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Disassembly and Assembly: Disassembly

WARNING: This page is about a different car, the 2007 Nissan Pathfinder. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the drain plug and filler plug.
  2. Remove the transfer control device from the rear case.
  3. Remove the O-ring from the transfer control device.
    Fig 1: Identifying Transfer Control Device Bolts
    G04898506
  4. Remove the self-lock nut from the companion flange using Tool.

    Tool number : KV40104000 ( - ) 

    Fig 2: Tightening Self-Lock Nut
    G04901626
  5. Put a matching mark on top of the front drive shaft in line with the mark on the companion flange.
    CAUTION: Use paint to make the matching mark on the front drive shaft. Do not damage the front drive shaft.
    Fig 3: Aligning Front Drive Shaft Matching Mark With Companion Flange Mark
    G04901627
  6. Remove the companion flange using suitable tool.
    Fig 4: Identifying Companion Flange
    G04901628
  7. Remove the front oil seal from the front case using Tool.

    Tool number : ST33290001 (J-34286) 

    CAUTION: Do not damage front case or front drive shaft.
    Fig 5: Identifying Front Oil Seal From Front Case
    G04898522
  8. Remove the 4LO switch [gray (with green paint)] and ATP switch (black) from the front case.
    Fig 6: Identifying 4LO Switch And ATP Switch
    G04898523
  9. Remove the wait detection switch (gray) from the rear case.
    Fig 7: Identifying Wait Detection Switch
    G04898524
  10. Remove the dust cover from the rear case using suitable tool.
    CAUTION: Do not damage rear case.
    Fig 8: Identifying Dust Cover From Rear Case
    G04898526
  11. Remove the rear oil seal from the rear case using Tool.

    Tool number : ST33290001 (J-34286) 

    CAUTION: Do not damage rear case or mainshaft.
    Fig 9: Identifying Rear Oil Seal From Rear Case
    G04898527
  12. Remove the input oil seal from the front case using suitable tool.
    CAUTION: Do not damage front case, sun gear or input bearing.
    Fig 10: Identifying Input Oil Seal From Front Case
    G04898528
  13. Remove the retainer bolts and gaskets.
    Fig 11: Identifying Retainer Bolts
    G04898529
  14. Remove the rear case bolts, harness bracket and air breather hose clamp from the rear case.
    Fig 12: Identifying Rear Case Bolts Tightening Sequence
    G04898530
  15. Separate the front case from the rear case. Then remove the rear case by prying it up using suitable tool.
    CAUTION: Do not damage the mating surface.
    Fig 13: Identifying Rear Case
    G04898531
  16. Remove the spacer from the control shift rod.
    CAUTION: Do not drop spacer.
  17. Remove the snap ring from the mainshaft using suitable tool.
    Fig 14: Identifying Snap Ring To Mainshaft
    G04898532
  18. Remove the mainshaft rear bearing from the mainshaft using suitable tool.
    Fig 15: Identifying Mainshaft Rear Bearing
    G04898533
  19. Remove the retainer from the mainshaft.
  20. Remove the snap ring from the mainshaft using suitable tool.
  21. Remove the oil pump assembly from the mainshaft.
    Fig 16: Identifying Oil Pump Assembly
    G04898534
  22. Remove the snap ring from the mainshaft using suitable tool.
  23. Remove the clutch gear from the mainshaft.
    Fig 17: Identifying Clutch Gear To Mainshaft
    G04898535
  24. Remove the snap ring from the L-H shift rod assembly using suitable tool.
    Fig 18: Identifying Snap Ring To L-H Shift Rod Assembly
    G04898536
  25. Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.
  26. Remove the drive chain together with the sprocket and front drive shaft from the front case.
    Fig 19: Identifying Drive Chain Together With Front Drive Shaft And Sprocket To Front Case
    G04898537
  27. Remove the mainshaft from the sun gear assembly.
  28. Remove the L-H shift rod assembly and control shift rod assembly from the front case.
  29. Remove the L-H sleeve together with the L-H shift fork from the planetary carrier assembly.
  30. Remove the snap ring from the sun gear.
    CAUTION: Do not damage sun gear or input bearing.
    Fig 20: Identifying Snap Ring
    G04898538
  31. Press the sun gear assembly and planetary carrier assembly from the front case using Tool.

    Tool number : KV38100200 ( - ) 

    Fig 21: Pressing Sun Gear Assembly And Planetary Carrier Assembly
    G04898539
  32. Remove the snap ring from the front case.
    Fig 22: Identifying Snap Ring To Front Case
    G04898540
  33. Remove the internal gear from the front case.
    Fig 23: Identifying Internal Gear From Front Case
    G04898541
  34. Remove the snap ring from the front case.
    Fig 24: Identifying Snap Ring
    G04898542
  35. Remove the input bearing from the front case using Tool.

    Tool number : KV38100200 ( - ) 

    Fig 25: Identifying Input Bearing From Front Case
    G04898543
  36. Remove the baffle plate from the front case.
    Fig 26: Locating Baffle Plate
    G04898544
  37. Remove the breather tube from the front case.
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