Nissan Sentra/Pulsar/NX 1982-1996 Repair Guide

Transfer Case Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: 4WD Control system component locations



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Fig. Fig. 2: Transfer case removal and installation service points



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Fig. Fig. 3: Transfer case and transaxle drain plug locations



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Fig. Fig. 4: When removing the transfer case assembly, support the engine/transaxle assembly as shown



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Fig. Fig. 5: Before assembling the transfer case to the transaxle, apply proper sealant to the point shown



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Fig. Fig. 6: Transfer case/transaxle fill plug location

  1. Drain the gear oil from the transaxle and the transfer case.
  2.  
  3. Disconnect and remove the forward exhaust pipe.
  4.  
  5. Using chalk or paint, matchmark the flanges on the driveshaft and then unbolt and remove the driveshaft from the transfer case.
  6.  
  7. Unbolt and remove the transfer control actuator from the side of the transfer case.
  8.  
  9. Disconnect and remove the right side halfshaft.
  10.  
  11. Unscrew and withdraw the speedometer pinion gear from the transfer case. Position it out of the way and secure it with wire.
  12.  
  13. Unbolt and remove the front, rear and side transfer case gussets (support members).
  14.  
  15. Use a hydraulic floor jack and a block of wood to support the transfer case, remove the transfer case-to-transaxle mounting bolts and then remove the case itself. Be careful when moving it while supported on the jack.
  16.  

To install:
  1. Apply Nissan KP510-00150 sealant or equivalent to transaxle case mating surface.
  2.  
  3. Install the transfer case in the vehicle. Tighten the transfer case-to-transaxle mounting bolts and the transfer case gusset mounting bolts to 22-30 ft. lbs. (30-40 Nm).
  4.  
  5. Be sure to use a multi-purpose grease to lubricate all oil seal surfaces prior to reinstallation.
  6.  
  7. Install the speedometer pinion gear.
  8.  
  9. Install the halfshaft.
  10.  
  11. Connect the transfer control actuator to the side of the transfer case.
  12.  
  13. Install the driveshaft to the transfer case.
  14.  
  15. Install the forward exhaust pipe.
  16.  
  17. Refill all fluid levels, the transfer case and the transaxle use different types and weights of lubricant then road test for proper operation.
  18.  

 
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