boot NISSAN NAVARA 2005 Repair User Guide

DRIVE SHAFT
FAX-7
C
E
F
G
H
I
J
K
L
MA
B
FA X
DRIVE SHAFTPFP:39100
Removal and InstallationEDS003I9
REMOVAL
1. Remove wheel.
2. Remove ABS sensor harness from mount on knuckle, then disconnect ABS sensor harness connector.
CAUTION:
Do not pull on ABS sensor harness.
3. Remove steering knuckle. Refer toFSU-16, "
Removal and Installation".
4. Using a slide hammer, remove the drive shaft from final drive.
CAUTION:
lWhen removing drive shaft from vehicle, be careful to
avoid interfering with brake hose, ABS wheel speed sen-
sor harness, and other parts.
lWhen removing drive shaft, do not apply an excessive
angle (22°or more) to drive shaft joint. Also be careful
not to excessively extend slide joint.
INSPECTION AFTER REMOVAL
lMove joint up, down, left, right, and in axial direction. Check for any rough movement or significant loose-
ness.
lCheck boot for cracks or other damage, and for grease leakage.
lIf damaged, disassemble drive shaft to verify damage, and
repair or replace as necessary.
1. Differential side oil seal 2. Drive shaft 3. Drive shaft nut
4. Cotter pin 5. Circlip
MDIB9012E
SFA092A
SFA108A

FAX-8
DRIVE SHAFT
INSTALLATION
Installation is in the reverse order of removal.
lWhen installing drive shaft onto front final drive, use Tool to pre-
vent damage to the oil seal while inserting drive shaft. Slide
drive shaft sliding joint and tap with a hammer to install securely.
CAUTION:
Be sure to check that circlip is securely fastened.
Never reuse the differential side oil seal.
Disassembly and AssemblyEDS003IA
DISASSEMBLY
Final Drive Side
1. Mount the drive shaft in a vise.
CAUTION:
When mounting the drive shaft in a vise, use copper or aluminum plates between the vise and the
drive shaft.
2. Remove boot bands and slide the boot back.
3. Put matching marks on housing and shaft before separating joint assembly.
CAUTION:
Use paint or similar substance for matching marks. Do not scratch the surfaces.Tool number : KV38105500
MDIB9015E
1. Circlip 2. Dust cover 3. Housing (slide joint)
4. Snap ring 5. Spider assembly 6. Boot band
7. Boot 8. Shaft 9. Joint sub-assembly*
*: Do not disassemble
MDIB9014E

DRIVE SHAFT
FAX-9
C
E
F
G
H
I
J
K
L
MA
B
FA X
4. Put match marks on shaft and spider assembly.
CAUTION:
Use paint or similar substance for alignment marks. Do not
scratch the surface.
5. Remove snap ring. Remove spider assembly from shaft.
6. Remove boot from shaft.
Wheel Side
1. Mount the drive shaft in a vise.
CAUTION:
When mounting the drive shaft in a vise, use copper or aluminum plates between the vise and the
drive shaft.
2. Remove the boot bands and slide the boot back.
3. Screw a sliding hammer or suitable tool into threaded part of
joint sub-assembly. Pull joint sub-assembly out of drive shaft as
shown.
NOTE:
Align the sliding hammer and drive shaft and remove the joint
sub-assembly by pulling directly.
CAUTION:
lIf the joint sub-assembly cannot be removed after five or
more unsuccessful attempts, replace the entire drive
shaft assembly.
lJoint sub-assembly cannot be disassembled. Do not
attempt to disassemble it.
4. Remove boot from the drive shaft.
5. Remove circlip from the drive shaft.
6. While rotating the ball cage, clean the old grease off of the joint sub-assembly using paper towels.
INSPECTION AFTER DISASSEMBLY
Shaft
lReplace the shaft if there is any bending, cracking, or other damage.
Joint Sub-assembly
lCheck for any rough rotation or unusual axial looseness.
lClean any foreign material from inside the joint sub-assembly.
lCheck for any compression scars, cracks, or fractures.
CAUTION:
lIf any irregular conditions are found in the joint sub-assembly components, replace the entire
joint sub-assembly.
lJoint sub-assembly can not be disassembled. Do not attempt to disassemble it.
Housing
NOTE:
Housing, ball cage, steel ball, and inner race are in a set.
lCheck for any compression scars, cracks, fractures, or unusual wear on the ball rolling surface.
lCheck for any deformation of the boot installation components.
Ball Cage
lCheck the sliding surface for any compression scars, cracks, or fractures of sliding surface.
Steel Ball
lCheck for any compression scars, cracks, fractures, or unusual wear.
SDIA0594E
SDIA0606E

FAX-10
DRIVE SHAFT
Inner Race
lCheck the ball sliding surface for any compression scars, cracks, or fractures.
lCheck for any damage to the serrated part.
ASSEMBLY
Final Drive Side
1. Wrap the serrated part of the drive shaft with tape. Install the
boot band and boot to drive shaft.
CAUTION:
Discard the old boot band and boot: replace with new ones.
2. Remove the tape wound around the serrated part of the shaft.
3. Line up alignment marks which were made when spider assem-
bly was removed. Install spider assembly, with serration chamfer
facing drive shaft.
4. Secure spider assembly with snap ring.
CAUTION:
Discard the old snap ring: replace with new ones.
5. Apply Nissan genuine grease or equivalent to spider assembly
and sliding surface.
6. Line up matching marks on shaft and housing, and install sliding
joint housing to spider assembly. Add remaining grease up to
the amount listed below.
7. Install the stopper ring onto the housing.
CAUTION:
lDo not reuse stopper rings.
lMake sure that housing and stopper ring are fully engaged.
SFA800
SDIA0598E
Grease capacity: MT: 134 - 144g (4.73 - 5.08 oz)
AT: 134 - 144g (4.73 - 5.08 oz)
SDIA1446E

DRIVE SHAFT
FAX-11
C
E
F
G
H
I
J
K
L
MA
B
FA X
8. Install the boot securely into the grooves (indicated by * marks)
as shown.
CAUTION:
If there is grease on boot mounting surfaces (indicated by *
marks) of shaft and housing, boot may come off. Remove
all grease from surfaces.
9. Check that the boot installation length “L” is the length indicated below. Insert a flat-tip screwdriver or sim-
ilar tool into bigger side of boot. Bleed air from boot to prevent boot deformation.
CAUTION:
lThe boot may break if the boot installation length is less than the specified value.
lDo not to touch the tip of the screwdriver to the inside of the boot.
10. Usingabootbandcrimpingtool,securethesmallendofthe
boot with a new boot band as shown.
CAUTION:
Discard the old boot band and boot: replace with new ones.
lWhen fixing boot band, fix so that the M diameter on the
drawing becomes as follows.
11. Secure the boot big end with a new boot band as shown.
NOTE:
Discard old boot band; replace with new one.
12. After the installation of boot bands, make sure that they stay in the correct position when rotating boot.
Install them with new boot band when the mounting positions become incorrect.
MDIB9037E
Boot installation length “L ” MT: 176 - 178 mm (6.93 - 7.01 in)
AT: 176 - 178 mm (6.93 - 7.01 in)
MDIB9040E
M diameter (big ends): 1.0 - 4.0 mm (0.39 - 1.57 in)
M diameter (small ends): 1.0 - 4.0 mm (0.39 - 1.57 in)
DSF0047D
SFA443B

FAX-12
DRIVE SHAFT
13. Install circlip and dust cover to housing.
NOTE:
Do not reuse circlip and dust cover.
Wheel Side
1. Insert the Genuine NISSAN Grease or equivalent, into the joint
sub-assembly serration hole until the grease begins to ooze
from the ball groove and serration hole. Refer toMA-14, "
REC-
OMMENDED FLUIDS AND LUBRICANTS". After inserting the
grease, use a shop cloth to wipe off the grease that has oozed
out.
2. Wrap the serrated part of the drive shaft with tape. Install the
boot band and boot onto the shaft. Do not damage the boot.
CAUTION:
Discard the old boot band and boot: replace with new ones.
3. Remove the protective tape wound around the serrated part of
the drive shaft.
4. Attach the circlip to the shaft. The circlip must fit securely into
the shaft groove. Attach the nut to the joint sub-assembly.
Useasofthammertopress-fitthecirclip.
CAUTION:
lCirclips cannot be reused. Do not attempt to reuse them.
lBe sure to check that circlip is securely fastened.
5. Insert the specified quantity of Genuine NISSAN Grease or
equivalent, into the joint sub-assembly and the large end of the
boot. Refer toMA-14, "
RECOMMENDED FLUIDS AND LUBRI-
CANTS".
6. Install the boot securely into the grooves (indicated by the *
marks) as shown.
CAUTION:
If there is grease on the boot mounting surfaces (indicated
by the * marks) of the drive shaft and joint sub-assembly,
the boot may come off. Remove all grease from the drive
shaft surfaces.
7. Check that the boot installation length “L” is the specified length.
Insert a flat-tip screwdriver or similar tool into the bigger side of
the boot. Bleed the air from the boot to prevent boot deforma-
tion.
CAUTION:
lThe boot may break if the boot installation length is less than the specified length.
SDIA1127E
SFA800
Grease capacity MT: 226 - 246 g (7.97 - 8.68 oz)
AT: 110 - 130 g (3.88 - 4.59 oz)RAC0049D
Boot installation length “L” MT: 154mm (6.06 in)
AT: 150.4 mm (5.92 in)
MDIB9038E

DRIVE SHAFT
FAX-13
C
E
F
G
H
I
J
K
L
MA
B
FA X
lDo not contact inside surface of boot with the tip of the screwdriver.
8. Secure small end of the boot using a new boot band and a boot
band crimping tool as shown.
CAUTION:
Discard the old boot band and boot: replace with new ones.
lWhen fixing boot band, fix so that the M diameter on the
drawing becomes as follows.
9. Secure the boot big end with a new boot band as shown.
NOTE:
Discard old boot band; replace with new one.
10. After the installation of boot bands, rotate the boot to check that
it is positioned correctly. If the boot is not positioned correctly,
remove the old boot bands then reposition the boot and secure
the boot with new boot bands.Tool number : KV40107300
MDIB9040E
M diameter (big ends): 1.0 - 4.0 mm (0.39 - 1.57 in)
M diameter (small ends): 1.0 - 4.0 mm (0.39 - 1.57 in)
DSF0047D
SFA443B

FAX-14
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Wheel BearingEDS003IB
Drive ShaftEDS003IC
Wheel bearing axial end play 0.05 mm (0.002 in) or less
Wheel Side Final Drive Side
Applied modelEngine YD25, VQ40
Transaxle MT AT
Drive shaft joint type Final drive side AAR3300I AAR3300I
Wheel side UF3700I AC3300I
GreaseQuality Nissan genuine grease or equivalent
Capacity g (oz)Final drive side 134 - 144 (4.73 - 5.08) 134 - 144 (4.73 - 5.08)
Wheel side 226 - 246 (7.97 - 8.68) 110 - 130 (3.88 - 4.59)
Boot length “L” mm (in)Final drive side 176 - 178 (6.93 - 7.01) 176 - 178 (6.93 - 7.01)
Wheel side 154 (6.06) 150.4 (5.92)
MDIB9038EMDIB9037E

KNUCKLE
FSU-17
C
D
F
G
H
I
J
K
L
MA
B
FSU
7. Disconnect steering outer socket from steering knuckle using
Tool. Be careful not to damage ball joint boot.
CAUTION:
To prevent damage to threads and to prevent Tool from
coming off suddenly, temporarily tighten mounting nut.
8. On 4WD models remove drive shaft from wheel hub and bearing
assembly using a suitable extractor.
9. Remove cotter pin and nut from upper link ball joint.
10. Separate upper link ball joint from steering knuckle using Tool.
11. Remove pinch bolt from steering knuckle, then separate lower
link ball joint from steering knuckle.
12. Remove steering knuckle from vehicle.
13. Remove wheel hub and bearing assembly bolts.
14. Remove splash guard and wheel hub and bearing assembly from steering knuckle.
CAUTION:
Do not pull on wheel sensor harness.
INSPECTION AFTER REMOVAL
Check for deformity, cracks and damage on each part, replace if necessary.
lPerform ball joint inspection. Refer toFSU-15, "Inspection". Tool number : HT72520000
SDIA1434E
MDIB9013E
Tool number : ST29020001
WEIA0119E
LEIA0097E

GI-10
HOW TO USE THIS MANUAL
Components
EAS001GW
lTHE LARGE ILLUSTRATIONSare exploded views (see the following) and contain tightening torques,
lubrication points, section number of thePARTS CATALOG(e.g. SEC. 440) and other information neces-
sary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriatePARTS CATALOG.
Components shown in an illustration may be identified by a circled number. When this style of illustration
is used, the text description of the components will follow the illustration.
SYMBOLS
1. Union bolt 2. Copper washer 3. Brake hose
4. Cap 5. Bleed valve 6. Sliding pin bolt
7. Piston seal 8. Piston 9. Piston boot
10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt
13. Washer 14. Sliding pin boot 15. Bushing
16. Torque member 17. Inner shim cover 18. Inner shim
19. Inner pad 20. Pad retainer 21. Pad wear sensor
22. Outer pad 23. Outer shim 24. Outer shim cover
1: PBC (Poly Butyl Cuprysil) grease
or silicone-based grease2: Rubber grease : Brake fluid
Refer to GI section for additional symbol definitions.
SFIA2959E
SAIA0749E