Front Case And Rear Case: Assembly

WARNING: This page is about a different variant/trim than selected.

Install breather tube to rear case within the angle (A) shown as follows.
A: 80 - 100°

CAUTION: Never reuse breather tube.
Install baffle plate to rear case.
Install rear bearing to rear case.
CAUTION: Never use tools. Always install by hand.

Fig 1: Installing Breather Tube To Rear Case Within Specified Angle
Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring (1) to rear case.
CAUTION: Never reuse snap ring.

Fig 2: Locating Snap Ring In Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Install main shaft assembly to rear case with the drift (A) [SST: ST35321000 (-)].
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.
Install retainer to AWD solenoid harness connector.

Fig 3: Installing Main Shaft Assembly To Rear Case With Drift
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).

Fig 4: Cross-Sectional View Of Electric Controlled Coupling Harness, Oil Cover Hold Plate, Oil Cover And Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Install transfer fluid temperature sensor (1) to rear case.

Fig 5: Locating Transfer Fluid Temperature Sensor
Courtesy of NISSAN MOTOR CO., U.S.A.
Set 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.
Install drive chain to main shaft, and then install front drive shaft.
CAUTION: Never use tools. Always install by hand.
Install oil pump to main shaft.

Fig 6: Locating Identification Mark Of Drive Chain In Side Of Front Bearing Of Front Drive Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Install spacer (1) and steel ball (2) to main shaft.

Fig 7: Locating Spacer And Steel Ball On Main Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring (1) to main shaft.
CAUTION: Never reuse snap ring.
Install main shaft bearing to front case.
CAUTION: Never use tools. Always install by hand.

Fig 8: Locating Snap Ring On Main Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Install snap ring (1) to front case.
CAUTION: Never reuse snap ring.

Fig 9: Locating Snap Ring In Front Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply liquid gasket (1) 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.
Set front case to rear case.
CAUTION: Never damage the mating surface transmission side.

Fig 10: Applying Liquid Gasket To Mating Surface Of Rear Case
Courtesy of NISSAN MOTOR CO., U.S.A.

Tighten front case and rear case fixing bolts.

REAR CASE FIXING BOLTS REFERENCE CHART

Bolts symbol

Quantity

T (TORX bolt)

⁽¹⁾	With harness bracket.

Install spacer to main shaft.
CAUTION: Apply transfer fluid to spacer.

Fig 11: Identifying Front And Rear Case Fixing Bolt Tightening Sequence
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply transfer fluid to outside of rear oil seal, and install rear oil seal to rear case with the drifts within the dimension (L) shown as follows.

Fig 12: Installing Rear Oil Seal To Rear Case With Drifts Within Specified Dimension
Courtesy of NISSAN MOTOR CO., U.S.A.

L: 6.7 - 7.3 mm (0.264 - 0.287 in)
CAUTION:
- Never reuse rear oil seal.
- Apply petroleum jelly to oil seal lip.
- When installing, never incline rear oil seal.
Install companion flange while aligning the matching mark (A) of main shaft with the mark (B) of companion flange.

Fig 13: Aligning Matching Mark Of Main Shaft 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 14: Tightening Self-Lock Nut Of Companion Flange Using Special Service Tool & Flange Wrench
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply transfer fluid to outside of main shaft oil seal, and install main shaft oil seal until it is flush with the end face of front case with the drift (A) [SST: ST30720000 (J-25405)].
CAUTION:
- Never reuse main shaft oil seal.
- Apply petroleum jelly to oil seal lip.
- When installing, never incline main shaft oil seal.
Fig 15: Installing Main Shaft Oil Seal Until It Is Flush With End Face Of Front Case With Drift
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply transfer fluid to outside of front oil seal, and install front oil seal until it is flush with the end face of front case with the drift (A) [SST: ST27862000 (-)].
CAUTION:
- Never reuse front oil seal.
- Apply petroleum jelly to oil seal lip.
- When installing, never incline front oil seal.
Set gasket to drain plug. Install it to rear case and tighten it to specified torque.
CAUTION: Never reuse gasket.
Set gasket to filler plug. Install it to rear case.

CAUTION:

Never reuse gasket.
After oil is filled, tighten filler plug to specified torque.

Fig 16: Installing Front Oil Seal Until It Is Flush With End Face Of Front Case With Drift

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