Service Procedure

1. If the MIL is ON and P0500 is stored and/or the speedometer is operating abnormally, inspect the speed sensor pinion gear.

A. If the speed sensor pinion gear is not stripped, this bulletin does not apply. Look for other causes for the incident.





B. If the speed sensor pinion gear is stripped (see Figure 1), proceed with step two.

2. Drain the automatic transmission fluid (ATF) from the transfer unit lower front drain plug.

3. Remove the exhaust system between the catalytic converters and the rear muffler inlet pipe as follows:

A. Remove the nuts that secure the exhaust pipes to the catalytic converters.

B. Remove the nuts that secure the center muffler outlet pipe the rear muffler inlet pipe.





C. Remove the exhaust pipe support bracket from the transfer unit (see Figure 2).

NOTE:
Only remove the center mounting bolt from the support bracket.

D. Disconnect the muffler rubber mounts from the support hangers and carefully lower the exhaust system from the vehicle.

4. Remove the rear propeller shaft as follows:





A. Mark a line across the edges of the propeller shaft flange and differential pinion flange (see Figure 3).

B. Remove the bolts/nuts that secure the propeller shaft flange to the differential pinion flange.

C. Carefully remove the propeller shaft by sliding the propeller shaft front yoke out of the transfer unit.





5. Remove the three heat shields and ground strap near the right side catalytic converter (see Figure 4).





6. Remove the exhaust pipe support hanger bracket from the transfer unit (see Figure 5).

7. Remove the mass damper from the transfer unit (see Figure 5).

8. Disconnect all electrical connections from the transfer unit and reposition the harnesses towards the right side frame rail to access the right side of the transfer unit.

NOTE:
Repositioning the harnesses will require the removal of two harness support brackets.





9. Remove the vent hose and its mounting bracket from the top of the transfer unit (see Figure 6).

10. Disconnect the shifter cable and support brackets from the transfer unit and reposition them to access the right side of the transfer unit.





11. Remove the speed sensor from the transfer unit (see Figure 7).

12. Remove all bolts from the transfer unit rear cover.

13. Carefully remove the rear cover from the transfer unit.

CAUTION:
When removing the rear cover, do not pry against the gasket sealing surfaces of the cover or transfer unit.





14. Pull the oil cover (white cone shaped plastic) off of the transfer output shaft (see Figure 8).

15. Remove the speedometer drive gear as follows:





A. Rotate the transfer output shaft until the steel ball, that indexes (locates) the speedometer drive gear on the transfer output shaft, is positioned between 11 and 1 o'clock (see Figure 9).

NOTE:
Positioning the speedometer drive gear steel ball (as indicated) will help prevent it from falling from the shaft when the speedometer drive gear is removed.

B. Remove the retainer clip from the transfer output shaft (see Figure 9).

C. Remove the speedometer drive gear.

NOTE:
If, when removing the speedometer drive gear, the steel ball falls from the shaft, apply petroleum jelly to the ball and re-insert it in the transfer output shaft mating hole to keep it in place.

D. Once removed, discard the speedometer drive gear and retainer clip.





16. Install the new speedometer drive gear on the transfer output shaft so that the recessed side of the gear faces the transfer unit (see Figure 10).

17. Install the new retainer clip on the transfer shaft.





18. Re-install the plastic cover (white cone shaped plastic) on the transfer shaft making sure the end of the oil gutter is between the tabs on the plastic cover (see Figure 11).

19. Clean the sealing surfaces of both the transfer unit and the rear cover.

20. Apply a thin coat of Loctite(TM) Anaerobic Liquid Gasket P/N 51813 (or equivalent) to the rear cover sealing surface.

21. Carefully position the rear cover on the transfer unit.

CAUTION:
When positioning the rear cover, be careful not to damage the switch that protrudes from the top of the rear cover.

22. Re-install the harness securing tab to the right side of the transfer rear cover using one bolt.

NOTE:
Do not tighten the harness securing tab mounting bolt at this time.

23. Reinstall the vent hose mounting bracket to the top of the transfer unit using two bolts and re-connect the vent hose to the transfer unit.

NOTE:
Do not tighten the vent hose mounting bracket bolts at this time.

24. Re-install (finger tight) the remaining bolts that secure the rear cover to the transfer unit.

25. Tighten all rear cover securing bolts evenly in a criss-cross pattern to 26 - 36 N.m (2.7 - 3.7 kg-m, 20 - 27 ft-lb).





26. Replace the pinion gear and snap ring on the speed sensor (see Figure 12).

27. Re-install the speed sensor to the transfer unit.

28. Re-install the shifter cable and its mounting brackets to the transfer unit.

29. Re-install the mass damper to the transfer unit.

30. Re-install the wire harness support bracket to the mass damper.





31. Route the wire harnesses over the shifter cable and secure them in the harness support bracket (see Figure 13).

32. Re-connect all wire harness connections to the transfer unit.

33. Re-install the exhaust pipe hanger bracket to the transfer unit.

34. Re-install the front heat shield.

35. Re-install the rear heat shield.

36. Re-install the middle heat shield.

37. Re-connect the ground strap to the middle heat shield.

38. Re-install the exhaust system using new gaskets.

^ Tighten the nuts that secure the exhaust pipes to the catalytic converters to 43 - 50 Nm (4.4 - 5.1 kg-m, 32 - 37 ft-lb).

^ Tighten the nuts that secure the center muffler outlet pipe the rear muffler inlet pipe to 25 - 32 Nm (2.6 - 3.3 kg-m, 19 - 24 ft-lb).

NOTE:
Make sure the ground strap is re-connected to the right exhaust pipe flange.

39. Re-install the ATF drain plug in the transfer unit.

40. Fill the transfer unit with Nissan Matic-D ATF through the filler plug facing the rear of the vehicle. Fill until the fluid reaches the level of the filler plug.

41. Re-install the propeller shaft making sure the marks on the propeller shaft flange and differential pinion flange are lined up. Tighten the bolts/nuts that secure the propeller shaft to the differential to 69 - 78 Nm (7 - 8 kg-m, 51 - 58 ft-lb).