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TF


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D DRIVELINE/AXLE

                                                                                                                                                                A


                                                                                                                                                                B
                                                                                                      SECTION
                                                                                                                          TRANSFER                              C


                                                                                                                                                                TF


                                                                                                                                                                E
                                                                 CONTENTS
PREPARATION .......................................................... 2.           DISASSEMBLY .................................................. 32  .         F
 Special Service Tools .............................................. 2 .           INSPECTION ..................................................... 33.
 Commercial Service Tools ....................................... 4     .           ASSEMBLY ........................................................ 33
                                                                                                                                                       .
NOISE, VIBRATION, AND HARSHNESS (NVH)                                             Main Gear .............................................................. 33
                                                                                                                                                       .        G
TROUBLESHOOTING ............................................... 5       .           DISASSEMBLY .................................................. 33  .
 NVH Troubleshooting Chart .................................... 5       .           INSPECTION ..................................................... 34.
DESCRIPTION ........................................................... 7
                                                                        .           ASSEMBLY ........................................................ 34
                                                                                                                                                       .
                                                                                                                                                                H
 Cross-sectional View ............................................... 7 .         Front Case ............................................................. 35
                                                                                                                                                       .
ON-VEHICLE SERVICE ............................................ 8       .           SHIFT SHAFT OIL SEAL ................................... 35        .
 Replacing Oil Seal ................................................... 8
                                                                        .         Front Case Cover .................................................. 36
                                                                                                                                                       .
   CENTER CASE OIL SEAL ................................... 8           .           COVER OIL SEAL .............................................. 36   .         I
   SHIFT SHAFT OIL SEAL ..................................... 9         .         Bearing Retainer .................................................... 36
                                                                                                                                                       .
   REAR OIL SEAL .................................................. 9   .           OIL CATCHER .................................................... 36.
 Position Switch Check ........................................... 10   .         Center Case .......................................................... 37
                                                                                                                                                       .         J
REMOVAL AND INSTALLATION .............................11                .           CENTER CASE OIL SEAL ................................. 37          .
 Removal .................................................................11
                                                                        .         Rear Case ............................................................. 37
                                                                                                                                                       .
 Installation ..............................................................11
                                                                        .           REAR OIL SEAL ................................................ 37  .
                                                                                                                                                                K
OVERHAUL ............................................................. 12
                                                                        .           AIR BREATHER ................................................. 38  .
 Transfer Gear Control ........................................... 12   .         Shift Control Components ..................................... 38    .
 Case Components ................................................ 13    .           INSPECTION ..................................................... 38.
 Gear Components ................................................. 14   .        SERVICE DATA AND SPECIFICATIONS (SDS) ..... 40                        .         L
 Shift Control Components ..................................... 15      .         General Specifications ........................................... 40.
TRANSFER ASSEMBLY ......................................... 16          .         Inspection and Adjustment .................................... 40    .
 Disassembly .......................................................... 16
                                                                        .           CLEARANCE BETWEEN FRONT DRIVE                                               M
 Assembly ............................................................... 21
                                                                        .           SPROCKET AND 2-4 COUPLING SLEEVE ...... 40                         .
REPAIR FOR COMPONENT PARTS ...................... 29                    .           GEAR END PLAY ............................................... 40   .
 Mainshaft ............................................................... 29
                                                                        .           CLEARANCE BETWEEN BAULK RING AND
   DISASSEMBLY .................................................. 29    .           CLUTCH GEAR .................................................. 40  .
   INSPECTION ..................................................... 30  .         Available Shim ....................................................... 40
                                                                                                                                                       .
   ASSEMBLY ........................................................ 31 .           COUNTER GEAR REAR BEARING .................. 40                    .
 Front Drive Shaft ................................................... 32
                                                                        .         Available Snap Ring .............................................. 40.
   DISASSEMBLY .................................................. 32    .           MAINSHAFT FRONT BEARING ........................ 40                .
   INSPECTION ..................................................... 32  .           MAIN GEAR BEARING ...................................... 40        .
   ASSEMBLY ........................................................ 32 .           MAINSHAFT REAR BEARING .......................... 41               .
 Counter Gear ........................................................ 32
                                                                        .




                                                                            TF-1
                                                       PREPARATION

PREPARATION                                                                                                                   PFP:00002

Special Service Tools                                                                                                            EDS000M8

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool number                                                                             Description
  (Kent-Moore No.)
  Tool name
  KV38108300                                                                             Removing companion flange nut
  (     --       )                                                                       Installing companion flange nut
  Companion flange wrench




                                                                         NT771


  ST30021000                                                                             Removing counter gear front bearing
  (J22912-01)                                                                            (Use with ST36710010)
  Puller                                                                                 Removing L & H hub
                                                                                         a: 110 mm (4.33 in) dia.
                                                                                         b: 68 mm (2.68 in) dia.


                                                                         NT411


  ST30031000                                                                             Removing counter gear rear bearing
  (J22912-01)                                                                            (Use with ST36710010)
  Puller                                                                                 a: 90 mm (3.54 in) dia.
                                                                                         b: 50 mm (1.97 in) dia.



                                                                         NT411


  ST33290001                                                                             Removing center case oil seal
  (J34286)                                                                               Removing rear oil seal
  Puller                                                                                 a: 250 mm (9.84 in)
                                                                                         b: 160 mm (6.30 in)



                                                                         NT414


  ST33051001                                                                             Removing companion flange
  (J22888)                                                                               a: 135 mm (5.31 in)
  Puller                                                                                 b: 100 mm (3.94 in)
                                                                                         c: 130 mm (5.12 in)



                                                                         NT657


  ST30720000                                                                             1 Installing center case oil seal
  1 (J25273)                                                                             2 Installing rear oil seal
  2 (J25405)                                                                             a: 77 mm (3.03 in) dia.
  Drift                                                                                  b: 55.5 mm (2.185 in) dia.



                                                                         NT658


  ST36710010                                                                             Removing counter gear front bearing
  (     --         )                                                                     (Use with ST30021000)
  Drift                                                                                  Removing counter gear rear bearing
                                                                                         (Use with ST30031000)
                                                                                         a: 34.5 mm (1.358 in) dia.


                                                                         NT063




                                                                 TF-2
                             PREPARATION

Tool number                                    Description
(Kent-Moore No.)                                                                          A
Tool name
ST33061000                                     Removing main gear bearing
(J8107-2)                                      a: 28.5 mm (1.122 in) dia.                 B
Drift                                          b: 38 mm (1.50 in) dia.


                                                                                          C

                                       NT116


ST30613000                                     1 Installing main gear bearing             TF
1 (J25742-3)                                   2 Installing front case cover oil seal
2 (J34339)                                     a: 72 mm (2.83 in) dia.
Drift                                          b: 48 mm (1.89 in) dia.
                                                                                          E

                                       NT073


(J35864)                                       Installing shift shaft oil seal
                                                                                           F
Drift                                          a: 26 mm (1.02 in) dia.
                                               b: 20 mm (0.79 in) dia.
                                               c: 150 mm (5.91 in)                        G


                                       NT117                                              H
(J26092)                                       Seating counter gear assembly
Drift                                          a: 44.5 mm (1.752 in) dia.
                                               b: 38.5 mm (1.516 in) dia.
                                                                                           I


                                                                                           J
                                       NT065


(J34291)                                       Selecting counter gear rear bearing shim
Shim setting gauge set
                                                                                          K


                                                                                           L
                                       NT101


(J34291-20)                                    Selecting counter gear rear bearing shim
Plunger-shim setting gauge                                                                M




                                       NT118




                                TF-3
                                                       PREPARATION

Commercial Service Tools                                                                                                            EDS000M9

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool name                                                                               Description
  Puller                                                                                 Removing front drive shaft front bearing
                                                                                         Removing front drive shaft rear bearing
                                                                                         Removing main gear bearing




                                                                         NT077


  Drift                                                                                  1 Installing mainshaft rear bearing
                                                                                         2 Installing L & H hub
                                                                                         1 a: 50 mm (1.97 in) dia.
                                                                                            b: 42 mm (1.65 in) dia.
                                                                                            c: 180 mm (7.09 in)
                                                                                         2 a: 60 mm (2.36 in) dia.
                                                                                            b: 50 mm (1.97 in) dia.
                                                                         NT117              c: 60 mm (2.36 in)




                                                                 TF-4
           NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING                                                                                                                                                                                                                                                                                                                    PFP:00003
                                                                                                                                                                                                                                                                                                                                                                                                                                        A
NVH Troubleshooting Chart                                                                                                                                                                                                                                                                                                                                                                               EDS000MA


Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.
If necessary, repair or replace these parts.                                                                                                                                                                                                                                                                                                                                                                                            B




                                                                                        MA-37, "Checking Transfer Fluid"
                                                                                                                                                                                                                                                                                                                                                                                                                                        C




                                                                                                                                                                                                                          TF-13, TF-15


                                                                                                                                                                                                                                                                               TF-15, TF-29




                                                                                                                                                                                                                                                                                                                                                          TF-14, TF-29
                                                                                                                                                                                     TF-13, TF-8
                                                                                                                                                        TF-13
 Reference page
                                                                                                                                                                                                                                                                                                                                                                                                                                        TF


                                                                                                                                                                                                                                                                                                                                                                                                                                        E




                                                                                                                                                                                                                                  CHECK SPRING AND CHECK BALL (Worn damaged)
                                                                                                                                                                                                                                                                                                                                                                                                                                         F




                                                                                                                                                                                                                                                                                                                                                                         BAULK RING (Worn or damaged)


                                                                                                                                                                                                                                                                                                                                                                                                            SHIFTING INSERT (Damaged)
                                                                                                                                                                                             OIL SEAL (Worn or damaged)
                                                                                                                                                           LIQUID GASKET (Damaged)




                                                                                                                                                                                                                                                                                                                                    Bearing (Worn or damaged)
                                                                                                                                                                                                                                                                                                                                                                                                                                        G




                                                                                                                                                                                                                                                                                                           GEAR (Worn or damaged)
                                                                                                                               FLUID (Level too high)




                                                                                                                                                                                                                                                                                       SHIFT FORK (Worn)
                                                                   FLUID (Level low)


                                                                                                               FLUID (Wrong)




 SUSPECTED PARTS                                                                                                                                                                                                                                                                                                                                                                                                                        H
 (Possible cause)


                                                                                                                                                                                                                                                                                                                                                                                                                                         I


                                                                                                                                                                                                                                                                                                                                                                                                                                         J



                 Noise                                            1                                 2                                                                                                                                                                                                      3                        3
                                                                                                                                                                                                                                                                                                                                                                                                                                        K

                 Fluid leakage                                                                      3                          1                          2                              2
 Symptom
                 Hard to shift or will not shift                                                    1                          1                                                                                                                                                                                                                                         2                                 2                             L
                 Jumps out of gear                                                                                                                                                                                            1                                                    2                       2

Transfer Case Diagnostic Table
                                                                                                                                                                                                                                                                                                                                                                                                                                        M
          Symptom                          Possible cause                                                                                                                                              Service Information
                                                                                       No repair needed.
                                 When checking or changing the
                                                                                       The transfer case oil (Nissan-Matic-D) may turn dark in color after the
 Dark oil and/or small           oil; oil level may be okay, but the
                                                                                       vehicle accumulates miles or after operating at high temperatures.
 debris in the oil.              oil color is dark and small metallic
                                 debris are on the drain plug.
                                                                                       Small metal debris are residual material from the transfer case com-
                                                                                       ponents. This is normal.
                                                                                       Inspect the tires for different sizes.

                                                                                       All tires must be the same "height" and "distance around" (circumfer-
                                                                                       ence).
                                 Differences in the front and rear
 Difficult, or no shift from     ties size (circumference); caused
                                                                                       If there are differences in the size, or if one or more tires are exces-
 4H into 2H.                     by tire wear or excessive load on
                                                                                       sively worn when compared to the other tires, make corrections as
                                 the rear of the vehicle.
                                                                                       needed so all of the tires are the same size (circumference) before
                                                                                       evaluating the transfer case operation.

                                                                                       *Size = tire height and circumference (distance "around").

                                                                                       TF-5
         NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

        Symptom                        Possible cause                                          Service Information
                              When engaging 4H, the 2-4 cou-        If difficulty in shifting/clunk noise is gone when the vehicle is stationary
                              pling sleeve has resistance when      (not moving), inform the customer this is a normal characteristic of the
                              engaging the clutch gear. This        transfer case.
Difficult to shift from 2H
                              resistance is caused by rotating
into 4H and/or clunk noise
                              parts attempting to bring station-    CAUTION: never attempt shifting to 4H above 25 mph (50 mph for
when the vehicle is
                              ary parts (parts that are not mov-    Pathfinder).
moving.
                              ing) "up to speed" (transfer case
                              chain, front propshaft and differ-    If difficulty in shifting/clunk noise can be duplicated when the vehicle is
                              ential).                              stopped, refer to TF-5, "NVH Troubleshooting Chart" .
                                                                    This is a normal characteristic when there is more than usual torque
                                                                    applied to the transfer case.

                                                                    When the vehicle is driven in 4H on a dry, hard surface, above normal
"Whine" noise while driv-
                              Additional torque is applied to the   torque is applied to the mainshaft, front driveshaft, and transfer case
ing in 4H on dry, hard sur-
                              transfer case components.             chain. With this extra torque, the transfer case chain will have a
face (i.e. dry paved road).
                                                                    "whine" noise.

                                                                    Instruct the customer not to drive the vehicle in 4H on a dry, hard sur-
                                                                    face.
                              Excessive friction of the prop
                                                                    Inspect the rear prop shaft u-joint (transfer case end) to determine if
"Clunk" noise, seems to       shaft u-joint (transfer case end),
                                                                    there is excessive friction of the u-joint (u-joint feels "notchy").
come from the transfer        causing the prop shaft sleeve
case.                         yoke to stick against the transfer
                                                                    Refer to PR-3, "NVH Troubleshooting Chart" .
                              case output shaft.
                                                                    This is a normal characteristic of the transfer case due to all of the
"Grind" noise when slowly
                                                                    gears "spooling up" in Neutral.
shifting the transfer case    Gear clashing occurs as the Low/
from 4H to Neutral and        High (L/H) coupling sleeve
                                                                    Instruct the customer to depress the transfer case lever, and then
then into 4L, or from 4L to   "engages" the main or low gear.
                                                                    quickly and smoothly shift from 4H to 4L or 4L to 4H, without stopping
Neutral and then into 4H.
                                                                    in Neutral.
                                                                    Determine which hub is "ratcheting" and inspect the opposite hub for
                                                                    possible damage. Check to see if it is unlocking. The ratcheting hub is
                                                                    likely okay.

                                                                    To check Automatic Hub operation, place the vehicle on a lift with the
                                                                    transfer case in 2H (engine off).
                              One of the automatic hubs may
"Ratcheting" noise from       be stuck in the "Lock" position,      q   Hand turn the front propshaft to observe both wheels "lock-in".
the front hub.                causing the other hub to make a
                              "ratcheting" noise.                   q   Reversing direction of the propshaft should first "un-lock" the
                                                                        wheels and then "lock" them again.

                                                                    q   This action should repeat each time the propshaft is reversed.

                                                                    Refer to FAX-4, "NVH Troubleshooting Chart" , and RAX-5, "NVH
                                                                    Troubleshooting Chart" .




                                                                    TF-6
                       DESCRIPTION

DESCRIPTION                           PFP:00000
                                                         A
Cross-sectional View                          EDS000MB




                                                         B



                                                         C


                                                         TF


                                                         E



                                                          F


                                                         G


                                                         H



                                                          I


                                                          J



                                                         K


                                                          L



                                                         M




                                     ATF021




                          TF-7
                                        ON-VEHICLE SERVICE

ON-VEHICLE SERVICE                                                               PFP:00000

Replacing Oil Seal                                                                  EDS000MC

CENTER CASE OIL SEAL
1.   Remove front propeller shaft. Refer to PR-8, "Removal and Installation" .
2.   Remove companion flange nut using Tool, as shown.




                                                                                  SMT844D



3.   Remove companion flange using Tool, as shown.




                                                                                  SMT486A



4.   Remove center case oil seal using Tool, as shown.




                                                                                  AMT086



5.   Install center case oil seal.
     q Before installing, apply multi-purpose grease to seal lip.

6.   Install companion flange.
7.   Tighten companion flange nut using Tool, as shown.
        Companion flange       : 226 - 324 N



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