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Nissan Pathfinder (2009 year). Manual - part 210

DLN-162

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TRANSFER ASSEMBLY

22. Remove the mainshaft from the clutch drum and clutch hub

using suitable tool.

23. Remove the needle bearing and spacer from the mainshaft.

24. Remove the snap ring from the clutch hub using suitable tool.

25. Remove the oil pressure check plug from the oil pressure check

port.

26. Apply air gradually from the oil pressure check port, and remove

the clutch piston assembly from the center case.

27. Remove the thrust needle bearing race from the clutch piston by

hooking a edge into 3 notches of the thrust needle bearing race
using suitable tool.

CAUTION:

Do not damage clutch piston or thrust needle bearing race.

SMT914C

WDIA0101E

WDIA0227E

SDIA2116E

SDIA2118E

2009 Pathfinder

TRANSFER ASSEMBLY

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28. Remove the two D-rings from the clutch piston.

29. Remove the mainshaft rear bearing from the center case using

Tool.

30. Remove the two bolts and oil strainer.

31. Remove the two O-rings from the oil strainer.

32. Remove the snap ring. Then push the connector assembly into

the center case to remove the control valve assembly.

SDIA2781E

Tool number

: KV38100300 (J-25523)

SDIA2129E

SDIA2119E

SDIA2782E

SDIA2122E

2009 Pathfinder

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TRANSFER ASSEMBLY

33. Remove the control valve assembly bolts.

34. Remove the control valve assembly.

CAUTION:

• Do not reuse any part that has been dropped or damaged.
• Make sure valve is assembled in the proper direction.
• Do not use a magnet because residual magnetism stays

during disassembly.

35. Remove the lip seals from the center case.

CAUTION:

There are two kinds of lip seals (lip seal of large inner diam-
eter: 5 pieces, lip seal of small inner diameter: 2 pieces).
Confirm the position before disassembly.

36. Disassemble the control valve assembly with the following procedure.

CAUTION:

• Do not reuse any part that has been dropped or damaged.
• Make sure valve is assembled in the proper direction.
• Do not use a magnet because residual magnetism stays during disassembly.

Remove all the bolts except for the two shown.

Remove the following from the control valve assembly:
• Clutch pressure solenoid valve
• Clutch pressure switch
• 2-4WD shift solenoid valve
• Line pressure switch
• Transfer fluid temperature sensor

Remove the O-rings from each solenoid valve, switch and termi-
nal body.

SDIA2121E

SDIA2123E

WDIA0198E

WDIA0199E

2009 Pathfinder

TRANSFER ASSEMBLY

DLN-165

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Place the control valve with the lower body facing up. Remove
the two bolts, and then remove the lower body and separator
plate from the upper body.

CAUTION:

Do not drop relief balls. Detach lower body carefully.

Make sure the reverse balls, relief balls, relief springs, accumu-
lator pistons and valve springs are securely installed as shown,
and remove them.

Remove the retainer plates.

Remove each retainer plate (1), plug (2), control valve (3) and
spring (4) from the upper body (5).

37. Remove the transfer motor bolts and motor from the center

case. Then remove the O-ring from the transfer motor.

WDIA0200E

SDIA2126E

SDIA2127E

WDIA0284E

SDIA2133E

2009 Pathfinder

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TRANSFER ASSEMBLY

38. Remove the sub oil pump cover bolts.

39. Thread two bolts (M4 x 0.8) into the holes of sub oil pump cover

as shown, and pull out to remove the sub oil pump assembly.

40. Remove the outer gear and inner gear from the sub oil pump

housing.

41. Remove the oil filter bolts and oil filter.

CAUTION:

• Do not damage center case and oil filter.
• Loosen bolts and detach oil filter evenly.

42. Remove the O-rings (1) from the oil filter (2).

SDIA2134E

SMT934C

SDIA2135E

SDIA2136E

WDIA0285E

2009 Pathfinder

TRANSFER ASSEMBLY

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43. Remove the oil filter stud from the oil filter.

44. Remove the O-ring from the oil filter stud.

INSPECTION AFTER DISASSEMBLY

Shift Rod Components

• Check the working face of the shift rod and fork for wear, partial

wear, bending and other abnormality. If any is found, replace with a
new one.

• Measure the clearance between the shift fork and sleeve. If it is out

of specification, replace it with a new one.

Planetary Carrier

• Measure the end play of each pinion gear. If it is out of specifica-

tion, replace the planetary carrier assembly with a new one.

• Check the working face of each gear and bearing for damage,

burrs, partial wear, dents and other abnormality. If any is found,
replace the planetary carrier assembly with a new one.

Sun Gear

SDIA3180E

SMT009D

Specification

: Less than 0.36 mm (0.0142 in)

SMT010D

Pinion gear end play

: 0.1 - 0.7 mm (0.004 - 0.028 in)

PDIA0185E

2009 Pathfinder

DLN-168

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TRANSFER ASSEMBLY

• Check if the oil passage of the sun gear assembly is clogged. For

this, try to pass a 3.6 mm (0.142 in) dia. pin through the oil pas-
sage as shown.

• Check the sliding and contact surface of each gear and bearing for

damage, burrs, partial wear, dents, and other abnormality. If any is
found, replace the sun gear assembly with a new one.

Internal Gear

• Check the internal gear teeth for damage, partial wear, dents and

other abnormality. If any is found, replace the internal gear with a
new one.

Gears and Drive Chain

• Check the gear faces and shaft for wear, cracks, damage, and sei-

zure.

• Check the surfaces which contact the sun gear, clutch drum, clutch

hub, press flange, clutch piston and each bearing for damage,
peel, partial wear, dents, bending, or other abnormal damage. If
any is found, replace with a new one.

Bearing

• Make sure the bearings roll freely and are free from noise, pitting

and cracks.

Main Oil Pump

PDIA0186E

SMT008D

SMT944C

SDIA2175E

2009 Pathfinder

TRANSFER ASSEMBLY

DLN-169

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Check the inner and outer circumference, tooth face, and side-
face of the inner and outer gears for damage or abnormal wear.

Measure the side clearance between the main oil pump housing
edge and the inner and outer gears.

Make sure the side clearance is within specification. If the mea-
surement is out of specification, replace the inner and outer
gears with new ones as a set. Refer to

DLN-187, "Inspection

and Adjustment"

Sub-oil Pump

Check the inner and outer circumference, tooth face, and side-
face of the inner and outer gears for damage or abnormal wear.

Measure the side clearance between the sub oil pump housing
edge and the inner and outer gears.

Make sure the side clearance is within specification. If the mea-
surement is out of specification, replace the inner and outer
gears with new ones as a set. Refer to

DLN-187, "Inspection

and Adjustment"

Control Valve

• Check resistance between the terminals of the clutch pressure

solenoid valve, 2-4WD shift solenoid valve, clutch pressure switch,
line pressure switch and the transfer fluid temperature sensor.
Refer to

DLN-60, "Component Inspection"

(clutch pressure sole-

noid valve),

DLN-65, "Component Inspection"

(2-4WD solenoid

valve),

DLN-76, "Component Inspection"