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Home >> Nissan-Datsun >> 2012 >> Frontier SL, 4WD >> Repair and Diagnosis >> Transmission >> Transfer Case >> Unit Disassembly And Assembly >> Transfer Assembly >> Disassembly and Assembly >> Disassembly

Disassembly and Assembly: Disassembly

  1. Remove the drain plug and filler plug.
  2. Remove the transfer control device from the rear case.
  3. Remove the O-ring from the transfer control device.
    CAUTION: Do not reuse O-ring.
    Fig 1: Identifying Transfer Control Device Bolts
    G04898506Courtesy of NISSAN NORTH AMERICA, INC.
  4. Remove the self-lock nut from the companion flange, using suitable tool.
    Fig 2: Removing Self-Lock Nut
    G04901626Courtesy of NISSAN NORTH AMERICA, INC.
  5. 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 Matching Marks
    G04901627Courtesy of NISSAN NORTH AMERICA, INC.
  6. Remove the companion flange, using suitable tool.
    Fig 4: Removing Companion Flange
    G04901628Courtesy of NISSAN NORTH AMERICA, INC.
  7. Remove the front oil seal from the front case, using Tool.

    Tool number: ST33290001 (J-34286) 

    Fig 5: Removing Front Oil Seal
    G04898522Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Do not damage front case or front drive shaft.
  8. Remove the 4LO switch [gray (with green paint)] and ATP switch (black) from the front case.
    Fig 6: Identifying 4LO Switch & ATP Switch
    G04898523Courtesy of NISSAN NORTH AMERICA, INC.
  9. Remove the wait detection switch (gray) from the rear case.
    Fig 7: Identifying Wait Detection Switch
    G04898524Courtesy of NISSAN NORTH AMERICA, INC.
  10. Remove check plug, check shift spring and check ball (M/T models only).
    Fig 8: Identifying Check Plug, Spring & Ball
    G04898525Courtesy of NISSAN NORTH AMERICA, INC.
  11. Remove the dust cover from the rear case, using suitable tool.
    CAUTION: Do not damage rear case.
  12. Remove oil cover from the dust cover.
    Fig 9: Removing Dust Cover
    G04898526Courtesy of NISSAN NORTH AMERICA, INC.
  13. Remove the rear oil seal from the rear case, using Tool.
    CAUTION: Do not damage rear case or mainshaft.

    Tool number: ST33290001 (J-34286) 

    Fig 10: Removing Rear Oil Seal
    G04898527Courtesy of NISSAN NORTH AMERICA, INC.
  14. 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
    G04898528Courtesy of NISSAN NORTH AMERICA, INC.
  15. Remove the retainer bolts and gaskets.
    Fig 12: Locating Retainer Bolts
    G04898529Courtesy of NISSAN NORTH AMERICA, INC.
  16. Remove the rear case bolts, harness bracket and air breather hose clamp from the rear case.
    Fig 13: Locating Rear Case Bolts
    G04898530Courtesy of NISSAN NORTH AMERICA, INC.
  17. 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.
  18. 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
    G04898531Courtesy of NISSAN NORTH AMERICA, INC.
  19. Remove the snap ring from the mainshaft, using suitable tool.
    Fig 15: Removing Snap Ring
    G04898532Courtesy of NISSAN NORTH AMERICA, INC.
  20. Remove the mainshaft rear bearing from the mainshaft, using suitable tool.
  21. Remove the retainer from the mainshaft.
    Fig 16: Removing Mainshaft Rear Bearing
    G04898533Courtesy of NISSAN NORTH AMERICA, INC.
  22. Remove the snap ring from the mainshaft, using suitable tool.
  23. Remove the oil pump assembly from the mainshaft.
    Fig 17: Removing Snap Ring & Oil Pump
    G04898534Courtesy of NISSAN NORTH AMERICA, INC.
  24. Remove the snap ring from the mainshaft, using suitable tool.
  25. Remove the clutch gear from the mainshaft.
    Fig 18: Removing Snap Ring & Clutch Gear
    G04898535Courtesy of NISSAN NORTH AMERICA, INC.
  26. Remove the snap ring from the L-H shift rod assembly, using suitable tool.
  27. Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.
    Fig 19: Removing Snap Ring & L-H Shift Rod Assembly
    G04898536Courtesy of NISSAN NORTH AMERICA, INC.
  28. Remove the drive chain together with the sprocket and front drive shaft from the front case.
  29. Remove the mainshaft from the sun gear assembly.
  30. Remove the L-H shift rod assembly and control shift rod assembly from the front case.
  31. Remove the L-H sleeve together with the L-H shift fork from the planetary carrier assembly.
    Fig 20: Removing Drive Chain With Front Drive Shaft & Sprocket
    G04898537Courtesy of NISSAN NORTH AMERICA, INC.
  32. Remove the snap ring from the sun gear.
    CAUTION: Do not damage sun gear or input bearing.
    Fig 21: Identifying Snap Ring
    G04898538Courtesy of NISSAN NORTH AMERICA, INC.
  33. Press the sun gear assembly and planetary carrier assembly from the front case, using Tool.

    Tool number: KV38100200 (-) 

    Fig 22: Pressing Sun Gear Assembly
    G04898539Courtesy of NISSAN NORTH AMERICA, INC.
  34. Remove the snap ring from the front case.
    Fig 23: Identifying Snap Ring & Internal Gear
    G04898540Courtesy of NISSAN NORTH AMERICA, INC.
  35. Remove the internal gear from the front case.
    Fig 24: Removing Internal Gear
    G04898541Courtesy of NISSAN NORTH AMERICA, INC.
  36. Remove the snap ring from the front case.
    Fig 25: Identifying Snap Ring
    G04898542Courtesy of NISSAN NORTH AMERICA, INC.
  37. Remove the input bearing from the front case, using Tool.

    Tool number: KV38100200 (-) 

    Fig 26: Removing Input Bearing
    G04898543Courtesy of NISSAN NORTH AMERICA, INC.
  38. Remove the baffle plate from the front case.
  39. Remove the breather tube from the front case.
Fig 27: Identifying Baffle Plate
G04898544Courtesy of NISSAN NORTH AMERICA, INC.
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