Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2004 Nissan Maxima. However, it is still accessible from the selected car via links, so may be relevant.

Install the 3rd needle bearing.
Install the 3rd input gear and 3rd baulk ring.
Install the spread spring, shifting insert, and a new 3rd-4th synchronizer hub onto the 3rd-4th coupling sleeve.
CAUTION:
- Install with orientation of the synchronizer hub as shown.
- Do not reuse the 3rd-4th synchronizer hub.
  
  Fig 1: Assembly (1 Of 17)
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Install with orientation of coupling sleeve as shown.
  
  Fig 2: Assembly (2 Of 17)
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Be sure not to hook the ends of the 2 spread springs (front and back have two each) on the same shifting insert.
  
  Fig 3: Assembly (3 Of 17)
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install 3rd-4th synchronizer hub assembly using Tool as shown.
CAUTION: Align grooves of shifting insert and 3rd baulk ring.

Fig 4: Assembly (4 Of 17)
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the 4th bushing using Tool as shown.
Install the 4th baulk ring.
Install the 4th input gear and 4th needle bearing.

Fig 5: Assembly (5 Of 17)
Courtesy of NISSAN MOTOR CO., U.S.A.
Measure the dimension "C2" as shown. Select a thrust washer so that dimension "C2" satisfies standard dimension specification. Then install the thrust washer onto the input shaft.
Standard for dimension "C2" : 154.7 - 154.8 mm (6.091 - 6.094 in)

CAUTION: Only 1 thrust washer can be selected.

Fig 6: Assembly (6 Of 17)
Courtesy of NISSAN MOTOR CO., U.S.A.

Thrust Washer

Fig 7: Assembly (7 Of 17) Available Thrust Washers
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the 5th bushing using Tool as shown.
Install the 5th needle bearing and 5th input gear.
Install the 5th baulk ring.

Fig 8: Assembly (8 Of 17)
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the synchronizer assembly onto a new 5th-6th synchronizer hub.
CAUTION:
- Install with the orientation of the synchronizer hub as shown.
- Do not reuse the 5th-6th synchronizer hub.
  
  Fig 9: Assembly (9 Of 17)
  Courtesy of NISSAN MOTOR CO., U.S.A.
- Be sure not to hook the ends of the 2 spread springs (front and back have two each) on the same shifting insert.
  
  Fig 10: Assembly (10 Of 17)
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install the 5th-6th synchronizer hub assembly using Tool as shown.
CAUTION: Align the grooves of the 5th-6th shifting insert and 5th-6th baulk ring.

Fig 11: Assembly (11 Of 17)
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the needle bearing, 6th input gear and then 6th bushing using Tool as shown.

Fig 12: Assembly (12 Of 17)
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the snap ring onto the input shaft, and measure to check that end play (gap between snap ring and groove) of the 6th bushing is within specification.
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
- If the measurement is outside the standard value, select the appropriate size snap ring.
  
  Fig 13: Assembly (13 Of 17)
  Courtesy of NISSAN MOTOR CO., U.S.A.
Snap Rings

Fig 14: Assembly (14 Of 17) Available Snap Rings
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the input shaft rear bearing using Tool as shown.
CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.

Fig 15: Assembly (15 Of 17)
Courtesy of NISSAN MOTOR CO., U.S.A.
Install the input shaft front bearing using Tool as shown.
Install the oil channel onto the input shaft.

Fig 16: Assembly (16 Of 17)
Courtesy of NISSAN MOTOR CO., U.S.A.
Check the end play of the 3rd, 4th, 5th and 6th input gears as shown.
End play standard value

3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)

4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)

5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

6th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)

Fig 17: Assembly (17 Of 17)
Courtesy of NISSAN MOTOR CO., U.S.A.