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Transfer Assembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. Remove companion flange nut and companion flange using Tool, as shown in Fig 1.
    Fig 1: Removing Companion Flange Nut And Companion Flange Using Tool
    G00782233Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Remove 4WD switch.
  3. Remove rear case using screwdriver or suitable tool, as shown in Fig 2.
    • Be careful not to damage the mating surface. 
    Fig 2: Removing Rear Case Using Screwdriver
    G00782234Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Remove oil cover and oil gutter.
  5. Remove snap ring and retainer ring from 2-4 shift rod.
    Fig 3: Removing Oil Cover And Oil Gutter
    G00782235Courtesy of NISSAN MOTOR CO., U.S.A.
  6. 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: 

    1. 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.
    2. A - B = C
    3. To determine dimension A, measure at 3 or 4 different points by rotating sprocket and obtain average value of 3 or 4 measurements.
    4. 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
    G00782236Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Remove bolts securing bearing retainer.
    • This step is necessary to remove mainshaft from center case. 
    Fig 5: Removing Bolts Securing Bearing Retainer
    G00782237Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Remove bolts securing center case to front case and then separate center case and front case using screwdriver or suitable tool, as shown in Fig 6.
    • Be careful not to damage the mating surface. 
    Fig 6: Removing Bolts Securing Center Case
    G00782238Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Measure low gear end play.
    1. Low gear end play : 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
    G00782239Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Disassemble center case assembly.
    1. Remove snap ring from mainshaft.
      Fig 8: Removing Snap Ring From Mainshaft
      G00782240Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Pull out low gear with L & H hub using Tool, as shown in Fig 9.
      Fig 9: Pulling Out Low Gear With L & H Hub Using Tool
      G00782241Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Remove needle bearing from mainshaft.
      Fig 10: Removing Needle Bearing From Mainshaft
      G00782242Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Make sure of the direction of the drive chain before removing it.

      It must be reinstalled in the same direction. 

      Fig 11: Identifying Drive Chain Direction
      G00782243Courtesy 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 using a soft hammer, as shown in Fig 12.
      CAUTION: Be careful not to bend drive chain.
      Fig 12: Removing Mainshaft, Front Drive And Drive Chain
      G00782244Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Disassemble front case assembly.
    1. Remove transfer neutral position switch, plugs, check springs and check balls.
      Fig 13: Removing Transfer Neutral Position Switch, Plugs, Check Springs And Check Balls
      G00782245Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Remove lock pin from outer shift lever using a drift or suitable tool, as shown in Fig 14. Then remove outer shift lever.
      Fig 14: Removing Lock Pin From Outer Shift Lever Using Drift
      G00782246Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Remove lock pin of inner shift lever and drive out cross shaft with plug using a soft hammer, as shown in Fig 15.
      Fig 15: Removing Lock Pin Of Inner Shift Lever And Drive Out Cross Shaft With Plug Using Soft Hammer
      G00782247Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Remove 2-4 shift rod.
      Fig 16: Removing 2-4 Shift Rod
      G00782248Courtesy of NISSAN MOTOR CO., U.S.A.
    5. Remove L & H shift rod and fork assembly with coupling sleeve.
      Fig 17: Removing L & H Shift Rod And Fork Assembly With Coupling Sleeve
      G00782249Courtesy of NISSAN MOTOR CO., U.S.A.
    6. Remove needle bearing from main gear.
      Fig 18: Removing Needle Bearing From Main Gear
      G00782250Courtesy of NISSAN MOTOR CO., U.S.A.
    7. Remove bolts securing front case cover and then remove case using screwdriver or suitable tool.
      • Be careful not to damage the mating surface. 
      Fig 19: Removing Bolts Securing Front Case Cover
      G00782251Courtesy of NISSAN MOTOR CO., U.S.A.
    8. Remove counter gear by tapping lightly using a soft hammer, as shown in Fig 20.
      Fig 20: Removing Counter Gear By Tapping Lightly Using Soft Hammer
      G00782252Courtesy of NISSAN MOTOR CO., U.S.A.
    9. Remove main gear by tapping lightly using a soft hammer, as shown in Fig 21.
    Fig 21: Removing Main Gear By Tapping Lightly Using Soft Hammer
    G00782253Courtesy of NISSAN MOTOR CO., U.S.A.
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