Transfer Case: Other Nissan Frontier D22

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

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Commercial Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

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Sprocket and Shaft

1. Check sprocket for excessive wear, chips or cracks.
2. Check shaft for cracks or wear.

Scheme 68

1. Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

Scheme 69

1. Press front drive shaft front and rear bearings onto front drive shaft.

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1. Press out counter gear front bearing. Remove front sub-gear, dish plate and spacer (M/T model only).
2. Press out counter gear rear bearing. Remove rear sub-gear, dish plate and spacer (M/T model only).

Gear and Shaft

1. Check gears for excessive wear, chips or cracks.
2. Check shaft for cracks or wear.

Scheme 72

1. Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

Scheme 73

1. Install front sub-gear, dish plate and spacer (M/T model only).
2. Press on counter gear front bearing.
3. Install rear sub-gear, dish plate and spacer (M/T model only).
4. Press on counter gear rear bearing.

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1. Remove snap ring.
2. Pull out main gear bearing.

Scheme 76

1. Always replace it with new one whenever it has been removed.

1. Check gears for excessive wear, chips or cracks.
2. Check shaft for cracks or wear.

Scheme 77

1. Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

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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 " «MAIN GEAR BEARING»(ref-183506-S06399567612005081400000) " .

Plug

Apply sealant to plug, then install.

Scheme 80

1. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite part No. 51813 or equivalent.

Scheme 81

1. Use a screwdriver to pry out old seal.
2. Be careful not to damage case.
3. Always replace with a new one whenever it has been removed.

Scheme 82

1. Install new shift shaft oil seal until flush with case.
2. Before installing, apply multi-purpose grease to seal lip.

Scheme 83

1. Drive out old seal from inside of front case cover.
2. Be careful not to damage front case cover.

Scheme 84

1. Install new front case cover oil seal until it stops.
2. Before installing, apply multipurpose grease to seal lip.

Scheme 85

1. Drive out oil catcher from inside of bearing retainer.
2. Be careful not to damage bearing retainer.

Scheme 86

1. Install oil catcher until it stops.
2. Be careful not to damage or distort oil catcher or bearing retainer.
3. Before installing, apply multi-purpose grease to seal lip.

Scheme 87

1. Remove center case oil seal.

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1. Pull out rear oil seal.

Scheme 90

1. Install new rear oil seal until it stops.
2. Before installing, apply multi-purpose grease to seal lip.

Air Breather

Install as shown in illustration.

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1. Check contact surface and sliding surface for wear, scratches, projections or other faulty conditions.

Scheme 93

1. Assemble as shown in illustration. *Retaining pin is the same size as the one for 2-4 shift rod.

Scheme 94

1. Assemble as shown in illustration. *Retaining pins are the same size.

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1. Pay special attention to the direction of fork guide collar.

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1. Assemble front case. Install main gear assembly by tapping lightly. Apply sealant to the mating surface and bolts of front case cover, then attach it to the 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: 20 - 24 N.m (2.0 - 2.4 kg-m, 14 - 17 ft-lb) Bolts B: 24 - 28 N.m (2.4 - 2.9 kg-m, 17 - 21 ft-lb) Apply ATF to needle bearing and install it into main gear. Install counter gear assembly by tapping lightly. Install cross shaft and inner shift lever. When replacing cross shaft, outer shift lever or outer shift lever lock pin, replace them as a set. Apply sealant to plug and install it into front case. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent. Insert interlock plunger into front case. Install L & H shift rod and fork assembly with coupling sleeve. Install 2-4 shift rod. Install transfer neutral position switch, check balls, check springs and plugs. Apply sealant to switches and plugs. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
2. Select counter gear rear bearing shim. Seat counter gear assembly. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (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. Insert J34291-20 (gauging plunger) into J34291-5 (gauging cylinder). Place bridge, legs, gauging cylinder and gauging plunger onto machined surface of front case assembly, allowing gauging plunger to drop until it contacts counter gear rear bearing mating surface. 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 " «COUNTER GEAR REAR BEARING»(ref-183506-S38017199532005081400000) " .
3. Place suitable shim with grease on counter gear rear bearing.
4. Apply ATF to each part in front case.
5. Assemble center case assembly. Install mainshaft on center case by tapping lightly. Apply ATF to mainshaft front bearing. Install bearing retainer. : 16 - 21 N.m (1.6 - 2.1 kg-m, 12 - 15 ft-lb) Put drive chain onto the front drive sprocket and front drive shaft, and then put them in center case. Install front drive shaft by tapping lightly. Make sure shafts are aligned in the case. Apply ATF to needle bearings and install them into front drive sprocket. These needle bearings can be installed more easily if front drive sprocket is rotated while installing them. Install 2-4 coupling sleeve with 2-4 shift fork. Pay special attention to direction of coupling sleeve. Install shifting inserts and spread spring. Pay attention to the direction of shifting inserts. Install baulk ring, then install clutch gear and mainshaft rear bearing. Place wooden block under mainshaft in order to protect mainshaft front bearing. Install spacer. 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 mainshaft rear bearing: Refer to " «MAINSHAFT REAR BEARING»(ref-183506-S26687299402005081400000) " . Install steel ball, speedometer drive gear and retainer ring. Steel ball is the smallest of check balls for this unit. Install low gear and its bearing onto mainshaft. Apply ATF to needle bearing. Install L & H hub and snap ring to mainshaft. Pay attention to direction of L & H hub. Measure low gear end play. Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in)
6. Apply sealant to mating surface of center case then attach to front case and tighten bolts. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
7. Install snap ring to 2-4 shift rod.
8. Install oil gutter and oil cover.
9. Apply ATF to each part in center case.
10. Apply sealant to mating surface of rear case then attach it to center case and tighten bolts. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
11. Install 4WD switch. Apply sealant to switch threads. Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
12. Install the companion flange and the companion flange nut. Tighten the companion flange nut to specification. Refer to " «GEAR COMPONENTS»(ref-183506-S42532812022005081400000) " .