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Nissan Pathfinder (2008 year). Manual - part 225

DLN-384

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: M205]

FRONT FINAL DRIVE

• Keep side bearing outer races together with side bearing

inner races. Do not mix them up.

12. For proper reinstallation, paint matching marks on the differential

case and drive gear.

CAUTION:

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

13. Remove the drive gear bolts.

14. Tap the drive gear off the differential case using suitable tool.

CAUTION:

Tap evenly all around to keep drive gear from bending.

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

side using suitable tool.

16. Remove the pinion mate shaft.

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

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

SPD022

PDIA0496E

SPD025

SDIA0031J

SDIA0032J

FRONT FINAL DRIVE

DLN-385

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: M205]

DLN

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

SDIA2234E

Tool number

: ST30021000 (

—

)

S-PD179

DLN-386

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: M205]

FRONT FINAL DRIVE

Place a small hole in the front oil seal case using suitable tool.

Remove the front oil seal using Tool as shown.

Remove the drive pinion front bearing inner race.

10. Remove the drive pinion front bearing outer race using Tool as

shown. Locate the driver on the back edge of the drive pinion
front bearing outer race, then drive the drive pinion front bearing
outer race out.

CAUTION:

Do not damage gear carrier.

11. Remove the drive pinion rear bearing outer race using Tool as

shown. Locate the driver on the back edge of the drive pinion
rear bearing outer race, then drive the drive pinion rear bearing
outer race out.

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.

LDIA0129E

Tool number

: SP8P

LDIA0130E

Tool number

A: C-4171

B: D-103

LDIA0131E

Tool number

A: C-4171

B: C-4307

LDIA0132E

FRONT FINAL DRIVE

DLN-387

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: M205]

DLN

• 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"

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

PDIA0460E

DLN-388

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: M205]

FRONT FINAL DRIVE

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-395, "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

• Drive gear and drive pinion are supplied in matched sets only.

Matching numbers on both drive pinion and drive gear are etched
for verification. If a new gear set is being used, verify the numbers
of each drive pinion and drive gear before proceeding with assem-
bly.

• The mounting distance from the centerline of the drive gear to the back face of the drive pinion for the M205

final drive assembly is 103.5 mm (4.0748 inches).
On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0),
which indicates the best running position for each particular gear set. This dimension is controlled by a
selective drive pinion height adjusting washer between the drive pinion rear bearing inner race and drive pin-
ion.
For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 inch) less drive pinion
height adjusting washer than a drive pinion etched “0”. This means decreasing drive pinion height adjusting
washer thickness; increases the mounting distance of the drive pinion to 103.6 mm (4.0778 inches). If a
drive pinion is etched m-8 (-3), it would require adding 0.08mm (0.003 inch) more to the drive pinion height
adjusting washer than would be required if the drive pinion were etched “0”. By adding 0.08 mm (0.003 inch),
the mounting distance of the drive pinion was decreased to 103.4 mm (4.0718 inches) which is just what a
m-8 (-3) etching indicated.

• To change the drive pinion height, use different drive pinion height adjusting washers which come in different

thickness.

• Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to

add or subtract from the old drive pinion height adjusting washer.

Side gear back clearance:

0.20 mm (0.0079 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

SDIA2241E

FRONT FINAL DRIVE

DLN-389

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: M205]

DLN

ASSEMBLY

Drive Pinion Assembly

Install drive pinion rear bearing outer race using Tools.

Install drive pinion front bearing outer race using Tools.

Select drive pinion height adjusting washer. Refer to

DLN-364, "Inspection and Adjustment"

OLD DRIVE

PINION

MARKING

NEW DRIVE PINION MARKING mm (in)

-10 (-4)

-8 (-3)

-5 (-2)

-3 (-1)

0 (0)

+3 (+1)

+5 (+2)

+8 (+3)

+10 (+4)

+0.20

(+0.008)

+0.18

(+0.007)

+0.15

(+0.006)

+0.13

(+0.005)

+0.10

(+0.004)

+0.08

(+0.003)

+0.05

(+0.002)

+0.02

(+0.001)

(0)

+8 (+3)

+0.18

(+0.007)

+0.15

(+0.006)

+0.13

(+0.005)

+0.10

(+0.004)

+0.08

(+0.003)

+0.05

(+0.002)

+0.02

(+0.001)

(0)

-0.02

(-0.001)

+5 (+2)

+0.15

(+0.006)

+0.13

(+0.005)

+0.10

(+0.004)

+0.08

(+0.003)

+0.05

(+0.002)

+0.02

(+0.001)

(0)

-0.02

(-0.001)

-0.05

(-0.002)

+3 (+1)

+0.13

(+0.005)

+0.10

(+0.004)

+0.08

(+0.003)

+0.05

(+0.002)

+0.02

(+0.001)

(0)

-0.02

(-0.001)

-0.05

(-0.002)

-0.08

(-0.003)

0 (0)

+0.10

(+0.004)

+0.08

(+0.003)

+0.05

(+0.002)

+0.02

(+0.001)

(0)

-0.02

(-0.001)

-0.05

(-0.002)

-0.08

(-0.003)

-0.10

(-0.004)

-3 (-1)

+0.08

(+0.003)

+0.05

(+0.002)

+0.02

(+0.001)

(0)

-0.02

(-0.001)

-0.05

(-0.002)

-0.08

(-0.003)

-0.10

(-0.004)

-0.13

(-0.005)

-5 (-2)

+0.05

(+0.002)

+0.02

(+0.001)

(0)

-0.02

(-0.001)

-0.05

(-0.002)

-0.08

(-0.003)

-0.10

(-0.004)

-0.13

(-0.005)

-0.15

(-0.006)

-8 (-3)

+0.02

(+0.001)

(0)

-0.02

(-0.001)

-0.05

(-0.002)

-0.08

(-0.003)

-0.10

(-0.004)

-0.13

(-0.005)

-0.15

(-0.006)

-0.18

(-0.007)

-10 (-4)

(0)

-0.02

(-0.001)

-0.05

(-0.002)

-0.08

(-0.003)

-0.10

(-0.004)

-0.13

(-0.005)

-0.15

(-0.006)

-0.18

(-0.007)

-0.20

(-0.008)

Tool number

A: ST30901000

B: KV40105230

SDIA2251E

Tool number

A: ST35271000

B: KV40104810

SDIA2252E

DLN-390

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: M205]

FRONT FINAL DRIVE

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:

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.

Apply multi-purpose grease to the lips of the new front oil seal.
Then drive the new front oil seal in evenly 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 of the new front oil

seal.

Install the companion flange to the drive pinion while aligning the
matching marks. Tap the companion flange until fully seated
using suitable tool.

Tool number

: C-4040

SDIA2253E

PDIA0708E

Tool number

A: KV38100500 (J-25273)

B: KV38102200 (

—

)

PDIA0717E

SDIA2266E

FRONT FINAL DRIVE

DLN-391

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: M205]

DLN

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

Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly, or reinstall the old ones on
the side gears.

Install the side gears and side gear thrust washers into the dif-
ferential case.

Install the pinion mate thrust washers to the two pinion mate
gears. Then install the pinion mate gears with the pinion mate
thrust washers by aligning them in diagonally opposite positions
and rotating them into the differential case.

Tool number

A: KV38108300 (J-44195)

B: ST3127S000 (J-25765-A)

Drive pinion bearing preload torque:

2.3 - 3.4 N·m (24 - 34 kg-cm, 21 - 30 in-lb)

WDIA0382E

SDIA0193J

SDIA2025E

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