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Front Case And Rear Case: Disassembly

  1. Remove drain plug and filler plug.
  2. Remove harness brackets.
  3. Remove main shaft oil seal from front case.
    CAUTION: Never damage the front case and main shaft.
  4. Remove front oil seal from front case.
    CAUTION: Never damage the front case and front drive shaft.
  5. Remove self-lock nut.
  6. Put a matching mark (A) on the end of main shaft. The mark should be in line with the mark (B) on the companion flange.
    CAUTION: For the matching mark, use paint. Never damage main shaft.
    Fig 1: Identifying Matching Marks
    G05727164Courtesy of NISSAN NORTH AMERICA, INC.
  7. Remove companion flange with a puller (A) (commercial service tool).
    CAUTION: Never damage the companion flange.
    Fig 2: Removing Companion Flange
    G07016514Courtesy of NISSAN NORTH AMERICA, INC.
  8. Remove rear oil seal from rear case with the puller (A) [SST: KV381054S0 (J-34286)].
    CAUTION: Never damage the rear case.
  9. Remove spacer from main shaft.
    Fig 3: Removing Rear Oil Seal
    G07016503Courtesy of NISSAN NORTH AMERICA, INC.
  10. Remove front case and rear case fixing bolts, then remove harness bracket.
    Bolts symbol Quantity
    A 14
    T (TORX bolt) 1
    *: With harness bracket.
    Fig 4: Identifying Front Case And Rear Case Fixing Bolts
    G05979359Courtesy of NISSAN NORTH AMERICA, INC.
  11. Remove front case (1) from rear case by levering it up with a suitable tool.
    CAUTION: Never damage the mating surface.
    Fig 5: Removing Front Case From Rear Case
    G07016517Courtesy of NISSAN NORTH AMERICA, INC.
  12. Remove snap ring (1) from front case.
    CAUTION: Never damage front case.
  13. Remove main shaft bearing from front case.
    CAUTION: Never use tools. Always remove by hand.
    Fig 6: Identifying Snap Ring
    G05979361Courtesy of NISSAN NORTH AMERICA, INC.
  14. Remove snap ring (1) from main shaft.
    CAUTION: Never damage main shaft.
    Fig 7: Identifying Main Shaft Snap Ring
    G05979362Courtesy of NISSAN NORTH AMERICA, INC.
  15. Remove spacer (1) and steel ball (2) from main shaft.
    CAUTION: Be careful not to drop the steel ball.
  16. Remove Oil pump from main shaft.
  17. Remove drive chain and front drive shaft.
    CAUTION: Never use tools. Always remove by hand.
    Fig 8: Identifying Main Shaft Spacer And Steel Ball
    G05979363Courtesy of NISSAN NORTH AMERICA, INC.
  18. Remove transfer fluid temperature sensor bolt from rear case. And then, remove transfer fluid temperature sensor (1).
    Fig 9: Identifying Transfer Fluid Temperature Sensor
    G06626629Courtesy of NISSAN NORTH AMERICA, INC.
  19. Remove oil cover bolts from rear case. And then, remove oil cover (1).
    20. Fig 10: Identifying Oil Cover
    G06626630Courtesy of NISSAN NORTH AMERICA, INC.
  20. Remove retainer from AWD solenoid harness connector.
  21. Remove AWD solenoid harness connector from rear case.
  22. Remove O-ring from AWD solenoid harness connector.
  23. Remove main shaft assembly from rear case with the drift (A) [SST: ST33052000 (-)].
    Fig 11: Removing Main Shaft Assembly From Rear Case
    G05979366Courtesy of NISSAN NORTH AMERICA, INC.
  24. Remove snap ring (1) from rear case.
  25. Remove rear bearing from rear case.
    CAUTION: Never use tools. Always remove by hand.
    Fig 12: Identifying Snap Ring
    G05979367Courtesy of NISSAN NORTH AMERICA, INC.
  26. Remove baffle plate (1) from rear case.
  27. Remove breather tube from rear case.
  28. Perform inspection after disassembly. Refer to "INSPECTION ".
    Fig 13: Identifying Rear Case Baffle Plate
    G05979368Courtesy of NISSAN NORTH AMERICA, INC.
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