Nissan Pathfinder: Driveline - Unit Disassembly and Assembly

Nissan Pathfinder (R53) 2022-2025 Service Manual / Transmission & Driveline :: Driveline / Transfer: Ty92b / Unit Disassembly and Assembly

Transfer Cover
Ring Gear Shaft
Drive Pinion
Transfer Case

Transfer Cover Nissan Pathfinder 5th Gen

Exploded View

1.	Transfer cover dust seal	2.	Transfer cover	3.	Filler plug
4.	Gasket	5.	Transfer cover oil seal	6.	O-ring
7.	Ring gear bearing adjusting shim (transfer cover side)	8.	Ring gear bearing (transfer cover side)	9.	Gasket
10.	Transfer oil temperature sensor	11.	Ring gear shaft	12.	Ring gear
13.	Ring gear bearing (transfer case side)	14.	Baffle plate	15.	Snap ring
16.	Ring gear bearing outer race (transfer case side)	17.	Ring gear bearing adjusting shim (transfer case side)	18.	Transfer case
19.	Drain plug	20.	Plug	21.	O-ring
22.	Oil seal	23.	Dowel pin	24.	Drive pinion
25.	Drive pinion adjusting shim	26.	O-ring	27.	Pinion bearing assembly
28.	Oil seal	29.	Dust cover	30.	Companion flange
31.	Pinion lock nut	A.	Oil seal lip	B.	Comply with the assembly procedure when tightening. Refer to Assembly.

Disassembly

Remove the oil temperature sensor using the following procedure:Disconnect the harness connector from the oil temperature sensor connector and release clip.

CAUTION:

Do not damage harness connector.

Remove the oil temperature sensor and gasket from the transfer cover.

Remove transfer cover mounting bolts ( ).

Lightly tap transfer cover (1) with a plastic hammer to remove the transfer cover.

Remove O-ring from transfer cover.

CAUTION:

Do not use a tool.

Do not damage transfer cover.

Lightly tap the metal part of oil seals (1) with a punch from the back side of the transfer cover to remove oil seals.

CAUTION:

When removing, do not damage the transfer cover by scooping it out with a tool.

Remove the ring gear bearing adjusting shim [transfer cover side (1)] and ring gear bearing outer race [transfer cover side (2)] using drift (commercial service tool).

Remove drain plug and gasket.

CAUTION:

Do not reuse gasket.

Remove filler plug and gasket.

CAUTION:

Do not reuse gasket.

Perform inspection after disassembly. Refer to Inspection.

Assembly

Select the ring gear bearing adjusting shim (transfer cover side). Refer to Adjustment.

Install the selected ring gear bearing adjusting shim [transfer cover side (1)] and ring gear bearing outer race [transfer cover side (2)] using drift (commercial service tool).

CAUTION:

Do not reuse ring gear bearing.

Apply gear oil to the ring gear bearing.

Install gasket onto drain plug and install them to transfer cover.

CAUTION:

Do not reuse gasket.

Install the transfer cover to the transfer case, and apply anti-corrosive oil onto the thread and seats on the mounting bolts. Then tighten mounting bolts to the specified torque.

NOTE:

At this time, O-ring installing to transfer cover is not necessary. Install O-ring after tooth contact is checked.

Check the backlash, tooth contact, total preload and companion flange runout. Refer to Adjustment.

CAUTION:

Measure the total preload without oil seals of transfer cover and transfer case.

Remove transfer cover to install O-ring.

Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the transfer cover.

CAUTION:

Do not reuse O-ring.

When installing O-ring, do not use a tool.

Do not damage O-ring.

Install the transfer cover to the transfer case, and apply anti-corrosive oil onto thread and seats on the mounting bolts. Then tighten mounting bolts to the specified torque.

Using drift (commercial service tool), drive the transfer cover oil seal.

Depth

: 0 +0.6/-0 mm (0 +0.024/-0 in)

CAUTION:

When checking the total preload torque, measure it without the transfer cover oil seal and the transfer cover dust seal, then install the transfer cover dust seal.

Do not reuse the transfer cover oil seal.

When installing, do not incline transfer cover oil seal.

Apply gear oil onto the circumference of the transfer cover oil seal.

Using Tool, drive the transfer cover dust seal.

Tool	: — (NI-53127)

CAUTION:

When checking the total preload torque, measure it without the transfer cover oil seal and the transfer cover dust seal, then install the transfer cover dust seal.

Do not reuse the transfer cover dust seal.

When installing, do not incline transfer cover dust seal.

Apply multi-purpose grease onto transfer cover dust seal lips.

NOTE:

When installing the transfer cover dust seal (1), the notch is located on the lower side (A)

Install the oil temperature sensor using the following procedure:Attach the gasket to the oil temperature sensor and attach the main body to the transfer cover.

CAUTION:

Do not reuse gasket.

Install the oil temperature sensor clip and connect harness connector.

CAUTION:

Do not damage the harness connector.

Install gasket onto filler plug and install them to transfer cover.

CAUTION:

Do not reuse gasket.

Install filler plug after oil is filled.

Inspection

Inspection After Disassembly

Check items below. If necessary, replace them with new ones.

Transfer Cover

Check the bearing mounting surface for wear, cracks and damages.

Ring Gear Shaft Nissan Pathfinder

Exploded View

1.	Transfer cover dust seal	2.	Transfer cover	3.	Filler plug
4.	Gasket	5.	Transfer cover oil seal	6.	O-ring
7.	Ring gear bearing adjusting shim (transfer cover side)	8.	Ring gear bearing (transfer cover side)	9.	Gasket
10.	Transfer oil temperature sensor	11.	Ring gear shaft	12.	Ring gear
13.	Ring gear bearing (transfer case side)	14.	Baffle plate	15.	Snap ring
16.	Ring gear bearing outer race (transfer case side)	17.	Ring gear bearing adjusting shim (transfer case side)	18.	Transfer case
19.	Drain plug	20.	Plug	21.	O-ring
22.	Oil seal	23.	Dowel pin	24.	Drive pinion
25.	Drive pinion adjusting shim	26.	O-ring	27.	Pinion bearing assembly
28.	Oil seal	29.	Dust cover	30.	Companion flange
31.	Pinion lock nut	A.	Oil seal lip	B.	Comply with the assembly procedure when tightening. Refer to Assembly.

Disassembly

Remove transfer cover assembly. Refer to Disassembly.

Remove ring gear bearing outer race (transfer cover side) and ring gear bearing adjusting shim (transfer cover side) from the transfer cover. Refer to Disassembly.

Remove ring gear shaft assembly from the transfer case.

Remove ring gear bearing outer race (transfer case side) and ring gear bearing adjusting shim (transfer case side) from the transfer case. Refer to Disassembly.

Remove ring gear bearing inner race (transfer cover side) from ring gear shaft with drift (A) (commercial service tool) and bearing separator (commercial service tool).

Remove ring gear bearing inner race (transfer case side) from ring gear shaft with drift [commercial service tool (A)] and bearing separator (commercial service tool).

Remove snap ring. Refer to Exploded View.

CAUTION:

Do not reuse snap ring.

Remove ring gear bearing from ring gear shaft with drift [commercial service tool (A)] and separator (commercial service tool).

Perform inspection after disassembly. Refer to Inspection.

Assembly

Select ring gear bearing adjusting shim (transfer case side) and ring gear bearing adjusting shim (transfer cover side). Refer to Adjustment.

Assemble the selected ring gear bearing adjusting shim (transfer case side) and ring gear bearing outer race (transfer case side) to transfer case. Refer to Assembly.

CAUTION:

Do not reuse ring gear bearing.

Apply gear oil to the ring gear bearing.

Assemble the selected ring gear bearing adjusting shim (transfer cover side) and ring gear bearing outer race (transfer cover side) to transfer cover. Refer to Assembly.

CAUTION:

Do not reuse ring gear bearing.

Apply gear oil to the ring gear bearing.

Install the ring gear to ring gear shaft.

Install snap ring.

CAUTION:

Do not reuse snap ring.

Install the ring gear bearing inner race (transfer cover side) with drift [commercial service tool(A)].

CAUTION:

Do not reuse ring gear bearing.

Apply gear oil to the ring gear bearing.

Install the ring gear bearing inner race (transfer case side) to ring gear shaft with drift [commercial service tool (A)].

CAUTION:

Do not reuse ring gear bearing.

Apply gear oil to the ring gear bearing.

Install the ring gear shaft assembly to the transfer case.

CAUTION:

Protect transfer case oil seals beforehand from being damaged by the spline of the ring gear shaft below method following.

Apply multi-purpose grease to spline part indicated in the figure.

Wrap piece of vinyl to the spline part only indicated in the figure. [(A): limit line].

CAUTION:

Do not wrap sliding surface on oil seal.

Install transfer cover to check and adjust each part. Refer to Assembly.

NOTE:

At this timing, O-ring installing to transfer cover is not necessary. Install O-ring after backlash and tooth contact are checked.

Check backlash, tooth contact, total preload and companion flange runout. Refer to Adjustment.

CAUTION:

Measure the total preload without oil seals of transfer cover and transfer case.

Reinstall transfer cover for installing O-ring. Refer to Assembly.

After installing transfer case oil seals, remove wrapped vinyl from the spline of ring gear shaft.

Inspection

inspection AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones.

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.

CAUTION:

If a malfunction is detected on the ring gear or drive pinion, replace the ring gear and drive pinion as a set.

Bearing

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other damage.

CAUTION:

When replacing the bearing, always replace the inner race and outer race as a pair.

Shim

Check for seizure, damage, and unusual wear.

Drive Pinion Nissan Pathfinder 2025

Exploded View

1.	Transfer cover dust seal	2.	Transfer cover	3.	Filler plug
4.	Gasket	5.	Transfer cover oil seal	6.	O-ring
7.	Ring gear bearing adjusting shim (transfer cover side)	8.	Ring gear bearing (transfer cover side)	9.	Gasket
10.	Transfer oil temperature sensor	11.	Ring gear shaft	12.	Ring gear
13.	Ring gear bearing (transfer case side)	14.	Baffle plate	15.	Snap ring
16.	Ring gear bearing outer race (transfer case side)	17.	Ring gear bearing adjusting shim (transfer case side)	18.	Transfer case
19.	Drain plug	20.	Plug	21.	O-ring
22.	Oil seal	23.	Dowel pin	24.	Drive pinion
25.	Drive pinion adjusting shim	26.	O-ring	27.	Pinion bearing assembly
28.	Oil seal	29.	Dust cover	30.	Companion flange
31.	Pinion lock nut	A.	Oil seal lip	B.	Comply with the assembly procedure when tightening. Refer to Assembly.

Disassembly

Remove pinion bearing assembly bolts.

Lightly tap companion flange with a plastic hammer to remove drive pinion assembly (1).

Remove the O-ring from the pinion bearing.

CAUTION:

Do not reuse O-ring.

Remove the pinion lock nut.

CAUTION:

Do not reuse the pinion lock nut.

Remove drive pinion from pinion bearing assembly with drift [commercial service tool (A) and bearing separator [commercial service tool (B)].

Remove the adjusting shim.

Remove the companion flange.

Remove the dust cover.

Remove the oil seal.

CAUTION:

Do not reuse oil seal.

Perform inspection after disassembly. Refer to Inspection.

Assembly

Select drive pinion adjusting shim. Refer to Adjustment.

Assemble the selected drive pinion adjusting shim to drive pinion.

Install the drive pinion to pinion bearing assembly with drift (commercial service tool).

CAUTION:

Do not reuse pinion bearing assembly.

Apply gear oil to pinion bearing part.

Install oil seal to pinion bearing assembly with drift (A) (commercial service tool).

CAUTION:

Do not reuse the oil seal.

When installing, do not incline oil seal.

Apply multi-purpose grease onto oil seal lips, and gear oil onto the oil seal’s circumference.

Install dust cover.

NOTE:

Tighten dust cover together with pinion bearing assembly.

Install companion flange (1) to pinion bearing with drift (A) (commercial service tool).

Apply anti-corrosive oil to the thread and seat of the lock nut, and adjust the pinion lock nut tightening torque and pinion bearing preload torque, using a preload gauge.Install pinion lock nut, and then tighten to the specified torque.

Pinion lock nut tightening torque

: 90±9 N·m (9.2±0.92kg-m, 66±7 ft-lb)

CAUTION:

Do not reuse pinion lock nut.

Check that pinion lock nut is seated on the companion flange.

After tightening pinion lock nut to the specified torque, retighten the pinion lock nut by 57 degrees. Measure the pinion bearing preload.

Pinion bearing preload

: Refer to Preload Torque.

Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion bearing assembly.

CAUTION:

Do not reuse O-ring.

When installing O-ring, do not use a tool.

Do not damage O-ring.

Install drive pinion assembly, and apply anti-corrosive oil onto thread and seats on the mounting bolts. Tighten to the specified torque.

NOTE:

Tighten dust cover together with pinion bearing assembly.

Check backlash, tooth contact, total preload and companion flange runout. Refer to Adjustment.

CAUTION:

Measure the total preload without oil seals of transfer cover and transfer case.

Adjustment

ADJUSTING SHIM SELECTION

Select adjusting shim of T1, T2, and T3, respectively, by using the following equation.

T1 [Ring gear bearing adjusting shim (transfer case side)]

T1 = A −(B +X/2) +C +W −V −F −(M/100) +0.055 mm (0.0022 in)

T2 [Ring gear bearing adjusting shim (transfer cover side)]

T2 = −Y +Z +(B +X/2) −C −W −H +(M/100) +0.055 mm (0.0022 in)

T3 (Drive pinion adjusting shim)

T3 = −Q +(R +S/2) −K +(O/100)

Check dimension (M) on the ring gear side face.

NOTE:
Dimension “M” indicates the difference between the optimum engagement and standard dimensions in increments of 0.01 mm (0.0004 in) written on the ring gear side face.
Check dimension (O) on the gear end of the drive pinion.

NOTE:
Dimension “O” indicates the difference between the optimum engagement and the standard dimensions in increments of 0.01 mm (0.0004 in) written on the gear end of the drive pinion.

PINION BEARING PRELOAD

CAUTION:

When measuring preload, the rotating speed must be set to 30 rpm.

Remove ring gear shaft assembly from the transfer case. Refer to Disassembly.

Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking, and so on.

Rotate the companion flange at least 20 times to check for smooth operation of the bearing.

Measure the pinion bearing preload with the preload gauge (A) [SST: ST3127S000 (NI-25765-A)].

Pinion bearing preload

: Refer to Preload Torque.

CAUTION:

Each rotational part should rotate smoothly with the specified gear oil.

If outside the standard, disassemble the drive pinion assembly to check and adjust each part.

TOTAL PRELOAD

CAUTION:

When measuring preload, the rotating speed must be set to 30 rpm.

Measure pinion bearing preload.

CAUTION:

Check that the pinion bearing preload is within the standard.

Assemble the ring gear shaft assembly to the transfer case. Refer to Assembly.

Install transfer cover to check and adjust each part. Refer to Assembly.

Rotate the companion flange at least 20 times to check for smooth operation of the bearing.

Measure the total preload with the preload gauge (A) [SST: ST3127S000 (NI-25765-A)].

Total preload

: Refer to Preload Torque.

CAUTION:

Each rotational part should rotate smoothly with the specified gear oil.

If outside the standard, disassemble the transfer assembly to check and adjust each part. Measure it with the transfer case oil seal and transfer cover oil seal removed when measuring total preload after disassembly. Then install transfer case oil seals and transfer cover oil seal.

BACKLASH

Install the bolt to the companion flange.

Fit a dial indicator onto the bolt (A).

Measure the circumference backlash of the companion flange.

Backlash

: Refer to Backlash.

If outside the standard, disassemble the transfer assembly to check and adjust each part.

TOOTH CONTACT

Remove transfer cover. Refer to Disassembly.

Remove ring gear shaft assembly from transfer case. Refer to Disassembly.

Apply red lead onto the ring gear.

CAUTION:

Apply red lead to both faces of 3 to 4 gears at 4 locations evenly spaced on the ring gear.

Assemble the ring gear shaft assembly to the transfer case. Refer to Assembly.

Install transfer cover to check and adjust each part. Refer to Assembly.

NOTE:

At this timing, O-ring installing to transfer cover is not necessary. Install O-ring after backlash and tooth contact are checked.

Remove the plug from the transfer case.

Rotate the companion flange back and forth several times, and check the drive pinion gear to ring gear tooth contact by viewing from the plug hole.

Tooth Contact Judgment Guide

Follow the procedure below to adjust pinion height (dimension X) if tooth contact is improper. For selecting adjusting shim, refer to the latest parts information.

CAUTION:

If no adjusting shim with the calculated value is available, select the thicker and closest one.

Thicken the drive pinion adjusting shim to move the drive pinion closer to the ring gear in case of face contact or heel contact.

CAUTION:
Only one adjusting shim can be selected.
Thin the drive pinion adjusting shim to move the drive pinion farther from the ring gear in case of flank contact or toe contact.

CAUTION:
Only one adjusting shim can be selected.

COMPANION FLANGE RUNOUT

Fit a dial indicator onto the companion flange face (inner side of the propeller shaft mounting bolt holes).

Rotate the companion flange to check for runout.

Companion flange runout

: Refer to Companion Flange Runout.

Fit a test indicator to the inner side of the companion flange (socket diameter).

Rotate the companion flange to check for runout.

Companion flange runout

: Refer to Companion Flange Runout.

Follow the procedure below to adjust if runout value is outside the repair limit.Check for runout while changing the phase between companion flange and drive pinion in 90° steps. Then search for the minimum point. Replace companion flange if runout value is still outside the limit after the phase has been changed. Adjust assembly status of the pinion bearing and drive pinion, or replace pinion bearing assembly if runout is outside the standard after the companion flange is replaced.

Inspection

INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones.

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.

CAUTION:

Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring gear or drive pinion.

Bearing

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other damage.

Shim

Check for seizure, damage, and unusual wear.

Transfer Case Nissan Pathfinder 5th Gen

Exploded View

1.	Transfer cover dust seal	2.	Transfer cover	3.	Filler plug
4.	Gasket	5.	Transfer cover oil seal	6.	O-ring
7.	Ring gear bearing adjusting shim (transfer cover side)	8.	Ring gear bearing (transfer cover side)	9.	Gasket
10.	Transfer oil temperature sensor	11.	Ring gear shaft	12.	Ring gear
13.	Ring gear bearing (transfer case side)	14.	Baffle plate	15.	Snap ring
16.	Ring gear bearing outer race (transfer case side)	17.	Ring gear bearing adjusting shim (transfer case side)	18.	Transfer case
19.	Drain plug	20.	Plug	21.	O-ring
22.	Oil seal	23.	Dowel pin	24.	Drive pinion
25.	Drive pinion adjusting shim	26.	O-ring	27.	Pinion bearing assembly
28.	Oil seal	29.	Dust cover	30.	Companion flange
31.	Pinion lock nut	A.	Oil seal lip	B.	Comply with the assembly procedure when tightening. Refer to Assembly.

Disassembly

Remove transfer cover. Refer to Disassembly.

Remove ring gear shaft assembly. Refer to Disassembly.

Remove drive pinion assembly. Refer to Disassembly.

Remove O-ring from transfer case.

CAUTION:

Do not use a tool.

Do not damage transfer case.

Remove bolts (A) and baffle plate (1).

Remove the ring gear bearing adjusting shim (transfer case side) (1) and ring gear bearing outer race (transfer case side) (2) by tapping from the 2 cutouts ( ) on the transfer case.

CAUTION:

Do not damage transfer case.

Remove plug and gasket.

Perform inspection after disassembly. Refer to Inspection.

Assembly

Select the ring gear bearing adjusting shim (transfer case side). Refer to Adjustment.

Install the selected ring gear bearing adjusting shim (transfer case side) and the ring gear bearing outer race (transfer case side) using drift (A) (commercial service tool).

CAUTION:

Do not reuse ring gear bearing.

Apply gear oil to the ring gear bearing.

Install drive pinion assembly. Refer to Assembly.

Install baffle plate (1) and bolts (A).

Install ring gear shaft assembly. Refer to Assembly.

CAUTION:

Protect transfer case oil seals beforehand from being damaged by the spline of ring gear shaft.

Install transfer cover to check and adjust each part. Refer to Assembly.

NOTE:

At this timing, O-ring installing to transfer cover is not necessary. Install O-ring after backlash and tooth contact are checked.

Check backlash, tooth contact, total preload and companion flange runout. Refer to Adjustment.

CAUTION:

Measure the total preload without oil seals of transfer cover and transfer case.

Reinstall transfer cover for installing O-ring. Refer to Assembly.

Install oil seals with drift (commercial service tool).

A	: 67.5 ± 0.5 mm (2.657 ± 0.020 in)

CAUTION:

When checking the total preload torque, measure it without the oil seal, then install the oil seal.

Do not reuse the oil seal.

When installing, do not incline oil seal.

Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of the oil seal.

Do not damage oil seals by spline of ring gear shaft.