Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2013 Nissan Xterra. However, it is still accessible from the selected car via links, so may be relevant.

Install the breather tube.
CAUTION: Install breather tube in the direction shown below.

Fig 1: Installing Breather Tube
Courtesy of NISSAN NORTH AMERICA, INC.
Install the baffle plate to the front case. Tighten the bolt to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
CAUTION: Install baffle plate by pushing it in the direction shown below while tightening the bolt.

Fig 2: Identifying Baffle Plate
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Install the input bearing to the front case, using Tool.
Tool number: ST30720000 (J-25405)

Fig 3: Installing Input Bearing To Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the new snap ring to the front case.
CAUTION: Do not reuse snap ring.

Fig 4: Identifying Front Case Snap Ring
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Install the internal gear with the groove facing up into the front case.

Fig 5: Installing Internal Gear With Groove Into Front Case
Courtesy of NISSAN NORTH AMERICA, INC.
Install the snap ring to the front case.
CAUTION: Do not reuse snap ring.

Fig 6: Identifying Internal Gear And Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Install the planetary carrier assembly and sun gear assembly to the front case, using Tool.
Tool number: KV38100200 (-)

Fig 7: Installing Planetary Carrier Assembly And Sun Gear Assembly To Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the snap ring to the sun gear.
CAUTION:
- Do not reuse snap ring.
- Do not damage sun gear.
Fig 8: Identifying Snap Ring
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Set the L-H sleeve together with the L-H shift fork assembly onto the planetary carrier assembly.

Fig 9: Identifying L-H Sleeve, L-H Shift Fork Assembly And Planetary Carrier Assembly
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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.
Turn the control shift rod assembly fully counterclockwise.

Fig 10: Identifying L-H Shift Fork Assembly, Drum Cam And Pin
Courtesy of NISSAN NORTH AMERICA, INC.
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.
Install the mainshaft to the sun gear assembly.

Fig 11: Identifying L-H Shift Rod Assembly, Drum Cam And Pin
Courtesy of NISSAN NORTH AMERICA, INC.
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 Mark On Sprocket
Courtesy of NISSAN NORTH AMERICA, INC.
Install the drive chain together with the front drive shaft and sprocket to the front case.

Fig 13: Installing Drive Chain, Sprocket And Front Drive Shaft From Front Case
Courtesy of NISSAN NORTH AMERICA, INC.
Install the 2-4 sleeve and 2-4 shift fork assembly to the mainshaft.
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 Sleeve And 2-4 Shift Fork Assembly
Courtesy of NISSAN NORTH AMERICA, INC.
Install the snap ring to the L-H shift rod assembly, using suitable tool.
CAUTION: Do not reuse snap ring.
Install the clutch gear to the mainshaft.

Fig 15: Removing/Installing L-H Shift Rod Assembly And Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Install the snap ring to the mainshaft, using suitable tool.
CAUTION: Do not reuse snap ring.
Install the oil pump assembly to the mainshaft.

Fig 16: Removing/Installing Snap Ring And Clutch Gear From Mainshaft
Courtesy of NISSAN NORTH AMERICA, INC.
Install the snap ring to the mainshaft, using suitable tool.
CAUTION: Do not reuse snap ring.

Fig 17: Removing/Installing Snap Ring And Oil Pump Assembly From Mainshaft
Courtesy of NISSAN NORTH AMERICA, INC.
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: Identifying L-H Shift Rod Assembly, Identification Hole And Retainer
Courtesy of NISSAN NORTH AMERICA, INC.
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: Installing Mainshaft Rear Bearing To Mainshaft Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the snap ring to the mainshaft, using suitable tool.
CAUTION: Do not reuse snap ring.
Install the spacer to the control shift rod (A/T models only).

Fig 20: Removing/Installing Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Apply liquid gasket to the mating surface of the front case.
- Use Genuine Anaerobic Liquid Gasket or equivalent . Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
CAUTION: Remove old sealant stuck to mating surfaces. Also remove any moisture, oil, or foreign material stuck to mating surfaces.
Install the rear case to the front case.

Fig 21: Identifying Liquid Gasket
Courtesy of NISSAN NORTH AMERICA, INC.
Tighten the bolts to the specified torque. Refer to "EXPLODED VIEW ".
CAUTION: Be sure to install the harness brackets and air breather hose clamp.

Fig 22: Locating Rear Case Mounting Bolts
Courtesy of NISSAN NORTH AMERICA, INC.
Install the retainer bolts with new gaskets. Tighten the bolts to the specified torque. Refer to "EXPLODED VIEW ".
CAUTION:
- Do not reuse gasket.
- Tighten them to the specified torque again.
Fig 23: Locating Retainer Bolts
Courtesy of NISSAN NORTH AMERICA, INC.
Apply petroleum jelly to the circumference of the oil seal, and install it to the front case, using Tools.
Dimension (A): 4.0 - 4.6 mm (0.157 - 0.181 in)

Tool number (A): ST3072000 (J-25405)

(B): KV40104830 (-)
CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal.
Fig 24: Installing Oil Seal To Front Case Using Tools
Courtesy of NISSAN NORTH AMERICA, INC.
Install the 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 Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the oil cover until it reaches the end face of the new dust cover.
CAUTION:
- Do not reuse dust cover.
- Position the oil cover with the notch at bottom position.
Apply petroleum jelly to the circumference of the new dust cover (1). Position the dust cover (1) as shown below.
CAUTION:
- Do not reuse dust cover (1).
- Position the protrusions (A) at the position shown below.
- (2): Rear case assembly
Fig 26: Identifying Dust Cover, Rear Case Assembly And Protrusions
Courtesy of NISSAN NORTH AMERICA, INC.
Install the 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 To Rear Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install check ball and check spring to rear case (M/T models only).
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 "EXPLODED VIEW ".
- Use Genuine Silicone RTV or equivalent . Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
CAUTION: Remove old sealant and oil from threads.

Fig 28: Identifying Check Ball, Check Spring And Check Plug
Courtesy of NISSAN NORTH AMERICA, INC.
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 "EXPLODED VIEW ".
- Use Genuine Silicone RTV or equivalent . Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
CAUTION: Remove old sealant and oil from threads.

Fig 29: Identifying Wait Detection Switch
Courtesy of NISSAN NORTH AMERICA, INC.
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 "EXPLODED VIEW ".
- Use Genuine Silicone RTV or equivalent . Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
CAUTION: Remove old sealant and oil from threads.

Fig 30: Identifying 4LO Switch And ATP Switch
Courtesy of NISSAN NORTH AMERICA, INC.
Install the front oil seal until it is flush with the end face of the front case, using Tool.
Tool number: KV38100500 (-)

Fig 31: Installing Front Oil Seal Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal.
Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.

Fig 32: Identifying Matching Mark On Front Drive Shaft And Companion Flange
Courtesy of NISSAN NORTH AMERICA, INC.
Install the companion flange self-lock nut. Tighten to the specified torque, using suitable tool. Refer to "EXPLODED VIEW ".
CAUTION: Do not reuse self-lock nut.

Fig 33: Tightening Companion Flange Self-Lock Nut Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the O-ring to the transfer control device.
CAUTION:
- Do not reuse O-ring.
- Apply petroleum jelly to O-ring.
Fig 34: Identifying Transfer Control Device O-Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Install the transfer control device to the rear case.
1. Turn the control shift rod fully counterclockwise using a suitable tool, and then put a mark on the control shift rod.
  
  Fig 35: Turning Control Shift Rod Fully Counterclockwise
  Courtesy of NISSAN NORTH AMERICA, INC.
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: Identifying Alignment Position Of Transfer Control Device Shaft Cutout And Control Shift Rod
  Courtesy of NISSAN NORTH AMERICA, INC.
3. Tighten the bolts to the specified torque. Refer to "EXPLODED VIEW ".
  
  Fig 37: Locating Transfer Control Device Mounting Bolts
  Courtesy of NISSAN NORTH AMERICA, INC.
Install the drain plug and filler plug with new gaskets to the rear case. Tighten to the specified torque. Refer to "EXPLODED VIEW ".
CAUTION: Do not reuse gaskets.