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Nissan Frontier D40. Manual - part 302

REAR FINAL DRIVE

DLN-229

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DLN

Remove differential case assembly using suitable tool.

• Keep side bearing outer races together with inner races. Do

not mix them up. Also, keep side bearing adjusting washers
together with bearings.

Remove side bearing inner race using Tools.

CAUTION:

• Engage puller jaws in groove to prevent damage.
• To prevent damage to the side bearing and drive gear,

place copper plates between these parts and vise.

• It is not necessary to remove side bearing inner race

except if it is replaced.

For proper reinstallation, paint matching mark on one differential
case assembly.

CAUTION:

Use paint for matching marks. Do not damage differential
case or drive gear.

Remove drive gear bolts.

Tap the drive gear off the differential case assembly using suit-
able tool.

CAUTION:

Tap evenly all around to keep drive gear from binding.

SPD193

SPD745

Tool number

A: ST33051001 (J-22888-20)

B: ST33061000 (J-8107-2)

SPD920

PDIA0496E

DLN-230

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REAR FINAL DRIVE

10. Remove the lock pin of pinion mate shaft from the drive gear

side using suitable tool.

11. Remove pinion mate shaft.

12. Turn the pinion mate gear, then remove the pinion mate gear,

pinion mate thrust washer, side gear and side gear thrust
washer from differential case.

Drive Pinion Assembly

Remove differential case assembly. Refer to

DLN-224, "Disassembly and Assembly"

Remove drive pinion lock nut using suitable tool.

Put matching marks on the companion flange and drive pinion
using paint.

CAUTION:

Use paint to make the matching marks. Do not damage the
companion flange or drive pinion.

SPD025

SDIA0031J

SDIA0032J

WDIA0241E

REAR FINAL DRIVE

DLN-231

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DLN

Remove companion flange using suitable Tool.

Remove drive pinion assembly from gear carrier using suitable
tool.

CAUTION:

Do not drop drive pinion assembly.

Remove front oil seal.

Remove drive pinion front bearing inner race.

Remove collapsible spacer.

Remove drive pinion rear bearing inner race and drive pinion
height adjusting washer using Tool.

10. Tap drive pinion front and rear bearing outer races uniformly with

a brass bar or equivalent to remove.

CAUTION:

Do not damage gear carrier.

INSPECTION AFTER DISASSEMBLY

Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.

Drive Pinion and Drive Gear

• If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust,

repair, or replace as necessary.

• If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably,

replace with new drive pinion and drive gear.

• Drive pinion and drive gear are supplied in matched sets only. Matching numbers on both drive pinion and

drive gear are etched for verification. If a new drive pinion and drive gear set are being used, verify the num-
bers of each drive pinion and drive gear before proceeding with assembly.

SPD014

SPD206

Tool number

: ST30031000 (J-22912-01)

S-PD179

SDIA0817E

DLN-232

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REAR FINAL DRIVE

Bearing

• If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bearing,

replace with new bearing assembly (as a new set).

• Bearing must be replaced with a new one whenever disassembled.

Side Gear and Pinion Mate Gear

• If any cracks or damage are found on the surface of the teeth, replace with new one.
• If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact the

thrust washer, replace with new one.

• Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.

Side Gear Thrust Washer and Pinion Mate Thrust Washer

• If any chips (by friction), damage, or unusual wear are found, replace with new one.

Gear Carrier

• If any wear or cracks are found on the contact sides of gear carrier, replace with new one.

Companion Flange

• If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the

front oil seal lips are found, replace with new one.

ADJUSTING AND SELECTING WASHERS

Side Gear Back Clearance

• Assemble the differential parts if they are disassembled. Refer to "Differential Assembly".

Place the differential case straight up so that the side gear to be
measured is upward.

Using feeler gauges, measure the clearance between the side
gear back and differential case at three different points, while
rotating the side gear. Average the three readings to calculate
the clearance. (Measure the clearance of the other side as well.)

• If the side gear back clearance is outside of the specification,

use a thicker or thinner side gear thrust washer to adjust.
Refer to

DLN-224, "Disassembly and Assembly"

CAUTION:

• Insert feeler gauges with the same thickness on both

sides to prevent side gear from tilting.

• Each gear should rotate smoothly without excessive

resistance during differential motion.

• Select a side gear thrust washer for right and left individually.

PDIA0460E

Side gear back clearance:

Refer to