Ins INFINITI QX56 2004 Factory Service Manual

FFD-8
FRONT OIL SEAL
Revision: August 20072004 QX56
FRONT OIL SEALPFP:38189
Removal and InstallationEDS0035J
REMOVAL
1. Remove front propeller shaft. Refer to PR-5, "REMOVAL" .
2. Separate the RH and LH drive shafts from the front final drive. Refer to FA X -7 , "
REMOVAL" .
3. Measure the drive pinion bearing preload with front oil seal resistance using Tool.
NOTE:
Record the preload measurement.
4. Loosen drive pinion nut while holding the companion flange
using Tool.
5. Remove companion flange using a suitable puller.
6. Place a small hole in seal case, using a suitable punch or drill.
7. Install slide hammer tool as shown and remove seal.Tool number : ST3127S000 (J-25765-A)
Tool number : KV38108300 (J-44195)
BDIA0001E
LDIA0129E
LDIA0130E

FRONT OIL SEAL
FFD-9
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Revision: August 20072004 QX56
INSTALLATION
1. Apply multi-purpose grease to cavity at sealing lips of front oil
seal. Press front oil seal into gear carrier using suitable tool.
2. Install companion flange and a new drive pinion nut. Tighten
drive pinion nut while holding the companion flange using Tool
until there is no end play.
3. Measure the drive pinion bearing preload with front oil seal
resistance using Tool.
NOTE:

Drive pinion bearing preload should equal the measurement
taken during removal plus an additional 0.56 N·m (0.06 Kg-m,
5 in-lb).

If drive pinion bearing preload is low, tighten drive pinion nut in 6.8 N·m (0.69 Kg-m, 5ft-lb) increments
until drive pinion preload is met.
CAUTION:
Never loosen the drive pinion nut to decrease drive pinion bearing preload. Do not exceed speci-
fied preload. If preload torque is exceed a new collapsible spacer must be installed. If maximum
torque is reached prior to reaching the required preload, the collapsible spacer may have been
damaged. Replace the collapsible spacer.
4. Attach the RH and LH drive shafts. Refer to FAX-8, "
INSTALLATION" .
5. Install the front propeller shaft. Refer to PR-5, "
INSTALLATION" .
BDIA0003E
Tool number : KV38108300 (J-44195)
Tool number : ST3127S000 (J-25765-A)
Drive pinion nut : 298 - 678 N·m (31 - 69Kg-m, 220 - 500 ft-lb)
BDIA0001E

FFD-10
SIDE OIL SEALS
Revision: August 20072004 QX56
SIDE OIL SEALSPFP:33142
Removal and InstallationEDS0035K
REMOVAL
1. Remove front final drive. Refer to FFD-12, "REMOVAL" .
2. Remove differential side shaft and side flange using suitable
tool.
3. Place a small hole in seal case, using suitable tool.
4. Install slide hammer tool as shown and remove seal.
5. Installation is in the reverse order of removal.
BDIA0006E
LDIA0129E
LDIA0130E

REAR COVER GASKET
FFD-11
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FFD
Revision: August 20072004 QX56
REAR COVER GASKETPFP:38320
Removal and InstallationEDS0035L
REMOVAL
1. Remove front final drive. Refer to FFD-12, "REMOVAL" .
2. Drain gear oil. Refer to MA-25, "
Changing Final Drive Oil" .
3. Remove rear cover using Tool.
INSTALLATION
1. Apply 3.2mm (0.126 in) bead of sealant to the rear cover using
Tool.

Use Genuine Silicone RTV sealant or equivalent. Refer to. GI-
45, "Recommended Chemical Products and Sealants" .
2. Install rear cover and tighten rear cover bolts in the order shown
FFD-11, "
INSTALLATION" .
3. Fill final drive with recommended gear oil. Refer to GI-45, "
Rec-
ommended Chemical Products and Sealants" .
4. Install front final drive. Refer to FFD-13, "
INSTALLATION" . Tool number : KV10111100 (J-37228)
Tool number :WS39930000 ( — )
SDIA3204E
WDIA0290E

FFD-12
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
FRONT FINAL DRIVE ASSEMBLYPFP:38500
Removal and InstallationEDS0035M
REMOVAL
1. Remove front propeller shaft. Refer to PR-5, "REMOVAL" .
CAUTION:
Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft.
2. Separate LH and RH drive shafts from front final drive. Refer to FAX-7, "
REMOVAL" .
3. Remove front cross member.
4. Disconnect the vent hose.
1. Gear carrier assembly 2. Front cross member 3. Skid plate (If equipped)
SDIA3220E

FRONT FINAL DRIVE ASSEMBLY
FFD-13
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Revision: August 20072004 QX56
5. Support the front final drive with suitable jack and remove the
front final drive bolts. Carefully remove front final drive.
INSTALLATION
1. Install front final drive assembly.
2. Connect the vent hose.
3. Install the front cross member.
4. Install LH and RH drive shaft. Refer to FAX-8, "
INSTALLATION"
.
5. Install front propeller shaft. Refer to PR-5, "
INSTALLATION" .
BDIA0008E
Front final drive bolts : 182.5 N·m (19 kg-m, 135 ft-lb)
BDIA0008E

FRONT FINAL DRIVE ASSEMBLY
FFD-15
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Revision: August 20072004 QX56
ASSEMBLY INSPECTION AND ADJUSTMENT

Before inspection and adjustment, drain gear oil.
Total Preload Torque
1. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
2. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
3. Measure total preload with preload gauge.

If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload
and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bear-
ing preload.
Tooth Contact
1. Remove rear cover. Refer to FFD-11, "REMOVAL" .
2. Thoroughly clean drive gear and drive pinion teeth.
3. 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.
4. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
34. Bushing 35. Bearing 36 Screw
37 Dowel pin
Tool number : ST3127S000 (J-25765-A)
Total preload (with oil seal):
2.98 - 4.76 N·m (0.31 - 0.48 kg-m, 27 - 42 in-lb)
SDIA2220E
When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Loosen the side bearing adjust nuts at the same force on each side.
When the preload is small
On pinion bearings: Tighten the drive pinion nut.
On side bearings: Tighten the side bearing adjust nuts at the same force on each side.
SDIA2248E
SDIA2249E

FFD-18
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
6. Install slide hammer tool as shown and remove seal.
7. Remove rear cover from gear carrier.
8. For proper reinstallation, paint matching mark on one side bear-
ing cap.
CAUTION:

For matching mark, use paint. Do not damage bearing
caps and gear carrier.

Bearing caps are line-board during manufacture. The
matching marks are used to reinstall them in their origi-
nal positions.
9. Remove side bearing caps.
10. Remove side bearing adjust nuts.
LDIA0130E
LDIA0128E
SDIA2228E
SDIA2229E
SDIA2230E

FRONT FINAL DRIVE ASSEMBLY
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Revision: August 20072004 QX56
5. Remove drive pinion (together with rear bearing inner race, col-
lapsible spacer.)
6. Remove pinion front bearing inner race.
7. Place a small hole in seal case, using a suitable punch or drill.
8. Install slide hammer tool as shown and remove seal.
9. Turn nose of gear carrier down. Remove drive pinion front bear-
ing outer race using Tool. Locate driver on back edge of outer
race, then drive outer race out.
CAUTION:
Do not nick gear carrier.
10. Turn nose of gear carrier up. Remove drive pinion rear bearing
outer race using Tool. Locate driver on back edge of outer race,
then drive outer race out.
CAUTION:
Do not nick gear carrier.
SDIA2234E
LDIA0129E
LDIA0130E
Tool number A: — C-4171
B: — D-103
LDIA0131E
Tool number A: — C-4171
B: — C-4307
LDIA0132E

FFD-22
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
11. Remove drive pinion rear bearing inner race and drive pinion
height adjusting washer using Tool.
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.Tool number : ST30021000 ( — )
SDIA2236E
Content Conditions and Measures
Hypoid gear

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

If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
Bearing

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

If any cracks or damage on the surface of the tooth is found, replace.

If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
Side gear thrust washer and
pinion mate thrust washer

If it is chipped (by friction), damaged, or unusually worn, replace.
Oil seal

Whenever disassembled, replace.

If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case

If any wear or crack on the contact sides of the differential case is found, replace.
Companion flange

If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the
companion flange is found, replace.