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Home >> Infiniti >> 2011 >> EX35 Base, AWD >> Repair and Diagnosis >> Transmission >> Transfer Case >> Unit Disassembly And Assembly >> Front Case And Rear Case >> Assembly
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Front Case And Rear Case: Assembly

  1. Install breather tube to rear case within the angle (A) shown as follows.

    Angle (A) : 80 - 100° 

    CAUTION: Never reuse breather tube.
  2. Install baffle plate to rear case.
  3. Install rear bearing to rear case.
    CAUTION: Never use tools. Always install by hand.
    Fig 1: Installing Breather Tube To Rear Case
    G05979369Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install snap ring (1) to rear case.
    CAUTION: Never reuse snap ring.
    Fig 2: Identifying Rear Case Snap Ring
    G05979367Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install main shaft assembly to rear case with the drift (A) [SST: ST35321000 (-)].
    CAUTION: Apply transfer fluid to the sliding surface of main shaft and needle bearing.
  6. Install O-ring to AWD solenoid harness connector.
    CAUTION:
    • Never reuse O-ring.
    • Apply transfer fluid to O-ring.
    Fig 3: Installing Main Shaft Assembly To Rear Case With Drift
    G05979371Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install AWD solenoid harness connector into rear case.
  8. Install retainer to AWD solenoid harness connector.
  9. Hold electric controlled coupling harness (1) with oil cover hold plate (2), install oil cover (3) to rear case (4).
    Fig 4: Identifying Electric Controlled Coupling Harness, Oil Cover Hold Plate, Oil Cover And Rear Case
    G06626637Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install transfer fluid temperature sensor (1) to rear case.
    Fig 5: Identifying Transfer Fluid Temperature Sensor
    G06626629Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Set drive chain to front drive shaft.
    CAUTION: Identification mark (A) of drive chain should be in the side of front bearing (1) of front drive shaft.
  12. Install drive chain to main shaft, and then install front drive shaft.
    CAUTION: Never use tools. Always install by hand.
  13. Install oil pump to main shaft.
    Fig 6: Identifying Drive Chain Identification Mark And Front Drive Shaft Front Bearing
    G05727203Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install spacer (1) and steel ball (2) to main shaft.
    Fig 7: Identifying Main Shaft Spacer And Steel Ball
    G05979363Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install snap ring (1) to main shaft.
    CAUTION:
    • Never reuse snap ring.
    • Never damage main shaft.
  16. Install main shaft bearing to front case.
    CAUTION: Never use tools. Always install by hand.
    Fig 8: Identifying Main Shaft Snap Ring
    G05979362Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install snap ring (1) to front case.
    CAUTION:
    • Never reuse snap ring.
    • Never damage front case.
    Fig 9: Identifying Front Case Snap Ring
    G05979361Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Apply liquid gasket (1) to mating surface of rear case. Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
    CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
  19. Set front case to rear case.
    CAUTION: Never damage the mating surface transmission side.
    Fig 10: Applying Liquid Gasket To Mating Surface Of Rear Case
    G05979378Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Tighten front case and rear case fixing bolts.
    BOLT SPECIFICATION

    Bolts symbol Quantity
    A 14
    T (TORX bolt) 1
    *: With harness bracket.
  21. Install spacer to main shaft.
    CAUTION: Apply transfer fluid to spacer.
    Fig 11: Identifying Front Case And Rear Case Fixing Bolts
    G05979359Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Apply transfer fluid to outside of rear oil seal, and install rear oil seal to rear case with the drifts within the dimension (L) shown as follows.

    L : 6.7 - 7.3 mm (0.264 - 0.287 in) 

    Fig 12: Installing Rear Oil Seal
    G06329984Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Never reuse rear oil seal.
    • Apply petroleum jelly to oil seal lip.
    • When installing, never incline rear oil seal.
  23. Install companion flange while aligning the matching mark (A) of main shaft with the mark (B) of companion flange.
    Fig 13: Identifying Matching Mark On End Of Main Shaft And Companion Flange
    G05727164Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Tighten self-lock nut to the specified torque with flange wrench (A) (commercial service tool).
    CAUTION: Never reuse self-lock nut.
    Fig 14: Tightening Companion Flange Self-Lock Nut Using Flange Wrench
    G05979336Courtesy of NISSAN MOTOR CO., U.S.A.
  25. Apply transfer fluid to outside of main shaft oil seal, and install main shaft oil seal until it is flush with the end face of front case with the drift (A) [SST: ST30720000 (J-25405)].
    CAUTION:
    • Never reuse main shaft oil seal.
    • Apply petroleum jelly to oil seal lip.
    • When installing, never incline main shaft oil seal.
    Fig 15: Installing Main Shaft Oil Seal With Drift
    G05979383Courtesy of NISSAN MOTOR CO., U.S.A.
  26. Apply transfer fluid to outside of front oil seal, and install front oil seal until it is flush with the end face of front case with the drift (A) [SST: ST27862000 (-)].
    CAUTION:
    • Never reuse front oil seal.
    • Apply petroleum jelly to oil seal lip.
    • When installing, never incline front oil seal.
    Fig 16: Installing Front Oil Seal To End Face Of Front Case With Drift
    G05979384Courtesy of NISSAN MOTOR CO., U.S.A.
  27. Set gasket to drain plug. Install it to rear case.
    CAUTION: Never reuse gasket.
  28. Set gasket to filler plug. Install it to rear case.
CAUTION:
  • Never reuse gasket.
  • After oil is filled, tighten filler plug to specified torque.
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