INFINITI FX35 2004 Service Manual

FFD-26
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
11. If clearance exceed limit, adjust the clearance by selecting adjusting shim.

If clearance too large, increase thrust washer thickness.

If clearance too small, decrease thrust washer thickness.
12. Drive the lock pin into the pinion mate shaft using punch.
CAUTION:
Do not reuse the lock pin. Always replace the with a new
one.
13. Apply genuine medium strength locking agent or equivalent to
the drive gear bolt hole thread.
14. Assemble the drive gear and differential case.
15. Apply oil to the mounting bolt seating surface., tighten the bolt in
crisscross pattern to specified torque. Refer to FFD-16, "
COM-
PONENTS (VK45DE)" or FFD-14, "COMPONENTS (VQ35DE)"
.
16. Press-fit side bearing inner race on differential case with tool.Tool number : KV31100300 ( – )
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Tool number A: ST33230000 ( – )
B: ST35321000 ( – )
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FRONT FINAL DRIVE ASSEMBLY
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Installation Drive Pinion AssemblyADS000NP
1. Press-fit the drive pinion bearing outer race into the carrier case
with tool.
CAUTION:
First lightly tap outer race using a hammer, place the carrier
case and outer race parallel. Then press-fit outer race with
press.
2. Temporarily install the removed drive pinion height adjusting
washer or same thickness washer to drive pinion.
3. If the hypoid gear set has been replaced, select the adjusting
washer.
Temporarily install washer to the drive pinion.
CAUTION:
Select the washer form the drive pinion height adjusting washer selecting table. Refer to FFD-38,
"AVAILABLE PINION HEIGHT ADJUSTING WASHERS" .
4. Press-fit the drive pinion bearing onto the drive pinion using drift
and press.
NOTE:
Note the direction of washer.
5. Install the drive pinion and drive pinion bearing as follows:
a. Apply gear oil to the bearing portion.
b. Install the drive pinion and drive pinion bearing (front side) into
the carrier case.Tool number : KV31103000 ( – )
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Washer selection equation:
T = T0 + (t1 - t2)
T = Correct washer thickness
T0 = Removed washer thickness
t1 = Old drive pinion head letter
(machined tolerance 1/100 mm x 100)
t2 = New drive pinion head letter
(machined tolerance 1/100 mm x 100)
Example:
In case the T0 = 3.21, t1 = +2, t2 = -1
T = 3.21 + ((2 x 0.01) - (-1 x 0.01)) = 3.24
Tool number : ST30032000 ( – )
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FFD-28
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:
Do not install the drive pinion adjusting washer and drive pinion bearing adjusting washer at this
time.
c. Install the companion flange without installing oil seal.
d. Apply oil drive pinion lock nut threads and seating surface, then temporarily install it.
e. Tighten the drive pinion lock nut until it reach standard preload.
CAUTION:
Tighten the drive pinion nut by very small degrees until the
specified preload in achieved. Do not tighten nut more than
necessary.
DIFFERENTIAL CASE INSTALLATION
1. Drive side bearing outer race into the carrier case with tool.
CAUTION:
Do not apply excessive force to the race.
2. Drive side bearing outer race into the side retainer with tool.
3. Apply oil to the bearing portion.
4. Install the deferential case assembly to the carrier case.
CAUTION:
Be careful not to damage the carrier cover mating surface.
5. Install the side bearing adjusting shim to the side retainer, tighten the bolt to specified torque.
CAUTION:
Install removed adjusting shim or same thickness shim.
NOTE:
Do not install O-ring.Tool number : KV40104000(−)
Pinion bearing preload without oil seal
: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
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Tool number : KV31103000 ( – )
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Tool number : KV31103000 ( – )
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
6. Turn the companion flange more than 20 times, measure the
preload using preload gauge.

If the preload value is out of standard, adjust preload by changing adjusting shim thickness (side
retainer side).Tool number : ST3127S000(see J25765-A)
Total preload standard (without oil seal)
: 1.56 - 2.65 N·m (0.16 - 0.27 kg-m, 14 - 23 in-lb)
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If preload too large, decrease side bearing adjusting shim thickness.
If preload too small, increase side bearing adjusting shim thickness.

FFD-30
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
TOOTH CONTACT INSPECTION
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive
pinion.
Hypoid gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check
gear tooth contact pattern to obtain the best contact for low noise and long life.
1. Thoroughly clean drive gear and drive pinion teeth.
2. Lightly apply a mixture of powdered ferric oxide and oil or the
equivalent. Apply it to 3 or 4 teeth on the drive side of drive
gear.
3. Hold companion flange steady by hand and rotate the drive gear
in both directions.
4. Check the tooth contact on both sides (drive side and coast
side).
NOTE:
Refer to FFD-31, "
TOOTH CONTACT PATTERN AND HEIGHT
ADJUSTING WASHER SELECTION" for detail of tooth contact
pattern.
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
TOOTH CONTACT PATTERN AND HEIGHT ADJUSTING WASHER SELECTION
TOOTH CONTACT ADJUSTMENT
1. If tooth contact is incorrect, adjust tooth contact by replacing
drive pinion height adjusting washer.
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FFD-32
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
2. If there is heel contact or face contact, increase point height
adjusting washer in order to bring drive pinion close to drive
gear.
3. If there is toe contact or flank contact, decrease pinion adjusting
washer in order to make drive pinion go away from drive gear.
4. Set dial indicator to the drive gear face and measure the bak-
clash.

If the measured value out of standard, adjust the backlash by
replacing the side bearing adjusting shim (carrier case side).
–If backlash too large, decrease side bearing adjusting shim
thickness.
–If backlash too small, increase side bearing adjusting shim
thickness.
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Standard drive gear back-
lash: 0.10 - 0.15 mm
(0.0039 - 0.0059 in)
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
TOTAL PRELOAD INSPECTION
1. Turn companion flange in both directions 20 times or more to set
bearing rollers, then check total preload with special service tool.

If the preload value is out of standard, adjust by changing side
bearing adjusting shim thickness (side retainer side).
–If preload value too large, increase the side bearing adjusting
shim thickness.
–If preload value too small, decrease the side bearing adjusting shim thickness.
DRIVE PINION PRELOAD ADJUSTMENT
Removal of differential case assembly
1. Unfasten the retainer tab using a flat blade screwdriver.
2. Remove the retainer by pulling it and tapping carrier case using a plastic hammer.
3. Remove the differential case assembly from the carrier case.
CAUTION:
Be careful not to damage the carrier cover mating surface.
Removal of drive pinon assembly
1. Hold the companion flange using cam sprocket wrench or flange
wrench, remove the drive pinion lock nut.
2. Remove the companion flange using puller.
3. Temporarily install drive pinion lock nut.
CAUTION:
Avoid damaging drive pinion threads, install the drive pinion lock nut unit it flash with drive pinion
end.
4. Remove the drive pinion from the carrier case using a copper hammer.
Preload Adjustment
1. Install drive pinion adjusting washer and drive pinion bearing adjusting washer onto the drive pinion, then
install drive pinion into the carrier case.
CAUTION:
Install the removed pinion height adjusting washer and drive pinion bearing adjusting washer or
same thickness washers to drive pinion.
2. Apply gear oil to the bearing portion.
3. Install drive pinion and drive pinion bearing into the carrier case.
4. Install the companion flange without installing oil seal.
5. Apply oil to drive pinion nut threads and seating surface, then temporarily install it.
6. Turn companion flange several times to seat the bearing.
7. Tighten the drive pinion nut while measuring preload using preload gauge.
8. Select drive pinion adjusting washer and drive pinion bearing adjusting washer so that standard preload is
obtain when the drive pinion nut is tightened to specified torque.Tool number : ST3127S000 (see J25765-A)
Total preload (without oil seal)
: 1.56 - 2.65 N·m
(0.16 - 0.27 kg-m, 14 - 23 in-lb)
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Tool number : KV40104000 (−)
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FFD-34
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:

Tighten the drive pinion nut by very small degrees until the specified preload in achieved. Do
not tighten nut more than necessary.

First select the thicker washer, then gradually select thinner one.

Do not apply preload more than necessary.
Reassembly of drive pinion assembly
1. The standard preload is obtain when the drive pinion nut is tightened to specified toque, remove the pin-
ion.
2. Remove the companion flange using puller.
3. Drive out the drive pinion from carrier case using copper hammer.
4. Apply gear oil to bearing portion.
5. Install the drive pinion with selected drive pinion adjusting washer and drive pinion bearing adjusting
washer into the carrier case, then install bearing.
6. Apply multi-purpose grease to oil seal lips.
7. Drive oil seal into the final drive using drift.
8. Install companion flange.
9. Apply oil to new drive pinion lock nut threads and seating sur-
face, then install it onto the drive pinion.
CAUTION:
Do not reuse drive pinion lock nut. Always replace nut with
new one.
10. Turn the companion flange more than 20 times to seat bearing.
11. Tighten the drive pinion lock nut to specified torque.
CAUTION:
Do not overtighten the nut.
12. Measure the preload using preload gauge.Drive pinion lock nut torque : 186.2 N·m (19 kg-m, 137 ft-lb)
Pinion bearing preload without oil seal : 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
When the washer thickness is increased : Preload will decrease.
When the washer thickness is decreased : Preload will increase.
Tool number A: ST33400001 (J26082)
B: KV38102510 ( – )
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Tool number : KV40104000 (−)
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Tool number : ST3127S000 (see J25765-A)
Pinion bearing preload without oil seal
: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
Installation of differential case assembly
1. Apply gear oil to side bearing, then install the differential case assembly into carrier case.
CAUTION:
Be careful not damage the carrier cases mating surface.
2. Apply multi-purpose grease to the oil seal lips.
3. Install oil seal into the side retainer using drift.
CAUTION:
After tightening the bolt, wipe off excess sealant from
inside of case.
4. Apply liquid sealant to side retainer mounting hole of carrier case.
5. Install selected side bearing adjusting shim and O-ring to the side retainer, then install it to carrier case.
CAUTION:
After installing adjusting shim onto side retainer, apply gear oil to O-ring and install it.
6. Tighten side retainer mounting bolt to specified torque. Refer to FFD-14, "
COMPONENTS (VQ35DE)" or
FFD-16, "
COMPONENTS (VK45DE)" .
After InspectionADS000NS
1. Turn drive pinion and drive gear several times.
Set dial indicator to the drive gear face and measure the back-
lash.

If the measured value out of standard, adjust the backlash by
replacing the side bearing adjusting shim (carrier case side.)
–If backlash too large, decrease side bearing adjusting shim
thickness.
–If backlash too small, increase side bearing adjusting shim
thickness.
2. Check the back face of drive gear runout.
3. Set dial gauge to back of drive gear and measure the drive gear runout.

If the runout is exceed limit, check for drive gear assembly:
–any object between the drive gear and differential case.
–deformed differential case.
–deformed drive gear

if drive gear is deformed, replace the hypoid gear as an
assembly. If the differential case is deformed, replace the dif-
ferential case.
4. Check the companion flange face and inside diameter runout.
a. Set the dial gauge to the companion flange face and measure
runout.
b. Set the dial gauge to the inside diameter of the companion flange and measure the runout.
Mark paint to maximum runout position.Tool number : ST33400001 (J26082)
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Standard drive gear backlash : 0.10 - 0.15 mm
(0.0039 - 0.0059 in)
Runout limit : 0.05 mm (0.0020 in) or less
Runout limit : 0.18 mm (0.0070 in) or less
Runout limit : 0.13 mm (0.0051 in) less
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