NISSAN PATROL 1998 Y61 / 5.G Transfer Owner's Manual

Bearing
+Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
ASSEMBLY
1. Press mainshaft front bearing onto mainshaft.
+Pay special attention to its direction.
2. Install spacer.
3. Select mainshaft front bearing snap ring with proper thickness
and install it.
Allowable clearance between mainshaft front bearing
snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Mainshaft front bearing snap ring:
Refer to SDS, TF-33.
Front Drive Shaft
DISASSEMBLY
+Front drive shaft front bearing
+Front drive shaft rear bearing
SMT351A
SMT294A
SMT295A
SMT296A
SMT297A
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont'd)
TF-20

INSPECTION
Sprocket and shaft
+Check sprocket for excessive wear, chips or cracks.
+Check shaft for cracks or wear.
Bearing
+Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
ASSEMBLY
+Press front drive shaft front bearing.
+Press front drive shaft rear bearing.
Counter Gear
DISASSEMBLY
1. Press out counter gear front bearing and then remove front
sub-gear, spacer and dish spring.
2. Press out counter gear rear bearing and then remove rear
sub-gear, spacer and dish spring.
SMT357A
SMT298A
SMT299A
SMT134B
SMT135B
REPAIR FOR COMPONENT PARTS
Front Drive Shaft (Cont'd)
TF-21

INSPECTION
Gear and shaft
+Check gears for excessive wear, chips or cracks.
+Check shaft for cracks or wear.
Bearing
+Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
ASSEMBLY
1. Press on counter gear rear bearing.
2. Install front sub-gear, dish spring and spacer, and then press on
counter gear front bearing.
+Pay attention to direction of dish spring.
Main Gear
DISASSEMBLY
Main gear bearing
1. Remove snap ring and spacer.
2. Pull out main gear bearing.
SMT266D
SMT267D
SMT137B
SMT304A
SMT305AA
REPAIR FOR COMPONENT PARTS
Counter Gear (Cont'd)
TF-22

Plug
+Always replace it with new one whenever it is removed.
INSPECTION
Gear and shaft
+Check gears for excessive wear, chips or cracks.
+Check shaft for cracks or wear.
Bearing
+Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
ASSEMBLY
Main gear bearing
1. Press on main gear bearing.
+Pay attention to its direction.
2. Install spacer.
3. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Snap ring (main gear bearing):
Refer to SDS, TF-33.
Plug
+Apply sealant to plug and install it.
SMT306A
SMT359A
SMT307AA
SMT308A
SMT309A
REPAIR FOR COMPONENT PARTS
Main Gear (Cont'd)
TF-23

Front Case
SHIFT SHAFT OIL SEAL
Removal
+Use a screwdriver to pry out old seal.
+Be careful not to damage case.
+Always replace with a new one whenever it has been removed.
Installation
+Install new shift shaft oil seal until ¯ush with case.
+Before installing, apply multi-purpose grease to seal lip.
Front Case Cover
Removal
+Take out old seal from inside of front case cover.
+Be careful not to damage front case cover.
Installation
+Install new front case cover oil seal until it stops.
+Before installing, apply multi-purpose grease to seal lip.
Center Case
CENTER CASE OIL SEAL
Removal
+Remove center case oil seal.
SMT138B
SMT139B
SMT263D
SMT141B
SMT146B
REPAIR FOR COMPONENT PARTS
TF-24

Installation
+Install center case oil seal.
Bearing Retainer
OIL CATCHER
Removal
+Drive out oil catcher from inside of bearing retainer.
+Be careful not to damage bearing retainer.
Installation
+Install oil catcher until it stops.
+Be careful not to damage or distort oil catcher or bearing
retainer.
+Before installing, apply multi-purpose grease to seal lip.
Rear Case
REAR OIL SEAL
Removal
+Pull out rear oil seal.
Installation
+Install new rear oil seal until it stops.
+Before installing, apply multi-purpose grease to seal lip.
SMT147B
SMT142B
SMT143B
SMT144B
SMT145B
REPAIR FOR COMPONENT PARTS
TF-25

AIR BREATHER
+Install as shown in illustration.
Thread locker:
Refer to TF-10.
Shift Control Components
INSPECTION
+Check contact surface and sliding surface for wear, scratches,
projections or other faulty conditions.
L & H SHIFT ROD & FORK
+Assemble as shown in illustration.
* This pin is the same size as the one for 2-4 shift rod.
2-4 SHIFT ROD & FORK
+Assemble as shown in illustration.
* These pins are the same size.
+Pay attention to the direction of fork guide collar.
SMT148B
SMT360A
SMT149B
SMT150B
SMT033B
REPAIR FOR COMPONENT PARTS
TF-26

1. Install cross shaft.
2. Assemble front case.
a. Install main gear assembly by tapping it lightly with a soft ham-
mer.
b. Apply sealant to the mating surface and bolts of front case
cover and install it on front case.
+Apply recommended sealant to these ten bolts.
+Tightening torque
A:
:16-21Nzm (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
B:
:19-24Nzm (1.9 - 2.4 kg-m, 14 - 17 ft-lb)
c. Apply gear oil to needle bearing and install it into main gear.
d. Install counter gear assembly by tapping it lightly with a soft
hammer.
SMT151B
SMT152B
SMT153B
SMT326A
SMT264D
ASSEMBLY
TF-27

e. Insert interlock plunger into front case.
f. Install L & H shift rod and fork assembly with coupling sleeve.
g. Install 2-4 shift rod.
h. Install switches, check balls, check springs and plugs.
+Apply sealant to switches and plugs.
3. Select counter gear rear bearing shim.
Counter gear end play:
0 - 0.2 mm (0 - 0.008 in)
a. Measure distance ``A'' between upper surface of counter gear
rear bearing and mating surface of front case.
SMT090B
SMT155B
SMT265D
SMT259D
SMT335A
ASSEMBLY
TF-28

b. Select suitable shim using SDS table as a guide.
Counter gear rear bearing shim:
Refer to SDS, TF-33.
4. Place suitable shim on counter gear rear bearing with grease.
5. Apply gear oil to each part in front case.
6. Install mainshaft on center case.
a. Install mainshaft on center case by tapping it lightly.
+Apply gear oil to mainshaft front bearing.
b. Install bearing retainer.
c. Install low gear and its bearing to mainshaft.
+Apply gear oil to needle bearing.
SMT157B
SMT158B
SMT159B
SMT407A
SMT160B
ASSEMBLY
TF-29