Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Xterra 2000-2004 Approved Nissan Xterra 2004 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" .
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◦ Jabse Service Manual Search 2024 ◦ Jabse Pravopis ◦ onTap.bg ◦ Other service manual resources online : Fixya ◦ eServiceinfo