NISSAN PATROL 1998 Y61 / 5.G Transfer User Guide

Case Components
SMT255D
MAJOR OVERHAUL
TF-10

Gear Components
SMT256D
MAJOR OVERHAUL
TF-11

Shift Control Components
SMT257D
MAJOR OVERHAUL
TF-12

1. Remove nut of front companion ¯ange.
2. Remove center brake components.
a. Remove rear companion ¯ange nut.
b. Remove brake drum.
c. Remove rear companion ¯ange.
d. Remove center brake components.
3. Remove rear case.
+Be careful not to damage the mating surface.
4. Remove front companion ¯ange.
SMT101B
SMT258D
SMT103B
SMT104B
SMT105B
DISASSEMBLY
TF-13

5. Remove speedometer drive gear and oil gutter.
6. Remove snap ring from 2-4 shift rod.
7. Check front drive sprocket end play.
a. While holding front drive sprocket forward as far as it will go,
measure distance ``A'' between rear surface of front drive
sprocket and front surface of 2-4 coupling sleeve.
b. While holding front drive sprocket back as far as it will go,
measure distance ``B'' as same as step a.
c. Determine front drive sprocket end play to be used by the fol-
lowing equation.
Front drive sprocket end play = A þ B
Standard:
0.20 - 0.35 mm (0.0079 - 0.0138 in)
+If not within speci®cation, disassemble and check contact sur-
face of gear to hub, washer, bushing, needle bearing and shaft.
8. Shift 2-4 coupling sleeve to 2WD position.
SMT106B
SMT107B
SMT108B
SMT110B
DISASSEMBLY
TF-14

9. Pull out clutch gear and mainshaft rear bearing.
10. Remove 2-4 coupling sleeve with 2-4 shift fork.
11. Remove front drive shaft assembly, drive chain and front drive
sprocket by tapping front end of front drive shaft.
12. Remove bolts securing bearing retainer and then remove bear-
ing retainer.
SMT111B
SMT112B
SMT113B
SMT115B
DISASSEMBLY
TF-15

13. Remove bolts securing center case to front case and then
separate center case and front case.
14. Measure end play of low gear.
Standard:
0.20 - 0.35 mm (0.0079 - 0.0138 in)
Refer to SDS, TF-33.
+If end play is beyond the maximum value, check low gear and
L & H hub for wear.
15. Disassemble center case assembly.
a. Remove snap ring from mainshaft.
b. Pull out low gear with L & H hub.
c. Remove mainshaft by tapping front end of mainshaft.
SMT116B
SMT117B
SMT118B
SMT119B
SMT120B
DISASSEMBLY
TF-16

16. Disassemble front case assembly.
a. Remove the following parts.
+4WD switch
+Neutral position switch
+Check plugs
+Check springs
+Check balls
+Be careful not to lose the check balls.
b. Remove 2-4 shift rod.
c. Remove L & H shift rod and fork assembly with coupling sleeve.
d. Remove needle bearing from main gear.
e. Remove bolts securing front case cover and then remove it.
SMT259D
SMT122B
SMT260D
SMT124B
SMT125B
DISASSEMBLY
TF-17

f. Remove counter gear by tapping it lightly with a soft hammer.
g. Remove main gear by tapping it lightly with a soft hammer.
SMT261D
SMT262D
DISASSEMBLY
TF-18

Mainshaft
DISASSEMBLY
1. Remove snap ring and spacer.
2. Press out mainshaft front bearing from mainshaft.
INSPECTION
Gear and shaft
+Check gears for excessive wear, chips or cracks.
+Check shaft for cracks, wear or bending.
+Check coupling sleeve for wear or damage.
Baulk ring
+Check baulk ring for cracks or deformation.
+Measure clearance between baulk ring and gear.
Baulk ring to gear clearance:
Unit: mm (in)
Standard Wear limit
1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020)
+If not within wear limit, replace baulk ring.
SMT129B
SMT130B
SMT180B
SMT349A
SMT350A
REPAIR FOR COMPONENT PARTS
TF-19