Section 4 (Transfer Case): Disassembly

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

Remove companion flange nut.
Remove companion flange.

Fig 1: Removing Companion Flange Nut
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove 4WD switch.
Remove rear case.
- Be careful not to damage the mating surface.
  
  Fig 2: Removing Rear Case
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove oil cover and oil gutter.
Remove snap ring and retainer ring from 2-4 shift rod.

Fig 3: Removing Oil Cover, Oil Gutter And Snap Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Using calipers, measure the difference between front drive sprocket and 2-4 coupling sleeve as outlined under measuring method below. If it is outside specifications, check front drive sprocket, 2-4 coupling sleeve, clutch gear, 2-4 shift fork and 2-4 fork rod for abnormalities. Replace faulty part(s) as required.
Measuring method

Move coupling sleeve until it is in contact with sprocket, then measure dimension A. Move coupling sleeve until it is in contact with clutch gear, then measure dimension B. Obtain dimension difference C between two measurements A and B.

A - B = C

To determine dimension A, measure at 3 or 4 different points by rotating sprocket and obtain average value of 3 or 4 measurements.

Specification C: Refer to " CLEARANCE BETWEEN FRONT DRIVE SPROCKET AND 2-4 COUPLING SLEEVE " .

Fig 4: Measuring Difference Between Front Drive Sprocket And 2 - 4 Coupling Sleeve
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove bolts securing bearing retainer.
- This step is necessary to remove mainshaft from center case.
  
  Fig 5: Removing Bolts Securing Bearing Retainer Using Torx Wrench
  Courtesy of NISSAN MOTOR CO., U.S.A.
Remove bolts securing center case to front case and then separate center case and front case.

Fig 6: Separating Center Case And Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Measure low gear end play.
Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in)
- If end play is beyond the maximum value, check low gear and L & H hub for wear.
  
  Fig 7: Measuring Low Gear End Play
  Courtesy of NISSAN MOTOR CO., U.S.A.
Disassemble center case assembly.
1. Remove snap ring from mainshaft.
  
  Fig 8: Removing Snap Ring From Mainshaft Using Plier
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Pull out low gear with L & H hub.
  
  Fig 9: Pulling Out Low Gear With L And H Hub
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Remove needle bearing from main shaft.
  
  Fig 10: Removing Needle Bearing From Main Shaft
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Make note of the direction of the drive chain before removing it. (It must be reinstalled in the same direction.)
  
  Fig 11: Removing Driving Chain
  Courtesy of NISSAN MOTOR CO., U.S.A.
5. Remove mainshaft, front drive and drive chain as a set by tapping front end of mainshaft and front drive shaft alternately.
  - Be careful not to bend drive chain.
    
    Fig 12: Removing Mainshaft, Front Drive And Drive Chain
    Courtesy of NISSAN MOTOR CO., U.S.A.
Disassemble front case assembly.
1. Remove transfer neutral position switch, plug, check springs and check balls.
  
  Fig 13: Removing Transfer Neutral Position Switch And Plug
  Courtesy of NISSAN MOTOR CO., U.S.A.
2. Remove lock pin from outer shift lever, then remove outer shift lever.
  
  Fig 14: Removing Lock Pin From Outer Shift Lever
  Courtesy of NISSAN MOTOR CO., U.S.A.
3. Remove lock pin of inner shift lever and drive out cross shaft with plug.
  
  Fig 15: Removing Lock Pin Of Inner Shift Lever
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Remove 2-4 shift rod.
  
  Fig 16: Removing 2-4 Shift Rod
  Courtesy of NISSAN MOTOR CO., U.S.A.
5. Remove L & H shift rod and fork assembly with coupling sleeve.
  
  Fig 17: Removing L And H Shift Rod And Fork Assembly With Coupling Sleeve
  Courtesy of NISSAN MOTOR CO., U.S.A.
6. Remove needle bearing from main gear.
  
  Fig 18: Removing Needle Bearing From Main Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
7. Remove bolts securing front case cover and then remove case.
  
  Fig 19: Removing Bolts Securing Front Case Cover And Case
  Courtesy of NISSAN MOTOR CO., U.S.A.
8. Remove counter gear by tapping lightly.
  
  Fig 20: Removing Counter Gear
  Courtesy of NISSAN MOTOR CO., U.S.A.
9. Remove main gear by tapping lightly.
  
  Fig 21: Removing Main Gear By Tapping Lightly
  Courtesy of NISSAN MOTOR CO., U.S.A.