Disassembly and Assembly: Disassembly

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.

Remove drain plug and filler plug.
Remove transfer control device from rear case.
Remove O-ring form transfer control device.

Fig 1: Identifying Transfer Control Device
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the self-lock nut from the companion flange, using Tool.
Tool number: KV40104000 ( - )

Fig 2: Removing Self-Lock Nut From Companion Flange Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
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: Identifying Matching Mark On Top Of Front Drive Shaft & Mark On Companion Flange
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the companion flange, using suitable tool.

Fig 4: Removing Companion Flange
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove front oil seal from front case, using Tool.
Tool number: KV381054S0 (J-34286)

Fig 5: Removing Front Oil Seal From Front Case Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Do not damage the front case or front drive shaft.
Remove the 4LO switch [gray (with green paint)] and ATP switch (black) from front case.

Fig 6: Identifying 4LO Switch And ATP Switch
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove wait detection switch (gray) from rear case.

Fig 7: Identifying Wait Detection Switch
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove dust cover from rear case, using suitable tool.
CAUTION: Do not damage the rear case.

Fig 8: Removing Dust Cover From Rear Case Using Suitable Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove rear oil seal from rear case, using Tool.
Tool number: KV381054S0 (J-34286)

Fig 9: Removing Rear Oil Seal From Rear Case Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.

CAUTION: Do not damage the rear case or mainshaft.
Remove the input oil seal from front case, using suitable tool.
CAUTION: Do not damage the front case, sun gear or input bearing.

Fig 10: Removing Input Oil Seal From Front Case Using Suitable Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the retainer bolts and gaskets.

Fig 11: Identifying Retainer Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the rear case bolts, harness bracket and air breather hose clamp from the rear case.

Fig 12: Identifying Rear Case Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Separate front case and rear case. Then remove rear case by prying it up, using suitable tool.
CAUTION: Do not damage the mating surface.
Remove spacer from the control shift rod.
CAUTION: Do not drop spacer.

Fig 13: Separating Front Case From Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove snap ring from mainshaft, using suitable tool.

Fig 14: Removing Snap Ring From Mainshaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the mainshaft rear bearing from mainshaft, using suitable tool.
Remove retainer from mainshaft.

Fig 15: Removing Mainshaft Rear Bearing From Mainshaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove snap ring from mainshaft, using suitable tool.
Remove oil pump assembly from mainshaft.

Fig 16: Removing Snap Ring & Oil Pump Assembly From Mainshaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove snap ring from mainshaft, using suitable tool.
Remove clutch gear from mainshaft.

Fig 17: Identifying Snap Ring & Clutch Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove snap ring from L-H shift rod assembly, using suitable tool.
Remove 2-4 sleeve and 2-4 shift fork assembly from mainshaft.

Fig 18: Identifying Snap Ring & L-H Shift Rod Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove drive chain together with sprocket and front drive shaft from front case.
Remove spacer and needle bearing from mainshaft.
Remove mainshaft from sun gear assembly.
Remove L-H shift rod assembly and control shift rod assembly from front case.
Remove L-H sleeve together with L-H shift fork assembly from planetary carrier assembly.

Fig 19: Identifying Drive Chain & Sprocket
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove snap ring from sun gear.
CAUTION: Do not damage the sun gear or input bearing.

Fig 20: Identifying Snap Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Press the sun gear assembly and planetary carrier assembly from front case, using Tool.
Tool number: KV38100200 ( - )

Fig 21: Identifying Sun Gear Assembly And Planetary Carrier Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove snap ring from front case.

Fig 22: Identifying Snap Ring From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove internal gear from front case.

Fig 23: Removing Internal Gear From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove snap ring from front case.

Fig 24: Identifying Snap Ring From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the input bearing from front case, using Tool.
Tool number: KV38100200 ( - )

Fig 25: Removing Input Bearing From Front Case Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove baffle plate from front case.
Remove the breather tube from front case.

Fig 26: Identifying Baffle Plate
Courtesy of NISSAN MOTOR CO., U.S.A.