differential INFINITI FX35 2005 Workshop Manual

REAR FINAL DRIVE ASSEMBLY RFD-19
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Revision: 2005 July 2005 FX
4. If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X).

If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken pinon height adjusting washers to
move drive pinion closer to drive gear.
Refer to RFD-37, "
Pinion Height Adjusting Washer" .

If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin pinion height adjusting washers to move
drive pinion farther from drive gear.
Refer to RFD-37, "
Pinion Height Adjusting Washer" .
Backlash
1. Remove rear cover. Refer to RFD-21, "Differential Assembly" .
2. Fit a dial indicator to the drive gear face to measure the back- lash.

If the backlash is outside of the specified value, change the
thickness of side bearing adjusting washer.
CAUTION:
Do not change the total amount of washers as it will change the bearing preload.
SDIA0517E
PDIA0440E
PDIA0441E
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
When the backlash is large: Make drive gear back side adjusting washer thicker,
and drive gear tooth side adjusting washer thinner by
the same amount. Refer to RFD-37, "
Side Bearing
Adjusting Washer" .
When the backlash is small: Make drive gear back side adjusting washer thinner,
and drive gear tooth side adjusting washer thicker by
the same amount. Refer to RFD-37, "
Side Bearing
Adjusting Washer" .
SPD513

REAR FINAL DRIVE ASSEMBLY RFD-21
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Revision: 2005 July 2005 FX
DISASSEMBLY
Differential Assembly
1. Drain gear oil, if necessary.
2. Remove side flange.
3. Remove rear cover mounting bolts.
4. Remove rear cover to insert the seal cutter between gear carrier and rear cover.
CAUTION:

Be careful not to damage the mating surface.

Do not insert flat-bladed screwdriver, this way damage
the mating surface.
5. Using two 45 mm (1.77 in) spacers, mount carrier on the attach- ment.
6. For proper reinstallation, paint matching marks on one side of the bearing cap.
CAUTION:

For matching mark, use paint. Do not damage bearing
caps and gear carrier.

Bearing caps are line-board during manufacture. The
matching marks are used to reinstall them in their origi-
nal positions.
7. Remove bearing caps. Tool number : KV10111100 (J-37228)
PDIA0491E
Tool number : KV38100800 (J-25604-01)
SDIA1008E
SDIA1795E
S-PD343

RFD-22
REAR FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
8. Lift differential case assembly out with a suitable tool.

Keep side bearing outer races together with inner race. Do
not mix them up.
Also, keep side bearing adjusting washers together with bear-
ings.
9. 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 inner race
except it is replaced.
10. For proper reinstallation, paint matching mark on one differential case assembly.
CAUTION:
For matching mark, use paint. Do not damage differential
case and drive gear.
11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer. CAUTION:
Tap evenly all around to keep drive gear from bending.
PDIA0547E
SPD527
Tool number A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)
SPD920
PDIA0496E

REAR FINAL DRIVE ASSEMBLY RFD-23
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Revision: 2005 July 2005 FX
13. Remove lock pin of pinion mate shaft with a punch from drive
gear side.
14. Remove pinion mate shaft.
15. Turn pinion mate gear, then remove pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from
differential case.
Drive Pinion Assembly
1. Remove differential assembly. Refer to RFD-21, "Differential Assembly" .
2. Remove drive pinion lock nut with the flange wrench.
SPD025
SDIA0031J
SDIA0032J
Tool number : KV40104000 ( — )
SDIA2054E

REAR FINAL DRIVE ASSEMBLY RFD-25
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Revision: 2005 July 2005 FX
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.
ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS
Differential Side Gear Clearance

Assemble the differential parts if they are disassembled. Refer to RFD-32, "Differential Assembly" .
1. Place differential case straight up so that side gear to be mea- sured comes upward.
Content Conditions and Measures
Hypoid gear

If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.

If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
Bearing

If any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing
is observed, replace as a bearing assembly (as a new set).
Side gear and Pinion mate
gear

If any cracks or damage on the surface of the tooth is found, replace.

If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
Side gear thrust washer and
pinion mate thrust washer

If it is chipped (by friction), damaged, or unusually worn, replace.
Oil seal

Whenever disassembled, replace.

If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case

If any wear or crack on the contact sides of the differential case is found, replace.
Companion flange

If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the
companion flange is found, replace.
PDIA0460E

RFD-26
REAR FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
2. Using feeler gauge, measure the clearance between side gear
back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance of the other side as well.
CAUTION:
To prevent side gear from tilting, insert feeler gauges with
the same thickness from both sides.
3. If the back clearance is outside the specification, use a thicker/ thinner side gear thrust washer to adjust. Refer to RFD-36,
"Side Gear Thrust Washer" .
CAUTION:
Select a side gear thrust washer for right and left individu-
ally.
Side Bearing Preload

Selecting 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 gear carrier. Side gear back clearance specification:
0.2 mm (0.008 in) or less.
(Each gear should rotate smoothly without excessive
resistance during differential motion.)
When the back clearance is large: Use a thicker thrust washer.
When the back clearance is small: Use a thinner thrust washer.
PDIA0576E
SPD527
SPD558

REAR FINAL DRIVE ASSEMBLY RFD-27
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Revision: 2005 July 2005 FX
4. Install bearing caps in their correct locations and tighten bearing
cap mounting bolts to the specified torque. Refer to RFD-16,
"COMPONENTS" .
5. Turn the carrier several times to seat the bearings.
6. Measure the turning torque of the carrier at the drive gear mounting bolts with a spring gauge.
7. If the turning torque is outside the specification, use a thicker/ thinner side bearing adjusting washer to adjust. Refer to RFD-
37, "Side Bearing Adjusting Washer" .
CAUTION:
Select a side bearing adjusting washer for right and left
individually.
8. Record the total amount of washer thickness required for the correct carrier side bearing preload.
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.
SDIA1795E
Tool number : — (J-8129)
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
If the turning torque is less than the specified range:
Use a thicker thrust washer.
If the turning torque is greater than the specification: Use a thinner thrust washer.
SPD772
Tool number : — (J-34309)
SPD769

RFD-30
REAR FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
12. Select the correct pinion height adjusting washer. Refer to RFD-37, "Pinion Height Adjusting Washer" .
13. Remove the J-34309 differential shim selector tool from the final drive housing. Then disassemble to retrieve the pinion bearings.
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.
2. Select drive pinion height adjusting washer. Refer to RFD-27,
"Pinion Gear Height" .
Pinion head height number Add or remove from the standard pinion height
adjusting washer thickness measurement
- 6
- 5
- 4
- 3
- 2
- 1
0
+1
+2
+3
+4
+5
+6 Add 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
Tool number A: ST30720000 (J-25405)
B: KV40105230 ( — )
C: ST30611000 (J-25742-1)
D: ST30613000 (J-25742-3)
PDIA0562E

RFD-32
REAR FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
10. Apply gear oil to the thread and seat of drive pinion lock nut, and
temporarily tighten drive pinion lock nut to drive pinion.
CAUTION:
Do not reuse drive pinion lock nut.
11. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque.
CAUTION:

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

If the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Do not
loosen drive pinion lock nut to adjust the preload torque.

After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction, and other malfunctions.
12. Install differential case assembly. Refer to RFD-32, "
Differential Assembly" .
CAUTION:
Do not install rear cover yet.
13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer to RFD-17, "
Drive Gear Runout" , RFD-18, "Tooth Contact" , RFD-19, "Backlash" ,
RFD-20, "
Companion Flange Runout" .
Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque. Refer to RFD-17, "
Total Preload Torque" .
15. Install rear cover. Refer to RFD-32, "
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.
2. Install side gears and thrust washers into differential case. CAUTION:
Make sure that the circular clip is installed to side gears.
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. Tool number A: KV40104000 ( — )
B: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 147 - 323 N·m (15 - 32 kg-m, 109 - 238 ft-lb)
Drive pinion bearing preload: 2.65 - 3.23 N·m (0.27 - 0.32 kg-m, 24 - 28 in-lb)
PDIA0548E
SDIA0193J
SDIA2025E

REAR FINAL DRIVE ASSEMBLY RFD-33
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Revision: 2005 July 2005 FX
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 RFD-25, "
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 differential case with the mark of drive gear, then place drive gear.
8. Apply thread locking sealant into the thread hole of drive gear.

Use Genuine High 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.
9. Install drive gear on the mounting bolts, and then tighten to the specified torque. Refer to RFD-16, "
COMPONENTS" .
CAUTION:

Tighten bolts in a crisscross fashion.

After tightening the bolt to the specified torque, tighten
the bolts additionally by turning the bolts 31 to 36
degrees.
SDIA0195J
SPD030
SDIA2593E
SDIA2594E
SDIA0247J