Section 4 (Transfer Case): Assembly

WARNING: This page is about a different variant/trim than selected.

Assemble front case.
1. Install main gear assembly by tapping lightly.
  
  Fig 1: Installing Main Gear Assembly By Tapping
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Apply sealant to the mating surface and bolts of front case cover, then attach it to the front case.
  - Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
  - These ten bolts should be coated with sealant.
    Bolts A: 20 - 24 N.m (2.0 - 2.4 kg-m, 14 - 17 ft-lb)
    
    Bolts B: 24 - 28 N.m (2.4 - 2.9 kg-m, 17 - 21 ft-lb)
    
    Fig 2: Applying Sealant To Mating Surface And Bolts Of Front Case Cover
    Courtesy of NISSAN MOTOR CO., U.S.A.
3. Apply ATF to needle bearing and install it into main gear.
  
  Fig 3: Installing Needle Bearing Into Main Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Install counter gear assembly by tapping lightly.
  
  Fig 4: Installing Counter Gear Assembly By Tapping
  Courtesy of NISSAN MOTOR CO., U.S.A.
5. Install cross shaft and inner shift lever.
  - When replacing cross shaft, outer shift lever or outer shift lever lock pin, replace them as a set.
    
    Fig 5: Installing Cross Shaft And Inner Shift Lever
    Courtesy of NISSAN MOTOR CO., U.S.A.
6. Apply sealant to plug and install it into front case.
  Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
  
  Fig 6: Installing Plug Into Front Case
  Courtesy of NISSAN MOTOR CO., U.S.A.
7. Insert interlock plunger into front case.
  
  Fig 7: Inserting Interlock Plunger Into Front Case
  Courtesy of NISSAN MOTOR CO., U.S.A.
8. Install L & H shift rod and fork assembly with coupling sleeve.
  
  Fig 8: Installing L H Shift Rod And Fork Assembly With Coupling Sleeve
  Courtesy of NISSAN MOTOR CO., U.S.A.
9. Install 2-4 shift rod.
  
  Fig 9: Installing 2-4 Shift Rod
  Courtesy of NISSAN MOTOR CO., U.S.A.
10. Install transfer neutral position switch, check balls, check springs and plugs.
  - Apply sealant to switches and plugs.
  - Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
    
    Fig 10: Installing Transfer Neutral Position Switch
    Courtesy of NISSAN MOTOR CO., U.S.A.
Select counter gear rear bearing shim.
1. Seat counter gear assembly.
  
  Fig 11: Selecting Counter Gear Rear Bearing Shim
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of center case, allowing gauging cylinder to rest on top outer portion of counter gear rear bearing. Lock gauging cylinder in place.
  
  Fig 12: Installing SST
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Insert J34291-20 (gauging plunger) into J34291-5 (gauging cylinder).
  
  Fig 13: Inserting Gauge Plunger Into Gauging Cylinder
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Place bridge, legs, gauging cylinder and gauging plunger onto machined surface of front case assembly, allowing gauging plunger to drop until it contacts counter gear rear bearing mating surface.
  
  Fig 14: Placing Bridge, Legs, Gauging Cylinder And Gauging Plunger
  Courtesy of NISSAN MOTOR CO., U.S.A.
5. Lock gauging plunger in place and use feeler gauge to measure end play between gauging cylinder and gauging plunger.
6. Use measured distance to select correct counter gear rear bearing shim.
  Allowable counter gear end play: 0 - 0.2 mm (0 - 0.008 in)
  
  Allowable counter gear rear bearing shim: Refer to " COUNTER GEAR REAR BEARING " .
  
  Fig 15: Measuring Counter Gear End Play
  Courtesy of NISSAN MOTOR CO., U.S.A.
Place suitable shim with grease on counter gear rear bearing.
Apply ATF to each part in front case.

Fig 16: Placing Suitable Shim With Counter Gear Rear Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Assemble center case assembly.
1. Install mainshaft on center case by tapping lightly.
  - Apply ATF to mainshaft front bearing.
    
    Fig 17: Installing Mainshaft On Center Case By Tapping Lightly
    Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install bearing retainer.
  : 16 - 21 N.m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
  
  Fig 18: Installing Bearing Retainer
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Put drive chain onto the front drive sprocket and front drive shaft, and then put them in center case.
  
  Fig 19: Putting Drive Chain Onto Front Drive Sprocket And Front Drive Shaft (1 Of 2)
  Courtesy of NISSAN MOTOR CO., U.S.A.
  
  Fig 20: Putting Drive Chain Onto Front Drive Sprocket And Front Drive Shaft (2 Of 2)
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Install front drive shaft by tapping lightly.
  - Make sure shafts are aligned in the case.
    
    Fig 21: Installing Front Drive Shaft By Tapping
    Courtesy of NISSAN MOTOR CO., U.S.A.
5. Apply ATF to needle bearings and install them into front drive sprocket.
  - These needle bearings can be installed more easily if front drive sprocket is rotated while installing them.
    
    Fig 22: Installing Needle Bearing Into Front Drive Sprocket
    Courtesy of NISSAN MOTOR CO., U.S.A.
6. Install 2-4 coupling sleeve with 2-4 shift fork.
  - Pay special attention to direction of coupling sleeve.
    
    Fig 23: Installing 2-4 Coupling Sleeve With 2-4 Shift Fork
    Courtesy of NISSAN MOTOR CO., U.S.A.
7. Install shifting inserts and spread spring.
  - Pay attention to the direction of shifting inserts.
    
    Fig 24: Installing Shifting Inserts And Spread Spring
    Courtesy of NISSAN MOTOR CO., U.S.A.
8. Install baulk ring, then install clutch gear and mainshaft rear bearing.
  - Place wooden block under mainshaft in order to protect mainshaft front bearing.
    
    Fig 25: Installing Baulk Ring
    Courtesy of NISSAN MOTOR CO., U.S.A.
9. Install spacer.
10. Select and install snap ring with proper thickness.
  Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 in)
  
  Available snap ring for mainshaft rear bearing: Refer to " MAINSHAFT REAR BEARING " .
  
  Fig 26: Installing Snap Ring
  Courtesy of NISSAN MOTOR CO., U.S.A.
11. Install steel ball, speedometer drive gear and retainer ring.
  - Steel ball is the smallest of check balls for this unit.
    
    Fig 27: Installing Steel Ball, Speedometer Drive Gear And Retainer Ring
    Courtesy of NISSAN MOTOR CO., U.S.A.
12. Install low gear and its bearing onto mainshaft.
  - Apply ATF to needle bearing.
    
    Fig 28: Installing Low Gear And Its Bearing Onto Mainshaft
    Courtesy of NISSAN MOTOR CO., U.S.A.
13. Install L & H hub and snap ring to mainshaft.
  - Pay attention to direction of L & H hub.
    
    Fig 29: Installing L H Hub And Snap Ring To Mainshaft
    Courtesy of NISSAN MOTOR CO., U.S.A.
14. Measure low gear end play.
  Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in)
  
  Fig 30: Measuring Low Gear End Play
  Courtesy of NISSAN MOTOR CO., U.S.A.
Apply sealant to mating surface of center case then attach to front case and tighten bolts.
- Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
  
  Fig 31: Attaching Front Case To Center Case
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring to 2-4 shift rod.

Fig 32: Installing Snap Ring To 2-4 Shift Rod
Courtesy of NISSAN MOTOR CO., U.S.A.
Install oil gutter and oil cover.
Apply ATF to each part in center case.

Fig 33: Installing Oil Gutter And Oil Cover
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply sealant to mating surface of rear case then attach it to center case and tighten bolts.
- Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
Install 4WD switch.
- Apply sealant to switch threads.
- Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
  
  Fig 34: Attaching Rear Case To Center Case
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install the companion flange and the companion flange nut.
- Tighten the companion flange nut to specification. Refer to " GEAR COMPONENTS " .
  
  Fig 35: Installing Companion Flange And Companion Flange Nut
  Courtesy of NISSAN MOTOR CO., U.S.A.