Nissan Pathfinder. Manual - part 413

DLN-94

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

TRANSFER CASE

TRANSFER CASE

Exploded View

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1.

Oil seal

2.

Transfer cover

3.

Filler plug

4.

Gasket

5.

Drain plug

6.

Oil seal

JSDIA4191GB

TRANSFER CASE

DLN-95

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

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Disassembly

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1. Remove transfer cover. Refer to 

DLN-78, "Disassembly"

.

2. Remove ring gear shaft assembly. Refer to 

DLN-82, "Disassembly"

.

3. Remove drive pinion assembly. Refer to 

DLN-87, "Disassembly"

.

4. Remove O-ring from transfer case.

CAUTION:

• Never use a tool.

• Never damage transfer case.

5. Remove oil seals (1).

CAUTION:

Never damage transfer case.

6. Remove baffle plate (1).

7.

O-ring

8.

Ring gear bearing adjusting shim 
(transfer cover side)

9.

Ring gear bearing (transfer cover 
side)

10. Drive shaft oil seal

11. Ring gear shaft

12. Ring gear bearing (transfer case 

side)

13. Ring gear bearing adjusting shim 

(transfer case side)

14. Ring gear

15. Baffle plate

16. Transfer case

17. Plug

18. O-ring

19. Oil seal

20. Dowel pin

21. Drive pinion

22. Drive pinion adjusting shim

23. O-ring

24. Pinion bearing assembly

25. Oil seal

26. Dust cover

27. Companion flange

28. Pinion lock nut
A.  Oil seal lip

B.  Comply with the assembly proce-

dure when tightening. Refer to 

DLN-

96, "Assembly"

.

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

: Apply gear oil.

*

: Apply anti-corrosive oil.

: Apply multi-purpose grease.

: Select with proper thickness.

JSDIA3983ZZ

JSDIA3982ZZ

DLN-96

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

TRANSFER CASE

7. Remove the ring gear bearing adjusting shim (transfer case

side) (1) and ring gear bearing outer race (transfer case side) (2)
by tapping from the 2 cutouts (

) on the transfer case.

CAUTION:

Never damage transfer case.

8. Remove plug and gasket.
9. Perform inspection after disassembly. Refer to 

DLN-97, "Inspec-

tion"

.

Assembly

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1. Select the ring gear bearing adjusting shim (transfer case side). Refer to 

DLN-89, "Adjustment"

.

2. Install the selected ring gear bearing adjusting shim (transfer

case side) and ring gear bearing outer race (transfer case side)

using drift (A) (commercial service tool).

CAUTION:

• Never reuse ring gear bearing.

• Apply gear oil to the ring gear bearing.

3. Install baffle plate (1).
4. Install ring gear shaft assembly. Refer to 

DLN-83, "Assembly"

.

CAUTION:

Protect transfer case oil seals beforehand from being dam-

aged by the spline of ring gear shaft.

5. Install drive pinion assembly. Refer to 

DLN-88, "Assembly"

.

6. Install transfer cover to check and adjust each part. Refer to

DLN-79, "Assembly"

.

NOTE:

At this timing, O-ring installing to transfer cover is not necessary.

Install O-ring after backlash and tooth contact are checked.

7. Check backlash, tooth contact, total preload and companion flange runout. Refer to 

DLN-89, "Adjust-

ment"

.

CAUTION:

Measure the total preload without oil seals of transfer cover and transfer case.

8. Reinstall transfer cover for installing O-ring. Refer to 

DLN-79, "Assembly"

.

9. Install oil seals with drift (commercial service tool).

CAUTION:

• When checking the total preload torque, measure it with-

out the oil seal, then install the oil seal.

• Never reuse the oil seal.

• When installing, never incline oil seal.

• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of the oil seal.

• Never damage oil seals by spline of ring gear shaft.

10. After installing oil seals to transfer case, remove wrapped vinyl from the spline of ring gear shaft.
11. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the transfer case.

JSDIA3984ZZ

JSDIA3998ZZ

A

: 24.8 mm (0.976 in)

B

: 10.3 mm (0.406 in)

JSDIA3982ZZ

JSDIA4047ZZ

TRANSFER CASE

DLN-97

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CAUTION:

• Never reuse O-ring.

• When installing O-ring, never use a tool.

• Never damage O-ring.

Inspection

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INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones.

Case

Check the bearing mounting surface for wear, cracks and damages.