Content .. 219 220 221 222 ..

Nissan Pathfinder (2008 year). Manual - part 221

DLN-352

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

Drive Pinion Assembly

Remove the differential assembly. Refer to

DLN-345, "Disassembly and Assembly"

Remove the drive pinion lock nut using 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.

Remove the companion flange using suitable tool.

Press the drive pinion assembly (with rear inner bearing race
and collapsible spacer) out of the gear carrier.

CAUTION:

Do not drop drive pinion assembly.

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

Tool number

: KV38108300 (J-44195)

PDIA0702E

PDIA0703E

PDIA0704E

Tool number

: ST30031000 (J-22912-01)

S-PD179

FRONT FINAL DRIVE

DLN-353

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

DLN

Remove the front oil seal using suitable tool.

CAUTION:

Do not damage gear carrier.

Remove the drive pinion front bearing inner race.

Remove the drive pinion front and rear bearing outer races by
tapping them uniformly using suitable tool.

CAUTION:

Do not damage gear carrier.

INSPECTION AFTER DISASSEMBLY

Clean the disassembled parts. Then inspect the parts for wear or damage. If wear or damage are found, 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.

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 "

DLN-345, "Disassembly and Assembly"

PDIA0716E

PDIA0705E

DLN-354

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

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-364, "Inspection and Adjustment"

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 individu-

ally.

NOTE:
Side gear back clearance is clearance between side gear and differential case for adjusting side gear
backlash.

Drive Pinion Height

Make sure all parts are clean and that the bearings are well lubricated.

Assemble the drive pinion bearings onto the Tool.

PDIA0460E

Side gear back clearance:

0.1 mm (0.004 in) or less.

If the side gear back clearance is greater than
specification:

Use a thicker side gear thrust washer.

If the side gear back clearance is less than spec-
ification:

Use a thinner side gear thrust washer.

PDIA0576E

Tool number

—

(J-34309)

SPD769

FRONT FINAL DRIVE

DLN-355

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

DLN

• Drive pinion front bearing; make sure the J-34309-3 drive

pinion front bearing seat is secured tightly against the J-
34309-2 gauge anvil. Then turn the J-34309-7 drive pinion
front bearing pilot to secure the drive pinon front bearing in its
proper position.

• Drive pinion rear bearing; the J-34309-8 drive pinion rear

bearing pilot is used to center the drive pinion rear bearing
only. The J-34309-4 drive pinion rear bearing locking seat is
used to lock the drive pinion rear bearing to the assembly.

• Installation of J-34309-9 and J-34309-16; place a suitable

2.5 mm (0.098 in) thick plain washer between J-34309-9 and
J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must
be parallel with a clearance of 2.5 mm (0.098 in).

Install the drive pinion rear bearing inner race into the gear car-
rier. Then insert the drive pinion height adjusting washer selec-
tor tool, J-34309-1, gauge screw assembly.

Assemble the drive pinion front bearing inner race and the J-
34309-2 gauge anvil. Assemble them together with the J-34309-
1 gauge screw in the gear carrier. Make sure that the drive pin-
ion height gauge plate, J-34309-16, will turn a full 360

. Tighten

the two sections together by hand.

Turn the assembly several times to seat the drive pinon bear-
ings.

SPD197A

SPD893

SPD199A

SPD770

DLN-356

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

Measure the turning torque at the end of the J-34309-2 gauge
anvil using Tool.

Place the J-34309-10 “R180A” drive pinion height adapter onto
the gauge plate and tighten it by hand.

CAUTION:

Make sure all machined surfaces are clean.

Position the side bearing discs, Tool, and arbor firmly into the
side bearing bores. Install the side bearing caps and tighten the
side bearing cap bolts to the specified torque. Refer to

DLN-345,

"Disassembly and Assembly"

Select the correct standard drive pinion height adjusting washer
thickness. Select by using a standard gauge of 3 mm (0.12 in)
and your J-34309-101 feeler gauge. Measure the distance
between the J-34309-10 drive pinion height adapter, including
the standard gauge and the arbor.

10. Write down the exact measurement (the value of feeler gauge).

Tool number

: ST3127S000 (J-25765- A)

Turning torque specification:

1.0 - 1.6 N·m (0.11 - 0.16 kg-m, 9 - 14 in-lb)

PDIA0566E

SPD208A

Tool number

—

(J-25269-18)

SPD211A

SPD204A

SPD775

FRONT FINAL DRIVE

DLN-357

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

DLN

11. Correct the drive pinion height adjusting washer size by referring

to the drive pinion “head number”.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and drive gear as a matched
set. This number should be the same as the number on the
drive gear. The second number is the drive pinion “head
number”. It refers to the ideal drive pinion height from stan-
dard for quietest operation. Use the following chart to
determine the correct drive pinion height adjusting washer.

12. Select the correct drive pinion height adjusting washer. Refer to

DLN-364, "Inspection and Adjustment"

13. Remove the Tool from the gear carrier and disassemble to

retrieve the drive pinion bearings.

ASSEMBLY

Drive Pinion Assembly

Head number

Add or remove from the standard drive pinion

height adjusting washer thickness measurement

- 6
- 5
- 4
- 3
- 2
- 1

+1
+2
+3
+4
+5
+6

Add 0.06 mm (0.0024 in)
Add 0.05 mm (0.0020 in)
Add 0.04 mm (0.0016 in)
Add 0.03 mm (0.0012 in)
Add 0.02 mm (0.0008 in)
Add 0.01 mm (0.0004 in)

Use the selected washer thickness

Subtract 0.01 mm (0.0004 in)
Subtract 0.02 mm (0.0008 in)
Subtract 0.03 mm (0.0012 in)
Subtract 0.04 mm (0.0016 in)
Subtract 0.05 mm (0.0020 in)
Subtract 0.06 mm (0.0024 in)

Tool number

—

(J-34309)

SPD542

SPD205A

DLN-358

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

Install drive pinion rear bearing outer race and drive pinion front
bearing outer race using Tools.

CAUTION:

• First tap the drive pinion bearing outer race until it

becomes flush with the gear carrier.

• Do not reuse drive pinion front and rear bearing outer

race.

Select drive pinion height adjusting washer. Refer to

DLN-364, "Inspection and Adjustment"

Install the selected drive pinion height adjusting washer to the
drive pinion. Press the drive pinion rear bearing inner race to it
using Tool.

CAUTION:

• Install the drive pinion height adjusting washer in the

proper direction as shown.

• Do not reuse drive pinion rear bearing inner race.

Install the collapsible spacer to the drive pinion.

CAUTION:

Do not reuse collapsible spacer.

Apply differential gear oil to the drive pinion rear bearing, and
install the drive pinion assembly to the gear carrier.

Apply differential gear oil to the drive pinion front bearing, and
install the drive pinion front bearing inner race to the drive pinion
assembly.

CAUTION:

Do not reuse drive pinion front bearing inner race.

Tool number

A: ST30611000 (J-25742-1)

B: ST30613000 (J-25742-3)

C: KV38100200 (J-26233)

PDIA0707E

Tool number

: ST30901000 (J-26010-01)

SDIA0048E

PDIA0708E

FRONT FINAL DRIVE

DLN-359

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

DLN

Press the drive pinion front bearing inner race to the drive pinion
as far as drive pinion lock nut can be tightened using Tool.

Apply multi-purpose grease to the lips and differential gear oil to
the circumference of the new front oil seal. Then drive the new
front oil seal in evenly until it becomes flush with the gear carrier
using Tools.

CAUTION:

• Do not reuse front oil seal.
• Do not incline the new front oil seal when installing.
• Apply multi-purpose grease to the lips and differential

gear oil to the circumference of the new front oil seal.

Install the companion flange to the drive pinion while aligning the matching marks.

10. Apply anti-corrosive oil to the threads of the drive pinion and the

seating surface of the new drive pinion lock nut. Then adjust the
drive pinion lock nut tightening torque using Tool A, and check
the drive pinion bearing preload torque using Tool B.

CAUTION:

• Do not reuse drive pinion lock nut.
• Apply anti-corrosive oil to the threads of the drive pinion

and the seating surface of the new drive pinion lock nut.

• Adjust the drive pinion lock nut tightening torque to the

lower limit first. Do not exceed the drive pinion lock nut
specified torque. Refer to

DLN-345, "Disassembly and

Assembly"

• If the drive pinion bearing preload torque exceeds the

specified value, replace collapsible spacer and tighten it
again to adjust. Do not loosen drive pinion lock nut to
adjust the drive pinion bearing preload torque.

• After adjustment, rotate drive pinion back and forth 2 to 3

times to check for unusual noise, rotation malfunction, and other malfunctions.

11. Check companion flange runout. Refer to

DLN-364, "Inspection and Adjustment"

12. Install the differential case assembly. Refer to

DLN-345, "Disassembly and Assembly"

Differential Assembly

Tool number

: ST33200000 (J-26082)

PDIA0709E

Tool number

A: ST30720000 (J-25405)

B: ST27863000 (

—

)

PDIA0717E

Tool number

A: KV38108300 (J-44195)

B: ST3127S000 (J-25765-A)

Drive pinion bearing preload torque:

1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)

WDIA0382E

Content .. 219 220 221 222 ..