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Home › Nissan-Datsun › 2005 › Armada LE, 4WD › Repair and Diagnosis › Transmission › Transfer Case › Transfer Assembly › Disassembly and Assembly › Assembly › Front Case

Front Case

  1. Install the carrier bearing to the sun gear, using Tools.
    • Tool number A: ST30911000 (-) 

      B: KV31103300 (-) 

    Fig 1: Installing Carrier Bearing To Sun Gear Using Tools
    G02444895Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install the snap ring to the sun gear assembly, using suitable tool.
    CAUTION: Do not reuse snap ring. 
    Fig 2: Installing Snap Ring To Sun Gear Assembly Using Suitable Tool
    G02444896Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Apply ATF to the circumference of the metal bushing and install it to the sun gear assembly, using Tool.
    • Dimension A: 7.7 - 8.3 mm (0.303 - 0.327 in) 
    • Tool number: ST35300000 (-) 
    CAUTION:
    • Do not reuse metal bushing. 
    • Apply ATF to metal bushing before installing. 
    Fig 3: Installing Metal Bushing To Sun Gear Assembly
    G02444897Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Apply ATF to the needle bearing and install it to the sun gear assembly, using Tool.
    • Dimension B: 62.5 - 63.1 mm (2.461 - 2.484 in) 
    • Tool number: ST33220000 (-) 
    CAUTION:
    • Do not reuse needle bearing. 
    • Apply ATF to needle bearing before installing. 
    Fig 4: Installing Needle Bearing To Sun Gear Assembly
    G02444898Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install the sun gear assembly to the planetary carrier assembly.
    Fig 5: Installing Sun Gear Assembly To Planetary Carrier Assembly
    G02444899Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install the snap ring to the planetary carrier assembly.
    CAUTION: Do not reuse snap ring. 
    Fig 6: Installing Snap Ring To Planetary Carrier Assembly
    G02444900Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Set the mainshaft front bearing into the front case and install, using Tool.
    • Tool number: ST30720000 (J-25405) 
    Fig 7: Installing Mainshaft Front Bearing Into Front Case
    G02444901Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install the snap ring into the front case.
    CAUTION: Do not reuse snap ring. 
    Fig 8: Installing Snap Ring Into Front Case
    G02444902Courtesy 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 snap ring.
    CAUTION: Do not reuse snap ring. 
    Fig 9: Installing Internal Gear With Its Groove Facing Snap Ring Into Front Case
    G02444903Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install new 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 10: Installing Oil Seal
    G02444904Courtesy 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 11: Installing Planetary Carrier Assembly & Sun Gear Assembly To Front Case
    G02444905Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install the snap ring to the sun gear assembly.
    CAUTION: Do not reuse snap ring. 
    Fig 12: Installing Snap Ring To Sun Gear Assembly
    G02444906Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Apply petroleum jelly to the circumference of the oil seal, and install it to the front case, using Tools.
    • Dimension: 4.0 - 4.6 mm (0.157 - 0.181 mm) 
    • Tool number A: ST30720000 (J-25405) 

      B: ST33200000 (J-26082) 

    CAUTION:
    • Do not reuse oil seal. 
    • Apply petroleum jelly to oil seal. 
    Fig 13: Installing Oil Seal To Front Case
    G02444907Courtesy 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 retaining pins.
    CAUTION: Do not reuse retaining pins. 
    Fig 14: Installing Fork Guide, Shift Fork Spring, 2-4 Fork & L-H Fork To Shift Rod
    G02444908Courtesy 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 15: Installing Shift Cross To Front Case
    G02444909Courtesy of NISSAN MOTOR CO., U.S.A.
  17. While aligning the L-H sleeve with the planetary carrier, install the shift rod assembly to the front case.
    Fig 16: Installing Shift Rod Assembly To Front Case
    G02444910Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Apply liquid gasket to the entire center case mounting surface of the front case assembly as shown.
    CAUTION: Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces. 
    Fig 17: Identifying Liquid Gasket Application Surface
    G02444911Courtesy 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 18: Installing Center Case Assembly To Front Case Assembly
    G02444912Courtesy of NISSAN MOTOR CO., U.S.A.
  21. Tighten the front case bolts to the specified torque. Refer to COMPONENTS .
    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 19: Tightening Front Case Bolts
    G02444913Courtesy 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 20: Installing Companion Flange
    G02444914Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Install the companion flange self-lock nut. Tighten to the specified torque, using Tool. Refer to COMPONENTS .
    • Tool number: KV40104000 (-) 
    CAUTION: Do not reuse self-lock nut. 
    Fig 21: Installing Companion Flange Self-Lock Nut
    G02444915Courtesy 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 mounting 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 silicone gasket, to the check plug and wait detection switch and install them to the front case. Tighten to the specified torque. Refer to COMPONENTS .
    Fig 22: Removing Sealant From Check Plug
    G02444916Courtesy of NISSAN MOTOR CO., U.S.A.
    NOTE: Wait detection switch harness connector is black.
  27. Install the 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 COMPONENTS .
    Fig 23: Installing Oil Seal In Front Case
    G02444917Courtesy of NISSAN MOTOR CO., U.S.A.
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