Disassembly and Assembly: Disassembly

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.

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.
CAUTION: Do not reuse O-ring.

Fig 1: Locating Transfer Control Device Mounting Bolts
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the self-lock nut from the companion flange, using suitable tool.

Fig 2: Removing Self-Lock Nut From Companion Flange Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
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: Identifying Matching Mark On Front Drive Shaft And Companion Flange
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the companion flange, using suitable tool.

Fig 4: Removing Companion Flange Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the front oil seal from the front case, using Tool.
Tool number: ST33290001 (J-34286)

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

Fig 5: Removing Front Oil Seal From Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the 4LO switch [gray (with green paint)] and ATP switch (black) from the front case.

Fig 6: Identifying 4LO Switch And ATP Switch
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the wait detection switch (gray) from the rear case.

Fig 7: Identifying Wait Detection Switch
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Remove check plug, check shift spring and check ball (M/T models only).

Fig 8: Identifying Check Plug, Check Shift Spring And Check Ball
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the dust cover from the rear case, using suitable tool.
CAUTION: Do not damage rear case.
Remove oil cover from the dust cover.

Fig 9: Removing Dust Cover From Rear Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the rear oil seal from the rear case, using Tool.
Tool number: ST33290001 (J-34286)

CAUTION: Do not damage rear case or mainshaft.

Fig 10: Removing Rear Oil Seal From Rear Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
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: Removing Input Oil Seal From Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the retainer bolts and gaskets.
CAUTION: Do not reuse gaskets.

Fig 12: Locating Retainer Bolts
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the rear case bolts, harness bracket and air breather hose clamp from the rear case.

Fig 13: Locating Rear Case Mounting Bolts
Courtesy of NISSAN NORTH AMERICA, INC.
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: Removing Rear Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the snap ring from the mainshaft, using suitable tool.
CAUTION: Do not reuse snap ring.

Fig 15: Removing/Installing Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the mainshaft rear bearing from the mainshaft, using suitable tool.
Remove the retainer from the mainshaft.

Fig 16: Removing Mainshaft Rear Bearing From Mainshaft Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the snap ring from the mainshaft, using suitable tool.
CAUTION: Do not reuse snap ring.
Remove the oil pump assembly from the mainshaft.

Fig 17: Removing/Installing Snap Ring And Oil Pump Assembly From Mainshaft
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the snap ring from the mainshaft, using suitable tool.
CAUTION: Do not reuse snap ring.
Remove the clutch gear from the mainshaft.

Fig 18: Removing/Installing Snap Ring And Clutch Gear From Mainshaft
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the snap ring from the L-H shift rod assembly, using suitable tool.
CAUTION: Do not reuse snap ring.
Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.

Fig 19: Removing/Installing Snap Ring From L-H Shift Rod Assembly
Courtesy of NISSAN NORTH AMERICA, INC.
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, Sprocket And Front Drive Shaft From Front Case
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the snap ring from the sun gear.
CAUTION:
- Do not reuse snap ring.
- Do not damage sun gear or input bearing.
Fig 21: Identifying Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Press the sun gear assembly and planetary carrier assembly from the front case, using Tool.
Tool number: KV38100200 (-)

Fig 22: Pressing Sun Gear Assembly And Planetary Carrier Assembly From Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the snap ring from the front case.
CAUTION: Do not reuse snap ring.

Fig 23: Identifying Internal Gear And Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the internal gear from the front case.

Fig 24: Removing Internal Gear From Front Case
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the snap ring from the front case.
CAUTION: Do not reuse snap ring.

Fig 25: Identifying Front Case Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the input bearing from the front case, using Tool.
Tool number: KV38100200 (-)

Fig 26: Removing Input Bearing From Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Remove the baffle plate from the front case.
Remove the breather tube from the front case.

Fig 27: Identifying Baffle Plate
Courtesy of NISSAN NORTH AMERICA, INC.