lan s INFINITI FX35 2004 Service Manual

PREPARATION
FFD-5
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Revision: 2004 November 2004 FX35/FX45
Commercial Service ToolsADS000N5
ST35321000 ( – )
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
DriftInstalling side bearing
KV40104000 ( – )
a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia.
Drive pinion flange wrenchRemoving and installing drive pinion lock
nut
ST3127S000 (see J25765-A)
1. GG91030000
Torque wrench (J25765)
2. HT62940000 ( – )
Socket adapter (1/2″)
3. HT62900000 ( – )
Socket adapter (3/8″)
Preload gaugeInspecting pinion bearing preload and total
preload Tool number (Kent-Moore No.)
Tool nameDescription
ZZA1000D
NT659
NT124
Tool nameDescription
Power toolLoosening bolts and nuts
PBIC0190E

FFD-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: 2004 November 2004 FX35/FX45
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartADS000N6
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
Refer to FFD-24, "
INSPECTION
" .
Refer to FFD-30, "
TOOTH CONTACT INSPECTION
" .
Refer to FFD-24, "
INSPECTION
" .
Refer to RFD-13, "
Pre-Inspection
"
—
Refer to MA-31, "
Checking Differential Gear Oil
" .
NVH in PR section.
NVH in FAX, RAX, FSU and RSU sections.
NVH in WT section.
NVH in WT section.
NVH in FAX section.
NVH in BR section.
NVH in PS section.
Possible cause and suspected parts
Rough gear tooth
Improper gear contact
Tooth surfaces worn
Incorrect backlash
Companion flange excessive runout
Improper gear oil
Propeller shaft
Axle and suspension
Tire s
Road wheel
Drive shaft
Brakes
Steering
Symptom Differential Noise×××××××××××××

FRONT OIL SEAL
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Revision: 2004 November 2004 FX35/FX45
FRONT OIL SEALPFP:38189
Removal and InstallationADS000N7
REMOVAL
1. Remove the front propeller shaft. Refer to PR-4, "REMOVAL" .
2. Put a matching mark on the end of the drive pinion correspond-
ing to the B position matching mark on the final drive companion
flange.
CAUTION:

For matching mark, use paint. Never damage drive pin-
ion.

The matching mark B on the final drive companion flange
indicates the maximum vertical runout position.
3. Using the drive pinion flange wrench.Remove drive pinion lock
nut with tool.
4. Remove the companion flange using puller (commercial service
tool)
5. Remove the front oil seal using outer race puller.
SDIA1609E
Tool number : KV40104000 ( – )
SDIA1647E
SDIA1642E
Tool number : ST33290001 (J34286)
SDIA1643E

FFD-8
FRONT OIL SEAL
Revision: 2004 November 2004 FX35/FX45
INSTALLATION
1. Apply multi-purpose grease to sealing lips of the oil seal. Drive
the oil seal into the differential case using special service tool so
that the oil seal flush with the gear carrier end.
NOTE:

When installing the front oil seal, be careful not to get it
inclined.

Discard the old front oil seal. Always replace it with a new
one.
2. Install the companion flange while align the matching mark of
the drive pinion with the matching mark B of the companion
flange.
3. Apply oil to the drive pinion threads and the seating surface of
drive pinion lock nut.
4. Using the drive pinion flange wrench. Install drive pinion lock nut
with tool.
CAUTION:
Do not reuse the drive pinion lock nut. Always replace it
with a new one.
5. Install the front propeller shaft. Refer to PR-5, "
INSTALLATION"
.Tool number A : ST33400001 (J26082)
B : KV38102510 ( – )
SDIA1645E
SDIA1609E
Tool number : KV40104000 ( – )
SDIA1647E

FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
1. Washer 2. Carrier cover 3. Gear oil defence
4. Breather joint 5. Dowel pin 6. Drive pinion height adjusting washer
7. Drive pinion 8. Drive gear 9. Side bearing adjusting washer
10. Differential case 11. Side bearing 12. O-ring
13. Front oil seal 14. Side retainer 15. Side bearing adjusting shim
16. Air breather hose 17. Bushing 18. Breather tube
19. Companion flange 20. Drive pinion bearing 21. Drive pinion bearing adjusting
washer
22. Drive pinion adjusting washer 23. Extension tube retainer 24. Dust sealed
25. Side shaft 26. Extension tube 27. Carrier case
28. Side gear thrust washer 29. Lock pin 30. Pinion mate gear
31. Pinion mate thrust washer 32. Pinion mate shaft 33. Circlip
34. Side gear 35. Filler plug 36. Drain plug
37. Drive pinion lock nut 38. Side oil seal 39. Side shaft oil seal
40. Bearing

FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
7. Drive pinion 8. Drive gear 9. Side bearing adjusting washer
10. Differential case 11. Side bearing 12. O-ring
13. Front oil seal 14. Side retainer 15. Side bearing adjusting shim
16. Air breather hose 17. Bushing 18. Breather tube
19. Companion flange 20. Drive pinion bearing 21. Drive pinion bearing adjusting
washer
22. Drive pinion adjusting washer 23. Extension tube retainer 24. Dust sealed
25. Side shaft 26. Extension tube 27. Carrier case
28. Side gear thrust washer 29. Lock pin 30. Pinion mate gear
31. Pinion mete thrust washer 32. Pinion mate shaft 33. Circlip
34. Side gear 35. Filler plug 36. Drain plug
37. Drive pinion lock nut 38. Side oil seal 39. Side shaft oil seal
40. Bearing

FFD-20
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
4. Turn the companion flange in both direction 20 times or more to
seat the bearing rollers.
5. Check total preload with special service tool.

If the preload value is out of standard, adjust pinion bearing
preload and side bearing preload.
Drive Gear to Drive Pinion Gear Backlash
Set the dial indicator to the drive gear face and measure the back-
lash.
If the measured value is out of standard, adjust the backlash by
replacing the side bearing adjusting shim (differential case side).

If the backlash too large, decrease side bearing adjusting shim
thickness.

If the backlash too small, increase side bearing adjusting shim
thickness.
Drive Gear Runout
1. Set dial gauge to behind the drive gear and measure the ring gear runout.
a. 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
b. If drive gear is deformed, replace the drive gear and pinion gear as a set. If the differential case is
deformed, replace the differential case.
Companion Flange Runout
1. Set the dial gauge to the companion flange face and measure
runout.
2. Set the dial gauge to the inside face of the companion flange
and measure the runout.
CAUTION:
Clean inside face of companion flange before measuring
runout.
a. If runout is out side limit, remove the companion from the drive
pinion. Turn the companion flange position 90° each, and measure the runout again.
b. If runout valve still out side of the limit, replace companion flange.Tool number : ST3127S000 (see J25765-A)
Total preload : 1.56 - 2.65 N·m
(0.16 - 0.27 kg-m, 14 - 23 in-lb)
SDIA1649E
If the preload value too large : Decrease the drive pinion bearing adjusting washer thickness.
: Decrease the drive pinion adjusting washer thickness.
: Increase the side bearing adjusting shim thickness.
If the preload value too small : Increase the drive pinion bearing adjusting washer thickness.
: Increase the drive pinion adjusting washer thickness.
: Decrease the side bearing adjusting shim thickness.
Standard drive gear backlash
: 0.10 - 0.15 mm(0.0039 - 0.0059) in
SDIA0009J
Runout limit : 0.05 mm (0.0020 in) or less
Runout limit : 0.18 mm (0.007 in) or less
Runout limit : 0.13 mm (0.005 in) or less
SDIA1651E

FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
c. If runout valve still out side of limit after replacing companion flange, check pinion bearing and drive pinion
assembly, and pinion bearing damage.
Tooth Contact
Check tooth contact. Refer to FFD-30, "TOOTH CONTACT INSPECTION" .
DISASSEMBLY AND ASSEMBLY
REMOVAL OF DRIVE GEAR AND DIFFERENTIAL CASE ASSEMBLY
1. Remove the side retainer mounting bolt.
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.
4. Remove the side bearing outer race using puller.
5. Keep the side bearing outer races together with inner race. Do
not mix them up. Also, keep adjusting washers together with
bearings.
6. Drive out the side oil seals from the carrier case.
SDIA1656E
SDIA0181J

FFD-22
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
REMOVAL OF DRIVE PINION ASSEMBLY
1. Hold the companion flange using cam sprocket wrench or flange wrench, remove the pinion lock nut.
2. Remove the companion flange using puller.
3. Temporarily install drive pinion lock nut.
CAUTION:
Install the drive pinion lock nut until it flash with the drive
pinion end.
4. Remove the drive pinion from the carrier case.
5. Remove the bearing outer race by tapping the race evenly.
6. On companion flange side, remove the bearing outer race with
bearing and oil seal.
7. Press out the drive pinion bearing from the drive pinion using
puller.
DIFFERENTIAL CASE DISASSEMBLY
1. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove.
CAUTION:

To prevent damage to the side bearing and drive gear,
place copper plates between these parts and vise.

If is not necessary to remove side bearing except it is
replaced.Tool number : KV40104000 ( – )
Tool number : ST30031000 (J22912–01 )
SDIA1658E
SDIA1663E
Tool number
A: ST3305S001 (−)
B: ST33061000(J8107−2)
SPD920

FFD-24
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
d. Check mating surfaces of differential case, side gears, pinion
mate gears, pinion mate shaft and thrust washers.
INSPECTION

Clean up the disassemble parts. Then, inspect if the parts are wear or damaged. If so, follow the mea-
sures below.
Differential Case AssemblyADS000NO
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.
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 new gears.
Bearing

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

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 thrust washer 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 0.10 mm,
0.0038 in) or other damage on the contact sides of the lip of the companion
flange.
SDIA0193J