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Home >> Nissan-Datsun >> 2003 >> Sentra SE-R, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1894 (Transfer Case) >> Transfer Assembly >> Disassembly >> Assembly
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Transfer Assembly: Disassembly: Assembly

WARNING: This page is about a different car, the 2006 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: Identifying Breather Tube
    G04204326Courtesy 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: Identifying Baffle Plate
    G04204327Courtesy 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: Identifying Input Bearing To Front Case
    G04204328Courtesy 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: Identifying Snap Ring To Front Case
    G04204329Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install the internal gear with the groove facing up into the front case.
    Fig 5: Identifying Internal Gear
    G04204330Courtesy 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: Identifying Snap Ring To Front Case
    G04204331Courtesy 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: Identifying Planetary Carrier Assembly And Sun Gear Assembly To Front Case
    G04204332Courtesy 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: Identifying Snap Ring To Sun Gear
    G04204333Courtesy 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: Setting L-H Sleeve Together With L-H Shift Fork Assembly Onto Planetary Carrier Assembly
    G04204334Courtesy 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: Setting Pin Of L-H Shift Fork Assembly Into Groove Of Drum Cam
    G04204335Courtesy 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: Setting Pin Of L-H Shift Rod Assembly Into Groove Of Drum Cam
    G04204336Courtesy 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 Drive Shaft Identification Mark
    G04204337Courtesy 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 Together With Front Drive Shaft And Sprocket To Front Case
    G04204338Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Install the 2-4 sleeve and 2-4 shift fork assembly to the main-shaft.
    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: Identifying 2-4 Shift Fork With Engaging Grooves Of 2-4 Shift Fork In Retaining Pin Of 2-4 Shift Bracket
    G04204339Courtesy 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: Identifying Snap Ring To L-H Shift Rod Assembly
    G04204340Courtesy 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: Identifying Clutch Gear To Mainshaft
    G04204341Courtesy 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: Identifying Oil Pump Assembly
    G04204342Courtesy 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
    G04204343Courtesy 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: Identifying Mainshaft Rear Bearing To Mainshaft
    G04204344Courtesy 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 (A/T models only).
    Fig 20: Identifying Snap Ring To Mainshaft
    G04204345Courtesy of NISSAN MOTOR CO., U.S.A.
  26. Apply liquid gasket to the mating surface of the front case.
    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.

    For GI section, go to GENERAL INFORMATION .

    Fig 21: Applying Liquid Gasket To Mating Surface Of Front Case
    G04204346Courtesy 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 and air breather hose clamp.
    Fig 22: Locating Front Case Bolts
    G04204347Courtesy 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: Identifying Retainer Bolts With Gaskets
    G04204348Courtesy 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 Front Case Oil Seal
    G04204349Courtesy 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
    G04204350Courtesy 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: Identifying Dust Cover Identification Mark
    G04204351Courtesy 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
    G04204352Courtesy 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 ".
    CAUTION: Remove old sealant and oil adhering to threads.
    Fig 28: Identifying Check Ball And Check Spring To Rear Case (M/T Models Only)
    G04204353Courtesy 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 ".
    CAUTION: Remove old sealant and oil adhering to threads.
    Fig 29: Applying Sealant To Threads Of Wait Detection Switch (Gray)
    G04204354Courtesy 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 ".
    CAUTION: Remove old sealant and oil adhering to threads.
    Fig 30: Applying Sealant To Threads Of 4LO Switch And ATP Switch
    G04204355Courtesy 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
    G04204356Courtesy 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
    G04204357Courtesy 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: Installing Self-Lock Nut
    G04204358Courtesy 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.
    Fig 34: Identifying O-Ring To Transfer Control Device
    G04204359Courtesy of NISSAN MOTOR CO., U.S.A.
  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 35: Identifying Control Shift Rod Mark
      G04204360Courtesy 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 36: Aligning Transfer Control Device Shaft Cutout With Mark On Control Shift Rod
      G04204361Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Tighten the bolts to the specified torque. Refer to "COMPONENTS ".
    Fig 37: Identifying Transfer Control Device
    G04204362Courtesy 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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