NISSAN NAVARA 2005 Repair Workshop Manual

FRONT FINAL DRIVE ASSEMBLY
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FRONT FINAL DRIVE ASSEMBLYPFP:38500
Removal and InstallationEDS00356
REMOVAL
1. Remove the front wheels and tires using power tool.
2. Without disassembling the hydraulic lines, remove the caliper torque member bolts using power tool.
Then reposition the brake caliper aside using suitable wire. Refer toBR-26, "
Removal and Installation of
Brake Caliper Assembly".
CAUTION:
Do not press the brake pedal while brake caliper is removed.
3. Remove the ABS sensor harness from the mount on the knuckle.
1. Breather hose 2. Front final drive assembly 3. Front crossmember
4. Engine under cover rear
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FFD-16
FRONT FINAL DRIVE ASSEMBLY
CAUTION:
Do not pull on the ABS sensor harness.
4. Support the lower link using a suitable jack.
5. Separate the upper link ball joint stud from the steering knuckle
using Tool.
CAUTION:
Support the lower link using a jack.
6. Remove the engine under cover rear using power tool.
7. Drain the front final drive fluid. Refer toFFD-8, "
Changing Differ-
ential Gear Oil".
8. Remove the RH and LH drive shafts from the front final drive
using suitable tool.
9. Remove the front crossmember.
10. Disconnect the front propeller shaft from the front final drive. Then reposition the front propeller shaft
aside using suitable wire. Refer toPR-4, "
Removal and Installation".
11. Disconnect the vent hose from the front final drive.
12. Support the front final drive using a suitable jack.
13. Remove the front final drive bolts, then remove the front final
drive assembly.
CAUTION:
Secure rear the front final drive assembly to a suitable jack
while removed it.
INSTALLATION
Installation is the reverse order of removal.
lInstall new side oil seals into the front final drive assembly. Refer toFFD-13, "Removal and Installation".
CAUTION:
lWhen installing the drive shaft assembly into the front final drive assembly, do not damage the
side oil seal.
lMake sure there are no pinched or restricted areas on the breather hose caused by bending or
winding when installing it.
lFill the final drive with recommended gear oil after installation. Refer toFFD-8, "Changing Differ-
ential Gear Oil".
lTighten the upper link ball joint stud nut to specifications. Refer toFSU-6, "Components".
lTighten the wheel nuts to specification. Refer toWT-5, "Rotation". Tool number : ST29020001
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FRONT FINAL DRIVE ASSEMBLY
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Disassembly and AssemblyEDS00357
COMPONENTS
1. Drive pinion lock nut 2. Companion flange 3. Front oil seal
4. Pinion front bearing 5. Gear carrier 6. Side oil seal
7. Bushing 8. Side shaft 9. Side shaft bearing
10. Snap ring 11. Snap ring 12. Gasket
13. Drain plug 14. Collapsible spacer 15. Pinion rear bearing
16. Pinion height adjusting washer 17. Drive pinion 18. Side bearing adjusting washer
19. Side bearing 20. Side gear thrust washer 21. Side gear
22. Pinion mate shaft 23. Lock pin 24. Pinion mate gear
25. Pinion mate thrust washer 26. Drive gear 27. Differential case
28. Housing spacer 29. Bearing cap 30. Filler plug
31. Rear cover
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FRONT FINAL DRIVE ASSEMBLY
ASSEMBLY INSPECTION AND ADJUSTMENT
lBefore 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 opera-
tion of the bearing.
3. Measure total preload using Tool.
NOTE:
Total preload torque = Pinion bearing preload torque + Side
bearing preload torque
lIf 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 bearing preload.
CAUTION:
Select a side bearing adjusting washer for right and left individually.
Drive Gear Runout
1. Remove rear cover. Refer toFFD-22, "Differential Assembly".
2. Fit a dial indicator to the drive gear back face.
3. Rotate the drive gear to measure runout.
lIf the runout is outside of the repair limit, check drive gear
assembly condition; foreign material may be caught between
drive gear and differential case, or differential case or drive gear
may be deformed.
CAUTION:
Replace drive gear and drive pinion gear as a set.Tool number : ST3127S000
Total preload torque:
1.67 - 2.74 N·m (0.17 - 0.27 kg-m, 15 - 24 in-lb)
PDIA0697E
When the preload torque is greater than specification
On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same amount to
each side. Refer toFFD-38, "
Side Bearing Adjusting Washer".
When the preload torque is less than specification
On pinion bearings: Tighten the drive pinion nut.
On side bearings: Use thicker side bearing adjusting washers by the same amount to
each side. Refer toFFD-38, "
Side Bearing Adjusting Washer".
Runout limit: 0.08 mm (0.0031 in) or less
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FRONT FINAL DRIVE ASSEMBLY
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Tooth Contact
1. Remove rear cover. Refer toFFD-22, "Differential Assembly".
2. Apply red lead to drive gear.
CAUTION:
Applyredleadtoboththefacesof3to4gearsat4loca-
tions evenly spaced on drive gear.
3. Rotate drive gear back and forth several times, check drive pin-
iongeartodrivegeartoothcontact.
CAUTION:
Check tooth contact on drive side and reverse side.
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FFD-20
FRONT FINAL DRIVE ASSEMBLY
4. If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X).
lIf the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken pinion height adjusting washers to
move drive pinion closer to drive gear.
Refer toFFD-38, "
Pinion Height Adjusting Washer".
lIf the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin pinion height adjusting washers to move
drive pinion farther from drive gear.
Refer toFFD-38, "
Pinion Height Adjusting Washer".
Backlash
1. Remove rear cover. Refer toFFD-22, "Differential Assembly".
2. Fit a dial indicator to the drive gear face to measure the back-
lash.
lIf the backlash is outside of the specified value, change the
thickness of side bearing adjusting washer.
CAUTION:
Do not change the total amount of washers as it will change the bearing preload.
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Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
When the backlash is greater than specification:
Make drive gear back side adjusting washer thicker,
and drive gear tooth side adjusting washer thinner by
the same amount. Refer toFFD-38, "
Side Bearing
Adjusting Washer".
When the backlash is less than specification:
Make drive gear back side adjusting washer thinner,
and drive gear tooth side adjusting washer thicker by
the same amount. Refer toFFD-38, "
Side Bearing
Adjusting Washer".
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FRONT FINAL DRIVE ASSEMBLY
FFD-21
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Companion Flange Runout
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft bolt holes).
2. Rotate companion flange to check for runout.
3. Fit a test indicator to the inner side of companion flange (socket
diameter).
4. Rotate companion flange to check for runout.
5. If the runout value is outside the runout limit, follow the proce-
dure below to adjust.
a. Rotate the companion flange on the drive pinion by 90°,180°and 270°, while checking for the position
where the runout is minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an
assembly malfunction of drive pinion and pinion bearing or a malfunctioning pinion bearing.
c. If the runout value is still outside of the limit after repair of the assembly of drive pinion and pinion bearing
or pinion bearing, replace the companion flange.
DISASSEMBLY
Side Shaft
1. Drain gear oil, if necessary.
2. Remove side oil seal.
CAUTION:
Do not damage gear carrier.
3. Remove snap ring (hole side) using suitable tool.
4. Remove side shaft assembly out of gear carrier using suitable
tool.
NOTE:
Tap on side shaft assembly from side gear side.
5. Remove snap ring (shaft side).Runout limit: 0.1 mm (0.004 in) or less
Runout limit: 0.1 mm (0.004 in) or less
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FRONT FINAL DRIVE ASSEMBLY
6. Press side shaft out of side shaft bearing.
CAUTION:
Do not drop side shaft.
Differential Assembly
1. Remove side shaft assembly. Refer toFFD-35, "Side Shaft".
2. Remove rear cover bolts.
3. Separate the rear cover from the gear carrier using Tool.
CAUTION:
lDo not damage the mating surface.
lDo not insert flat-bladed screwdriver, this will damage the
mating surface.
4. For proper reinstallation, paint matching marks on one side of
the bearing cap.
CAUTION:
lFor matching mark, use paint. Do not damage bearing
caps and gear carrier.
lBearing caps are line-board during manufacture. The
matching marks are used to reinstall them in their origi-
nal positions.
5. Remove bearing caps.
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Tool number : KV10111100
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6. Lift differential case assembly out using suitable tool.
CAUTION:
lKeep side bearing outer races together with inner race.
Do not mix them up.
lKeep side bearing adjusting washers together with bear-
ings.
7. Remove housing spacer.
8. Remove side bearing inner races, using Tools.
CAUTION:
lPlace copper plates between the side bearing and drive
gear and the vise to prevent damage.
lDo not remove side bearing inner race unless it is being
replaced.
9. For proper reinstallation, paint matching mark on one side of dif-
ferential case assembly.
CAUTION:
Use paint for matching mark. Do not damage differential
case or drive gear.
10. Remove drive gear bolts.
11. Tap drive gear off differential case assembly using suitable tool.
CAUTION:
Tap evenly all around to keep drive gear from bending.
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SPD527
Tool number A: ST33051001
B: ST33061000
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12. Remove lock pin of pinion mate shaft from drive gear side using
suitable tool.
13. Removepinionmateshaft.
14. Turn pinion mate gear, then remove pinion mate gear, pinion
mate thrust washer, side gear and side gear thrust washer from
differential case.
Drive Pinion Assembly
1. Remove side shaft assembly. Refer toFFD-21, "Side Shaft".
2. Remove differential assembly. Refer toFFD-22, "
Differential Assembly".
3. Remove drive pinion lock nut using flange wrench.
SPD025
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