pin INFINITI FX35 2006 Service Manual

FRONT FINAL DRIVE ASSEMBLY FFD-31
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Revision: 2006 December 2006 FX35/FX45
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. Use the formula below to calculate pinion height adjusting washer thickness.
2. Select the proper pinion height adjusting washer. Refer to FFD-40, "
Pinion Height Adjusting Washer" .
If impossible 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 (1). NOTE:
When reusing drive pinion, align the matching mark (B) of drive
pinion with the matching mark (A) of companion flange, and then
install companion flange (1). 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
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FFD-32
FRONT FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
3. Temporarily tighten removed drive pinion lock nut to drive pinion. NOTE:
Use removed drive pinion 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 pinion 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 pinion 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 A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 127.4 - 245.0 N·m (13.0 - 25.0 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.
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Tool number A: ST37820000 ( — )
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FRONT FINAL DRIVE ASSEMBLY FFD-33
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Revision: 2006 December 2006 FX35/FX45
2. Temporarily install pinion height adjusting washer (1). 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 pinion height adjusting washer (2) to drive pin- ion. Press pinion rear bearing inner race (1) 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 (A), press the pinion front bearing inner race to drive pinion 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 drifts, 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.
PDIA0971E
Tool number A: ST30032000 (J-26010-01)
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PDIA0681E
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Tool number A: ST33400001 (J-26082)
B: KV38102510 ( — )
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FFD-34
FRONT FINAL DRIVE ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
10. Install companion flange (1). NOTE:
When reusing drive pinion, align the matching mark (B) of drive
pinion with the matching mark (A) of companion flange, and then
install companion flange (1).
11. Apply anti-corrosion oil to the thread and seat of new drive pin- ion lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Do not reuse drive pinion lock nut.
12. Tighten to drive pinion 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-21, "
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-24, "
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.
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Tool number A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque:
127.4 - 245.0 N·m (13.0 - 25.0 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)
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FRONT FINAL DRIVE ASSEMBLY FFD-35
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Revision: 2006 December 2006 FX35/FX45
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.
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SPD030
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FRONT FINAL DRIVE ASSEMBLY FFD-37
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Revision: 2006 December 2006 FX35/FX45
15. Install selected side bearing adjusting shim (1).
16. Apply multi-purpose grease to O-ring (2), 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-17, "
COMPONENTS (VQ35DE MODELS)" , FFD-19,
"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-21, "
Drive Gear Runout" , FFD-21, "Tooth Contact" , FFD-23, "Backlash" , FFD-20,
"Total Preload Torque" .
Recheck above items. Readjust the above description, if necessary.
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Tool number A: ST33400001 (J-26082)
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Tool number A: KV38102100 (J-25803-01)
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SERVICE DATA AND SPECIFICATIONS (SDS) FFD-39
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Revision: 2006 December 2006 FX35/FX45
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsNDS000BF
Inspection and AdjustmentNDS000BG
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)
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)
Inner side of the companion flange 0.13 (0.0051)
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

FFD-40
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: 2006 December 2006 FX35/FX45
Pinion Height Adjusting Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Drive Pinion Bearing Adjusting Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Drive Pinion Adjusting Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Side Bearing Adjusting Shim
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information.
Side Bearing Adjusting Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information. Thickness Part number* Thickness Part number*
3.09 (0.1217)
3.12 (0.1228)
3.15 (0.1240)
3.18 (0.1252)
3.21 (0.1264)
3.24 (0.1276)
3.27 (0.1287)
3.30 (0.1299)
3.33 (0.1323)
3.36 (0.1323) 38154 U1500
38154 U1501
38154 U1502
38154 U1503
38154 U1504
38154 U1505
38154 U1506
38154 U1507
38154 U1508
38154 U1509 3.39 (0.1335)
3.42 (0.1346)
3.45 (0.1358)
3.48 (0.1370)
3.51 (0.1382)
3.54 (0.1394)
3.57 (0.1406)
3.60 (0.1429)
3.63 (0.1429)
3.66 (0.1441) 38154 U1510
38154 U1511 38154U1512
38154 U1513
38154 U1514
38154 U1515
38154 U1516
38154 U1517
38154 U1518
38154 U1519
Thickness Part number* Thickness Part number*
3.81 (0.1500)
3.83 (0.1508)
3.85 (0.1516)
3.87 (0.1524)
3.89 (0.1531)
3.91 (0.1539)
3.93 (0.1547)
3.95 (0.1555) 38125 61001
38126 61001
38127 61001
38128 61001
39129 61001
38130 61001
38131 61001
38132 61001 3.97 (0.1563)
3.99 (0.1571)
4.01 (0.1579)
4.03 (0.1587)
4.05 (0.1594)
4.07 (0.1602)
4.09 (0.1610) 38133 61001
38134 61001
38135 61001
38136 61001
38137 61001
38138 61001
38139 61001
Thickness Part number* Thickness Part number*
5.19 (0.2043)
5.49 (0.2161)
5.79 (0.2280) 38151 AR000
38151 AR001
38151 AR002 6.09 (0.2398)
6.39 (0.2516) 38151 AR003
38151 AR004
Thickness Part number* Thickness Part number*
0.20 (0.0079)
0.25 (0.0098)
0.30 (0.0118) 38453 AR000
38453 AR001
38453 AR002 0.40 (0.0157)
0.50 (0.0197) 38453 AR003
38453 AR004
Thickness Part number* Thickness Part number*
0.10 (0.0040)
0.12 (0.0047)
0.15 (0.0059)
0.17 (0.0067)
0.20 (0.0079) 38453 AR010
38453 AR011
38453 AR012
38453 AR013
38453 AR014 0.25 (0.0098)
0.30 (0.0118)
0.40 (0.0157)
0.50 (0.0197) 38453 AR015
38453 AR016
38453 AR017
38453 AR018

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY FL-7
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Revision: 2006 December 2006 FX35/FX45
Main and Sub Fuel Level Sensor Unit

When installing fuel hose connector insert them fully until a click
sound of full stopper engagement is heard.

Face main and sub fuel level sensor units as shown in the fig-
ure, and install them with the knock pin on back aligned with pin
hole on fuel tank.

Install retainer so that its notch becomes parallel with the notch
on fuel tank.

Tighten retainer mounting bolts evenly.
Quick Connector
Connect quick connector as follows:
1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a click sound is heard.
3. After connecting, make sure that the connection is secure by following method.

Pull the tube and the connector to make sure they are
securely connected.

Visually confirm that the two retainer tabs are connected to
the connector.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
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FL-8
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
1. Turn ignition switch “ON” (with engine stopped), then check connections for leaks by applying fuel pres- sure to fuel piping.
2. Start engine and let it idle and make sure there are no fuel leaks at the fuel system connections.
ComponentsNBS004IJ
Disassembly and AssemblyNBS005S3
CAUTION:
Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit.
DISASSEMBLY
Remove fuel level sensor unit as follows.
1. Disconnect harness connector.

Hold connector by fingers and pull it out, because there is no
stopper release tab.
2. Using suitable tool, pull up tabs points as shown in the figure (two points) to release the lock.
CAUTION:
Be careful not to damage it.
3. After fixing tabs are disengaged, slide fuel level sensor unit out in direction shown by the arrow.
CAUTION:
Do not disassemble fuel filter and fuel pump assembly.
1. Fuel level sensor unit 2. Fuel filter and fuel pump assembly
PBIC1081E
PBIC1078E
PBIC1654E
PBIC1080E