service INFINITI FX35 2004 Service Manual

FAX-26
[AWD]
SERVICE DATA
Revision: 2004 November 2004 FX35/FX45

FFD-1
FRONT FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTION FFD
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Revision: 2004 November 2004 FX35/FX45
FRONT FINAL DRIVE
PRECAUTIONS .......................................................... 2
Precautions .............................................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6
NVH Troubleshooting Chart ..................................... 6
FRONT OIL SEAL ...................................................... 7
Removal and Installation .......................................... 7
REMOVAL ............................................................. 7
INSTALLATION ..................................................... 8
SIDE OIL SEAL .......................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
FRONT FINAL DRIVE ASSEMBLY .......................... 10
Removal and Installation (VQ35DE) ...................... 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
Removal and Installation (VK45DE) ........................ 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
Front Final Drive Breather Hose ............................ 12
REMOVAL AND INSTALLATION (VQ35DE) ....... 12
REMOVAL AND INSTALLATION (VK45DE) ....... 13
Components ........................................................... 14
COMPONENTS (VQ35DE) ................................. 14
COMPONENTS (VK45DE) ................................. 16Side Shaft ............................................................... 18
BEARING AND OIL SEAL REPLACEMENT ....... 18
EXTENSION TUBE REPLACEMENT ................. 19
PRE-DISASSEMBLY INSPECTION .................... 19
DISASSEMBLY AND ASSEMBLY ...................... 21
Differential Case Assembly .................................... 24
Installation Drive Pinion Assembly ......................... 27
DIFFERENTIAL CASE INSTALLATION .............. 28
TOOTH CONTACT INSPECTION ....................... 30
TOOTH CONTACT PATTERN AND HEIGHT
ADJUSTING WASHER SELECTION .................. 31
TOOTH CONTACT ADJUSTMENT ..................... 31
TOTAL PRELOAD INSPECTION ........................ 33
DRIVE PINION PRELOAD ADJUSTMENT ......... 33
After Inspection ....................................................... 35
Carrier Cover Installation ........................................ 36
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 37
General Specifications ............................................ 37
Drive Gear Runout .................................................. 37
Side Gear Adjustment ............................................ 37
Available Side Gear Thrust Washers ...................... 37
SIDE BEARING PRELOAD ADJUSTING SHIMS ... 37
Drive Pinion Height Adjustment .............................. 38
AVAILABLE PINION HEIGHT ADJUSTING
WASHERS .......................................................... 38
Drive Pinion Preload Adjustment ............................ 38
AVAILABLE PINION HEIGHT ADJUSTING
WASHERS .......................................................... 38
Total Preload Adjustment ........................................ 38

PREPARATION
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Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Special Service ToolsADS000N4
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number (Kent-Moore No.)
Tool nameDescription
ST33400001 (J26082)
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
Drift

Installing front oil seal

Installing right side oil sea
KV38100500 (J25273)
ST3620000 ( – )
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
DriftInstalling drive pinion oil seal
Installing side shaft oil seal (retainer side)
ST33290001 (J34286)
Outer race puller

Removing side bearing outer race

Removing side oil seal

Removing front oil seal
ST3306S001 ( – )
ST33051001 (J22888-20) body
ST33061000 (J8107-2) adapter.
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
Puller setRemoving side bearing
ST30031000 (J22912-01)
PullerRemoving drive pinion bearing
ST33230000 ( – )
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28mm (1.10 in) dia.
DriftInstalling side bearing
ST33220000 ( – )
a: 32 mm (1.26 in) dia.
b: 31.5 mm (1.24 in) dia.
c: 21 mm (0.83 in) dia.
DriftInstalling side shaft bearing
ZZA0702D
ZZA0811D
NT713
NT072
ZZA0700D
ZZA1046D
ZZA1046D

PREPARATION
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Revision: 2004 November 2004 FX35/FX45
Commercial Service ToolsADS000N5
ST35321000 ( – )
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
DriftInstalling side bearing
KV40104000 ( – )
a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia.
Drive pinion flange wrenchRemoving and installing drive pinion lock
nut
ST3127S000 (see J25765-A)
1. GG91030000
Torque wrench (J25765)
2. HT62940000 ( – )
Socket adapter (1/2″)
3. HT62900000 ( – )
Socket adapter (3/8″)
Preload gaugeInspecting pinion bearing preload and total
preload Tool number (Kent-Moore No.)
Tool nameDescription
ZZA1000D
NT659
NT124
Tool nameDescription
Power toolLoosening bolts and nuts
PBIC0190E

FRONT OIL SEAL
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Revision: 2004 November 2004 FX35/FX45
FRONT OIL SEALPFP:38189
Removal and InstallationADS000N7
REMOVAL
1. Remove the front propeller shaft. Refer to PR-4, "REMOVAL" .
2. Put a matching mark on the end of the drive pinion correspond-
ing to the B position matching mark on the final drive companion
flange.
CAUTION:

For matching mark, use paint. Never damage drive pin-
ion.

The matching mark B on the final drive companion flange
indicates the maximum vertical runout position.
3. Using the drive pinion flange wrench.Remove drive pinion lock
nut with tool.
4. Remove the companion flange using puller (commercial service
tool)
5. Remove the front oil seal using outer race puller.
SDIA1609E
Tool number : KV40104000 ( – )
SDIA1647E
SDIA1642E
Tool number : ST33290001 (J34286)
SDIA1643E

FFD-8
FRONT OIL SEAL
Revision: 2004 November 2004 FX35/FX45
INSTALLATION
1. Apply multi-purpose grease to sealing lips of the oil seal. Drive
the oil seal into the differential case using special service tool so
that the oil seal flush with the gear carrier end.
NOTE:

When installing the front oil seal, be careful not to get it
inclined.

Discard the old front oil seal. Always replace it with a new
one.
2. Install the companion flange while align the matching mark of
the drive pinion with the matching mark B of the companion
flange.
3. Apply oil to the drive pinion threads and the seating surface of
drive pinion lock nut.
4. Using the drive pinion flange wrench. Install drive pinion lock nut
with tool.
CAUTION:
Do not reuse the drive pinion lock nut. Always replace it
with a new one.
5. Install the front propeller shaft. Refer to PR-5, "
INSTALLATION"
.Tool number A : ST33400001 (J26082)
B : KV38102510 ( – )
SDIA1645E
SDIA1609E
Tool number : KV40104000 ( – )
SDIA1647E

FFD-18
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.
SDIA1628E
SDIA1629E
Tool number : ST19820000 ( – )
SDIA1630E
Tool number : ST30032000 ( – )
SDIA1631E

FFD-20
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)
SDIA1649E
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
SDIA0009J
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
SDIA1651E

FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
TOTAL PRELOAD INSPECTION
1. Turn companion flange in both directions 20 times or more to set
bearing rollers, then check total preload with special service tool.

If the preload value is out of standard, adjust by changing side
bearing adjusting shim thickness (side retainer side).
–If preload value too large, increase the side bearing adjusting
shim thickness.
–If preload value too small, decrease the side bearing adjusting shim thickness.
DRIVE PINION PRELOAD ADJUSTMENT
Removal of differential case assembly
1. Unfasten the retainer tab using a flat blade screwdriver.
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.
Removal of drive pinon assembly
1. Hold the companion flange using cam sprocket wrench or flange
wrench, remove the drive pinion lock nut.
2. Remove the companion flange using puller.
3. Temporarily install drive pinion lock nut.
CAUTION:
Avoid damaging drive pinion threads, install the drive pinion lock nut unit it flash with drive pinion
end.
4. Remove the drive pinion from the carrier case using a copper hammer.
Preload Adjustment
1. Install drive pinion adjusting washer and drive pinion bearing adjusting washer onto the drive pinion, then
install drive pinion into the carrier case.
CAUTION:
Install the removed pinion height adjusting washer and drive pinion bearing adjusting washer or
same thickness washers to drive pinion.
2. Apply gear oil to the bearing portion.
3. Install drive pinion and drive pinion bearing into the carrier case.
4. Install the companion flange without installing oil seal.
5. Apply oil to drive pinion nut threads and seating surface, then temporarily install it.
6. Turn companion flange several times to seat the bearing.
7. Tighten the drive pinion nut while measuring preload using preload gauge.
8. Select drive pinion adjusting washer and drive pinion bearing adjusting washer so that standard preload is
obtain when the drive pinion nut is tightened to specified torque.Tool number : ST3127S000 (see J25765-A)
Total preload (without oil seal)
: 1.56 - 2.65 N·m
(0.16 - 0.27 kg-m, 14 - 23 in-lb)
SDIA1649E
Tool number : KV40104000 (−)
SDIA1658E

SERVICE DATA AND SPECIFICATIONS (SDS)
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Revision: 2004 November 2004 FX35/FX45
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsADS000NE
Drive Gear RunoutADS000NF
Unit: mm (in)
Side Gear Adjustment ADS000NG
Unit: mm (in)
Available Side Gear Thrust WashersADS000OG
Unit: mm (in)
SIDE BEARING PRELOAD ADJUSTING SHIMS
Side Retainer Side:
Differential Case to Side Bearing:
Applied modelVQ35DE engine VK45DE engine
5A/T 5A/T
Final drive model F160A (2-pinion)
Gear ratio3.692
Number of teeth (Drive gear/drive pinion) 48/13
Oil capacity (Approx.) (US qt, lmp qt)0.65 (0.7,0.6)
Type F160 A
Drive gear runout limit 0.05 mm (0.002 in)
Type F16 0A
Clearance limit between side gear and differential case 0.20 mm (0.0079 in) or less
Type F16 0A
Thrust washerThickness Part number Thickness Part number
0.68 (0.0268) 38424 W1010 0.86 (0.0339) 38424 W1016
0.71 (0.0280) 38424 W1011 0.89 (0.0350) 38424 W1017
0.74 (0.0291) 38424 W1012 0.92 (0.0362) 38424 W1018
0.77 (0.0303) 38424 W1013 0.95 (0.0374) 38424 W1019
0.80 (0.0315) 38424 W1014 0.98 (0.0386) 38424 W1020
0.83 (0.0327) 38424 W1015 1.01 (0.0398) 38424 W1021
Type F16 0A
Adjusting shimsThickness Part number Thickness Part number
0.20 (0.0079) 38453 AR000 0.40 (0.0157) 38453 AR003
0.25 (0.0098) 38453 AR001 0.50 (0.0197) 38453 AR004
0.30 (0.0118) 38453 AR002
Type F16 0A
Adjusting shimsThickness Part number Thickness Part number
0.10 (0.0040) 38453 AR010 0.25 (0.0098) 38453 AR015
0.12 (0.0047) 38453 AR011 0.30 (0.0118) 38453 AR016
0.15 (0.0059) 38453 AR012 0.40 (0.0157) 38453 AR017
0.17 (0.0067) 38453 AR013 0.50 (0.0197) 38453 AR018
0.20 (0.0079) 38453 AR014 - -