INFINITI FX35 2005 Service Manual

FFD-30
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
3. Press-fit side bearing outer race into gear carrier with tool.
CAUTION:

At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.

Do not reuse side bearing outer race.
4. Place the differential case assembly into gear carrier.
5. Install side bearing adjusting shim before disassembling or shim which thickness is the same as the one before disassembling.
6. Install side retainer assembly to gear carrier.
CAUTION:
Do not install O-ring.
7. Install side retainer mounting bolts to the specified torque. Refer to FFD-16, "
COMPONENTS (VQ35DE MODELS)" , FFD-18,
"COMPONENTS (VK45DE MODELS)" .
8. Measure the turning torque of the gear carrier at the drive gear mounting bolts with a spring gauge. Tool number A: KV31103000 ( — )
B: ST30611000 (J-25742-1)
PDIA0824E
PDIA0671E
PDIA0678E
PDIA0669E
Tool number : — (J-8129)
Specification:
0.78 - 1.08 N (0.08 - 0.11 kg, 0.57 - 0.80 lb) of pulling
force at the drive gear bolt
SPD194A

FRONT FINAL DRIVE ASSEMBLY FFD-31
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9. If the turning torque is outside the specification, use a thicker/
thinner side bearing adjusting shim to adjust. Refer to FFD-40,
"Side Bearing Adjusting Shim" .
10. Record the total amount of shim thickness required for the cor- rect carrier side bearing preload.
Pinion Gear Height
If the hypoid gear set has been replaced, select the pinion height adjusting washer.
1. Substitute these values into the equation to calculate the thick- ness of the washer.
2. Select the proper pinion height adjusting washer. Refer to FFD-40, "
Pinion Height Adjusting Washer" .
If you cannot find the desired thickness of washer, use washer with thickness closest to the calculated
value.
Pinion Bearing Preload

Assemble the drive pinion parts if they are disassembled. Refer to FFD-32, "Drive Pinion Assembly" .
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
2. Install companion flange. NOTE:
When reusing drive pinion, align the matching mark of drive pin-
ion with the matching mark A of companion flange, then install
companion flange. If the turning torque is less than the specified range:
Decrease the side bearing adjusting shim thickness.
If the turning torque is greater than the specification:
Increase the side bearing adjusting shim thickness.
SPD772
Washer selection equation:
T = T
0 + (t1 - t2 )
T: Correct washer thickness
T
0 : Removed washer thickness
t
1 : Old drive pinion head letter “H × 0.01”
(“H”: machined tolerance 1/100 mm × 100)
t
2 : New drive pinion head letter “H × 0.01”
(“H”: machined tolerance 1/100 mm × 100)
Example:
T = 3.21 + [(2 × 0.01) - (-1 × 0.01)] = 3.24
T
0 :3.21
t
1 :+2
t
2 :-1
Example: Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm
SDIA0249J
PDIA0675E

FFD-32
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
3. Temporarily tighten removed drive pinon lock nut to drive pinion.
NOTE:
Use removed drive pinon lock nut only for the preload measure-
ment.
4. Rotate drive pinion at least 20 times to check for smooth opera- tion of the bearing.
5. Tighten to drive pinon lock nut, while adjust pinion bearing pre- load torque.
CAUTION:

Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.

After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
6. If the pinion bearing preload torque is outside the specification, use a thicker/thinner drive pinion bearing adjusting washer and drive pinion adjusting washer to adjust.
Refer to FFD-40, "
Drive Pinion Bearing Adjusting Washer" and FFD-40, "Drive Pinion Adjusting Washer" .
7. Remove companion flange, after adjustment.
ASSEMBLY
Drive Pinion Assembly
1. Install front and rear bearing outer races using drifts.
CAUTION:

At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.

Do not reuse pinion front and rear bearing outer race. Tool number : ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 127.4 - 245.0 N·m (13 - 25 kg-m, 94 - 181 ft-lb)
Pinion bearing preload: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
When the preload torque is large: Decrease the drive pinion bearing adjusting washer and drive pinion adjusting
washer thickness.
When the preload is small: Increase the drive pinion bearing adjusting washer and drive pinion adjusting
washer thickness.
PDIA0778E
Tool number : ST37820000 ( — )
PDIA0680E

FRONT FINAL DRIVE ASSEMBLY FFD-33
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2. Temporarily install pinion height adjusting washer.
When hypoid gear set has been replaced

Select pinion height adjusting washer. Refer to FFD-31, "Pin-
ion Gear Height" .
When hypoid gear set has been reused

Temporarily install the removed pinion height adjusting
washer or same thickness washer to drive pinion.
3. Install selected drive pinion height adjusting washer to drive pin- ion. Press pinion rear bearing inner race to it, using drift.
CAUTION:

Pay attention to the direction of pinion height adjusting
washer. (Assemble as shown in the figure.)

Do not reuse pinion rear bearing inner race.
4. Temporarily assemble removed drive pinion adjusting washer and drive pinion bearing adjusting washer or same thickness
them to drive pinion.
5. Apply gear oil to pinion rear bearing, and assemble drive pinion into gear carrier.
6. Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion assembly.
CAUTION:
Do not reuse pinion front bearing inner race.
7. Using suitable spacer, press the pinion front bearing inner race to drive pinon as far as drive pinion nut can be tightened.
8. Adjust pinion bearing preload. If necessary, select the appropri- ate drive pinion adjusting washer and drive pinion bearing
adjusting washer. Refer to FFD-31, "
Pinion Bearing Preload" .
9. Using the drift, install front oil seal as shown in figure. CAUTION:

Do not reuse oil seal.

When installing, do not incline oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
SDIA1666E
Tool number : ST30032000 (J-26010-01)
SDIA0048E
PDIA0681E
PDIA0682E
Tool number A: ST33400001 (J-26082)
B: KV38102510 ( — )
PDIA0683E

FFD-34
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
10. Install companion flange.
NOTE:
When reusing drive pinion, align the matching mark of drive pin-
ion with the matching mark A of companion flange, then install
companion flange.
11. Apply gear oil to the thread and seat of new drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.
CAUTION:
Do not reuse drive pinion lock nut.
12. Tighten to drive pinon lock nut, while adjust pinion bearing pre- load torque.
CAUTION:

Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.

After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
13. Install differential case assembly. Refer to FFD-34, "
Differential
Assembly" .
CAUTION:
Do not install carrier cover yet.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer to FFD-20, "
Drive Gear Runout" , FFD-21, "Tooth Contact" , FFD-23, "Backlash" ,
FFD-23, "
Companion Flange Runout" .
Recheck above items. Readjust the above description, if necessary.
15. Check total preload torque. Refer to FFD-20, "
Total Preload Torque" .
16. Install carrier cover. Refer to FFD-34, "
Differential Assembly" .
Differential Assembly
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
the side gears.
PDIA0675E
Tool number : ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 127.4 - 245.0 N·m (13 - 25 kg-m, 94 - 181 ft-lb)
Pinion bearing preload: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
PDIA0778E
SDIA0193J

FRONT FINAL DRIVE ASSEMBLY FFD-35
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2. Install side gears and thrust washers into differential case.
CAUTION:

Do not reuse circular clip.

Make sure that the circular clip is installed to side gear
(side retainer side).
3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust
washer to pinion mate gear.
4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to FFD-29, "
Differential Side
Gear Clearance" .
6. Drive a lock pin into pinion mate shaft, using a punch. Make sure lock pin is flush with differential case.
CAUTION:
Do not reuse lock pin.
7. Align the matching mark of drive gear with the mark of differen- tial case, then place drive gear.
8. Apply thread locking sealant into the thread hole of drive gear.

Use Genuine Medium Strength Thread Locking Sealant or
equivalent. Refer to GI-48, "
Recommended Chemical
Products and Sealants" .
CAUTION:
Drive gear back and threaded holes shall be cleaned and
degreased sufficiently.
SDIA2025E
SDIA0195J
SPD030
SDIA2593E
SDIA2594E

FFD-36
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
9. Install drive gear on the mounting bolts, and then tighten to the
specified torque. Refer to FFD-16, "
COMPONENTS (VQ35DE
MODELS)" , FFD-18, "COMPONENTS (VK45DE MODELS)" .
CAUTION:
Tighten bolts in a crisscross fashion.
10. Press side bearing inner races to differential case, using the drift and the base.
CAUTION:
Do not reuse side bearing inner race.
11. Press-fit side bearing outer race into side retainer with the drift and the drift bar.
CAUTION:

At first, using a hammer, tap bearing outer race until it
becomes flat to side retainer.

Do not reuse side bearing outer race.
12. Press-fit side bearing outer race into gear carrier with the drift and the drift bar.
CAUTION:

At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.

Do not reuse side bearing outer race.
13. Place the differential case assembly into gear carrier.
14. Measure side bearing preload. If necessary, select the appropri- ate side bearing adjusting shim. Refer to FFD-29, "
Side Bearing
Preload" .
SDIA0247J
Tool number A: ST33230000 (J-25805-01)
B: ST33061000 (J-8107-2)
SDIA1678E
Tool number A: KV31103000 (J-38982)B: ST30611000 (J-25742-1)
PDIA0679E
Tool number A: KV31103000 (J-38982)B: ST30611000 (J-25742-1)
PDIA0824E
PDIA0671E

FRONT FINAL DRIVE ASSEMBLY FFD-37
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15. Install selected side bearing adjusting shim.
16. Apply multi-purpose grease to O-ring, and install it to side retainer.
CAUTION:
Do not reuse O-ring.
17. Install side retainer assembly to gear carrier.
18. Install side retainer mounting bolts to the specified torque. Refer to FFD-16, "
COMPONENTS (VQ35DE MODELS)" , FFD-18,
"COMPONENTS (VK45DE MODELS)" .
19. Using the drift, press-fit side oil seal so that its surface comes face to face with the end surface of the side retainer.
CAUTION:

Do not reuse oil seal.

When installing, do not incline oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
20. Using the drift, press-fit side oil seal so that its surface comes face to face with the end surface of gear carrier.
CAUTION:

Do not reuse oil seal.

When installing, do not incline oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
21. Apply multi-purpose grease to O-ring, and install it to gear car- rier.
CAUTION:
Do not reuse O-ring.
22. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to FFD-20, "
Drive Gear Runout" , FFD-21, "Tooth Contact" , FFD-23, "Backlash" , FFD-20,
"Total Preload Torque" .
Recheck above items. Readjust the above description, if necessary.
PDIA0685E
PDIA0669E
Tool number : ST33400001 (J-26082)
SDIA1646E
Tool number : KV38102100 (J-25803-01)
SDIA1662E

FFD-38
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
23. Apply sealant to mating surface of carrier cover.

Use Genuine Silicone RTV or equivalent. Refer to GI-48,
"Recommended Chemical Products and Sealants" .
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
24. Install carrier cover on gear carrier and tighten mounting bolts with the specified torque. Refer to FFD-16, "
COMPONENTS
(VQ35DE MODELS)" , FFD-18, "COMPONENTS (VK45DE
MODELS)" .
Side Shaft Assembly
1. Using the drift, install side shaft oil seal.
CAUTION:

Do not reuse oil seal.

When installing, do not incline oil seal.

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
2. Install dust sealed.
3. Support side shaft bearing with the drift, then press side shaft into the side shaft bearing using a press.
4. Apply multi-purpose grease to O-ring, and install it to extension tube retainer.
CAUTION:
Do not reuse O-ring.
PDIA0742E
SDIA1648E
Tool number :KV38100200 ( — )
PDIA0665E
Tool number : ST30032000 (J-26010-01)
SDIA1631E

SERVICE DATA AND SPECIFICATIONS (SDS) FFD-39
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Revision: 2005 July 2005 FX
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsADS0019Z
Inspection and AdjustmentADS001A0
DRIVE GEAR RUNOUT
Unit: mm (in)
DIFFERENTIAL SIDE GEAR CLEARANCE
Unit: mm (in)
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in)
SELECTIVE PARTS
Side Gear Thrust Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information. Applied model VQ35DE VK45DE
Final drive model F160A
Gear ratio 3.692
Number of teeth (Drive gear/Drive pinion) 48/13
Oil capacity (Approx.) (US pt, lmp pt) 0.65 (1-3/8, 1-1/8)
Number of pinion gears 2
Drive pinion adjustment spacer type Solid
Item Runout limit
Drive gear back face 0.05 (0.0020) or less
Item Specification
Side gear backlash (Clearance between side gear and differential
case) 0.2 (0.008) or less
(Each gear should rotate smoothly without excessive resistance
during differential motion.)
Item Specification
Pinion bearing (P
1 ) 0.78 - 1.57 (0.08 - 0.16, 7 - 13)
Side bearing (P
2 ) 0.78 - 1.08 (0.08 - 0.11, 7 - 9)
Side bearing to pinion bearing (Total preload)
(Total preload = P
1 + P2 ) 1.56 - 2.65 (0.16 - 0.27, 14 - 23)
Item Specification
Drive gear to drive pinion gear 0.10 - 0.15 (0.0039 - 0.0059)
Item Runout limit
Companion flange face 0.18 (0.0070) or less
Inner side of the companion flange 0.13 (0.0051) or less
Thickness Part number* Thickness Part number*
0.68 (0.0268)
0.71 (0.0280)
0.74 (0.0291)
0.77 (0.0303)
0.80 (0.0315)
0.83 (0.0327) 38424 W1010
38424 W1011
38424 W1012
38424 W1013
38424 W1014
38424 W1015 0.86 (0.0339)
0.89 (0.0350)
0.92 (0.0362)
0.95 (0.0374)
0.98 (0.0386)
1.01 (0.0398) 38424 W1016
38424 W1017
38424 W1018
38424 W1019
38424 W1020
38424 W1021