INFINITI QX56 2004 Factory Service Manual

TF-136
FRONT CASE
Revision: August 20072004 QX56
FRONT CASEPFP:33107
AssemblyEDS00193
PLANETARY CARRIER, SUN GEAR AND INTERNAL GEAR
1. Install new oil seal until it is seated flush with end face of the
front case, using Tool.
NOTE:

Before installing, apply ATF or petroleum jelly to new oil seal
lip.

Do not reuse oil seal.
2. Install internal gear with its groove facing snap ring into front
case. Then secure it with new snap ring.
NOTE:
Do not reuse snap ring.
3. Set mainshaft front bearing into front case and install, using
Tool.
4. Install new snap ring into front case.
NOTE:
Do not reuse snap ring.
5. Install shift cross to front case.Tool number : KV38100500 ( — )
SDIA2177E
WDIA0100E
Tool number : ST30720000 (J-25405)
SDIA2172E
SDIA2171E

FRONT CASE
TF-137
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Revision: August 20072004 QX56
6. Install oil new seal in front case, using Tool.
NOTE:

Before installing, apply ATF or petroleum jelly to seal lip.

Do not reuse oil seal.
7. Install the shift lever to the shift cross, and lock pin and tighten to
specified torque. Refer to TF-110, "
Transfer Components" .
8. Install the carrier bearing to the sun gear assembly, using Tool.
9. Install new snap ring to sun gear assembly, using suitable tool.
NOTE:
Do not reuse snap ring.
10. Apply ATF to the circumference of the new metal busing prior to
installing it to the sun gear assembly, using Tool.
NOTE:
Do not reuse old metal bushing.
11. Install the needle bearing to the sun gear assembly, using Tool.
NOTE:

Before installing, apply ATF to needle bearing.

Do not reuse old needle bearing.Tool number : ST22360002 (J25679-01)
SDIA2182E
To o l n u m b e r
A : ST30911000 ( — )
B : KV31103300 ( — )
SDIA2179E
SDIA2148E
Dimension A : 7.7 - 8.3 mm (0.303 - 0.327 in)
Tool number : ST35300000 ( — )
SDIA2187E
Dimension B : 62.5 - 63.1 mm (2.461 - 2.484 in)
Tool number : ST33220000 ( — )
SDIA2478E

TF-138
FRONT CASE
Revision: August 20072004 QX56
12. Install the sun gear assembly to the planetary carrier assembly.
13. Install new snap ring to planetary carrier assembly.
NOTE:
Do not reuse snap ring.
14. Install front case to planetary carrier assembly, using Tool.
15. Install new snap ring to the sun gear assembly.
NOTE:
Do not reuse snap ring.
16. Apply ATF or petroleum jelly to the circumference of the new oil
seal, and install it to the front case using Tool.
NOTE:
Do not reuse oil seal.
SDIA2180E
SDIA2181E
Tool number : ST33200000 (J-26082)
SDIA2183E
SDIA2144E
Tool number
A : ST30720000 (J-25405)
B : ST33200000 (J-26082)
Dimension : 4.0 - 4.6 mm (0.157 - 0.181 mm)
SDIA2184E

FRONT CASE
TF-139
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Revision: August 20072004 QX56
17. Install shift rod assembly to front case assembly. Refer to TF-139, "SHIFT ROD ASSEMBLY" .
SHIFT ROD ASSEMBLY
1. Install fork guide, shift fork spring, 2-4 fork, and L-H fork to shift
rod, and secure them with new retaining pins.
NOTE:
Do not reuse retaining pins.
2. Install 2-4 sleeve and L-H sleeve to each fork.
3. While aligning L-H sleeve with planetary carrier, install shift rod
assembly to front case.
4. Remove all the liquid gasket on check plug and front case, and
install check ball and check spring to front case. Apply specified
sealant or equivalent, to check plug. Install it to front case, and
tighten to specified torque. Refer to GI-45, "
Recommended
Chemical Products and Sealants" .
5. Remove all the liquid gasket on the switch fitting and inner side
of front case, and with wait detection switch threaded one pitch
into the hole. Apply specified sealant or equivalent, to the
thread. Install it, and tighten to specified torque. Refer to GI-45,
"Recommended Chemical Products and Sealants" .
NOTE:
Wait detection switch harness connector is black.
6. Install center case assembly to front case assembly. Refer to TF-149, "
Final Assembly" .
7. Install rear case assembly to center case. Refer to TF-149, "
Final Assembly" .
SDIA2142E
SMT992C
SDIA2140E
Front case check plug : 22 N·m (2.2 kg-m, 16 ft-lb)
Wait detection switch : 28 N·m (2.9 kg-m, 21 ft-lb)
SDIA2139E

TF-140
CENTER CASE
Revision: August 20072004 QX56
CENTER CASEPFP:33105
AssemblyEDS00194
OIL FILTER
1. Apply ATF to the two new O-rings (1), and install them on the oil
filter (2).
NOTE:
Do not reuse O-rings.
2. Apply ATF or petroleum jelly to the new O-ring, and install them
on filter stud.
NOTE:
Do not reuse O-rings.
3. Install filter stud to oil filter.
4. Install oil filter to center case and tighten bolts to specifications.
CAUTION:
Do not knock oil filter with a tool such as a hammer.
SUB OIL PUMP
1. Install outer gear and inner gear in to sub oil pump housing, and
measure side clearance. Refer to TF-133, "
SUB-OIL PUMP" .
2. Align dowel pin hole and mounting bolt hole of sub oil pump
assembly with center case. Install sub oil pump cover then
tighten bolts.
WDIA0285E
PDIA0184E
Oil filter bolts : 7.9 N·m (0.81 kg-m, 70 in-lb)
SDIA2135E
Sub oil pump bolts : 7.9 N·m (0.81 kg-m, 70 in-lb)
SDIA2328E

CENTER CASE
TF-141
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Revision: August 20072004 QX56
3. Apply ATF or petroleum jelly to new O-ring and install it to trans-
fer motor.
NOTE:
Do not reuse O-rings.
4. Fit double-flat end of transfer motor shaft into slot of sub-oil
pump assembly. Then tighten bolts.
CAUTION:
Be sure to install connector bracket.
MAIN OIL PUMP
1. Install inner gear and outer gear in the main oil pump housing.
Then, measure the side clearance. Refer to TF-133, "
MAIN OIL
PUMP" .
2. Install main oil pump housing, outer gear and inner gear to cen-
ter case.
3. Apply ATF or petroleum jelly to the new seal ring and install it to
main oil pump cover.
NOTE:
Do not reuse seal ring.
4. Install main oil pump cover to the center case, and install bolts.Transfer motor bolts : 45 N·m (4.6 kg-m, 33 ft-lb)
SDIA2185E
SDIA2174E
Main oil pump bolts : 7.8 N·m (0.8 kg-m, 69 in-lb)
SDIA2188E
SDIA2132E
Main oil pump cover bolts : 7.8 N·m (0.8 kg-m, 69 in-lb)
SDIA2130E

TF-142
CENTER CASE
Revision: August 20072004 QX56
CONTROL VALVE
1. Clean upper body, control valves and springs with cleaning agent, and dry with compressed air.
2. Dip control valves in ATF, and apply ATF to the valve-mounting area of upper body.
3. Install each control valve (3), spring (4) and plug (2) to 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 dam-
age.

Make sure each control valve is smoothly inserted.
4. Install reverse balls, relief balls and relief springs, accumulator
pistons and valve springs to upper body.
5. Install lower body and separator plate to upper body.
NOTE:
Do not reuse separator plates.
WDIA0284E
SDIA2127E
SDIA2126E
SDIA2125E

CENTER CASE
TF-143
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Revision: August 20072004 QX56
6. With lower body down, tighten two bolts in the position shown.
7. Apply ATF or petroleum jelly to new O-ring, and install it to 2-
4WD shift solenoid valve, line pressure switch and 4WD sole-
noid valve. Install them to control valve assembly.
NOTE:
Do not reuse O-rings.
8. Apply ATF or petroleum jelly to lip seals, and install them to cen-
ter case.
CAUTION:
There are 2 kinds of lip seals (lip seal of large inner diame-
ter: 5 pieces, lip seal of small inner diameter: 2 pieces).
Confirm their position for installation.
NOTE:
Do not reuse lip seals.
9. Install the other 13 bolts and tighten them to specified torque.
10. Install control valve assembly to center case, and tighten bolts.
11. Install connector assembly into center case installation hole, and
secure terminal body with snap ring.
SDIA2124E
SDIA2123E
Control valve case bolts : 7.9 N·m (0.81 mm, 70 in-lb)
SDIA2100E
Control valve bolts : 7.9 N·m (0.81 kg-m, 70 in-lb)
SDIA2121E
SDIA2122E

TF-144
CENTER CASE
Revision: August 20072004 QX56
12. Apply ATF or petroleum jelly to new O-rings, and install them on
oil strainer.
NOTE:
Do not reuse O-rings.
13. Install oil strainer to control valve assembly.
CLUTCH PISTON
1. Apply ATF or petroleum jelly to new D-rings, and install them to
clutch piston.
NOTE:
Do not reuse D-rings.
2. Install thrust needle bearing race to clutch piston.
3. Install clutch piston to the center case as shown.
CAUTION:
Install so the fitting protrusion of the clutch piston with
aligns the dent of the center case.
SDIA2120E
SDIA2 117 E
SDIA2189E
SDIA2190E

CENTER CASE
TF-145
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Revision: August 20072004 QX56
4. Remove all the liquid gasket from oil pressure check port and
inside center case. With the new oil pressure check plug
threaded in 1 or 2 pitches, apply specified sealant or equivalent,
to the oil pressure check plug thread of plug, and tighten. Refer
to GI-45, "
Recommended Chemical Products and Sealants" .
NOTE:
Do not reuse oil pressure check plug.
5. Install mainshaft and clutch drum. Refer to TF-145, "
MAIN-
SHAFT AND CLUTCH DRUM" .
MAINSHAFT AND CLUTCH DRUM
1. Apply ATF or petroleum jelly to needle bearing, and install nee-
dle bearing, clutch drum, clutch hub and new snap ring to main-
shaft.
2. Install new snap ring to the clutch hub, using suitable tool.
NOTE:
Do not reuse snap ring.
3. Install new snap ring to clutch hub from clutch hub to mainshaft,
and secure them with snap rings.
NOTE:
Do not reuse snap rings.Oil pressure check plug : 15 N·m (1.5 kg-m, 11 in-lb)
SMT915C
SMT974C
WDIA0101E
SDIA2192E