Nissan Altima 2007-2012 Service Manual: Input shaft and gear

Exploded View

Refer to TM-28, "Exploded View".

Disassembly

1. Before disassembling, measure end play for 3rd, 4th, 5th, and 6th input gears.

End play standard value : Refer to TM-83, "End Play".

2. Remove oil channel.

3. Press out input shaft rear bearing using Tool and a puller.

Tool number : ST33052000 ( — )

4. Remove snap ring.

5. Press out 6th input gear, 6th needle bearing, 6th input gear bushing, 5th-6th synchronizer hub assembly, and 5th input gear using Tool (A) and a puller (B).

Tool number : ST33052000 ( — )

6. Remove 5th needle bearing.

7. Press out 5th input gear bushing, thrust washer, 4th input gear, 4th needle bearing, 4th input gear bushing, 3rd-4th synchronizer hub assembly, and 3rd input gear using Tool and a puller.

Tool number : ST33052000 ( — )

8. Remove 3rd needle bearing.

9. Press out input shaft front bearing using a puller.

Assembly

1. Install 3rd needle bearing to input shaft.

2. Install 3rd input gear, 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring to input shaft.

CAUTION: Replace 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring as a set. 3. Install 3rd-4th spread spring, 3rd-4th shifting insert, and 3rd-4th synchronizer hub onto 3rd-4th coupling sleeve.

CAUTION: • Be careful with orientation of 3rd-4th synchronizer hub.

• 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 orientation of 3rd-4th coupling sleeve.

• Be sure not to hook center projection of 2 spread springs on same shifting insert.

4. Press in 3rd-4th synchronizer hub assembly using Tool.

Tool number : KV40105710 ( — )

CAUTION: Align grooves of 3rd-4th shifting insert and 3rd outer baulk ring.

5. Press in 4th input gear bushing using Tool.

Tool number : KV40105710 ( — )

6. Install 4th baulk ring.

7. Install 4th needle bearing and 4th input gear to input shaft.

8. Select thrust washer so that dimension “C2” satisfies the standard value below. Then install thrust washer onto input shaft.

Standard value for dimension “C2” : Refer to TM-84, "Dimension".

CAUTION: Only one thrust washer can be selected.

9. Press in 5th input gear bushing using Tool.

Tool number : KV40105710 ( — )

CAUTION: Do not reuse 5th input gear bushing.

10. Install 5th needle bearing and 5th input gear to input shaft.

11. Install 5th baulk ring.

12. Install 5th-6th synchronizer hub, 5th-6th spread spring, and 5th-6th shifting insert onto 5th-6th coupling sleeve.

CAUTION: • Be careful with orientation of 5th-6th synchronizer hub.

A : Front side

B : Rear side

• 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 orientation of 5th-6th coupling sleeve.

A : 5th input gear side

B : 6th input gear side

• Be sure not to hook center projection of 2 spread springs on same shifting insert.

13. Press in 5th-6th synchronizer hub assembly using Tool

Tool number : KV40105710 ( — )

CAUTION: Align grooves of 5th-6th shifting insert and 5th baulk ring.

14. Install 6th needle bearing, 6th input gear, 6th baulk ring onto 6th input gear bushing and then press in 6th input gear bushing onto input shaft using Tool.

Tool number : ST33200000 (J-26082)

15. Install snap ring onto input shaft and make sure that end play (gap between snap ring and groove) of 6th input gear bushing satisfies the standard value.

End play standard value :Refer to TM-83, "End Play".

• If measurement is outside the standard range, select snap ring.

CAUTION: Do not reuse snap ring.

16. Press in input shaft rear bearing using Tool.

Tool number : ST30901000 (J-26010-01)

CAUTION: Install input shaft rear bearing with its brown surface facing the 6th input gear side.

17. Press in input shaft front bearing using Tools.

Tool number : ST33052000 ( — ) : ST30032000 (J-26010-01

18. Install oil channel onto input shaft.

19. Check end play of 3rd, 4th, 5th, and 6th input gears.

End play standard value : Refer to TM-83, "End Play".

Inspection

INPUT SHAFT AND GEAR

Check items below. If necessary, replace them with new ones.

• Damage, peeling, dent, uneven wear, bending, etc. of shaft

• Excessive wear, damage, peeling, etc. of gears

SYNCHRONIZER

Synchronizer Hub and Coupling Sleeve

Check items below. If necessary, replace them with new ones.

• Damage and excessive wear of contact surfaces of coupling sleeve, synchronizer hub and shifting insert

• Coupling sleeve and synchronizer hub must move smoothly.

Baulk Ring and Spread Spring

Check items below. If necessary, replace them with new ones.

• If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.

Baulk Ring Clearance for Single Cone Synchronizer (4th, 5th, and 6th) • Push baulk ring on the cone and measure the clearance between baulk ring and cone. If measurement is below limit, replace it with a new one.

Baulk Ring Clearance for Double Cone Synchronizer (3rd)

• Check the clearance between outer baulk ring, synchronizer cone, and inner baulk ring as follows.

CAUTION: The clearances “A” and “B” are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set.

Replace them as a set if the clearances are outside the limit value.

1. Measure the clearance “A” at 2 points or more diagonally opposite using Tool. Then calculate mean value.

2. Measure the clearance “B” at 2 points or more diagonally opposite using a feeler gauge. And then calculate mean value.

BEARING

Check bearing for damage and rough rotation. If necessary, replace with new one.

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