main NISSAN PATROL 2006 Service Manual

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

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
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

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

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

d. Install L & H hub and snap ring to mainshaft.
+Pay attention to direction of L & H hub.
e. Measure end play of low gear.
Standard:
0.20 - 0.35 mm (0.0079 - 0.0138 in)
7. Apply sealant to mating surface and put center case assembly
onto front case and tighten bolts.
8. Assemble center case assembly.
a. Put drive chain onto front drive sprocket and front drive shaft,
and then put them in center case.
b. Install front drive shaft by tapping it lightly with a soft hammer.
+Make sure shafts are lined up in case.
SMT161B
SMT117B
SMT163B
SMT164B
SMT165B
ASSEMBLY
TF-30

c. Apply gear oil to needle bearings and install them into front
drive sprocket.
+These needle bearings can be easily installed if front drive
sprocket is rotated during their installation.
d. Install 2-4 coupling sleeve with 2-4 shift fork.
+Pay attention to direction of coupling sleeve.
e. Install shifting inserts and spread spring.
+Pay attention to direction of shifting inserts.
f. Install baulk ring and then install clutch gear.
g. Install mainshaft rear bearing.
+Pay attention to its direction.
SMT166B
SMT167B
SMT168B
SMT169B
SMT170B
ASSEMBLY
TF-31

General Speci®cations
Transfer model TX12A
Gear ratioHigh 1.000
Low 2.020
Number of teethMain gear 29
Low gear 37
Counter
gearHigh 38
Low 24
Front drive sprocket 41
Front drive shaft 41
Fluid capacity liters (Imp qt) 1.9 (1-5/8)
Inspection and Adjustment
GEAR END PLAY
Unit: mm (in)
Front drive sprocket 0.20 - 0.35 (0.0079 - 0.0138)
Low gear 0.20 - 0.35 (0.0079 - 0.0138)
Counter gear 0 - 0.2 (0 - 0.008)
CLEARANCE BETWEEN BAULK RING AND
CLUTCH GEAR
Unit: mm (in)
Standard Wear limit
1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020)
AVAILABLE SNAP RING
Mainshaft front bearing
Unit: mm (in)
Allowable clearance 0 - 0.15 (0 - 0.0059)
Thickness Part number
3.0 (0.118)
3.1 (0.122)
3.2 (0.126)33138-73P10
33138-73P11
33138-73P12
Main gear bearing
Unit: mm (in)
Allowable clearance 0 - 0.15 (0 - 0.0059)
Thickness Part number
2.6 (0.102)
2.7 (0.106)
2.8 (0.110)33114-73P00
33114-73P01
33114-73P02
AVAILABLE SHIM
Counter gear rear bearing
Distance ``A''
mm (in)Shim(s)
Thickness mm (in) Part number
40.6 - 40.5
(1.598 - 1.594)Not necessary
40.5 - 40.4
(1.594 - 1.591)0.1 (0.004) 33112-C6900
40.4 - 40.3
(1.591 - 1.587)0.2 (0.008) 33112-C6901
40.3 - 40.2
(1.587 - 1.583)0.3 (0.012) 33112-C6902
40.2 - 40.1
(1.583 - 1.579)0.4 (0.016) 33112-C6903
40.1 - 40.0
(1.579 - 1.575)0.5 (0.020) 33112-33G00
40.0 - 39.9
(1.575 - 1.571)0.6 (0.024) 33112-33G01
SMT335A
SERVICE DATA AND SPECIFICATIONS (SDS)
TF-33