NISSAN PICK-UP 1998 Repair Manual

Removal
1. Drain oil from transfer and transmission.
2. Remove front and rear propeller shaft. Refer to PD section
(``Removal and Installation'', ``PROPELLER SHAFT'').
Insert plug into rear oil seal after removing propeller shaft.
lBe careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft.
3. Remove torsion bar spring. Refer to FA section (``Torsion Bar
Spring'', ``FRONT SUSPENSION''). Then remove second
crossmember.
4. Disconnect 4WD and neutral position switches.
5. Remove transfer control lever from transfer outer shift lever.
6. Separate transfer from transmission.
WARNING:
Support transfer while removing it.
Installation
lApply recommended sealant to mating surface to transmis-
sion.
Recommended sealant:
Nissan genuine part KP610-00250, Three Bond
1215 or equivalent
lTighten bolts securing transfer.
Bolt No.Tightening torque
(kg-m, ft-lb)!mm (in)
V131 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)
V231 - 41 (3.2 - 4.2, 23 - 30) 60 (2.36)
SMT142D
SMT863C
SMT495A
SMT496A
REMOVAL AND INSTALLATION
TF-6

SMT864CB
TRANSFER GEAR CONTROL
TF-7

Case Components
SMT599D
MAJOR OVERHAUL
TF-8

Gear Components
SMT141DA
MAJOR OVERHAUL
TF-9

Shift Control Components
SMT600D
MAJOR OVERHAUL
TF-10

1. Remove nut of companion flange.
2. Remove companion flange.
3. Remove 4WD switch.
4. Remove rear case.
lBe careful not to damage the mating surface.
5. Remove oil cover and oil gutter.
6. Remove snap ring and retainer ring from 2-4 shift rod.
7. Using calipers, measure the difference between front drive
sprocket and 2-4 coupling sleeve as outlined under Measur-
ing method below. If it is outside specifications, check front
drive sprocket, 2-4 coupling sleeve, clutch gear, 2-4 shift fork
and 2-4 fork rod for abnormalities. Replace faulty part(s) as
required.
Measuring method
a. Move coupling sleeve until it is in contact with sprocket,
then measure dimension A. Move coupling sleeve until
it is in contact with clutch gear, then measure dimension
B. Obtain dimensional difference C between two mea-
surements A and B.
C=AþB
b. To determine dimension A, measure at 3 or 4 different
points by rotating sprocket and obtain average value of
3 or 4 measurements.
Specification C:
Refer to TF-30.
SMT434CA
SMT270A
SMT435C
SMT799CA
DISASSEMBLY
TF-11

8. Remove bolts securing bearing retainer.
lThis step is necessary to remove mainshaft from center
case.
9. Remove bolts securing center case to front case and then
separate center case and front case.
10. Measure end play of low gear.
Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
lIf end play is beyond the maximum value, check low gear
andL&Hhubforwear.
11. Disassemble center case assembly.
a. Remove snap ring from mainshaft.
b. Pull out low gear withL&Hhub.
SMT273A
SMT274A
SMT342A
SMT275A
SMT757AA
DISASSEMBLY
TF-12

c. Remove needle bearing of low gear.
d. Make sure of the direction of the drive chain before remov-
ing it. (It must be reinstalled in the same direction.)
e. Remove mainshaft, front drive and drive chain as a set by
tapping front end of mainshaft and front drive shaft alter-
nately.
lBe careful not to bend drive chain.
12. Disassemble front case assembly.
a. Remove switch, plugs, check springs and check balls.
b. Remove outer shift lever.
SMT758A
SMT788C
SMT279A
SMT789C
SMT867C
DISASSEMBLY
TF-13

c. Remove lock pin of inner shift lever and drive out cross shaft
with plug.
d. Remove 2-4 shift rod.
e. RemoveL&Hshift rod and fork assembly with coupling
sleeve.
f. Remove needle bearing from main gear.
g. Remove bolts securing front case cover and then remove
case.
SMT282A
SMT283A
SMT284A
SMT286A
SMT287A
DISASSEMBLY
TF-14

h. Remove counter gear by tapping lightly.
i. Remove main gear by tapping lightly.
SMT759A
SMT288A
DISASSEMBLY
TF-15