Disassembly and Assembly: Disassembly

Rear Case

1. Remove the rear case bolts.
   Fig 1: Identifying Rear Case To Center Case

   Courtesy of NISSAN MOTOR CO., U.S.A.
2. Remove the rear case from the center case.
   Fig 2: Identifying Rear Case From Center Case

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3. Remove the dust cover using suitable tool.
   Fig 3: Identifying Dust Cover

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4. Remove the rear oil seal using suitable tool.
   CAUTION: Do not damage rear case.
5. Remove the breather tube.
   Fig 4: Identifying Rear Oil Seal

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

Front Case

1. Remove the rear case assembly. Refer to "DISASSEMBLY AND ASSEMBLY ".
2. Remove the lock pin nut.
3. Remove the lock pin using suitable tool.
4. Remove the shift lever.
   Fig 5: Identifying Lock Pin

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5. Remove the side oil seal from the front case using suitable tool.
   CAUTION: Do not damage front case or shift cross.
   Fig 6: Identifying Side Oil Seal From Front Case

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6. Remove the check plug, check spring and check ball.
7. Remove the wait detection switch.
   Fig 7: Identifying Check Plug, Check Spring And Check Ball

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8. Remove the self-lock nut from the companion flange using Tool.

   Tool number: KV40104000 ( - ) 

   Fig 8: Identifying Self-Lock Nut

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9. Put a matching mark on top of the front drive shaft thread in line with the mark on the companion flange.
   CAUTION: Use paint to make the matching mark on the front drive shaft thread. Never damage the front drive shaft.
   Fig 9: Aligning Front Drive Shaft Matching Mark With Companion Flange Mark

   Courtesy of NISSAN MOTOR CO., U.S.A.
10. Remove the companion flange using suitable tool.
    Fig 10: Identifying Companion Flange

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11. Remove the center case bolts, harness bracket and air breather.
12. Remove the filler plug and gasket.
    Fig 11: Identifying Drain Plug With Gasket

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13. Separate the center case from the front case. Then remove the center case from the front case by prying it up using suitable tool.
    CAUTION: Do not damage the mating surfaces.
    Fig 12: Identifying Center Case From Front Case

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14. Remove the shift rod components together with the 2-4 sleeve and L-H sleeve.
15. Remove the shift cross from the front case, using shift rod (A).
    Fig 13: Identifying Shift Rod Components

    Courtesy of NISSAN MOTOR CO., U.S.A.
16. Remove the 2-4 sleeve and L-H sleeve from the 2-4 fork and LH fork respectively.
    Fig 14: Identifying 2-4 Sleeve And L-H Sleeve To Each Fork

    Courtesy of NISSAN MOTOR CO., U.S.A.
17. Drive out the retaining pin from the shift rod using suitable tool.
    Fig 15: Identifying Drive Out Retaining Pin From Shift Rod

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18. Remove the L-H fork, 2-4 fork, shift fork spring and fork guide from the shift rod.
    Fig 16: Identifying Fork Guide, Shift Fork Spring, 2-4 Fork, And L-H Fork To Shift Rod

    Courtesy of NISSAN MOTOR CO., U.S.A.
19. Remove the input oil seal from the front case using suitable tool.
    CAUTION: Do not damage front case or sun gear.
    Fig 17: Identifying Input Oil Seal From Front Case

    Courtesy of NISSAN MOTOR CO., U.S.A.
20. Remove the snap ring from the sun gear.
    CAUTION: Do not damage front case or sun gear.
    Fig 18: Identifying New Snap Ring To Sun Gear Assembly

    Courtesy of NISSAN MOTOR CO., U.S.A.
21. Remove the sun gear assembly and planetary carrier assembly from the front case using Tool.

    Tool number: ST35300000 ( - ) 

    Fig 19: Identifying Sun Gear Assembly And Planetary Carrier Assembly From Front Case

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22. Remove the snap ring and internal gear using suitable tool.
    Fig 20: Identifying Snap Ring And Internal Gear

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23. Remove the front oil seal using suitable tool.
    CAUTION: Do not damage front case.
    Fig 21: Identifying Front Oil Seal

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24. Remove the snap ring from the front case.
    Fig 22: Identifying Snap Ring

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25. Remove the input bearing from the front case using Tool.

    Tool number: ST33200000 (J-26082) 

    Fig 23: Identifying Input Bearing From Front Case

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26. Remove the snap ring from the planetary carrier assembly using suitable tool.
    Fig 24: Identifying Snap Ring

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27. Remove the sun gear assembly from the planetary carrier assembly.
    Fig 25: Identifying Sun Gear Assembly From Planetary Carrier Assembly

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28. Remove the snap ring from the sun gear assembly using suitable tool.
    Fig 26: Identifying Snap Ring To Sun Gear Assembly

    Courtesy of NISSAN MOTOR CO., U.S.A.
29. Remove the carrier bearing from the sun gear using Tools.

    Tool number A: ST35300000 ( - ) 

    B: ST30031000 ( - ) 

    Fig 27: Identifying Carrier Bearing From Sun Gear

    Courtesy of NISSAN MOTOR CO., U.S.A.
30. Remove the needle bearing from the sun gear using Tool.

    Tool number: ST33710000 ( - ) 

    Fig 28: Identifying Needle Bearing On Sun Gear

    Courtesy of NISSAN MOTOR CO., U.S.A.
31. Remove the metal bushing from the sun gear using Tools.

    Tool number A: ST33710000 ( - ) 

    B: ST35325000 ( - ) 

    C: KV381054S0 (J-34286) 

    Fig 29: Identifying Metal Bushing From Sun Gear

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

Center Case

1. Remove the rear case assembly. Refer to "DISASSEMBLY AND ASSEMBLY ".
2. Remove the front case assembly. Refer to "DISASSEMBLY AND ASSEMBLY ".
3. Hold the front drive shaft with one hand and tap to remove the front drive shaft with the drive chain.
   CAUTION: Do not tap drive chain.
   Fig 30: Identifying Front Drive Shaft With Drive Chain

   Courtesy of NISSAN MOTOR CO., U.S.A.
4. Remove the front drive shaft front bearing using Tools.

   Tool number A: ST33052000 ( - ) 

   B: ST30031000 ( - ) 

   Fig 31: Identifying Front Bearing

   Courtesy of NISSAN MOTOR CO., U.S.A.
5. Remove the front drive shaft rear bearing using Tools.

   Tool number A: ST33052000 ( - ) 

   B: ST30031000 ( - ) 

   Fig 32: Identifying Front Drive Shaft Rear Bearing

   Courtesy of NISSAN MOTOR CO., U.S.A.
6. Remove the neutral-4LO and ATP switches.
   Fig 33: Identifying Neutral-4LO And ATP Switches

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7. Remove the bolts and main oil pump cover.
   Fig 34: Identifying Main Oil Pump Cover Bolts

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8. Remove the outer gear, inner gear and main oil pump housing from the center case.
   Fig 35: Identifying Outer Gear, Inner Gear And Main Oil Pump Housing From Center Case

   Courtesy of NISSAN MOTOR CO., U.S.A.
9. Remove the seal ring from the main oil pump cover.
   Fig 36: Applying ATF To New Seal Ring

   Courtesy of NISSAN MOTOR CO., U.S.A.
10. Remove the stem bleeder from the bleed hole.
    Fig 37: Applying Petroleum Jelly To Stem Bleeder

    Courtesy of NISSAN MOTOR CO., U.S.A.
11. Remove the snap ring and washer holder from the mainshaft.
    Fig 38: Identifying Snap Ring And Washer Holder From Mainshaft

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12. Remove the C-rings from the mainshaft using suitable tool.
    Fig 39: Identifying C-Rings

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13. Set the center case on the press stand. Remove the mainshaft from the center case.
    Fig 40: Identifying Mainshaft From Center Case

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14. Remove the snap ring from the mainshaft using suitable tool.
    Fig 41: Identifying Snap Ring

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15. Remove the thrust needle bearing from the press flange.
    Fig 42: Applying ATF To Thrust Needle Bearing And Install It On Press Flange

    Courtesy of NISSAN MOTOR CO., U.S.A.
16. Press the press flange until the snap ring is out of place using Tools.

    Tool number A: ST22452000 (J-34335) 

    B: ST30911000 ( - ) 

    C: KV31103300 ( - ) 

    Fig 43: Pressing Flange

    Courtesy of NISSAN MOTOR CO., U.S.A.
17. Remove the snap ring from the mainshaft using suitable tool.
    Fig 44: Identifying Snap Ring

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18. Remove the press flange from the mainshaft.
    Fig 45: Identifying Press Flange From Mainshaft

    Courtesy of NISSAN MOTOR CO., U.S.A.
19. Remove the return spring assembly from the clutch hub.
    Fig 46: Identifying Return Spring Assembly Into Clutch Hub

    Courtesy of NISSAN MOTOR CO., U.S.A.
20. Remove each plate from the clutch drum.
    Fig 47: Identifying Each Plate From Clutch Drum

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21. Remove the snap ring from the mainshaft.
    Fig 48: Identifying Snap Ring

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22. Remove the mainshaft from the clutch drum and clutch hub using suitable tool.
23. Remove the needle bearing and spacer from the mainshaft.
    Fig 49: Identifying Mainshaft From Clutch Drum And Clutch Hub

    Courtesy of NISSAN MOTOR CO., U.S.A.
24. Remove the snap ring from the clutch hub using suitable tool.
    Fig 50: Identifying Snap Ring To Clutch Hub

    Courtesy of NISSAN MOTOR CO., U.S.A.
25. Remove the oil pressure check plug from the oil pressure check port.
    Fig 51: Identifying Oil Pressure Check Plug From Oil Pressure Check Port

    Courtesy of NISSAN MOTOR CO., U.S.A.
26. Apply air gradually from the oil pressure check port, and remove the clutch piston assembly from the center case.
    Fig 52: Identifying Clutch Piston Assembly From Center Case

    Courtesy of NISSAN MOTOR CO., U.S.A.
27. Remove the thrust needle bearing race from the clutch piston by hooking a edge into 3 notches of the thrust needle bearing race using suitable tool.
    CAUTION: Do not damage clutch piston or thrust needle bearing race.
    Fig 53: Identifying Thrust Needle Bearing Race From Clutch Piston

    Courtesy of NISSAN MOTOR CO., U.S.A.
28. Remove the two D-rings from the clutch piston.
    Fig 54: Applying ATF To New D-Rings

    Courtesy of NISSAN MOTOR CO., U.S.A.
29. Remove the mainshaft rear bearing from the center case using Tool.

    Tool number: KV38100300 (J-25523) 

    Fig 55: Identifying Mainshaft Rear Bearing From Center Case

    Courtesy of NISSAN MOTOR CO., U.S.A.
30. Remove the two bolts and oil strainer.
    Fig 56: Identifying Bolts And Oil Strainer

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31. Remove the two O-rings from the oil strainer.
    Fig 57: Applying ATF To New O-Rings

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32. Remove the snap ring. Then push the connector assembly into the center case to remove the control valve assembly.
    Fig 58: Identifying Connector Assembly Into Center Case

    Courtesy of NISSAN MOTOR CO., U.S.A.
33. Remove the control valve assembly bolts.
34. Remove the control valve 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 disassembly.
      Fig 59: Identifying Control Valve Assembly To Center Case

      Courtesy of NISSAN MOTOR CO., U.S.A.
35. Remove the lip seals from the center case.
    CAUTION: There are two kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm the position before disassembly.
    Fig 60: Applying ATF To New Lip Seals

    Courtesy of NISSAN MOTOR CO., U.S.A.
36. Disassemble 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 disassembly.
    1. Remove all the bolts except for the two shown.
       Fig 61: Disassembling Control Valve Assembly

       Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Remove the following from the control valve assembly:
       • Clutch pressure solenoid valve
       • Clutch pressure switch
       • 2-4WD shift solenoid valve
       • Line pressure switch
       • Transfer fluid temperature sensor
    3. Remove the O-rings from each solenoid valve, switch and terminal body.
       Fig 62: Checking Control Valve

       Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Place the control valve with the lower body facing up. Remove the two bolts, and then remove the lower body and separator plate from the upper body.
       CAUTION: Do not drop relief balls. Detach lower body carefully.
       Fig 63: Identifying Lower Body And New Separator Plate To Upper Body

       Courtesy of NISSAN MOTOR CO., U.S.A.
    5. Make sure the reverse balls, relief balls, relief springs, accumulator pistons and valve springs are securely installed as shown, and remove them.
       Fig 64: Identifying Reverse Balls, Relief Balls, Relief Springs, Accumulator Pistons And Valve Springs

       Courtesy of NISSAN MOTOR CO., U.S.A.
    6. Remove the retainer plates.
       Fig 65: Identifying Each Control Valve, Spring And Plug To Upper Body

       Courtesy of NISSAN MOTOR CO., U.S.A.
    7. Remove each retainer plate (1), plug (2), control valve (3) and spring (4) from the upper body (5).
       Fig 66: Identifying Upper Body, Control Valves And Springs

       Courtesy of NISSAN MOTOR CO., U.S.A.
37. Remove the transfer motor bolts and motor from the center case. Then remove the O-ring from the transfer motor.
    Fig 67: Identifying Transfer Motor

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38. Remove the sub oil pump cover bolts.
    Fig 68: Identifying Sub Oil Pump Cover Bolts

    Courtesy of NISSAN MOTOR CO., U.S.A.
39. Thread two bolts (M4 x 0.8) into the holes of sub oil pump cover as shown, and pull out to remove the sub oil pump assembly.
    Fig 69: Identifying Sub Oil Pump Assembly

    Courtesy of NISSAN MOTOR CO., U.S.A.
40. Remove the outer gear and inner gear from the sub oil pump housing.
    Fig 70: Identifying Outer Gear And Inner Gear Into Sub Oil Pump Housing

    Courtesy of NISSAN MOTOR CO., U.S.A.
41. Remove the oil filter bolts and oil filter.
    CAUTION:

    • Do not damage center case and oil filter.
    • Loosen bolts and detach oil filter evenly.
      Fig 71: Attaching Oil Filter And Tighten Bolts

      Courtesy of NISSAN MOTOR CO., U.S.A.
42. Remove the O-rings (1) from the oil filter (2).
    Fig 72: Applying ATF To O-Rings

    Courtesy of NISSAN MOTOR CO., U.S.A.
43. Remove the oil filter stud from the oil filter.
44. Remove the O-ring from the oil filter stud.
    Fig 73: Identifying Oil Filter Stud To Oil Filter

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