This is not a step by step write up, it only shows that you can do the install in your garage.

A few members of pnwx (rrdstarr, chuckh, schlud, synchro) got together a few weeks ago to do the install of calminis new 3.92 to 1 transfer case gears.

first off we removed the torsion bars and torsion bar cross member as well as the exhaust hanger right behind the cross member. also disconnect all electrical hook ups to the tcase. also drain both the tcase and transmission.



next we removed the front and rear drivelines and removed the shifter linkage to the tcase.



then get a transmission jack under the tcase and begin removing all the bolts where the tcase meets the transmission. the top bolts have to be removed from above by lifting the shifter boot housing in the interior. after all the bolts are free get a long screw driver and a rubber mallet and break the case loose from the transmission. the transmission jack is very handy since the case is heavy and not easy to balance.



once you get the case out you can finally start using the calmini instructions. the directions skipped a few small steps but its pretty easy to tell what bolts need to be removed on the back half of the case. the pictures with the instructions are great in guiding you along.
get the case on the floor and start removing the housing bolts and popping the seals. be careful not to damage the input shaft, a thick blanket on the ground is good.



once the case is apart the directions tell you what needs to be removed and which parts of the case need to be ground down. you have to reuse the some of the bearings and install one new bearing. here is what the new 4lo gear looks like with the bearings pressed on.


using paper plates and an ink pen work great to seperate nuts, bolts and everything else. pizza crust doesn't go into the tcase :cwm27:


there are alot of small parts in the case, the neutral check balls are easy to lose so be careful and take your time when dealing with the inside of the tcase.


install the new gears, bearings, and housing shim. reassemble the housing using plenty of rtv sealer.


letting the sealer dry overnight is a good idea. then reinstall the case and reassemble the truck. fill the tcase with the supplied gear oil and refill the transmission. your now done. time for BEER!!



the gears are expensive, but they are worth it the first time you get it in 4lo. the gear reductions will blow your mind!! 4lo 1st gear at 3500rpm is about 2mph.
4hi is unchanged.

a good set of hand tools, a cutting tool, lots of swearing, and a few buddies is all ya need to do this in your garage. the only thing that most people don't have is a bearing press which can be found at dealerships and machine shops. usual labor rate is about $40 for them to press the bearings.

Member PNWX

Darn interesting and enlightening!

Do you think that just as a matter of preventative maintenance, any of the bearings or other components are candidates for replacing while the t-case is open?

Rob

www.nissanoffroad.net

another convert!

(note: you can get the top tramnsmission to tcase bolts undone without going through the shifterhole if you lower the case and transmission down almost as far as it goes and use a nubby 14mm wrench. The screws through the floorboards will, however, beat up your hands! )

enjoy those gears. They make a HUGE difference in the rough stuff.


1998 Frontier 4x4 with ALL the goodies!
2002 Xterra 4x4 still stock
Grow the Nissan Community and stand up for ORV user rights!

Totally cool that you posted, I am going to get the gears too. Looks like you dudes did a clean install.

I just noticed the blood in this pic.

yeah...looks familiar. My hands are turning to scar tissue.


1998 Frontier 4x4 with ALL the goodies!
2002 Xterra 4x4 still stock
Grow the Nissan Community and stand up for ORV user rights!

quote:

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Originally posted by Hootowl:
Darn interesting and enlightening!

Do you think that just as a matter of preventative maintenance, any of the bearings or other components are candidates for replacing while the t-case is open?

Rob


http://www.nissanoffroad.net

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its not necessary to replace the bearings or the seals but its probably a good idea on higher mileage rigs.

Member PNWX

quote:

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Originally posted by Desert Rat:
another convert!

(note: you can get the top tramnsmission to tcase bolts undone without going through the shifterhole if you lower the case and transmission down almost as far as it goes and use a nubby 14mm wrench. The screws through the floorboards will, however, beat up your hands! )

enjoy those gears. They make a HUGE difference in the rough stuff.

http://groups.msn.com/_Secure/0UQAuA*IZok9fHvgSdwM9nHgTRGwCnkl8OlALuORwKdds47tK!mp!8go2sCg9*XaWL2687Wm59RHWFLhnT3qVF0aZ0qidFWUoMduEL7HqSpFBBRtjk4ZkTP6U6tJVV0jF/rollsig.jpg
1998 Frontier 4x4 with ALL the goodies!
2002 Xterra 4x4 still stock
_Grow the Nissan Community and stand up for ORV user rights!_

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i was tired of bleeding and so was rrdstarr, so i went in from the shifter boot with a stubby ratcheting wrench.
the gears are worth every penny. it took me a full day on the trail to re-learn my shift points, brake, and clutch control. i'm sure it would be a little easier for those with an auto trans. its crazy going down a steep hill in 3rd gear riding the gas, when before it was first gear riding the brakes....

Member PNWX

quote:

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Originally posted by TF&J:
I just noticed the blood in this pic. http://www.pnwx.net/gallerytest/album68/DSCN0951.sized.jpg

http://www.msnusers.com/_Secure/0VADdAr4ZNDnNsvrVHqk5kvttOQH7UxuqVFATcYPSGqL*JoGxtW8ZtRigC5VOlImCvnj0QRW7v3F9kXVcFABfGZy4l374k8vLEEC5xjhwZeojAOE51eW0nL2RmkmxeD9D/DSCF0221.JPG?dc=4675425782998463428

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Nice