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Nissan Pathfinder (2009 year). Manual - part 212

DLN-178

< DISASSEMBLY AND ASSEMBLY >

[TRANSFER: ATX14B]

TRANSFER ASSEMBLY

35. Apply petroleum jelly to the stem bleeder and install it to the cen-

ter case.

36. Apply ATF to the new seal ring and install it to the main oil pump

cover.

CAUTION:

Do not reuse seal ring.

37. Install the inner gear and outer gear in the main oil pump hous-

ing. Then, measure the side clearance. Refer to

DLN-187,

"Inspection and Adjustment"

38. Install the main oil pump housing, outer gear and inner gear to

the center case.

39. Install the main oil pump cover to the center case, and tighten to

the specified torque. Refer to

DLN-150, "Disassembly and

Assembly"

SDIA2780E

SDIA2783E

SDIA2174E

SDIA2188E

SDIA2130E

2009 Pathfinder

TRANSFER ASSEMBLY

DLN-179

< DISASSEMBLY AND ASSEMBLY >

[TRANSFER: ATX14B]

DLN

40. Remove all the sealant from the switch location area and inside

the center case.

CAUTION:

Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.

41. Thread the ATP switch and neutral-4LO switch in one to two

pitches and apply sealant to the threads of the switches. Tighten
to the specified torque. Refer to

DLN-150, "Disassembly and

Assembly"

• Use Genuine Silicone RTV or equivalent. Refer to

GI-26,

NOTE:
• Neutral-4LO switch harness connector is gray.
• ATP switch harness connector is black.

42. Install the front drive shaft rear bearing using Tools.

43. Install the front drive shaft to the front bearing using Tools.

44. Install the drive chain to the front drive shaft and clutch drum.

CAUTION:

Install drive chain by aligning identification marks to the
rear as shown.

Tool number

A: KV40100621 (J-25273)

B: ST30032000 (J-26010-01)

SDIA3435E

SDIA2198E

Tool number

A: KV40100621 (J-25273)

B: ST30032000 (J-26010-01)

SDIA2199E

SDIA2200E

2009 Pathfinder

DLN-180

< DISASSEMBLY AND ASSEMBLY >

[TRANSFER: ATX14B]

TRANSFER ASSEMBLY

45. Tap the front drive shaft while keeping it upright and press-fit the

front drive shaft rear bearing.

CAUTION:

Do not tap drive chain.

46. Install the front case assembly. Refer to

DLN-150, "Disassembly

and Assembly"

47. Install the rear case assembly. Refer to

DLN-150, "Disassembly

and Assembly"

Front Case

Install the carrier bearing to the sun gear using Tools.

Install the new snap ring to the sun gear assembly using suitable
tool.

CAUTION:

Do not reuse snap ring.

Apply ATF to the circumference of the new metal bushing and
install it to the sun gear assembly using suitable tool.

CAUTION:

• Do not reuse metal bushing.
• Apply ATF to metal bushing before installing.

Apply ATF to the new needle bearing and install it to the sun
gear assembly using Tool.

CAUTION:

• Do not reuse needle bearing.
• Apply ATF to needle bearing before installing.

SMT988C

Tool number

A: ST30911000 (

—

)

B: KV31103300 (

—

)

SDIA2179E

SDIA2148E

Dimension A

: 7.7 - 8.3 mm (0.303 - 0.327 in)

SDIA3189E

Tool number

: ST33220000 (

—

)

Dimension B

: 62.5 - 63.1 mm (2.461 - 2.484 in)

SDIA3190E

2009 Pathfinder

TRANSFER ASSEMBLY

DLN-181

< DISASSEMBLY AND ASSEMBLY >

[TRANSFER: ATX14B]

DLN

Install the sun gear assembly to the planetary carrier assembly.

Install the new snap ring to the planetary carrier assembly.

CAUTION:

Do not reuse snap ring.

Set the input bearing into the front case and install using Tool.

Install the new snap ring into the front case.

CAUTION:

Do not reuse snap ring.

Install the internal gear with its groove facing the snap ring into
the front case. Then secure it with the new snap ring.

CAUTION:

Do not reuse snap ring.

SDIA2180E

SDIA2794E

Tool number

: ST30720000 (J-25405)

SDIA2172E

SDIA2171E

WDIA0100E

2009 Pathfinder

DLN-182

< DISASSEMBLY AND ASSEMBLY >

[TRANSFER: ATX14B]

TRANSFER ASSEMBLY

10. Install the new front oil seal until it is seated flush with the end

face of the front case using Tool.

CAUTION:

• Do not reuse oil seal.
• Apply petroleum jelly to oil seal lip before installing.

11. Install the planetary carrier assembly and sun gear assembly to

the front case using Tool.

12. Install the new snap ring to the sun gear.

CAUTION:

Do not reuse snap ring.

13. Apply petroleum jelly to the circumference of the new oil seal,

and install it to the front case using Tools.

CAUTION:

• Do not reuse oil seal.
• Apply petroleum jelly to oil seal.

14. Install the fork guide, shift fork spring, 2-4 fork, and L-H fork to

the shift rod, and secure them with new retaining pins.

CAUTION:

Do not reuse retaining pins.

Tool number

: KV38100500 (

—

)

SDIA3383E

Tool number

: ST33200000 (J-26082)

SDIA2791E

SDIA2144E

Tool numbers

A: ST30720000 (J-25405)

B: ST33200000 (J-26802)

Dimension (A)

: 4.0 - 4.6 mm (0.157 - 0.181 in)

SDIA3191E

SDIA2142E

2009 Pathfinder

TRANSFER ASSEMBLY

DLN-183

< DISASSEMBLY AND ASSEMBLY >

[TRANSFER: ATX14B]

DLN

15. Install the 2-4 sleeve and L-H sleeve to each fork.

16. Install the shift cross to the front case.

17. While aligning the L-H sleeve with the planetary carrier, install

the shift rod assembly (A) to the front case.

18. Apply liquid gasket to the entire center case mating surface of

the front case assembly as shown.
• Use Genuine Anaerobic Liquid Gasket or equivalent.

Refer to

Sealants"

CAUTION:

Remove all foreign materials such as water, oil and grease
from center case and front case mating surfaces.

19. Install the center case assembly to the front case assembly.

CAUTION:

Do not damage mainshaft end.

20. Tap the center case lightly and press-fit the front drive shaft

bearing into the front case.

SMT992C

AWDIA0015ZZ

WDIA0157E

SDIA2138E

2009 Pathfinder

DLN-184

< DISASSEMBLY AND ASSEMBLY >

[TRANSFER: ATX14B]

TRANSFER ASSEMBLY

21. Tighten the front case bolts to the specified torque. Refer to

DLN-150, "Disassembly and Assembly"

CAUTION:

Be sure to install air breather hose clamp, connector
bracket and harness clip.

22. Install the drain plug with a new gasket.

CAUTION:

Do not reuse gasket.

23. Align the matching mark on the front drive shaft with the mark on

the companion flange, then install the companion flange.

24. Install a new companion flange self-lock nut. Tighten to the specified torque using Tool. Refer to

DLN-150,

"Disassembly and Assembly"

CAUTION:

Do not reuse self-lock nut.

25. Remove all the sealant from the check plug, switch and front

case.

CAUTION:

Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.

26. Install the check ball and check spring to the front case. Apply

sealant to the check plug and wait detection switch and install
them to the front case. Tighten to the specified torque. Refer to

DLN-150, "Disassembly and Assembly"

• Use Genuine Silicone RTV or equivalent. Refer to

GI-26,

NOTE:
Wait detection switch harness connector is black.

SDIA2100E

SDIA2779E

Tool number

: KV38108300 (J-44195)

WDIA0219E

WDIA0158E

2009 Pathfinder

TRANSFER ASSEMBLY

DLN-185

< DISASSEMBLY AND ASSEMBLY >

[TRANSFER: ATX14B]

DLN

27. Install the new oil seal in the front case using Tool.

CAUTION:

• Do not reuse oil seal.
• Apply petroleum jelly to seal lip before installing.

28. Install the shift lever to the shift cross.
29. Install the lock pin and lock pin nut. Tighten to the specified

torque. Refer to

DLN-150, "Disassembly and Assembly"

Rear Case

Apply petroleum jelly to the circumference of the new rear oil
seal. Install the new rear oil seal so that it is flush with the case
tip face using Tool.

CAUTION:

• Do not reuse oil seal.
• Apply petroleum jelly to seal lip before installing.

Apply petroleum jelly to the circumference of the new dust cover
(1). Position the new dust cover with protrusions (A) as shown.
• 2: Rear case assembly

CAUTION:

• Do not reuse dust cover.
• Position the identification mark at the position shown.

Install the new dust cover using Tool.

Install the air breather into the rear case.

Remove all the sealant from the rear case to center case mating
surfaces.

CAUTION:

Remove all foreign materials such as water, oil, and grease
from center case and rear case mating surfaces.

Apply liquid gasket to the entire rear case mating surface of the
center case.
• Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to

GI-26, "Recommended Chemical

Products and Sealants"

CAUTION:

Do not to allow Liquid Gasket to enter stem bleeder hole.

Tool number

: ST22360002 (J-25679-01)

SDIA2182E

Tool number

: ST30720000 (J-25405)

SDIA2204E

AWDIA0550GB

Tool number

: KV40105310 (

—

)

SDIA2205E

2009 Pathfinder

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