drive INFINITI FX35 2004 Service Manual

REAR FINAL DRIVE ASSEMBLY
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DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY
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.

It is not necessary to remove side bearing except it is
replaced.

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 bolts in a crisscross fashion.
3. Tap drive gear off the differential case with a soft hammer.

Tap evenly all around to keep drive gear from binding.Tool number
A : ST3305S001 ( – )
B : ST33061000 (J8107 - 2)
SPD920
SPD022
SDIA0246J

RFD-18
REAR FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
4. Drive out pinion mate shaft lock pin with punch from drive gear
side.
5. Remove the pinion mate shaft.
6. 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.
7. Check mating surfaces of differential case, side gears, pinion
mate gears, pinion mate shaft and thrust washers.
INSPECTION

Clean up the disassembled parts. Then, inspect if the parts are wear or damaged. If so, follow the mea-
sures below.
SPD025
SDIA0031J
SDIA0032J
SDIA0187J
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 a
new gears.
Bearing

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

REAR FINAL DRIVE ASSEMBLY
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ADJUSTMENT OF DIFFERENTIAL CASE
Thrust Washer Selection
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.
3. Install the side gears, thrust washers, pinion mate gears, thrust
washers into differential case.
CAUTION:
Install the circlip equipped side gear to the side retainer
side.
4. Fit pinion mate shaft to differential case so that it meets lock pin
holes.
Side gear thrust washer and
pinion mate thrust washer
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 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 0.10mm, 0.0039in) or other damage
on the contact sides of the lips of the companion flange. Content Measures
SDIA0193J
SPD552
SDIA0195J

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Revision: 2004 November 2004 FX35/FX45
5. Adjust clearance between rear face of side gear and thrust
washer by selecting side gear thrust washer. Refer to RFD-31,
"AVAILABLE PINION HEIGHT ADJUSTING WASHERS" .
Use two feeler gauges to prevent leaning of side gear as show-
ing figure.
SIDE BEARING PRELOAD
A selection of carrier side bearing adjusting washers is required for successful completion of this procedure.
1. Make sure all parts are clean. Also, make sure the bearings are
well lubricated with gear oil.
2. Place the differential case, with side bearings and bearing races
installed, into gear carrier.
3. Insert left and right original side bearing adjusting washers in
place between side bearings and carrier.
4. Install the side bearing caps in their correct locations and torque
the bearing cap retaining bolts.
5. Turn the carrier several times to seat the bearings.Clearance between side gear thrust washer and dif-
ferential case
: 0.20 mm (0.0079 in) or less
SPD828
SPD527
SPD924
SDIA1795E

REAR FINAL DRIVE ASSEMBLY
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6. Measure the turning torque of the carrier at the drive gear retain-
ing bolts with a spring gauge, J-8129.
7. If the turning torque is not within the specifications, correct the
torque as follows:

If the turning torque is less than the specified range, install
washers of greater thickness.

If the turning torque is greater than the specification, install
thinner washers.

See the SDS section for washer dimensions and part num-
bers.
8. Record the total amount of washer thickness required for the
correct carrier side bearing preload.
9. Remove the carrier from the final drive housing. Save the
selected washers for later use during the assembly of the final
drive unit.
PINION GEAR HEIGHT
1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the differential shim
selector tool, J34309.

Pinion front bearing; make sure the J34309-3 pinion front bear-
ing seat is secured tightly against the J34309-2 gauge anvil.
Then turn the pinion front bearing pilot, J34309-5, to secure the
bearing in its proper position.

Pinion rear bearing; the pinion rear bearing pilot, J34309-8, is
used to center the pinion rear bearing only. The pinion rear bear-
ing locking seat, J34309-4, is used to lock the bearing to the
assembly.Specification
: 34.2 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb)
of pulling force at the drive gear bolt
SPD194A
SPD772
Tool number : HT72400000 ( – )
S-PD344
SPD769
SPD197A

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Revision: 2004 November 2004 FX35/FX45

Installation of J34309-9 and J34309-16; place a suitable 2.5 mm (0.098 in) thick plain washer between
J34309-9 and J34309-16. Both surfaces of J34309-9 and J34309-16 must be parallel with a clearance of
2.5 mm (0.098 in).
3. Install the pinion rear bearing inner race into the final drive hous-
ing. Then place the pinion preload shim selector tool, J34309-1,
gauge screw assembly.
4. Assemble the pinion front bearing inner race and the J34309-2
gauge anvil. Assemble them together with the J34309-1 gauge
screw in the final drive housing. Make sure that the pinion height
gauge plate, J34309-16, will turn a full 360 degrees. Tighten the
two sections together by hand.
5. Turn the assembly several times to seat the bearings.
6. Measure the turning torque at the end of the J34309-2 gauge
anvil using torque wrench J-25765A.
SPD893
SPD199A
SPD770
Turning torque specification
: 1.0 - 1.3 N·m ( 0.11 - 0.13 kg-m, 9 - 11 in-lb)
SPD234A

REAR FINAL DRIVE ASSEMBLY
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7. Place the J34309-11 “R200A” pinion height adapter onto the
gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.
Pinion Height Adjusting Washer Selection
1. Now, position the side bearing discs, J25269-4, and arbor firmly
into the side bearing bores. Install the bearing caps and tighten
the cap bolts to proper torque.
2. Select the correct standard pinion height adjusting washer thick-
ness. Select by using a standard gauge of 3 mm (0.12 in) and
your J34309-101 feeler gauge. Measure the distance between
the J34309-11 pinion height adapter including the standard
gauge and the arbor.
3. Write down your exact measurement (the value of feeler gauge).
SPD208A
SPD211A
SPD204A
SPD775

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4. Correct the pinion height washer size by referring to the “pinion
head number”.
There are two numbers painted on the drive pinion. The first one refers to the drive pinion and drive gear as a
matched set. This number should be the same as the number on the drive gear. The second number is the
“pinion head height number”. It refers to the ideal pinion height from standard for quietest operation. Use the
following chart to determine the correct pinion height washer.
5. Select the correct pinion height adjusting washer as follows. Refer to RFD-31, "
AVAILABLE PINION
HEIGHT ADJUSTING WASHERS" .
6. Remove the J34309 differential shim selector tool from the final
drive housing. Then disassemble to retrieve the pinion bearings.
TOOTH CONTACT
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.
SPD542
Pinion head height numberAdd or remove from the standard
pinion height washer thickness measurement
- 6
- 5
- 4
- 3
- 2
- 1
0
+1
+2
+3
+4
+5
+6Add 0.06 mm (0.0024 in)
Add 0.05 mm (0.0020 in)
Add 0.04 mm (0.0016 in)
Add 0.03 mm (0.0012 in)
Add 0.02 mm (0.0008 in)
Add 0.01 mm (0.0004 in)
Use the selected washer thickness
Subtract 0.01 mm (0.0004 in)
Subtract 0.02 mm (0.0008 in)
Subtract 0.03 mm (0.0012 in)
Subtract 0.04 mm (0.0016 in)
Subtract 0.05 mm (0.0020 in)
Subtract 0.06 mm (0.0024 in)
SPD205A

REAR FINAL DRIVE ASSEMBLY
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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 of drive gear drive side.
3. Hold companion flange steady by hand and rotate the drive gear
in both directions.
ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY
1. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.
CAUTION:
Do not reuse the lock pin. Always replace the lock pin with
a new one.
SPD357
SDIA0813E
SDIA1796E
SPD030

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2. Place differential case on drive gear.
3. Apply genuine medium strength locking sealant or equivalent.
Refer to GI-48, "
RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS" to drive gear bolts, and install them.
CAUTION:
Do not reuse the bolts. Always replace the bolts with a new
one.

Tighten bolts in a crisscross fashion.

After tightening the bolt to the specified torque, turn the bolt
31 to 36 more degrees.
4. Press-fit side bearing inner race on differential case with tool.
INSTALLATION OF DRIVE PINION ASSEMBLY
1. Press-fit front and rear bearing outer races with tools.
2. Select drive pinion height adjusting washer. Refer to RFD-31, "
AVAILABLE PINION HEIGHT ADJUSTING
WASHERS"
SPD554
Tool number A : KV38100300 (J25523)
B : ST33061000 (J8107-2)
SPD353
Tool number A : Suitable tool
B : ST30611000 (J25742-1)
C : ST30613000 (J25742-3)
SPD992