Disassembly and Assembly: Assembly

Center Case

1. Apply ATF to the new O-ring, and install it on the oil filter stud.
   CAUTION: Do not reuse O-rings.
2. Install the oil filter stud to the oil filter.
   Fig 1: Identifying Oil Filter Stud To Oil Filter

   Courtesy of NISSAN MOTOR CO., U.S.A.
3. Apply ATF to the two new O-rings (1), and install them on the oil filter (2).
   CAUTION: Do not reuse O-rings.
   Fig 2: Applying ATF To O-Rings

   Courtesy of NISSAN MOTOR CO., U.S.A.
4. Install the oil filter to the center case. Tighten the bolts to the specified torque. Refer to "REMOVAL AND INSTALLATION ".
   CAUTION:

   • Do not damage oil filter.
   • Attach oil filter and tighten bolts evenly.
     Fig 3: Attaching Oil Filter And Tighten Bolts

     Courtesy of NISSAN MOTOR CO., U.S.A.
5. Install the outer gear and inner gear into the sub oil pump housing, and measure the side clearance. Refer to "DISASSEMBLY AND ASSEMBLY ".
   Fig 4: Identifying Outer Gear And Inner Gear Into Sub Oil Pump Housing

   Courtesy of NISSAN MOTOR CO., U.S.A.
6. Align the dowel pin hole and bolt hole of the sub oil pump assembly with the center case. Install the sub oil pump cover. Then tighten to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY "
   Fig 5: Identifying Sub Oil Pump Cover

   Courtesy of NISSAN MOTOR CO., U.S.A.
7. Apply ATF to the new O-ring and install it to the transfer motor.
   CAUTION: Do not reuse O-rings.
8. Fit the double-flat end of the transfer motor shaft into the slot of the sub-oil pump assembly. Then tighten to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY "
   CAUTION: Be sure to install connector bracket.
   Fig 6: Applying ATF To New O-Ring

   Courtesy of NISSAN MOTOR CO., U.S.A.
9. Assemble the control valve assembly with the following procedure.
   CAUTION:

   • Do not reuse any part that has been dropped or damaged.
   • Make sure valve is assembled in the proper direction.
   • Do not use a magnet because residual magnetism stays during assembly.
   1. Clean the upper body (5), control valves (3) and springs (4) with cleaning agent, and dry with compressed air.
   2. Dip the control valves in ATF, and apply ATF to the valve-mounting area of the upper body.
      Fig 7: Identifying Upper Body, Control Valves And Springs

      Courtesy of NISSAN MOTOR CO., U.S.A.
   3. Install each control valve (3), springs (4), and plugs (2) to the upper body (5), and install retainer plates (1) to hold them in place.
      CAUTION:

      • To insert control valves into upper body, place upper body on a level surface in order to prevent flaw or damage.
      • Make sure each control valve is smoothly inserted.
        Fig 8: Identifying Each Control Valve, Spring And Plug To Upper Body

        Courtesy of NISSAN MOTOR CO., U.S.A.
   4. Install the reverse balls, relief balls and relief springs, accumulator pistons and valve springs to the upper body.
      Fig 9: Identifying Reverse Balls, Relief Balls, Relief Springs, Accumulator Pistons And Valve Springs

      Courtesy of NISSAN MOTOR CO., U.S.A.
   5. Install the lower body and separator plate to the upper body.
      CAUTION: Do not reuse separator plates.
      Fig 10: Identifying Lower Body And New Separator Plate To Upper Body

      Courtesy of NISSAN MOTOR CO., U.S.A.
   6. With the lower body down, tighten the two bolts shown.
   7. Apply ATF to the new O-rings, and install them to each solenoid valve, switch and terminal body.
      CAUTION: Do not reuse O-rings.
   8. Install the following to the control valve assembly:
      • Clutch pressure solenoid valve
      • Clutch pressure switch
      • 2-4WD shift solenoid valve
      • Line pressure switch
      • Transfer fluid temperature sensor
        Fig 11: Disassembling Control Valve Assembly

        Courtesy of NISSAN MOTOR CO., U.S.A.
10. Apply ATF to the new lip seals, and install them to the center case.
    CAUTION:

    • Do not reuse lip seals.
    • There are 2 kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm their position for installation.
      Fig 12: Applying ATF To New Lip Seals

      Courtesy of NISSAN MOTOR CO., U.S.A.
11. Install the control valve assembly to the center case, and tighten to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    CAUTION:

    • Do not reuse any part that has been dropped or damaged.
    • Make sure valve is assembled in the proper direction.
    • Do not use a magnet because residual magnetism stays during assembly.
      Fig 13: Identifying Control Valve Assembly To Center Case

      Courtesy of NISSAN MOTOR CO., U.S.A.
12. Install the connector assembly into the center case, and secure with a snap ring.
    Fig 14: Identifying Connector Assembly Into Center Case

    Courtesy of NISSAN MOTOR CO., U.S.A.
13. Apply ATF to the new O-rings, and install them on the oil strainer.
    CAUTION: Do not reuse O-rings.
14. Install the oil strainer to the control valve assembly.
    Fig 15: Applying ATF To New O-Rings

    Courtesy of NISSAN MOTOR CO., U.S.A.
15. Tighten the bolts to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    Fig 16: Identifying Bolts And Oil Strainer

    Courtesy of NISSAN MOTOR CO., U.S.A.
16. Apply ATF to the new D-rings, and install them to the clutch piston.
    CAUTION: Do not reuse D-rings.
    Fig 17: Applying ATF To New D-Rings

    Courtesy of NISSAN MOTOR CO., U.S.A.
17. Install the thrust needle bearing race to the clutch piston.
    Fig 18: Identifying Thrust Needle Bearing Race To Clutch Piston

    Courtesy of NISSAN MOTOR CO., U.S.A.
18. Install the clutch piston to the center case as shown.
    CAUTION: Install so the fitting protrusion of clutch piston aligns with the dent of center case.
    Fig 19: Identifying Clutch Piston To Center Case

    Courtesy of NISSAN MOTOR CO., U.S.A.
19. Remove all the sealant from the oil pressure check port and inside the center case.
    CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.
20. Thread the new oil pressure check plug in 1 or 2 pitches and apply sealant to the oil pressure check plug threads. Tighten to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    Fig 20: Identifying Oil Pressure Check Plug From Oil Pressure Check Port

    Courtesy of NISSAN MOTOR CO., U.S.A.
    • Use Genuine Silicone RTV or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Do not reuse oil pressure check plug.
21. Install the new snap ring to the clutch hub using suitable tool.
    CAUTION: Do not reuse snap ring.
    Fig 21: Identifying Snap Ring To Clutch Hub

    Courtesy of NISSAN MOTOR CO., U.S.A.
22. Apply petroleum jelly to the needle bearing, and install the needle bearing, spacer, clutch drum and clutch hub to the mainshaft.
    Fig 22: Identifying Needle Bearing, Spacer, Clutch Drum And Clutch Hub To Main-Shaft

    Courtesy of NISSAN MOTOR CO., U.S.A.
23. Install the new snap ring to the mainshaft.
    CAUTION: Do not reuse snap rings.
    Fig 23: Identifying Snap Ring To Mainshaft

    Courtesy of NISSAN MOTOR CO., U.S.A.
24. Apply ATF each plate, then install them into the clutch drum as shown.
    Fig 24: Identifying Clutch Drum And Plates

    Courtesy of NISSAN MOTOR CO., U.S.A.
25. Install the return spring assembly into the clutch hub.
    Fig 25: Identifying Return Spring Assembly Into Clutch Hub

    Courtesy of NISSAN MOTOR CO., U.S.A.
26. Install the press flange by aligning the notches to the clutch hub as shown.
    Fig 26: Identifying Press Flange

    Courtesy of NISSAN MOTOR CO., U.S.A.
27. Press the press flange to install the new snap ring into snap ring groove on mainshaft using Tools.

    Tool number A: ST22452000 (J-34335) 

    B: ST30911000 ( - ) 

    C: KV31103300 ( - ) 

    CAUTION: Do not reuse snap ring.
    Fig 27: Pressing Flange

    Courtesy of NISSAN MOTOR CO., U.S.A.
28. Install the new snap ring to the mainshaft using suitable tool.
    CAUTION: Do not reuse snap ring.
    Fig 28: Identifying Snap Ring

    Courtesy of NISSAN MOTOR CO., U.S.A.
29. Apply ATF to the thrust needle bearing and install it on the press flange.
    Fig 29: Applying ATF To Thrust Needle Bearing And Install It On Press Flange

    Courtesy of NISSAN MOTOR CO., U.S.A.
30. Install the new snap ring to the main shaft.
    CAUTION: Do not reuse snap ring.
    Fig 30: Identifying Snap Ring To Main Shaft

    Courtesy of NISSAN MOTOR CO., U.S.A.
31. Install the mainshaft rear bearing to the center case using Tool.

    Tool number: ST15310000 (J-25640-B) 

    Fig 31: Identifying Mainshaft Rear Bearing To Center Case

    Courtesy of NISSAN MOTOR CO., U.S.A.
32. Install the mainshaft assembly using a press.
    • Press the mainshaft into the center case using Tools.

      Tool number A: ST30911000 ( - ) 

      B: ST33052000 ( - ) 

      Fig 32: Identifying Mainshaft Assembly

      Courtesy of NISSAN MOTOR CO., U.S.A.
33. Install the C-rings to the mainshaft.
    Fig 33: Identifying C-Rings To Mainshaft

    Courtesy of NISSAN MOTOR CO., U.S.A.
34. Set the washer holder on the mainshaft, and secure it with a new snap ring.
    CAUTION: Do not reuse snap ring.
    Fig 34: Identifying Snap Ring And Washer Holder From Mainshaft

    Courtesy of NISSAN MOTOR CO., U.S.A.
35. Apply petroleum jelly to the stem bleeder and install it to the center case.
    Fig 35: Applying Petroleum Jelly To Stem Bleeder

    Courtesy of NISSAN MOTOR CO., U.S.A.
36. Apply ATF to the new seal ring and install it to the main oil pump cover.
    CAUTION: Do not reuse seal ring.
    Fig 36: Applying ATF To New Seal Ring

    Courtesy of NISSAN MOTOR CO., U.S.A.
37. Install the inner gear and outer gear in the main oil pump housing. Then, measure the side clearance. Refer to "INSPECTION AND ADJUSTMENT ".
    Fig 37: Checking Main Oil Pump

    Courtesy of NISSAN MOTOR CO., U.S.A.
38. Install the main oil pump housing, outer gear and inner gear to the center case.
    Fig 38: Identifying Main Oil Pump Housing, Outer Gear And Inner Gear To Center Case

    Courtesy of NISSAN MOTOR CO., U.S.A.
39. Install the main oil pump cover to the center case, and tighten to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    Fig 39: Identifying Main Oil Pump Cover Bolts

    Courtesy of NISSAN MOTOR CO., U.S.A.
40. Remove all the sealant from the switch location area and inside the center case.
    CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
41. Thread the ATP switch and neutral-4LO switch in one to two pitches and apply sealant to the threads of the switches. Tighten to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    Fig 40: Applying Sealant To Threads Of Switches

    Courtesy of NISSAN MOTOR CO., U.S.A.
    • Use Genuine Silicone RTV or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      NOTE:

      • Neutral-4LO switch harness connector is gray.
      • ATP switch harness connector is black.
42. Install the front drive shaft rear bearing using Tools.

    Tool number A: KV40100621 (J-25273) 

    B: ST30032000 (J-26010-01) 

    Fig 41: Applying Sealant To Threads Of Switches

    Courtesy of NISSAN MOTOR CO., U.S.A.
43. Install the front drive shaft to the front bearing using Tools.

    Tool number A: KV40100621 (J-25273) 

    B: ST30032000 (J-26010-01) 

    Fig 42: Identifying Front Drive Shaft To Front Bearing

    Courtesy of NISSAN MOTOR CO., U.S.A.
44. Install the drive chain to the front drive shaft and clutch drum.
    CAUTION: Install drive chain by aligning identification marks to the rear as shown.
    Fig 43: Identifying Drive Chain By Aligning Identification Marks To Rear

    Courtesy of NISSAN MOTOR CO., U.S.A.
45. Tap the front drive shaft while keeping it upright and press-fit the front drive shaft rear bearing.
    CAUTION: Do not tap drive chain.
46. Install the front case assembly. Refer to "DISASSEMBLY AND ASSEMBLY ".
47. Install the rear case assembly. Refer to "DISASSEMBLY AND ASSEMBLY ".
    Fig 44: Pressing Front Drive Shaft Rear Bearing

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

Front Case

1. Install the carrier bearing to the sun gear using Tools.

   Tool number A: ST30911000 ( - ) 

   B: KV31103300 ( - ) 

   Fig 45: Identifying Carrier Bearing To Sun Gear

   Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install the new snap ring to the sun gear assembly using suitable tool.
   CAUTION: Do not reuse snap ring.
   Fig 46: Identifying Snap Ring To Sun Gear Assembly

   Courtesy of NISSAN MOTOR CO., U.S.A.
3. Apply ATF to the circumference of the new metal bushing and install it to the sun gear assembly using Tool.

   Tool number: ST35300000 ( - ) 

   Dimension A: 7.7 - 8.3 mm (0.303 - 0.327 in) 

   CAUTION:

   • Do not reuse metal bushing.
   • Apply ATF to metal bushing before installing.
     Fig 47: Applying ATF To Metal Bushing

     Courtesy of NISSAN MOTOR CO., U.S.A.
4. Apply ATF to the new needle bearing and install it to the sun gear assembly using Tool.

   Tool number: ST33220000 ( - ) 

   Dimension B: 62.5 - 63.1 mm (2.461 - 2.484 in) 

   CAUTION:

   • Do not reuse needle bearing.
   • Apply ATF to needle bearing before installing.
     Fig 48: Applying ATF To New Needle Bearing

     Courtesy of NISSAN MOTOR CO., U.S.A.
5. Install the sun gear assembly to the planetary carrier assembly.
   Fig 49: Identifying Sun Gear Assembly To Planetary Carrier Assembly

   Courtesy of NISSAN MOTOR CO., U.S.A.
6. Install the new snap ring to the planetary carrier assembly.
   CAUTION: Do not reuse snap ring.
   Fig 50: Identifying Planetary Carrier Assembly Snap Ring

   Courtesy of NISSAN MOTOR CO., U.S.A.
7. Set the input bearing into the front case and install using Tool.

   Tool number: ST30720000 (J-25405) 

   Fig 51: Identifying Input Bearing On Front Case

   Courtesy of NISSAN MOTOR CO., U.S.A.
8. Install the new snap ring into the front case.
   CAUTION: Do not reuse snap ring.
   Fig 52: Identifying Snap Ring

   Courtesy of NISSAN MOTOR CO., U.S.A.
9. Install the internal gear with its groove facing the snap ring into the front case. Then secure it with the new snap ring.
   CAUTION: Do not reuse snap ring.
   Fig 53: Identifying Internal Gear With Its Groove Facing

   Courtesy of NISSAN MOTOR CO., U.S.A.
10. Install the new front oil seal until it is seated flush with the end face of the front case using Tool.

    Tool number: KV38100500 ( - ) 

    CAUTION:

    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal lip before installing.
      Fig 54: Identifying Front Oil Seal

      Courtesy of NISSAN MOTOR CO., U.S.A.
11. Install the planetary carrier assembly and sun gear assembly to the front case using Tool.

    Tool number: ST33200000 (J-26082) 

    Fig 55: Identifying Planetary Carrier Assembly And Sun Gear Assembly To Front Case

    Courtesy of NISSAN MOTOR CO., U.S.A.
12. Install the new snap ring to the sun gear.
    CAUTION: Do not reuse snap ring.
    Fig 56: Identifying New Snap Ring To Sun Gear Assembly

    Courtesy of NISSAN MOTOR CO., U.S.A.
13. Apply petroleum jelly to the circumference of the new oil seal, and install it to the front case using Tools.

    Tool number A: ST30720000 (J-25405) 

    B: ST33200000 (J-26082) 

    Dimension: 4.0 - 4.6 mm (0.157 - 0.181 mm) 

    CAUTION:

    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal.
      Fig 57: Applying Petroleum Jelly To Circumference Of New Input Oil Seal

      Courtesy of NISSAN MOTOR CO., U.S.A.
14. Install the fork guide, shift fork spring, 2-4 fork, and L-H fork to the shift rod, and secure them with new retaining pins.
    CAUTION: Do not reuse retaining pins.
    Fig 58: Identifying Fork Guide, Shift Fork Spring, 2-4 Fork, And L-H Fork To Shift Rod

    Courtesy of NISSAN MOTOR CO., U.S.A.
15. Install the 2-4 sleeve and L-H sleeve to each fork.
16. Install the shift cross to the front case.
    Fig 59: Identifying 2-4 Sleeve And L-H Sleeve To Each Fork

    Courtesy of NISSAN MOTOR CO., U.S.A.
17. While aligning the L-H sleeve with the planetary carrier, install the shift rod assembly (A) to the front case.
    Fig 60: Identifying Shift Rod Components

    Courtesy of NISSAN MOTOR CO., U.S.A.
18. Apply liquid gasket to the entire center case mating surface of the front case assembly as shown.
    • Use Genuine Anaerobic Liquid Gasket or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces.
      Fig 61: Applying Liquid Gasket To Entire Center Case Mating Surface Of Front Case Assembly

      Courtesy of NISSAN MOTOR CO., U.S.A.
19. Install the center case assembly to the front case assembly.
    CAUTION: Do not damage mainshaft end.
20. Tap the center case lightly and press-fit the front drive shaft bearing into the front case.
    Fig 62: Identifying Center Case Assembly To Front Case Assembly

    Courtesy of NISSAN MOTOR CO., U.S.A.
21. Tighten the front case bolts to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    CAUTION: Be sure to install air breather hose clamp, connector bracket and harness clip.
22. Install the drain plug with a new gasket.
    CAUTION: Do not reuse gasket.
    Fig 63: Identifying Drain Plug With Gasket

    Courtesy of NISSAN MOTOR CO., U.S.A.
23. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.
    Fig 64: Aligning Front Drive Shaft Matching Mark With Companion Flange Mark

    Courtesy of NISSAN MOTOR CO., U.S.A.
24. Install a new companion flange self-lock nut. Tighten to the specified torque using Tool. Refer to "DISASSEMBLY AND ASSEMBLY ".

    Tool number: KV40104000 ( - ) 

    CAUTION: Do not reuse self-lock nut.
    Fig 65: Identifying Companion Flange Self-Lock Nut

    Courtesy of NISSAN MOTOR CO., U.S.A.
25. Remove all the sealant from the check plug, switch mounting and front case.
    CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
26. Install the check ball and check spring to the front case. Apply sealant to the check plug and wait detection switch and install them to the front case. Tighten to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    • Use Genuine Silicone RTV or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      NOTE: Wait detection switch harness connector is black.
      Fig 66: Identifying Check Ball And Check Spring On Front Case

      Courtesy of NISSAN MOTOR CO., U.S.A.
27. Install the new oil seal in the front case using Tool.

    Tool number: ST22360002 (J-25679-01) 

    CAUTION:

    • Do not reuse oil seal.
    • Apply petroleum jelly to seal lip before installing.
28. Install the shift lever to the shift cross.
29. Install the lock pin and lock pin nut. Tighten to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    Fig 67: Identifying Oil Seal In Front Case

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

Rear Case

1. Apply petroleum jelly to the circumference of the new rear oil seal. Install the new rear oil seal so that it is flush with the case tip face using Tool.

   Tool number: ST30720000 (J-25405) 

   CAUTION:

   • Do not reuse oil seal.
   • Apply petroleum jelly to seal lip before installing.
     Fig 68: Identifying Rear Oil Seal

     Courtesy of NISSAN MOTOR CO., U.S.A.
2. Apply petroleum jelly to the circumference of the new dust cover (1). Position the new dust cover with protrusions (A) as shown.
   • Rear case (2)
     CAUTION:

     • Do not reuse dust cover.
     • Position the projection in the position as shown.
       Fig 69: Identifying Rear Case Assembly And Dust Cover

       Courtesy of NISSAN MOTOR CO., U.S.A.
3. Install the new dust cover using Tool.

   Tool number: KV40105310 ( - ) 

4. Install the air breather into the rear case.
5. Remove all the sealant from the rear case to center case mating surfaces.
   CAUTION: Remove all foreign materials such as water, oil, and grease from center case and rear case mating surfaces.
6. Apply liquid gasket to the entire rear case mating surface of the center case.
   Fig 70: Identifying Dust Cover

   Courtesy of NISSAN MOTOR CO., U.S.A.
   • Use Genuine Anaerobic Liquid Gasket or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
     CAUTION: Do not to allow Liquid Gasket to enter stem bleeder hole.
7. Install the rear case to the center case. Tighten the bolts to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
   Fig 71: Identifying Rear Case To Center Case

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