differential NISSAN NAVARA 2005 Repair User Guide

SIDE OIL SEAL
FFD-13
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SIDE OIL SEALPFP:33142
Removal and InstallationEDS00354
REMOVAL
1. Remove the front wheels and tires using power tool.
2. Without disassembling the hydraulic lines, remove the caliper torque member bolts using power tool.
Then reposition the brake caliper aside using suitable wire. Refer toBR-26, "
Removal and Installation of
Brake Caliper Assembly".
CAUTION:
Do not press the brake pedal while brake caliper is removed.
3. Remove the ABS sensor harness from the mount on the knuckle.
CAUTION:
Do not pull on the ABS sensor harness.
4. Support the lower link using a suitable jack.
5. Separate the upper link ball joint stud from the steering knuckle
using Tool.
CAUTION:
Support the lower link using jack.
6. Remove the engine under cover rear using power tool.
7. Remove the RH and LH drive shafts from the front final drive
using suitable tool.
8. Remove the side oil seal using suitable tool.
CAUTION:
Be careful not to damage gear carrier.
INSTALLATION
Installation is the reverse order of removal.
lDrive the side oil seal in evenly until it becomes flush with the
case end using Tools.
CAUTION:
lDo not reuse oil seal.
lDo not incline oil seal when installing.
lApply multi-purpose grease onto oil seal lips and gear oil
onto the circumference of oil seal.
lWhen installing the drive shaft assembly into the front
final drive assembly, do not damage the side oil seal.
lCheck the final drive gear oil level. Refer toFFD-8, "Checking Differential Gear Oil".
lTighten the upper link ball joint stud nut to specifications. Refer toFSU-6, "Components".
lTighten the wheel nuts to specification. Refer toWT-5, "Rotation". Tool number : ST29020001
WEIA0119E
LDIA0173E
Tool number A: ST30720000
B: ST27863000
PDIA0826E

FFD-14
REAR COVER GASKET
REAR COVER GASKET
PFP:38320
Removal and InstallationEDS00355
REMOVAL
1. Remove front final drive. Refer toFFD-15, "Removal and Installation".
2. Remove the rear cover bolts, then remove the rear cover from the gear carrier.
INSTALLATION
1. Apply a 3 mm (0.12 in) bead of sealant to the mating surface of
the rear cover.
CAUTION:
Remove any old sealant adhering to the mating surfaces.
Also remove any moisture, oil, or foreign material adhering
to the application and mating surfaces.
2. Install the rear cover to the gear carrier. Tighten the bolts to the
specified torque. Refer toFFD-17, "
COMPONENTS".
3. Install the front final drive assembly. Refer toFFD-15, "
Removal
and Installation".
4. Fill the final drive with recommended gear oil. Refer toFFD-8,
"Checking Differential Gear Oil".
PDIA0952E

FRONT FINAL DRIVE ASSEMBLY
FFD-17
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FFD
Disassembly and AssemblyEDS00357
COMPONENTS
1. Drive pinion lock nut 2. Companion flange 3. Front oil seal
4. Pinion front bearing 5. Gear carrier 6. Side oil seal
7. Bushing 8. Side shaft 9. Side shaft bearing
10. Snap ring 11. Snap ring 12. Gasket
13. Drain plug 14. Collapsible spacer 15. Pinion rear bearing
16. Pinion height adjusting washer 17. Drive pinion 18. Side bearing adjusting washer
19. Side bearing 20. Side gear thrust washer 21. Side gear
22. Pinion mate shaft 23. Lock pin 24. Pinion mate gear
25. Pinion mate thrust washer 26. Drive gear 27. Differential case
28. Housing spacer 29. Bearing cap 30. Filler plug
31. Rear cover
PDIA0954E

FFD-18
FRONT FINAL DRIVE ASSEMBLY
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 opera-
tion of the bearing.
3. Measure total preload using Tool.
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 the pinion bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.
CAUTION:
Select a side bearing adjusting washer for right and left individually.
Drive Gear Runout
1. Remove rear cover. Refer toFFD-22, "Differential Assembly".
2. Fit a dial indicator to the drive gear back face.
3. Rotate the drive gear to measure runout.
lIf 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.
CAUTION:
Replace drive gear and drive pinion gear as a set.Tool number : ST3127S000
Total preload torque:
1.67 - 2.74 N·m (0.17 - 0.27 kg-m, 15 - 24 in-lb)
PDIA0697E
When the preload torque is greater than specification
On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same amount to
each side. Refer toFFD-38, "
Side Bearing Adjusting Washer".
When the preload torque is less than specification
On pinion bearings: Tighten the drive pinion nut.
On side bearings: Use thicker side bearing adjusting washers by the same amount to
each side. Refer toFFD-38, "
Side Bearing Adjusting Washer".
Runout limit: 0.08 mm (0.0031 in) or less
SPD886

FRONT FINAL DRIVE ASSEMBLY
FFD-19
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Tooth Contact
1. Remove rear cover. Refer toFFD-22, "Differential Assembly".
2. Apply red lead to drive gear.
CAUTION:
Applyredleadtoboththefacesof3to4gearsat4loca-
tions evenly spaced on drive gear.
3. Rotate drive gear back and forth several times, check drive pin-
iongeartodrivegeartoothcontact.
CAUTION:
Check tooth contact on drive side and reverse side.
SPD357
SDIA0570E
SDIA2549E

FFD-20
FRONT FINAL DRIVE ASSEMBLY
4. If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X).
lIf 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 toFFD-38, "
Pinion Height Adjusting Washer".
lIf 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 toFFD-38, "
Pinion Height Adjusting Washer".
Backlash
1. Remove rear cover. Refer toFFD-22, "Differential Assembly".
2. Fit a dial indicator to the drive gear face to measure the back-
lash.
lIf the backlash is outside of the specified value, change the
thickness of side bearing adjusting washer.
CAUTION:
Do not change the total amount of washers as it will change the bearing preload.
SDIA0517E
PDIA0440E
PDIA0441E
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
When the backlash is greater than specification:
Make drive gear back side adjusting washer thicker,
and drive gear tooth side adjusting washer thinner by
the same amount. Refer toFFD-38, "
Side Bearing
Adjusting Washer".
When the backlash is less than specification:
Make drive gear back side adjusting washer thinner,
and drive gear tooth side adjusting washer thicker by
the same amount. Refer toFFD-38, "
Side Bearing
Adjusting Washer".
SPD513

FFD-22
FRONT FINAL DRIVE ASSEMBLY
6. Press side shaft out of side shaft bearing.
CAUTION:
Do not drop side shaft.
Differential Assembly
1. Remove side shaft assembly. Refer toFFD-35, "Side Shaft".
2. Remove rear cover bolts.
3. Separate the rear cover from the gear carrier using Tool.
CAUTION:
lDo not damage the mating surface.
lDo not insert flat-bladed screwdriver, this will damage the
mating surface.
4. For proper reinstallation, paint matching marks on one side of
the bearing cap.
CAUTION:
lFor matching mark, use paint. Do not damage bearing
caps and gear carrier.
lBearing caps are line-board during manufacture. The
matching marks are used to reinstall them in their origi-
nal positions.
5. Remove bearing caps.
PDIA0718E
Tool number : KV10111100
PDIA0699E
PDIA0700E
PDIA0701E

FRONT FINAL DRIVE ASSEMBLY
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6. Lift differential case assembly out using suitable tool.
CAUTION:
lKeep side bearing outer races together with inner race.
Do not mix them up.
lKeep side bearing adjusting washers together with bear-
ings.
7. Remove housing spacer.
8. Remove side bearing inner races, using Tools.
CAUTION:
lPlace copper plates between the side bearing and drive
gear and the vise to prevent damage.
lDo not remove side bearing inner race unless it is being
replaced.
9. For proper reinstallation, paint matching mark on one side of dif-
ferential case assembly.
CAUTION:
Use paint for matching mark. Do not damage differential
case or drive gear.
10. Remove drive gear bolts.
11. Tap drive gear off differential case assembly using suitable tool.
CAUTION:
Tap evenly all around to keep drive gear from bending.
PDIA0547E
SPD527
Tool number A: ST33051001
B: ST33061000
PDIA0827E
PDIA0496E

FFD-24
FRONT FINAL DRIVE ASSEMBLY
12. Remove lock pin of pinion mate shaft from drive gear side using
suitable tool.
13. Removepinionmateshaft.
14. Turn pinion mate gear, then remove pinion mate gear, pinion
mate thrust washer, side gear and side gear thrust washer from
differential case.
Drive Pinion Assembly
1. Remove side shaft assembly. Refer toFFD-21, "Side Shaft".
2. Remove differential assembly. Refer toFFD-22, "
Differential Assembly".
3. Remove drive pinion lock nut using flange wrench.
SPD025
SDIA0031J
SDIA0032J
PDIA1020E

FFD-26
FRONT FINAL DRIVE ASSEMBLY
11. Tap pinion front/rear bearing outer races uniformly to remove
them, using suitable tool.
CAUTION:
Do not damage gear carrier.
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If parts are worn or dam-
aged, follow the measures below.
PDIA0705E
Content Conditions and Measures
Hypoid gear
lIf the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.
lIf the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
Bearing
lIf 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
lIf any cracks or damage on the surface of the tooth is found, replace.
lIf 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
lIf it is chipped (by friction), damaged, or unusually worn, replace.
Oil seal
lWhenever disassembled, replace.
lIf wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case
lIf any wear or crack on the contact sides of the differential case is found, replace.
Companion flange
lIf 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.