Disassembly and Assembly: Disassembly

WARNING: This page is about a different car, the 2008 Nissan Titan. However, it is still accessible from the selected car via links, so may be relevant.

Remove the drain plug and filler plug.
Remove the transfer control device from the rear case.
Remove the O-ring from the transfer control device.

Fig 1: Locating Transfer Control Device Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the self-lock nut from the companion flange using Tool.
Tool number : KV40104000 ( - )

Fig 2: Removing Self-Lock Nut And Companion Flange
Courtesy of NISSAN MOTOR CO., U.S.A.
Put a matching mark on top of the front drive shaft in line with the mark on the companion flange.
CAUTION: Use paint to make the matching mark on the front drive shaft. Do not damage the front drive shaft.

Fig 3: Identifying Matching Mark On Front Drive Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the companion flange using suitable tool.

Fig 4: Removing Companion Flange Using Suitable Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the front oil seal from the front case using Tool.
Tool number : ST33290001 (J-34286)

CAUTION: Do not damage front case or front drive shaft.

Fig 5: Removing Front Oil Seal
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the 4LO switch [gray (with green paint)] and ATP switch (black) from the front case.

Fig 6: Identifying 4LO Switch And ATP Switch
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the wait detection switch (gray) from the rear case.

Fig 7: Identifying Wait Detection Switch
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the dust cover from the rear case using suitable tool.
CAUTION: Do not damage rear case.

Fig 8: Removing Dust Cover Of Rear Case Using Suitable Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the rear oil seal from the rear case using Tool.
Tool number : ST33290001 (J-34286)

CAUTION: Do not damage rear case or mainshaft.

Fig 9: Identifying Rear Oil Seal From Rear Case Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the input oil seal from the front case using suitable tool.
CAUTION: Do not damage front case, sun gear or input bearing.

Fig 10: Identifying Input Oil Seal From Front Case Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the retainer bolts and gaskets.

Fig 11: Locating Retainer Bolts And Gaskets
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the rear case bolts, harness bracket and air breather hose clamp from the rear case.

Fig 12: Locating Rear Case Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Separate the front case from the rear case. Then remove the rear case by prying it up using suitable tool.
CAUTION: Do not damage the mating surface.
Remove the spacer from the control shift rod.
CAUTION: Do not drop spacer.

Fig 13: Removing Rear Case By Prying
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the mainshaft using suitable tool.

Fig 14: Removing Snap Ring Of Mainshaft Using Suitable Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the mainshaft rear bearing from the mainshaft using suitable tool.
Remove the retainer from the mainshaft.

Fig 15: Identifying Mainshaft Rear Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the mainshaft using suitable tool.
Remove the oil pump assembly from the mainshaft.

Fig 16: Removing Oil Pump Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the mainshaft using suitable tool.
Remove the clutch gear from the mainshaft.

Fig 17: Identifying Snap Ring And Clutch Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the L-H shift rod assembly using suitable tool.
Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.

Fig 18: Identifying Snap Ring And L-H Shift Rod Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the drive chain together with the sprocket and front drive shaft from the front case.
Remove the mainshaft from the sun gear assembly.
Remove the L-H shift rod assembly and control shift rod assembly from the front case.
Remove the L-H sleeve together with the L-H shift fork from the planetary carrier assembly.

Fig 19: Removing Drive Chain, Sprocket And Front Drive Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the sun gear.
CAUTION: Do not damage sun gear or input bearing.

Fig 20: Identifying Snap Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Press the sun gear assembly and planetary carrier assembly from the front case using Tool.
Tool number : KV38100200 ( - )

Fig 21: Pressing Sun Gear Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the front case.

Fig 22: Identifying Snap Ring On Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the internal gear from the front case.

Fig 23: Identifying Internal Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the front case.

Fig 24: Identifying Snap Ring And Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the input bearing from the front case using Tool.
Tool number : KV38100200 ( - )

Fig 25: Removing Input Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the baffle plate from the front case.
Remove the breather tube from the front case.

Fig 26: Identifying Baffle Plate To Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.