NISSAN PICK-UP 1998 Repair Manual

Inspection
CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow
dry with compressed air.
2. If the following surfaces are found with burrs or scratches,
smooth with oil stone.
V1Differential case B
V2Differential case A
V3Side gear
V4Pinion mate gear
V5Pinion mate shaft
V6Thrust block
V7Friction plate guide
DISC AND PLATE
1. Clean the discs and plates in suitable solvent and blow dry
with compressed air.
2. Inspect discs and plates for wear, nicks and burrs.
3. Check friction discs or plates for warpage.
Maximum allowable warpage:
0.08 mm (0.0031 in)
If it exceeds limits, replace with a new disc or plate to elimi-
nate possibility of clutch slippage or sticking.
SPD291
SPD279
LIMITED SLIP DIFFERENTIALC200
PD-40

4. Measure frictional surfaces and projected portions of friction
discs, plates and spring plate. If any part has worn beyond
the wear limit, replace it with a new one that is the same
thickness as the projected portion.
Wear limit:
0.1 mm (0.004 in) or less
Adjustment
FRICTION DISC AND FRICTION PLATE END PLAY
End play of friction disc and friction plate can be calculated by
using the following equation and should be adjusted within the
following range.
Adjustment can be made by selecting friction disc having two
different thicknesses.
End play E:
0.05 - 0.15 mm (0.0020 - 0.0059 in)
E=Aþ(B+C)
A: Length of differential case contact surface to differential
case inner bottom.
B: Total thickness of friction discs, friction plates and spring
plate in differential case on one side.
C: Length of differential case contact surface to back side of
side gear.
1. Measure values of ``A''.
Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in)
SPD421A
SPD428A
SPD417
LIMITED SLIP DIFFERENTIALC200
Inspection (Cont'd)
PD-41

2. Measure thickness of each disc and plate.
Total thickness ``B'':
19.24 - 20.36 mm (0.7575 - 0.8016 in)
No. of discs and plates (One side):
Friction disc 6
Friction plate 6
Spring plate 1
3. Measure values of ``C''.
a. Attach a dial indicator to the base plate.
b. Place differential case B on the base plate, and install a
master gauge on case B.
Then adjust the dial indicator scale to zero with its tip on the
master gauge.
c. Install pinion mate gears, side gears and pinion mate shaft
in differential case B.
d. Set dial indicator's tip on the side gear, and read the indica-
tion.
Example:
E=AþD
=Aþ(B+C)
= 0.05 to 0.15 mm
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D=B+C
B ... 19.45
+ C ... 29.7
49.15
E=AþD
A ... 49.52
þD ... 49.15
0.37
From the above equation, end play of 0.37 mm exceeds the
specified range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.
SPD420
SPD418
SPD419
LIMITED SLIP DIFFERENTIALC200
Adjustment (Cont'd)
PD-42

Assembly
Prior to assembling discs and plates, properly lubricate them by
dipping them in limited slip differential oil.
1. Alternately position specified number of friction plates and
friction discs on rear of side gear.
Always position a friction plate first on rear of side gear.
2. Install spring plate.
3. Install friction plate guides.
Correctly align the raised portions of friction plates, and
apply grease to inner surfaces of friction plate guides to
prevent them from falling.
4. Install differential case B over side gear, discs, plates and
friction plate guide assembly.
lInstall differential case B while supporting friction plate
guides with your middle finger by inserting through oil
hole in differential case.
lBe careful not to detach spring plate from the hexagonal
part of the side gear.
5. Install pinion mate gears and pinion shaft to differential
case B.
SPD421
SPD432A
SPD424
SPD425
SPD426
LIMITED SLIP DIFFERENTIALC200
PD-43

6. Install thrust block.
7. Install side gear to pinion mate gears.
8. Install each disc and plate.
Use same procedures as outlined in steps 1. through 3.
9. Install differential case A.
Position differential cases A and B by correctly aligning
marks stamped on cases.
10. Tighten differential case bolts.
11. Place ring gear on differential case and install new bolts.
Tighten bolts in a criss-cross fashion, lightly tapping bolt
head with a hammer.
12. Install side bearing inner cone.
13. Check differential torque.
SPD427
SPD429
SPD430
SPD422A
LIMITED SLIP DIFFERENTIALC200
Assembly (Cont'd)
PD-44

For quiet and reliable final drive operation, the following five
adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload. Refer to ``ASSEMBLY'', PD-53.
4. Ring gear-to-pinion backlash. Refer to ``ASSEMBLY'',
PD-54.
5. Ring and pinion gear tooth contact pattern
Side Bearing Preload
A selection of carrier side bearing preload shims is required
for successful completion of this procedure.
1. Make sure all parts are clean. Make sure, also, the bearings
are well lubricated with light oil or type ``DEXRON
TM'' auto-
matic transmission fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.
3. Put the side bearing spacer in place.
CAUTION:
Side bearing spacer is placed on either the right or left
depending upon final drive gear ratio. Be sure to replace it
on the correct side.
4. Use Tool to place original carrier side bearing preload shims
on the carrier end, opposite the ring gear.
Tool number: KV38100600
SPD919
SPD894
SPD986
ADJUSTMENTC200
PD-45

5. Install the side bearing caps in their correct locations and
torque the bearing cap retaining bolts.
Specification:
88-98N´m
(9.0 - 10.0 kg-m, 65 - 72 ft-lb)
6. Turn the carrier several times to seat the bearings.
7. Measure the turning torque of the carrier at the ring gear
retaining bolts with a spring gauge.
Specification:
34.3 - 39.2 N
(3.5 - 4.0 kg, 7.7 - 8.8 lb)
of pulling force at the ring gear bolt
8. If the turning torque is not within the specifications, correct
the torque as follows:
lIf the turning torque is less than the specified range, install
washers of greater thickness.
lIf the turning torque is greater than the specification, install
thinner washers.
lSee the SDS section for washer dimensions and part num-
bers.
9. Record the total amount of washer thickness required for the
correct carrier side bearing preload.
10. Remove the carrier from the final drive housing. Save the
selected preload washers for later use during the assembly
of the final drive unit.
SPD526
SPD194A
SPD772
PD344
ADJUSTMENTC200
Side Bearing Preload (Cont'd)
PD-46

Drive Pinion Height
1. Prepare Tools for pinion height adjustment.
V1Dummy Shaft (KV38103910)
V2Height Gauge (KV38100120)
V3Stopper (KV38100140)
V4Feeler Gauge
2. To simplify the job, make a chart, like the one below, to
organize your calculations.
LETTERS HUNDREDTHS OF A MILLIMETER
H: Head number
N: Measuring clearance
3. Write the following numbers down the chart.
H: Head number
4. Set Tool (Dummy shaft) as shown at left and tighten drive
pinion nut carefully to correct preload of 1.0 to 1.3 N´m (10
to 13 kg-cm, 8.7 to 11.3 in-lb).
Tool number: KV38103910
SPD233
SPD542
SPD756
ADJUSTMENTC200
PD-47

5. Attach Tool (Height gauge) to gear carrier, and measure the
clearance ``N'' between the height gauge and the dummy
shaft face.
Tool number: KV38100120
6. Substitute these values into the equation to calculate the
thickness of the washer.
If value signifying H is not given, regard it as zero and cal-
culate.
T (Thickness of washer)=Nþ(Hx0.01) + 3.00
Example:
N = 0.23
H=1
T=Nþ(Hx0.01) + 3.00 = 0.23 þ (1 x 0.01) + 3.00
(1) H ................................................................. 1
x 0.01
+0.01
(2) N ............................................................ 0.23
þ (+0.01)
0.22
(3) 0.22
+3.00
3.22
\T = 3.22
7. Select the proper washer. (Refer to SDS.)
If you cannot find the desired thickness of washer, use
washer with thickness closest to the calculated value.
Example:
Calculated value ... T = 3.22 mm
Used washer ... T = 3.21 mm
SPD757
ADJUSTMENTC200
Drive Pinion Height (Cont'd)
PD-48

Tooth Contact
Checking gear tooth contact pattern is necessary to verify cor-
rect relationship between ring gear and drive pinion.
Hypoid gear set which is not positioned properly may be noisy,
or have short life or both. With the checking or gear tooth con-
tact pattern, the most desirable contact for low noise level and
long life can be assured.
1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.
3. Hold companion flange steady and rotate the ring gear in
both directions.
SPD199
SPD200
SPD007
ADJUSTMENTC200
PD-49