light NISSAN TERRANO 2004 Service Workshop Manual

d. Remove 2-4 shift rod.
e. Remove L & H shift 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.
h. Remove counter gear by tapping lightly.
SMT283A
SMT284A
SMT286A
SMT287A
SMT759A
DISASSEMBLY
TF-15
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i. Remove main gear by tapping lightly.
SMT288A
DISASSEMBLY
TF-16
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1. Assemble front case.
a. Install main gear assembly by tapping lightly.
b. Apply sealant to the mating surface and bolts of front casecover and install it on front case.
I These ten bolts should be coated with sealant.
Tightening torque
q
A: 20-23N ×m
(2.1 - 2.3 kg-m, 15 - 16 ft-lb)
q
B: 24-28N ×m
(2.5 - 2.8 kg-m, 18 - 20 ft-lb)
c. Apply gear oil to needle bearing and install it into main gear.
d. Install counter gear assembly by tapping lightly.
e. Install cross shaft and inner shift lever.
When replacing cross shaft, outer shift lever of lock pin of
outer shift lever, replace them as a set.
SMT323A
YMT027
SMT326A
SMT327A
SMT798A
ASSEMBLY
TF-26
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2. Select counter gear rear bearing shim.Counter gear end play:0 - 0.2 mm (0 - 0.008 in)
a. Measure distance ªAº between upper surface of counter gear rear bearing and mating surface of front case.
b. Select suitable shim using chart below.
Distance ªAº mm (in) Suitable shim
Thickness mm (in) Part number
32.65 - 32.55
(1.2854 - 1.2815) Not necessary
32.55 - 32.45
(1.2815 - 1.2776) 0.1 (0.004) 33112-C6900
32.45 - 32.35
(1.2776 - 1.2736) 0.2 (0.008) 33112-C6901
32.35 - 32.25
(1.2736 - 1.2697) 0.3 (0.012) 33112-C6902
32.25 - 32.15
(1.2697 - 1.2657) 0.4 (0.016) 33112-C6903
32.15 - 32.05
(1.2657 - 1.2618) 0.5 (0.020) 33112-33G00
32.05 - 31.95
(1.2618 - 1.2579) 0.6 (0.024) 33112-33G01
3. Place suitable shim on counter gear rear bearing with grease.
4. Apply gear oil to each part in front case.
5. Assemble center case assembly.
a. Install mainshaft on center case by tapping lightly.
Apply gear oil to mainshaft front bearing.
SMT335A
SMT334A
SMT336A
SMT406A
ASSEMBLY
TF-28
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b. Install bearing retainer.
c. Put drive chain onto the front drive sprocket and front driveshaft, and then put them in center case.
d. Install front drive shaft by tapping lightly.
e. Apply gear oil to needle bearings and install them into front drive sprocket.
These needle bearings will be installed more easily if front
drive sprocket is rotated while installing them.
SMT407A
SMT408A
SMT409A
SMT410A
SMT411A
ASSEMBLY
TF-29
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2. Remove snap ring.
3. Remove pushed out journal bearing by lightly tapping yoke witha hammer, taking care not to damage journal and yoke hole.
4. Remove bearing at opposite side in above operation.
Put marks on disassembled parts so that they can be rein-
stalled in their original positions from which they were
removed.
Assembly
JOURNAL
1. Assemble journal bearing. Apply recommended multi-purpose grease on bearing inner surface.
When assembling, be careful that needle bearing does not fall
down.
2. Select snap rings that will provide specified play in axial direc- tion of journal, and install them. (Refer to PD-57.)
Select snap rings with a difference in thickness at both sides
within 0.06 mm (0.0024 in).
SPD731
SPD732
SPD131
SPD133
SPD134
PROPELLER SHAFT
Disassembly (Cont'd)
PD-8
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Differential Case
1. Measure clearance between side gear thrust washer and dif-ferential case.Clearance between side gear thrust washer and differ-
ential case (A þ B): 0.10 - 0.20 mm (0.0039 - 0.0079 in)
The clearance can be adjusted with side gear thrust washer.
(Refer to PD-57.)
2. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see the turn properly.
3. Install L.H. and R.H. differential cases.
4. Place differential case on ring gear.
5. Apply locking agent [Locktite (stud lock) or equivalent] to ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.
6. Press-fit side bearing inner cones on differential case with Tool. Tool number:q
AST33230000
q
BST33061000
SPD656
SPD643
SPD746
PD353
ASSEMBLY (R180A)
PD-29
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6. Install pinion mate gears and pinion shaft to differential case B.
7. Install side gear to pinion mate gears.
8. Install each disc and plate.
Use same procedures as outlined in steps 1. through 4. above.
9. Install differential case A.
Position differential cases A and B by correctly aligning marks
stamped on cases.
10. Tighten differential case bolts.
:64-69N×m (6.5 - 7.0 kg-m, 47 - 51 ft-lb)
11. Place ring gear on differential case and install new lock straps and bolts.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.
Then bend up lock straps to lock the bolts in place.
12. Install side bearing inner cone.
13. Check differential torque.
SPD426
SPD429
SPD430
SPD288
LIMITED SLIP DIFFERENTIAL (C200)
Assembly (Cont'd)
PD-48
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11. Position side bearing on gear carrier with threads properlyengaged; screw in adjusters lightly at this stage of assembly.Tool number: ST32580000
12. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.
I Do not tighten at this point to allow further tightening of side
bearing adjusters.
13. Tighten both right and left side bearing adjusters alternately and measure ring gear backlash and total preload at the same time.
Adjust right and left side bearing adjusters by tightening them
alternately so that proper ring gear backlash and total preload
can be obtained.Ring gear-to-drive pinion backlash: 0.10 - 0.20 mm (0.0039 - 0.0079 in)
I When checking preload, turn drive pinion in both direc-
tions several times to set bearing rollers.
Tool number: ST3127S000
The total pinion bearing preload value with the differential case
assembly should be in accordance with the same value measured
without the differential case assembly. (See point 9.)
The relationship between both is:
Pinion bearing preload
With differential case assembly Without differential case assembly kg-cm N×m kg-cmN×m
14 1.417 - 23 1.7 - 2.3
15 1.518 - 24 1.8 - 2.4
16 1.619 - 25 1.9 - 2.5
17 1.720 - 26 2.0 - 2.6
SPD684
SPD265
SPD246
SPD149
ASSEMBLY (C200)
Differential Carrier (Cont'd)
PD-55
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Removal
IRemove free-running hub assembly.
Refer to ªFRONT AXLE Ð Auto-lock Free-running Hubº, FA-14.
I Separate drive shaft from knuckle spindle by slightly tapping
drive shaft end.
I Separate tie-rod from knuckle spindle with Tool.
Install stud nut conversely on stud bolt so as not to damage
stud bolt.
I Separate knuckle spindle from ball joints.
(1) Loosen (not remove) upper and lower ball joint tightening nuts.
(2) Separate upper and lower ball joints to knuckle spindle with Tool.
During above operation, never remove ball joint nuts which
are loosened in step (1) above. Tool: HT72520000
NFA008
NFA009
NFA010
SFA927
SFA079
FRONT AXLE Ð Knuckle Spindle
FA-20
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