2004 NISSAN TERRANO Service Repair Manual

OIL PUMP AND LOW ONE-WAY CLUTCH
Oil pump clearance mm (in)Cam ring Ð oil pump housingStandard 0.01 - 0.024 (0.0004 - 0.0009)
Rotor, vanes and control piston
Ð oil pump housing Standard 0.03 - 0.044 (0.0012 - 0.0017)
Seal ring clearance mm (in) Standard 0.10 - 0.25 (0.0039 - 0.0098)
Allowable limit 0.25 (0.0098)
TOTAL END PLAY
Total end play ªT1º0.25 - 0.55 mm
(0.0098 - 0.0217 in)
Thickness of oil pump
cover bearing race Thickness
mm (in) Part number
0.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.4 (0.055)
1.6 (0.063)
1.8 (0.071)
2.0 (0.079) 31435-41X01
31435-41X02
31435-41X03
31435-41X04
31435-41X05
31435-41X06
31435-41X07
REVERSE CLUTCH DRUM END PLAY
Reverse clutch drum
end play ªT
2º
0.55 - 0.90 mm
(0.0217 - 0.0354 in)
Thickness of oil pump
thrust washer Thickness
mm (in) Part number
0.9 (0.035)
1.1 (0.043)
1.3 (0.051)
1.5 (0.059)
1.7 (0.067)
1.9 (0.075) 31528-21X01
31528-21X02
31528-21X03
31528-21X04
31528-21X05
31528-21X06
REMOVAL AND INSTALLATION
Manual control linkage
Number of returning revolutions
for lock nut 2
Lock nut tightening torque N×m (kg-m, in-lb) 4.4 - 5.9
(0.45 - 0.60, 39.1 - 52.1)
Distance between end of converter
housing and torque converter mm (in)26.0 (1.024) or more
SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont'd)
AT-204
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TRANSFER
SECTION
TF
CONTENTS
PREPARATION ................................................................2
ON-VEHICLE SERVICE ..................................................4
Replacing Oil Seal .......................................................4
REMOVAL AND INSTALLATION ....................................7
Removal .......................................................................7
Installation ....................................................................7
TRANSFER GEAR CONTROL .......................................8
MAJOR OVERHAUL .......................................................9
Case Components .......................................................9
Gear Components .....................................................10
Shift Control Components ......................................... 11
DISASSEMBLY ..............................................................12
REPAIR FOR COMPONENT PARTS ............................17Mainshaft ...................................................................17
Front Drive Shaft .......................................................19
Counter Gear .............................................................20
Main Gear ..................................................................21
Front Case .................................................................23
Front Case Cover ......................................................23
Bearing Retainer ........................................................23
Rear Case..................................................................24
Shift Control Components .........................................24
ASSEMBLY ....................................................................26
SERVICE DATA AND SPECIFICATIONS (SDS) ..........33
General Specifications ...............................................33
Inspection and Adjustment ........................................33
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SPECIAL SERVICE TOOLS
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST38060002*
Flange wrench
Removing companion flange nut
Installing companion flange nut
ST30021000*
Puller
Removing counter gear front bearing
(Use with ST36710010)
ST30031000*
Puller
Removing counter gear rear bearing
(Use with ST36710010)
ST33290001*
Puller
Removing center case oil seal
Removing rear oil seal
ST33051001*
Puller
Removing companion flange
ST30720000*
Drift
Installing center case oil seal
Installing rear oil seal
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST36710010*
DriftRemoving counter gear front bearing
(Use with ST30021000)
Removing counter gear rear bearing
(Use with ST30031000)
a: 34.5 mm (1.358 in) dia.
ST33061000*
DriftRemoving main gear bearing
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
PREPARATION
TF-2
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*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST30613000*
Drift
Installing main gear bearing
Installing cover oil seal
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
COMMERCIAL SERVICE TOOLS
Tool name Description
Puller
Removing front drive shaft front bearing
Removing front drive shaft rear bearing
Removing main gear bearing
Drift
Installing shift shaft oil seal
a: 26 mm (1.02 in) dia.
b: 20 mm (0.79 in) dia.
c: 150 mm (5.91 in)
DriftInstalling mainshaft rear bearing
a: 50 mm (1.97 in) dia.
b: 42 mm (1.65 in) dia.
c: 180 mm (7.09 in)
DriftInstalling L & H hub
a: 60 mm (2.36 in) dia.
b: 50 mm (1.97 in) dia.
c: 60 mm (2.36 in)
PREPARATION
TF-3
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Replacing Oil Seal
CENTER CASE OIL SEAL
1. Remove front propeller shaft Ð Refer to PD section.
2. Remove companion flange nut.
3. Remove companion flange.
4. Remove center case oil seal.
5. Install center case oil seal.
Before installing, apply multi-purpose grease to seal lip.
6. Install companion flange.
7. Tighten nut to the specified torque.
: 226 - 324 N×m (23 - 33 kg-m, 166 - 239 ft-lb)
8. Install front propeller shaft.
YMT010
YMT011
YMT012
SMT488A
YMT013
ON-VEHICLE SERVICE
TF-4
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SHIFT SHAFT OIL SEAL
1. Remove front propeller shaft Ð Refer to PD section.
2. Install companion flange Ð Refer to ªCENTER CASE OILSEALº, TF-4.
3. Remove transfer control lever from transfer outer shift lever. Then remove outer shift lever.
4. Remove shift shaft oil seal.
Be careful not do damage cross shaft.
5. Install shift shaft oil seal.
Before installing, apply multi-purpose grease to seal lip.
6. Install transfer control linkage.
7. Install companion flange Ð Refer to ªCENTER CASE OIL SEALº, TF-4.
8. Install front propeller shaft.
REAR OIL SEAL
1. Remove rear propeller shaft Ð Refer to PD section.
2. Remove rear oil seal.
YTF001
SMT491A
YMT014
YMT015
ON-VEHICLE SERVICE
Replacing Oil Seal (Cont'd)
TF-5
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3. Install rear oil seal.
Before installing apply multi-purpose grease to seal lip.
4. Install rear propeller shaft.
YMT016
ON-VEHICLE SERVICE
Replacing Oil Seal (Cont'd)TF-6
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Removal
IDrain oil from transfer and transmission.
I Remove front and rear propeller shafts Ð Refer to PD section.
I Insert plug into oil seal after removing propeller shaft.
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal,
when removing propeller shaft.
I Remove torsion bar spring Ð Refer to removal and installation
of lower link in FA section. Then remove fifth crossmember.
I Remove transfer control lever from transfer outer shift lever.
I Remove transfer from transmission.
WARNING:
Support transfer while removing it.
Installation
I Apply recommended sealant to mating surface to transmission.
Recommended sealant: Nissan genuine part (KP610-00250) or equivalent
I Tighten bolts securing transfer.
Bolt No. Tightening torque
N×m (kg-m, ft-lb) 
mm (in)
q
127 - 36 (2.8 - 3.6, 20 - 26) 45 (1.77)
q
227 - 36 (2.8 - 3.6, 20 - 26) 60 (2.36)
SMT478A
YTF001
SMT495A
SMT496A
REMOVAL AND INSTALLATION
TF-7
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