Gear Components

WARNING: This page is about a different car, the 2003 Infiniti G35. However, it is still accessible from the selected car via links, so may be relevant.

Install coupling sleeve and shifting insert in the 5th-6th synchronizer hub.
CAUTION: Install coupling sleeve with the larger chamfer on the rear side.

Fig 1: Installing Coupling Sleeve And Shifting Insert Of 5th-6th Synchronizer Hub
Courtesy of NISSAN MOTOR CO., U.S.A.
Install spread spring in the shifting insert.

Fig 2: Installing Spread Spring In Shifting Insert
Courtesy of NISSAN MOTOR CO., U.S.A.
- Be careful with the shape of shifting insert to avoid misassembly.
CAUTION: Do not install spread spring hook onto the same shifting insert.

Fig 3: Identifying Different Shifting Insert
Courtesy of NISSAN MOTOR CO., U.S.A.
After installing the 6th needle bearing and 6th main gear, 6th baulk ring on the main shaft, using an inserter and a press to press fit the 5th - 6th synchronizer assembly.
1. Tool number: ST30911000 ( - )
Fig 4: Fitting 5th - 6th Synchronizer Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- The synchronizer hub is not reusable. Never reuse it.
- When press fitting, install with the side having the three boss edge oil grooves facing the rear side.
Fig 5: Identifying Synchronizer Hub Front And Rear Side
Courtesy of NISSAN MOTOR CO., U.S.A.
Select and install a snap ring so that the end play comes within the standard value.
1. End play: 0 - 0.10 mm (0 - 0.004 in)
CAUTION: Snap rings are not reusable. Never reuse them.

Fig 6: Installing End Play In Snap Ring
Courtesy of NISSAN MOTOR CO., U.S.A.

Fig 7: Identifying Main shaft Snap Ring (Front Side) Specification Table
Courtesy of NISSAN MOTOR CO., U.S.A.
Install coupling sleeve and shifting insert into the 1st - 2nd synchronizer hub.
CAUTION: Install 1st-2nd coupling sleeve with the thicker flange faced the front side.

Fig 8: Installing Coupling Sleeve And Shifting Insert
Courtesy of NISSAN MOTOR CO., U.S.A.
Install spread spring in the shifting insert.

Fig 9: Installing Spread Spring In Shifting Insert
Courtesy of NISSAN MOTOR CO., U.S.A.
- Be careful with the shape of shifting insert to avoid misassembly.
CAUTION: Do not install spread spring hook onto the same shifting insert.

Fig 10: Identifying Different Shifting Insert
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 2nd needle bearing, 2nd main gear, 2nd inner baulk ring, 2nd synchronizer cone, 2nd outer baulk ring on the main shaft and then using a support ring and a press to press fit the 1st - 2nd synchronizer assembly.
1. Tool number: ST27861000 ( - )
Fig 11: Fitting 1st - 2nd Synchronizer Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- The synchronizer hub is not reusable. Never reuse it.
- When press fitting, install with the side having the three boss edge oil grooves facing the front side.
Fig 12: Locating Identification Mark
Courtesy of NISSAN MOTOR CO., U.S.A.
Using a support ring and a press to press fit the 1st gear bushing.
1. Tool number: ST27861000 ( - )
Fig 13: Fitting 1st Gear Bushing
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 1st needle bearing and 1st main gear on the main shaft and then using the inserter and a press to press fit the 3rd main gear.
1. Tool number: ST30022000 ( - )
CAUTION: 3rd main gear is not reusable. Never reuse it.

Fig 14: Fitting 3rd Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 3rd - 4th main spacer on the main shaft and then using the inserter and a press to press fit the 4th main gear.
1. Tool number: ST30022000 ( - )
CAUTION:
- 4th main gear is not reusable. Never reuse it.
- When installing, set boss to rear side.
Fig 15: Fitting 4th Main Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Using the inserter and a press to press fit the main shaft bearing onto the main shaft.
1. Tool number: ST30911000 ( - )
Fig 16: Fitting Main Shaft Bearing Onto Main Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Using the inserter and a press to press fit the reverse main gear bushing onto the main shaft.
1. Tool number: ST30911000 ( - )
Fig 17: Fitting Reverse Main Gear Bushing Onto Main Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Using the inserter to press fit the 3rd gear bushing onto the counter shaft.
1. Tool number: ST30911000 ( - )
Fig 18: Fitting 3rd Gear Bushing Onto Counter Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Install coupling sleeve and shifting insert into the 3rd - 4th synchronizer hub.
CAUTION: Install 3rd-4th coupling sleeve with the thicker flange faced the front side.

Fig 19: Installing Coupling Sleeve And Shifting Insert
Courtesy of NISSAN MOTOR CO., U.S.A.
Install spread spring in the shifting insert.
Install coupling sleeve with the identification groove side facing the rear side.

Fig 20: Installing Spring & Coupling Sleeve
Courtesy of NISSAN MOTOR CO., U.S.A.
- Be careful with the shape of shifting insert to avoid misassembly.
  CAUTION: Do not install spread spring hook onto the same shifting insert.
Fig 21: Identifying Different Shifting Insert
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 3rd needle bearing, 3rd counter gear, 3rd inner baulk ring, 3rd synchronizer cone, 3rd outer baulk ring on the counter shaft and then using the drift and a press to press fit the 3rd - 4th synchronizer assembly
1. Tool number: ST30911000 ( - )
CAUTION:
- The synchronizer hub is not reusable. Never reuse it.
Fig 22: Fitting 3rd - 4th Synchronizer Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 4th outer baulk ring, 4th synchronizer cone, 4th gear bushing, 4th needle bearing, 4th counter gear onto the counter shaft and then using the drift and a press to press fit the counter shaft rear thrust washer.
1. Tool number: KV40100630 (J26029)
Fig 23: Fitting Counter Shaft Rear Thrust Washer
Courtesy of NISSAN MOTOR CO., U.S.A.
Using the drift and a press to press fit the counter rear bearing inner race onto the counter shaft.
1. Tool number: ST30032000 (J26010-1)
Fig 24: Fitting Counter Rear Bearing Inner Race Onto Counter Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Using the drift and a press to press fit the main drive gear bearing onto the main drive gear.
1. Tool number: KV32102700 ( - )
Fig 25: Fitting Main Drive Gear Bearing Onto Main Drive Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Select and install a snap ring to the main drive gear so that the end play comes within the standard value.
1. End play: 0 - 0.10 mm (0 - 0.004 in)
CAUTION: Snap rings are not reusable. Never reuse them.

Fig 26: Measuring End Play Of Snap Ring
Courtesy of NISSAN MOTOR CO., U.S.A.

Fig 27: Identifying Main Drive Gear Specification Table
Courtesy of NISSAN MOTOR CO., U.S.A.
Install 5th baulk ring, main pilot bearing, pilot bearing spacer, main drive gear onto the main shaft.
Install main shaft and counter shaft combined in one unit to adapter plate, and fix bearing with snap ring.
1. Hammer main shaft bearing slightly via brass bar or the equivalent to install snap ring.
  
  Fig 28: Hammering Snap Ring
  Courtesy of NISSAN MOTOR CO., U.S.A.
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: Snap rings are not reusable. Never reuse them.
Install counter rear bearing outer race onto the adapter plate using soft hammer or the equivalent.

Fig 29: Installing Counter Rear Bearing Outer Race Onto Adapter Plate
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply genuine medium strength locking sealant or equivalent refer to GI section to the end of the bolt (first 3 to 4 threads), screw the bolt into the main shaft bearing retainer and tighten it to the specified torque.
1. : 19 - 24 N.m (2.0 - 2.4 kg-m, 14 - 17 ft-lb)
Fig 30: Applying Genuine Medium Strength Locking Sealant Or Equivalent End Of Bolt
Courtesy of NISSAN MOTOR CO., U.S.A.
Install reverse coupling sleeve and reverse shifting insert into the reverse synchronizer hub.
CAUTION: Install reverse coupling sleeve with the flat flange on the rear side.

Fig 31: Installing Reverse Coupling Sleeve & Reverse Shifting Insert
Courtesy of NISSAN MOTOR CO., U.S.A.
Install spread spring in the shifting insert.
CAUTION: Do not install spread spring hook onto the same shifting insert.

Fig 32: Installing Spread Spring In Shifting Insert
Courtesy of NISSAN MOTOR CO., U.S.A.
After installing the reverse main needle bearing, reverse main gear and reverse baulk ring onto the main shaft, using the drift and install the reverse synchronizer assembly.
1. Tool number (A): KV32103300 (J46529)
2. Tool number (B): ST01530000 ( - )
Fig 33: Installing Reverse Synchronizer Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
CAUTION:
- The synchronizer hub is not reusable. Never reuse it.
- When installing, face the side with three ditches to the front side.
Fig 34: Identifying Synchronizer Hub From Front And Rear Side
Courtesy of NISSAN MOTOR CO., U.S.A.
Select and install a snap ring to the main shaft so that the end play comes within the standard value.
1. End play: 0 - 0.10 mm (0 - 0.004 in)
CAUTION: Snap rings are not reusable. Never reuse them.

Fig 35: Installing Snap Ring To Main Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.

Fig 36: Identifying Main shaft Snap Ring (Shaft Rear End) Specification Table
Courtesy of NISSAN MOTOR CO., U.S.A.
After installing counter rear bearing spacer to counter shaft, press reverse counter gear to counter shaft using drift and press.
1. Tool number: ST23860000 ( - )
CAUTION:
- Reverse counter gear is not reusable. Never reuse it.
- When installing counter rear bearing spacer, maker's stamp should face to the rear.
Fig 37: Pressing Reverse Counter Gear To Counter Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Select and install a snap ring to the counter shaft so that the end play comes within the standard value.
1. End play: 0 - 0.10 mm (0 - 0.004 in)
CAUTION: Snap rings are not reusable. Never reuse them.

Fig 38: Installing Snap Ring To Counter Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.

Fig 39: Identifying Counter Shaft Specification Table
Courtesy of NISSAN MOTOR CO., U.S.A.