Nissan Pathfinder. Manual - part 412

DLN-90

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

DRIVE PINION

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

• T2  = 

−Y +Z +(B +X/2) −C −D −H +(M/100) +0.071 mm (0.0028 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 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 drive pinion.

PINION BEARING PRELOAD

CAUTION:

When measuring preload, the rotating speed must be set to 30 rpm.
1. Remove ring gear shaft assembly from the transfer case. Refer to 

DLN-82, "Disassembly"

.

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

and so on.

3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4. Measure the pinion bearing preload with the preload gauge (A)

[SST: ST3127S000 (J-25765-A)].

CAUTION:

Each rotational part should rotate smoothly with the speci-

fied 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.
1. Measure pinion bearing preload.

CAUTION:

Check that the pinion bearing preload is within the standard.

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

DLN-83, "Assembly"

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

DLN-79, "Assembly"

.

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

JSDIA2495ZZ

JSDIA2496ZZ

Pinion bearing preload

: Refer to 

DLN-98, "Preload 

Torque"

.

JSDIA2500ZZ

DRIVE PINION

DLN-91

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

5. Measure the total preload with the preload gauge (A) [SST:

ST3127S000 (J-25765-A)].

CAUTION:

Each rotational part should rotate smoothly with the speci-

fied 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

1. Install the bolt to the companion flange.
2. Fit a dial indicator onto the bolt (A).
3. Measure the circumference backlash of the companion flange.

• If outside the standard, disassemble the transfer assembly to

check and adjust each part.

TOOTH CONTACT

1. Remove transfer cover. Refer to 

DLN-78, "Disassembly"

.

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

DLN-82, "Disassembly"

.

3. 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.

4. Assemble the ring gear shaft assembly to the transfer case.

Refer to 

DLN-83, "Assembly"

.

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

DLN-79, "Assembly"

.

NOTE:

At this timing, O-ring installing to transfer cover is not necessary.

Install O-ring after backlash and tooth contact are checked.

6. Remove the plug from the transfer case.
7. 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.

Total preload

: Refer to 

DLN-98, "Preload 

Torque"

.

JSDIA2500ZZ

Backlash

: Refer to 

DLN-98, "Backlash"

.

JSDIA2501ZZ

JSDIA2188ZZ

DLN-92

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

DRIVE PINION

Tooth Contact Judgment Guide

8. 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 pin-

ion closer to the ring gear in case of face contact or heel con-

tact.

CAUTION:

Only one adjusting shim can be selected.

JSDIA4035GB

JSDIA1221ZZ

PDIA0440E

DRIVE PINION

DLN-93

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

• Thin the drive pinion adjusting shim to move the drive pinion

farther from the ring gear in case of flank contact or toe con-

tact.

CAUTION:

Only one adjusting shim can be selected.

COMPANION FLANGE RUNOUT

1. Fit a dial indicator onto the companion flange face (inner side of

the propeller shaft mounting bolt holes).

2. Rotate the companion flange to check for runout.

3. Fit a test indicator to the inner side of the companion flange

(socket diameter).

4. Rotate the companion flange to check for runout.

5. Follow the procedure below to adjust if runout value is outside

the repair limit.

a. Check for runout while changing the phase between companion

flange and drive pinion in 90

° steps. Then search for the mini-

mum point.

b. Replace companion flange if runout value is still outside the limit

after the phase has been changed.

c. 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

INFOID:0000000009177787

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.

PDIA0441E

Companion flange runout : Refer to 

DLN-98, "Com-

panion Flange Runout"

.

Companion flange runout : Refer to 

DLN-98, "Com-

panion Flange Runout"

.

JSDIA3981ZZ