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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2005 Nissan Titan. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install breather tube.
    CAUTION: Install breather tube in the direction shown.
    Fig 1: Installing Breather Tube
    G03602837Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install baffle plate to front case, and tighten 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
    G03602838Courtesy of NISSAN MOTOR CO., U.S.A.
  3. Install the input bearing to front case, using Tool.

    Tool number: ST30720000 (J-25405) 

    Fig 3: Installing Input Bearing To Front Case
    G03602839Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Install snap ring to front case.
    CAUTION: Do not reuse snap ring.
    Fig 4: Installing Snap Ring To Front Case
    G03602840Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Install internal gear with groove facing up into front case.
    Fig 5: Installing Internal Gear With Groove Facing Up Into Front Case
    G03602841Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Install snap ring to front case.
    CAUTION: Do not reuse snap ring.
    Fig 6: Installing Snap Ring To Front Case
    G03602842Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install the planetary carrier assembly and sun gear assembly to front case, using Tool.

    Tool number: KV38100200 (-) 

    Fig 7: Installing Planetary Carrier Assembly And Sun Gear Assembly To Front Case
    G03602843Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Install snap ring to sun gear.
    CAUTION:
    • Do not reuse snap ring.
    • Do not damage the sun gear.
      Fig 8: Installing Snap Ring To Sun Gear
      G03602844Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Set L-H sleeve together with L-H shift fork assembly onto planetary carrier assembly.
    Fig 9: Setting L-H Sleeve Together With L-H Shift Fork Assembly
    G03602845Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install control shift rod assembly to front case.
    CAUTION: Set pin of L-H shift fork assembly into the groove of drum cam.
    11. Fig 10: Installing Control Shift Rod Assembly
    G03602846Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Turn control shift rod assembly fully counterclockwise.
  12. Install L-H shift rod assembly through L-H shift fork assembly opening to front case.
    CAUTION: Set pin of L-H shift rod assembly into the groove of drum cam.
    13. Fig 11: Installing L-H Shift Rod Assembly Through L-H Shift Fork Assembly Opening To Front Case
    G03602847Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Install mainshaft to sun gear assembly.
  14. Apply ATF to spacer and periphery of needle bearing, install to mainshaft.
  15. Set front drive shaft and sprocket to drive chain.
    CAUTION: Identification mark of drive chain should be on the side of rear bearing of front drive shaft.
    Fig 12: Installing Drive Chain To Front Drive Shaft And Sprocket
    G03602848Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Install drive chain together with front drive shaft and sprocket to front case.
    Fig 13: Installing Drive Chain Together With Front Drive Shaft And Sprocket To Front Case
    G03602849Courtesy of NISSAN MOTOR CO., U.S.A.
  17. Install 2-4 sleeve and 2-4 shift fork assembly to mainshaft.
    Fig 14: Installing Sleeve & Shift Fork Assembly To Mainshaft
    G03602850Courtesy of NISSAN MOTOR CO., U.S.A.
    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.
  18. Install snap ring to L-H shift rod assembly, using suitable tool.
    Fig 15: Installing Snap Ring To Shift Rod Assembly
    G03602851Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Do not reuse snap ring.
  19. Install clutch gear to mainshaft.
  20. Install snap ring to mainshaft, using suitable tool.
    CAUTION: Do not reuse snap ring.
    21. Fig 16: Installing Snap Ring To Mainshaft
    G03602852Courtesy of NISSAN MOTOR CO., U.S.A.
  21. Install oil pump assembly to mainshaft.
  22. Install snap ring to mainshaft, using suitable tool.
    CAUTION: Do not reuse snap ring.
    Fig 17: Installing Oil Pump Assembly & Snap Ring To Mainshaft
    G03602853Courtesy of NISSAN MOTOR CO., U.S.A.
  23. Install retainer to mainshaft.
    CAUTION: Set the projection of oil pump assembly to identification hole, and then align locating hole of retainer to L-H shift rod assembly.
    Fig 18: Installing Retainer To Mainshaft
    G03602854Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Install the mainshaft rear bearing to 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
    G03602855Courtesy of NISSAN MOTOR CO., U.S.A.
  25. Install snap ring to mainshaft, using suitable tool.
    CAUTION: Do not reuse snap ring.
  26. Install spacer to control shift rod.
    Fig 20: Installing Spacer To Control Shift Rod
    G03602856Courtesy of NISSAN MOTOR CO., U.S.A.
  27. Apply liquid gasket to mating surface of 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.
    28. Fig 21: Applying Liquid Gasket To Mating Surface Of Front Case
    G03602857Courtesy of NISSAN MOTOR CO., U.S.A.
  28. Install rear case to front case.
  29. Tighten bolts to specified torque. Refer to "COMPONENTS ".
    CAUTION: Be sure to install the harness brackets.
    Fig 22: Installing Harness Brackets & Tightening Bolts
    G03602858Courtesy of NISSAN MOTOR CO., U.S.A.
  30. Install the retainer bolts with new gaskets. Tighten the bolts to the specified torque. Refer to "COMPONENTS ".
    Fig 23: Installing Retainer Bolts
    G03602859Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse gasket.
    • Tighten them to the specified torque again.
  31. Install input oil seal to front case, using Tools.

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

    Tool number A: ST30720000 (J-25405) 

    B: KV40104830 (-) 

    Fig 24: Installing Input Oil Seal To Front Case
    G03602860Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal.
  32. Install rear oil seal until it is flush with end face of rear case, using Tool.

    Tool number: KV38100500 (-) 

    Fig 25: Installing Rear Oil Seal
    G03602861Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal.
  33. Apply petroleum jelly to the circumference of the new dust cover. Position the dust cover using the identification mark as shown.
    Fig 26: Applying Petroleum Jelly To Circumference Of Dust Cover & Position
    G03602862Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse dust cover.
    • Position the identification mark at the position shown.
  34. Install the dust cover to the rear case, using Tool.

    Tool number: KV40105310 (-) 

    Fig 27: Installing Dust Cover To Rear Case
    G03602863Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse dust cover.
    • Apply petroleum jelly to dust cover.
  35. Apply sealant to threads of wait detection switch (gray). Then install it to rear case and tighten to the specified torque. Refer to "COMPONENTS ".
    Fig 28: Applying Sealant To Threads Of Wait Detection Switch
    G03602864Courtesy of NISSAN MOTOR CO., U.S.A.
  36. Apply sealant to threads of 4LO switch (gray with green paint) and ATP switch (black). Then install them to front case and tighten to the specified torque. Refer to "COMPONENTS ".
    Fig 29: Applying Sealant To Threads Of 4LO Switch & ATP Switch
    G03602865Courtesy of NISSAN MOTOR CO., U.S.A.
  37. Install front oil seal until it is flush with end face of front case, using Tool.

    Tool number: KV38100500 (-) 

    Fig 30: Installing Front Oil Seal
    G03602866Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not reuse oil seal.
    • Apply petroleum jelly to oil seal.
  38. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.
    Fig 31: Aligning Matching Mark On Front Drive Shaft With Mark On Companion Flange
    G03602867Courtesy of NISSAN MOTOR CO., U.S.A.
  39. Tighten self-lock nut to the specified torque, using Tool. Refer to "COMPONENTS ".

    Tool number: KV40104000 (-) 

    CAUTION: Do not reuse self-lock nut.
    40. Fig 32: Tightening Self-Lock Nut
    G03602868Courtesy of NISSAN MOTOR CO., U.S.A.
  40. Install O-ring to transfer control device.
    CAUTION:
    • Do not reuse O-ring.
    • Apply petroleum jelly.
  41. Install transfer control device to rear case.
    1. Turn control shift rod fully counterclockwise using flat-bladed screwdriver, and then put a mark on control shift rod.
      Fig 33: Turning Control Shift Rod Fully Counterclockwise
      G03602869Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Align transfer control device shaft cutout with mark on control shift rod, and install.
      NOTE: Turn transfer control device when transfer control device connection does not match.
      Fig 34: Aligning Transfer Control Device Shaft Cutout With Mark On Control Shift Rod
      G03602870Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Tighten bolts to the specified torque. Refer to "COMPONENTS ".
      Fig 35: Tightening Bolts
      G03602871Courtesy of NISSAN MOTOR CO., U.S.A.
  42. 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 gasket.
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