Shop manual ô tô NISSAN 2000 Xterra CONTENTS FRONT AXLE 2 Precautions 2 PRECAUTIONS .2 Preparation 2 SPECIAL SERVICE TOOLS 2 COMMERCIAL SERVICE TOOLS 2
TRANSFERSECTIONTFCONTENTSPREPARATION .2Special Service Tools 2Commercial Service Tools .3NOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING .5NVH Troubleshooting Chart .5TRANSFER .5DESCRIPTION .6Cross-sectional View .6ON-VEHICLE SERVICE 7Replacing Oil Seal .7CENTER CASE OIL SEAL 7SHIFT SHAFT OIL SEAL 8REAR OIL SEAL 8Position Switch Check .9REMOVAL AND INSTALLATION .10Removal .10Installation 10M/T MODEL 10A/T MODEL .10OVERHAUL .11Transfer Gear Control 11Case Components .12Gear Components .13Shift Control Components .14DISASSEMBLY 15REPAIR FOR COMPONENT PARTS .20Mainshaft .20DISASSEMBLY 20INSPECTION .21ASSEMBLY .22Front Drive Shaft .22DISASSEMBLY 22INSPECTION .22ASSEMBLY .22Counter Gear .23DISASSEMBLY 23INSPECTION .23ASSEMBLY .23Main Gear 23DISASSEMBLY 23INSPECTION .24ASSEMBLY .24Front Case .25REMOVAL .25INSTALLATION 25Front Case Cover 25REMOVAL .25INSTALLATION 25Bearing Retainer 26REMOVAL .26INSTALLATION 26Center Case .26REMOVAL .26INSTALLATION 26Rear Case 26REMOVAL .26INSTALLATION 27Shift Control Components .27INSPECTION .27ASSEMBLY 29SERVICE DATA AND SPECIFICATIONS (SDS) .37General Specifications .37Inspection and Adjustment 37CLEARANCE BETWEEN FRONT DRIVESPROCKET AND 2-4 COUPLING SLEEVE 37GEAR END PLAY 37CLEARANCE BETWEEN BAULK RING ANDCLUTCH GEAR .37Available Shim .37COUNTER GEAR REAR BEARING .37Available Snap Ring 38MAINSHAFT FRONT BEARING 38MAIN GEAR BEARING .38MAINSHAFT REAR BEARING 38GIMAEMLCECFECLMTATPDAXSUBRSTRSBTHASCELIDX Special Service ToolsNGTF0001The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool number(Kent-Moore No.)Tool nameDescriptionKV38108300(—)Companion FlangewrenchNT771Removing companion flange nutInstalling companion flange nutST30021000(J22912-01)PullerNT411Removing counter gear front bearing(Use with ST36710010)Removing L & H huba: 110 mm (4.33 in) dia.b: 68 mm (2.68 in) dia.ST30031000(J22912-01)PullerNT411Removing counter gear rear bearing(Use with ST36710010)a: 90 mm (3.54 in) dia.b: 50 mm (1.97 in) dia.ST33290001(J25810-A)PullerNT414Removing center case oil sealRemoving rear oil seala: 250 mm (9.84 in)b: 160 mm (6.30 in)ST33051001(J22888)PullerNT657Removing companion flangea: 135 mm (5.31 in)b: 100 mm (3.94 in)c: 130 mm (5.12 in)ST307200001 (J25273)2 (J25405)DriftNT6581 Installing center case oil seal2 Installing rear oil seala: 77 mm (3.03 in) dia.b: 55.5 mm (2.185 in) dia.PREPARATIONSpecial Service ToolsTF-2 Tool number(Kent-Moore No.)Tool nameDescriptionST36710010(—)DriftNT063Removing counter gear front bearing(Use with ST30021000)Removing counter gear rear bearing(Use with ST30031000)a: 34.5 mm (1.358 in) dia.ST33061000(J8107-2)DriftNT116Removing main gear bearinga: 28.5 mm (1.122 in) dia.b: 38 mm (1.50 in) dia.ST306130001 (J25742-3)2 (J34339)DriftNT0731 Installing main gear bearing2 Installing front case cover oil seala: 72 mm (2.83 in) dia.b: 48 mm (1.89 in) dia.(J35864)DriftNT117Installing shift shaft oil seala: 26 mm (1.02 in) dia.b: 20 mm (0.79 in) dia.c: 150 mm (5.91 in)(J26092)DriftNT065Seating counter gear assemblya: 44.5 mm (1.752 in) dia.b: 38.5 mm (1.516 in) dia.(J34291)Shim setting gauge setNT101Selecting counter gear rear bearing shim(J34291-20)Plunger-shim settinggaugeNT118Selecting counter gear rear bearing shimCommercial Service ToolsNGTF0002The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool name DescriptionPullerNT077Removing front drive shaft front bearingRemoving front drive shaft rear bearingRemoving main gear bearingGIMAEMLCECFECLMTATPDAXSUBRSTRSBTHASCELIDXPREPARATIONSpecial Service Tools (Cont’d)TF-3 Tool name DescriptionDriftNT1171 Installing mainshaft rear bearing2 Installing L & H hub1 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.c: 60 mm (2.36 in)PREPARATIONCommercial Service Tools (Cont’d)TF-4 NGTF0039NVH Troubleshooting ChartNGTF0039S01Use 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.TRANSFERNGTF0039S0101Reference pageRefer to MA-37,(″Checking Transfer Fluid″, ″CHASSIS ANDBODY MAINTENANCE″).TF-12TF-12TF-12, TF-14TF-14TF-13TF-13TF-13TF-13SUSPECTED PARTS(Possible cause)FLUID (Level low)FLUID (Wrong)FLUID (Level too high)LIQUID GASKET (Damaged)OIL SEAL (Worn or damaged)CHECK SPRING AND CHECK BALL (Worn damaged)SHIFT FORK (Worn)GEAR (Worn or damaged)Bearing (Worn or damaged)BAULK RING (Worn or damaged)SHIFTING INSERT (Damaged)SymptomNoise 1 2 3 3Fluid leakage 3122Hard to shift or will not shift 1 1 2 2Jumps out of gear 1 2 2GIMAEMLCECFECLMTATPDAXSUBRSTRSBTHASCELIDXNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGNVH Troubleshooting ChartTF-5 Cross-sectional ViewNGTF0003ATF021DESCRIPTIONCross-sectional ViewTF-6 SMT844DReplacing Oil SealNGTF0004CENTER CASE OIL SEALNGTF0004S011. Remove front propeller shaft. Refer toPD-7, (“Removal andInstallation”, “PROPELLER SHAFT”).2. Remove companion flange nut.SMT486A3. Remove companion flange.AMT0864. Remove center case oil seal.5. Install center case oil seal.¼ Before installing, apply multi-purpose grease to seal lip.6. Install companion flange.SMT845D7. Tighten companion flange nut.: 226 - 324 N·m (23 - 33 kg-m, 166 - 239 ft-lb)8. Install front propeller shaft. Refer toPD-7, (“Removal andInstallation”, “PROPELLER SHAFT”).GIMAEMLCECFECLMTATPDAXSUBRSTRSBTHASCELIDXON-VEHICLE SERVICEReplacing Oil SealTF-7 ATF007SHIFT SHAFT OIL SEALNGTF0004S021. Remove front propeller shaft. Refer toPD-7, (“Removal andInstallation”, “PROPELLER SHAFT”).2. Remove companion flange. Refer to “CENTER CASE OILSEAL”, TF-7.3. Remove transfer control lever from transfer outer shift lever.Then remove outer shift lever.SMT491A4. Remove shift shaft oil seal.¼ Be careful not to damage cross shaft.SMT492A5. Install shift shaft oil seal.¼ Before installing, apply multi-purpose grease to seal lip.6. Install transfer control linkage.7. Install companion flange. Refer to “CENTER CASE OILSEAL”, TF-7.8. Install front propeller shaft. Refer toPD-7, (“Removal andInstallation”, “PROPELLER SHAFT”).AMT087REAR OIL SEALNGTF0004S031. Remove rear propeller shaft. Refer toPD-7, (“Removal andInstallation”, “PROPELLER SHAFT”).2. Remove rear oil seal.SMT494A3. Install rear oil seal.¼ Before installing apply multi-purpose grease to seal lip.4. Install rear propeller shaft. Refer toPD-7, (“Removal andInstallation”, “PROPELLER SHAFT”).ON-VEHICLE SERVICEReplacing Oil Seal (Cont’d)TF-8 SMT790CAPosition Switch CheckNGTF0042Switch Gear Position Continuity4WD Switch4WD YesExcept 4WD NONeutral Position SwitchNeutral NOExcept Neutral YesGIMAEMLCECFECLMTATPDAXSUBRSTRSBTHASCELIDXON-VEHICLE SERVICEPosition Switch CheckTF-9 ATF020ATF007RemovalNGTF00061. Drain fluid from transfer, and drain oil from transmission.2. Remove front and rear propeller shaft. Refer toPD-7,(“Removal and Installation”, “PROPELLER SHAFT”).Insert plug into rear oil seal after removing propeller shaft.¼ Be careful not to damage spline, sleeve yoke and rear oilseal, when removing propeller shaft.3. Remove torsion bar spring. Refer toSU-14, (“Torsion BarSpring”, “FRONT SUSPENSION”). Then remove secondcrossmember.4. Remove exhaust front and rear tubes. Refer toFE-8,(“EXHAUST SYSTEM”).5. Disconnect vehicle speed sensor, transfer neutral positionswitch and 4WD switch harness connectors.6. Remove air breather hose.7. Remove transfer control lever from transfer outer shift lever.8. Separate transfer from transmission.WARNING:Support transfer while removing it.SMT495AInstallationNGTF0007¼ Apply sealant to mating surface to transmission. (M/T modelonly)Use genuine anaerobic liquid gasket, Three BondTB1215, Loctite Part No. 51813 or equivalent.ATF026¼ Tighten bolts securing transfer.M/T MODELNGTF0007S01Bolt No.Tightening torqueN·m (kg-m, ft-lb) mm (in)1 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)2 31 - 41 (3.2 - 4.2, 23 - 30) 60 (2.36)A/T MODELNGTF0007S02Bolt No.Tightening torqueN·m (kg-m, ft-lb) mm (in)1 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)2 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)REMOVAL AND INSTALLATIONRemovalTF-10 [...]... front case Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No 51813 or equivalent These ten bolts should be coated with sealant Bolts A: 16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb) Bolts B: 19 - 24 N·m (1.9 - 2.4 kg-m, 14 - 17 ft-lb) EC FE CL MT SMT325A c Apply ATF to needle bearing and install it into main gear AT PD AX SMT326A d Install counter gear assembly by tapping lightly SU... TF-30 ASSEMBLY 2 a Select counter gear rear bearing shim Seat counter gear assembly GI MA EM LC SMT590A b Place J3429 1-1 (bridge), J3429 1-2 (legs) and J3429 1-5 (gauging cylinder) on machined surface of center case, allowing gauging cylinder to rest on top outer portion of counter gear rear bearing Lock gauging cylinder in place EC FE CL MT SMT591A c Insert J3429 1-2 0 (gauging plunger) into J3429 1-5 ... front case 5 a ¼ Assemble center case assembly Install mainshaft on center case by tapping lightly Apply ATF to mainshaft front bearing b Install bearing retainer : 16 - 21 N·m (1.6 - 21 kg-m, 12 - 15 ft-lb) SMT336A SMT406A SMT407A TF-32 ASSEMBLY c ¼ Put drive chain onto the front drive sprocket and front drive shaft, and then put them in center case Be sure to install drive chain in same direction... NGTF0024 NGTF0024S01 1 Press on main gear bearing 2 Select and install snap ring with proper thickness Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 in) Available snap ring for main gear bearing: Refer to SDS, TF-38 SMT307A ATF014 TF-24 REPAIR FOR COMPONENT PARTS Main Gear (Cont’d) Plug NGTF0024S02 Apply sealant to plug, then install ¼ Use genuine anaerobic liquid gasket, Three... illustration * Retaining pin is the same size as the one for 2-4 shift rod SU BR ST RS SMT319A 2-4 Shift Rod & Fork ¼ Assemble as shown in illustration * Retaining pins are the same size NGTF0033S02 BT HA SC EL SMT320A TF-27 IDX REPAIR FOR COMPONENT PARTS Shift Control Components (Cont’d) ¼ Pay special attention to the direction of fork guide collar SMT321A TF-28 NGTF0034 ASSEMBLY 1 a Assemble front case Install... GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC ATF027 TF-11 EL IDX OVERHAUL Case Components Case Components NGTF0009 ATF023 TF-12 OVERHAUL Gear Components Gear Components NGTF0010 GI MA EM LC EC FE CL MT AT PD AX SU BR ST RS BT HA SC ATF028 TF-13 EL IDX OVERHAUL Shift Control Components Shift Control Components NGTF0011 ATF025 TF-14 NGTF0012 DISASSEMBLY 1 2 Remove companion flange nut Remove... measurements Specification C: Refer to TF-37 SU BR ST RS BT HA SC EL SMT799CA TF-15 IDX DISASSEMBLY 8 ¼ Remove bolts securing bearing retainer This step is necessary to remove mainshaft from center case 9 Remove bolts securing center case to front case and then separate center case and front case SMT273A SMT274A 10 Measure low gear end play Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in) ¼ If end play is beyond... surface SU BR ST RS BT HA SC EL SMT593A TF-31 IDX ASSEMBLY e f Lock gauging plunger in place and use feeler gauge to measure end play between gauging cylinder and gauging plunger Use measured distance to select correct counter gear rear bearing shim Allowable counter gear end play: 0 - 0.2 mm (0 - 0.008 in) Allowable counter gear rear bearing shim: Refer to SDS, TF-37 SMT594A 3 4 Place suitable shim with... special attention to its direction 2 Select snap ring with proper thickness Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 in) Available snap ring for mainshaft front bearing: Refer to SDS, TF-38 Regarding to further procedures, refer to “ASSEMBLY”, TF-29 SMT294A 3 SMT295A Front Drive Shaft DISASSEMBLY ¼ NGTF0016 Using a gear puller, remove front drive shaft front and rear bearings... clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 in) Available snap ring for mainshaft rear bearing: Refer to SDS, TF-38 k ¼ Install steel ball, speedometer drive gear and retainer ring Steel ball is the smallest of check balls for this unit l ¼ Install low gear and its bearing onto mainshaft Apply ATF to needle bearing SMT414A SMT415A SMT340A TF-34 ASSEMBLY m Install L & H hub and snap . parts.TRANSFERNGTF0039S0101Reference pageRefer to MA-37,(″Checking Transfer Fluid″, ″CHASSIS ANDBODY MAINTENANCE″).TF-12TF-12TF-12, TF-14TF-14TF-13TF-13TF-13TF-13SUSPECTED PARTS(Possible. torqueN·m (kg-m, ft-lb) mm (in)1 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)2 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)REMOVAL AND INSTALLATIONRemovalTF-10 Transfer