INFINITI FX35 2007 Service Manual

FRONT FINAL DRIVE ASSEMBLY FFD-19
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Revision: 2006 July 2007 FX35/FX45
COMPONENTS (VK45DE MODELS)
1. Drive pinion lock nut 2. Companion flange 3. Front oil seal
4. Pinion front bearing 5. Drive pinion bearing adjusting washer 6. Drive pinion adjusting washer
7. Gear carrier 8. Pinion rear bearing 9. Pinion height adjusting washer
10. Drive pinion 11. Drive gear 12. Side oil seal (right side)
13. Side retainer 14. O-ring 15. Side bearing adjusting shim
16. Side bearing 17. Differential case 18. Breather connector
19. Dowel pin 20. Filler plug 21. Drain plug
22. Gasket 23. Carrier cover 24. Gear oil defence
25. Side gear thrust washer 26. Side gear 27. Circular clip
28. Pinion mate thrust washer 29. Pinion mate gear 30. Pinion mate shaft
31. Lock pin 32. Side bearing adjusting washer 33. Side oil seal (left side)
34. Side shaft bearing 35. Extension tube retainer 36. Side shaft oil seal
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FRONT FINAL DRIVE ASSEMBLY
Revision: 2006 July 2007 FX35/FX45
ASSEMBLY INSPECTION AND ADJUSTMENT

Before inspection and adjustment, drain gear oil.
Total Preload Torque
1. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
2. Rotate drive pinion at least 20 times to check for smooth opera- tion of the bearing.
3. Measure total preload with preload gauge.
NOTE:
Total preload torque = Pinion bearing preload torque + Side
bearing preload torque

If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.
37. Dust sealed 38. Side shaft
A: Oil seal lip
B: Screw hole
Refer to GI-11, "
Components" and the followings for the symbols in the figure.
: Apply multi-purpose grease.
: Apply gear oil.
: Apply anti-corrosion oil.
: Apply Genuine Silicone RTV or equivalent. Refer to
GI-48, "
Recommended Chemical Products and Sealants" .
: Apply Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to
GI-48, "
Recommended Chemical
Products and Sealants" .
Tool number A: ST3127S000 (J-25765-A)
Total preload torque:
1.56 - 2.65 N·m (0.16 - 0.27 kg-m, 14 - 23 in-lb)
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When the preload torque is largeOn pinion bearings: Decrease the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness. Refer to FFD-40, "
Drive Pinion Bearing
Adjusting Washer" and FFD-40, "Drive Pinion Adjusting Washer" .
On side bearings: Increase the side bearing adjusting shim thickness. Refer to FFD-40,
"Side Bearing Adjusting Shim" .
When the preload torque is small On pinion bearings: Increase the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness. Refer to FFD-40, "
Drive Pinion Bearing
Adjusting Washer" and FFD-40, "Drive Pinion Adjusting Washer" .
On side bearings: Decrease the side bearing adjusting shim thickness. Refer to FFD-40,
"Side Bearing Adjusting Shim" .

FRONT FINAL DRIVE ASSEMBLY FFD-21
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Revision: 2006 July 2007 FX35/FX45
Drive Gear Runout
1. Remove carrier cover. Refer to FFD-34, "Differential Assembly" .
2. Fit a dial indicator to the drive gear back face.
3. Rotate the drive gear to measure runout.

If the runout is outside of the repair limit, check drive gear
assembly condition; foreign material may be caught between
drive gear and differential case, or differential case or drive gear
may be deformed, etc.
CAUTION:
Replace drive gear and drive pinion gear as a set.
Tooth Contact
1. Remove carrier cover. Refer to FFD-34, "Differential Assembly" .
2. Apply red lead to drive gear. CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.
3. Rotate drive gear back and forth several times, check drive pin- ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side. Runout limit: 0.05 mm (0.0020 in)
SPD886
SPD357
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Revision: 2006 July 2007 FX35/FX45
4. If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X).
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FRONT FINAL DRIVE ASSEMBLY FFD-23
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Revision: 2006 July 2007 FX35/FX45

If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken pinion height adjusting washers to
move drive pinion closer to drive gear.
Refer to FFD-40, "
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 FFD-40, "
Pinion Height Adjusting Washer" .
Backlash
1. Remove carrier cover. Refer to FFD-34, "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.
Companion Flange Runout
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
3. Fit a test indicator to the inner side of companion flange (socket diameter).
4. Rotate companion flange to check for runout.
5. If the runout value is outside the runout limit, follow the proce- dure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90 ° step, and
search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for
these items and repair if necessary.
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Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
When the backlash is large: Decrease side bearing adjusting washer thickness.
Refer to FFD-40, "
Side Bearing Adjusting Washer" .
When the backlash is small: Increase side bearing adjusting washer thickness.
Refer to FFD-40, "
Side Bearing Adjusting Washer" .
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Runout limit: 0.18 mm (0.0070 in)
Runout limit: 0.13 mm (0.0051 in)
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FRONT FINAL DRIVE ASSEMBLY
Revision: 2006 July 2007 FX35/FX45
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.
DISASSEMBLY
Side Shaft Assembly
1. Hold extension tube retainer with puller, then press out side shaft using a press.
2. Remove side shaft oil seal (1) from extension tube retainer with a flat- blade screwdriver.
CAUTION:
Be careful not to damage extension tube retainer.
3. Remove side shaft bearing from extension tube retainer.
4. Remove O-ring from extension tube retainer.
5. Remove dust sealed from side shaft.
Differential Assembly
1. Drain gear oil.
2. Remove carrier cover mounting bolts.
3. Remove carrier cover to insert the seal cutter between gear car- rier and carrier cover.
CAUTION:

Be careful not to damage the mating surface.

Do not insert flat-bladed screwdriver, this way damage
the mating surface.
4. Remove side retainer.
5. Remove side bearing adjusting shim.
6. Remove O-ring from side retainer.
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Tool number A: KV10111100 (J-37228)
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FRONT FINAL DRIVE ASSEMBLY FFD-25
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7. Remove differential case assembly from gear carrier.
8. Remove side oil seal (right side) from side retainer.
9. Remove side bearing outer race with puller.
10. Remove O-ring from gear carrier.
11. Remove side oil seal (left side) from gear carrier.
12. Remove side bearing outer race with puller.
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Tool number A: KV381054S0 (J-34286)
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Tool number A: KV381054S0 (J-34286)
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Revision: 2006 July 2007 FX35/FX45
13. 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.
14. For proper reinstallation, paint matching marks on one differen- tial case assembly.
CAUTION:
For matching marks, use paint. Do not damage differential
case and drive gear.
15. Remove drive gear mounting bolts.
16. Tap drive gear off differential case assembly with a soft hammer. CAUTION:
Tap evenly all around to keep drive gear from bending.
17. Remove lock pin of pinion mate shaft with a punch from drive gear side.
18. Remove pinion mate shaft. Tool number A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)
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FRONT FINAL DRIVE ASSEMBLY FFD-27
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Revision: 2006 July 2007 FX35/FX45
19. Turn pinion mate gear, then remove pinion mate gears, pinion
mate thrust washers, side gears and side gear thrust washers
from differential case.
Drive Pinion Assembly
1. Remove differential assembly. Refer to FFD-34, "Differential Assembly" .
2. Remove drive pinion lock nut with a flange wrench.
3. Put matching mark (B) on the end of drive pinion. The matching mark should be in line with the matching mark (A) on companion
flange (1).
CAUTION:
For matching mark, use paint. Do not damage companion
flange and drive pinion.
NOTE:
The matching mark (A) on the final drive companion flange (1)
indicates the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
4. Remove companion flange using the suitable puller.
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Revision: 2006 July 2007 FX35/FX45
5. Press drive pinion assembly out of gear carrier.
CAUTION:
Do not drop drive pinion assembly.
6. Remove front oil seal.
7. Remove pinion front bearing inner race.
8. Remove drive pinion bearing adjusting washer and drive pinion adjusting washer.
9. Remove pinion rear bearing inner race and pinion height adjust- ing washer with replacer.
10. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.
CAUTION:
Be careful not to damage gear carrier.
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.
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Tool number A: ST30031000 (J-22912-01)
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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.