NISSAN ALMERA N16 2003 Electronic Repair Manual

FRONT & REAR AXLE
SECTION
AX
CONTENTS
FRONT AXLE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...2
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..............2
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>2
Preparation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..............2
SPECIAL SERVICE TOOLS........................................2
COMMERCIAL SERVICE TOOLS................................2
Noise, Vibration and Harshness (NVH)
Troubleshooting ...........................................................3
NVH TROUBLESHOOTING CHART............................3
On-vehicle Service.......................................................3
FRONT AXLE PARTS................................................3
FRONT WHEEL BEARING.........................................3
DRIVE SHAFT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>4
Wheel Hub and Knuckle ..............................................5
COMPONENTS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>5
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..5
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011>7
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011>7
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>8
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[8
Drive Shaft <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............10
COMPONENTS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>0
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[11
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>2
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>3
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>5
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>6
Service Data and Specifications (SDS).....................20
DRIVE SHAFT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011>0
DYNAMIC DAMPER (WHERE FITTED).....................21
WHEEL BEARING (FRONT).....................................21
REAR AXLE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....22
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............22
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>2
Preparation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............22
SPECIAL SERVICE TOOLS......................................22
COMMERCIAL SERVICE TOOLS..............................22
Noise, Vibration and Harshness (NVH)
Troubleshooting .........................................................23
On-vehicle Service.....................................................23
REAR AXLE PARTS.................................................23
REAR WHEEL BEARING.........................................23
Wheel Hub <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[..........24
COMPONENTS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>4
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[24
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>5
Service Data and Specifications (SDS).....................27
WHEEL BEARING (REAR).......................................27
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SBR686C
Precautions
PRECAUTIONSNJAX0001When installing rubber parts, final tightening must be car-
ried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
After installing removed suspension parts, check wheel
alignment and adjust if necessary.
Use flare nut wrench when removing or installing brake
tubes.
Always torque brake lines when installing.
Preparation
SPECIAL SERVICE TOOLSNJAX0002
Tool number
Tool nameDescription
HT72520000
Ball joint remover
NT146
Removing tie-rod outer end and lower ball joint
KV38106800
Differential side oil seal
protector
NT147
Installing drive shaft
KV38106800
COMMERCIAL SERVICE TOOLSNJAX0003
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing each brake piping
a: 10 mm (0.39 in)
FRONT AXLE
Precautions
AX-2

Noise, Vibration and Harshness (NVH)
Troubleshooting
=NJAX0004NVH TROUBLESHOOTING CHARTNJAX0004S01Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
Reference page—
AX-15
—
AX-5, 24
—
AX-3, 23
—
—
SU-4
SU-4
SU-4
BR-6
ST-5
Possible cause and
SUSPECTED PARTS
Excessive joint angle
Joint sliding resistance
Imbalance
Improper installation, looseness
Parts interference
Wheel bearing damage
DRIVE SHAFT
AXLE
SUSPENSION
TIRES
ROAD WHEEL
BRAKES
STEERING
SymptomDRIVE SHAFTNoise, Vibration××———— —× ×××××
Shake×—×——— —× ×××××
AXLENoise — — —××—×—×××××
Shake — — —××—×—×××××
Vibration — — —××—×—××——×
Shimmy — — —××—— —×××××
Judder — — —×—— — —×××××
Poor quality ride or
handling———×××——×××——
×: Applicable
—: Not applicable
SMA525A
On-vehicle Service
FRONT AXLE PARTSNJAX0005Check front axle and front suspension parts for excessive play,
cracks, wear or other damage.
Shake each front wheel to check for excessive play.
Make sure that cotter pin is inserted.
Retighten all axle and suspension nuts and bolts to the speci-
fied torque.
Tightening torque:
Refer to SU-5, “FRONT SUSPENSION”.
SFA805B
FRONT WHEEL BEARINGNJAX0006Check that wheel bearings operate smoothly.
Check axial end play.
Axial end play:
0.05 mm (0.0020 in)
If out of specification or wheel bearing does not turn smoothly,
replace wheel bearing assembly.
Refer to “Wheel Hub and Knuckle”, “FRONT AXLE”, AX-5.
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FRONT AXLE
Noise, Vibration and Harshness (NVH) Troubleshooting
AX-3

SFA108A
DRIVE SHAFTNJAX0007Check for grease leakage or other damage.
FRONT AXLE
On-vehicle Service (Cont’d)
AX-4

Wheel Hub and Knuckle
COMPONENTS=NJAX0008
NAX013
1. Drive shaft
2. Knuckle
3. Baffle plate (where fitted)
4. ABS sensor5. Wheel bearing assembly
6. Snap ring
7. Hub bolt
8. Wheel hub9. Wheel bearing lock nut
10. Cotter pin
11. Brake disc
12. Wheel nut
REMOVALNJAX0009CAUTION:
Before removing the front axle assembly, disconnect the ABS
wheel sensor from the assembly. Then move it away from the
front axle assembly area.
Failure to do so may result in damage to the sensor wires and
the sensor becoming inoperative.
SFA090A
1. Remove wheel bearing lock nut.
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FRONT AXLE
Wheel Hub and Knuckle
AX-5

SFA898A
2. Remove brake caliper assembly and rotor.
Brake hose need not be disconnected from brake caliper. In
this case, suspend caliper assembly with wire so as not to
stretch brake hose. Be careful not to depress brake pedal, or
piston will pop out.
Make sure brake hose is not twisted.
SFA372-A
3. Separate tie-rod from knuckle with Tool.
Install stud nut on stud bolt to prevent damage to stud bolt.
SFA181A
4. Separate drive shaft from knuckle by lightly tapping it. If it is
hard to remove, use a puller.
Cover boots with shop towel so as not to damage them when
removing drive shaft.
SFA153B
5. Remove strut lower mounting bolts.
SFA113AC
6. Loosen lower ball joint tightening nut.
7. Separate knuckle from lower ball joint stud with Tool.
8. Remove knuckle from transverse link.
FRONT AXLE
Wheel Hub and Knuckle (Cont’d)
AX-6

SFA114A
INSTALLATIONNJAX00101. Install knuckle with wheel hub.
When installing knuckle to strut, be sure to hold bolts and
tighten nuts.
: 114 - 133 N·m (11.6 - 13.6 kg-m, 84 - 98 ft-lb)
Before tightening, apply oil to threaded portion of drive shaft.
2. Tighten wheel bearing lock nut.
QG engine
: 226 - 313 N·m (23 - 32 kg-m, 167 - 231 ft-lb)
YD engine
: 255 - 333 N·m (26 - 34 kg-m, 188 - 245 ft-lb)
3. Check that wheel bearings operate smoothly.
SFA543A
4. Check wheel bearing axial end play.
Axial end play:
0.05 mm (0.0020 in)
SFA116A
DISASSEMBLYNJAX0011CAUTION:
When removing wheel hub or wheel bearing from knuckle,
replace wheel bearing assembly (outer race and inner races)
with a new one.
Wheel HubNJAX0011S01Drive out hub with inner race (outside) from knuckle with a suitable
tool.
SFA654A
Wheel BearingNJAX0011S02When replacing wheel bearing, replace complete wheel bear-
ing assembly (Inner races and outer race).
1. Remove bearing inner race (outside).
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FRONT AXLE
Wheel Hub and Knuckle (Cont’d)
AX-7

SAX008
2. Remove snap rings.
SFA905A
3. Press out bearing outer race.
INSPECTIONNJAX0012Wheel Hub and KnuckleNJAX0012S01Check wheel hub and knuckle for cracks by using a magnetic
exploration or dyeing test.
Snap RingNJAX0012S02Check snap ring for wear or cracks. Replace if necessary.
SFA921B
ASSEMBLYNJAX0013When removing baffle plate, replace it with a new one. (If baffle
plate is equipped)
When installing the baffle plate, press new plate so that it is in
contact with knuckle wall. Refer to figure at left. (If baffle plate
is equipped)
SAX009
1. Install inner snap ring into groove of knuckle.
2. Press new wheel bearing assembly into knuckle until it con-
tacts steering knuckle.
Maximum load P:
29 kN (3 ton, 3.3 US ton, 3.0 Imp ton)
CAUTION:
Do not press inner race of wheel bearing assembly.
Do not apply oil or grease to mating surfaces of wheel
bearing outer race and knuckle.
3. Install outer snap ring into groove of knuckle.
FRONT AXLE
Wheel Hub and Knuckle (Cont’d)
AX-8

SAX010
4. Press wheel hub into knuckle until it stops when the end of the
wheel bearing is hit.
Maximum load P:
29 kN (3 ton, 3.3 US ton, 3.0 Imp ton)
SFA182A
5. Check bearing operation.
a. Add load P with press.
Load P:
49.0 kN
(5.0 ton, 5.5 US ton, 4.92 Imp ton)
b. Spin knuckle several turns in both directions.
c. Make sure that wheel bearings operate smoothly.
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FRONT AXLE
Wheel Hub and Knuckle (Cont’d)
AX-9

Drive Shaft
COMPONENTS=NJAX0016
NAX018
1. Joint assembly
2. Boot
3. Boot band
4. Circular clip
5. Drive shaft
6. Dynamic damper band (where fit-
ted)
7. Dynamic damper (where fitted)
8. Boot
9. Boot band
10. Stopper ring11. Inner race
12. Cage
13. Ball
14. Snap ring
15. Slide joint housing
16. Circular clip
17. Spider assembly
18. Snap ring
19. Slide joint housing
20. Circular clip21. Slide joint housing with extension
shaft
22. Dust shield
23. Snap ring
24. Support bearing
25. Support bearing retainer
26. Bracket
27. Snap ring
28. Dust shield
FRONT AXLE
Drive Shaft
AX-10