1998 NISSAN PICK-UP Repair Manual

1. Assemble front case.
a. Install main gear assembly by tapping lightly.
b. Apply sealant to the mating surface and bolts of front case
cover and install it on front case.
Sealant:
Refer to ``Case Components'', TF-8.
lThese ten bolts should be coated with sealant.
lTightening torque
A:16-21
(1.6 - 2.1 kg-m, 12 - 15 ft-lb)
B:19-24
(1.9 - 2.4 kg-m, 14 - 17 ft-lb)
c. Apply gear oil to needle bearing and install it into main gear.
d. Install counter gear assembly by tapping lightly.
e. Install cross shaft and inner shift lever.
lWhen replacing cross shaft, outer shift lever or lock pin
of outer shift lever, replace them as a set.
SMT323A
SMT325A
SMT326A
SMT327A
SMT032D
ASSEMBLY
TF-24

f. Apply sealant to plug and install it into front case.
Sealant:
Refer to ``Shift Control Components'', TF-10.
g. Insert interlock plunger into front case.
h. InstallL&Hshift rod and fork assembly with coupling sleeve.
i. Install 2-4 shift rod.
j. Install switches, check balls, check springs and plugs.
lApply sealant to switches and plugs.
Sealant:
Refer to ``Case Components'', TF-8.
SMT330A
SMT331A
SMT332A
SMT333A
SMT789C
ASSEMBLY
TF-25

2. Select counter gear rear bearing shim.
Counter gear end play:
0 - 0.2 mm (0 - 0.008 in)
Counter gear rear bearing shim:
Refer to SDS, TF-30.
a. Measure distance ``A'' between upper surface of counter
gear rear bearing and mating surface of front case.
b. Select suitable shim using SDS chart. Refer to SDS, TF-30.
3. Place suitable shim on counter gear rear bearing with
grease.
4. Apply gear oil to each part in front case.
5. Assemble center case assembly.
a. Install mainshaft on center case by tapping lightly.
lApply gear oil to mainshaft front bearing.
b. Install bearing retainer.
SMT335A
SMT612D
SMT036D
SMT406A
SMT407A
ASSEMBLY
TF-26

c. Put drive chain onto the front drive sprocket and front drive
shaft, and then put them in center case.
d. Install front drive shaft by tapping lightly.
lMake sure shafts are lined up in the case.
e. Apply gear oil to needle bearings and install them into front
drive sprocket.
lThese needle bearings will be installed move easily if
front drive sprocket is rotated while installing them.
f. Install 2-4 coupling sleeve with 2-4 shift fork.
lPay special attention to direction of coupling sleeve.
SMT408A
SMT409A
SMT410A
SMT411A
SMT412A
ASSEMBLY
TF-27

g. Install clutch gear and mainshaft rear bearing.
lPlace wooden block under mainshaft in order to protect
mainshaft front bearing.
h. Install spacer.
i. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for mainshaft rear bearing:
Refer to SDS, TF-30.
j. Install steel ball, speedometer drive gear and retainer ring.
lSteel ball is the smallest of check balls for this unit.
k. Install low gear and its bearing to mainshaft.
lApply gear oil to needle bearing.
l. InstallL&Hhubandsnap ring to mainshaft.
lPay special attention to direction ofL&Hhub.
SMT413A
SMT414A
SMT415A
SMT340A
SMT760A
ASSEMBLY
TF-28

m. Measure end play of low gear.
Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in)
6. Apply sealant to mating surface and put center case assem-
bly onto front case and tighten bolts.
Sealant:
Refer to ``Case Components'', TF-8.
7. Install snap ring to 2-4 shift rod.
8. Install oil gutter and oil cover.
9. Apply gear oil to each part in center case.
10. Apply sealant to mating surface and install rear case on
center case.
11. Install 4WD switch.
lApply sealant to thread of switch.
Sealant:
Refer to ``Case Components'', TF-8.
SMT342A
SMT343A
SMT272A
SMT344A
SMT497C
ASSEMBLY
TF-29

General Specifications
Transfer model TX10A
Gear ratioHigh 1.000
Low 2.020
Number of teethMain gear 29
Low gear 37
Counter
gearHigh 38
Low 24
Front drive sprocket 41
Front drive shaft 41
Fluid oil capacity*!(Imp qt) 2.2 (2)
* Refer to MA section (``Fluids and Lubricants'', RECOMMENDED
FLUIDS AND LUBRICANTS).
Inspection and Adjustment
CLEARANCE BETWEEN FRONT DRIVE
SPROCKET AND 2-4 COUPLING SLEEVE
Allowable clearance ``C''0.2 - 0.54 mm
(0.0079 - 0.0213 in)
GEAR END PLAY
Unit: mm (in)
Front drive sprocket 0.2 - 0.35 (0.0079 - 0.0138)
Low gear 0.2 - 0.35 (0.0079 - 0.0138)
Counter gear 0 - 0.2 (0 - 0.008)
CLEARANCE BETWEEN BAULK RING
AND CLUTCH GEAR
Unit: mm (in)
Standard Wear limit
1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020)
AVAILABLE SNAP RING
Mainshaft front bearing
Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)
Thickness mm (in) Part number
3.10 (0.1220) 33138-73P10
3.19 (0.1256) 33138-73P11
3.28 (0.1291) 33138-73P12
Mainshaft rear bearing
Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)
Thickness mm (in) Part number
1.80 (0.0709) 33138-73P20
1.89 (0.0744) 33138-73P21
1.98 (0.0780) 33138-73P22
2.07 (0.0815) 33138-73P23
2.16 (0.0850) 33138-73P24
Main gear bearing
Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)
Thickness mm (in) Part number
2.60 (0.1024) 33114-73P00
2.69 (0.1059) 33114-73P01
2.78 (0.1094) 33114-73P02
AVAILABLE SHIM
Counter gear rear bearing
Distance ``A''
mm (in)Shim(s)
Thickness mm (in) Part number
32.65 - 32.55
(1.2854 - 1.2815)Not necessary
32.55 - 32.45
(1.2815 - 1.2776)0.1 (0.004) 33112-C6900
32.45 - 32.35
(1.2776 - 1.2736)0.2 (0.008) 33112-C6901
32.35 - 32.25
(1.2736 - 1.2697)0.3 (0.012) 33112-C6902
32.25 - 32.15
(1.2697 - 1.2657)0.4 (0.016) 33112-C6903
32.15 - 32.05
(1.2657 - 1.2618)0.5 (0.020) 33112-33G00
32.05 - 31.95
(1.2618 - 1.2579)0.6 (0.024) 33112-33G01
SMT335A
SERVICE DATA AND SPECIFICATIONS (SDS)
TF-30

ELECTRICAL SYSTEM
SECTION
EL
When you read wiring diagrams:
lRead GI section, ``HOW TO READ WIRING DIAGRAMS''.
When you perform trouble diagnoses, read GI section, ``HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES'' and ``HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRI-
CAL INCIDENT''.
CONTENTS
PRECAUTIONS......................................................... 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (4WD models).............................................. 1
Supplemental Restraint System (SRS) ``AIR
BAG'' (2WD models).............................................. 1
HARNESS CONNECTOR.......................................... 2
Description ............................................................. 2
STANDARDIZED RELAY.......................................... 3
Description ............................................................. 3
POWER SUPPLY ROUTING..................................... 5
Schematic .............................................................. 5
Wiring Diagram - POWER -................................... 6
Fuse ..................................................................... 13
Fusible Link .......................................................... 13
Circuit Breaker Inspection.................................... 13
GROUND DISTRIBUTION....................................... 14
BATTERY................................................................. 18
How to Handle Battery......................................... 18
Battery Test and Charging Chart......................... 21
Service Data and Specifications (SDS) ............... 25
STARTING SYSTEM............................................... 26
Wiring Diagram - START - .................................. 26
Trouble Diagnoses ............................................... 27
Construction ......................................................... 28
Removal and Installation ..................................... 30
Inspection ............................................................. 30
Assembly.............................................................. 32
Service Data and Specifications (SDS) ............... 33
CHARGING SYSTEM.............................................. 34
Wiring Diagram - CHARGE -/Gasoline Engine ... 34
Wiring Diagram - CHARGE -/Diesel Engine ....... 35Trouble Diagnoses ............................................... 36
Construction ......................................................... 38
Removal and Installation ..................................... 39
Disassembly ......................................................... 39
Inspection ............................................................. 39
Assembly.............................................................. 40
Service Data and Specifications (SDS) ............... 41
COMBINATION SWITCH........................................ 42
Check ................................................................... 42
Replacement ........................................................ 43
HEADLAMP - Conventional Type -....................... 44
Wiring Diagram - H/LAMP -/LHD Models ............ 44
Wiring Diagram - H/LAMP -/RHD Models ........... 46
Trouble Diagnoses ............................................... 48
Bulb Replacement................................................ 49
Aiming Adjustment ............................................... 49
Low Beam ............................................................ 50
HEADLAMP - Daytime Light System -................. 51
System Description .............................................. 51
Schematic ............................................................ 53
Wiring Diagram - DTRL - ..................................... 54
Trouble Diagnoses ............................................... 57
Bulb Replacement................................................ 57
Aiming Adjustment ............................................... 57
HEADLAMP - Dim-dip Lamp System -................. 58
System Description .............................................. 58
Schematic ............................................................ 58
Wiring Diagram - DIMDIP -.................................. 59
Trouble Diagnoses ............................................... 62
Bulb Replacement................................................ 62
Aiming Adjustment ............................................... 62
EL