Nissan Frontier, Xterra 1998-05

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front and rear driveshafts
     
    Torsion bars and mounts
     
    Rear torsion bar crossmember
     
    Exhaust front pipes
     
    Exhaust rear pipes
     
    Vehicle Speed (VSS) sensor connector
     
    Transfer case shift linkage
     
    Transfer case neutral switch connector
     
    4 wheel drive switch connector
     
    Vent hose
     
    Transfer case flange bolts
     
    Transfer case
     

  4.  

To install:

  1. Install or connect the following:

    Transfer case. Tighten the flange bolts to 23-30 ft. lbs. (31-41 Nm).
     
    Vent hose
     
    4 wheel drive switch connector
     
    Transfer case neutral switch connector
     
    Transfer case shift linkage
     
    VSS sensor connector
     
    Exhaust rear pipes
     
    Exhaust front pipes
     
    Rear torsion bar crossmember
     
    Torsion bars and mounts
     
    Front and rear driveshafts
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front and rear driveshafts
     
    Torsion bars and mounts
     
    Rear torsion bar crossmember
     
    Exhaust front pipes
     
    Exhaust rear pipes
     
    Vehicle Speed (VSS) sensor connector
     
    Transfer case shift linkage
     
    Transfer case neutral switch connector
     
    4 wheel drive switch connector
     
    Vent hose
     
    Transfer case flange bolts
     
    Transfer case
     

  4.  

To install:

  1. Install or connect the following:

    Transfer case. Tighten the flange bolts to 23-30 ft. lbs. (31-41 Nm).
     
    Vent hose
     
    4 wheel drive switch connector
     
    Transfer case neutral switch connector
     
    Transfer case shift linkage
     
    VSS sensor connector
     
    Exhaust rear pipes
     
    Exhaust front pipes
     
    Rear torsion bar crossmember
     
    Torsion bars and mounts
     
    Front and rear driveshafts
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front and rear driveshafts
     
    Torsion bars and mounts
     
    Rear torsion bar crossmember
     
    Exhaust front pipes
     
    Exhaust rear pipes
     
    Vehicle Speed (VSS) sensor connector
     
    Transfer case shift linkage
     
    Transfer case neutral switch connector
     
    4 wheel drive switch connector
     
    Vent hose
     
    Transfer case flange bolts
     
    Transfer case
     

  4.  

To install:

  1. Install or connect the following:

    Transfer case. Tighten the flange bolts to 23-30 ft. lbs. (31-41 Nm).
     
    Vent hose
     
    4 wheel drive switch connector
     
    Transfer case neutral switch connector
     
    Transfer case shift linkage
     
    VSS sensor connector
     
    Exhaust rear pipes
     
    Exhaust front pipes
     
    Rear torsion bar crossmember
     
    Torsion bars and mounts
     
    Front and rear driveshafts
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front and rear driveshafts
     
    Torsion bars and mounts
     
    Rear torsion bar crossmember
     
    Exhaust front pipes
     
    Exhaust rear pipes
     
    Vehicle Speed (VSS) sensor connector
     
    Transfer case shift linkage
     
    Transfer case neutral switch connector
     
    4 wheel drive switch connector
     
    Vent hose
     
    Transfer case flange bolts
     
    Transfer case
     

  4.  

To install:

  1. Install or connect the following:

    Transfer case. Tighten the flange bolts to 23-30 ft. lbs. (31-41 Nm).
     
    Vent hose
     
    4 wheel drive switch connector
     
    Transfer case neutral switch connector
     
    Transfer case shift linkage
     
    VSS sensor connector
     
    Exhaust rear pipes
     
    Exhaust front pipes
     
    Rear torsion bar crossmember
     
    Torsion bars and mounts
     
    Front and rear driveshafts
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front and rear driveshafts
     
    Torsion bars and mounts
     
    Rear torsion bar crossmember
     
    Exhaust front pipes
     
    Exhaust rear pipes
     
    Vehicle Speed (VSS) sensor connector
     
    Transfer case shift linkage
     
    Transfer case neutral switch connector
     
    4WD switch connector
     
    Vent hose
     
    Transfer case flange bolts
     
    Transfer case
     

  4.  

To install:

  1. Install or connect the following:

    Transfer case. Tighten the flange bolts to 23-30 ft. lbs. (31-41 Nm).
     
    Vent hose
     
    4WD switch connector
     
    Transfer case neutral switch connector
     
    Transfer case shift linkage
     
    VSS sensor connector
     
    Exhaust rear pipes
     
    Exhaust front pipes
     
    Rear torsion bar crossmember
     
    Torsion bars and mounts
     
    Front and rear driveshafts
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Switch the 4WD switch to 2WD. Set the transfer case to 2WD.
  6.  
  7. Raise and support the vehicle safely. Drain the transfer case fluid.
  8.  
  9. Remove the transmission undercover.
  10.  
  11. Remove the center exhaust tube and main muffler.
  12.  
  13. Remove the front and rear driveshafts.
  14.  
  15. Remove the transmission bolts. Properly support the transmission and transfer case assembly, using a suitable jack.
  16.  
  17. Remove the transmission crossmember.
    NOTE
    Support the transmission and transfer case using two suitable jacks while removing the transmission crossmember.

  18.  
  19. Disconnect the ATP electrical connector, the 4LO switch connector, the wait detection switch and the transfer control device.
  20.  
  21. Disconnect each air breather hose from the transfer control device and the breather tube.
  22.  
  23. Remove the transfer case to transmission retaining bolts.
    NOTE
    Support the transmission and transfer case, using a suitable jack.

  24.  
  25. Remove the transfer case from the vehicle.
  26.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the transfer case to transmission retaining bolts to specification and in the proper sequence. Specification is 27 ft. lbs.

    Click image to see an enlarged view

    Fig. Transfer case bolt tightening sequence-2005

  4.  
  5. Start the engine and check for leaks, correct as required.
  6.  

 
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