Front Case

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.

Install the carrier bearing to the sun gear using Tools.
Tool number A: ST30911000 ( - )

B: KV31103300 ( - )

Fig 1: Identifying Carrier Bearing To Sun Gear
Install the new snap ring to the sun gear assembly using suitable tool.
CAUTION: Do not reuse snap ring.

Fig 2: Identifying Snap Ring To Sun Gear Assembly
Apply ATF to the circumference of the new metal bushing and install it to the sun gear assembly using Tool.
Tool number : ST35300000 ( - )

Dimension A : 7.7 - 8.3 mm (0.303 - 0.327 in)
CAUTION:
- Do not reuse metal bushing.
- Apply ATF to metal bushing before installing.
  
  Fig 3: Applying ATF To Metal Bushing
Apply ATF to the new needle bearing and install it to the sun gear assembly using Tool.
Tool number : ST33220000 ( - )

Dimension B : 62.5 - 63.1 mm (2.461 - 2.484 in)
CAUTION:
- Do not reuse needle bearing.
- Apply ATF to needle bearing before installing.
  
  Fig 4: Applying ATF To Needle Bearing
Install the sun gear assembly to the planetary carrier assembly.

Fig 5: Identifying Sun Gear Assembly To Planetary Carrier Assembly
Install the new snap ring to the planetary carrier assembly.
CAUTION: Do not reuse snap ring.

Fig 6: Identifying Snap Ring To Planetary Carrier Assembly
Set the input bearing into the front case and install using Tool.
Tool number : ST30720000 (J-25405)

Fig 7: Identifying Input Bearing On Front Case
Install the new snap ring into the front case.
CAUTION: Do not reuse snap ring.

Fig 8: Identifying Snap Ring
Install the internal gear with its groove facing the snap ring into the front case. Then secure it with the new snap ring.
CAUTION: Do not reuse snap ring.

Fig 9: Identifying Internal Gear With Its Groove Facing
Install the new front oil seal until it is seated 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 lip before installing.
  
  Fig 10: Tapping Front Oil Seal
Install the planetary carrier assembly and sun gear assembly to the front case using Tool.
Tool number : ST33200000 (J-26082)

Fig 11: Identifying Planetary Carrier Assembly And Sun Gear Assembly To Front Case
Install the new snap ring to the sun gear.
CAUTION: Do not reuse snap ring.

Fig 12: Identifying Snap Ring To Sun Gear Assembly
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: ST33200000 (J-26082)

Dimension : 4.0 - 4.6 mm (0.157 - 0.181 mm)
CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal.
  
  Fig 13: Applying Petroleum Jelly To Circumference Of New Input Oil Seal
Install the fork guide, shift fork spring, 2-4 fork, and L-H fork to the shift rod, and secure them with new retaining pins.
CAUTION: Do not reuse retaining pins.

Fig 14: Identifying Fork Guide, Shift Fork Spring, 2-4 Fork, And L-H Fork To Shift Rod
Install the 2-4 sleeve and L-H sleeve to each fork.

Fig 15: Identifying 2-4 Sleeve And L-H Sleeve To Each Fork
Install the shift cross to the front case.
While aligning the L-H sleeve with the planetary carrier, install the shift rod assembly to the front case.

Fig 16: Identifying Shift Rod Assembly To Front Case
Apply liquid gasket to the entire center case mating surface of the front case assembly as shown.
- Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
CAUTION: Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces.

Fig 17: Applying Liquid Gasket To Entire Center Case Mating Surface Of Front Case Assembly
Install the center case assembly to the front case assembly.
CAUTION: Do not damage mainshaft end.

Fig 18: Identifying Center Case Assembly To Front Case Assembly
Tap the center case lightly and press-fit the front drive shaft bearing into the front case.
Tighten the front case bolts to the specified torque. Refer to "COMPONENTS ".
CAUTION: Be sure to install air breather hose clamp, connector bracket and harness clip.

Fig 19: Identifying Front Case Bolts
Install the drain plug with a new gasket.
CAUTION: Do not reuse gasket.
Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.

Fig 20: Aligning Front Drive Shaft Matching Mark With Companion Flange Mark
Install a new companion flange self-lock nut. Tighten to the specified torque using Tool. Refer to "COMPONENTS ".
Tool number : KV40104000 ( - )

CAUTION: Do not reuse self-lock nut.

Fig 21: Tightening Companion Flange Self-Lock Nut
Remove all the sealant from the check plug, switch mounting and front case.
CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.

Fig 22: Identifying Check Plug Switch Mounting And Front Case
Install the check ball and check spring to the front case. Apply sealant to the check plug and wait detection switch and install them to the front case. Tighten to the specified torque. Refer to "COMPONENTS ".
- Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
NOTE: Wait detection switch harness connector is black.
Install the new oil seal in the front case using Tool.
Tool number : ST22360002 (J-25679-01)
CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to seal lip before installing.
Install the shift lever to the shift cross.
Install the lock pin and lock pin nut. Tighten to the specified torque. Refer to "COMPONENTS ".