oil NISSAN PATROL 1998 Y61 / 5.G Transfer Workshop Manual

TRANSFER
SECTION
TF
CONTENTS
PREPARATION................................................................1
Special Service Tools ..................................................1
Commercial Service Tools ...........................................2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................3
NVH Troubleshooting Chart.........................................3
DESCRIPTION.................................................................4
Cross-sectional View ...................................................4
ON-VEHICLE SERVICE..................................................5
Replacing Oil Seal .......................................................5
Checking Position Switch ............................................7
REMOVAL AND INSTALLATION....................................8
Removal .......................................................................8
Installation ....................................................................8
TRANSFER GEAR CONTROL.......................................9
MAJOR OVERHAUL.....................................................10
Case Components .....................................................10
Gear Components ..................................................... 11Shift Control Components .........................................12
DISASSEMBLY..............................................................13
REPAIR FOR COMPONENT PARTS............................19
Mainshaft ...................................................................19
Front Drive Shaft .......................................................20
Counter Gear .............................................................21
Main Gear ..................................................................22
Front Case .................................................................24
Front Case Cover ......................................................24
Center Case...............................................................24
Bearing Retainer ........................................................25
Rear Case..................................................................25
Shift Control Components .........................................26
ASSEMBLY....................................................................27
SERVICE DATA AND SPECIFICATIONS (SDS)..........33
General Speci®cations ...............................................33
Inspection and Adjustment ........................................33
TF

Special Service Tools
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
KV38104700*
Flange wrench
NT428
Removing front companion ¯ange nut
Installing front companion ¯ange nut
ST30021000*
Puller
NT411
Removing counter gear front bearing
ST30031000*
Puller
NT411
Removing counter gear rear bearing
ST33290001*
Puller
NT414
Removing center case oil seal
Removing rear oil seal
ST22452000*
Drift
NT065
Installing mainshaft rear bearing
a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
ST33061000*
Drift
NT116
Removing main gear bearing
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
ST30613000*
Drift
NT073
Installing counter gear rear bearing
Installing main gear bearing
Installing cover oil seal
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
ST33200000*
Drift
NT091
Installing counter gear front bearing
Removing cover oil seal
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ST30720000*
Drift
NT115
Installing counter case oil seal
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
PREPARATION
TF-1

Commercial Service Tools
Tool name Description
Puller
NT077
Removing front and rear companion ¯anges
Removing mainshaft rear bearing and clutch
gear
Removing L & H hub
Removing front drive shaft front bearing
Removing front drive shaft rear bearing
Removing main gear bearing
Drift
NT117
Installing shift shaft oil seal
a: 26 mm (1.02 in) dia.
b: 20 mm (0.79 in) dia.
c: 40 mm (1.57 in)
Drift
NT117
Installing L & H hub
a: 60 mm (2.36 in) dia.
b: 50 mm (1.97 in) dia.
c: 60 mm (2.36 in)
Drift
NT117
Installing clutch gear
a: 55 mm (2.17 in) dia.
b: 45 mm (1.77 in) dia.
c: 160 mm (6.30 in)
Drift
NT117
Installing rear oil seal
a: 75 mm (2.95 in) dia.
b: 67 mm (2.64 in) dia.
c: 60 mm (2.36 in)
PREPARATION
TF-2

NVH Troubleshooting Chart
Use the chart below to help you ®nd the cause of the problem. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
TRANSFER
Reference page
Refer to MA section (``Checking Transfer Fluid'',
``CHASSIS AND BODY MAINTENANCE'').
TF-10
TF-10
TF-10, TF-12
TF-12
TF-11
TF-11
TF-11
TF-11
SUSPECTED PARTS (Possible cause)
FLUID (Level low)
FLUID (Wrong)
FLUID (Level too high)
LIQUID GASKET (Damaged)
OIL SEAL (Worn or damaged)
CHECK SPRING AND CHECK BALL (Worn or damaged)
SHIFT FORK (Worn)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
BAULK RING (Worn or damaged)
SHIFTING INSERT (Damaged)
SymptomNoise 1 2 3 3
Fluid leakage3122
Hard to shift or will not shift 1 1 2 2
Jumps out of gear 1 2 2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
TF-3

Replacing Oil Seal
CENTER CASE OIL SEAL
1. Remove front propeller shaft. Refer to PD section (``Removal
and Installation'', ``PROPELLER SHAFT'').
2. Remove companion ¯ange nut.
3. Remove front companion ¯ange.
4. Remove center case oil seal.
5. Install center case oil seal.
+Before installing, apply multi-purpose grease to seal lip.
6. Reinstall any part removed.
SHIFT SHAFT OIL SEAL
1. Remove transfer control lever from transfer cross shaft.
SMT091B
SMT092B
SMT093B
SMT094B
SMT251D
ON-VEHICLE SERVICE
TF-5

2. Remove shift shaft oil seal.
+Be careful not to damage inner shift lever.
3. Install shift shaft oil seal.
+Before installing, apply multi-purpose grease to seal lip.
4. Install transfer control lever.
REAR OIL SEAL
1. Remove rear propeller shaft. Refer to PD section (``Removal
and Installation'', ``PROPELLER SHAFT'').
2. Remove brake drum.
3. Remove companion ¯ange nut.
4. Remove rear companion ¯ange.
5. Remove center brake assembly.
6. Remove rear oil seal.
7. Install rear oil seal.
+Before installing, apply multi-purpose grease to seal lip.
8. Reinstall any part removed.
SMT097B
SMT096B
SMT323B
SMT324B
SMT325B
ON-VEHICLE SERVICE
Replacing Oil Seal (Cont'd)
TF-6

Removal
1. Drain ¯uid and oil from transfer and transmission (M/T model
only).
2. Remove exhaust front and rear tubes. Refer to FE section
(``EXHAUST SYSTEM'').
3. Remove front and rear propeller shaft. Refer to PD section
(``Removal and Installation'', ``PROPELLER SHAFT'').
4. Disconnect neutral position switch and 4WD switch harness
connectors.
5. Remove transfer control lever from transfer cross shaft.
6. Remove transfer from transmission.
WARNING:
Support transfer while removing it.
Installation
+Apply recommended sealant to mating surface to transmission.
(M/T models only)
Recommended sealant:
Genuine anaerobic liquid gasket, Three Bond
TB1215, Loctite Part No. 51813 or equivalent
+Tighten transfer bolts.
Transfer ®xing bolts:
:32-42Nzm (3.3 - 4.3 kg-m, 24 - 31 ft-lb)
SMT251D
SMT268D
SMT176BA
REMOVAL AND INSTALLATION
TF-8

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

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