INFINITI QX56 2009 Factory Service Manual

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REMOVAL AND INSTALLATION
FRONT FINAL DRIVE
Removal and InstallationINFOID:0000000004193545
REMOVAL
1. Drain the differential gear oil. Refer to DLN-209, "Changing Differential Gear Oil".
2. Remove the drive shafts from the front final drive assembly. Refer to FAX-9, "Removal and Installation"
.
3. Remove the front cross member.
4. Remove the front propeller shaft from the front final drive assembly. Refer to DLN-186, "Removal and
Installation".
5. Disconnect the vent hose from the front final drive assembly.
6. Support the front final drive assembly using a suitable jack.
1. Front final drive assembly 2. Front cross member 3. Undercover
SDIA3220E
Revision: December 20092009 QX56

DLN-216
< REMOVAL AND INSTALLATION >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
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 ar eas on the breather hose caused by folding or bend-
ing when installing it.
 Fill the front final drive assembly with differen tial gear oil after installation. Refer to DLN-209,
"Checking Differential Gear Oil".
BDIA0008E
Revision: December 20092009 QX56

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DISASSEMBLY AND ASSEMBLY
FRONT FINAL DRIVE
Disassembly and AssemblyINFOID:0000000005875038
COMPONENTS
1. Side bearing adjuster 2. 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
AWDIA0707GB
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DLN-218
< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
ASSEMBLY INSPECTION AND ADJUSTMENT
 Drain the differential gear oil before inspection and adjustment. Refer to
DLN-209, "Changing Differential
Gear Oil".
 Remove and install the carrier cover as neces sary for inspection and adjustment. Refer to DLN-214,
"Removal and Installation".
Total Preload Torque
1. Install the differential side shaft and differential side flange if necessary.
CAUTION:
The differential side shaft and differential side flan ge 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.
Tooth Contact
28. Plate 29. Differential case 30. Drive gear
31. Side bearing cap 32. Filler plug 33. Carrier cover
34. Bushing 35. Bearing 36 Screw
37 Dowel pin
Tool number : ST3127S000 (J-25765-A)
Total preload torque
: Refer to DLN-234, "Inspection and Adjust-
ment"
PDIA0697E
If the total preload torque is greater than specification
On drive pinion bearings: R eplace the collapsible spacer.
On side bearings: Loosen the side bearin g 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 bear ing adjuster by the same amount on each
side.
Runout limit: 0.08 mm (0.0031 in) or less
SPD886
Revision: December 20092009 QX56

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1. Apply red lead to the drive gear. NOTE:
Apply red lead to both faces of thr ee to four gears, at four loca-
tions evenly spaced on the drive gear.
2. Rotate the drive gear back and forth several times. Then check for correct drive pinion to drive gear tooth contact as shown.
CAUTION:
Check tooth contact on dri ve side and reverse side.
3. If the tooth contact is improper ly adjusted, follow the procedure
below to adjust the drive pinion height (dimension X).
 If the tooth contact is near the face (face contact), or near the heel (heel contact), use a thicker drive pinion height adjusting washer to
move drive pinion closer to the drive gear.
Refer to DLN-234, "Inspection and Adjustment"
.
 If the tooth contact is near the flank (flank contact), or near the toe
(toe contact), use a thinner drive pinion height adjusting washer to
move the drive pinion farther from the drive gear.
Refer to DLN-234, "Inspection and Adjustment"
.
SPD357
SDIA0570E
SDIA0517E
PDIA0440E
PDIA0441E
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< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
Backlash
1. Fit a dial indicator to the drive gear face to measure the back-
lash.
 If the backlash is outside of t he specification, adjust each side
bearing adjuster.
CAUTION:
Do not change the side bearing adjusters by different
amounts as it will change the side bearing preload torque.
Companion Flange Runout
1. Rotate companion flange and check for runout on the compan-
ion flange face (inner side of the bolt holes) and companion
flange inner side (socket diameter) using suitable tool.
2. If the runout is outside the runout limit, follow the procedure below to adjust.
a. Rotate the companion flange on the drive pinion by 90 °, 180 ° and 270 ° while checking for the position
where the runout is minimum.
b. If the runout is still outside of the runout limit af ter the companion flange has been rotated on the drive pin-
ion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a mal-
functioning drive pinion bearing.
c. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion
bearing or drive pinion bearing, replace the companion flange.
DISASSEMBLY
Differential Assembly
1. Drain the differential gear oil if necessary. Backlash : Refer to
DLN-234, "Inspection and Ad-
justment"
SPD513
If the backlash is greater than specification:
Loosen side bearing adjuster A and tighten side bear-
ing adjuster B by the same amount.
If the backlash is less than specification: Loosen side bearing adjuster B and tighten side bear-
ing adjuster A by the same amount.
SDIA2262E
Runout limit
Companion flange face : Refer to DLN-234, "Inspec-
tion and Adjustment"
Companion flange inner
side: Refer to
DLN-234, "Inspec-
tion and Adjustment"
SDIA2078E
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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.
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 screw driver, this will damage the
mating surface.
BDIA0006E
SDIA3205E
LDIA0129E
Tool number : SP8P
LDIA0130E
Tool number : KV10111100 (J-37228)
PDIA0699E
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DLN-222
< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
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 re install 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.
11. Remove side bearing inner race using Tools as shown. CAUTION:
 Do not remove side bearing inner race unless it is beingreplaced.
 Place copper plates between th e vise and the side bearing
inner race and drive gear to prevent damage.
 Engage puller jaws in groo ve to prevent damage to bear-
ing.
PDIA0700E
PDIA0701E
SDIA2230E
SPD527
Tool number A: ST33081000 ( — )
B: ST30021000 ( — )
SDIA2237E
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 Keep side bearing outer races together with si de 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.
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.
PDIA0496E
SPD025
SDIA0031J
SDIA0032J
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DLN-224
< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
2. Remove the drive pinion lock nut using suitable 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.
6. Remove the drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.
PDIA0702E
PDIA0703E
SDIA2234E
Tool number : ST30021000 ( — )
S-PD179
Revision: December 20092009 QX56