Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2012 Nissan Pathfinder. However, it is still accessible from the selected car via links, so may be relevant.

Control Valve Assembly

Assemble the control valve assembly with the following procedure.
CAUTION:
- Do not reuse any part that has been dropped or damaged.
- Make sure valve is assembled in the proper direction.
- Do not use a magnet because residual magnetism stays during assembly.
1. Clean the upper body (5), control valves (3) and springs (4) with cleaning agent, and dry with compressed air.
2. Dip the control valves in ATF, and apply ATF to the valve-mounting area of the upper body.
  
  Fig 1: Identifying Upper Body, Control Valve, Retainers Plates, Plugs And Springs Transfer Assembly
  Courtesy of NISSAN NORTH AMERICA, INC.
3. Install each control valve (3), springs (4), and plugs (2) to the upper body (5), and install retainer plates (1) to hold them in place.
  CAUTION:
  - To insert control valves into upper body, place upper body on a level surface in order to prevent flaw or damage.
  - Make sure each control valve is smoothly inserted.
    
    Fig 2: Locating Retainer Plates
    Courtesy of NISSAN NORTH AMERICA, INC.
4. Install the reverse balls, relief balls and relief springs, accumulator pistons and valve springs to the upper body.
  
  Fig 3: Identifying Reverse Balls, Relief Balls, Relief Springs, Accumulator Pistons And Valve Springs
  Courtesy of NISSAN NORTH AMERICA, INC.
5. Install the lower body and separator plate to the upper body.
  CAUTION: Do not reuse separator plate.
  
  Fig 4: Identifying Separator Plate, Lower And Upper Body
  Courtesy of NISSAN NORTH AMERICA, INC.
6. With the lower body down, tighten the two bolts shown.
7. Apply ATF to the new O-rings, and install them to each solenoid valve, switch and terminal body.
  CAUTION: Do not reuse O-rings.
8. Install the following to the control valve assembly:
  - Clutch pressure solenoid valve
  - Clutch pressure switch
  - 2-4WD shift solenoid valve
  - Line pressure switch
  - Transfer fluid temperature sensor
    
    Fig 5: Locating Transfer Assembly Bolts
    Courtesy of NISSAN NORTH AMERICA, INC.

Center Case

Apply ATF to the new O-ring, and install it on the oil filter stud.
CAUTION: Do not reuse O-rings.
Install the oil filter stud to the oil filter.

Fig 6: Identifying Oil Filter, Stud And O-Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Apply ATF to the two new O-rings (1), and install them on the oil filter (2).
CAUTION: Do not reuse O-rings.

Fig 7: Identifying Oil Filter And O-Rings
Courtesy of NISSAN NORTH AMERICA, INC.
Install the oil filter to the center case. Tighten the bolts to the specified torque. Refer to "COMPONENT PARTS LOCATION ".
CAUTION:
- Do not damage oil filter.
- Attach oil filter and tighten bolts evenly.
  
  Fig 8: Locating Oil Filter Bolts
  Courtesy of NISSAN NORTH AMERICA, INC.
Install the outer gear and inner gear into the sub oil pump housing, and measure the side clearance. Refer to "INSPECTION AND ADJUSTMENT ".

Fig 9: Identifying Outer Gear And Inner Gear, Sub Oil Pump Housing And Cover
Courtesy of NISSAN NORTH AMERICA, INC.
Align the dowel pin hole and bolt hole of the sub oil pump assembly with the center case. Install the sub oil pump cover. Then tighten to the specified torque. Refer to "COMPONENT PARTS LOCATION ".

Fig 10: Identifying Sub Oil Pump Cover And Dowel Pins
Courtesy of NISSAN NORTH AMERICA, INC.
Apply ATF to the new O-ring and install it to the transfer motor.
CAUTION: Do not reuse O-rings.
Fit the double-flat end of the transfer motor shaft into the slot of the sub-oil pump assembly. Then tighten to the specified torque. Refer to "COMPONENT PARTS LOCATION ".
CAUTION: Be sure to install connector bracket.

Fig 11: Identifying Sub-Oil Pump Assembly And O-Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Apply ATF to the new lip seals, and install them to the center case.
CAUTION:
- Do not reuse lip seals.
- There are 2 kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm their position for installation.
  
  Fig 12: Identifying Small And Large Lip Seals Of Center Case
  Courtesy of NISSAN NORTH AMERICA, INC.
Install the control valve assembly to the center case, and tighten to the specified torque. Refer to "COMPONENT PARTS LOCATION ".
CAUTION:
- Do not reuse any part that has been dropped or damaged.
- Make sure valve is assembled in the proper direction.
- Do not use a magnet because residual magnetism stays during assembly.
  
  Fig 13: Locating Control Valve Assembly Bolts
  Courtesy of NISSAN NORTH AMERICA, INC.
Install the connector assembly into the center case, and secure with a snap ring.

Fig 14: Identifying Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Apply ATF to the new O-rings, and install them on the oil strainer.
CAUTION: Do not reuse O-rings.
Install the oil strainer to the control valve assembly.

Fig 15: Identifying Oil Strainer And O-Rings
Courtesy of NISSAN NORTH AMERICA, INC.
Tighten the bolts to the specified torque. Refer to "COMPONENT PARTS LOCATION ".

Fig 16: Locating Oil Strainer Bolts
Courtesy of NISSAN NORTH AMERICA, INC.
Apply ATF to the new D-rings, and install them to the clutch piston.
CAUTION: Do not reuse D-rings.

Fig 17: Identifying D-Rings, Clutch Piston And Thrust Needle Bearing Race
Courtesy of NISSAN NORTH AMERICA, INC.
Install the thrust needle bearing race to the clutch piston.

Fig 18: Installing Thrust Needle Bearing Race To Clutch Piston
Courtesy of NISSAN NORTH AMERICA, INC.
Install the clutch piston to the center case as shown.
CAUTION: Install so the fitting protrusion of clutch piston aligns with the dent of center case.

Fig 19: Identifying Clutch Piston Fit Are On Center Case
Courtesy of NISSAN NORTH AMERICA, INC.
Remove all the sealant from the oil pressure check port and inside the center case.
CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.
Thread the new oil pressure check plug in 1 or 2 pitches and apply sealant to the oil pressure check plug threads. Tighten to the specified torque. Refer to "COMPONENT PARTS LOCATION ".
- Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
  
  Fig 20: Identifying Oil Pressure Check Plug And Port And Center Case
  Courtesy of NISSAN NORTH AMERICA, INC.
CAUTION: Do not reuse oil pressure check plug.
Install the new snap ring to the clutch hub using suitable tool.
CAUTION: Do not reuse snap ring.

Fig 21: Removing/Installing Snap Ring From Clutch Hub Using Suitable Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Apply petroleum jelly to the needle bearing, and install the needle bearing, spacer, clutch drum and clutch hub to the mainshaft.

Fig 22: Identifying Needle Bearing, Spacer, Clutch Drum And Hub, Main Shaft And Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Install the new snap ring to the mainshaft.
CAUTION: Do not reuse snap rings.

Fig 23: Identifying Snap Ring And Mainshaft
Courtesy of NISSAN NORTH AMERICA, INC.
Apply ATF each plate, then install them into the clutch drum as shown.

Fig 24: Identifying Press Flange, Drive Plate, Clutch Hub And Drum
Courtesy of NISSAN NORTH AMERICA, INC.
Install the return spring assembly into the clutch hub.

Fig 25: Removing Return Spring Assembly From Clutch Hub
Courtesy of NISSAN NORTH AMERICA, INC.
Install the press flange by aligning the notches to the clutch hub as shown.

Fig 26: Locating Press Flange Aligning Notches
Courtesy of NISSAN NORTH AMERICA, INC.
Press the press flange to install the new snap ring into snap ring groove on mainshaft using Tools.
Tool number (A): ST22452000 (J-34335)

(B): ST30911000 (-)

(C): KV31103300 (-)

Fig 27: Pressing Flange Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.

CAUTION: Do not reuse snap ring.
Install the new snap ring to the mainshaft using suitable tool.
CAUTION: Do not reuse snap ring.

Fig 28: Removing Snap Ring From Mainshaft Using Suitable Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Apply ATF to the thrust needle bearing and install it on the press flange.

Fig 29: Removing Thrust Needle Bearing From Press Flange
Courtesy of NISSAN NORTH AMERICA, INC.
Install the new snap ring to the main shaft.
CAUTION: Do not reuse snap ring.

Fig 30: Identifying Snap Ring On Main Shaft
Courtesy of NISSAN NORTH AMERICA, INC.
Install the mainshaft rear bearing to the center case using Tool.
Tool number: ST15310000 (J-25640-B)

Fig 31: Installing Mainshaft Rear Bearing To Center Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the mainshaft assembly using a press.
- Press the mainshaft into the center case using Tools.
  Tool number (A): ST30911000 (-)
  
  (B): ST35300000 (-)
  
  Fig 32: Press Mainshaft Into Center Case Using Tools
  Courtesy of NISSAN NORTH AMERICA, INC.
Install the C-rings to the mainshaft.

Fig 33: Identifying C-Rings Of Mainshaft
Courtesy of NISSAN NORTH AMERICA, INC.
Set the washer holder on the mainshaft, and secure it with a new snap ring.
CAUTION: Do not reuse snap ring.

Fig 34: Removing Snap Ring Of Mainshaft
Courtesy of NISSAN NORTH AMERICA, INC.
Apply petroleum jelly to the stem bleeder and install it to the center case.

Fig 35: Removing/Installing Stem Bleeder Using Magnet
Courtesy of NISSAN NORTH AMERICA, INC.
Apply ATF to the new seal ring and install it to the main oil pump cover.
CAUTION: Do not reuse seal ring.

Fig 36: Identifying Seal Ring Of Main Oil Pump Cover
Courtesy of NISSAN NORTH AMERICA, INC.
Install the inner gear and outer gear in the main oil pump housing. Then, measure the side clearance. Refer to "INSPECTION AND ADJUSTMENT ".

Fig 37: Checking Inner And Outer Circumference, Tooth Face And Side-Face Of Gears For Damage Or Abnormal Wear
Courtesy of NISSAN NORTH AMERICA, INC.
Install the main oil pump housing, outer gear and inner gear to the center case.

Fig 38: Identifying Main Oil Pump Housing, Outer And Inner Gear Of Center Case
Courtesy of NISSAN NORTH AMERICA, INC.
Install the main oil pump cover to the center case, and tighten to the specified torque. Refer to "COMPONENT PARTS LOCATION ".

Fig 39: Locating Main Oil Pump Cover Bolts
Courtesy of NISSAN NORTH AMERICA, INC.
Remove all the sealant from the switch location area and inside the center case.
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
Thread the ATP switch and neutral-4LO switch in one to two pitches and apply sealant to the threads of the switches. Tighten to the specified torque. Refer to "COMPONENT PARTS LOCATION ".

Fig 40: Identifying ATP And Neutral-4LO Switches
Courtesy of NISSAN NORTH AMERICA, INC.
- Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
  NOTE:
  - Neutral-4LO switch harness connector is gray.
  - ATP switch harness connector is black.
Install the front drive shaft rear bearing using Tools.
Tool number (A): KV40100621 (J-25273)

(B): ST30032000 (J-26010-01)

Fig 41: Installing Front Drive Shaft Rear Bearing Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the front drive shaft to the front bearing using Tools.
Tool number (A): KV40100621 (J-25273)

(B): ST30032000 (J-26010-01)

Fig 42: Installing Front Drive Shaft On Front Bearing Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the drive chain to the front drive shaft and clutch drum.
CAUTION: Install drive chain by aligning identification marks to the rear as shown.

Fig 43: Identifying Drive Chain, Alignment Identification Marks, Main Shaft And Front Case
Courtesy of NISSAN NORTH AMERICA, INC.
Tap the front drive shaft while keeping it upright and press-fit the front drive shaft rear bearing.
CAUTION: Do not tap drive chain.
Install the front case assembly.
Install the rear case assembly.

Fig 44: Tapping Of Front Drive Shaft Rear Bearing
Courtesy of NISSAN NORTH AMERICA, INC.

Front Case

Install the carrier bearing to the sun gear using Tools.
Tool number (A): ST30911000 (-)

(B): KV31103300 (-)

Fig 45: Installing Carrier Bearing On Sun Gear Using Tools
Courtesy of NISSAN NORTH AMERICA, INC.
Install the new snap ring to the sun gear assembly using suitable tool.
CAUTION: Do not reuse snap ring.

Fig 46: Removing/Installing Snap Ring From Sun Gear Assembly Using Suitable Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Apply ATF to the circumference of the new metal bushing and install it to the sun gear assembly using suitable tool.
Dimension (A): 7.7 - 8.3 mm (0.303 - 0.327 in)

Fig 47: Installing Metal Bushing To Sun Gear Assembly Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
CAUTION:
- Do not reuse metal bushing.
- Apply ATF to metal bushing before installing.
Apply ATF to the new needle bearing and install it to the sun gear assembly using Tool.
Tool number: ST33220000 (-)

Dimension (B): 62.5 - 63.1 mm (2.461 - 2.484 in)

Fig 48: Installing Needle Bearing To Sun Gear Assembly Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
CAUTION:
- Do not reuse needle bearing.
- Apply ATF to needle bearing before installing.
Install the sun gear assembly to the planetary carrier assembly.

Fig 49: Installing Sun Gear Assembly To Planetary Carrier Assembly
Courtesy of NISSAN NORTH AMERICA, INC.
Install the new snap ring to the planetary carrier assembly.
CAUTION: Do not reuse snap ring.

Fig 50: Installing Planetary Carrier Assembly Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Set the input bearing into the front case and install using Tool.
Tool number: ST30720000 (J-25405)

Fig 51: Setting Input Bearing Into Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the new snap ring into the front case.
CAUTION: Do not reuse snap ring.

Fig 52: Identifying Snap Ring
Courtesy of NISSAN NORTH AMERICA, INC.
Install the internal gear with its groove facing the snap ring into the front case. Then secure it with the new snap ring.
CAUTION: Do not reuse snap ring.

Fig 53: Identifying Snap Ring And Snap Ring Grooves
Courtesy of NISSAN NORTH AMERICA, INC.
Install the new front oil seal until it is seated flush with the end face of the front case using Tool.
Tool number: KV38100500 (-)

Fig 54: Installing Front Oil Seal Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal lip before installing.
Install the planetary carrier assembly and sun gear assembly to the front case using Tool.
Tool number: ST33200000 (J-26082)

Fig 55: Installing Planetary Carrier Assembly And Sun Gear Assembly To Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the new snap ring to the sun gear.
CAUTION: Do not reuse snap ring.

Fig 56: Identifying Snap Ring From Sun Gear Assembly
Courtesy of NISSAN NORTH AMERICA, INC.
Apply petroleum jelly to the circumference of the new oil seal, and install it to the front case using Tools.
Tool numbers (A): ST30720000 (J-25405)

(B): ST33200000 (J-26802)

Dimension (A): 4.0 - 4.6 mm (0.157 - 0.181 in)

Fig 57: Installing Input Oil Seal Into Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal.
Install the fork guide, shift fork spring, 2-4 fork, and L-H fork to the shift rod, and secure them with new retaining pins.
CAUTION: Do not reuse retaining pins.

Fig 58: Identifying Fork Guide, Shift Fork Spring, 2-4 Fork And L-H Fork To Shift Rod
Courtesy of NISSAN NORTH AMERICA, INC.
Install the 2-4 sleeve and L-H sleeve to each fork.
Install the shift cross to the front case.

Fig 59: Identifying Shift Rod, 2-4 And L-H Sleeve And Fork
Courtesy of NISSAN NORTH AMERICA, INC.
While aligning the L-H sleeve with the planetary carrier, install the shift rod assembly (A) to the front case.

Fig 60: Removing/Installing Shift Cross From Front Case Using Shift Rod
Courtesy of NISSAN NORTH AMERICA, INC.
Apply liquid gasket to the entire center case mating surface of the front case assembly as shown.
- Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
  CAUTION: Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces.
  
  Fig 61: Identifying Liquid Gasket Applying Dia And Area Of Center Case Mating Surface
  Courtesy of NISSAN NORTH AMERICA, INC.
Install the center case assembly to the front case assembly.
CAUTION: Do not damage mainshaft end.
Tap the center case lightly and press-fit the front drive shaft bearing into the front case.

Fig 62: Installing Center Case Assembly To Front Case Assembly
Courtesy of NISSAN NORTH AMERICA, INC.
Tighten the front case bolts to the specified torque. Refer to "COMPONENT PARTS LOCATION ".
CAUTION: Be sure to install air breather hose clamp, connector bracket and harness clip.
Install the drain plug with a new gasket.
CAUTION: Do not reuse gasket.

Fig 63: Locating Center Case Bolts
Courtesy of NISSAN NORTH AMERICA, INC.
Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.

Fig 64: Identifying Matching Mark Of Front Drive Shaft Thread And Companion Flange
Courtesy of NISSAN NORTH AMERICA, INC.
Install a new companion flange self-lock nut. Tighten to the specified torque using suitable tool. Refer to "COMPONENT PARTS LOCATION ".
CAUTION: Do not reuse self-lock nut.

Fig 65: Installing Companion Flange Self-Lock Nut Using Suitable Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Remove all the sealant from the check plug, switch and front case.
CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
Install the check ball and check spring to the front case. Apply sealant to the check plug and wait detection switch and install them to the front case. Tighten to the specified torque. Refer to "COMPONENT PARTS LOCATION ".

Fig 66: Identifying Check Ball, Spring And Plug And Front Case
Courtesy of NISSAN NORTH AMERICA, INC.
- Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
  NOTE: Wait detection switch harness connector is black.
Install the new oil seal in the front case using Tool.
Tool number: ST22360002 (J-25679-01)

Fig 67: Installing Oil Seal In Front Case Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to seal lip before installing.
Install the shift lever to the shift cross.
Install the lock pin and lock pin nut. Tighten to the specified torque. Refer to "COMPONENT PARTS LOCATION ".

Rear Case

Apply petroleum jelly to the circumference of the new rear oil seal. Install the new rear oil seal so that it is flush with the case tip face using Tool.
Tool number: ST30720000 (J-25405)

Fig 68: Installing Rear Oil Seal Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to seal lip before installing.
Apply petroleum jelly to the circumference of the new dust cover. Position the new dust cover as shown.
CAUTION:
- Do not reuse dust cover .
- Position the protrusions at the position shown .
- 1: Dust cover
- 2: Rear case assembly
- A: Protrusions
  
  Fig 69: Identifying Protrusions, Rear Case Assembly And Dust Cover
  Courtesy of NISSAN NORTH AMERICA, INC.
Install the new dust cover using Tool.
Tool number: KV40105310 (-)

Fig 70: Installing Dust Cover Using Tool
Courtesy of NISSAN NORTH AMERICA, INC.
Install the air breather into the rear case.
Remove all the sealant from the rear case to center case mating surfaces.
CAUTION: Remove all foreign materials such as water, oil, and grease from center case and rear case mating surfaces.
Apply liquid gasket to the entire rear case mating surface of the center case.
- Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
CAUTION: Do not to allow Liquid Gasket to enter stem bleeder hole.
Install the rear case to the center case. Tighten the bolts to the specified torque. Refer to "COMPONENT PARTS LOCATION ".

Fig 71: Locating Rear Case Bolts
Courtesy of NISSAN NORTH AMERICA, INC.