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Nissan Pathfinder (2009 year). Manual - part 242

DLN-418

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

Remove the side bearing caps.

Lift the differential case assembly out using Tool.

CAUTION:

• Keep side bearing outer races together with inner race.

Do not mix them up.

• Keep side bearing adjusting washers together with side

bearings.

S-PD343

Tool number

: HT72400000 (

—

)

S-PD344

SPD919

2009 Pathfinder

REAR FINAL DRIVE

DLN-419

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

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: ST33051001 (J-22888-20)

B: ST33061000 (J-8107-2)

SPD920

PDIA0496E

WDIA0132E

SDIA0031J

2009 Pathfinder

DLN-420

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

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-410, "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

2009 Pathfinder

REAR FINAL DRIVE

DLN-421

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

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-413, "Disassembly and Assembly"

Tool number

: ST30031000 (J-22912-01)

S-PD179

SDIA0817E

2009 Pathfinder

DLN-422

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR 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-432, "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:

0.2 mm (0.008 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

2009 Pathfinder

REAR FINAL DRIVE

DLN-423

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

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-413, "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-432, "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-

432, "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.

Drive Pinion Height

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

2009 Pathfinder

DLN-424

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

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

Assemble the drive pinion bearings onto the Tool.

• 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-34309-5 drive pinion
front bearing pilot to secure the drive pinion 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.

Tool number

—

(J-34309)

SPD769

SPD197A

SPD893

SPD199A

2009 Pathfinder

REAR FINAL DRIVE

DLN-425

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

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

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

Place the J-34309-11 “R200A” 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-413,

"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-34309-11 drive pinion height adapter, including
the standard gauge and the arbor.

SPD770

Tool number

: ST3127S000 (J-25765- A)

Turning torque:

1.0 - 1.3 N·m (0.11 - 0.13 kg-m,
9 - 11 in-lb)

PDIA0566E

SPD208A

Tool number

—

(J-25269-4)

SPD211A

SPD204A

2009 Pathfinder

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