NISSAN NAVARA 2005 Repair Workshop Manual

TF-124
TRANSFER ASSEMBLY
21. Install the snap ring to the mainshaft, using suitable tool.
CAUTION:
Do not reuse snap ring.
22. Install the retainer to the mainshaft.
CAUTION:
Set the projection of oil pump assembly to the identification
hole, and then align locating hole of retainer to the L-H shift
rod assembly.
23. Install the mainshaft rear bearing to the mainshaft, using Tool.
CAUTION:
Do not push too hard in order to avoid snap rings becoming
dislodged from mainshaft.
24. Install the snap ring to the mainshaft, using suitable tool.
CAUTION:
Do not reuse snap ring.
25. Install the spacer to the control shift rod (A/T models only).
26. Apply recommended sealant to the mating surface of the front
case. Refer toTF-112, "
COMPONENTS".
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
27. Install the rear case to the front case.
SDIA2461E
SDIA2468E
Tool number : KV32102700
SDIA2469E
SDIA2430E
SDIA3305E

TRANSFER ASSEMBLY
TF-125
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B
TF
28. Tighten the bolts to the specified torque. Refer toTF-112, "COM-
PONENTS".
CAUTION:
Be sure to install the harness brackets and air breather
hose clamp.
29. Install the retainer bolts with new gaskets. Tighten the bolts to
the specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
lDo not reuse gasket.
lTighten them to the specified torque again.
30. Apply petroleum jelly to the circumference of the input oil seal,
and install it to the front case, using Tools.
CAUTION:
lDo not reuse oil seal.
lApply petroleum jelly to oil seal.
31. Install the rear oil seal until it is flush with the end face of the rear
case, using Tool.
CAUTION:
lDo not reuse oil seal.
lApply petroleum jelly to oil seal.
32. Apply petroleum jelly to the circumference of the new dust cover.
Position the dust cover using the identification mark as shown.
CAUTION:
lDo not reuse dust cover.
lPosition the identification mark at the position shown.
SDIA3422E
SDIA2789E
Dimension A : 4.0 - 4.6 mm (0.157 - 0.181 in)
Tool number A: ST30720000
B: KV40104830
SDIA3191E
Tool number : KV38100500
PDIA0115E
SDIA3377E

TF-126
TRANSFER ASSEMBLY
33. Install the dust cover to the rear case, using suitable tool.
CAUTION:
lDo not reuse dust cover.
lApply petroleum jelly to dust cover.
34. Install check ball and check spring to rear case (M/T models
only).
35. Apply recommended sealant to thread of check plug, then install
it to rear case and tighten to the specified torque (M/T models
only). Refer toTF-112, "
COMPONENTS".
CAUTION:
Remove old sealant and oil adhering to threads.
36. Apply recommended sealant to the threads of the wait detection
switch(gray).Theninstallittotherearcaseandtightentothe
specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
Remove old sealant and oil adhering to threads.
37. Apply recommended sealant to the threads of the 4LO switch
(gray with green paint) and ATP switch (black). Then install them
to the front case and tighten to the specified torque. Refer toTF-
11 2 , "COMPONENTS".
CAUTION:
Remove old sealant and oil adhering to threads.
SDIA3257E
SDIA3380E
SDIA3389E
SDIA3390E

TRANSFER ASSEMBLY
TF-127
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TF
38. Install the front oil seal until it is flush with the end face of the
front case, using Tool.
CAUTION:
lDo not reuse oil seal.
lApply petroleum jelly to oil seal.
39. Align the matching mark on the front drive shaft with the mark on
the companion flange, then install the companion flange.
40. Install the companion flange self-lock nut. Tighten to the speci-
fied torque, using Tool. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse self-lock nut.
41. Install the O-ring to the transfer control device.
CAUTION:
lDo not reuse O-ring.
lApply petroleum jelly to O-ring.
42. Install the transfer control device to the rear case.
a. Turn the control shift rod fully counterclockwise using a flat-
bladed screwdriver, and then put a mark on the control shift rod.Tool number : KV38100500
PDIA0117E
SDIA2779E
Tool number : KV40104000
WDIA0219E
SDIA3378E
PDIA0119E

TF-128
TRANSFER ASSEMBLY
b. Align the transfer control device shaft cutout with the mark on
the control shift rod, and install it.
NOTE:
Turn the transfer control device when the transfer control device
connection does not match.
c. Tighten the bolts to the specified torque. Refer toTF-112, "
COM-
PONENTS".
43. Install the drain plug and filler plug with new gaskets to the rear
case. Tighten to the specified torque. Refer toTF-112, "
COM-
PONENTS".
CAUTION:
Do not reuse gaskets.
PDIA0120E
SDIA2212E

PLANETARY CARRIER
TF-129
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TF
PLANETARY CARRIERPFP:33113
Disassembly and AssemblyEDS0032Q
DISASSEMBLY
1. Remove the snap ring.
2. Remove the sun gear assembly from the planetary carrier
assembly, using suitable tool.
3. Remove the snap ring from the sun gear assembly, using suit-
able tool.
4. Remove the carrier bearing from the sun gear, using Tools.
5. Remove the needle bearing from the sun gear, using Tools.
SDIA2792E
SDIA2353E
Tool number A: ST35300000
B: ST30021000
SDIA2149E
Tool number : ST33710000
SDIA2354E

TF-130
PLANETARY CARRIER
6. Remove the metal bushing from the sun gear, using Tools.
INSPECTION AFTER DISASSEMBLY
Bearing
Check the bearing for damage and rough rotation. If necessary,
replace the bearing with a new one.
Planetary Carrier
lMeasure the end play of each pinion gear. If it is out of specifica-
tion, replace the planetary carrier assembly with new one.
lCheck the working face of each gear and bearing for damage,
burrs, partial wear, dents and other abnormality. If any is found,
replace the planetary carrier assembly with a new one.
Sun Gear
lCheck if the oil passage of the sun gear assembly is clogged.
For this, try to pass a 3.6 mm (0.142 in) dia. wire through the oil
passage as shown.
lCheck the sliding and contact surface of each gear and bearing
for damage, burrs, partial wear, dents and other abnormality. If
any is found, replace the sun gear assembly with a new one.Tool number A: ST33710000
B: ST35325000
C: KV381054S0
SDIA2168E
MTF0041D
Pinion gear end play : 0.1 - 0.7 mm (0.004 - 0.028 in)
PDIA0146E
PDIA0147E

PLANETARY CARRIER
TF-131
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TF
Internal Gear
Check the internal gear teeth for damage, partial wear, dents or
other abnormality. If any is found, replace the internal gear with a
new one.
ASSEMBLY
1. Apply ATF to the metal bushing, then install the metal bushing
until it becomes “Dimension A”, using Tool.
CAUTION:
Do not reuse metal bushing.
2. Apply ATF to the needle bearing, then install the needle bearing
until it becomes “Dimension B”, using Tool.
CAUTION:
Do not reuse needle bearing.
3. Install the carrier bearing to the sun gear, using Tools.
PDIA0157E
Dimension A : 7.7 - 8.3mm (0.303 - 0.327in)
Tool number : ST35300000
SDIA3189E
Dimension B : 62.5 - 63.1mm (2.461 - 2.484in)
Tool number : ST33220000
SDIA3190E
Tool number A: ST30720000
B: ST27863000
PDIA0149E

TF-132
PLANETARY CARRIER
4. Install the snap ring to the sun gear assembly, using suitable
tool.
CAUTION:
Do not reuse snap ring.
5. Install the sun gear assembly to the planetary carrier assembly.
6. Install the snap ring to the planetary carrier assembly.
CAUTION:
Do not reuse snap ring.
SDIA2353E
SDIA2794E

FRONT DRIVE SHAFT
TF-133
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TF
FRONT DRIVE SHAFTPFP:39100
Disassembly and AssemblyEDS0032R
DISASSEMBLY
1. Remove the front bearing, using Tools.
2. Remove the rear bearing, using Tools.
INSPECTION AFTER DISASSEMBLY
Front Drive Shaft
Check the items below. If necessary, replace them with new ones.
lDamage, peeling, dent, uneven wear and bending of the shaft.
lExcessive wear, damage and peeling of the gear.
Bearing
Check the bearing for damage and rough rotation. If necessary,
replace the bearing with a new one.Tool number A: ST35300000
B: ST30021000
SDIA2106E
Tool number A: ST33710000
B: ST30021000
PDIA0153E
PDIA0154E
MTF0041D