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Transfer Assembly: Disassembly: Notes

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.

Remove the drain plug and filler plug.
Remove the transfer control device from the rear case.
Remove the O-ring from the 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: Identifying Self-Lock Nut From Companion Flange
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: Aligning Front Drive Shaft Matching Mark With Companion Flange Mark
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the companion flange, using suitable tool.

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

CAUTION: Do not damage front case or front drive shaft.

Fig 5: Identifying Front Oil Seal From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the 4LO switch [gray (with green paint)] and ATP switch (black) from the front case.

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

Fig 7: Identifying Wait Detection Switch (Gray) From Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove check plug, check shift spring and check ball (M/T models only).

Fig 8: Identifying Check Plug, Check Shift Spring And Check Ball (M/T Models Only)
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the dust cover from the rear case, using suitable tool.
CAUTION: Do not damage rear case.

Fig 9: Removing Dust Cover From Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the rear oil seal from the rear case, using Tool.
Tool number: KV381054S0 (J-34286)

CAUTION: Do not damage rear case or mainshaft.

Fig 10: Identifying Rear Oil Seal From Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the input oil seal from the front case, using suitable tool.
CAUTION: Do not damage front case, sun gear or input bearing.

Fig 11: Identifying Input Oil Seal From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the retainer bolts and gaskets.

Fig 12: Identifying Retainer Bolts And Gaskets
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 13: Identifying Rear Case Bolts, Harness Bracket And Air Breather Hose Clamp From Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Separate the front case from the rear case. Then remove the rear case by prying it up, using suitable tool.
CAUTION: Do not damage the mating surface.
Remove the spacer from the control shift rod (A/T models only).
CAUTION: Do not drop spacer.

Fig 14: Separating Front Case From Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the mainshaft, using suitable tool.

Fig 15: Identifying Snap Ring From Mainshaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the mainshaft rear bearing from the mainshaft, using suitable tool
Remove the retainer from the mainshaft

Fig 16: Identifying Mainshaft Rear Bearing
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the mainshaft, using suitable tool
Remove the oil pump assembly from the mainshaft.

Fig 17: Identifying Oil Pump Assembly From Mainshaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the mainshaft, using suitable tool.
Remove the clutch gear from the mainshaft.

Fig 18: Identifying Clutch Gear From Mainshaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the L-H shift rod assembly, using suitable tool.
Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.

Fig 19: Identifying 2-4 Sleeve And 2-4 Shift Fork Assembly From Mainshaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the drive chain together with the sprocket and front drive shaft from the front case.
Remove the mainshaft from the sun gear assembly.
Remove the L-H shift rod assembly and control shift rod assembly from the front case.
Remove the L-H sleeve together with the L-H shift fork from the planetary carrier assembly.

Fig 20: Removing Drive Chain Together With Sprocket And Front Drive Shaft From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the sun gear.
CAUTION: Do not damage sun gear or input bearing.

Fig 21: Identifying Snap Ring From Sun Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Press the sun gear assembly and planetary carrier assembly from the front case, using Tool.
Tool number: KV38100200( - )

Fig 22: Identifying Sun Gear Assembly And Planetary Carrier Assembly From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the front case.

Fig 23: Identifying Snap Ring From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the internal gear from the front case.

Fig 24: Removing Internal Gear From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the snap ring from the front case.

Fig 25: Identifying Snap Ring From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the input bearing from the front case, using Tool.
Tool number: KV38100200( - )

Fig 26: Removing Input Bearing From Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Remove the baffle plate from the front case.
Remove the breather tube from the front case.

Fig 27: Identifying Baffle Plate From Front Case

G04204321

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