NISSAN NAVARA 2005 Repair Workshop Manual

RFD-8
[WITH LIMITED SLIP DIFFERENTIAL]
DESCRIPTION
DESCRIPTION
PFP:00000
Cross-Sectional ViewEDS00393
1. Companion flange 2. Drive pinion 3. Drive gear
4. Differential case 5. Pinion mate gear 6. Axle shaft
7. Side gear 8. Pinion mate shaft
PDIA1037E

DIFFERENTIAL GEAR OIL
RFD-9
[WITH LIMITED SLIP DIFFERENTIAL]
C
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B
RFD
DIFFERENTIAL GEAR OILPFP:KLD30
Changing Differential Gear OilEDS00394
DRAINING
1. Stop engine.
2. Remove drain plug and drain gear oil.
3. Apply sealant to drain plug. Install drain plug to final drive
assembly and tighten to the specified torque. Refer toRFD-15,
"COMPONENTS".
FILLING
1. Remove filler plug. Fill with new gear oil until oil level reaches
the specified limit near filler plug hole.
2. After refilling oil, check oil level. Apply sealant to filler plug.
Install filler plug to final drive assembly and tighten to the speci-
fied torque. Refer toRFD-15, "
COMPONENTS".
Checking Differential Gear OilEDS00395
OIL LEAKAGE AND OIL LEVEL
1. Make sure that gear oil is not leaking from final drive assembly or around it.
2. Check oil level from filler plug hole as shown.
CAUTION:
Do not start engine while checking oil level.
3. Apply sealant to filler plug. Install filler plug to final drive assem-
bly and tighten to the specified torque. Refer toRFD-15, "
COM-
PONENTS".
PDIA1038E
OilgradeandViscosity:
Refer toMA-14, "
Fluids and Lubricants".
Oil capacity:
Approx. 2.01 (3-1/2pt)
PDIA1039E
PDIA1039E

RFD-10
[WITH LIMITED SLIP DIFFERENTIAL]
FRONT OIL SEAL
FRONT OIL SEAL
PFP:38189
Removal and InstallationEDS00396
REMOVAL
1. Remove the rear propeller shaft. Refer toPR-8, "Removal and Installation".
2. Remove the rear tires.
3. Remove rear drum brake. Refer toBR-31, "
Removal and Installation of Drum Brake Assembly".
4. Rotate the drive pinion back and forth 2 to 3 times using Tool
and record the rotating torque.
5. Remove the drive pinion lock nut and washer using Tool.
6. Put a matching mark on the thread edge of drive pinion. The
mark should be in line with the mark on companion flange.
CAUTION:
For matching mark, use paint. Do not damage drive pinion
and companion flange.
7. Remove the companion flange using suitable tool.Tool number : ST3127S000
PDIA0309E
Tool number : KV40104000
LDIA0122E
SDIA2590E
WDIA0249E

FRONT OIL SEAL
RFD-11
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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MA
B
RFD
8. Remove the front oil seal using Tool.
CAUTION:
Do not damage axle housing.
INSTALLATION
1. Install the front oil seal into the axle housing using a suitable
tool.
CAUTION:
lDo not reuse oil seal.
lDo not incline oil seal when installing.
lApply multi-purpose grease onto oil seal lip, and gear oil
onto the circumference of oil seal.
2. Align the matching mark of the drive pinion with the mark of the
companion flange, then install the companion flange.
3. Install the washer and drive pinion lock nut. Tighten the nut until
there is zero bearing end play using Tool.
CAUTION:
Do not reuse drive pinion lock nut and washer.Tool number : KV381054S0
LDIA0124E
PDIA1040E
SDIA2590E
Tool number : KV40104000
LDIA0122E

RFD-12
[WITH LIMITED SLIP DIFFERENTIAL]
FRONT OIL SEAL
4. Rotate the drive pinion using Tool. Rotating torque should be
equaltothereadingrecordedinstep4aboveduringremoval
plus an additional 0.56 N·m (5 in-lb).
5. If the rotating torque is low, continue to tighten the drive pinion
lock nut in 6.8 N·m (5 ft-lb) increments without overtightening.
Refer toRFD-15, "
COMPONENTS". Tighten until proper rotat-
ing torque is achieved.
CAUTION:
lDo not loosen the drive pinion lock nut to decrease drive
pinion rear bearing rotating torque.
lDo not exceed specified rotating preload torque. If preload torque or rotating torque is exceeded
a new collapsible spacer must be installed.
lDo not exceed maximum tightening torque. If maximum tightening torque is reached prior to
reaching the required rotating torque, the collapsible spacer may have been damaged. Replace
the collapsible spacer.
6. Check the gear oil level. Refer toRFD-9, "
Checking Differential Gear Oil".
7. Install the remaining components in the reverse order of removal.Tool number : ST3127S000
PDIA0309E

CARRIER COVER
RFD-13
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
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MA
B
RFD
CARRIER COVERPFP:38351
Removal and InstallationEDS00397
REMOVAL
1. Remove the drain plug and drain the gear oil. Refer toRFD-9, "DRAINING".
2. Disconnect the rear cable (LH) from the carrier cover. Refer toPB-3, "
Components".
3. Remove bracket from the axle housing.
4. Remove the carrier cover bolts. Then separate carrier cover
from the axle housing using Tool.
CAUTION:
lBe careful not to damage the mating surface.
lDo not insert flat-bladed screwdriver, this will damage the
mating surface.
INSTALLATION
1. Apply sealant to mating surface of carrier cover. Refer toRFD-
15, "COMPONENTS".
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
2. Install carrier cover and bracket on axle housing. Then tighten
carrier cover bolts to the specified torque. Refer toRFD-15,
"COMPONENTS".
3. Connect the rear cable (LH) to the carrier cover and tighten to
the specified torque. Refer toPB-3, "
Components".
4. Fill with new gear oil until oil level reaches the specified limit
near filler plug hole. Refer toRFD-9, "
Checking Differential Gear
Oil".
PDIA1066E
Tool number : KV10111100
PDIA1041E
PDIA1042E
PDIA1066E

RFD-14
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
REAR FINAL DRIVE ASSEMBLY
PFP:38300
Removal and InstallationEDS00398
REMOVAL
1. Remove the rear propeller shaft. Refer toPR-8, "Removal and Installation".
lPlug rear end of transmission or transfer.
2. Remove the axle shafts and back plate and torque members. Refer toRAX-7, "
Removal and Installation".
3. Disconnect the following components from the rear final drive.
lABS sensor wire harness
lRear cable (LH) and rear cable (RH)
lBrake hoses and brake tube
CAUTION:
Position the wire harness, cable and hoses away from the final drive assembly. Failure to do so
may result in components being damaged during rear axle assembly removal.
4. Support the rear final drive using a suitable jack.
5. Remove rear shock absorber lower bolts. Refer toRSU-6, "
Removal and Installation".
6. Remove leaf spring U-bolt nuts. Refer toRSU-7, "
Removal and Installation".
WARNING:
Support the rear final drive assembly using suitable jack before removing leaf spring U-bolt nuts.
7. Remove rear final drive assembly using suitable jack.
INSTALLATION
Installation is the reverse order of removal.
lWhen oil leaks while removing rear final drive assembly, check oil level after the installation. Refer to
RFD-9, "
Checking Differential Gear Oil".
lRefill brake fluid and bleed the air from the brake system. Refer toBR-11, "Bleeding Brake System".

REAR FINAL DRIVE ASSEMBLY
RFD-15
[WITH LIMITED SLIP DIFFERENTIAL]
C
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MA
B
RFD
Disassembly and AssemblyEDS00399
COMPONENTS
1. Drive pinion lock nut 2. Washer 3. Companion flange
4. Front oil seal 5. Front bearing thrust washer 6. Drive pinion front bearing
7. Axle housing 8. Breather 9. Drain plug
10. Side bearing cap 11. Adjuster lock plate 12. Carrier cover
13. Filler plug 14. Bracket 15. Drive pinion
16. Drive pinion height adjusting washer 17. Drive pinion rear bearing 18. Collapsible spacer
19. Side bearing adjuster 20. Side bearing 21. Differential case assembly
22. Drive gear
PDIA1083E

RFD-16
[WITH LIMITED SLIP DIFFERENTIAL]
REAR 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 operation of the bearing.
3. Turn drive pinion in both directions several times to set bearing
rollers.
4. Measure total preload with preload gauge.
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 pinion
bearing preload and side bearing preload.
Adjust pinion bearing preload first, then adjust side bearing preload.
Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive
pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check
gear tooth contact pattern to obtain the best contact for low noise and long life.
1. Remove carrier cover. Refer toRFD-13, "
Removal and Installation".
2. Thoroughly clean drive gear and drive pinion teeth.
3. Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.Tool number : ST3127S000
To ta l p r e l o a d
Gear ratio 3.357 Type:
2.38 - 4.46 N·m (0.25 - 0.45 kg-m, 21- 39 in-lb)
Gear ratio 3.538 Type:
2.34 - 4.34 N·m (0.24 - 0.44 kg-m, 21- 38 in-lb)
Gear ratio 3.692 Type:
2.32 - 4.34 N·m (0.24 - 0.44 kg-m, 21 - 38 in-lb)
When the preload torque is greater than specification
On pinion bearings: Replace collapsible spacer.
On side bearings: Loosen side bearing adjuster.
When the preload torque is less than specification
On pinion bearings: Tighten drive pinion lock nut.
On side bearings: Tighten side bearing adjuster.
PDIA0309E
PDIA0321E

REAR FINAL DRIVE ASSEMBLY
RFD-17
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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B
RFD
4. Hold companion flange steady by hand and rotate drive gear in
both directions.
5. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer toRFD-23, "
Drive
Pinion Height Adjusting Washer"andRFD-17, "Backlash".
Backlash
1. Remove carrier cover. Refer toRFD-19, "Differential Assembly".
2. Check drive gear to drive pinion backlash using a dial indicator
at several points.
3. If outside the standard, adjust side bearing adjusters.
CAUTION:
Check tooth contact and total preload after adjusting side
bearing adjusters. Refer toRFD-16, "
Total Preload Torque",
RFD-16, "
Tooth Contact".
a. Remove adjuster lock plates.
b. Loosen side bearing cap bolts.
PDIA0322E
SDIA2591E
Drive gear to drive pinion backlash:
0.08 - 0.13 mm (0.0031 - 0.0051 in)
SDIA2640E