INFINITI QX56 2004 Factory Service Manual

FFD-20
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
16. Remove the pinion mate shaft.
17. 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.
Drive Pinion Assembly
1. Remove differential assembly. Refer to FFD-17, "Differential Assembly" .
2. Put matching marks on companion flange and drive pinion with
paint.
3. Loosen drive pinion nut using Tool.
4. Remove companion flange using a suitable puller.
SDIA0031J
SDIA0032J
Tool number : KV38108300 (J-44195)
SDIA2232E
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FRONT FINAL DRIVE ASSEMBLY
FFD-21
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Revision: August 20072004 QX56
5. Remove drive pinion (together with rear bearing inner race, col-
lapsible spacer.)
6. Remove pinion front bearing inner race.
7. Place a small hole in seal case, using a suitable punch or drill.
8. Install slide hammer tool as shown and remove seal.
9. Turn nose of gear carrier down. Remove drive pinion front bear-
ing outer race using Tool. Locate driver on back edge of outer
race, then drive outer race out.
CAUTION:
Do not nick gear carrier.
10. Turn nose of gear carrier up. Remove drive pinion rear bearing
outer race using Tool. Locate driver on back edge of outer race,
then drive outer race out.
CAUTION:
Do not nick gear carrier.
SDIA2234E
LDIA0129E
LDIA0130E
Tool number A: — C-4171
B: — D-103
LDIA0131E
Tool number A: — C-4171
B: — C-4307
LDIA0132E

FFD-22
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
11. Remove drive pinion rear bearing inner race and drive pinion
height adjusting washer using Tool.
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.Tool number : ST30021000 ( — )
SDIA2236E
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.

FRONT FINAL DRIVE ASSEMBLY
FFD-23
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ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS
Differential Side Gear Clearance

Assemble the differential parts if they are disassembled. Refer to FFD-28, "Differential Assembly" .
1. Place differential case straight up so that side gear to be mea-
sured comes upward.
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 FFD-32, "
Side
Gear Thrust Washer" .
CAUTION:
Select a side gear thrust washer for right and left individually.
Pinion Gear Height

Drive gear and pinions are supplied in matched sets only.
Matching numbers on both pinion and drive gear are etched for
verification. If a new gear set is being used, verify the numbers
of each pinion gear and drive gear before proceeding with
assembly.

The mounting distance from the center line of the drive gear to the back face of the pinion gear for the
M205 final drive is 103.5 mm (4.0748 inches).
On the button end of each pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0),
which indicates the best running position for each particular gear set. This dimension is controlled by a
selective shim between the inner pinion bearing race and pinion gear.
For example: If a pinion is etched m+8 (+3), it would require 0.08 mm (0.003 inch) less shim than a pinion
etched “0”. This means decreasing shim thickness; increases the mounting distance of the pinion to 103.6
mm (4.0778 inches). If a pinion is etched m+8 (-3), it would require adding 0.08mm (0.003 inch) more to
the shim than would be required if the pinion were etched “0”. By adding 0.08 mm (0.003 inch), the mount-
PDIA0460E
Side gear back clearance specification
: 0.20 mm (0.0079 in) or less
When the back clearance is large:
Use a thicker thrust washer.
When the back clearance is small:
Use a thinner thrust washer.
SPD8 28
SDIA2241E

FFD-24
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
ing distance of the pinion was decreased to 103.4 mm (4.0718 inches) which is just what a m-8 (-3) etch-
ing indicated.

To change the pinion adjustment, use different shims which come in different thickness.

Use the following tables as a guide for selecting the correct shim thickness to add or subtract from the old
shim.
ASSEMBLY
Drive Pinion Assembly
1. Press-fit rear bearing outer race with Tools.
OLD PINION
MARKINGNEW PINION MARKING (ENGLISH 0.000)
-4 -3 -2 -1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
OLD PINION
MARKINGNEW PINION MARKING (METRIC 0.00)
-10 -8 -5 -3 0 +3 +5 +8 +10
+10 +0.20 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0
+8 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02
+5 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05
+3 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08
0 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10
-3 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13
-5 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15
-8 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18
-10 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18 -0.20
Tool number A: ST30901000 ( — )
B: KV40105230 ( — )
SDIA2251E

FRONT FINAL DRIVE ASSEMBLY
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Revision: August 20072004 QX56
2. Press-fit front bearing outer race with Tools.
3. Temporarily install drive pinion height adjusting washer.
When hypoid gear set has been replaced

Select drive pinion height adjusting washer. Refer to FFD-33,
"Pinion Height Adjusting Washer" .
When hypoid gear set has been reused

Temporarily install the removed drive pinion height adjusting
washer or same thickness washer to drive pinion.
4. Install selected drive pinion height adjusting washer to drive pin-
ion, and press-fit pinion rear bearing inner race in it, using a
press and Tool.
5. Place pinion front bearing inner race in gear carrier.
6. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Install front oil seal, using Tools.
7. Perform checking and adjusting the tooth contact and backlash
of the hypoid gear following the procedure below.
a. Assemble the drive pinion to the gear carrier.
CAUTION:
Do not assemble a collapsible spacer.Tool number A: ST35271000 ( — )
B: KV40104810 ( — )
SDIA2252E
SDIA1666E
Tool number : — C-4040
SDIA2253E
SDIA2254E
Tool number A: KV38100500 (J-25273)
B: KV38102200 ( — )
SDIA2264E

FFD-26
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
b. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated.
c. Temporarily tighten removed drive pinon nut to drive pinion.
NOTE:
Use removed drive pinon nut only for the preload measurement.
d. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
e. Tighten to drive pinon nut, while adjust pinion bearing preload
torque.
CAUTION:

Adjust to the lower limit of the drive pinion nut tightening
torque first.

Drive pinon nut is tightened with no collapsible spacer. Be careful not to overtighten it. While
measuring the preload, tighten it by 5° to 10°.

After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rota-
tion malfunction, and other malfunctions.
f. Install side bearing adjust nut into gear carrier.
g. Install differential case assembly with side bearing outer races
into gear carrier.
SDIA2266E
Tool number : KV38108300 (J-44195)
PDIA0182E
Tool number : ST3127S000 (J-25765-A)
Drive pinion nut tightening torque:
298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
Pinion bearing preload:
2.3 - 3.4 N·m (24 - 34 kg-cm, 21 - 30 in-lb)
SDIA2220E
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FRONT FINAL DRIVE ASSEMBLY
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h. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.

Do not tighten at this step. This allows further tightening of
side bearing adjusters.
i. Check and adjust the tooth contact and backlash. Refer to FFD-
15, "Tooth Contact" and FFD-16, "Backlash" .
j. Remove differential case assembly.
k. Remove companion flange.
l. Remove drive pinion (together with rear bearing inner race.)
8. Assemble collapsible spacer to drive pinion.
CAUTION:
Do not reuse collapsible spacer.
9. Place collapsible spacer, drive pinion height adjusting washer
and drive pinion in gear carrier.
10. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated.
11. Apply anti-corrosive oil to the thread and seat of drive pinion nut,
and temporarily tighten drive pinion nut to drive pinion.
CAUTION:
Do not reuse drive pinion nut.
12. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
SDIA2258E
SDIA2234E
SDIA2255E
SDIA2266E
Tool number : KV38108300 (J-44195)
PDIA0182E

FFD-28
FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
13. Tighten to drive pinon nut, while adjust pinion bearing preload
torque.
CAUTION:

Adjust the lower limit of the drive pinion nut tightening
torque first.

If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again
to adjust. Never loosen drive pinion nut to adjust the preload torque.

After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rota-
tion malfunction, and other malfunctions.
14. Install differential case assembly. Refer to FFD-28, "
Differential Assembly" .
CAUTION:
Do not install rear cover yet.
15. Check and adjust tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer
to FFD-15, "
Tooth Contact" , FFD-16, "Backlash" , FFD-16, "Companion Flange Runout" .
Recheck above items. Readjust the above description, if necessary.
16. Check total preload torque. Refer to FFD-15, "
Total Preload Torque" .
17. Install rear cover. Refer toFFD-11, "
INSTALLATION" .
Differential Assembly
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 and
thrust washers into differential case.Tool number : ST3127S000 (J-25765-A)
Drive pinion nut tightening torque:
298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
Pinion bearing preload:
2.3 - 3.4 N·m (24 - 34 kg-cm, 21 - 30 in-lb)
SDIA2220E
SDIA0193J
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FRONT FINAL DRIVE ASSEMBLY
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4. Install pinion mate shaft to differential case so that it meets lock
pin holes.
5. Measure side gear end play. If necessary, select the appropriate
side gear thrust washers. Refer to FFD-23, "
Differential Side
Gear Clearance" .
6. Drive a lock pin into pinion mate shaft, using a suitable punch.
Make sure lock pin is flush with differential case.
CAUTION:
Do not reuse lock pin.
7. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.
8. Install differential case assembly on drive gear.

Tighten bolts in a crisscross pattern, lightly tapping bolt head
with a hammer.
9. Place differential case on drive gear. Tighten bolts in a criss-
cross fashion.
10. Press-fit side bearing inner race on differential case using Tools.
SDIA0195J
SPD0 30
SPD3 22
SDIA2239E
Tool number A: KV38100300 (J-25523)
B: ST33081000 ( — )
SDIA2240E