rack INFINITI FX35 2004 Service Manual

SERVICE DATA AND SPECIFICATIONS (SDS)
PS-47
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Revision: 2004 November 2004 FX35/FX45
Steering GearAGS000HB
Oil PumpAGS000HC
Steering FluidAGS000HD
Tie-rod length “L” 135.2 mm (5.32 in)
SGIA0167E
Steering gear modelPR26AM
Rack neutral position, dimension “L” (rack stroke) 67.0 mm (2.638 in)
Rack sliding forceAt the neutral point:
Range within ± 11.5 mm
(±0.453 in) from the neutral
position
(in power ON)Area average value 147 − 211 N (14.99 − 21.52 kg, 33.1 − 47.52 lb)
Allowable variation 98 N (10 kg, 22 lb) or less
Whole area (in power OFF)Peak value 294 N (30.0 kg, 66 lb) or less
Allowable variation 147 N (16 kg, 35 lb) or less
SGIA0629J
Oil pump relief hydraulic pressure
9,900 − 10,700 kPa (101 − 109 kg/cm2 , 1449 − 1564, psi)
Fluid capacity
Approx. 1.0 (1-1/8 US qt, 7/8 Imp qt)

WHEEL HUB
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Revision: 2004 November 2004 FX35/FX45
3. Using a drift (SST) and a puller (suitable tool), press wheel bear-
ing outer side inner race out to remove from wheel hub.
Bushing
Using a suitable drift, remove each bushing from axle.
INSPECTION AFTER DISASSEMBLY
Check for deformity, cracks and damage of each parts, replace if necessary.
Wheel Hub
Inspect wheel hub for deformation, cracks, and other damage. If any irregular conditions are found, replace
wheel hub.
Axle
Inspect axle for deformation, cracks, and other damage. If any irregular conditions are found, replace axle.
Back Plate
Inspect back plate for deformation, cracks, and other damage. If any irregular conditions are found, replace
back plate.
ASSEMBLY
Bushing
Using a suitable drift to install each bushing onto axle.
SDIA1483E
SDIA1484E
SDIA1485E

REAR DRIVE SHAFT
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Revision: 2004 November 2004 FX35/FX45
REAR DRIVE SHAFTPFP:39600
Removal and InstallationADS000C7
REMOVAL
1. Remove tire with power tool.
2. Remove cotter pin. Then remove lock nut from drive shaft.
3. Remove fixing nuts and bolts between side flange and drive shaft with power tool.
4. Separate drive shaft from wheel hub and bearing assembly by lightly tapping the end with a suitable ham-
mer and wood block. If it is hard to separate, use a suitable puller.
5. Remove drive shaft from axle.
CAUTION:
When removing drive shaft, do not apply an excessive angle to drive shaft joint. Also be careful
not to excessively extend slide joint.
INSPECTION AFTER REMOVAL

Move joint up/down, left/right, and in the axial direction. Check
for any rough movement or significant looseness.

Check boot for cracks or other damage, and also for grease
leakage.

If a trouble is found, disassemble drive shaft, and then replace
with new one.
INSTALLATION
Refer to RAX-9, "Removal and Installation" for tightening torque. Install in the reverse order of removal.
NOTE:
Refer to component parts location and do not reuse non-reusable parts.
1. Side flange 2. Cotter pin
SDIA1487E
RAA0030D

REAR DRIVE SHAFT
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Revision: 2004 November 2004 FX35/FX45
Wheel Side
1. Place shaft in a vice.
CAUTION:
When retaining drive shaft in a vise, always use copper or aluminum plates between vise and
shaft.
2. Remove boot bands. Then remove boot from joint sub-assembly.
3. Screw a drive shaft puller 30 mm (1.18 in) or more into threaded
part of joint sub-assembly. Pull joint sub-assembly out of shaft.
CAUTION:

If joint sub-assembly cannot be removed after five or
more unsuccessful attempts, replace shaft and joint sub-
assembly as a set.

Align sliding hammer and drive shaft and remove them
by pulling directly.
4. Remove boot from shaft.
5. Remove circular clip from shaft.
6. While rotating ball cage, remove old grease on joint sub-assem-
bly with paper towels.
INSPECTION AFTER DISASSEMBLY
Shaft
Replace shaft if there is any runout, cracking, or other damage.
Joint sub-assembly

Make sure there is no rough rotation or unusual axial looseness.

Make sure there is no foreign material inside joint.

Check joint sub-assembly for compression scars, cracks, or fractures.
CAUTION:
If there are any irregular conditions of joint sub-assembly components, replace the entire joint
sub-assembly.
Sliding Joint Side (Housing)

Make sure there are no compression scars, cracks, fractures or unusual wear of ball rolling surface.

Make sure there is no damage to shaft screws.

Make sure there is no deformation of boot installation parts.
Ball Cage
Make sure there are no compression scars, cracks, fractures of sliding surface.
Steel Ball
Make sure there are no compression scars, cracks, fractures or unusual wear.
Inner Race

Check ball sliding surface for compression scars, cracks, or fractures.

Make sure there is no damage to serrated part.
CAUTION:
If there are any irregular conditions in the component, replace with a new set of housing, ball
cage, steel ball and inner race.
SDIA0606E

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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Revision: 2004 November 2004 FX35/FX45
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. Trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sunvisor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. Rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.

SUNROOF
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Revision: 2004 November 2004 FX35/FX45
SUNROOF UNIT ASSEMBLY
Removal
CAUTION:

Always work with a helper.

When taking sunroof unit out, use clothes to protect the seats and trim from damage.

After installing the sunroof unit and glass lid, be sure to perform the leakage test and make sure
there is no malfunction.
1. Tilt up glass lid.
2. Remove the headlining. Refer to EI-42, "
Removal and Installation" .
3. Disconnect drain hoses.
4. Remove glass lid. Refer to RF-28, "
GLASS LID" .
5. Remove motor mounting screws. Remove sunroof motor
assembly and disconnect harness connector.
CAUTION:

Before removing sunroof motor assembly, make sure
that sunroof is fully closed.

After removing sunroof motor assembly, do not attempt
to rotate sunroof motor as a single unit.
6. Remove nuts on the front end and side rail.
7. Remove curtain air bag bracket bolts, then remove curtain air
bag bracket from the rail side. Refer to SRS-43, "
Removal and
Installation" .
8. Remove front/rear sunroof bracket bolts, then remove sunroof
unit assembly from roof panel.
9. Remove sunroof unit assembly through the passenger room while being careful not to damage the seats
and trim.
1. Glass lid 2. TORX bolt (T25) 3. Washer
4. Rear sunroof bracket 5. Front sunroof bracket 6. Wind deflector
7. Sunroof unit assembly 8. Noise cover 9. Sunroof motor assembly
10. Screw 11. Sunshade 12. Nut
13. Bolt 14. Drain plate 15. Sunshade stopper
16. Drain hose
PIIA6189E
PIIA6191E
PIIA6193E

RF-28
SUNROOF
Revision: 2004 November 2004 FX35/FX45
Installation
1. Temporarily tighten the mounting bolts on the front/rear sunroof
brackets (RH/LH).
2. Bring sunroof unit assembly into passenger room and place the
rear end of the rail onto the sunroof brackets.
3. Tighten the mounting nuts on the front end.
4. Tighten the installation points diagonally excluding the installation point of the sunroof bracket around the
roof opening.
5. Tighten the bolts on the sunroof bracket to the vehicle side and
then tighten the bolt to the rail side.
6. Tighten the bolts on the curtain air bag bracket to the rail side.
Refer to SRS-43, "
Removal and Installation" .
GLASS LID
Removal
1. Tilt up glass lid.
2. Remove TORX bolts (T25) from remove glass lid.
Installation
1. Tighten bolts diagonally on the glass lid.
2. After installation, carry out fitting adjustment.
PIIA6193E
PIIA6191E
PIIA6193E
PIIA6192E

RFD-18
REAR FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
4. Drive out pinion mate shaft lock pin with punch from drive gear
side.
5. Remove the pinion mate shaft.
6. 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.
7. Check mating surfaces of differential case, side gears, pinion
mate gears, pinion mate shaft and thrust washers.
INSPECTION

Clean up the disassembled parts. Then, inspect if the parts are wear or damaged. If so, follow the mea-
sures below.
SPD025
SDIA0031J
SDIA0032J
SDIA0187J
Content Measures
Drive gear and drive pinion

If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or
replace as necessary.

if the gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with a
new gears.
Bearing

If found any chipped (by friction), pitted, worn, rusted, scratched mark, or unusual noise from the
bearing, replace with a new bearing assembly (as a new set).

REAR FINAL DRIVE ASSEMBLY
RFD-19
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Revision: 2004 November 2004 FX35/FX45
ADJUSTMENT OF DIFFERENTIAL CASE
Thrust Washer Selection
1. Apply gear oil to contact surfaces of each gear, thrust washers
and differential case.
2. Install the removed thrust washer or same thickness washer to
side gear.
3. Install the side gears, thrust washers, pinion mate gears, thrust
washers into differential case.
CAUTION:
Install the circlip equipped side gear to the side retainer
side.
4. Fit pinion mate shaft to differential case so that it meets lock pin
holes.
Side gear thrust washer and
pinion mate thrust washer
Replace with a new one if found any cracks or damage on the surface of the tooth.

Replace with a new one if found any worn or chipped mark on the contact sides of the thrust
washer.
Side gear and pinion mate
thrust washer

Replace with a new one if found that it is chipped (by friction), damaged, or unusual worn.
Oil seal

Oil seals must be replaced with a new one whenever disassembled.
Differential case

Replace with a new one if found any wear or cracks on the contact sides of the differential case.
Companion flange

Replace with a new one if found any chipped marks (about 0.10mm, 0.0039in) or other damage
on the contact sides of the lips of the companion flange. Content Measures
SDIA0193J
SPD552
SDIA0195J

REAR SUSPENSION ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
REAR SUSPENSION ASSEMBLYPFP:55020
On-Vehicle Inspection and ServiceAES000MJ
Make sure the mounting conditions (looseness, back lash) of each component and component status (wear,
damage) are normal.
INSPECTION OF SUSPENSION ARM BALL JOINT END PLAY
Measure axial end play by installing and moving up/down between suspension arm and axle with an iron pry
bar or something similar.
CAUTION:
Be careful not to damage ball joint boot.
SHOCK ABSORBER INSPECTION
Check shock absorber for oil leakage, damage and replace if necessary.
Wheel Alignment InspectionAES000MK
DESCRIPTION
Measure wheel alignment under unladen conditions. “Unladen conditions” mean that fuel, engine coolant, and
lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.
PRELIMINARY CHECK
1. Check tires for improper air pressure and wear.
2. Check road wheels for runout.
3. Check wheel bearing axial end play.
4. Check suspension arm ball joint axial end play.
5. Check shock absorber operation.
6. Check each mounting part of axle and suspension for looseness and deformation.
7. Check each link, arm and member for cracks, deformation, and other damage.
8. Check vehicle posture.
CAMBER INSPECTION
Measure camber of both right and left wheels with a suitable align-
ment gauge and adjust in accordance with the following procedures.
If outside the standard value, adjust with adjusting bolt in front lower
link.
NOTE:
After adjusting camber, be sure to check toe-in.Axial end play : 0 mm (0 in)
Camber : Refer to RSU-18, "
Wheel Alignment" .
SRA096A
SEIA0318E