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Disassembly And Assembly: Disassembly

WARNING: This page is about a different car, the 2004 Nissan Titan. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove drain plug and filler plug.
  2. Remove transfer control device from rear case.
  3. Remove O-ring form transfer control device.
    Fig 1: Removing Transfer Control Device
    G00728882Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Remove self-lock nut.
  5. Put a matchmark on top of front drive shaft thread. The mark should be in line with the mark on the companion flange.
    CAUTION: Always mark top of front drive shaft screw using paint.
    Fig 2: Marking Front Drive Shaft & Companion Flange
    G00728883Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Remove companion flange, using a puller.
    Fig 3: Removing Companion Flange
    G00728884Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Remove front oil seal from front case, using puller.
    1. Tool number : ST33290001 (J34286) 
    CAUTION: Be careful not to damage the front case.
    Fig 4: Removing Front Oil Seal
    G00728885Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Remove 4LO switch [gray (with green paint)] and ATP switch (black) from front case.
    Fig 5: Removing Switches
    G00728886Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Remove wait detection switch (gray) from rear case.
    Fig 6: Removing Wait Detection Switch
    G00728887Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Remove dust cover from rear case, using a brass rod.
    CAUTION: Be careful not to damage the rear case.
    Fig 7: Removing Dust Cover
    G00728888Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Remove rear oil seal from rear case, using puller.
    CAUTION: Be careful not to damage the rear case.

    Tool number : ST33290001 (J34286)

    Fig 8: Removing Rear Oil Seal
    G00728889Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Remove input oil seal from front case, using a flat-bladed screwdriver.
    CAUTION: Be careful not to damage the front case and sun gear and input bearing.
    Fig 9: Removing Input Oil Seal
    G00728890Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Remove retainer fixing bolts and gaskets.
    Fig 10: Removing Retainer Fixing Bolts
    G00728891Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Remove rear case mounting bolts and harness bracket from rear case.
    Fig 11: Removing Rear Case Mounting Bolts
    G00728892Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Separate front case and rear case. Then remove rear case by levering it up with tire lever or the like.
    CAUTION: Be careful not to damage the mating surface.
  16. Remove spacer from control shift rod.
    CAUTION: Be careful not to drop spacer.
    Fig 12: Separating Front Case And Rear Case
    G00728893Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Remove snap ring from mainshaft.
    Fig 13: Removing Snap Ring
    G00728894Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Remove the mainshaft rear bearing from mainshaft, using pullers.
  19. Remove retainer from mainshaft.
    Fig 14: Removing Mainshaft Rear Bearing
    G00728895Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Remove snap ring from mainshaft.
  21. Remove oil pump assembly from mainshaft.
    Fig 15: Removing Snap Ring & Oil Pump Assembly
    G00728896Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Remove snap ring from mainshaft.
  23. Remove clutch gear from mainshaft.
    Fig 16: Removing Clutch Gear
    G00728897Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Remove snap ring from L-H shift rod assembly.
  25. Remove 2-4 sleeve and 2-4 shift fork assembly from mainshaft.
    Fig 17: Removing 2-4 Sleeve And 2-4 Shift Fork Assembly
    G00728898Courtesy of NISSAN MOTOR CO., U.S.A.
  26. Remove drive chain together with sprocket and front drive shaft from front case.
  27. Remove spacer and needle bearing from mainshaft.
  28. Remove mainshaft from sun gear assembly.
  29. Remove L-H shift rod assembly and control shift rod assembly from front case.
  30. Remove L-H sleeve together with L-H shift fork assembly from planetary carrier assembly.
    Fig 18: Removing Drive Chain
    G00728899Courtesy of NISSAN MOTOR CO., U.S.A.
  31. Remove snap ring from sun gear.
    CAUTION: Be careful not to damage the sun gear and input bearing.
    Fig 19: Removing Snap Ring
    G00728900Courtesy of NISSAN MOTOR CO., U.S.A.
  32. Remove the sun gear assembly from front case with a press, using drift.
    1. Tool number : KV38100200 (-) 
    Fig 20: Removing The Sun Gear Assembly
    G00728901Courtesy of NISSAN MOTOR CO., U.S.A.
  33. Remove snap ring from front case.
    Fig 21: Removing Snap Ring
    G00728902Courtesy of NISSAN MOTOR CO., U.S.A.
  34. Remove internal gear from front case.
    Fig 22: Removing Internal Gear
    G00728903Courtesy of NISSAN MOTOR CO., U.S.A.
  35. Remove snap ring from front case.
    Fig 23: Removing Snap Ring
    G00728904Courtesy of NISSAN MOTOR CO., U.S.A.
  36. Remove the input bearing from front case, using a drift.
    1. Tool number : KV38100200 (-) 
    Fig 24: Removing Input Bearing
    G00728905Courtesy of NISSAN MOTOR CO., U.S.A.
  37. Remove baffle plate from front case.
  38. Remove the breather tube from front case.
Fig 25: Removing Baffle Plate
G00728906Courtesy of NISSAN MOTOR CO., U.S.A.
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