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Gear Components

WARNING: This page is about a different car, the 2005 Infiniti G35. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install 5th-6th coupling sleeve and 5th-6th shifting inserts onto 5th-6th synchronizer hub.
    CAUTION:
    • Do not reuse 5th-6th synchronizer hub and 5th-6th coupling sleeve.
    • Install 5th-6th coupling sleeve with the larger chamfer on the rear side.
    Fig 1: Identifying 5th-6th Coupling Sleeve
    G02334402Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
    Fig 2: Identifying Shape Of Shifting Insert Avoiding Misassembly
    G02334403Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install 5th-6th spread springs in 5th-6th shifting inserts.
    CAUTION: Install the hook of each spread spring onto separate shifting inserts.
    Fig 3: Installing Hook Of Spread Spring On 5th-6th Shifting Inserts
    G02334404Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install 6th needle bearing, 6th main gear, 6th baulk ring and 5th-6th synchronizer assembly onto main shaft using a press and the inserter.
    1. Tool number: ST30911000 ( - ) 
    Fig 4: Installing 6th Needle Bearing, 6th Main Gear, 6th Baulk Ring And 5th-6th Synchronizer Assembly On Main Shaft
    G02334405Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: The rear side of synchronizer hub has three oil grooves. When press fitting, install the rear side to the rearward.
    Fig 5: Locating Rear Side Of Synchronizer Hub With Three Oil Grooves
    G02334406Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Select and install snap ring onto the front side of main shaft so that the end play comes within the specifications. Refer to "SNAP RINGS ".
    1. End play: 0 - 0.1 mm (0 - 0.004 in) 
    CAUTION: Do not reuse snap ring.
    Fig 6: Installing Snap Ring On Front Side Of Main Shaft To Maintain End Play
    G02334407Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install 1st-2nd coupling sleeve and 1st-2nd shifting inserts onto 1st-2nd synchronizer hub.
    CAUTION:
    • Do not reuse 1st-2nd synchronizer hub and 1st-2nd coupling sleeve.
    • Install 1st-2nd coupling sleeve with the thicker flange faced the front side.
    Fig 7: Identifying 1st-2nd Coupling Sleeve
    G02334408Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
    Fig 8: Identifying Reverse Shifting Insert Groove
    G02334409Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install 1st-2nd spread spring in 1st-2nd shifting inserts onto 1st-2nd synchronizer hub.
    CAUTION: Install hook of each spread spring onto separate shifting inserts.
    Fig 9: Installing Hook Of Spread Spring On 1st-2nd Shifting Inserts
    G02334410Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install 2nd needle bearing, 2nd main gear, 2nd inner baulk ring, 2nd synchronizer cone, 2nd outer baulk ring and 1st-2nd synchronizer assembly onto main shaft using a press and the support ring.
    1. Tool number: ST27861000 (-) 
    Fig 10: Installing 2nd Main Gear And 1st-2nd Synchronizer Assembly On Main Shaft
    G02334411Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Install with the side, which has identification mark on one of four oil grooves on the boss edge surface, facing rearward.
    Fig 11: Locating Identification Mark On One Of Four Oil Grooves On Boss Edge Surface
    G02334412Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install 1st gear bushing onto main shaft using a press and the support ring.
    1. Tool number: ST27861000 (-) 
    Fig 12: Installing 1st Gear Bushing On Main Shaft Using Press
    G02334413Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install 1st needle bearing, 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 3rd main gear and 1st main gear onto main shaft using a press and the inserter.
    1. Tool number: ST30022000 (-) 
    CAUTION: Do not reuse 3rd main gear.
    Fig 13: Installing 3rd Main Gear And 1st Main Gear On Main Shaft Using Press And Inserter
    G02334414Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install 3rd-4th main spacer and 4th main gear onto main shaft using a press and the inserter.
    1. Tool number: ST30022000 (-) 
    CAUTION:
    • Do not reuse 4th main gear.
    • Install with the side on which the boss protrudes out of gear edge surface facing rearward.
    Fig 14: Installing 3rd-4th Main Spacer And 4th Main Gear On Main Shaft Using Press And Inserter
    G02334415Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install main shaft bearing onto main shaft using a press and the inserter.
    1. Tool number: ST30911000 (-) 
    Fig 15: Installing Main Shaft Bearing On Main Shaft Using Press And Inserter
    G02334416Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install reverse main gear bushing onto main shaft using a press and the inserter.
    1. Tool number: ST30911000 (-) 
    Fig 16: Installing Reverse Main Gear Bushing On Main Shaft Using Press And Inserter
    G02334417Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install 3rd gear bushing onto counter shaft using a press and the inserter.
    1. Tool number: ST30911000 (-) 
    Fig 17: Installing 3rd Gear Bushing On Counter Shaft Using Press And Inserter
    G02334418Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install 3rd-4th coupling sleeve and 3rd-4th shifting inserts onto 3rd-4th synchronizer hub.
    CAUTION:
    • Do not reuse 3rd-4th synchronizer hub and 3rd-4th coupling sleeve.
    • Install 3rd-4th coupling sleeve with the thicker flange faced the front side.
    Fig 18: Identifying 3rd-4th Coupling Sleeve
    G02334419Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
    Fig 19: Identifying Reverse Shifting Insert Groove
    G02334420Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install 3rd-4th spread springs into 3rd-4th shifting insert.
    CAUTION: Install the hook of each spread spring onto separate shifting inserts.
    Fig 20: Installing Hook Of Spread Spring On 3rd-4th Shifting Inserts
    G02334421Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Install 3rd needle bearing, 3rd counter gear, 3rd inner baulk ring, 3rd synchronizer cone, 3rd outer baulk ring and 3rd-4th synchronizer assembly onto counter shaft using a press and the drift.
    1. Tool number: ST30911000 (-) 
    Fig 21: Installing 3rd Counter Gear And 3rd-4th Synchronizer Assembly On Counter Shaft Using Press
    G02334422Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install 4th outer baulk ring, 4th synchronizer cone, 4th inner baulk ring, 4th gear bushing, 4th needle bearing, 4th counter gear and 4th counter shaft thrust washer onto counter shaft using a press and the drift.
    1. Tool number: KV40100630 (J-26029) 
    Fig 22: Installing 4th Counter Gear And 4th Counter Shaft Thrust Washer On Counter Shaft Using Press
    G02334423Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install counter rear bearing inner race onto counter shaft using a press and the drift.
    1. Tool number: ST30032000 (J-26010-01) 
    Fig 23: Installing Counter Rear Bearing Inner Race On Counter Shaft
    G02334424Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Install main drive bearing onto main drive gear using a press and the drift.
    1. Tool number: KV32102700 (-) 
    Fig 24: Installing Main Drive Bearing On Main Drive Gear
    G02334425Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Select and install snap ring on main drive gear so that comes within the specifications. Refer to "SNAP RINGS ".
    1. End play: 0 - 0.1 mm (0 - 0.004 in) 
    CAUTION: Do not reuse snap ring.
    Fig 25: Selecting And Installing Snap Ring On Main Drive Gear To maintaining End Play
    G02334426Courtesy of NISSAN MOTOR CO., U.S.A.
  21. Install 5th baulk ring, pilot bearing spacer, main pilot bearing and main drive gear onto main shaft.
  22. Install main shaft and counter shaft combined in one unit to adapter plate, and secure main shaft bearing with a snap ring.
    1. Tap main shaft bearing slightly via brass bar or the equivalent to install snap ring.
    2. After installing snap ring, hammer snap ring and adapter plate slightly in the reverse direction to make them in contact with each other.
      CAUTION: Do not reuse snap ring.
    Fig 26: Taping Main Shaft Bearing Slightly By Brass Bar
    G02334427Courtesy of NISSAN MOTOR CO., U.S.A.
  23. Install counter rear bearing outer race onto adapter plate using plastic hammer or equivalent.
    Fig 27: Installing Counter Rear Bearing Outer Race On Adapter Plate Using Plastic Hammer
    G02334428Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Apply genuine medium strength locking sealant or equivalent (refer to GENERAL INFORMATION - G35 COUPE ) to the end of the bolt (first 3 to 4 threads). Install main shaft bearing retainer onto adapter plate, and tighten bolts to the specified torque. Refer to "CASE COMPONENTS ".
    Fig 28: Installing Main Shaft Bearing Retainer On Adapter Plate And Tightening Bolts
    G02334429Courtesy of NISSAN MOTOR CO., U.S.A.
  25. Install reverse coupling sleeve and reverse shifting inserts onto reverse synchronizer hub.
    CAUTION:
    • Do not reuse reverse synchronizer hub and reverse coupling sleeve.
    • Install reverse coupling sleeve with the flat flange on the rear side.
    Fig 29: Identifying Reverse Coupling Sleeve
    G02334430Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
    Fig 30: Identifying Reverse Shifting Insert Groove
    G02334431Courtesy of NISSAN MOTOR CO., U.S.A.
  26. Install spread springs into shifting insert.
    CAUTION: Install the hook of each spread spring onto separate shifting inserts.
    Fig 31: Installing Hook Of Each Spread Spring On Reverse Shifting Inserts
    G02334432Courtesy of NISSAN MOTOR CO., U.S.A.
  27. Install reverse main needle bearing, reverse main gear, reverse baulk ring and reverse synchronizer assembly onto main shaft using a press, the press plate and the drift.
    1. Tool number (A): KV32103300 (J-46529) 
    2. Tool number (B): ST01530000 (-) 
    Fig 32: Installing Reverse Main Gear And Reverse Synchronizer Assembly On Main Shaft
    G02334433Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: When installing, face the side with three grooves to the front side.
    Fig 33: Correct Installation Of Synchronizer Hub
    G02334434Courtesy of NISSAN MOTOR CO., U.S.A.
  28. Select and install a snap ring to the main shaft rear side so that the end play comes within the standard value. Refer to "SNAP RINGS ".
    1. End play: 0 - 0.1 mm (0 - 0.004 in) 
    CAUTION: Do not reuse snap ring.
    Fig 34: Measuring Reverse Synchronizer Hub End Play
    G02334435Courtesy of NISSAN MOTOR CO., U.S.A.
  29. Install counter rear bearing spacer and reverse counter gear using a press and the drift.
    1. Tool number: ST23860000 (-) 
    CAUTION:
    • Do not reuse reverse counter gear.
    • When installing counter rear bearing spacer, maker's stamp should face to the rear.
    Fig 35: Installing Counter Rear Bearing Spacer And Reverse Counter Gear Using Press
    G02334436Courtesy of NISSAN MOTOR CO., U.S.A.
  30. Select and install a snap ring to the counter shaft so that the end play comes within the standard value. Refer to "SNAP RINGS ".
    1. End play: 0 - 0.1 mm (0 - 0.004 in) 
    CAUTION: Do not reuse snap ring.
    Fig 36: Selecting And Installing Snap Ring To Counter Shaft For Maintaining End Play
    G02334437Courtesy of NISSAN MOTOR CO., U.S.A.
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