2006 NISSAN PATROL main

16. Disassemble front case assembly.
a. Remove the following parts.
+4WD switch
+Neutral position switch
+Check plugs
+Check springs
+Check balls
+Be careful not to lose the check balls.
b. Remove 2-4 shift rod.
c. Remove L & H shift rod and fork assembly with coupling sleeve.
d. Remove needle bearing from main gear.
e. Remove bolts securing front case cover and then remove it.
SMT259D
SMT122B
SMT260D
SMT124B
SMT125B
DISASSEMBLY
TF-17

f. Remove counter gear by tapping it lightly with a soft hammer.
g. Remove main gear by tapping it lightly with a soft hammer.
SMT261D
SMT262D
DISASSEMBLY
TF-18

Mainshaft
DISASSEMBLY
1. Remove snap ring and spacer.
2. Press out mainshaft front bearing from mainshaft.
INSPECTION
Gear and shaft
+Check gears for excessive wear, chips or cracks.
+Check shaft for cracks, wear or bending.
+Check coupling sleeve for wear or damage.
Baulk ring
+Check baulk ring for cracks or deformation.
+Measure clearance between baulk ring and gear.
Baulk ring to gear clearance:
Unit: mm (in)
Standard Wear limit
1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020)
+If not within wear limit, replace baulk ring.
SMT129B
SMT130B
SMT180B
SMT349A
SMT350A
REPAIR FOR COMPONENT PARTS
TF-19

Bearing
+Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
ASSEMBLY
1. Press mainshaft front bearing onto mainshaft.
+Pay special attention to its direction.
2. Install spacer.
3. Select mainshaft front bearing snap ring with proper thickness
and install it.
Allowable clearance between mainshaft front bearing
snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Mainshaft front bearing snap ring:
Refer to SDS, TF-33.
Front Drive Shaft
DISASSEMBLY
+Front drive shaft front bearing
+Front drive shaft rear bearing
SMT351A
SMT294A
SMT295A
SMT296A
SMT297A
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont'd)
TF-20

INSPECTION
Gear and shaft
+Check gears for excessive wear, chips or cracks.
+Check shaft for cracks or wear.
Bearing
+Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
ASSEMBLY
1. Press on counter gear rear bearing.
2. Install front sub-gear, dish spring and spacer, and then press on
counter gear front bearing.
+Pay attention to direction of dish spring.
Main Gear
DISASSEMBLY
Main gear bearing
1. Remove snap ring and spacer.
2. Pull out main gear bearing.
SMT266D
SMT267D
SMT137B
SMT304A
SMT305AA
REPAIR FOR COMPONENT PARTS
Counter Gear (Cont'd)
TF-22

Plug
+Always replace it with new one whenever it is removed.
INSPECTION
Gear and shaft
+Check gears for excessive wear, chips or cracks.
+Check shaft for cracks or wear.
Bearing
+Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
ASSEMBLY
Main gear bearing
1. Press on main gear bearing.
+Pay attention to its direction.
2. Install spacer.
3. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Snap ring (main gear bearing):
Refer to SDS, TF-33.
Plug
+Apply sealant to plug and install it.
SMT306A
SMT359A
SMT307AA
SMT308A
SMT309A
REPAIR FOR COMPONENT PARTS
Main Gear (Cont'd)
TF-23

1. Install cross shaft.
2. Assemble front case.
a. Install main gear assembly by tapping it lightly with a soft ham-
mer.
b. Apply sealant to the mating surface and bolts of front case
cover and install it on front case.
+Apply recommended sealant to these ten bolts.
+Tightening torque
A:
:16-21Nzm (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
B:
:19-24Nzm (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 it lightly with a soft
hammer.
SMT151B
SMT152B
SMT153B
SMT326A
SMT264D
ASSEMBLY
TF-27

b. Select suitable shim using SDS table as a guide.
Counter gear rear bearing shim:
Refer to SDS, TF-33.
4. Place suitable shim on counter gear rear bearing with grease.
5. Apply gear oil to each part in front case.
6. Install mainshaft on center case.
a. Install mainshaft on center case by tapping it lightly.
+Apply gear oil to mainshaft front bearing.
b. Install bearing retainer.
c. Install low gear and its bearing to mainshaft.
+Apply gear oil to needle bearing.
SMT157B
SMT158B
SMT159B
SMT407A
SMT160B
ASSEMBLY
TF-29