Gear Components: Disassembly

WARNING: This page is about a different car, the 2003 Nissan Pathfinder. However, it is still accessible from the selected car via links, so may be relevant.

Before removing gears and shafts, measure each gear end play.
Gear end play:

Refer to SERVICE DATA AND SPECIFICATION (SDS) .
- If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.
  
  Fig 1: Measuring Gear End Play
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove rear side components on mainshaft and counter gear.
1. Remove reverse coupling sleeve.
  
  Fig 2: Removing Reverse Coupling Sleeve
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Remove mainshaft rear snap ring and counter gear rear snap ring.
3. Remove C-ring holder and mainshaft C-rings from mainshaft. Use punch and hammer to remove C-rings.
4. Pull out counter gear rear end bearing.
5. Remove reverse idler gear and reverse idler thrust washers.
  
  Fig 4: Pulling Out Counter Gear Rear End Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
6. Pull out reverse main gear together with mainshaft spacer and reverse synchronizer hub. Then remove reverse gear needle bearings.
  
  Fig 5: Pulling Out Reverse Main Gear Together With Mainshaft Spacer And Reverse Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
7. Pull out reverse counter gear.
8. Remove OD coupling sleeve together with OD baulk ring, reverse baulk ring and spring inserts.
  
  Fig 6: Pulling Out Reverse Counter Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
9. Pull out reverse gear bushing.
  
  Fig 7: Pulling Out Reverse Gear Bushing
  Courtesy of NISSAN MOTOR CO., U.S.A.
10. Pull out OD counter gear together with reverse cone.
  
  Fig 8: Pulling Out OD Counter Gear Together With Reverse Cone
  Courtesy of NISSAN MOTOR CO., U.S.A.
Press out mainshaft and counter gear alternately.

Fig 9: Pressing Out Mainshaft And Counter Gear Alternately
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove front side components on mainshaft.
1. Remove 1st gear washer and steel ball.
2. Remove 1st main gear and 1st gear needle bearing.
  - Be careful not to lose steel ball.
    
    Fig 10: Removing 1St Gear Steel Ball
    Courtesy of NISSAN MOTOR CO., U.S.A.
3. Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly.
4. Remove mainshaft front snap ring.
  
  Fig 11: Pressing Out 2nd Main Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
5. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing.
  
  Fig 12: Pressing Out 3rd Main Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove front side components on counter gear.
1. Remove counter gear rear thrust bearing.
  
  Fig 13: Removing Counter Gear Rear Thrust Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Remove sub-gear components.
  
  Fig 14: Removing Sub-Gear Components
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove main drive gear bearing.
1. Remove main drive gear snap ring.
2. Press out main drive gear bearing.
  
  Fig 15: Pressing Out Main Drive Gear Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove bearings from case components.

Fig 16: Removing Bearings From Case Components
Courtesy of NISSAN MOTOR CO., U.S.A.