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Nissan Pathfinder (2008 year). Manual - part 234

DLN-456

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230 (4WD)]

REAR FINAL DRIVE

Remove the side bearing inner races using Tools.

CAUTION:

• Engage Tool jaws in bearing groove to prevent damage.
• Place copper plates between the side bearing and drive

gear and the vise to prevent damage.

• Do not remove side bearing inner race unless it is being

replaced.

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.

10. Remove the drive gear bolts.

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

CAUTION:

Tap evenly all around to keep drive gear from bending.

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

side using suitable tool.

13. Remove the pinion mate shaft.

Tool number

A: ST3306S001 (

—

)

B: ST33061000 (J-8107-2)

SPD920

PDIA0496E

WDIA0132E

SDIA0031J

REAR FINAL DRIVE

DLN-457

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230 (4WD)]

DLN

14. 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.

Drive Pinion Assembly

Remove the differential assembly. Refer to

DLN-447, "Removal and Installation"

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 front oil seal.

CAUTION:

Do not damage gear carrier.

Remove the drive pinion front bearing inner race.

SDIA0032J

Tool number

: KV40104000 (

—

)

SDIA1144E

SDIA1132E

SPD892

DLN-458

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230 (4WD)]

REAR FINAL DRIVE

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

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-450, "Disassembly and Assembly"

Tool number:

: ST30021000 (

—

)

S-PD179

SDIA0817E

REAR FINAL DRIVE

DLN-459

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230 (4WD)]

DLN

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-466, "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.

Side Bearing Preload Torque

• A selection of side bearing adjusting washers is required for successful completion of this procedure.

Apply differential gear oil to the side bearings, and install the dif-
ferential case assembly with the side bearing outer races into
the gear carrier.

CAUTION:

Do not reuse side bearing outer race when replacing side
bearing inner race (replace as a set).

PDIA0460E

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

SPD527

DLN-460

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230 (4WD)]

REAR FINAL DRIVE

Insert the left and right original side bearing adjusting washers in
place between side bearings and gear carrier.

Align the matching mark on the side bearing cap with the match-
ing mark on the gear carrier.

Install the side bearing caps and tighten the side bearing cap
bolts to the specified torque. Refer to

DLN-450, "Disassembly

and Assembly"

Turn the differential assembly several times to seat the side
bearings.

To determine side bearing preload torque, measure the pulling
force of the differential assembly at the drive gear bolt using
Tool.

NOTE:
If pulling force of the differential assembly at the drive gear bolt
is within specification, side bearing preload torque will also be
within specification. Refer to

DLN-466, "Inspection and Adjustment"

If the pulling force is outside the specification, use a thicker or
thinner side bearing adjusting washer to adjust. Refer to

DLN-

466, "Inspection and Adjustment"

CAUTION:

Select a side bearing adjusting washer for right and left
individually.

Record the total amount of washer thickness required for the correct side bearing preload torque.

ASSEMBLY

Drive Pinion Assembly

SPD924

SDIA1795E

Tool number

—

(J-8129)

Specification

: 34.2 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb)
of pulling force at the drive gear bolt

SPD194A

If the pulling force is less than the specification:

Use a thicker side bearing adjusting washer.

If the pulling force is greater than the specification:

Use a thinner side bearing adjusting washer.

SPD772

REAR FINAL DRIVE

DLN-461

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230 (4WD)]

DLN

Install the drive pinion front and rear bearing outer races using
Tools.

CAUTION:

Do not reuse drive pinion front and rear bearing outer race.

Select a drive pinion height adjusting washer. Refer to

DLN-466, "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.

Assemble 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: ST15310000 (

—

)

B: ST35325000 (

—

)

C: ST30621000 (

—

)

SPD992

Tool number

: ST30022000 (

—

)

SPD377

PDIA0492E

DLN-462

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230 (4WD)]

REAR FINAL DRIVE

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

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

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.

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-450, "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-466, "Inspection and Adjustment"

12. Install the differential case assembly. Refer to

DLN-450, "Disassembly and Assembly"

Differential Assembly

SPD896

Tool number

: ST15310000 (

—

)

PDIA0563E

Tool number

A: KV40104000 (

—

)

B: ST3127S000 (J-25765-A)

Drive pinion bearing preload torque:

1.77 - 2.64 N·m (0.18 - 0.26 kg-m, 16 - 23 in-lb)

WDIA0379E

REAR FINAL DRIVE

DLN-463

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230 (4WD)]

DLN

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.

CAUTION:

Make sure that the circular clip is installed to side gears.

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.

Align the lock pin hole on the differential case with the lock pin
hole on the pinion mate shaft, and install the pinion mate shaft.

Measure the side gear end play. If necessary, select the appro-
priate side gear thrust washers. Refer to

DLN-466, "Inspection

and Adjustment"

Drive a new lock pin into the pinion mate shaft until it is flush
with the differential case using suitable tool.

CAUTION:

Do not reuse lock pin.

Align the matching mark of the differential case with the mark of
the drive gear, then place the drive gear onto the differential
case.

SDIA0193J

SDIA2025E

SDIA0195J

WDIA0131E

SDIA2593E

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