Front Case And Rear Case: Assembly

Install breather tube with plastic hammer.
CAUTION: Pay attention to the direction of breather tube.
Install baffle plate to rear case.

Fig 1: Installing Breather Tube
Courtesy of NISSAN MOTOR CO., U.S.A.
Install rear bearing to rear case with the drift (A) [SST: KV38104010 (-)].
CAUTION: Apply transfer fluid to inside of rear bearing.

Fig 2: Installing Rear Bearing To Rear Case With Drift
Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring (1) to rear case.
CAUTION: Never reuse snap ring.

Fig 3: Identifying Snap Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Install mainshaft assembly to rear case with the drift (A) [SST: ST35321000 (-)].
CAUTION: Transfer fluid should be applied to contact surface of mainshaft and rear bearing.
Install O-ring to AWD solenoid harness connector.
CAUTION:
- Never reuse O-ring.
- Apply transfer fluid to O-ring.
Install AWD solenoid harness connector into rear case.

Fig 4: Installing Mainshaft Assembly To Rear Case With Drift
Courtesy of NISSAN MOTOR CO., U.S.A.
Install retainer (1) to AWD solenoid harness connector.

Fig 5: Identifying AWD Solenoid Harness Connector Retainer
Courtesy of NISSAN MOTOR CO., U.S.A.
Hold electric controlled coupling harness (1) with oil cover hold plate (2), install oil cover (3) to rear case (4).
CAUTION: The harness should be guided by a cut portion.

Fig 6: Locating Oil Cover Bolts
Courtesy of NISSAN MOTOR CO., U.S.A.
Install oil gutter (1) to rear case.
CAUTION: The tip of oil gutter should be put into rear case groove.

Fig 7: Identifying Rear Case Oil Gutter
Courtesy of NISSAN MOTOR CO., U.S.A.
Install drive chain to front drive shaft.
CAUTION: Identification mark (A) of drive chain should be in the side of front bearing (1) of front drive shaft.

Fig 8: Identifying Identification Mark Of Drive Chain
Courtesy of NISSAN MOTOR CO., U.S.A.
Install drive chain to mainshaft, and then install tap front drive shaft with plastic hammer. Press-fit rear bearing of front drive shaft to rear case.
CAUTION: Never tap drive chain.

Fig 9: Tapping Front Drive Shaft With Plastic Hammer
Courtesy of NISSAN MOTOR CO., U.S.A.
Install mainshaft bearing to front case with the drift (A) [SST: ST30621000 (J-25742-5)].

Fig 10: Installing Mainshaft Bearing To Front Case With Drift
Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring (1) to front case.
CAUTION: Never reuse snap ring.

Fig 11: Identifying Snap Ring
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply liquid gasket to mating surface of rear case.
Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.

Fig 12: Identifying Liquid Gasket Applying Area
Courtesy of NISSAN MOTOR CO., U.S.A.
Set front case to rear case.
CAUTION: Never damage the mating surface transmission side.

Fig 13: Setting Front Case To Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.

Tighten front case and rear case fixing bolts.

BOLTS REFERENCE CHART

Bolts symbol	Quantity	Bolt length "l " mm (in)
A	11	2 (1.65)
B	1	162 (6.38)
C	1	97 (3.82)
TORX bolt	1	40 (1.57)

Fig 14: Identifying Front Case And Rear Case Fixing Bolts

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

Install spacer (1) to mainshaft.
CAUTION: Apply transfer fluid to spacer.

Fig 15: Identifying Mainshaft Spacer
Courtesy of NISSAN MOTOR CO., U.S.A.
Install rear oil seal to rear case with the drifts within the dimension (L) shown as follows.
1. Drift [SST: ST30720000 (J-25405)]
2. Drift [SST: KV40104830 (-)]
L : 6.7 - 7.3 mm (0.264 - 0.287 in)
CAUTION:
- Never reuse rear oil seal.
- Apply transfer fluid to rear oil seal.
- When installing, never incline rear oil seal.
  
  Fig 16: Installing Rear Oil Seal To Rear Case With Drifts
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install companion flange while aligning the matching mark (A) of mainshaft with the mark (B) of companion flange.

Fig 17: Aligning Matching Mark Of Mainshaft With Mark Of Companion Flange
Courtesy of NISSAN MOTOR CO., U.S.A.
Tighten self-lock nut to the specified torque with flange wrench (A) (commercial service tool).
CAUTION: Never reuse self-lock nut.

Fig 18: Tightening Self-Lock Nut
Courtesy of NISSAN MOTOR CO., U.S.A.
Install mainshaft oil seal until it is flush with end face of front case with the drift (A) [SST: ST30720000 (J-25405)].
CAUTION:
- Never reuse mainshaft oil seal.
- Apply transfer fluid to mainshaft oil seal.
- When installing, never incline mainshaft oil seal.
  
  Fig 19: Identifying Mainshaft Oil Seal
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install front oil seal until it is flush with end face of front case with the drift (A) [SST: ST27862000 (-)].
CAUTION:
- Never reuse front oil seal.
- Apply transfer fluid to front oil seal.
- When installing, never incline front oil seal.
Apply sealant to threads of drain plug. Then, install it to rear case.
Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

CAUTION: Remove old sealant and oil adhering to threads.

Fig 20: Installing Front Oil Seal
Courtesy of NISSAN MOTOR CO., U.S.A.
Set gasket to filler plug. Install it to rear case.
CAUTION:
- Never reuse gasket.
- After oil is filled, tighten filler plug to specified torque.