Case Components

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.

Install main drive gear assembly, mainshaft assembly, counter gear assembly and reverse idler shaft assembly. Refer to "GEAR COMPONENTS ".
Install fork rods and shift forks. Refer to "SHIFT CONTROL COMPONENTS ".
Install oil gutter to transmission case.

Fig 1: Installing Oil Gutter To Transmission Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Install counter front bearing to transmission case.
CAUTION: Apply multi-purpose grease to counter front bearing.

Fig 2: Installing Counter Front Bearing To Transmission Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply recommended sealant to mating surface of transmission case as shown.
- Use Genuine Silicone RTV or the equivalent. Refer to " RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS " .
CAUTION: Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to both mating surfaces.

Fig 3: Applying Sealant To Mating Surface Of Transmission Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Install transmission case to adapter plate assembly.

Fig 4: Installing Transmission Case To Adapter Plate Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring to main drive gear bearing using suitable tool.
CAUTION: Do not reuse snap ring.

Fig 5: Installing Snap Ring To Main Drive Gear Bearing Using Suitable Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Tighten baffle plate nut to the specified torque. Refer to "CASE COMPONENTS ".

Fig 6: Tightening Baffle Plate Nut
Courtesy of NISSAN MOTOR CO., U.S.A.
Tighten baffle plate bolt to the specified torque. Refer to "CASE COMPONENTS ".

Fig 7: Tightening Baffle Plate Bolt
Courtesy of NISSAN MOTOR CO., U.S.A.
Install front cover oil seal to front cover using Tool.
Tool number: KV38102100 (J-25803-01)

Dimension A: 8.55 - 9.55 (0.336 - 0.376 in)
CAUTION:
- Do not reuse front cover oil seal.
- Apply multi-purpose grease onto oil seal lip.
- When installing, do not incline front cover oil seal.
Fig 8: Installing Front Cover Oil Seal To Front Cover Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Install front cover according to the following.
1. Install front cover gasket and front cover to transmission case.
  CAUTION: Do not reuse front cover gasket.
2. Temporarily tighten 2 bolts in the positions shown.
3. Temporarily tighten remaining 9 bolts.
  
  Fig 9: Tightening Bolts
  Courtesy of NISSAN MOTOR CO., U.S.A.
4. Tighten bolts to the specified torque in order as shown. Refer to "CASE COMPONENTS ".
  CAUTION: Do not reuse bolts indicated as A in the figure.
Fig 10: Identifying Tightening Sequence Of Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Install washer to withdrawal lever ball pin, and then install it to front cover. Tighten withdrawal lever ball pin to the specified torque. Refer to "CASE COMPONENTS ".

Fig 11: Installing Washer To Withdrawal Lever Ball Pin
Courtesy of NISSAN MOTOR CO., U.S.A.
Install counter end bearing to rear extension (or OD gear case) using suitable tool [32 mm (1.26 in) dia.].
Dimension A: 0.5 - 1.5 (0.020 - 0.059 in)
CAUTION:
- Do not reuse counter end bearing.
- Apply gear oil to counter end bearing.
- Install counter end bearing with maker stamp at upper side.
Fig 12: Installing Counter End Bearing To Rear Extension
Courtesy of NISSAN MOTOR CO., U.S.A.
Install rear extension oil gutter according to the following. (For 2WD models)
1. Install cap to rear extension oil gutter.
2. Install rear extension oil gutter to rear extension, and then tighten bolt to specified torque. Refer to "CASE COMPONENTS ".
  
  Fig 13: Installing Cap To Rear Extension Oil Gutter
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install rear oil seal (1) to rear extension (or OD gear case) using Tool A.
Tool number: ST33200000 (J-26082)

Dimension H1

2WD models: 1.2 - 2.2 mm (0.047 - 0.087 in)

4WD models: -0.5 - 0.5 mm (-0.020 - 0.020 in)

CAUTION: When installing, do not incline rear oil seal.

(B): Seal lip

Fig 14: Installing Rear Oil Seal To Rear Extension
Courtesy of NISSAN MOTOR CO., U.S.A.
Install dust seal (1) to rear extension using Tool A (for 2WD models).
Tool number: KV38100500( - )

Dimension H2: 0.5 - 1.5 mm (0.020 - 0.059 in)

CAUTION: When installing, do not incline dust seal.

(B): Seal lip

Fig 15: Installing Dust Seal To Rear Extension Using Tool (For 2WD Models)
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply recommended sealant to mating surface of rear extension as shown.
- Use Genuine Silicone RTV or the equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
CAUTION: Remove old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to both mating surfaces.

Fig 16: Applying Sealant To Mating Surface Of Rear Extension
Courtesy of NISSAN MOTOR CO., U.S.A.
Install rear extension (or OD gear case) to adapter plate, and then tighten bolts to the specified torque in order as shown. Refer to "CASE COMPONENTS ".

Fig 17: Identifying Tightening Sequence Of Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Install check shift pin and pivot bolt to transmission case, and then tighten them to the specified torque. Refer to "CASE COMPONENTS ".
CAUTION: Do not reuse check shift pin and pivot bolt.

Fig 18: Installing Check Shift Pin And Pivot Bolt To Transmission Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Install return spring plunger, return spring and return spring plug to rear extension (or OD gear case), and then tighten return spring plug to the specified torque. Refer to "SHIFT CONTROL COMPONENTS ".
CAUTION:
- Do not reuse return spring plug.
- Apply gear oil to return spring plunger.
Fig 19: Installing Return Spring Plunger
Courtesy of NISSAN MOTOR CO., U.S.A.
Install PNP switch and back-up lamp switch according to the following.
1. Install plunger to rear extension (or OD gear case).
2. Apply recommended sealant to threads of PNP switch and back-up lamp switch.
- Use Genuine Silicone RTV or the equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
1. Install PNP switch and back-up lamp switch to rear extension (or OD gear case), and tighten them to the specified torque. Refer to "CASE COMPONENTS ".
Fig 20: Installing PNP Switch And Back-Up Lamp Switch To Rear Extension
Courtesy of NISSAN MOTOR CO., U.S.A.
Install clips to PNP switch and back-up lamp switch.
CAUTION:
- Thread harness through the notch of clip.
Fig 21: Installing Clips To PNP Switch And Back-Up Lamp Switch
Courtesy of NISSAN MOTOR CO., U.S.A.
- Thread the harness as shown.
Fig 22: Identifying Thread Harness
Courtesy of NISSAN MOTOR CO., U.S.A.
Install striking arm according to the following.
1. Install striking arm to striking rod assembly.
2. Install retaining pin to striking arm using suitable tool.
CAUTION: Do not reuse retaining pin.

Fig 23: Installing Retaining Pin To Striking Arm Using Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Install control housing according to the following.
1. Install gasket and control housing to rear extension (or OD gear case).
  CAUTION: Do not reuse gasket.
2. Tighten bolts to the specified torque in order as shown. Refer to "CASE COMPONENTS ".
Fig 24: Identifying Tightening Sequence Of Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Install gasket to drain plug, and then install it to transmission case. Tighten drain plug to the specified torque. Refer to "CASE COMPONENTS ".
CAUTION: Do not reuse gasket.

Fig 25: Installing Gasket To Drain Plug
Courtesy of NISSAN MOTOR CO., U.S.A.
Install gasket to filler plug, and then install it to transmission case. Tighten filler plug to the specified torque. Refer to "CASE COMPONENTS ".

CAUTION:

Do not reuse gasket.
After oil is filled, tighten filler plug to specified torque.

Fig 26: Installing Gasket To Filler Plug

Courtesy of NISSAN MOTOR CO., U.S.A.