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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2006 Nissan Titan. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install breather tube.
    CAUTION: Install breather tube in the direction shown.
    Fig 1: Identifying Breather Tube
    G04186474Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install baffle plate to front case, and tighten bolt to the specified torque. Refer to "COMPONENTS ".
    CAUTION: Install baffle plate by pushing it in the direction shown while tightening the bolt.
    Fig 2: Identifying Baffle Plate
    G04186475Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install the input bearing to front case, using Tool.

    Tool number: ST30720000 (J-25405) 

    Fig 3: Installing Input Bearing To Front Case Using Tool
    G04186476Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install new snap ring to front case.
    CAUTION: Do not reuse snap ring.
    Fig 4: Identifying Snap Ring To Front Case
    G04186477Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install internal gear with groove facing up into front case.
    Fig 5: Identifying Internal Gear
    G04186478Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install new snap ring to front case.
    CAUTION: Do not reuse snap ring.
    Fig 6: Identifying Snap Ring To Front Case
    G04186479Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install the planetary carrier assembly and sun gear assembly to front case, using Tool.

    Tool number: KV38100200 ( - ) 

    Fig 7: Identifying Planetary Carrier Assembly And Sun Gear Assembly
    G04186480Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install new snap ring to sun gear.
    CAUTION:
    • Do not reuse snap ring.
    • Do not damage the sun gear.
      Fig 8: Identifying Snap Ring To Sun Gear
      G04186481Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Set L-H sleeve together with L-H shift fork assembly onto planetary carrier assembly.
    Fig 9: Setting L-H Sleeve Together With L-H Shift Fork Assembly Onto Planetary Carrier Assembly
    G04186482Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install control shift rod assembly to front case.
    CAUTION: Set pin of L-H shift fork assembly into the groove of drum cam.
  11. Turn control shift rod assembly fully counterclockwise.
    Fig 10: Setting Pin Of L-H Shift Fork Assembly Into Groove Of Drum Cam
    G04186483Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install L-H shift rod assembly through L-H shift fork assembly opening to front case.
    CAUTION: Set pin of L-H shift rod assembly into the groove of drum cam.
    13. Fig 11: Setting Pin Of L-H Shift Rod Assembly Into Groove Of Drum Cam
    G04186484Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install mainshaft to sun gear assembly.
  14. Apply ATF to spacer and periphery of needle bearing, install to mainshaft.
  15. Set front drive shaft and sprocket to drive chain.
    CAUTION: Identification mark of drive chain should be on the side of rear bearing of front drive shaft.
    Fig 12: Locating Identification Mark Of Drive Chain
    G04186485Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Install drive chain together with front drive shaft and sprocket to front case.
    Fig 13: Identifying Drive Chain, Sprocket And Front Drive Shaft
    G04186486Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install 2-4 sleeve and 2-4 shift fork assembly to mainshaft.
    CAUTION:
    • Install with proper orientation of 2-4 sleeve.
    • Install 2-4 shift fork with engaging the grooves of 2-4 shift fork in the retaining pin of 2-4 shift bracket.
      Fig 14: Installing 2-4 Sleeve And 2-4 Shift Fork Assembly To Mainshaft
      G04186487Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install new snap ring to L-H shift rod assembly, using suitable tool.
    CAUTION: Do not reuse snap ring.
  19. Install clutch gear to mainshaft.
    Fig 15: Identifying Snap Ring To L-H Shift Rod Assembly
    G04186488Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Install new snap ring to mainshaft, using suitable tool.
    CAUTION: Do not reuse snap ring.
  21. Install oil pump assembly to mainshaft.
    Fig 16: Identifying Snap Ring & Clutch Gear
    G04186489Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Install new snap ring to mainshaft, using suitable tool.
    CAUTION: Do not reuse snap ring.
    Fig 17: Identifying Snap Ring To Mainshaft
    G04186490Courtesy of NISSAN MOTOR CO., U.S.A.
  23. Install retainer to mainshaft.
    CAUTION: Set the projection of oil pump assembly to identification hole, and then align locating hole of retainer to L-H shift rod assembly.
    Fig 18: Installing Retainer To Mainshaft
    G04186491Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Install the mainshaft rear bearing to mainshaft, using Tool.

    Tool number: KV32102700 ( - ) 

    Fig 19: Installing Mainshaft Rear Bearing To Mainshaft
    G04186492Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Do not push too hard in order to avoid snap rings becoming dislodged from mainshaft.
  25. Install new snap ring to mainshaft, using suitable tool.
    Fig 20: Installing Snap Ring To Mainshaft
    G04186493Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Do not reuse snap ring.
  26. Install spacer to control shift rod.
  27. Apply liquid gasket to mating surface of front case.
    Fig 21: Installing Spacer To Control Shift Rod
    G04186494Courtesy of NISSAN MOTOR CO., U.S.A.
    • Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to " RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS  ". 
      CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.
  28. Install rear case to front case.
  29. Tighten bolts to specified torque. Refer to "COMPONENTS ".
    Fig 22: Identifying Rear Case Bolts
    G04186495Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Be sure to install the harness brackets and air breather hose clamp.
  30. Install the retainer bolts with new gaskets. Tighten the bolts to the specified torque. Refer to "COMPONENTS ".
    Fig 23: Identifying Retainer Bolts & Gaskets
    G04186496Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse gasket.
    • Tighten them to the specified torque again.
  31. Install new input oil seal to front case, using Tools.
    Fig 24: Installing Input Oil Seal To Front Case
    G04186497Courtesy of NISSAN MOTOR CO., U.S.A.

    Dimension A: 4.0 - 4.6 mm (0.157 - 0.181 in) 

    Tool number A: ST30720000 (J-25405) 

    B: KV40104830 ( - ) 

    CAUTION:
    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal.
  32. Install new rear oil seal until it is flush with end face of rear case, using Tool.
    Fig 25: Installing Rear Oil Seal
    G04186498Courtesy of NISSAN MOTOR CO., U.S.A.

    Tool number: KV38100500 ( - ) 

    CAUTION:
    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal.
  33. Apply petroleum jelly to the circumference of the new dust cover. Position the new dust cover using the identification mark as shown.
    Fig 26: Identifying Dust Cover Identification Mark
    G04186499Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse dust cover.
    • Position the identification mark at the position shown.
  34. Install new dust cover to the rear case, using Tool.
    Fig 27: Installing Dust Cover To Rear Case
    G04186500Courtesy of NISSAN MOTOR CO., U.S.A.

    Tool number: KV40105310 ( - ) 

    CAUTION:
    • Do not reuse dust cover.
    • Apply petroleum jelly to dust cover.
  35. Apply sealant to threads of wait detection switch (gray). Then install it to rear case and tighten to the specified torque. Refer to "COMPONENTS ".
    Fig 28: Applying Sealant To Threads Of Wait Detection Switch
    G04186501Courtesy of NISSAN MOTOR CO., U.S.A.
  36. Apply sealant to threads of 4LO switch (gray with green paint) and ATP switch (black). Then install them to front case and tighten to the specified torque. Refer to "COMPONENTS ".
    Fig 29: Applying Sealant To Threads Of 4LO Switch And ATP Switch
    G04186502Courtesy of NISSAN MOTOR CO., U.S.A.
  37. Install new front oil seal until it is flush with end face of front case, using Tool.
    Fig 30: Installing Front Oil Seal
    G04186503Courtesy of NISSAN MOTOR CO., U.S.A.

    Tool number: KV38100500 ( - ) 

    CAUTION:
    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal.
  38. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.
    Fig 31: Aligning Matching Mark On Front Drive Shaft
    G04186504Courtesy of NISSAN MOTOR CO., U.S.A.
  39. Tighten new self-lock nut to the specified torque, using Tool. Refer to "COMPONENTS ".

    Tool number: KV40104000 ( - ) 

    Fig 32: Installing Companion Flange Self-Lock Nut
    G04186505Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Do not reuse self-lock nut.
  40. Install new O-ring to transfer control device.
    Fig 33: Identifying O-Ring To Transfer Control Device
    G04186506Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse O-ring.
    • Apply petroleum jelly.
  41. Install transfer control device to rear case.
    1. Turn control shift rod fully counterclockwise using flat-bladed screwdriver, and then put a mark on control shift rod.
      Fig 34: Turning Control Shift Rod Fully Counterclockwise & Putting Mark On Control Shift Rod
      G04186507Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Align transfer control device shaft cutout with mark on control shift rod, and install.
      Fig 35: Aligning Transfer Control Device Shaft Cutout With Mark On Control Shift Rod
      G04186508Courtesy of NISSAN MOTOR CO., U.S.A.
      NOTE: Turn transfer control device when transfer control device connection does not match.
    3. Tighten bolts to the specified torque. Refer to "COMPONENTS ".
      Fig 36: Identifying Transfer Control Device Bolts
      G04186509Courtesy of NISSAN MOTOR CO., U.S.A.
  42. Install the drain plug and filler plug with new gaskets to the rear case. Tighten to the specified torque. Refer to "COMPONENTS ".
    CAUTION: Do not reuse gasket.
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