INFINITI FX35 2004 Service Manual

RF-24
SUNROOF
Revision: 2004 November 2004 FX35/FX45
Wind Deflector InspectionAIS003BP
1. Make sure the wind deflector is properly raised by manual. If a
malfunction is detected, remove and visually check it. If it is
damaged, replace it with a new one. If no damage is found, rein-
stall it properly.
Link and Wire AssemblyAIS003BQ
NOTE:
Before replacing a suspect part, carefully ensure it is the source of noise being experienced.
1. Check link to determine if coating film has peeled off to such an extent that substrate is visible. Check also
to determine if link is the source of noise. If it is, replace it.
2. Visually check to determine if a sufficient amount of grease has been applied to wire or rail groove. If not,
add grease as required.
3. Check wire for any damage or deterioration. If any damage is found, replace wire.
Fitting AdjustmentAIS003BR
PIIA5061E
PIIA6188E

SUNROOF
RF-25
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Revision: 2004 November 2004 FX35/FX45
LID WEATHERSTRIP OVERLAP ADJUSTMENT AND SURFACE MISMATCH ADJUSTMENT
1. Tilt up glass lid.
2. After loosening glass lid TORX bolts (T25) (left and right), tilt
down glass lid.
3. Adjust glass lid from outside of vehicle so it resembles “A–A” “B–
B” “C–C” as shown in the figure to the right.
4. To prevent glass lid from moving after adjustment, first tighten
the TORX bolts (T25) of front left, and then tighten the TORX
bolts (T25) of rear right.
5. Tighten remaining TORX bolts (T25), being careful to prevent
glass lid from moving.
6. Tilt glass lid up and down several times to make sure it moves
smoothly.
Removal and InstallationAIS003BS

After any adjustment, check sunroof operation and glass lid alignment.

Handle finisher plate and glass lid with care so as not to cause damage.

It is desirable for easy installation to mark each point before removal.
CAUTION:

Always work with a helper.

Fully close the glass lid assembly, before removal, then do not operate motor assembly after
removal.
PIIA3501E

RF-26
SUNROOF
Revision: 2004 November 2004 FX35/FX45
PIIA6190E

SUNROOF
RF-27
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Revision: 2004 November 2004 FX35/FX45
SUNROOF UNIT ASSEMBLY
Removal
CAUTION:

Always work with a helper.

When taking sunroof unit out, use clothes to protect the seats and trim from damage.

After installing the sunroof unit and glass lid, be sure to perform the leakage test and make sure
there is no malfunction.
1. Tilt up glass lid.
2. Remove the headlining. Refer to EI-42, "
Removal and Installation" .
3. Disconnect drain hoses.
4. Remove glass lid. Refer to RF-28, "
GLASS LID" .
5. Remove motor mounting screws. Remove sunroof motor
assembly and disconnect harness connector.
CAUTION:

Before removing sunroof motor assembly, make sure
that sunroof is fully closed.

After removing sunroof motor assembly, do not attempt
to rotate sunroof motor as a single unit.
6. Remove nuts on the front end and side rail.
7. Remove curtain air bag bracket bolts, then remove curtain air
bag bracket from the rail side. Refer to SRS-43, "
Removal and
Installation" .
8. Remove front/rear sunroof bracket bolts, then remove sunroof
unit assembly from roof panel.
9. Remove sunroof unit assembly through the passenger room while being careful not to damage the seats
and trim.
1. Glass lid 2. TORX bolt (T25) 3. Washer
4. Rear sunroof bracket 5. Front sunroof bracket 6. Wind deflector
7. Sunroof unit assembly 8. Noise cover 9. Sunroof motor assembly
10. Screw 11. Sunshade 12. Nut
13. Bolt 14. Drain plate 15. Sunshade stopper
16. Drain hose
PIIA6189E
PIIA6191E
PIIA6193E

RF-28
SUNROOF
Revision: 2004 November 2004 FX35/FX45
Installation
1. Temporarily tighten the mounting bolts on the front/rear sunroof
brackets (RH/LH).
2. Bring sunroof unit assembly into passenger room and place the
rear end of the rail onto the sunroof brackets.
3. Tighten the mounting nuts on the front end.
4. Tighten the installation points diagonally excluding the installation point of the sunroof bracket around the
roof opening.
5. Tighten the bolts on the sunroof bracket to the vehicle side and
then tighten the bolt to the rail side.
6. Tighten the bolts on the curtain air bag bracket to the rail side.
Refer to SRS-43, "
Removal and Installation" .
GLASS LID
Removal
1. Tilt up glass lid.
2. Remove TORX bolts (T25) from remove glass lid.
Installation
1. Tighten bolts diagonally on the glass lid.
2. After installation, carry out fitting adjustment.
PIIA6193E
PIIA6191E
PIIA6193E
PIIA6192E

SUNROOF
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Revision: 2004 November 2004 FX35/FX45
SUNSHADE
Removal
NOTE:
Detaching is possible even with the sunshade attached on the vehicle.
1. Remove the headlining. Refer to EI-42, "
Removal and Installation" .
2. Remove sunshade stopper.
3. The protection tape is pasted to the sunshade knob.
4. Pull sunshade out of the rear end of the sunroof frame, and
remove it from the frame.
CAUTION:
Do not damage the sunshade and sunshade knob while lift-
ing up a little.
Installation
Install in the reverse order of removal.
WIND DEFLECTOR
Removal
NOTE:
Detaching is possible even with the wind deflector attached on the vehicle.
1. The sunroof is opened.
2. Remove spring hinge screws, then remove hinge from the
frame.
3. Remove the wind deflector.
Installation
Install in the reverse order of removal.
SUNROOF MOTOR ASSEMBLY
Removal
1. Remove headlining. Refer to EI-42, "Removal and Installation" .
2. Remove motor mounting screw.
3. Disconnect harness connector from sunroof motor assembly,
then remove sunroof motor assembly.
CAUTION:

When removing the sunroof motor assembly, be sure that
the sunroof is in the fully closed position.

Do not run the removed sunroof motor assembly as a
single unit.
Installation
1. Move the sunroof motor assembly laterally little by little so that the gear is completely engaged into the
wire on the sunroof unit assembly and the mounting surface becomes parallel. Then secure the sunroof
motor assembly with screws.
PIIA5064E
PIIA3510E
PIIA6189E

RF-30
SUNROOF
Revision: 2004 November 2004 FX35/FX45
CAUTION:
1. Before installing the sunroof motor assembly, be sure to place the link and wire assembly in the
symmetrical and fully closed position.
2. Confirm the body ground of the noise cover is con-
nected.
3. Initialization of it after installing the sunroof motor. Refer to RF-12, "
INITIALIZATION PROCE-
DURE" .
PIIA5062E
PIIA5063E

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTION RFD
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RFD
Revision: 2004 November 2004 FX35/FX45
REAR 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 ..................................................... 7
SIDE OIL SEAL .......................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ................................................... 10
REAR FINAL DRIVE ASSEMBLY .............................11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
Components ........................................................... 12
R200 2-PINION ................................................... 12
Pre-Inspection ........................................................ 13
TOTAL PRELOAD ............................................... 13
DRIVE GEAR TO DRIVE PINION BACKLASH ... 13
DRIVE GEAR RUNOUT ...................................... 13
COMPANION FLANGE RUNOUT ...................... 14
TOOTH CONTACT .............................................. 14
Disassembly and Assembly ................................... 14
REMOVAL OF DIFFERENTIAL CASE ASSEM-BLY ...................................................................... 14
REMOVAL OF DRIVE PINION ASSEMBLY ........ 15
DISASSEMBLY OF DIFFERENTIAL CASE
ASSEMBLY ......................................................... 17
INSPECTION ...................................................... 18
ADJUSTMENT OF DIFFERENTIAL CASE ......... 19
SIDE BEARING PRELOAD ................................. 20
PINION GEAR HEIGHT ...................................... 21
TOOTH CONTACT .............................................. 24
ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
BLY ...................................................................... 25
INSTALLATION OF DRIVE PINION ASSEMBLY ... 26
INSTALLATION OF DIFFERENTIAL CASE
ASSEMBLY ......................................................... 28
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 31
General Specifications ............................................ 31
Drive Gear Runout .................................................. 31
Side Gear Adjustment ............................................ 31
AVAILABLE SIDE GEAR THRUST WASHERS ... 31
Drive Pinion Height Adjustment .............................. 31
AVAILABLE PINION HEIGHT ADJUSTING
WASHERS .......................................................... 31
Drive Pinion Preload Adjustment ............................ 31
Side Bearing Preload Adjustment ........................... 32
SIDE BEARING ADJUSTING WASHERS .......... 32
Total Preload Adjustment ........................................ 32
Companion Flange ................................................. 32

RFD-2
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
PrecautionsADS000K2
CAUTION:

Before starting diagnosis of the vehicle, understand symptoms well. Perform correct and system-
atic operations.

Check for the correct installation status prior removal or disassembly. When matching marks are
required, be sure they do not interfere with the function of the parts they are applied to.

Carry out an overhaul in a clean work place, Using a dust proof room is recommended.

Before disassembly, using steam or white gasoline, completely remove sand and mud from the
exterior the unit, preventing them from entering into the unit during disassembly or assembly.

Check appearance of the disassembled parts for damage, deformation, and abnormal wear. If a
malfunction is detected, replace it with a new one.

Normally replace lock pins, oil seals, and bearings with new ones every times they are removed.

In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to out-
side. If tightening sequence is specified, observe it.

Clean and flush the parts sufficiently and blow them dry.

Be careful not to damage the sliding surfaces and mating surface.

When applying sealant, remove the old sealant from the mounting surface; then remove any mois-
ture, oil, and foreign materials from the application and mounting surfaces.

Always use shop paper for cleaning the inside of components.

Avoid using cotton gloves or a shop cloth to prevent entering of lint.

During assembly, observe the specified tightening torque, and new differential gear oil, Vaseline,
or multi-purpose grease, as specified for each vehicle, when necessary.

PREPARATION
RFD-3
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Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Special Service ToolsADS000JM
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number (Kent-Moore No.)
Tool nameDescription
ST30720000 (J25405)
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
DriftInstalling front oil seal
KV38100200 (J26233)
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
DriftInstalling final drive side oil seal
KV38107900 (J39352)
ProtectorInstalling final drive side flange
KV38100800 (J25604-01)
a: 541 mm (21.30 in)
b: 200 mm (7.87 in)
Attachment Fixing unit assembly
ST3306S001 ( – )
1.ST3305S001 ( – )
2.ST33061000 (J8107–2)
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
Differential side bearing puller setRemoving and installing side bearing
ST30613000 (J25742-3)
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
DriftInstalling pinion front and rear bearing outer
race
KV38100300 (J25523)
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.
DriftInstalling side bearing
ZZA0811D
ZZA1143D
S-NT129
SDIA0267E
NT072
ZZA0810D
ZZA1046D