differential INFINITI QX56 2006 Factory User Guide

FRONT FINAL DRIVE ASSEMBLYFFD-13
CE F
G H
I
J
K L
M A
B
FFD
Revision: November 2009 2006 QX56
7. Remove the front final drive assembly bolts, then remove the
front final drive assembly.
CAUTION:
Support the front final drive assembly while removing using
a suitable jack.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:

Make sure there are no pinched or restricted areas on the breather hose caused by folding or
bending when installing it.

Fill the front final drive assembly with differential gear oil after installation. Refer to FFD-7, "DIF-
FERENTIAL GEAR OIL" .
BDIA0008E

FFD-14
FRONT FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
Disassembly and AssemblyEDS00457
COMPONENTS
1. Side bearing adjuster2. Side bearing 3. Side gear thrust washer
4. Side gear 5. Lock pin 6. Pinion mate thrust washer
7. Pinion mate gear 8. Pinion mate shaft 9. Drive pinion
10. Drive pinion height adjusting washer 11. Drive pinion rear bearing 12. Collapsible spacer
13. Breather tube 14. Differential side flange 15. Dust shield
16. Circular clip 17. Side oil seal 18. Drive pinion front bearing
19. Front oil seal 20. Companion flange 21. Drive pinion lock nut
22. Drain plug 23. Differential side shaft 24. Differential side shaft bearing
25. Extension tube 26. O-ring 27. Gear carrier
28. Plate 29. Differential case 30. Drive gear
31. Side bearing cap 32. Filler plug 33. Carrier cover
SDIA3207E

FRONT FINAL DRIVE ASSEMBLYFFD-15
CE F
G H
I
J
K L
M A
B
FFD
Revision: November 2009 2006 QX56
ASSEMBLY INSPECTION AND ADJUSTMENT

Drain the differential gear oil before inspection and adjustment. Refer to FFD-7, "DIFFERENTIAL GEAR
OIL" .

Remove and install the carrier cover as necessary for inspection and adjustment. Refer to FFD-11, "CAR-
RIER COVER" .
Total Preload Torque
1. Install the differential side shaft and differential side flange if necessary.
CAUTION:
The differential side shaft and differential side flange must be installed in order to measure total
preload torque.
2. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.
4. Measure total preload torque using Tool.
NOTE:
Total preload torque = Drive pinion bearing preload torque +
Side bearing preload torque

If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion
bearing preload torque first, then adjust the side bearing preload torque.
Drive Gear Runout
1. Fit a dial indicator to the drive gear back face.
2. Rotate the drive gear to measure runout.

If the runout is outside of the limit, check the condition of the
drive gear assembly. Foreign material may be caught between
the drive gear and differential case, or the differential case or
drive gear may be deformed.
CAUTION:
Replace drive gear and drive pinion as a set.
34. Bushing 35. Bearing36 Screw
37 Dowel pin
Tool number : ST3127S000 (J-25765-A)
Total preload torque: 2.98 - 4.76 N·m (0.31 - 0.48 kg-m, 27 - 42 in-lb)
PDIA0697E
If the total preload torque is greater than specificationOn drive pinion bearings: Replace the collapsible spacer.
On side bearings: Loosen the side bearing adjuster by the same amount on each side.
If the total preload torque is less than specification On drive pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Tighten the side bearing adjuster by the same amount on each side.
Runout limit: 0.08 mm (0.0031 in) or less
SPD886

FFD-18
FRONT FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
DISASSEMBLY
Differential Assembly
1. Drain the differential gear oil if necessary.
2. Remove the differential side shaft and differential side flange
using suitable tool.
3. Remove the extension tube and O-ring from the gear carrier.
4. Place a small hole in the side oil seal case using suitable tool.
5. Remove the side oil seal using Tool as shown.
BDIA0006E
SDIA3205E
LDIA0129E
Tool number : SP8P
LDIA0130E

FRONT FINAL DRIVE ASSEMBLYFFD-19
CE F
G H
I
J
K L
M A
B
FFD
Revision: November 2009 2006 QX56
6. Remove the carrier cover bolts and separate the carrier cover
from the gear carrier using Tool.
CAUTION:

Do not damage the mating surface.

Do not insert flat-bladed screwdriver, this will damage the
mating surface.
7. For proper reinstallation, paint matching marks on one side of the side bearing cap and gear carrier.
CAUTION:

For matching marks, use paint. Do not damage side bear-
ing cap or gear carrier.

Side bearing caps are line-board during manufacture.
The matching marks are used to reinstall them in their
original positions.
8. Remove the side bearing caps.
9. Remove the side bearing adjuster.
10. Lift the differential case assembly out of the gear carrier. CAUTION:
Keep side bearing outer races together with side bearing
inner races. Do not mix them up.Tool number : KV10111100 (J-37228)
PDIA0699E
PDIA0700E
PDIA0701E
SDIA2230E
SPD527

FFD-20
FRONT FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
11. Remove side bearing inner race using Tools as shown.
CAUTION:

Do not remove side bearing inner race unless it is being
replaced.

Place copper plates between the vise and the side bear-
ing inner race and drive gear to prevent damage.

Engage puller jaws in groove to prevent damage to bear-
ing.

Keep side bearing outer races together with side bearing
inner races. Do not mix them up.
12. For proper reinstallation, paint matching marks on the differential case and drive gear.
CAUTION:
Use paint for matching marks. Do not damage differential
case or drive gear.
13. Remove the drive gear bolts.
14. Tap the drive gear off the differential case using suitable tool. CAUTION:
Tap evenly all around to keep drive gear from bending.
15. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool.
16. Remove the pinion mate shaft. Tool number A: ST33081000 ( — )
B: ST30021000 ( — )
SDIA2237E
SPD022
PDIA0496E
SPD025
SDIA0031J

FRONT FINAL DRIVE ASSEMBLYFFD-21
CE F
G H
I
J
K L
M A
B
FFD
Revision: November 2009 2006 QX56
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 the differential assembly. Refer to FFD-18, "Differential Assembly" .
2. Remove the drive pinion lock nut using Tool.
3. Put matching marks on the companion flange and drive pinion using paint.
CAUTION:
Use paint to make the matching marks. Do not damage the
companion flange or drive pinion.
4. Remove the companion flange using suitable tool.
5. Press the drive pinion assembly (with rear inner bearing race and collapsible spacer) out of the gear carrier.
CAUTION:
Do not drop drive pinion assembly.
SDIA0032J
Tool number : KV38108300 (J-44195)
PDIA0702E
PDIA0703E
SDIA2234E

FRONT FINAL DRIVE ASSEMBLYFFD-23
CE F
G H
I
J
K L
M A
B
FFD
Revision: November 2009 2006 QX56
INSPECTION AFTER DISASSEMBLY
Clean the disassembled parts. Then inspect the parts for wear or damage. If wear or damage are found, follow
the measures below.
Drive Pinion and Drive Gear

If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust,
repair, or replace as necessary.

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

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

If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bear-
ing, replace with new bearing assembly (as a new set).

Bearing must be replaced with a new one whenever disassembled.
Side Gear and Pinion Mate Gear

If any cracks or damage are found on the surface of the teeth, replace with new one.

If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact
the thrust washer, replace with new one.

Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.
Side Gear Thrust Washer and Pinion Mate Thrust Washer

If any chips (by friction), damage, or unusual wear are found, replace with new one.
Gear Carrier

If any wear or cracks are found on the contact sides of gear carrier, replace with new one.
Companion Flange

If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the
front oil seal lips are found, replace with new one.
ADJUSTING AND SELECTING WASHERS
Side Gear Back Clearance

Assemble the differential parts if they are disassembled. Refer to FFD-27, "Differential Assembly" .
1. Place the differential case straight up so that the side gear to be measured is upward.
PDIA0460E

FFD-24
FRONT FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
2. Using feeler gauges, measure the clearance between the side
gear back and differential case at three different points, while
rotating the side gear. Average the three readings to calculate
the clearance. (Measure the clearance of the other side as well.)

If the side gear back clearance is outside of the specification,
use a thicker or thinner side gear thrust washer to adjust.
Refer to FFD-32, "
Side Gear Thrust Washer" .
CAUTION:

Insert feeler gauges with the same thickness on both
sides to prevent side gear from tilting.

Each gear should rotate smoothly without excessive
resistance during differential motion.

Select a side gear thrust washer for right and left individ-
ually.
NOTE:
Side gear back clearance is clearance between side gear and differential case for adjusting side gear
backlash.
Drive Pinion Height

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

The mounting distance from the centerline of the drive gear to the back face of the drive pinion for the
M205 final drive assembly is 103.5 mm (4.0748 inches).
On the button end of each drive 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 drive pinion height adjusting washer between the drive pinion rear bearing inner race and drive
pinion.
For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 inch) less drive pinion
height adjusting washer than a drive pinion etched “0”. This means decreasing drive pinion height adjust-
ing washer thickness; increases the mounting distance of the drive pinion to 103.6 mm (4.0778 inches). If
a drive pinion is etched m-8 (-3), it would require adding 0.08mm (0.003 inch) more to the drive pinion
height adjusting washer than would be required if the drive pinion were etched “0”. By adding 0.08 mm
(0.003 inch), the mounting distance of the drive pinion was decreased to 103.4 mm (4.0718 inches) which
is just what a m-8 (-3) etching indicated.

To change the drive pinion height, use different drive pinion height adjusting washers which come in differ-
ent thickness.

Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness
to add or subtract from the old drive pinion height adjusting washer. Side gear back clearance: 0.20 mm (0.0079 in) or less
If the side gear back clearance is greater than
specification:
Use a thicker side gear thrust washer.
If the side gear back clearance is less than
specification: Use a thinner side gear thrust washer.
PDIA0576E
SDIA2241E

FFD-26
FRONT FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
4. Install the selected drive pinion height adjusting washer to the
drive pinion. Press the drive pinion rear bearing inner race to it
using Tool.
CAUTION:
Do not reuse drive pinion rear bearing inner race.
5. Install the collapsible spacer to the drive pinion. CAUTION:
Do not reuse collapsible spacer.
6. Apply differential gear oil to the drive pinion rear bearing, and install the drive pinion assembly to the gear carrier.
7. Apply differential gear oil to the drive pinion front bearing, and install the drive pinion front bearing inner race to the drive pinion
assembly.
CAUTION:
Do not reuse drive pinion front bearing inner race.
8. Apply multi-purpose grease to the lips of the new front oil seal. Then drive the new front oil seal in evenly using Tools.
CAUTION:

Do not reuse front oil seal.

Do not incline the new front oil seal when installing.

Apply multi-purpose grease to the lips of the new front oil
seal.
9. Install the companion flange to the drive pinion while aligning the matching marks. Tap the companion flange until fully seated
using suitable tool.Tool number : C-4040
SDIA2253E
PDIA0708E
Tool number A: KV38100500 (J-25273)
B: KV38102200 ( — )
PDIA0717E
SDIA2266E