NISSAN NAVARA 2005 Repair Workshop Manual

FRONT FINAL DRIVE ASSEMBLY
FFD-25
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FFD
4. Put matching mark on the end of drive pinion. The matching
mark should be in line with the matching mark A on companion
flange.
CAUTION:
Use paint for matching mark. Do not damage companion
flange or drive pinion.
NOTE:
The matching mark A on the final drive companion flange indi-
cates the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
5. Remove companion flange using suitable tool.
6. Press drive pinion assembly out of gear carrier. (Together with
collapsible spacer.)
CAUTION:
Do not drop drive pinion assembly.
7. Remove pinion rear bearing inner race and drive pinion height
adjusting washer using Tool.
8. Remove front oil seal using suitable tool.
CAUTION:
Do not damage gear carrier.
9. Remove pinion front bearing inner race.
10. Remove collapsible spacer.
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Tool number : ST30031000
S-PD179
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FFD-26
FRONT FINAL DRIVE ASSEMBLY
11. Tap pinion front/rear bearing outer races uniformly to remove
them, using suitable tool.
CAUTION:
Do not damage gear carrier.
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If parts are worn or dam-
aged, follow the measures below.
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Content Conditions and Measures
Hypoid gear
lIf the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.
lIf the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
Bearing
lIf 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
lIf any cracks or damage on the surface of the tooth is found, replace.
lIf 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
lIf it is chipped (by friction), damaged, or unusually worn, replace.
Oil seal
lWhenever disassembled, replace.
lIf wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case
lIf any wear or crack on the contact sides of the differential case is found, replace.
Companion flange
lIf 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.

FRONT FINAL DRIVE ASSEMBLY
FFD-27
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FFD
ADJUSTMENT AND SELECTION ADJUSTING WASHERS
Differential Side Gear Clearance
lAssemble the differential parts if they are disassembled. Refer toFFD-32, "Differential Assembly".
1. Place differential case straight up so that side gear to be mea-
sured comes upward.
2. Using feeler gauge, measure the clearance between side gear
back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance. (Measure the clearance of the other side as well.)
CAUTION:
To prevent side gear from tilting, insert feeler gauges with
thesamethicknessfrombothsides.
3. If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. Refer toFFD-37, "
Side
Gear Thrust Washer".
CAUTION:
Select a side gear thrust washer for right and left individu-
ally.
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Side gear back clearance specification:
0.1 mm (0.004 in) or less.
(Each gear should rotate smoothly without excessive
resistance during differential motion.)
When the back clearance is greater than specification:
Use a thicker thrust washer.
When the back clearance is less than specification:
Use a thinner thrust washer.
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FFD-28
FRONT FINAL DRIVE ASSEMBLY
Pinion Gear Height
If the hypoid gear set has been replaced, select the pinion height adjusting washer.
1. Use the formula below to calculate pinion height adjusting
washer thickness.
2. Select the proper pinion height adjusting washer. Refer toFFD-38, "
Pinion Height Adjusting Washer".
If you cannot find the desired thickness of washer, use washer with thickness closest to the calculated
value.
ASSEMBLY
Drive Pinion Assembly
1. Install front and rear bearing outer races using Tools.
CAUTION:
lFirst tap the bearing outer race until it becomes flat to the
gear carrier.
lDo not reuse pinion front and rear bearing outer race.Washer selection equation:
T=T
0+(t1-t2)
T: Correct washer thickness
T
0: Removed washer thickness
t
1: Old drive pinion head letter “H´0.01”
(“H”: machined tolerance 1/100 mm´100)
t
2: New drive pinion head letter “H´0.01”
(“H”: machined tolerance 1/100 mm´100)
Example:
T = 3.21 + [(2´0.01) - (-1´0.01)] = 3.24
T
0:3.21
t
1:+2
t
2:-1
Example:
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm
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Tool number A: ST30611000
B: ST30613000
C: KV38100200
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FRONT FINAL DRIVE ASSEMBLY
FFD-29
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2. Temporarily install pinion height adjusting washer.
When hypoid gear set has been replaced
lSelect pinion height adjusting washer. Refer toFFD-28, "Pin-
ion Gear Height".
When hypoid gear set has been reused
lTemporarily install the removed pinion height adjusting
washer or same thickness washer to drive pinion.
3. Install selected pinion height adjusting washer to drive pinion.
Press pinion rear bearing inner race to it using Tool.
CAUTION:
lPay attention to the direction of pinion height adjusting
washer. (Assemble as shown in the figure.)
lDo not reuse pinion rear bearing inner race.
4. After checking and adjusting the tooth contact and backlash of
the hypoid gear following the procedure below.
a. Apply gear oil to the drive pinon rear bearing, and assemble the
drive pinion to the gear carrier.
CAUTION:
Do not assemble a collapsible spacer.
b. Apply gear oil to drive pinon front bearing, and assemble pinion front bearing inner race to drive pinion.
CAUTION:
Do not reuse pinion front bearing inner race.
c. Press the pinion front bearing inner race to drive pinion as far as
drive pinion lock nut can be tightened using drift.
d. Install companion flange.
CAUTION:
Do not assemble a front oil seal.
NOTE:
When reusing drive pinion, align the matching mark of drive pin-
ion with the matching mark A of companion flange, then install
companion flange.
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Tool number : ST30901000
Tool number : ST33200000
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FFD-30
FRONT FINAL DRIVE ASSEMBLY
e. Temporarily tighten removed drive pinon nut to drive pinion.
NOTE:
Use removed drive pinon nut only for the preload measurement.
f. Adjust the drive pinion lock nut tightening torque and pinion
bearing preload torque using Tool.
CAUTION:
Drive pinon nut is tightened with no collapsible spacer. Be
careful not to overtighten it. While measuring the preload,
tighten it by 5°to 10°.
g. Apply gear oil to side bearings, and install new side bearing
adjusting washer with the same thickness or re-install the old
ones to the same mounting position they were in prior to disas-
sembly. Install differential case assembly to gear carrier.
h. Align matching mark on bearing cap with that on gear carrier.
i. Check and adjust the tooth contact. Refer toFFD-19, "
To o t h
Contact".
j. Check and adjust the backlash. Refer toFFD-20, "
Backlash".
k. Remove bearing caps.
l. 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.
m. Remove companion flange.
n. Press drive pinion assembly out of gear carrier. (Together with
collapsible spacer.)
CAUTION:
Do not drop drive pinion assembly.
o. Remove pinion front bearing inner race.Tool number A: ST3127S000
Drive pinion bearing preload:
1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)
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FRONT FINAL DRIVE ASSEMBLY
FFD-31
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5. Assemble collapsible spacer to drive pinion.
CAUTION:
Do not reuse collapsible spacer.
6. Apply gear oil to pinion rear bearing, and assemble drive pinion
into gear carrier.
7. Apply gear oil to pinion front bearing, and assemble pinion front
bearing inner race to drive pinion assembly.
CAUTION:
Do not reuse pinion front bearing inner race.
8. Press the pinion front bearing inner race to drive pinion as far as
drive pinion lock nut can be tightened using Tool.
9. Install front oil seal until it becomes flush with the case end using
Tools.
CAUTION:
lDo not reuse oil seal.
lDo not incline oil seal when installing.
lApply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
10. Install companion flange.
NOTE:
When reusing drive pinion, align the matching mark of drive pin-
ion with the matching mark A of companion flange, then install
companion flange.
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SPD581
Tool number : ST33200000
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Tool number A: ST30720000
B: ST27863000
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FFD-32
FRONT FINAL DRIVE ASSEMBLY
11. Apply anti-corrosive oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Do not reuse drive pinion lock nut.
12. Adjust the drive pinion lock nut tightening torque and pinion
bearing preload torque using Tool.
CAUTION:
lAdjust the lower limit of the drive pinion lock nut tighten-
ing torque first.
lIf the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Do not
loosen drive pinion lock nut to adjust the preload torque.
lAfter adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
13. Install differential case assembly. Refer toFFD-32, "
Differential Assembly".
CAUTION:
Do not install rear cover yet.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer toFFD-18, "
Drive Gear Runout",FFD-19, "To o t h C o n t a c t",FFD-20, "Backlash",
FFD-21, "
Companion Flange Runout".
Recheck above items. Readjust the above description, if necessary.
15. Check total preload torque. Refer toFFD-18, "
Total Preload Torque".
16. Install rear cover. Refer toFFD-32, "
Differential Assembly".
17. Install side shaft assembly. Refer toFFD-35, "
Side Shaft".
Differential Assembly
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
the side gears.Tool number A: ST3127S000
Drive pinion lock nut tightening torque:
186 - 294 N·m (19 - 29 kg-m, 138 - 216 ft-lb)
Drive pinion bearing preload:
1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)
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FRONT FINAL DRIVE ASSEMBLY
FFD-33
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2. Install side gears and thrust washers into differential case.
3. Align 2 pinion mate gears in diagonally opposite positions, then
rotate and install them into differential case after installing thrust
washer to pinion mate gear.
4. Align the lock pin holes on differential case with shaft, and install
pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate
side gear thrust washers. Refer toFFD-27, "
Differential Side
Gear Clearance".
6. Drive a lock pin into pinion mate shaft, using suitable tool.
Make sure lock pin is flush with differential case.
CAUTION:
Do not reuse lock pin.
7. Align the matching mark of differential case with the mark of
drive gear, then place drive gear.
8. Apply recommended thread locking sealant into the thread hole
of drive gear. Refer toFFD-17, "
COMPONENTS".
CAUTION:
Make sure the drive gear back and threaded holes are
clean.
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FFD-34
FRONT FINAL DRIVE ASSEMBLY
9. Install drive gear on the bolts, and then tighten to the specified
torque. Refer toFFD-17, "
COMPONENTS".
CAUTION:
lTighten bolts in a crisscross pattern.
lAfter tightening the bolts to the specified torque, tighten
the bolts additionally by turning the bolts 34 to 39
degrees.
10. Press side bearing inner races to differential case, using Tools.
CAUTION:
Do not reuse side bearing inner race.
11. Install housing spacer.
12. Apply gear oil to side bearings, and install differential case
assembly with side bearing outer races into gear carrier.
13. Insert left and right original side bearing adjusting washers in
place between side bearings and gear carrier, using Tool.
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Tool number A: ST33230000
B: ST33061000
SPD353
SPD527
Tool number : KV38100600
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