Nissan Pick-ups and Pathfinder 1970-1988

Transfer Case

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REMOVAL & INSTALLATION



1981-86 Model T100L (720-D Series)

See Figures 1, 2, 3, 4 and 5

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support it with jackstands.
  4.  
  5. Remove the transfer case shield.
  6.  
  7. Remove the primary driveshaft securing nuts.
  8.  
  9. Remove the front and rear driveshafts.
  10.  
  11. Disconnect the 4wd switch wire.
  12.  
  13. Disconnect the speedometer cable.
  14.  
  15. Remove the exhaust pipe.
  16.  
  17. Support the transfer case with a jack.
  18.  
  19. Temporarily loosen the transfer case insulator bolts.
  20.  
  21. Remove the shift lever rubber boot from the floor.
  22.  
  23. Unbolt and remove the transfer case and primary driveshaft from the vehicle. Remove the insulators from the transfer case.
  24.  

To install:
  1. Install the insulators on the transfer case and then install the case itself. Tighten all bolts to 20-26 ft. lbs. (27-35 Nm).
  2.  
  3. Install the shift lever boot.
  4.  
  5. Connect the exhaust pipe to the manifold.
  6.  
  7. Connect the speedometer cable and the 4wd switch.
  8.  
  9. Install the front and rear driveshafts, then tighten the primary driveshaft nuts.
  10.  
  11. Install the case shield. Refill the transfer case with fluid, lower the truck and connect the battery cable. Road test the truck and check for any leaks of improper operation.
  12.  



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Fig. Fig. 1: Transfer case shield bolts-T100L



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Fig. Fig. 2: Transfer case mounting bolts-T100L



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Fig. Fig. 3: Transfer case insulator cover-T100L



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Fig. Fig. 4: Exploded view of the transfer case-T100L



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Fig. Fig. 5: Exploded view of the transfer case shift control components-T100L

1986-88 Model TX100 (D21-D Series)

See Figures 6, 7, 8 and 9

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the front of the vehicle and support it with jackstands.
  4.  
  5. Drain the fluid from the transmission and transfer cases.
  6.  
  7. Remove the front and rear driveshafts. Be sure to plug the oil seal openings after removal.
  8.  

Be very careful not to damage the transfer case spline, yoke or oil seal while removing the driveshafts.

  1. Remove the torsion bar spring.
  2.  
  3. Remove the second crossmember.
  4.  
  5. Disconnect the transfer control lever at the outer shift lever ball joint and position it out of the way.
  6.  
  7. Position a floor jack underneath the transfer case, then remove the case-to-transmission mounting bolts. Separate the transfer case from the transmission and slowly lower it out and away from the transmission.
  8.  

To install:
  1. Carefully position the transfer case so that it mates with the transmission and tighten the mounting bolts to 23-30 ft. lbs. (31-41 Nm). On models with manual transmissions, be sure to coat the case mating surface with sealant.
  2.  
  3. Connect the transfer control lever to the outer shift lever and tighten the nut to 18-22 ft. lbs. (25-30 Nm).
  4.  
  5. Install the second crossmember and tighten the bolts to 43-58 ft. lbs. (59-78 Nm). Install the torsion bar spring.
  6.  
  7. Unplug the oil seals and install the two driveshafts.
  8.  
  9. Refill the transmission and transfer case with fluid, lower the vehicle and connect the battery cable. Road test the truck and check for any leaks or improper operation.
  10.  



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Fig. Fig. 6: Exploded view of the transfer case-1986-87 TX100



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Fig. Fig. 7: Exploded view of the transfer case-1988 TX100



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Fig. Fig. 8: Exploded view of the transfer case shift control components-1986-87 TX100



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Fig. Fig. 9: Exploded view of the transfer case shift control components-1988 TX100

 
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