Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 1998-2002 Approved Nissan Frontier 2002 TF
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TRANSFER GI
SECTION TF MA
EM
LC
EC
CONTENTS FE
PREPARATION ...............................................................2 DISASSEMBLY ........................................................23
CL
Special Service Tools ..................................................2 INSPECTION ...........................................................23
Commercial Service Tools ...........................................3 ASSEMBLY .............................................................23
MT
NOISE, VIBRATION AND HARSHNESS (NVH) Main Gear ..................................................................23
TROUBLESHOOTING .....................................................5 DISASSEMBLY ........................................................23
INSPECTION ...........................................................24 AT
NVH Troubleshooting Chart.........................................5
ASSEMBLY .............................................................24
TRANSFER ...............................................................5
Front Case .................................................................25
DESCRIPTION .................................................................6
REMOVAL ...............................................................25
Cross-sectional View ...................................................6
INSTALLATION........................................................25
ON-VEHICLE SERVICE ..................................................7
Front Case Cover ......................................................25
Replacing Oil Seal .......................................................7
REMOVAL ...............................................................25 PD
CENTER CASE OIL SEAL ..........................................7
INSTALLATION........................................................25
SHIFT SHAFT OIL SEAL ............................................8
Bearing Retainer........................................................26
REAR OIL SEAL ........................................................8 AX
REMOVAL ...............................................................26
Position Switch Check .................................................9
INSTALLATION........................................................26
REMOVAL AND INSTALLATION .................................10 Center Case...............................................................26
Removal.....................................................................10 REMOVAL ...............................................................26 SU
Installation..................................................................10 INSTALLATION........................................................26
M/T MODEL ............................................................10 Rear Case..................................................................26
A/T MODEL .............................................................10 REMOVAL ...............................................................26
BR
OVERHAUL ...................................................................11 INSTALLATION........................................................27
Transfer Gear Control................................................11 Shift Control Components .........................................27
Case Components .....................................................12
ST
INSPECTION ...........................................................27
Gear Components .....................................................13 ASSEMBLY....................................................................29
Shift Control Components .........................................14 SERVICE DATA AND SPECIFICATIONS (SDS) .........37 RS
DISASSEMBLY..............................................................15 General Specifications...............................................37
REPAIR FOR COMPONENT PARTS ...........................20 Inspection and Adjustment ........................................37
Mainshaft ...................................................................20 CLEARANCE BETWEEN FRONT DRIVE BT
DISASSEMBLY ........................................................20 SPROCKET AND 2-4 COUPLING SLEEVE................37
INSPECTION ...........................................................21 GEAR END PLAY ....................................................37
ASSEMBLY .............................................................22 CLEARANCE BETWEEN BAULK RING AND HA
Front Drive Shaft .......................................................22 CLUTCH GEAR .......................................................37
DISASSEMBLY ........................................................22 AVAILABLE SHIM ....................................................37
INSPECTION ...........................................................22 AVAILABLE SNAP RING ..........................................37 SC
ASSEMBLY .............................................................22
Counter Gear .............................................................23
EL
IDX
PREPARATION
Special Service Tools
Special Service Tools NETF0001
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
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
TF-2
PREPARATION
Special Service Tools (Cont'd)
Tool number
(Kent-Moore No.) Description
Tool name GI
ST36710010 Removing counter gear front bearing
( -- ) (Use with ST30021000) MA
Drift Removing counter gear rear bearing
(Use with ST30031000)
a: 34.5 mm (1.358 in) dia.
NT063
EM
ST33061000 Removing main gear bearing
(J8107-2) a: 28.5 mm (1.122 in) dia. LC
Drift b: 38 mm (1.50 in) dia.
EC
NT116
ST30613000 1 Installing main gear bearing
1 (J25742-3) 2 Installing front case cover oil seal FE
2 (J34339) a: 72 mm (2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.
CL
NT073
(J35864) Installing shift shaft oil seal MT
Drift a: 26 mm (1.02 in) dia.
b: 20 mm (0.79 in) dia.
c: 150 mm (5.91 in) AT
NT117
(J26092) Seating counter gear assembly
Drift a: 44.5 mm (1.752 in) dia.
b: 38.5 mm (1.516 in) dia.
PD
NT065
(J34291) Selecting counter gear rear bearing shim
AX
Shim setting gauge set
SU
NT101
BR
(J34291-20) Selecting counter gear rear bearing shim
Plunger-shim setting ST
gauge
RS
NT118
Commercial Service Tools NETF0002
BT
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool name Description HA
Puller Removing front drive shaft front bearing
Removing front drive shaft rear bearing
Removing main gear bearing SC
EL
NT077
IDX
TF-3
PREPARATION
Commercial Service Tools (Cont'd)
Tool name Description
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.
NT117
b: 50 mm (1.97 in) dia.
c: 60 mm (2.36 in)
TF-4
NETF0039
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
NVH Troubleshooting Chart NETF0039S01
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. GI
TRANSFER NETF0039S0101
MA
Refer to MA-40, "Checking Transfer Fluid"
EM
LC
TF-12, 14
TF-12
TF-12
TF-14
TF-13
TF-13
TF-13
TF-13
Reference page
EC
FE
CL
CHECK SPRING AND CHECK BALL (Worn or damaged)
MT
BAULK RING (Worn or damaged)
SHIFTING INSERT (Damaged)
BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
LIQUID GASKET (Damaged)
AT
GEAR (Worn or damaged)
FLUID (Level too high)
SHIFT FORK (Worn)
FLUID (Level low)
FLUID (Wrong)
SUSPECTED PARTS
(Possible cause)
PD
AX
SU
Noise 1 2 3 3 BR
Fluid leakage 3 1 2 2
Symptom
Hard to shift or will not shift 1 1 2 2 ST
Jumps out of gear 1 2 2
RS
BT
HA
SC
EL
IDX
TF-5
DESCRIPTION
Cross-sectional View
Cross-sectional View NETF0003
ATF021
TF-6
ON-VEHICLE SERVICE
Replacing Oil Seal
Replacing Oil Seal NETF0004
CENTER CASE OIL SEAL
1.
NETF0004S01
Remove front propeller shaft. Refer to PD-9, "PROPELLER
GI
SHAFT".
2. Remove companion flange nut. MA
EM
SMT844D LC
3. Remove companion flange.
EC
FE
CL
SMT486A
MT
4. Remove center case oil seal.
5. Install center case oil seal. AT
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