Transfer: Other Nissan Murano Z50

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SUPPLEMENTAL RESTRAINT SYSTEM and SEAT BELTS articles.

Precautions Necessary for Steering Wheel Rotation After Battery Disconnect

Note. This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS). Remove and install all control units after disconnecting both battery cables with the ignition knob in the "LOCK" position. Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.

For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock mechanism is adopted on the key cylinder.

For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible.

If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation.

Service Notice

1. After overhaul refill the transfer with new transfer oil.
2. Check the oil level or replace the oil only with the vehicle parked on level surface.
3. During removal or installation, keep inside of transfer clear of dust or dirt.
4. Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern. Fitting improper size and unusual wear tires applies excessive force to vehicle mechanism and can cause longitudinal vibration.
5. Disassembly should be done in a clean work area.
6. Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter.
7. Check for the correct installation status prior to removal or disassembly. If matching marks are required, be certain they do not interfere with the function of the parts when applied.
8. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly.
9. Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them with a new ones if necessary.
10. Gaskets, seals, O-rings and lock nuts should be replaced any time when the transfer is disassembled.
11. In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tightening sequence is specified, use it.
12. Observe the specified torque when assembling.
13. Clean and flush the parts sufficiently and blow-dry them.
14. Be careful not to damage sliding surfaces and mating surfaces.
15. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transfer.

Special Service Tools

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

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OIL LEAKAGE AND OIL LEVEL

1. Check oil level from filler plug mounting hole as shown in the figure. CAUTION: Do not start engine while checking oil level.
2. Before installing filler plug, apply sealant. Install filler plug on transfer and tighten to the specified torque. Refer to «COMPONENTS»(ref-234001-S17423432212006052800000) . Use Genuine Silicone RTV or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) .

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1. AWD control unit supplies command current to electric controlled coupling (AWD solenoid).
2. Control clutch is engaged by electromagnet and torque is detected in control clutch.
3. The cam operates in response to control clutch torque and applies pressure to main clutch.
4. Main clutch transmits torque to front wheels according to pressing power. Transmission torque to rear wheels is determined according to command current.

Scheme 113

1. AWD control unit controls distribution of drive power between front-wheel drive (100:0) and AWD (50:50) conditions according to signals from the sensors.
2. Self-diagnosis results can be read with CONSULT-II.

AUTO Mode

1. Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
2. AUTO mode makes stable driving possible, with no wheel spin, on snowy roads or other slippery surfaces.
3. On roads which do not require AWD, it contributes to improved fuel economy by driving in conditions close to front-wheel drive.
4. Sensor inputs determine the vehicle's turning condition, and tight cornering/braking are controlled by distributing optimum torque to the rear wheels.

LOCK Mode

1. Front/rear wheel torque distribution is fixed, ensuring stable driving when climbing slopes.
2. Vehicle will switch automatically to AUTO mode if vehicle speed increases. If vehicle speed then decreases, the vehicle automatically returns to direct 4-wheel driving conditions. The AWD LOCK indicator lamp keeps illuminating.
3. LOCK mode will change to AUTO mode automatically, when the vehicle speed exceeds approx. 10 km/h (6 MPH) for a long time. The AWD LOCK indicator lamp turns off.
4. When the vehicle speed exceeds approx. 10 km/h (6 MPH), AUTO mode cannot be shifted to LOCK mode. In contrast, LOCK mode can be shifted to AUTO mode.
5. LOCK mode will change to AUTO mode automatically, when the ignition switch is turned "OFF".

Note. Every time AWD LOCK switch is pressed, AUTO mode and LOCK mode switch each other. When driving in AUTO mode or LOCK mode, if there is a large difference between front and rear wheel speed which continues for a long time, oil temperature of drive system parts becomes too high and AWD warning lamp flashes rapidly. (When AWD warning lamp flashes, vehicle changes to front-wheel drive conditions.) If AWD warning lamp is flashing rapidly, stop vehicle and allow it to idle for some time. Flashing will stop and AUTO mode will be restored. When driving in AUTO mode, AWD warning lamp may flash slowly if there is a significant difference in diameter of the tires. At this time, vehicle performance is not fully available and cautious driving is required. (Continues until engine is turned OFF.) If the warning lamp flashes slowly during driving but remains OFF after engine is restarted, the system is normal. If it again flashes slowly after driving for some time, vehicle must be inspected. If there is a difference of revolution speed between the front and rear wheel with AUTO mode the shift occasionally changes to LOCK mode automatically. This is not malfunction. If there is a significant difference in pressure or wear between tires, full vehicle performance is not available. Tire conditions are detected, and LOCK mode may be prohibited, or else speeds at which LOCK mode is enabled may be restricted.

AWD LOCK INDICATOR LAMP

The following is the indications of indicator lamp.

AWD LOCK INDICATOR LAMP CONDITION REFERENCE

Scheme 114

AWD WARNING LAMP

Turns ON when there is a malfunction in AWD system. It indicates that fail-safe mode is engaged and vehicle change to front-wheel drive or shifting driving force-AWD (Rear-wheels still have some driving torque).

Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately in 1 seconds after the engine starts if system is normal.

AWD Warning Lamp Indication

AWD WARNING LAMP INDICATOR LAMP CONDITION REFERENCE

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FUNCTION

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.

DIAGNOSTIC CHART

CONSULT-II SETTING PROCEDURE

1. For details, refer to the separate CONSULT-II Operations Manual.

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1. Turn ignition switch "OFF".
2. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector on vehicle.
3. Turn ignition switch "ON".
4. Touch "START (NISSAN BASED VHCL)".
5. Touch "ALL MODE AWD/4WD". "ALL MODE AWD/4WD" is not indicated, go to «CONSULT-II DATA LINK CONNECTOR (DLC) CIRCUIT»(ref-233992-S34507144402006052800000) .
6. Perform each diagnostic test mode according to each service procedure.

Scheme 120

1. Perform "CONSULT-II SETTING PROCEDURE". Refer to «CONSULT-II SETTING PROCEDURE»(ref-234001-S08048518832006052800000)
2. Start engine and drive at 30 km/h (19 MPH) or more for approx. 1 minute.
3. Stop vehicle. With engine at idle, touch "SELF-DIAG RESULTS". Display shows malfunction experienced since the last erasing operation. NOTE: "TIME" shows the status of self-diagnosis results: "0": Error is currently detected with AWD control unit. Except for "0": Error was detected in the past and memorized in AWD control unit. "TIME" means the frequency of driving after DTC had occurred (frequency of turning ignition switch "ON/OFF").

Display Item List

DISPLAY ITEM LIST CHART

AWD CONTROL UNIT PART NUMBER

Ignore the AWD control unit part number displayed in the "ECU PART NUMBER". Refer to parts catalog to order the AWD control unit.

CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE

Data are reference value.

DATA MONITOR MODE CHART

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1. CHECK POWER SUPPLY Turn ignition switch "OFF". Disconnect AWD control unit harness connector. Turn ignition switch "ON". (Do not start engine.) Check voltage between AWD control unit harness connector terminals and ground. Turn ignition switch "OFF". Check voltage between AWD control unit harness connector terminals and ground. OK or NG OK: GO TO 2 . NG: Check the following. If any items are damaged, repair or replace damaged parts. 10A fuse [No. 37, located in the fuse and fusible link block or No. 82, located in the IPDM E/R] Harness for short or open between battery and AWD control unit harness connector terminal 9 Harness for short or open between ignition switch and AWD control unit harness connector terminal 7 Ignition switch. Refer to «POWER SUPPLY ROUTING CIRCUIT»(ref-234031-S03943856592006052700000) .
2. CHECK GROUND CIRCUIT Turn ignition switch "OFF". Disconnect AWD control unit harness connector. Check continuity between AWD control unit harness connector E111 terminals 10 (B), 11 (B) and ground. Continuity should exist. Also check harness for short to ground and short to power. OK or NG OK: GO TO 3 . NG: Repair open circuit or short to ground or short to power in harness or connectors.
3. CHECK DTC Start engine. Does AWD warning lamp turn OFF? YES: INSPECTION END NO: Perform the self-diagnosis, repair or replace damaged parts. Refer to «SELF-DIAG RESULT MODE»(ref-234001-S37461624532006052800000) .

Data are reference value.

Scheme 126

Data are reference value.

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1. CHECK AWD LOCK SWITCH SIGNAL With CONSULT-II Turn ignition switch "ON". Select "DATA MONITOR" mode for "ALL MODE AWD/4WD" with CONSULT-II. Read out monitor "4WD MODE SW" with operating AWD lock switch. OK or NG OK: GO TO 6 . NG: GO TO 2 .
2. CHECK INPUT SIGNAL WITH UNIFIED METER AND A/C AMP. With CONSULT-II Turn ignition switch "ON". Select "DATA MONITOR" mode for "METER A/C AMP" with CONSULT-II. Read out monitor "4WD LOCK SW" with operating AWD lock switch. OK or NG OK: GO TO 6 . NG: GO TO 3 .
3. CHECK AWD LOCK SWITCH CIRCUIT Turn ignition switch "OFF". Disconnect unified meter and A/C amp. harness connector. Operate AWD lock switch and check continuity between unified meter and A/C amp. harness connector M49 terminal 5 (BR/Y) and ground. OK or NG OK: GO TO 6 . NG: GO TO 4 .
4. CHECK AWD LOCK SWITCH Turn ignition switch "OFF". Disconnect AWD lock switch harness connector. Operate AWD lock switch and check continuity between AWD lock switch harness connector M55 terminals 1 and 3. OK or NG OK: GO TO 5 . NG: Replace AWD lock switch.
5. CHECK HARNESS BETWEEN UNIFIED METER AND A/C AMP. AND AWD LOCK SWITCH Turn ignition switch "OFF". Disconnect unified meter and A/C amp. harness connector and AWD lock switch harness connector. Check continuity between unified meter and A/C amp. harness connector M49 terminal 5 (BR/Y) and AWD lock switch harness connector M55 terminal 1 (BR/Y). Continuity should exist. Also check harness for short to ground and short to power. OK or NG OK: GO TO 6 . NG: Repair or replace damaged parts.
6. CHECK AWD CONTROL UNIT Check AWD control unit input/output signal. Refer to «AWD CONTROL UNIT INPUT/OUTPUT SIGNAL REFERENCE VALUES»(ref-234001-S37218936782006052800000) . OK or NG OK: GO TO 7 . NG: Check AWD control unit pin terminals for damage or loose connection with harness connector. If any item is damaged, repair or replace damaged parts.
7. CHECK AWD LOCK INDICATOR LAMP Turn ignition switch "OFF". Check AWD LOCK indicator lamp "ON" for approx. 1 second when turned ignition switch "ON". Does AWD LOCK indicator lamp "ON" for approx. 1 second? YES: INSPECTION END NO: Go to «AWD LOCK INDICATOR LAMP DOES NOT TURN ON FOR APPROX. 1 SECOND WHEN THE IGNITION SWITCH IS TURNED TO ON»(ref-234001-S30293204212006052800000) .

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1. Turn ignition switch "OFF".
2. Disconnect AWD lock switch harness connector.
3. Operate AWD lock switch and check continuity between AWD lock switch harness connector M55 terminals 1 and 3.
4. If NG, replace AWD lock switch.

Vehicle Does Not Enter AWD Mode Even Though AWD Warning Lamp Turned to OFF

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1. CHECK PARKING BRAKE SWITCH SIGNAL With CONSULT-II Turn ignition switch "ON". Select "DATA MONITOR" mode for "ALL MODE AWD/4WD" with CONSULT-II. Operate parking brake and read out monitor "P BRAKE SW". OK or NG OK: GO TO 2 . NG: Check the following. If any items are damaged, repair or replace damaged parts. Parking brake switch Brake warning lamp circuit. Refer to «WIRING DIAGRAM - WARN»(ref-234025-S32574064312006052700000) .
2. CHECK AWD SOLENOID Check AWD solenoid. Refer to «COMPONENT INSPECTION»(ref-234001-S23316567002006052800000) . OK or NG OK: GO TO 3 . NG: Replace electric controlled coupling for malfunction of AWD solenoid. Refer to «DISASSEMBLY AND ASSEMBLY»(ref-234003-S09029987882006052700000) .
3. CHECK AWD CONTROL UNIT Check AWD control unit input/output signal. Refer to «AWD CONTROL UNIT INPUT/OUTPUT SIGNAL REFERENCE VALUES»(ref-234001-S37218936782006052800000) . OK or NG OK: GO TO 4 . NG: Check AWD control unit pin terminals for damage or loose connection with harness connector. If any items are damaged, repair or replace damaged parts.
4. SYMPTOM CHECK Check again. OK or NG OK: INSPECTION END NG: Replace electric controlled coupling for mechanical malfunction (mechanical engagement of clutch is not possible.). Refer to «DISASSEMBLY AND ASSEMBLY»(ref-234003-S09029987882006052700000) .

While Driving, AWD Warning Lamp Flashes Rapidly (When Flashing in Approx. 1 Minute and Then Turning OFF)

Note. Rapid flashing: 2 times/second

This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and multiple disc clutch temperature increases. It is not a malfunction.

When this symptom occurs, stop vehicle and allow it to idle for some times. Flashing will stop and system will be restored.

While Driving, AWD Warning Lamp Flashes Slowly (When Continuing to Flash until Turning Ignition Switch OFF)

Note. Slow flashing: 1 time/2 seconds

Scheme 141

1. CHECK TIRE Check the following. Tire pressure Wear condition Front and rear tire size (There is no difference between front and rear tires.) OK or NG OK: GO TO 2 . NG: Drive at vehicle speed of 20 km/h (12 MPH) or more for 5 seconds or more after repairing or replacing damaged parts. (Initialize improper size tire information.)
2. CHECK INPUT SIGNAL OF TIRE DIAMETER With CONSULT-II Start engine. Drive at 20 km/h (12 MPH) or more for approx. 200 seconds. Select "DATA MONITOR" mode for "ALL MODE AWD/4WD" with CONSULT-II. Check monitor "DIS-TIRE MONI". Display of "DIS-TIRE MONI" "0-4 mm": INSPECTION END Except for "0-4 mm": GO TO 3 .
3. CHECK AWD CONTROL UNIT Check AWD control unit input/output signals. Refer to «AWD CONTROL UNIT INPUT/OUTPUT SIGNAL REFERENCE VALUES»(ref-234001-S37218936782006052800000) . OK or NG OK: GO TO 4 . NG: Check AWD control unit pin terminals for damage or loose connection with harness connector. If any item is damaged, repair or replace damaged parts.
4. SYMPTOM CHECK Check again. OK or NG OK: INSPECTION END NG: Replace AWD control unit.

Scheme 142

1. Remove instrument driver lower panel. Refer to «REMOVAL AND INSTALLATION»(ref-234019-S40325796262006052700000) .
2. Remove fuse block (J/B).
3. Disconnect AWD control unit connector.
4. Remove AWD control unit.

Gears

1. Check the gear faces and shaft for wear, cracks, damage, and seizure.

Bearings

1. Check for seizure, peeling, wear, corrosion, sticking/abnormal noise/roughness in hand turning, and other damage.

Washers and Shims

1. Check for seizure, damage, and unusual wear.

Oil Seals

1. Discard old oil seals, replace with new ones.
2. If wear, deterioration of adherence (sealing force of lips), or damage is detected on the lips, replace them.

Scheme 143

1. Measure the points F, H, I, R and U shown in the measurement points.
2. Convert the values F, H, I, R and U according to the standards below. F: Value obtained by subtracting 163.00 mm (6.42 in) from the reading [in increments of 0.01 mm (0.0004 in)]. H: Value obtained by subtracting 83.00 mm (3.27 in) from the reading [in increments of 0.01 mm (0.0004 in)]. I: Value obtained by subtracting 131.90 mm (5.19 in) from the reading [in increments of 0.01 mm (0.0004 in)]. R: Value obtained by subtracting 17.00 mm (0.67 in) from the reading [in increments of 0.01 mm (0.0004 in)]. U: Value obtained by subtracting 89.50 mm (3.524 in) from the reading [in increments of 0.01 mm (0.0004 in)].
3. Check dimension Z on the drive gear side face. NOTE: Dimension Z indicates the difference between the optimum engagement and the standard dimensions in increments of 0.01 mm (0.0004 in) written on the drive gear side face.
4. Use the formula below to calculate gear ring bearing adjusting shim (transfer case side) thickness T1. T1 = (I - F + H + Z - U - R) x 0.01 mm (0.0004 in) + 1.49 mm (0.0587 in)
5. Select the gear ring bearing adjusting shim (transfer case side). For information on selecting an adjusting shim, refer to «GEAR RING BEARING ADJUSTING SHIM (TRANSFER CASE SIDE)»(ref-234001-S37167003842006052800000) .

Gear Ring Bearing Adjusting Shim (Adapter Case Side)

1. Measure the points F, H, J, K, U and V shown in the measurement points.
2. Convert the values F, H, J, K, U and V according to the standards below. F: Value obtained by subtracting 163.00 mm (6.42 in) from the reading [in increments of 0.01 mm (0.0004 in)]. H: Value obtained by subtracting 83.00 mm (3.27 in) from the reading [in increments of 0.01 mm (0.0004 in)]. J: Value obtained by subtracting 109.50 mm (4.31 in) from the reading [in increments of 0.01 mm (0.0004 in)]. K: Value obtained by subtracting 14.40 mm (0.5669 in) from the reading [in increments of 0.01 mm (0.0004 in)]. U: Value obtained by subtracting 89.50 mm (3.524 in) from the reading [in increments of 0.01 mm (0.0004 in)]. V: Value obtained by subtracting 17.00 mm (0.67 in) from the reading [in increments of 0.01 mm (0.0004 in)].
3. Check dimension Z on the drive gear side face. NOTE: Dimension Z indicates the difference between the optimum engagement and the standard dimensions in increments of 0.01 mm (0.0004 in) written on the drive gear side face.
4. Use the formula below to calculate gear ring bearing adjusting shim (adapter case side) thickness T2. T2 = (K + F-H-Z + U-J-V) x 0.01 mm (0.0004 in) + 1.49 mm (0.0587 in)
5. Select the gear ring bearing adjusting shim (adapter case side). For information on selecting an adjusting shim, refer to «GEAR RING BEARING ADJUSTING SHIM (ADAPTER CASE SIDE)»(ref-234001-S42273055142006052800000) .

Pinion Sleeve Shim

1. Measure the points L, N and Q shown in the measurement points.
2. Check the dimension S written on the gear end of the drive pinion. NOTE: The dimension S indicates the difference between the optimum engagement and the standard dimensions in increments of 0.01 mm (0.0004 in) written on the gear end of the drive pinion.
3. Use the formula below to calculate pinion sleeve shim thickness T3. T3 = [74.6 mm (2.937 in) + S] + N + Q - L
4. Select the pinion sleeve shim. For information on selecting a pinion sleeve shim, refer to «PINION SLEEVE SHIM»(ref-234001-S13338120302006052800000) .

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1. Select the gear ring bearing adjusting shim (transfer case side). Refer to «SELECTING ADJUSTING SHIMS»(ref-234001-S07083474462006052800000) .
2. Using the drifts, install the selected gear ring bearing adjusting shim (transfer case side) and gear ring bearing outer race (transfer case side). Tool number A: ST30720000 (J-25405) B:KV40101840( - )
3. Install the oil defense, and tighten the mounting bolts to the specified torque. Refer to «COMPONENTS»(ref-234001-S17423432212006052800000) . The clearance between the oil defense and transfer case (dimension A) should be the following. Clearance between oil defense and transfer case Dimension A: 1.0 - 3.5 mm (0.04 - 0.138 in) CAUTION: Do not reuse the mounting bolts.
4. Using the drift, drive the transfer case oil seal until it becomes flush with the case end. Tool number: ST30720000 (J-25405) CAUTION: When checking the total preload torque, measure it without the oil seal, then install the oil seal. Do not reuse the oil seal. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of the oil seal.
5. Apply sealant to filler plug and plug before installing them to the transfer case. Refer to «COMPONENTS»(ref-234001-S17423432212006052800000) . Use Genuine Silicone RTV or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) .
6. Apply sealant to breather tube and install it to the transfer case. Use Genuine Silicone RTV or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) .
7. Install the drive gear assembly. Refer to «DRIVE GEAR ASSEMBLY»(ref-234001-S19639919352006052800000) .
8. Install the adapter case. Refer to «ADAPTER CASE»(ref-234001-S16993706002006052800000) .
9. Install the pinion sleeve assembly. Refer to «PINION SLEEVE ASSEMBLY»(ref-234001-S19910891132006052800000) .
10. Check backlash, preload torque, tooth contact, and companion flange runout. Refer to «ASSEMBLY INSPECTION»(ref-234001-S41698004142006052800000) .

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1. Using the drift, drive the gear ring oil seal into the gear ring. Tool number: ST33230000 (J-25805-01) CAUTION: Do not reuse the oil seal. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of the oil seal. The oil seal back position after the installation shall be 56.5 mm (2.22 in) from the gear ring end.
2. Apply thread locking sealant into the thread hole for the drive gear. Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . Completely clean and degrease the drive gear back face, thread holes, and drive gear mounting bolts. Apply thread locking sealant onto the first and second threads under the thread hole chamfering of the drive gear on 3 or more different points. Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) .
3. Install the drive gear to gear ring, and apply anti-corrosive oil onto threads and seats on the mounting bolts, and then tighten to the specified torque. Refer to «COMPONENTS»(ref-234001-S17423432212006052800000) . CAUTION: Temporary installation before tightening the bolts through to the completion of the tightening should be within 90 seconds. If the thread locking sealant is applied aside, quickly wipe it off.
4. Apply gear oil to gear ring bearing inner race (transfer case side). Using the drifts, install gear ring bearing inner race. Tool number A: ST30720000 (J-25405) B: ST27863000 ( - ) C: KV40101630 (J-35870)
5. Apply gear oil to gear ring bearing inner race (adapter case side). Using the drifts, install gear ring bearing inner race. Tool number A: ST30720000 (J-25405) B: KV38102510 ( - )
6. Install the drive gear assembly to the transfer case.
7. Install the adapter case.
8. Check backlash, preload torque, tooth contact, and companion flange runout. Refer to «ASSEMBLY INSPECTION»(ref-234001-S41698004142006052800000) .

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1. Select the gear ring bearing adjusting shim (adapter case side). Refer to «SELECTING ADJUSTING SHIMS»(ref-234001-S07083474462006052800000) .
2. Install the oil gutter.
3. Using the drifts, install the selected gear ring bearing adjusting shim (adapter case side) and gear ring bearing outer race (adapter case side). Tool number A: ST30720000 (J-25405) B: KV40105230 ( - )
4. Using the drift, drive the adapter case oil seal until it becomes flush with the case end. Tool number: KV38101700 ( - ) CAUTION: When checking the total preload torque, measure it without the oil seal, then install the oil seal. Do not reuse the oil seal. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of the oil seal.
5. Apply sealant on drain plug and install it to the adapter case. Refer to «COMPONENTS»(ref-234001-S17423432212006052800000) . Use Genuine Silicone RTV or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) .
6. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the adapter case. CAUTION: Do not reuse the O-ring.
7. Install the adapter case to the transfer case, and apply anti-corrosive oil onto threads and seats on the mounting bolts. Tighten to the specified torque.
8. Check backlash, preload torque, tooth contact, and companion flange runout. Refer to «ASSEMBLY INSPECTION»(ref-234001-S41698004142006052800000) .

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1. Select the pinion sleeve shim. Refer to «SELECTING ADJUSTING SHIMS»(ref-234001-S07083474462006052800000) .
2. Install dust cover.
3. Using the drift, install the pinion rear bearing outer race. Tool number: KV38100300 (J-25523)
4. Using the drifts, install the pinion front bearing outer race. Tool number A: ST33400001 (J-26082) B: ST30901000 (J-26010-01)
5. Apply gear oil to pinion front bearing inner race and mating position on the drive pinion. Using the drift, install pinion front bearing inner race to the drive pinion. Tool number: ST30901000 (J-26010-01)
6. Install a collapsible spacer to the drive pinion. CAUTION: Do not reuse the collapsible spacer.
7. Apply gear oil to pinion rear bearing inner race and install it to the pinion sleeve.
8. Using the drift, install pinion sleeve oil seal to the pinion sleeve. Tool number: ST33400001 (J-26082) CAUTION: Do not reuse the oil seal. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of the oil seal.
9. Using the drift and press in the companion flange. Tool number: ST33200000 (J-26082)
10. Apply anti-corrosion oil onto threads and seat of the pinion lock nut and adjust the pinion lock nut tightening torque and pinion bearing preload torque (P'1), using a preload gauge. Pinion lock nut tightening torque : 128 - 294 N.m (13 - 29 kg-m, 95-216 ft-lb) Pinion bearing preload torque (P'1) : 0.40 - 0.78 N.m (0.04 - 0.08 kg-m, 4 - 6 in-lb) CAUTION: Do not reuse the pinion lock nut. Adjust the lower limit of the pinion lock nut tightening torque first. While confirming the preload torque, tighten pinion lock nut by 5° to 10°. Because preload will increase suddenly. If specified preload torque is exceeded, replace the collapsible spacer and tighten again. Never loosen the pinion lock nut for further preload torque adjustment. After the adjustment, rotate the companion flange back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
11. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion sleeve. CAUTION: Do not reuse the old O-ring.
12. Assemble the selected pinion sleeve shim.
13. Install the pinion sleeve assembly, and apply anti-corrosive oil onto threads and seats on the mounting bolts. Tighten to the specified torque. Refer to «COMPONENTS»(ref-234001-S17423432212006052800000) .
14. Check backlash, preload torque, tooth contact and companion flange runout. Refer to «ASSEMBLY INSPECTION»(ref-234001-S41698004142006052800000) . The total preload torque is as follows: Total preload torque With all oil seals installed: P'1 + 0.45 - 0.47 N.m (0.045 - 0.048 kg-m, 3.9 - 4.1 in-lb) Without transfer case oil seal and adapter case oil seal: P'1 + 0.35 - 0.37 N.m (0.035 - 0.038 kg-m, 3.1 - 3.2 in-lb)

BACKLASH

BACKLASH SPECIFICATION

Scheme 160

Scheme 161

Scheme 162

Scheme 163