Gear Components: Assembly

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.

Fig 1: Installing Bearings Into Case Components

Courtesy of NISSAN MOTOR CO., U.S.A.

Install bearings into case components.
Install main drive gear bearing.
1. Press main drive gear bearing.
  
  Fig 2: Pressing Main Drive Gear Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Select proper main drive gear snap ring to minimize clearance of groove.
  Allowable clearance of groove:
  
  0 - 0.1 mm (0 - 0.004 in)
  
  Main drive gear snap ring:
  
  Refer to SDS, 2ND AND 3RD BAULK RING .
3. Install selected snap ring on main drive gear.
  
  Fig 3: Selecting Proper Main Drive Gear Snap Ring To Minimize Clearance Of Groove
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install components on counter gear.
1. Install sub-gear components.
  - When installing sub-gear snap ring, tap sub-gear snap ring into position on counter gear.
    
    Fig 4: Installing Components On Counter Gear
    Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install counter gear rear thrust bearing.
  
  Fig 5: Installing Counter Gear Rear Thrust Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install front side components on mainshaft.
1. Assemble 1st & 2nd synchronizer.
  
  Fig 6: Assembling 1st And 2nd Synchronizer
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Assemble 3rd & 4th synchronizer.
  
  Fig 7: Assembling 3rd And 4th Synchronizer
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Press on 3rd & 4th synchronizer assembly together with 3rd main gear and 3rd gear needle bearing.
  - Pay attention to direction of synchronizer assembly.
    
    Fig 8: Pressing On 3rd And 4th Synchronizer Assembly
    Courtesy of NISSAN MOTOR CO., U.S.A.
4. Select proper snap ring to minimize clearance of groove.
  Allowable clearance of groove:
  
  0 - 0.1 mm (0 - 0.004 in)
  
  Mainshaft front snap ring:
  
  Refer to SDS, 2ND AND 3RD BAULK RING .
5. Install selected snap ring on mainshaft.
  
  Fig 9: Installing Proper Snap Ring To Minimize Clearance Of Groove
  Courtesy of NISSAN MOTOR CO., U.S.A.
6. Press on 1st & 2nd synchronizer assembly together with 2nd main gear and 2nd gear needle bearing.
  
  Fig 10: Pressing On 1st And 2nd Synchronizer Assembly
  Courtesy of NISSAN MOTOR CO., U.S.A.
7. Press on 1st gear bushing using 1st gear washer.
8. Install 1st main gear and needle bearing.
  
  Fig 11: Pressing On 1st Gear Bushing Using 1st Gear Washer
  Courtesy of NISSAN MOTOR CO., U.S.A.
9. Install steel ball and 1st gear washer.
  - Apply multi-purpose grease to steel ball and 1st gear washer before installing.
    
    Fig 12: Installing Steel Ball And 1st Gear Washer
    Courtesy of NISSAN MOTOR CO., U.S.A.
Select proper counter gear front bearing thrust washer when replacing transmission case, counter gear, counter gear rear thrust bearing or sub-gear components.
1. Install counter gear with sub-gear components, counter gear front and rear bearing thrust washer on adapter plate.
2. Remove counter gear front bearing thrust washer from transmission case.
3. Place adapter plate and counter gear assembly in transmission case (case inverted).
  
  Fig 13: Installing Counter Gear Sub-Gear Components And Counter Gear Front And Rear Bearing Thrust Washers
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Tighten adapter plate to transmission case using 2 bolts.
5. Place dial indicator on rear end of counter gear.
6. Move counter gear up and down and measure dial indicator deflection.
7. Select proper thrust washer using table below as a guide.
  Counter gear end play:
  
  0.10 - 0.25 mm (0.0039 - 0.0098 in)
  
  Table for selecting proper counter gear front bearing thrust washer:
  
  Refer to SDS, AVAILABLE SHIM AND WASHER .
  
  Fig 14: Measuring Counter Gear End Play
  Courtesy of NISSAN MOTOR CO., U.S.A.
Select proper reverse idler rear thrust washer when replacing OD gear case, reverse idler gear (with sub-gear components), reverse idler shaft.
1. Install reverse idler gear (with sub-gear components), reverse idler needle bearings and reverse idler shaft into OD gear case.
  - When replacing reverse idler rear thrust washer, install either A or B.
    Reverse idler rear thrust washer:
    
    Refer to SDS, AVAILABLE SHIM AND WASHER .
    
    Fig 15: Installing Reverse Idler Gear (With Sub-Gear Components), Reverse Idler Needle Bearings And Reverse Idler Shaft Into OD Gear Case
    Courtesy of NISSAN MOTOR CO., U.S.A.
2. Place dial indicator on front end of reverse idler shaft.
3. Put straightedge on front surface of rear extension (or OD gear case) as a stopper of reverse idler shaft.
4. Move reverse idler shaft up and down and measure reverse idler gear end play.
  Reverse idler gear end play:
  
  0.30 - 0.53 mm (0.0118 - 0.0209 in)
5. If not within specification, replace reverse idler rear thrust washer with the other (A or B) and check again.
  
  Fig 16: Measuring Reverse Idler Gear End Play
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft.
1. Mount adapter plate on vise and apply multi-purpose grease to counter gear rear bearing.
  
  Fig 17: Applying Multi-Purpose Grease To Counter Gear Rear Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install mainshaft a little on mainshaft front bearing.
  - To allow for installation of counter gear, do not install mainshaft completely.
    
    Fig 18: Installing Mainshaft On Mainshaft Front Bearing
    Courtesy of NISSAN MOTOR CO., U.S.A.
3. Install counter gear on counter gear rear bearing and install main drive gear, pilot bearing and spacer on mainshaft.
  
  Fig 19: Installing Counter Gear On Counter Gear Rear Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
  - When installing counter gear into counter gear rear bearing, push up on upper roller of counter gear rear bearing with screwdriver.
    
    Fig 20: Pushing Up On Upper Roller Of Counter Gear Rear Bearing With Screwdriver
    Courtesy of NISSAN MOTOR CO., U.S.A.
4. Install Tools (J26349-3) onto adapter plate and C-ring and C-ring holder on mainshaft.
5. Install Tool (J34328) on mainshaft.
  
  Fig 21: Installing Tools Onto Adapter Plate And C-Ring And C-Ring Holder On Mainshaft
  Courtesy of NISSAN MOTOR CO., U.S.A.
6. Install mainshaft and counter gear completely by extending length of (J26349-3).
  
  Fig 22: Installing Mainshaft And Counter Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install rear side components on mainshaft and counter gear.
1. Install OD gear bushing while pushing on the front of counter gear.
  
  Fig 23: Installing OD Gear Bushing
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install OD main gear.
  - Pay attention to direction of OD main gear. (B is wider than A as shown at left.)
3. Install adapter plate with gear assembly onto transmission case.
4. Install OD gear needle bearing and then install OD counter gear and reverse idler shaft.
  
  Fig 24: Installing OD Main Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
5. Install reverse cone.
  
  Fig 25: Installing Reverse Cone
  Courtesy of NISSAN MOTOR CO., U.S.A.
6. Install insert springs and reverse baulk ring on OD coupling sleeve. Then install them and OD baulk ring on OD counter gear.
  - Pay attention to direction of OD coupling sleeve.
    
    Fig 26: Installing Insert Springs And Reverse Baulk Ring On OD Coupling Sleeve
    Courtesy of NISSAN MOTOR CO., U.S.A.
    
    Fig 27: Installing OD Coupling Sleeve And OD Baulk Ring On OD Counter Gear
    Courtesy of NISSAN MOTOR CO., U.S.A.
7. Install reverse counter gear.
8. Install reverse gear needle bearing and then install reverse main gear, reverse idler gear and reverse idler thrust washers.
  
  Fig 28: Installing Reverse Counter Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
9. Install reverse hub.
  - Pay attention to its direction.
    
    Fig 29: Installing Reverse Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
10. Install counter gear rear end bearing.
11. Separate adapter plate from transmission case and mount adapter plate on vice again.
  
  Fig 30: Installing Counter Gear Rear End Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
12. Select proper mainshaft C-ring to minimize clearance of groove.
  Allowable clearance of groove:
  
  0 - 0.1 mm (0 - 0.004 in)
  
  Mainshaft C-ring:
  
  Refer to SDS, COUNTER GEAR REAR SNAP RING .
  
  Fig 31: Selecting Proper Mainshaft C-Ring To Minimize Clearance Of Groove
  Courtesy of NISSAN MOTOR CO., U.S.A.
13. Install selected C-ring, C-ring holder and mainshaft rear snap ring.
  
  Fig 32: Installing Selected C-Ring, C-Ring Holder And Mainshaft Rear Snap Ring
  Courtesy of NISSAN MOTOR CO., U.S.A.
14. Select proper counter gear rear snap ring to minimize clearance of groove.
  Allowable clearance of groove:
  
  0 - 0.1 mm (0 - 0.004 in)
  
  Counter gear rear snap ring:
  
  Refer to SDS, COUNTER GEAR REAR SNAP RING .
15. Install selected counter gear rear snap ring.
  
  Fig 33: Selecting Proper Counter Gear Rear Snap Ring To Minimize Clearance Of Groove
  Courtesy of NISSAN MOTOR CO., U.S.A.
  
  Fig 34: Installing Selected Counter Gear Rear Snap Ring
  Courtesy of NISSAN MOTOR CO., U.S.A.
16. Install reverse coupling sleeve.
  - Pay attention to its direction.
17. Measure each gear end play as a final check. Refer to DISASSEMBLY .
  
  Fig 35: Installing Reverse Coupling Sleeve
  Courtesy of NISSAN MOTOR CO., U.S.A.