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Front Case And Rear Case: Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Install breather tube to rear case within the angle shown as follows.
    Fig 1: Installing Breather Tube To Rear Case
    G09160833Courtesy of NISSAN NORTH AMERICA, INC.
    Angle : 80 - 100°
    CAUTION:

    Never reuse breather tube.

  2. Install baffle plate to rear case.
  3. Install rear bearing to rear case.
    CAUTION:

    Never use tools. Always install by hand.

  4. Install snap ring to rear case.
    Fig 2: Identifying Rear Case Snap Ring
    G05979367Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:

    Never reuse snap ring.

  5. Install main shaft assembly to rear case with the drift (A) [SST: ST35321000 (-)].
    Fig 3: Installing Main Shaft Assembly To Rear Case Using Drift
    G05979371Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:

    Apply transfer fluid to the sliding surface of main shaft and needle bearing.

  6. Install AWD solenoid harness connector into rear case.
    CAUTION:
    • O-ring is non-reusable. When replace it, replace electric controlled coupling.
    • Apply transfer fluid to O-ring.
  7. Install retainer to AWD solenoid harness connector.
  8. Hold electric controlled coupling harness with oil cover hold plate part, install oil cover to rear case.
    Fig 4: Identifying Electric Controlled Coupling Harness, Oil Cover Hold Plate, Oil Cover And Rear Case
    G06626637Courtesy of NISSAN NORTH AMERICA, INC.
  9. Install transfer fluid temperature sensor to rear case.
    Fig 5: Identifying Transfer Fluid Temperature Sensor
    G06626629Courtesy of NISSAN NORTH AMERICA, INC.
  10. Set drive chain to front drive shaft.
    CAUTION:

    Identification mark of drive chain should be in the side of front bearing of front drive shaft.

    Fig 6: Identifying Identification Mark Of Drive Chain
    G05727203Courtesy of NISSAN NORTH AMERICA, INC.
  11. Install drive chain to main shaft, and then install front drive shaft assembly.
    CAUTION:

    Never use tools. Always install by hand.

  12. Install oil pump to main shaft.
  13. Install spacer and steel ball to main shaft.
    Fig 7: Identifying Main Shaft Spacer And Steel Ball
    G05979363Courtesy of NISSAN NORTH AMERICA, INC.
  14. Install snap ring to main shaft.
    Fig 8: Identifying Main Shaft Snap Ring
    G05979362Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Never reuse snap ring.
    • Never damage main shaft.
  15. Install main shaft bearing to front case.
    CAUTION:

    Never use tools. Always install by hand.

  16. Install snap ring to front case.
    Fig 9: Identifying Front Case Snap Ring
    G05979361Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Never reuse snap ring.
    • Never damage front case.
  17. Apply liquid gasket to mating surface of rear case.
    Fig 10: Applying Liquid Gasket To Mating Surface Of Rear Case
    G05979378Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:

    Remove old sealant from mounting surfaces. Also remove any moisture, oil, or foreign material from application and mounting surfaces.

  18. Set front case to rear case.
    CAUTION:

    Never damage the mating surface transmission side.

  19. Tighten front case and rear case fixing bolts.
    Fig 11: Identifying Front Case And Rear Case Fixing Bolts
    G09160823Courtesy of NISSAN NORTH AMERICA, INC.
    • For " * " mark bolt, tighten it after attach harness bracket.
    Bolts symbol Quantity
      13
    (TORX bolt) 2

    * : With harness bracket.

  20. Install spacer to main shaft.
  21. Apply transfer fluid to outside of rear oil seal, and install rear oil seal to rear case with the drifts (A and B) within the dimension (L) shown as follows.
    Fig 12: Installing Rear Oil Seal To Rear Case With Drifts Within Specified Dimension
    G06329984Courtesy of NISSAN NORTH AMERICA, INC.
    A : Drift [SST: ST30720000 (J-25405)]
    B : Drift [SST: KV40104830 (-)]
    L : 6.7 - 7.3 mm (0.264 - 0.287 in)
    CAUTION:
    • Never reuse rear oil seal.
    • Apply multi-purpose grease to oil seal lip.
    • When installing, never incline rear oil seal.
  22. Install companion flange while aligning the matching mark of main shaft with the mark of companion flange.
    Fig 13: Identifying Matching Mark On End Of Main Shaft And Companion Flange
    G05727164Courtesy of NISSAN NORTH AMERICA, INC.
  23. Tighten self-lock nut to the specified torque with flange wrench (A) (commercial service tool).
    Fig 14: Installing Companion Flange Self-Lock Nut Using Flange Wrench
    G05979336Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:

    Never reuse self-lock nut.

  24. 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)].
    Fig 15: Installing Main Shaft Oil Seal
    G05979383Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Never reuse main shaft oil seal.
    • Apply multi-purpose grease to oil seal lip.
    • When installing, never incline main shaft oil seal.
  25. 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 (-)].
    Fig 16: Installing Front Oil Seal
    G05979384Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Never reuse front oil seal.
    • Apply multi-purpose grease to oil seal lip.
    • When installing, never incline front oil seal.
  26. Set gasket to drain plug. Install it to rear case.
    CAUTION:

    Never reuse gasket.

  27. Set gasket to filler plug. Install it to rear case.
    CAUTION:
    • Never reuse gasket.
    • After oil is filled, tighten filler plug to specified torque.
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