INFINITI FX35 2004 Service Manual

RFD-24
REAR FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
4. Correct the pinion height washer size by referring to the “pinion
head number”.
There are two numbers painted on the drive pinion. The first one refers to the drive pinion and drive gear as a
matched set. This number should be the same as the number on the drive gear. The second number is the
“pinion head height number”. It refers to the ideal pinion height from standard for quietest operation. Use the
following chart to determine the correct pinion height washer.
5. Select the correct pinion height adjusting washer as follows. Refer to RFD-31, "
AVAILABLE PINION
HEIGHT ADJUSTING WASHERS" .
6. Remove the J34309 differential shim selector tool from the final
drive housing. Then disassemble to retrieve the pinion bearings.
TOOTH CONTACT
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.
SPD542
Pinion head height numberAdd or remove from the standard
pinion height washer thickness measurement
- 6
- 5
- 4
- 3
- 2
- 1
0
+1
+2
+3
+4
+5
+6Add 0.06 mm (0.0024 in)
Add 0.05 mm (0.0020 in)
Add 0.04 mm (0.0016 in)
Add 0.03 mm (0.0012 in)
Add 0.02 mm (0.0008 in)
Add 0.01 mm (0.0004 in)
Use the selected washer thickness
Subtract 0.01 mm (0.0004 in)
Subtract 0.02 mm (0.0008 in)
Subtract 0.03 mm (0.0012 in)
Subtract 0.04 mm (0.0016 in)
Subtract 0.05 mm (0.0020 in)
Subtract 0.06 mm (0.0024 in)
SPD205A

REAR FINAL DRIVE ASSEMBLY
RFD-25
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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 of drive gear drive side.
3. Hold companion flange steady by hand and rotate the drive gear
in both directions.
ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY
1. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.
CAUTION:
Do not reuse the lock pin. Always replace the lock pin with
a new one.
SPD357
SDIA0813E
SDIA1796E
SPD030

RFD-26
REAR FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
2. Place differential case on drive gear.
3. Apply genuine medium strength locking sealant or equivalent.
Refer to GI-48, "
RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS" to drive gear bolts, and install them.
CAUTION:
Do not reuse the bolts. Always replace the bolts with a new
one.

Tighten bolts in a crisscross fashion.

After tightening the bolt to the specified torque, turn the bolt
31 to 36 more degrees.
4. Press-fit side bearing inner race on differential case with tool.
INSTALLATION OF DRIVE PINION ASSEMBLY
1. Press-fit front and rear bearing outer races with tools.
2. Select drive pinion height adjusting washer. Refer to RFD-31, "
AVAILABLE PINION HEIGHT ADJUSTING
WASHERS"
SPD554
Tool number A : KV38100300 (J25523)
B : ST33061000 (J8107-2)
SPD353
Tool number A : Suitable tool
B : ST30611000 (J25742-1)
C : ST30613000 (J25742-3)
SPD992

REAR FINAL DRIVE ASSEMBLY
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3. Install selected drive pinion height adjusting washer in drive pin-
ion. Using hydraulic press and tool, press-fit pinion rear bearing
inner race into it.
4. Apply multi-purpose grease to pinion rear bearing inner race
and pinion front bearing inner race.
5. Set drive pinion assembly (as shown in figure) in differential car-
rier and install drive pinion, with press and suitable tool.
Stop when drive pinion touches bearing.
6. Install front oil seal with tool. Refer to RFD-7, "
Removal and Installation" .
7. Install companion flange, and tighten drive pinion lock nut to
minimum.
Ascertain that threaded portion of drive pinion and drive pinion
lock nut are free from oil.
CAUTION:
The drive pinion lock nut is not reusable. Never reuse drive
pinion lock nut.Tool number : ST30901000 ( – )
SPD377
SDIA1797E
SPD896
Tool number : ST30720000 (J25405)
Tool number : KV40104000 ( – )
SDIA1011E

RFD-28
REAR FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
8. Tighten the drive pinion lock nut by very small degrees until the
specified preload in achieved, when checking the preload, turn
drive pinion in both directions several times.

If pinion bearing preload is too small, tighten the drive pinion lock nut more.

If pinion bearing preload is too great, replace pinion bearing adjusting spacer.
INSTALLATION OF DIFFERENTIAL CASE ASSEMBLY
1. Select side bearing adjusting washer.
Refer to RFD-32, "
SIDE BEARING ADJUSTING WASHERS" .
2. Install differential case assembly with side bearing outer races
into gear carrier.
3. Insert original left and right side bearing adjusting washers in
place between side bearings and carrier.
4. Align matching mark on bearing cap with that on gear carrier.
5. Install the side bearing cap.
6. Install side oil seal. Refer to RFD-9, "
Removal and Installation" . Tool number
: ST3127S000 (J25765-A)
Drive pinion bearing preload
: 2.65 - 3.23 N·m (0.27 - 0.32 kg-m, 24 - 28 in-lb)
SDIA1007E
SPD919
SPD924
SPD889
Tool number : KV38100200 (J26233)

REAR FINAL DRIVE ASSEMBLY
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7. Measure drive gear-to-drive pinion backlash with a dial indicator
at several point.

It backlash is too small, adjustment of washer thickness is required. Decrease thickness of left shim
and increase thickness of right by the same amount.
If backlash is too great, reverse the above procedure.

Never change the total amount of washers as it will change the bearing preload.
8. Check total preload with tool.
When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly.

If preload is too great, remove the same amount of washer to each side.

If preload is too small, add the same amount of washer to each side.
Never add or remove a different number of washers for each side. Difference in number of washers will
change drive gear to drive pinion backlash.
9. Recheck drive gear to drive pinion backlash. Increase or decrease in thickness of shims will cause
change to drive gear to pinion backlash.

Check whether the backlash varies excessively in different places. Foreign matter may be caught
between the drive gear and the differential case causing the trouble.

The backlash can vary greatly even when the drive gear runout is within a specified range. In that case,
replace the hypoid gear set or differential case.
10. Check runout of drive gear with a dial indicator.
11. Check tooth contact.
Refer to RFD-24, "
TOOTH CONTACT" . Drive gear to drive pinion backlash
: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
SPD513
Tool number : ST3127S000 (J25765-A)
SDIA1007E
Total preload : 2.84 - 3.75 N·m (0.29 - 0.38 kg-m, 26 - 33 in-lb)
Drive gear runout limit : 0.05 mm (0.0020 in) or less
SPD524

RFD-30
REAR FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
12. Install rear cover. Apply liquid sealant to rear cover side and
install gear carrier.
SDIA0970E

SERVICE DATA AND SPECIFICATIONS (SDS)
RFD-31
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Revision: 2004 November 2004 FX35/FX45
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsADS000JV
Drive Gear RunoutADS000JW
Unit: mm (in)
Side Gear Adjustment ADS000JX
Unit: mm (in)
AVAILABLE SIDE GEAR THRUST WASHERS
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Drive Pinion Height AdjustmentADS000JY
AVAILABLE PINION HEIGHT ADJUSTING WASHERS
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Drive Pinion Preload AdjustmentADS000JZ
Applied modelVQ35DE engine VK45DE engine
5A/T
Final drive model R200 (2-pinion)
Gear ratio 3.357 (2WD), 3.692 (AWD) 3.692
Number of teeth (Drive gear/drive pinion) 47/14 (2WD), 48/13 (AWD) 48/13
Oil capacity (Approx.) (US qt, lmp qt)1.4 (3, 2-1/2) 1.4 (3, 2-1/2)
Type R200
Drive gear runout limit 0.05 (0.0020) or less
Type R200
Clearance limit between side gear thrust washer and differential
case mm (in)0.20 (0.0079) less
Type R20 0
Thrust washerThickness Part number*
0.75 (0.0295) 38424 0C000
0.78 (0.0307) 38424 0C001
0.81 (0.0319) 38424 0C002
0.84 (0.0331) 38424 0C003
0.87 (0.0343) 38424 0C004
0.90 (0.0350) 38424 0C005
0.93 (0.0366) 38424 0C006
Type R200
Adjusting washerThickness Part number* Thickness Part number*
3.05 (0.1201) 38154 0C000 3.17 (0.1248) 38154 0C004
3.08 (0.1213) 38154 0C001 3.20 (0.1260) 38154 0C005
3.11 (0.1224) 38154 0C002 3.23 (0.1272) 38154 0C006
3.14 (0.1236) 38154 0C003 3.26 (0.1283) 38154 0C007
Type R200
Drive pinion preload 2.65 − 3.23 N·m (0.27 − 0.32 kg−m, 24 − 28 in-lb)

RFD-32
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: 2004 November 2004 FX35/FX45
Side Bearing Preload Adjustment ADS000K0
SIDE BEARING ADJUSTING WASHERS
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Total Preload AdjustmentADS000K1
Companion FlangeADS000OC
Type R200
Side bearing preload <Reference> 0.20 − 0.52 N·m (0.02 − 0.05 kg−m, 2 − 4 in-lb)
Torque by spring gauge 34.2 − 39.2 N (3.5 − 4.0 kg, 7.7 − 8.8 lb)
Type R200
Adjusting washerThickness Part number* Thickness Part number*
2.00 (0.0787) 38453 N3100 2.35 (0.0925) 38453 N3107
2.05 (0.0807) 38453 N3101 2.40 (0.0945) 38453 N3108
2.10 (0.0827) 38453 N3102 2.45 (0.0965) 38453 N3109
2.15 (0.0846) 38453 N3103 2.50 (0.0984) 38453 N3110
2.20 (0.0866) 38453 N3104 2.55 (0.1004) 38453 N3111
2.25 (0.0886) 38453 N3105 2.60 (0.1024) 38453 N3112
2.30 (0.0906) 38453 N3106 2.65 (0.1043) 38453 N3113
Type R200
Total preload (with oil seal) 2.84 − 3.75 N·m (0.29 − 0.38 kg−m, 26 − 33 in-lb)
Drive gear to drive pinion backlash 0.10 − 0.15 mm (0.0039 − 0.0059 in)
Type R200
Runout limit0.13 mm (0.0051 in)

RSU-1
REAR SUSPENSION
E SUSPENSION
CONTENTS
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SECTION RSU
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RSU
Revision: 2004 November 2004 FX35/FX45
REAR SUSPENSION
PRECAUTIONS .......................................................... 2
Cautions ................................................................... 2
PREPARATION ........................................................... 3
Special Service Tools (SST) ..................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
REAR SUSPENSION ASSEMBLY ............................. 5
On-Vehicle Inspection and Service .......................... 5
INSPECTION OF SUSPENSION ARM BALL
JOINT END PLAY ................................................. 5
SHOCK ABSORBER INSPECTION ..................... 5
Wheel Alignment Inspection ..................................... 5
DESCRIPTION ...................................................... 5
PRELIMINARY CHECK ........................................ 5
CAMBER INSPECTION ........................................ 5
TOE-IN .................................................................. 6
Components ............................................................. 7
Removal and Installation .......................................... 8
REMOVAL ............................................................. 8
INSTALLATION ..................................................... 8
SHOCK ABSORBER .................................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSPECTION AFTER REMOVAL ......................... 9
INSTALLATION ..................................................... 9
Disassembly and Assembly ..................................... 9
DISASSEMBLY ..................................................... 9
INSPECTION AFTER DISASSEMBLY ............... 10
ASSEMBLY ......................................................... 10SUSPENSION ARM .................................................. 11
Removal and Installation ........................................ 11
REMOVAL ........................................................... 11
INSPECTION AFTER REMOVAL ....................... 11
INSTALLATION ................................................... 12
RADIUS ROD ............................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSPECTION AFTER REMOVAL ....................... 13
INSTALLATION ................................................... 13
FRONT LOWER LINK .............................................. 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSPECTION AFTER REMOVAL ....................... 14
INSTALLATION ................................................... 14
REAR LOWER LINK & COIL SPRING ..................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSPECTION AFTER REMOVAL ....................... 15
INSTALLATION ................................................... 15
STABILIZER BAR ..................................................... 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSPECTION AFTER REMOVAL ....................... 16
INSTALLATION ................................................... 16
REAR SUSPENSION MEMBER ............................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 17
INSTALLATION ................................................... 17
SERVICE DATA ........................................................ 18
Wheel Alignment .................................................... 18
Ball Joint ................................................................. 18
Wheelarch Height (Unladen*) ................................. 18