Gear Components: Assembly

Install bearings into case components.

Fig 1: Installing Bearings Into Case Components
Courtesy of NISSAN MOTOR CO., U.S.A.
1. Tool numbers
2. Mainshaft ball bearing: ST30720000 (J25405)
3. Counter rear bearing: ST33200000 (J26082)
Assemble adapter plate parts.
1. Install oil gutter on adapter plate and expand on rear side.
2. Insert reverse idler shaft, then install bearing retainer.
  
  Fig 2: Installing Bearing Retainer
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3. Tighten bearing retainer screws, then stake each one at two points.
  1. Bearing retainer screws: 19 - 25 (1.9 - 2.5 kg-m, 14 - 18 lb-ft)
  Fig 3: Taping Bearing Retainer Screws
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Install main drive gear ball bearing.
  1. Press main drive gear ball bearing using Tool.
    1. Tool number: ST30613000 (J25742-3)
    Fig 4: Pressing Main Drive Gear Ball Bearing Using Tool
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  2. Select and install proper main drive ball bearing gear snap ring to achieve proper clearance of groove. Refer to MAIN DRIVE GEAR BALL BEARING SNAP RING .
    1. Main drive ball bearing gear snap ring groove allowable clearance: 0 - 0.13 mm (0 - 0.0051 in)
5. Assemble synchronizers.
  - Assemble the 1st and 2nd synchronizer.
    
    Fig 5: Installing Main Drive Ball Bearing Gear Snap Ring
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    Fig 6: Inserting Spring In To Synchronizer
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  - Check coupling sleeve and synchronizer hub orientation.
    
    Fig 7: Checking Coupling Sleeve And Synchronizer Hub Orientation
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  - Assemble the 3rd and 4th synchronizer.
    
    Fig 8: Assembling 3Rd And 4Th Synchronizer
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  - Assemble the overdrive and reverse synchronizer.
    
    Fig 9: Assembling Overdrive And Reverse Synchronizer
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6. Assemble front side components to mainshaft.
  1. Install 2nd main gear, 2nd main gear needle bearing and 1st and 2nd synchronizer assembly; then press 1st gear bushing onto the mainshaft.
  2. Install 1st main gear.
    
    Fig 10: Installing 1st Main Gear
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  3. Install steel ball and 1st gear thrust washer.
    - Before installation, apply multi-purpose grease to steel ball and to both sides of the 1st gear thrust washer.
  Fig 11: Installing Steel Ball And 1st Gear Thrust Washer
  Courtesy of NISSAN MOTOR CO., U.S.A.
7. Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft as follows:
  1. Press mainshaft assembly into adapter plate using Tool.
    1. Tool number: KV31100401 ( - )
    Fig 12: Pressing Mainshaft Assembly Into Adapter Plate Using Tool
    Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Press counter gear into adapter plate using Tool.
    1. Tool number: ST33200000 (J26082), KV31100401 ( - )
    Fig 13: Pressing Counter Gear Into Adapter Plate Using Tool
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  3. Install 3rd main gear and needle bearing, then press 3rd and 4th synchronizer assembly onto mainshaft.
    - Pay attention to the direction of 3rd and 4th synchronizer.
  4. Install mainshaft front snap ring.
    Select proper front mainshaft snap ring to achieve proper clearance of groove. Refer to MAINSHAFT FRONT SNAP RING .
    1. Mainshaft front snap ring groove allowable clearance: 0 - 0.13 mm (0 - 0.0051 in)
  5. Apply gear oil to mainshaft pilot bearing and install it on mainshaft.
    
    Fig 14: Installing Mainshaft Front Snap Ring
    Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Press counter drive gear together with main drive gear using Tool.
    - Pay attention to the direction of counter drive gear.
      1. Tool numbers: ST23860000 ( - ), KV31100401 ( - )
    Fig 15: Pressing Counter Drive Gear Together With Main Drive Gear Using Tool
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  7. Install sub-gear and sub-gear bracket on counter drive gear and then select proper counter gear snap ring that will minimize clearance of groove in counter gear.
    - Do not install sub-gear spring at this time. Refer to COUNTER DRIVE GEAR SNAP RING .
      1. Counter gear snap ring groove allowable clearance: 0 - 0.13 mm (0 - 0.0051 in)
    Fig 16: Installing Sub-Gear And Sub-Gear Bracket On Counter Drive Gear
    Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Remove snap ring, sub-gear bracket and sub-gear from counter gear.
  9. Reinstall sub-gear, sub-gear spring, sub-gear bracket and selected counter gear snap ring.
    
    Fig 17: Removing Snap Ring, Sub-Gear Bracket And Sub-Gear From Counter Gear
    Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Press counter gear front bearing onto counter gear using Tool.
    1. Tool number: ST22360002 (J25679-01), KV31100401 ( - )
  Fig 18: Pressing Counter Gear Front Bearing Onto Counter Gear Using Tool
  Courtesy of NISSAN MOTOR CO., U.S.A.
8. Install rear side components on mainshaft and counter gear as follows:
  1. Install sub-gear, sub-gear spring, sub-gear bracket, steel ball and snap ring on the reverse idler gear.
  2. Install reverse idler gear assembly, reverse idler thrust washer, snap ring and reverse idler gear bearing on the reverse idler shaft.
    
    Fig 19: Installing Sub-Gear, Sub-Gear Spring, Sub-Gear Bracket, Steel Ball And Snap Ring On Reverse Idler Gear
    Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install reverse main gear bushing, needle bearing, reverse main gear and overdrive and reverse synchronizer to mainshaft.
    - Pay attention to the direction of synchronizer hub.
    Fig 20: Installing Reverse Main Gear Bushing, Needle Bearing, Reverse Main Gear And Overdrive And Reverse Synchronizer To Mainshaft
    Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install overdrive gear bushing to mainshaft using Tool.
    1. Tool number: ST22350000 (J25678-01)
    Fig 21: Installing Overdrive Gear Bushing To Mainshaft Using Tool
    Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install overdrive main gear and needle bearing to mainshaft.
  6. Install reverse counter gear spacer, reverse counter gear and overdrive counter gear to counter gear.
    - OD main gear and OD counter gear should be handled as a matched set.
  7. Install washer, roller bearing, steel roller and thrust washer.
  8. Install steel ball and speedometer drive gear.
  9. Tighten mainshaft lock nut temporarily.
    - Always use new mainshaft lock nut.
  10. Install counter gear rear end bearing using Tool.
    1. Tool number: ST2236002 (J25679-01)
  Fig 22: Installing Counter Gear Rear End Bearing Using Tool
  Courtesy of NISSAN MOTOR CO., U.S.A.
9. Mesh 2nd and reverse gears, then tighten mainshaft lock nut using Tool.
  - Always use new mainshaft lock nut.
    1. Mainshaft lock nut: 138 - 166 N.m (14.0 - 17.0 kg-m, 102 - 122 ft-lb)
    2. Tool number: ST22520000 (J26348)
    Fig 23: Tightening Mainshaft Lock Nut Using Tool
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  - Use the chart shown in Fig 24 to determine the proper reading torque. (Length of torque wrench vs. setting or reading torque) Reference: Formula to convert torque wrench indication to the true torque value:
    T = (0.1 m (0.33 ft) + L) /L x C
    
    If the specified torque is T kg-m (ft-lb), the torque wrench scale indication C is determined using the following formula.
    
    C = (T x L)/(0.1 m (0.33 ft) + L)
  Fig 24: Reading Torque Determine Chart
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10. Tighten counter gear lock nut.
  - Always use new lock nut.
    1. Counter gear lock nut: 98 - 127 N.m (10.0 - 13.0 kg-m, 73 - 94 ft-lb)
11. Stake mainshaft lock nut and counter gear lock nut using a punch.
  
  Fig 25: Staking Mainshaft Lock Nut And Counter Gear Lock Nut Using Punch
  Courtesy of NISSAN MOTOR CO., U.S.A.
12. Measure the end play of each gear.
13. Install snap ring and press on OD mainshaft bearing using Tool, then install snap ring. Refer to OD MAINSHAFT BEARING SNAP RING .
  1. OD mainshaft bearing snap ring groove allowable clearance: 0 - 0.14 mm (0 - 0.0055 in)
  2. Tool number: (J-26349-A), (J-25726-B)
Fig 26: Identifying End Play Of Gear Dimensions
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