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Transfer Case: Assembly

  1. Select the gear ring bearing adjusting shim (transfer case side). Refer to "ADJUSTMENT ".
  2. Install the selected gear ring bearing adjusting shim (transfer side) and gear ring bearing outer race (transfer side) to the transfer case with drifts (A and B).
    Fig 1: Installing Selected Gear Ring Bearing Adjusting Shim And Outer Race (Transfer Side) Using Drifts
    G08856052Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Apply gear oil to the drive pinion bearing (transfer side).
    • Never reuse drive pinion bearing (transfer side).
  3. Install the oil defense, and tighten the mounting bolts to the specified torque. Refer to "EXPLODED VIEW ". The clearance (A) between the oil defense and transfer case should be the following.

    Clearance between oil defense and transfer case 

    A: 1.0 - 3.5 mm (0.04 - 0.138 in) 

    Fig 2: Identifying Clearance Between Oil Defense And Transfer Case
    G04921301Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Never reuse mounting bolts.
  4. Install the transfer case oil seal until it becomes flush with the case end with drift (A) [SST: ST30720000 (J-25405)].
    CAUTION:
    • When checking the total preload torque, measure it without the oil seal, then install the oil seal.
    • Never reuse oil seal.
    • Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of the oil seal.
    • Use the drift with larger diameter than outer diameter of oil seal.
    Fig 3: Installing Transfer Case Oil Seal Using Drift
    G05892815Courtesy of NISSAN NORTH AMERICA, INC.
  5. Apply sealant to filler plug and plug before installing them to the transfer case. Refer to "EXPLODED VIEW ".

    Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

  6. Install breather tube to the transfer case.
    CAUTION: Never reuse breather tube.
  7. Install drive gear assembly. Refer to "ASSEMBLY ".
  8. Install adapter case. Refer to "ASSEMBLY ".
  9. Install drive pinion assembly. Refer to "ASSEMBLY ".
  10. Install air breather hose.
    CAUTION:
    • Check that there are no pinched or restricted areas on the breather hose caused by bending or winding when installing it.
    • Be sure to insert air breather hose into breather tube (metal connector) until hose end reaches the tube's base.
    • Be sure to insert air breather hose in the hole of the transfer case.
  11. Check backlash, tooth contact, total preload and companion flange runout. Refer to "ADJUSTMENT ".
    CAUTION: Measure the total preload without the adapter case oil seals.
    Fig 4: Identifying Air Breather Hose And Tube
    G04875624Courtesy of NISSAN NORTH AMERICA, INC.
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