lan s INFINITI FX35 2004 Service Manual

FFD-28
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:
Do not install the drive pinion adjusting washer and drive pinion bearing adjusting washer at this
time.
c. Install the companion flange without installing oil seal.
d. Apply oil drive pinion lock nut threads and seating surface, then temporarily install it.
e. Tighten the drive pinion lock nut until it reach standard preload.
CAUTION:
Tighten the drive pinion nut by very small degrees until the
specified preload in achieved. Do not tighten nut more than
necessary.
DIFFERENTIAL CASE INSTALLATION
1. Drive side bearing outer race into the carrier case with tool.
CAUTION:
Do not apply excessive force to the race.
2. Drive side bearing outer race into the side retainer with tool.
3. Apply oil to the bearing portion.
4. Install the deferential case assembly to the carrier case.
CAUTION:
Be careful not to damage the carrier cover mating surface.
5. Install the side bearing adjusting shim to the side retainer, tighten the bolt to specified torque.
CAUTION:
Install removed adjusting shim or same thickness shim.
NOTE:
Do not install O-ring.Tool number : KV40104000(−)
Pinion bearing preload without oil seal
: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
SDIA1669E
Tool number : KV31103000 ( – )
SDIA1680E
Tool number : KV31103000 ( – )
SDIA1679E

FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
6. Turn the companion flange more than 20 times, measure the
preload using preload gauge.

If the preload value is out of standard, adjust preload by changing adjusting shim thickness (side
retainer side).Tool number : ST3127S000(see J25765-A)
Total preload standard (without oil seal)
: 1.56 - 2.65 N·m (0.16 - 0.27 kg-m, 14 - 23 in-lb)
SDIA1649E
If preload too large, decrease side bearing adjusting shim thickness.
If preload too small, increase side bearing adjusting shim thickness.

FFD-30
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
TOOTH CONTACT INSPECTION
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive
pinion.
Hypoid 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. Thoroughly clean drive gear and drive pinion teeth.
2. Lightly apply a mixture of powdered ferric oxide and oil or the
equivalent. Apply it to 3 or 4 teeth on the drive side of drive
gear.
3. Hold companion flange steady by hand and rotate the drive gear
in both directions.
4. Check the tooth contact on both sides (drive side and coast
side).
NOTE:
Refer to FFD-31, "
TOOTH CONTACT PATTERN AND HEIGHT
ADJUSTING WASHER SELECTION" for detail of tooth contact
pattern.
SDIA0054J
SDIA1711E

FFD-32
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
2. If there is heel contact or face contact, increase point height
adjusting washer in order to bring drive pinion close to drive
gear.
3. If there is toe contact or flank contact, decrease pinion adjusting
washer in order to make drive pinion go away from drive gear.
4. Set dial indicator to the drive gear face and measure the bak-
clash.

If the measured value out of standard, adjust the backlash by
replacing the side bearing adjusting shim (carrier case side).
–If backlash too large, decrease side bearing adjusting shim
thickness.
–If backlash too small, increase side bearing adjusting shim
thickness.
SDIA1712E
SDIA1713E
Standard drive gear back-
lash: 0.10 - 0.15 mm
(0.0039 - 0.0059 in)
SDIA0009J

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

FFD-34
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:

Tighten the drive pinion nut by very small degrees until the specified preload in achieved. Do
not tighten nut more than necessary.

First select the thicker washer, then gradually select thinner one.

Do not apply preload more than necessary.
Reassembly of drive pinion assembly
1. The standard preload is obtain when the drive pinion nut is tightened to specified toque, remove the pin-
ion.
2. Remove the companion flange using puller.
3. Drive out the drive pinion from carrier case using copper hammer.
4. Apply gear oil to bearing portion.
5. Install the drive pinion with selected drive pinion adjusting washer and drive pinion bearing adjusting
washer into the carrier case, then install bearing.
6. Apply multi-purpose grease to oil seal lips.
7. Drive oil seal into the final drive using drift.
8. Install companion flange.
9. Apply oil to new drive pinion lock nut threads and seating sur-
face, then install it onto the drive pinion.
CAUTION:
Do not reuse drive pinion lock nut. Always replace nut with
new one.
10. Turn the companion flange more than 20 times to seat bearing.
11. Tighten the drive pinion lock nut to specified torque.
CAUTION:
Do not overtighten the nut.
12. Measure the preload using preload gauge.Drive pinion lock nut torque : 186.2 N·m (19 kg-m, 137 ft-lb)
Pinion bearing preload without oil seal : 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
When the washer thickness is increased : Preload will decrease.
When the washer thickness is decreased : Preload will increase.
Tool number A: ST33400001 (J26082)
B: KV38102510 ( – )
SDIA1681E
Tool number : KV40104000 (−)
SDIA1669E
Tool number : ST3127S000 (see J25765-A)
Pinion bearing preload without oil seal
: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
SDIA1649E

FRONT FINAL DRIVE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
Installation of differential case assembly
1. Apply gear oil to side bearing, then install the differential case assembly into carrier case.
CAUTION:
Be careful not damage the carrier cases mating surface.
2. Apply multi-purpose grease to the oil seal lips.
3. Install oil seal into the side retainer using drift.
CAUTION:
After tightening the bolt, wipe off excess sealant from
inside of case.
4. Apply liquid sealant to side retainer mounting hole of carrier case.
5. Install selected side bearing adjusting shim and O-ring to the side retainer, then install it to carrier case.
CAUTION:
After installing adjusting shim onto side retainer, apply gear oil to O-ring and install it.
6. Tighten side retainer mounting bolt to specified torque. Refer to FFD-14, "
COMPONENTS (VQ35DE)" or
FFD-16, "
COMPONENTS (VK45DE)" .
After InspectionADS000NS
1. Turn drive pinion and drive gear several times.
Set dial indicator to the drive gear face and measure the back-
lash.

If the measured value out of standard, adjust the backlash by
replacing the side bearing adjusting shim (carrier case side.)
–If backlash too large, decrease side bearing adjusting shim
thickness.
–If backlash too small, increase side bearing adjusting shim
thickness.
2. Check the back face of drive gear runout.
3. Set dial gauge to back of drive gear and measure the drive gear runout.

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

if drive gear is deformed, replace the hypoid gear as an
assembly. If the differential case is deformed, replace the dif-
ferential case.
4. Check the companion flange face and inside diameter runout.
a. Set the dial gauge to the companion flange face and measure
runout.
b. Set the dial gauge to the inside diameter of the companion flange and measure the runout.
Mark paint to maximum runout position.Tool number : ST33400001 (J26082)
SDIA1682E
Standard drive gear backlash : 0.10 - 0.15 mm
(0.0039 - 0.0059 in)
Runout limit : 0.05 mm (0.0020 in) or less
Runout limit : 0.18 mm (0.0070 in) or less
Runout limit : 0.13 mm (0.0051 in) less
SDIA0009J
SDIA1651E

FFD-36
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:
Clean inside of companion flange before measuring runout.

If runout is exceed limit, remove the companion from the drive pinion. Turn the companion flange posi-
tion 90° each, and measure the runout again.

If runout still exceed limit, replace companion flange.

If runout still exceed limit after replacing companion flange, check pinion bearing and drive pinion
assembly, and pinion bearing damage.
5. Turn companion flange in both directions 20 times to more,
check total preload with tool.

If the preload value is out of standard, adjust pinion bearing
preload and side bearing preload.
If preload value too large:
–Decrease the drive pinion bearing adjusting washer thick-
ness.
–Decrease the drive pinion adjusting washer thickness.
–Increase the side bearing adjusting shim thickness.
If preload value too small:
If preload value to small:
–Increase the drive pinion bearing adjusting washer thickness.
–Increase the drive pinion adjusting washer thickness.
–Decrease the side bearing adjusting shim thickness.
Carrier Cover InstallationADS000NT
1. Apply sealant to mating surface of carrier cover and carrier case
as shown.
CAUTION:
Clean any residual gasket material off from mating surface
before applying sealant.
2. Install the carrier cover to carrier case, tighten the bolts to spec-
ified torque. Refer to FFD-14, "
COMPONENTS (VQ35DE)" or
FFD-16, "
COMPONENTS (VK45DE)" .
3. Apply sealant to drain plug and filler plug threads.
Install and tighten the plugs to specified torque.
NOTE:
After installing front final drive on vehicle, fill it with specified
amount of gear oil. Refer to FFD-14, "
COMPONENTS
(VQ35DE)" or FFD-16, "COMPONENTS (VK45DE)" . Tool number : ST3127S000 (see J25765-A)
Total preload with oil seal installed
: 1.56 - 2.65 N·m
(0.16 - 0.27 kg-m, 14 - 23 in-lb)
SDIA1649E
SDIA1683E
SDIA1648E

FSU-2
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
CautionAES000MZ

When installing rubber bushings, final tightening must be carried out under unladen conditions with tires
on ground. Oil will shorten the life of rubber bushings. Be sure to wipe off any spilled oil.

Unladen conditions mean that fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and
mats are in designated positions.

After servicing suspension parts, be sure to check wheel alignment.

Caulking nuts are not reusable. Always use new ones when installing. Since new caulking nuts are pre-
oiled, tighten as they are.

Avoid burden to front cross bar.

FSU-6
FRONT SUSPENSION ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
FRONT SUSPENSION ASSEMBLYPFP:54010
On-Vehicle Inspection and ServiceAES000N3
Make sure the mounting conditions (looseness, back lash) of each component and component statues (wear,
damage) are normal.
INSPECTION OF TRANSVERSE LINK BALL JOINT END PLAY
1. Set front wheels in a straight-ahead position. Do not depress brake pedal.
2. Measure axial end play by installing and moving up/down between transverse link and steering knuckle
with an iron pry bar or something similar.
CAUTION:
Be careful not to damage ball joint boot.
STRUT INSPECTION
Check strut for oil leakage, damage and replace if necessary. Refer to FSU-11, "COIL SPRING AND STRUT" .
Wheel Alignment InspectionAES000N4
DESCRIPTION
Measure wheel alignment under unladen conditions.
NOTE:
Unladen conditions mean that fuel, engine coolant, and lubricant are full. Spare tire, jack, hand tools and mats
are designated positions.
PRELIMINARY CHECK
1. Check tires for improper air pressure and wear.
2. Check road wheels for runout.
3. Check wheel bearing axial end play.
4. Check transverse link ball joint axial end play.
5. Check strut operation.
6. Check each mounting part of axle and suspension for looseness and deformation.
7. Check each link, rod and member for cracks, deformation and other damage.
8. Check vehicle posture.
INSPECTION OF CAMBER, CASTER AND KINGPIN INCLINATION ANGLES

Camber, caster, kingpin inclination angles cannot be adjusted.

Before inspection, mount front wheels onto turning radius gauge. Mount rear wheels onto a stand that has
same height so vehicle will remain horizontal.
Using a CCK Gauge
Install CCK gauge attachment (SST: KV991040S0) as following procedure in wheel, then measure wheel
alignment.
1. Remove wheel nuts (3), and install a guide bolt to hub bolt.
2. Screw adapter into plate body until it contacts body tightly.
3. Screw center plate into plate.
4. Insert plate on guide bolt. Put spring in, and then evenly screw
both guide bolt nut. When fastening guide bolt nut, do not com-
pletely compress spring.Axial end play : 0 mm (0 in)
SEIA0240E