Gear Components

WARNING: This page is about a different car, the 2006 Nissan Xterra. However, it is still accessible from the selected car via links, so may be relevant.

Install 5th-6th synchronizer hub assembly according to the following.
1. Install 5th-6th coupling sleeve to 5th-6th synchronizer hub.
  CAUTION:
  - Do not reuse 5th-6th synchronizer hub and 5th-6th coupling sleeve.
  - Replace 5th-6th synchronizer hub and 5th-6th coupling sleeve as a set.
  - Be careful with the orientation 5th-6th coupling sleeve.
    
    Fig 1: Installing 5th-6th Coupling Sleeve To 5th-6th Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the orientation 5th-6th synchronizer hub.
  Fig 2: Identifying Correct Orientation Position Of 5th-6th Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install shifting inserts and spread springs to 5th-6th synchronizer hub.
  CAUTION:
  - Do not install spread spring hook onto the same shifting insert.
    
    Fig 3: Installing Shifting Inserts And Spread Springs To 5th-6th Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the shape of reserve shifting insert to avoid misemploy.
    
    Fig 4: Identifying Ditch Area
    Courtesy of NISSAN MOTOR CO., U.S.A.
3. Press in 5th-6th synchronizer hub assembly, 6th bulk ring, 6th main gear and 6th needle bearing using Tool.
Tool number: ST30911000( - )
CAUTION:
- Apply gear oil to 6th bulk ring and 6th needle bearing.
- Be careful with the orientation 5th-6th coupling sleeve.
Fig 5: Pressing 5th-6th Synchronizer Hub Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.

NOTE: 5th and 6th bulk rings have three spaces that four gear teeth are missing as shown.

Fig 6: Locating Groove Of 5th And 6th Bulk Rings
Courtesy of NISSAN MOTOR CO., U.S.A.
Select and install a snap ring so that the end play comes within the standard value. Refer to "SNAP RINGS ".
End play: 0 - 0.10 mm (0 - 0.004 in)

CAUTION: Do not reuse snap ring.

Fig 7: Installing Snap Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 1st-2nd synchronizer hub assembly according to the following.
1. Install 1st-2nd coupling sleeve to 1st-2nd synchronizer hub.
  CAUTION:
  - Do not reuse 1st-2nd coupling sleeve and 1st-2nd synchronizer hub.
  - Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.
  - Be careful with the orientation 1st-2nd coupling sleeve.
    
    Fig 8: Installing 1st-2nd Coupling Sleeve To 1st-2nd Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the orientation 1st-2nd synchronizer hub.
  Fig 9: Identifying Correct Orientation Position Of 1st-2nd Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install spread springs and shifting inserts to 1st-2nd synchronizer hub.
  CAUTION:
  - Do not install spread spring hook onto the same shifting insert.
    
    Fig 10: Installing Spread Springs And Shifting Inserts To 1st-2nd Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the shape of reverse shifting insert to avoid misassembly.
  Fig 11: Identifying Ditch Area
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Press in 1st-2nd synchronizer hub assembly, 2nd inner bulk ring, 2nd synchronizer cone and 2nd outer bulk ring, 2nd main gear and 2nd needle bearing using Tool.
Tool number: ST27861000 ( - )
CAUTION:
- Apply gear oil to 2nd needle bearing, 2nd inner bulk ring, 2nd synchronizer cone and 2nd outer bulk ring, 1st-2nd synchronizer hub spline of mainshaft.
- Replace 2nd inner bulk ring, 2nd synchronizer cone and 2nd outer bulk ring as a set.
- Be careful with the orientation 1st-2nd coupling sleeve.
Fig 12: Pressing 1st-2nd Synchronizer Hub Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.

NOTE: 1st outer bulk ring has three spaces that three gear tooth is missing and 2nd outer bulk ring has three spaces that two gear teeth are missing.

Fig 13: Locating 1st Outer Bulk Ring And 2nd Outer Bulk Ring Groove
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in 1st gear bushing using Tool.
Tool number: ST27861000( - )
Install 1st outer bulk ring, 1st synchronizer cone, 1st inner bulk ring, 1st needle bearing and 1st main gear to mainshaft.
CAUTION:
- Apply gear oil to 1st outer bulk ring, 1st synchronizer cone, 1st inner bulk ring and 1st needle bearing.
- Replace 1st outer bulk ring, 1st synchronizer cone and 1st inner bulk ring as a set.
Fig 14: Pressing 1st Gear Bushing Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.

NOTE: 1st outer bulk ring has three spaces that three gear tooth is missing and 2nd outer bulk ring has three spaces that two gear teeth are missing.

Fig 15: Locating 1st Outer Bulk Ring And 2nd Outer Bulk Ring Groove
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in 3rd main gear using Tool.
Tool number: ST30022000 ( - )
CAUTION:
- Do not reuse 3rd main gear.
- Be careful with the orientation 3rd main gear.
Fig 16: Pressing 3rd Main Gear Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 3rd-4th main spacer to mainshaft.
Press in 4th main gear using Tool.
Tool number: ST30022000 ( - )
CAUTION:
- Do not reuse 4th main gear.
- Be careful with the orientation 4th main gear.
Fig 17: Pressing 4th Main Gear Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in mainshaft bearing using Tool.
Tool number: ST30911000( - )

CAUTION: Be careful with the orientation mainshaft bearing.

Fig 18: Pressing Mainshaft Bearing Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in reverse main gear bushing using Tool.
Tool number: ST30911000( - )

Fig 19: Pressing Reverse Main Gear Bushing Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in 3rd gear bushing using Tool.
Tool number: ST30911000( - )
Install 3rd-4th synchronizer hub assembly according to the following.
1. Install 3rd-4th coupling sleeve to 3rd-4th synchronizer hub.
  
  Fig 20: Pressing 3rd Gear Bushing Using Tool
  Courtesy of NISSAN MOTOR CO., U.S.A.
  CAUTION:
  - Do not reuse 3rd-4th synchronizer hub and 3rd-4th coupling sleeve.
  - Replace 3rd-4th synchronizer hub and 3rd-4th coupling sleeve as a set.
  - Be careful with the orientation 3rd-4th coupling sleeve.
  Fig 21: Installing 3rd-4th Coupling Sleeve To 3rd-4th Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install spread springs and shifting inserts to 3rd-4th synchronizer hub.
  CAUTION:
  - Do not install spread spring hook onto the same shifting insert.
    
    Fig 22: Installing Spread Springs And Shifting Inserts To 3rd-4th Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the shape of reverse shifting insert to avoid misassembly.
  Fig 23: Identifying Ditch Area
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Press in 3rd-4th synchronizer hub assembly, 3rd inner bulk ring, 3rd synchronizer cone, 3rd outer bulk ring, 3rd counter gear and 3rd needle bearing using Tool.
Tool number: ST30911000( - )

Fig 24: Pressing 3rd-4th Synchronizer Hub Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- Apply gear oil to 3rd inner bulk ring, 3rd synchronizer cone, 3rd outer bulk ring and 3rd needle bearing, hole spline of 3rd-4th synchronizer hub.
- Replace 3rd inner bulk ring, 3rd synchronizer cone and 3rd outer bulk ring as a set.
- Be careful with the orientation 3rd-4th coupling sleeve.
NOTE: 4th bulk ring has three spaces that one gear tooth is missing but 3rd bulk ring doesn't.

Fig 25: Locating 3rd Outer Bulk Ring And 4th Outer Bulk Ring Groove
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in 4th counter gear thrust washer, 4th gear bushing, 4th needle bearing, 4th counter gear, 4th outer bulk ring,4th synchronizer cone and 4th inner bulk ring using Tool.
Tool number: KV40100630 (J-26092)
CAUTION:
- Apply gear oil to 4th needle bearing, 4th outer bulk ring, 4th synchronizer cone and 4th inner bulk ring.
- Replace 4th outer bulk ring, 4th synchronizer cone and 4th inner bulk ring as a set.
- Be careful with the orientation 4th counter gear thrust washer.
Fig 26: Pressing 4th Counter Gear Thrust Washer
Courtesy of NISSAN MOTOR CO., U.S.A.

NOTE: 4th bulk ring has three spaces that one gear tooth is missing but 3rd bulk ring doesn't.

Fig 27: Locating 3rd Outer Bulk Ring And 4th Outer Bulk Ring Groove
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in counter rear bearing inner race using Tool.
Tool number: ST30032000 (J-26010-01)

CAUTION: Be careful with the orientation counter rear bearing inner race.

Fig 28: Pressing Counter Rear Bearing Inner Race Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Install main drive gear bearing according to the following.
1. Press in main drive gear bearing using Tool.
  Tool number: KV32102700 ( - )
  
  CAUTION: Be careful with the orientation main drive gear bearing.
  
  Fig 29: Installing Main Drive Gear Bearing
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Select and install a snap ring to main drive gear bearing so that the end play comes within the standard value. Refer to "SNAP RINGS ".
End play: 0 - 0.10 mm (0 - 0.004 in)

CAUTION: Do not reuse snap ring.

Fig 30: Installing Snap Ring To Main Drive Gear Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install breather to adapter plate.
CAUTION:
- Do not reuse breather.
- Be careful with the orientation breather.
Fig 31: Installing Breather To Adapter Plate
Courtesy of NISSAN MOTOR CO., U.S.A.
Install magnet to adapter plate.
CAUTION: Be careful with the orientation magnet.

Fig 32: Installing Magnet To Adapter Plate
Courtesy of NISSAN MOTOR CO., U.S.A.
Install baffle plate to adapter plate, and then tighten bolt to the specified torque. Refer to "CASE COMPONENTS ".

Fig 33: Installing Baffle Plate To Adapter Plate
Courtesy of NISSAN MOTOR CO., U.S.A.
Install main drive gear assembly, mainshaft assembly and counter gear assembly according to the following.
1. Install main pilot bearing, pilot bearing spacer and 5th bulk ring to main drive gear.
2. Install main drive gear assembly, mainshaft assembly and counter gear assembly combined in one unit to adapter plate using brass bar.
Fig 34: Installing Main Pilot Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install Tool to adapter plate, and then position in a vise.
Tool number: ST22490000 ( - )

CAUTION: Do not directly secure mating surface of adapter plate in a vise.

Fig 35: Installing Tool To Adapter Plate
Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring to mainshaft bearing.
CAUTION: Do not reuse snap ring.

Fig 36: Installing Snap Ring To Mainshaft Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install counter rear bearing to adapter plate using Tool.
Tool number: ST33200000 (J-26082)
Install counter rear bearing spacer to counter gear.
CAUTION: When installing counter rear bearing spacer, groove should face to the rear side.

Fig 37: Installing Counter Rear Bearing To Adapter Plate Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Install bearing retainer according to the following.
1. Instal bearing retainer to adapter plate.
2. Apply recommended thread locking sealant to threads of bolts, and then tighten bolts to the specified torque. Refer to "CASE COMPONENTS ".
  - Use Genuine Medium Strength Thread Locking Sealant or the equivalent. Refer to " RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS " .
  Fig 38: Applying Thread Locking Sealant To Threads Of Bolts
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install reverse synchronizer hub assembly according to the following.
1. Install reverse coupling sleeve to reverse synchronizer hub.
  CAUTION:
  - Do not reuse reverse coupling sleeve and reverse synchronizer hub.
  - Replace reuse reverse coupling sleeve and reverse synchronizer hub as a set.
  - Be careful with the orientation reverse coupling sleeve.
    
    Fig 39: Installing Reverse Coupling Sleeve To Reverse Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the orientation reverse synchronizer hub.
  Fig 40: Locating Reverse Synchronizer Hub Groove
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install spread springs to shifting inserts to reverse synchronizer hub.
  CAUTION:
  - Do not install spread spring hook onto the same shifting insert.
    
    Fig 41: Installing Spread Springs Shifting Inserts To Reverse Synchronizer Hub
    Courtesy of NISSAN MOTOR CO., U.S.A.
  - Be careful with the shape of 1st-2nd, 3rd-4th and 5th-6th shifting insert to avoid misassembly.
  Fig 42: Identifying Ditch Area
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Install snap ring to reverse synchronizer hub.
  CAUTION:
  - Do not reuse snap ring.
  - Do not align the snap ring notch with synchronizer hub groove when assembling.
  Fig 43: Installing Snap Ring To Reverse Synchronizer Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Press in reverse synchronizer hub assembly, reverse bulk ring, n reverse main gear and reverse main needle bearing using Tools.
  Tool number: ST01530000 ( - )
  
  : KV32103300 (J-46529)
  
  CAUTION: Apply gear oil to reverse bulk ring and reverse main needle bearing.
  
  Fig 44: Pressing Reverse Synchronizer Hub Assembly
  Courtesy of NISSAN MOTOR CO., U.S.A.
NOTE: Reverse bulk ring has three spaces that two gear teeth are missing, and each space has small ditch for identification as shown.

Fig 45: Locating Reverse Bulk Ring Groove
Courtesy of NISSAN MOTOR CO., U.S.A.
Select and install a snap ring so that the end play comes within the standard value. Refer to "SNAP RINGS ".
End play: 0 - 0.10 mm (0 - 0.004 in)

CAUTION: Do not reuse snap ring.

Fig 46: Measuring End Play Of Reverse Synchronizer Hub
Courtesy of NISSAN MOTOR CO., U.S.A.
Press in reverse counter gear using Tool.
Tool number: ST23860000 ( - )
CAUTION:
- Do not reverse counter gear.
- Be careful with the orientation counter gear.
Fig 47: Pressing Reverse Counter Gear Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Select and install a snap ring so that the end play comes within the standard value. Refer to "SNAP RINGS ".
End play: 0 - 0.10 mm (0 - 0.004 in)

CAUTION: Do not reuse snap ring.

Fig 48: Measuring End Play Of Reverse Counter Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Install reverse idler shaft assembly according to the following.
1. Install reverse idler needle bearing, reverse idler gear and reverse idler thrust washer to reverse idler shaft.
CAUTION: Apply gear oil to reverse idler needle bearing.
1. Install reverse idler shaft assembly to adapter plate.
Fig 49: Installing Reverse Idler Shaft Assembly To Adapter Plate
Courtesy of NISSAN MOTOR CO., U.S.A.