NISSAN MOTOR CO., U.S.A.

Adjusting Shim

Fig 11: Mainshaft Adjusting Shim Specification Table
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Only one adjusting shim can be selected.
Install 4th main gear.
CAUTION: Be careful with orientation of 4th main gear.

Fig 12: Installing 4th Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 5th main gear.
CAUTION: Be careful with orientation of 5th main gear.

Fig 13: Installing 5th Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring onto mainshaft, and check that end play of 5th main gear satisfies standard value.
End play standard value : 0 - 0.01 mm (0 - 0.004 in)
- If measurement is outside the standard range, reselect snap ring.
  
  Fig 14: Checking End Play Of 5th Main Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
  
  Snap Rings
  
  Fig 15: Main Gear Snap Rings Specification Table
  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 satisfied standard value.
End play standard value : 0 - 0.06 mm (0 - 0.0024 in)
- If measurement is outside the standard range, reselect C-ring.
  
  Fig 17: Checking End Play Of Mainshaft Rear Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
  
  C-Ring
  
  Fig 18: Mainshaft C-Ring Specification Table
  Courtesy of NISSAN MOTOR CO., U.S.A.
Fit the C-Ring holder, and install the snap ring.

Fig 19: Fitting C-Ring Holder And Installing Snap Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Check the end play of the 1st and 2nd main gears.
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)