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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2005 Nissan Xterra. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the breather tube.
    CAUTION: Install breather tube in the direction shown.
    Fig 1: Installing Breather Tube
    G03608380Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install the baffle plate to the front case. Tighten the 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: Installing Baffle Plate To Front Case
    G03608381Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install the input bearing to the front case, using Tool.

    Tool number: ST30720000 (J-25405) 

    Fig 3: Installing Input Bearing To Front Case, Using Tool
    G03608382Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install the new snap ring to the front case.
    CAUTION: Do not reuse snap ring.
    Fig 4: Installing Snap Ring To Front Case
    G03608383Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install the internal gear with the groove facing up into the front case.
    Fig 5: Installing Internal Gear With Groove Facing Up Into Front Case
    G03608384Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install the new snap ring to the front case.
    CAUTION: Do not reuse snap ring.
    Fig 6: Installing Snap Ring To Front Case
    G03608385Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install the planetary carrier assembly and sun gear assembly to the front case, using Tool.

    Tool number: KV38100200 (-) 

    Fig 7: Installing Planetary Carrier Assembly And Sun Gear Assembly To Front Case, Using Tool
    G03608386Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install the new snap ring to the sun gear.
    CAUTION:
    • Do not reuse snap ring.
    • Do not damage sun gear.
      Fig 8: Installing Snap Ring To Sun Gear
      G03608387Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Set the L-H sleeve together with the L-H shift fork assembly onto the planetary carrier assembly.
    Fig 9: Installing L-H Sleeve Together With L-H Shift Fork Assembly Onto Planetary Carrier Assembly
    G03608388Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install the control shift rod assembly to the front case.
    CAUTION: Set pin of L-H shift fork assembly into the groove of drum cam.
  11. Turn the control shift rod assembly to the fully counterclockwise.
    Fig 10: Installing Control Shift Rod Assembly To Front Case
    G03608389Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Install the L-H shift rod assembly through the L-H shift fork assembly opening to the front case.
    CAUTION: Set pin of L-H shift rod assembly into the groove of drum cam.
  13. Install the mainshaft to the sun gear assembly.
    Fig 11: Installing Mainshaft To Sun Gear Assembly
    G03608390Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Install the drive chain to the front drive shaft and sprocket.
    CAUTION: Install with the Identification mark of drive chain on the side of the rear bearing of front drive shaft.
    Fig 12: Identifying Mark On Rear Bearing
    G03608391Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install the drive chain together with the front drive shaft and sprocket to the front case.
    Fig 13: Installing Drive Chain To Front Case
    G03608392Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Install the 2-4 sleeve and 2-4 shift fork assembly to the 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
      G03608393Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install the new snap ring to the L-H shift rod assembly, using suitable tool.
    CAUTION: Do not reuse snap ring.
  18. Install the clutch gear to the mainshaft.
    Fig 15: Installing Snap Ring To L-H Shift Rod Assembly, Using Suitable Tool (Clutch Gear)
    G03608394Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Install the new snap ring to the mainshaft, using suitable tool.
    CAUTION: Do not reuse snap ring.
  20. Install the oil pump assembly to the mainshaft.
    Fig 16: Installing Snap Ring To Mainshaft, Using Suitable Tool (Oil Pump)
    G03608395Courtesy of NISSAN MOTOR CO., U.S.A.
  21. Install the new snap ring to the mainshaft, using suitable tool.
    CAUTION: Do not reuse snap ring.
    Fig 17: Installing Snap Ring To Mainshaft, Using Suitable Tool
    G03608396Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Install the retainer to the mainshaft.
    CAUTION: Set the projection of oil pump assembly to the identification hole, and then align locating hole of retainer to the L-H shift rod assembly.
    Fig 18: Aligning Locating Hole Of Retainer To L-H Shift Rod Assembly
    G03608397Courtesy of NISSAN MOTOR CO., U.S.A.
  23. Install the mainshaft rear bearing to the mainshaft, using Tool.

    Tool number: KV32102700 (-) 

    CAUTION: Do not push too hard in order to avoid snap rings becoming dislodged from mainshaft.
    Fig 19: Installing Mainshaft Rear Bearing To Mainshaft, Using Tool
    G03608398Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Install the new snap ring to the mainshaft, using suitable tool.
    CAUTION: Do not reuse snap ring.
  25. Install the spacer to the control shift rod.
    Fig 20: Installing Snap Ring To Mainshaft, Using Suitable Tool
    G03608399Courtesy of NISSAN MOTOR CO., U.S.A.
  26. Apply liquid gasket to the mating surface of the front case.
    • 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.
  27. Install the rear case to the front case.
    Fig 21: Applying Liquid Gasket To Mating Surface Of Front Case
    G03608400Courtesy of NISSAN MOTOR CO., U.S.A.
  28. Tighten the bolts to the specified torque. Refer to , "COMPONENTS ".
    CAUTION: Be sure to install the harness brackets.
    Fig 22: Tightening Front Case Bolts
    G03608401Courtesy of NISSAN MOTOR CO., U.S.A.
  29. Install the retainer bolts with new gaskets. Tighten the bolts to the specified torque. Refer to , "COMPONENTS ".
    CAUTION:
    • Do not reuse gasket.
    • Tighten them to the specified torque again.
      Fig 23: Installing Bolts
      G03608402Courtesy of NISSAN MOTOR CO., U.S.A.
  30. Apply petroleum jelly to the circumference of the new oil seal, and install it to the front case, using Tools.

    Tool number A: ST30720000 (J-25405) B: KV40104830 (-) 

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

    CAUTION:
    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal.
      Fig 24: Installing Oil Seal To Front Case, Using Tools
      G03608403Courtesy of NISSAN MOTOR CO., U.S.A.
  31. Install the new rear oil seal until it is flush with the end face of the rear case, using Tool.

    Tool number: KV38100500 (-) 

    CAUTION:
    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal.
      Fig 25: Installing Rear Oil Seal Of Rear Case, Using Tool
      G03608404Courtesy of NISSAN MOTOR CO., U.S.A.
  32. Apply petroleum jelly to the circumference of the new dust cover. Position the dust cover using the identification mark as shown.
    CAUTION:
    • Do not reuse dust cover.
    • Position the identification mark at the position shown.
      Fig 26: Positioning Dust Cover Identifying Mark
      G03608405Courtesy of NISSAN MOTOR CO., U.S.A.
  33. Install the new dust cover to the rear case, using Tool.

    Tool number: KV40105310 (-) 

    CAUTION:
    • Do not reuse dust cover.
    • Apply petroleum jelly to dust cover.
      Fig 27: Installing Dust Cover To Rear Case, Using Tool
      G03608406Courtesy of NISSAN MOTOR CO., U.S.A.
  34. Install check ball and check spring to rear case (M/T models only).
  35. Apply sealant to thread of check plug, then install it to rear case and tighten to the specified torque (M/T models only). Refer to , "COMPONENTS ".
    • Use Genuine Silicone RTV or equivalent. Refer to " RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS  "  .
      CAUTION: Remove old sealant and oil adhering to threads.
      Fig 28: Installing Check Ball And Check Spring To Rear Case
      G03608407Courtesy of NISSAN MOTOR CO., U.S.A.
  36. Apply sealant to the threads of the wait detection switch (gray). Then install it to the rear case and tighten to the specified torque. Refer to , "COMPONENTS ".
    • Use Genuine Silicone RTV or equivalent. Refer to " RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS  "  .
      CAUTION: Remove old sealant and oil adhering to threads.
      Fig 29: Installing Wait Detection Switch
      G03608408Courtesy of NISSAN MOTOR CO., U.S.A.
  37. Apply sealant to the threads of the 4LO switch (gray with green paint) and ATP switch (black). Then install them to the front case and tighten to the specified torque. Refer to , "COMPONENTS ".
    • Use Genuine Silicone RTV or equivalent. Refer to " RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS  "  .
      CAUTION: Remove old sealant and oil adhering to threads.
      Fig 30: Installing 4LO Switch And ATP Switch
      G03608409Courtesy of NISSAN MOTOR CO., U.S.A.
  38. Install the new front oil seal until it is 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.
      Fig 31: Installing Front Oil Seal Of Front Case, Using Tool
      G03608410Courtesy of NISSAN MOTOR CO., U.S.A.
  39. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.
    Fig 32: Aligning Matching Mark On Front Drive Shaft With Mark On Companion Flange
    G03608411Courtesy of NISSAN MOTOR CO., U.S.A.
  40. Install the new self-lock nut. Tighten to the specified torque, using Tool. Refer to , "COMPONENTS ".

    Tool number: KV40104000 (-) 

    CAUTION: Do not reuse self-lock nut.
    Fig 33: Tightening Self-Lock Nut
    G03608412Courtesy of NISSAN MOTOR CO., U.S.A.
  41. Install the new O-ring to the transfer control device.
    CAUTION:
    • Do not reuse O-ring.
    • Apply petroleum jelly to O-ring.
  42. Install the transfer control device to the rear case.
    1. Turn the control shift rod fully counterclockwise using suitable tool, and then put a mark on the control shift rod.
      Fig 34: Turning Control Shift Rod Identifying Mark
      G03608413Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Align the transfer control device shaft cutout with the mark on the control shift rod, and install it.
      NOTE: Turn the transfer control device when the transfer control device connection does not match.
      Fig 35: Aligning Transfer Control Device Shaft Cutout Identifying Mark On Control Shift Rod
      G03608414Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Tighten the bolts to the specified torque. Refer to , "COMPONENTS ".
      Fig 36: Tightening Transfer Control Device Bolts
      G03608415Courtesy of NISSAN MOTOR CO., U.S.A.
  43. 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 gaskets.
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