INFINITI FX35 2004 Service Manual

FFD-16
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
COMPONENTS (VK45DE)
1. Washer 2. Carrier cover 3. Gear oil defence
4. Breather joint 5. Dowel pin 6. Drive pinion height adjusting washer
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
7. Drive pinion 8. Drive gear 9. Side bearing adjusting washer
10. Differential case 11. Side bearing 12. O-ring
13. Front oil seal 14. Side retainer 15. Side bearing adjusting shim
16. Air breather hose 17. Bushing 18. Breather tube
19. Companion flange 20. Drive pinion bearing 21. Drive pinion bearing adjusting
washer
22. Drive pinion adjusting washer 23. Extension tube retainer 24. Dust sealed
25. Side shaft 26. Extension tube 27. Carrier case
28. Side gear thrust washer 29. Lock pin 30. Pinion mate gear
31. Pinion mete thrust washer 32. Pinion mate shaft 33. Circlip
34. Side gear 35. Filler plug 36. Drain plug
37. Drive pinion lock nut 38. Side oil seal 39. Side shaft oil seal
40. Bearing

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FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
Side ShaftADS000NN
BEARING AND OIL SEAL REPLACEMENT
1. Hold the extension tube retainer with commercial service tool,
then press out the side shaft using a press.
2. Remove the side shaft oil seal from the extension tube retainer
with a flat blade screwdriver.
3. Apply multi-purpose grease to the side shaft oil seal lips, the
install it into the extension tube retainer using special service
tool.
4. Support the new bearing inner race with special service tool,
then press the side shaft into the bearing using a press.
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Tool number : ST19820000 ( – )
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Tool number : ST30032000 ( – )
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
EXTENSION TUBE REPLACEMENT
1. Drain engine oil. Refer to MA-17, "Changing Engine Oil" (VQ35DE) or MA-24, "Changing Engine Oil"
(VK45DE).
2. Ply out the extension tube from the engine oil sump.
3. Remove the O-rings from the extension tube and replace them
with new ones.
4. Apply grease to the new extension tube O-rings.
5. Install the extension tube into the engine oil sump.
PRE-DISASSEMBLY INSPECTION
Before disassembling the front final drive, perform the following inspection.
To ta l P r e l o a d
1. Place the front final drive onto the attachment and secure it.
2. Drain the final drive oil.
3. Remove the carrier cover.
CAUTION:
When the carrier case is damaged, replace the final drive
assembly.
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FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
4. Turn the companion flange in both direction 20 times or more to
seat the bearing rollers.
5. Check total preload with special service tool.

If the preload value is out of standard, adjust pinion bearing
preload and side bearing preload.
Drive Gear to Drive Pinion Gear Backlash
Set the dial indicator to the drive gear face and measure the back-
lash.
If the measured value is out of standard, adjust the backlash by
replacing the side bearing adjusting shim (differential case side).

If the backlash too large, decrease side bearing adjusting shim
thickness.

If the backlash too small, increase side bearing adjusting shim
thickness.
Drive Gear Runout
1. Set dial gauge to behind the drive gear and measure the ring gear runout.
a. If the runout is exceed limit, check for drive gear assembly:

any object between the drive gear and differential case

deformed differential case

deformed drive gear
b. If drive gear is deformed, replace the drive gear and pinion gear as a set. If the differential case is
deformed, replace the differential case.
Companion Flange Runout
1. Set the dial gauge to the companion flange face and measure
runout.
2. Set the dial gauge to the inside face of the companion flange
and measure the runout.
CAUTION:
Clean inside face of companion flange before measuring
runout.
a. If runout is out side limit, remove the companion from the drive
pinion. Turn the companion flange position 90° each, and measure the runout again.
b. If runout valve still out side of the limit, replace companion flange.Tool number : ST3127S000 (see J25765-A)
Total preload : 1.56 - 2.65 N·m
(0.16 - 0.27 kg-m, 14 - 23 in-lb)
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If the preload value too large : Decrease the drive pinion bearing adjusting washer thickness.
: Decrease the drive pinion adjusting washer thickness.
: Increase the side bearing adjusting shim thickness.
If the preload value too small : Increase the drive pinion bearing adjusting washer thickness.
: Increase the drive pinion adjusting washer thickness.
: Decrease the side bearing adjusting shim thickness.
Standard drive gear backlash
: 0.10 - 0.15 mm(0.0039 - 0.0059) in
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Runout limit : 0.05 mm (0.0020 in) or less
Runout limit : 0.18 mm (0.007 in) or less
Runout limit : 0.13 mm (0.005 in) or less
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c. If runout valve still out side of limit after replacing companion flange, check pinion bearing and drive pinion
assembly, and pinion bearing damage.
Tooth Contact
Check tooth contact. Refer to FFD-30, "TOOTH CONTACT INSPECTION" .
DISASSEMBLY AND ASSEMBLY
REMOVAL OF DRIVE GEAR AND DIFFERENTIAL CASE ASSEMBLY
1. Remove the side retainer mounting bolt.
2. Remove the retainer by pulling it and tapping carrier case using a plastic hammer.
3. Remove the differential case assembly from the carrier case.
CAUTION:
Be careful not to damage the carrier cover mating surface.
4. Remove the side bearing outer race using puller.
5. Keep the side bearing outer races together with inner race. Do
not mix them up. Also, keep adjusting washers together with
bearings.
6. Drive out the side oil seals from the carrier case.
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FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
REMOVAL OF DRIVE PINION ASSEMBLY
1. Hold the companion flange using cam sprocket wrench or flange wrench, remove the pinion lock nut.
2. Remove the companion flange using puller.
3. Temporarily install drive pinion lock nut.
CAUTION:
Install the drive pinion lock nut until it flash with the drive
pinion end.
4. Remove the drive pinion from the carrier case.
5. Remove the bearing outer race by tapping the race evenly.
6. On companion flange side, remove the bearing outer race with
bearing and oil seal.
7. Press out the drive pinion bearing from the drive pinion using
puller.
DIFFERENTIAL CASE DISASSEMBLY
1. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove.
CAUTION:

To prevent damage to the side bearing and drive gear,
place copper plates between these parts and vise.

If is not necessary to remove side bearing except it is
replaced.Tool number : KV40104000 ( – )
Tool number : ST30031000 (J22912–01 )
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Tool number
A: ST3305S001 (−)
B: ST33061000(J8107−2)
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45

Be careful not to confuse left-hand and right-hand parts.
Keep bearing and bearing race for each side together.
2. Loosen drive gear mounting bolt in a crisscross fashion.
3. Tap drive gear off the differential case with a soft hammer.

Tap evenly all around to keep the drive gear from binding.
4. Disassembly the differential case.
a. Drive out the pinion mate shaft lock pin using punch.
b. Remove the pinion mate shaft.
c. Turn the pinion mate gear, then remove the pinion mate gear,
pinion mate thrust washer, side gear and side gear thrust
washer from the differential case.
SPD022
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Tool number : KV31100300 ( – )
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FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
d. Check mating surfaces of differential case, side gears, pinion
mate gears, pinion mate shaft and thrust washers.
INSPECTION

Clean up the disassemble parts. Then, inspect if the parts are wear or damaged. If so, follow the mea-
sures below.
Differential Case AssemblyADS000NO
1. Apply gear oil to contact surfaces of each gear, thrust washers
and differential case.
2. Install the removed thrust washer or same thickness washer to
side gear.
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Content Measures
Drive gear and drive pinion

If the gear teeth do not mesh or line-up correctly, determine the cause and
adjust, repair, or replace as necessary.

If the gear are worn, cracked, damaged, pitted or chipped (by friction)
noticeably, replace with new gears.
Bearing

If found any chipped (by friction), pitted, worn, rusted, scratched mark, or
unusual noise from the bearing, replace with new bearing assembly (as a
new set).
Side gear and pinion mate gear

Replace with a new one if found any cracks or damage on the surface of
the tooth.

Replace with a new one if found any worn or chipped mark on the contact
sides of the thrust washer.
Side gear thrust washer and pinion mate thrust washer

Replace with a new one if found that it is chipped (by friction), damaged, or
unusual worn.
Oil seal

Oil seals must be replaced with a new one whenever disassembled.
Differential case

Replace with a new one if found any wear or cracks on the contact sides of
the differential case.
Companion flange

Replace with a new one if found any chipped marks (about 0.10 mm,
0.0038 in) or other damage on the contact sides of the lip of the companion
flange.
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FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
3. Install the side gear, thrust washers, pinion mate gears and
thrust washers to differential case.
CAUTION:
Install the circlip equipped side gear to the side retainer
side.
4. Install pinion mate gears by placing the pair of gear facing each
other, and turning them.
5. Install the pinion mate shaft while aligning the lock pin holes
between the differential case and pinion mate shaft.
6. Place the differential gear case so that measurement point fac-
ing up as shown.
7. Use two feeler gauges to prevent leaning of side gear as shown.
8. Measure the clearance at 3 points by turning the side gear.
9. Select side gear thrust washer so that the clearance is within
standard.
CAUTION:
Check the smooth gear movement.
10. Place the differential gear case upside down, and measure the
opposite side clearance.
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Rear face of side gear and differential case clearance
: 0.20 mm (0.0079 in) or less
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