NISSAN TERRANO 2002 Service Repair Manual

Inspection
BALL JOINT AND SWIVEL JOINT
1. Check joints for play. If ball or swivel stud is worn and play in
axial direction is excessive or joint is hard to swing or does not
meet the specified values, replace as a complete unit.
Swinging force (Measuring point: Cotter pin hole) ªAº:
The ball joint must rotate smoothly in all direc-
tions.
Rotating torque ªBº: (both)
0.5 - 5.0 N×m (0.05 - 0.51 kg-m,4-44in-lb)
Axial end play ªCº: (both)
0 - 0.2 mm (0 - 0.008 in)
Radial play ªDº (both)
0mm(0in)
2. Check condition of dust cover. If it is cracked excessively,
replace ball joint or swivel joint as an assembly.
ICheck rotating torque ªBº.
EST015
EST016
YST025
STEERING LINKAGE
ST-20

IDLER ARM ASSEMBLY
ICheck idler arm assembly for breakage, wear or play, and if
necessary replace.
Rotating force ªAº:
1-6N×m (0.1 - 0.6 kg-m,9-52in-lb)
Axial end play ªBº:
0m(0in)
Deflection ªCº (when load is applied to the end of
arm):
Load N (kg, lb)1,569
(160, 353)3,923 (400, 882)
Deflection mm (in)
Max. 3 (0.12) 5.5 (0.217)
Min. 0.7 (0.028) 1.0 (0.039)
ILubricate idler arm assembly with recommended multipurpose
grease.
When lubricating, refer to section MA.
CROSS ROD AND TIE-ROD
Check tie-rod and cross rod for breakage, bend or cracks, and
replace with a new one if necessary.
FIXING LOCATION
ICheck fixing location (nuts and cotter pins) for looseness, play
or breakage.
IWhen looseness or play is found, check for wear on tapered
portion of joints, gear arm and idler arm.
SST631B
STEERING LINKAGE
Inspection (Cont'd)
ST-21

General Specifications
Models All
Steering gear type ZF 8054
Turns of steering
wheel
(Lock to lock)3.86
Overall gear ratio 17.1 : 1
Steering column type Collapsible, adjustable height
Inspection and Adjustment
STEERING WHEEL AND COLUMN
Applied model AIR BAG
Steering wheel axial play mm (in) 0 (0)
Steering wheel play mm (in) 35 (1.38) or less
Steering column length ªLº mm (in)830.5 - 832.7
(32.697 - 32.783)
EST018
STEERING GEAR AND LINKAGE
Ball joint and swivel joint
Rotating torque ªBº N×m (kg-m, in-lb)0.5 - 5.0
(0.05 - 0.51,
4 - 44)
Axial end play ªCº mm (in) 0 - 0.2 (0 - 0.008)
Radial play ªDº mm (in) 0 (0)
Length ªLº mm (in) 287 (11.30)
SST583B
OIL PUMP
Unit: kPa (bar, kg/cm2, psi)
Engine ZD30DDTi TD27Ti
Make UNISIA
Max. pressure9,800 - 10,500
(98.0 - 105.0,
99.96 - 107.10,
1,421 - 1,523)8,800 - 9,200
(88 - 92,
89 - 93,
1,276 - 1,334)
SERVICE DATA AND SPECIFICATIONS (SDS)
ST-22

TRANSFER
SECTION
TF
CONTENTS
PREPARATION................................................................2
ON-VEHICLE SERVICE..................................................4
Replacing Oil Seal .......................................................4
REMOVAL AND INSTALLATION....................................7
Removal .......................................................................7
Installation ....................................................................7
TRANSFER GEAR CONTROL.......................................8
MAJOR OVERHAUL.......................................................9
Case Components .......................................................9
Gear Components .....................................................10
Shift Control Components ......................................... 11
DISASSEMBLY..............................................................12
REPAIR FOR COMPONENT PARTS............................17Mainshaft ...................................................................17
Front Drive Shaft .......................................................19
Counter Gear .............................................................20
Main Gear ..................................................................21
Front Case .................................................................23
Front Case Cover ......................................................23
Bearing Retainer ........................................................23
Rear Case..................................................................24
Shift Control Components .........................................24
ASSEMBLY....................................................................26
SERVICE DATA AND SPECIFICATIONS (SDS)..........33
General Specifications ...............................................33
Inspection and Adjustment ........................................33

SPECIAL SERVICE TOOLS
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST38060002*
Flange wrench
Removing companion flange nut
Installing companion flange nut
ST30021000*
Puller
Removing counter gear front bearing
(Use with ST36710010)
ST30031000*
Puller
Removing counter gear rear bearing
(Use with ST36710010)
ST33290001*
Puller
Removing center case oil seal
Removing rear oil seal
ST33051001*
Puller
Removing companion flange
ST30720000*
Drift
Installing center case oil seal
Installing rear oil seal
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST36710010*
DriftRemoving counter gear front bearing
(Use with ST30021000)
Removing counter gear rear bearing
(Use with ST30031000)
a: 34.5 mm (1.358 in) dia.
ST33061000*
DriftRemoving main gear bearing
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
PREPARATION
TF-2

*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST30613000*
Drift
Installing main gear bearing
Installing cover oil seal
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
COMMERCIAL SERVICE TOOLS
Tool name Description
Puller
Removing front drive shaft front bearing
Removing front drive shaft rear bearing
Removing main gear bearing
Drift
Installing shift shaft oil seal
a: 26 mm (1.02 in) dia.
b: 20 mm (0.79 in) dia.
c: 150 mm (5.91 in)
DriftInstalling mainshaft rear bearing
a: 50 mm (1.97 in) dia.
b: 42 mm (1.65 in) dia.
c: 180 mm (7.09 in)
DriftInstalling L & H hub
a: 60 mm (2.36 in) dia.
b: 50 mm (1.97 in) dia.
c: 60 mm (2.36 in)
PREPARATION
TF-3

Replacing Oil Seal
CENTER CASE OIL SEAL
1. Remove front propeller shaft Ð Refer to PD section.
2. Remove companion flange nut.
3. Remove companion flange.
4. Remove center case oil seal.
5. Install center case oil seal.
Before installing, apply multi-purpose grease to seal lip.
6. Install companion flange.
7. Tighten nut to the specified torque.
: 226 - 324 N×m (23 - 33 kg-m, 166 - 239 ft-lb)
8. Install front propeller shaft.
YMT010
YMT011
YMT012
SMT488A
YMT013
ON-VEHICLE SERVICE
TF-4

SHIFT SHAFT OIL SEAL
1. Remove front propeller shaft Ð Refer to PD section.
2. Install companion flange Ð Refer to ªCENTER CASE OIL
SEALº, TF-4.
3. Remove transfer control lever from transfer outer shift lever.
Then remove outer shift lever.
4. Remove shift shaft oil seal.
Be careful not do damage cross shaft.
5. Install shift shaft oil seal.
Before installing, apply multi-purpose grease to seal lip.
6. Install transfer control linkage.
7. Install companion flange Ð Refer to ªCENTER CASE OIL
SEALº, TF-4.
8. Install front propeller shaft.
REAR OIL SEAL
1. Remove rear propeller shaft Ð Refer to PD section.
2. Remove rear oil seal.
NMT010
SMT491A
YMT014
YMT015
ON-VEHICLE SERVICE
Replacing Oil Seal (Cont'd)
TF-5

3. Install rear oil seal.
Before installing apply multi-purpose grease to seal lip.
4. Install rear propeller shaft.
YMT016
ON-VEHICLE SERVICE
Replacing Oil Seal (Cont'd)
TF-6

Removal
IDrain oil from transfer and transmission.
IRemove front and rear propeller shafts Ð Refer to PD section.
IInsert plug into oil seal after removing propeller shaft.
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal,
when removing propeller shaft.
IRemove torsion bar Ð Refer to removal and installation of
lower link in FA section. Then remove fifth crossmember.
IRemove transfer control lever from transfer outer shift lever.
IRemove transfer from transmission.
WARNING:
Support transfer while removing it.
Installation
IApply recommended sealant to mating surface to transmission.
Recommended sealant:
Nissan genuine part (KP610-00250) or equivalent
ITighten bolts securing transfer.
Bolt No.Tightening torque
N×m (kg-m, ft-lb)mm (in)
q
131 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)
q
231 - 41 (3.2 - 4.2, 23 - 30) 60 (2.36)
SMT478A
NMT010
SMT495A
SMT496A
REMOVAL AND INSTALLATION
TF-7