differential NISSAN NAVARA 2005 Repair Workshop Manual

REAR FINAL DRIVE ASSEMBLY
RFD-83
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
ASSEMBLY INSPECTION AND ADJUSTMENT
lBefore 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 operation of the bearing.
3. Turn drive pinion in both directions several times to set bearing
rollers.
4. Measure total preload with preload gauge.
NOTE:
Total preload torque = Pinion bearing preload torque + Side bearing preload torque
lIf measured value is out of the specification, disassemble it to check and adjust each part. Adjust pinion
bearing preload and side bearing preload.
Adjust pinion bearing preload first, then adjust side bearing preload.
Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive
pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check
gear tooth contact pattern to obtain the best contact for low noise and long life.
1. Remove carrier cover. Refer toRFD-86, "
Differential Assembly".
2. Thoroughly clean drive gear and drive pinion teeth.
3. Apply red lead to drive gear.
CAUTION:
Applyredleadtoboththefacesof3to4gearsat4loca-
tions evenly spaced on drive gear.Tool number : ST3127S000
To ta l p r e l o a d
Gear ratio 3.538 Type:
2.34 - 4.34 N·m (0.24 - 0.44 kg-m, 21- 38 in-lb)
Gear ratio 3.692 Type:
2.32 - 4.34 N·m (0.24 - 0.44 kg-m, 21 - 38 in-lb)
When the preload torque is greater than specification
On pinion bearings: Replace collapsible spacer.
On side bearings: Loosen side bearing adjuster.
When the preload torque is less than specification
On pinion bearings: Tighten drive pinion lock nut.
On side bearings: Tighten side bearing adjuster.
PDIA0309E
SDIA2623E

RFD-84
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
4. Hold companion flange steady by hand and rotate drive gear in
both directions.
5. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer toRFD-90, "
Drive
Pinion Height Adjusting Washer"andRFD-84, "Backlash".
Backlash
1. Remove carrier cover. Refer toRFD-86, "Differential Assembly".
2. Check drive gear to drive pinion backlash using a dial indicator
at several points.
3. If outside the standard, adjust side bearing adjusters.
CAUTION:
Check tooth contact and total preload after adjusting side
bearing adjusters. Refer toRFD-83, "
To ta l P r e l o a d To r q u e",
RFD-83, "
Tooth Contact".
a. Remove adjuster lock plates.
b. Loosen side bearing cap bolts.
PDIA0322E
SDIA2591E
Drive gear to drive pinion backlash:
0.08 - 0.13 mm (0.0031 - 0.0051 in)
SDIA2580E

REAR FINAL DRIVE ASSEMBLY
RFD-85
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
c. Tighten or loosen each side bearing adjusters using Tool.
d. In case of excessive backlash, loosen side bearing adjuster A
and tighten side bearing adjuster B. In case of insufficient back-
lash, loosen side bearing adjuster B and tighten side bearing
adjuster A.
e. After adjusting backlash, tighten side bearing cap bolts to the
specified torque. Refer toRFD-82, "
COMPONENTS".
f. Install adjuster lock plates and tighten to the specified torque.
Refer toRFD-82, "
COMPONENTS".
Companion Flange Runout
1. Fit a dial indicator onto companion flange face (inner side of pro-
peller shaft 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 repair limit, follow the procedure
below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90°,180°and
270°and search for the point where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.
c. If the runout value is still outside of the limit after companion flange has been replaced, check drive pinion
front bearing, drive pinion rear bearing and drive pinion assembly.Tool number : KV38108800
PDIA1044E
PDIA0330E
SDIA2582E
Runout limit : 0.10 mm (0.0039 in) or less
Runout limit : 0.13 mm (0.0051 in) or less
SDIA2078E

RFD-86
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
DISASSEMBLY
Differential Assembly
1. Remove carrier cover bolts and bracket.
2. Separate carrier cover from axle housing using Tool.
CAUTION:
lBe careful not to damage the mating surface.
lDo not insert flat-bladed screwdriver, this will damage the
mating surface.
3. Remove sensor connector bolt and differential lock solenoid
connector.
4. For proper reinstallation, paint matching mark on one side of
side bearing cap and axle housing.
CAUTION:
lSide bearing caps are line-board for initial assembly. The
matching marks are used to reinstall them in their origi-
nal positions.
lFor matching mark, use paint. Do not damage side bear-
ing cap and axle housing.
5. Remove adjuster lock plates.
PDIA1066E
Tool number : KV10111100
PDIA1041E
SDIA2585E
SDIA2583E

REAR FINAL DRIVE ASSEMBLY
RFD-87
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
6. Remove side bearing caps.
7. Loosen side bearing adjusters using Tool.
8. Keep side bearing outer races together with inner races. Do not
mix them up. Also, keep side bearing adjusters together with
bearing.
9. Remove side bearing adjusters from axle housing.
10. Remove bracket of differential lock position switch connector
and bolts.
11. Remove differential lock position switch.
12. Remove side bearing inner race using suitable tools.
CAUTION:
Be careful not to damage differential case assembly and
differential lock solenoid.
13. Remove differential lock solenoid and solenoid washer.
SDIA2587E
Tool number : KV38108800
PDIA1044E
SDIA2588E
SDIA2633E
SDIA3447E

RFD-88
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
14. Remove side bearing inner race using suitable tools.
CAUTION:
Be careful not to damage differential case assembly.
15. For proper reinstallation, paint matching mark on differential
case assembly and drive gear.
CAUTION:
For matching mark, use paint. Do not damage differential
case assembly and drive gear.
16. Remove drive gear bolts.
17. Tap drive gear off differential case assembly using suitable tool.
CAUTION:
Tap evenly all around to keep drive gear from binding.
Drive Pinion Assembly
1. Remove differential case assembly. Refer toRFD-86, "Differential Assembly".
2. Remove drive pinion lock nut and washer using Tool.
3. Put a matching mark on the thread edge of drive pinion. The
mark should be in line with the mark on companion flange.
CAUTION:
For matching mark, use paint. Do not damage drive pinion
and companion flange.
SDIA3448E
SDIA2238E
Tool number : KV40104000
PDIA0314E
SDIA2590E

REAR FINAL DRIVE ASSEMBLY
RFD-89
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
4. Remove companion flange using suitable tool.
5. Remove front oil seal using Tool.
CAUTION:
Be careful not to damage axle housing.
6. Remove front bearing thrust washer.
7. Press the drive pinion assembly and collapsible spacer from
axle housing.
CAUTION:
Do not drop drive pinion assembly.
8. Remove drive pinion front bearing inner race from axle housing.
9. Tap drive pinion front bearing outer race uniformly with a brass
bar or equivalent to remove.
CAUTION:
Be careful not to damage axle housing.
10. Tap drive pinion rear bearing outer race uniformly with a brass
bar or equivalent for removal.
CAUTION:
Be careful not to damage axle housing.
11. Remove drive pinion rear bearing inner race and drive pinion
height adjusting washer using Tool.
12. Remove the breather.
PDIA0315E
Tool number : KV381054S0
SDIA2586E
PDIA0316E
SDIA2641E
Tool number : ST30021000
SDIA2236E

RFD-90
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
INSPECTION AFTER DISASSEMBLY
Drive Gear and Drive Pinion
lIf the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as
necessary.
lIf the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new gears.
lDrive 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 pin-
ion and drive gear before proceeding with assembly.
Bearing
lIf 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).
lBearing must be replaced with a new one whenever disassembled.
Differential Case Assembly
lIf the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new differ-
ential case assembly.
lIf the movement is not smooth when pushing cam ring of differential case assembly by hand, repair or
replace as necessary.
Differential Lock Solenoid
lIf the operating part of differential lock solenoid is not smooth, perform component inspection. Refer to
RFD-68, "
COMPONENT INSPECTION".
SELECTION ADJUSTING WASHERS
Drive Pinion Height Adjusting Washer
lDrive 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 hypoid gear set is being used,
verify the numbers of each drive pinion and drive gear before
proceeding with assembly.
lThe mounting distance from the center line of drive gear to the back face of drive pinion for the M226 final
drive is 109.5 mm (4.312 in).
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 hypoid gear set. This dimension is con-
trolled by a selective drive pinion height adjusting washer between 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 in) 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 drive pinion to 109.6 mm (4.315 in). If a drive
pinion is etched m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting
washer than would be required if drive pinion were etched “0”. By adding 0.08 mm (0.003 in), the mount-
ing distance of drive pinion was decreased to 109.4 mm (4.309 in) which is just what a m-8 (-3) etching
indicated.
lTo change drive pinion adjustment, use different drive pinion height adjusting washer which come in differ-
ent thickness.
lUse 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.
SDIA2241E

REAR FINAL DRIVE ASSEMBLY
RFD-91
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
Unit: mm (in)
ASSEMBLY
Drive Pinion Assembly
1. Install the breather and then tighten to the specified torque. Refer toRFD-82, "COMPONENTS".
2. Press a drive pinion rear bearing outer race into axle housing
using suitable tool and Tool.
CAUTION:
Do not reuse drive pinion rear bearing.
3. Press drive pinion front bearing outer race into axle housing
using suitable tool.
CAUTION:
Do not reuse drive pinion front bearing.
OLD DRIVE
PINION
MARKINGNEW DRIVE PINION MARKING
-10
(-4)-8
(-3)-5
(-2)-3
(-1)0+3
(+1)+5
(+2)+8
(+3)+10
(+4)
+10
(+4)+0.20
(+0.008)+0.18
(+0.007)+0.15
(+0.006)+0.13
(+0.005)+0.10
(+0.004)+0.08
(+0.003)+0.05
(+0.002)+0.02
(+0.001)0
(0)
+8
(+3)+0.18
(+0.007)+0.15
(+0.006)+0.13
(+0.005)+0.10
(+0.004)+0.08
(+0.003)+0.05
(+0.002)+0.02
(+0.001)0
(0)-0.02
(-0.001)
+5
(+2)+0.15
(+0.006)+0.13
(+0.005)+0.10
(+0.004)+0.08
(+0.003)+0.05
(+0.002)+0.02
(+0.001)0
(0)-0.02
(-0.001)-0.05
(-0.002)
+3
(+1)+0.13
(+0.005)+0.10
(+0.004)+0.08
(+0.003)+0.05
(+0.002)+0.02
(+0.001)0
(0)-0.02
(-0.001)-0.05
(-0.002)-0.08
(-0.003)
0+0.10
(+0.004)+0.08
(+0.003)+0.05
(+0.002)+0.02
(+0.001)0
(0)-0.02
(-0.001)-0.05
(-0.002)-0.08
(-0.003)-0.10
(-0.004)
-3
(-1)+0.08
(+0.003)+0.05
(+0.002)+0.02
(+0.001)0
(0)-0.02
(-0.001)-0.05
(-0.002)-0.08
(-0.003)-0.10
(-0.004)-0.13
(-0.005)
-5
(-2)+0.05
(+0.002)+0.02
(+0.001)0
(0)-0.02
(-0.001)-0.05
(-0.002)-0.08
(-0.003)-0.10
(-0.004)-0.13
(-0.005)-0.15
(-0.006)
-8
(-3)+0.02
(+0.001)0
(0)-0.02
(-0.001)-0.05
(-0.002)-0.08
(-0.003)-0.10
(-0.004)-0.13
(-0.005)-0.15
(-0.006)-0.18
(-0.007)
-10
(-4)0
(0)-0.02
(-0.001)-0.05
(-0.002)-0.08
(-0.003)-0.10
(-0.004)-0.13
(-0.005)-0.15
(-0.006)-0.18
(-0.007)-0.20
(-0.008)
Tool number : ST30022000
PDIA1051E
PDIA1052E

RFD-92
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
4. Temporarily install drive pinion height adjusting washer.
When hypoid gear set has been replaced
lSelect drive pinion height adjusting washer. Refer toRFD-90,
"Drive Pinion Height Adjusting Washer".
When hypoid gear set has been reused
lTemporarily install the removed drive pinion height adjusting
washer or same thickness washer to drive pinion.
5. Install selected drive pinion height adjusting washer to drive pin-
ion, and press-fit drive pinion rear bearing inner race in it, using
a press and suitable tool.
CAUTION:
Do not reuse drive pinion rear bearing.
6. Apply gear oil to drive pinion rear bearing and drive pinion front
bearing.
7. Install drive pinion front bearing inner race in axle housing.
CAUTION:
Do not reuse drive pinion front bearing.
8. Install front bearing thrust washer to axle housing.
9. Perform checking and adjusting the tooth contact and backlash of the hypoid gear following the procedure
below.
a. Assemble the drive pinion assembly to the axle housing.
CAUTION:
Do not assemble a collapsible spacer.
b. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated.
CAUTION:
Do not assemble a front oil seal.
c. Temporarily tighten removed drive pinion lock nut and washer to
drive pinion.
NOTE:
Use removed drive pinion lock nut and washer only for the pre-
load measurement.
d. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
SDIA1666E
PDIA1053E
PDIA0328E
Tool number : KV40104000
PDIA0313E