torque NISSAN NAVARA 2005 Repair Workshop Manual

REAR FINAL DRIVE ASSEMBLY
RFD-81
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
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MA
B
RFD
REAR FINAL DRIVE ASSEMBLYPFP:38300
Removal and InstallationEDS003BF
REMOVAL
1. Remove the rear propeller shaft. Refer toPR-8, "Removal and Installation".
lPlug rear end of transmission or transfer.
2. Remove the axle shafts and back plate and torque members. Refer toRAX-7, "
Removal and Installation".
3. Disconnect the following components from the rear final drive.
lABS sensor wire harness
lRear cable (LH) and rear cable (RH)
lBrake hoses and brake tube
lDifferential lock position switch harness connector
lDifferential lock solenoid harness connector
CAUTION:
Position the wire harness, cable and hoses away from the final drive assembly. Failure to do so
may result in components being damaged during rear axle assembly removal.
4. Support the rear final drive using a suitable jack.
5. Remove rear shock absorber lower bolts. Refer toRSU-6, "
Removal and Installation".
6. Remove leaf spring U-bolt nuts. Refer toRSU-7, "
Removal and Installation".
WARNING:
Support the rear final drive assembly using suitable jack before removing leaf spring U-bolt nuts.
7. Remove rear final drive assembly using suitable jack.
INSTALLATION
Installation is the reverse order of removal.
lWhen oil leaks while removing rear final drive assembly, check oil level after the installation. Refer to
RFD-40, "
Checking Differential Gear Oil".
lRefill brake fluid and bleed the air from the brake system. Refer toBR-11, "Bleeding Brake System".
lAfter the installation, check DIFF LOCK indicator lamp. Refer toRFD-33, "Precautions for Differential
Case Assembly and Differential Lock Control Unit Replacement".

REAR FINAL DRIVE ASSEMBLY
RFD-83
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
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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

REAR FINAL DRIVE ASSEMBLY
RFD-85
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
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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

REAR FINAL DRIVE ASSEMBLY
RFD-91
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
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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

REAR FINAL DRIVE ASSEMBLY
RFD-93
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
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MA
B
RFD
e. Tighten to drive pinion lock nut, while adjust pinion bearing pre-
load torque.
CAUTION:
lAdjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
lDrive pinion lock nut is tightened with no collapsible spacer. Be careful not to overtighten it.
While measuring the preload, tighten it by 5°to 10°.
lAfter 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 adjusters into axle housing.
g. Apply gear oil to side bearings. Install differential case assembly
with side bearing outer races into axle housing.
h. Align paint matching mark on side bearing cap with that on axle
housing and install side bearing caps on axle housing.
lDo not tighten at this point. This allows further tightening of
side bearing adjusters.
i. Check and adjust the backlash and tooth contact. Refer toRFD-
84, "Backlash"andRFD-83, "To o t h C o n t a c t".
j. Remove side bearing caps.
k. Remove differential case assembly.
l. Remove companion flange.Tool number : ST3127S000
Drive pinion lock nut tightening torque:
298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
Pinion bearing preload:
1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb)
PDIA0309E
PDIA0381E
SDIA2588E
SDIA2632E

REAR FINAL DRIVE ASSEMBLY
RFD-95
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
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H
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MA
B
RFD
14. Apply anti-corrosive oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut and
washer to drive pinion.
CAUTION:
Do not reuse drive pinion lock nut and washer.
15. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
16. Tighten to drive pinion lock nut, while adjust pinion bearing pre-
load torque.
CAUTION:
lAdjust the lower limit of the drive pinion lock nut tighten-
ing torque first.
lIf the preload torque exceeds the specified value, replace collapsible spacer and tighten it again
to adjust. Never loosen drive pinion lock nut to adjust the preload torque.
lAfter adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rota-
tion malfunction, and other malfunctions.
17. Install differential case assembly. Refer toRFD-96, "
Differential Assembly".
CAUTION:
Do not install carrier cover yet.
18. Check and adjust backlash, tooth contact and companion flange runout. Refer toRFD-84, "
Backlash",
RFD-83, "
Tooth Contact"andRFD-85, "Companion Flange Runout". Recheck above items. Readjust the
above description, if necessary.
19. Check total preload torque. Refer toRFD-83, "
To t a l P r e l o a d To r q u e".
20. Apply sealant to mating surface of carrier cover. Refer toRFD-
82, "COMPONENTS".
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.Tool number : KV40104000
PDIA0313E
Tool number : ST3127S000
Drive pinion lock nut tightening torque:
298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
Pinion bearing preload:
1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb)
PDIA0309E
PDIA1042E

RFD-96
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
21. Install carrier cover and bracket on axle housing. Then tighten
carrier cover bolts to the specified torque. Refer toRFD-82,
"COMPONENTS".
Differential Assembly
1. Apply sealant to back face of drive gear. Refer toRFD-82,
"COMPONENTS".
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
2. Align the matching mark of differential case assembly with the
mark of drive gear, then install drive gear.
3. Apply thread locking sealant into the thread hole of drive gear.
Refer toRFD-82, "
COMPONENTS".
CAUTION:
Make sure threaded holes are clean.
PDIA1066E
PDIA1059E
SDIA2593E
SDIA2594E

REAR FINAL DRIVE ASSEMBLY
RFD-97
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
4. Install the drive gear bolts, and then tighten to the specified
torque. Refer toRFD-82, "
COMPONENTS".
CAUTION:
lDo not reuse the bolts.
lTighten bolts in a crisscross fashion.
5. Press side bearing inner race to differential case assembly using
suitable tool.
CAUTION:
Do not reuse side bearing.
6. Install differential lock solenoid and solenoid washer.
7. Press side bearing inner race to differential case assembly using
suitable tool and Tool.
CAUTION:
Do not reuse side bearing.
8. Apply sealant to threads of differential lock position switch. Refer
toRFD-82, "
COMPONENTS".
CAUTION:
Remove old sealant adhering to axle housing and differen-
tial lock position switch. Also remove any moisture, oil, or
foreign material adhering to application and axle housing
and differential lock position switch.
9. Install differential lock position switch on axle housing and
tighten differential lock position switch bolts with the specified
torque. Refer toRFD-82, "
COMPONENTS".
10. Install side bearing adjusters into axle housing.
SDIA0247J
SDIA3449E
Tool number : KV38100300
SDIA3450E
SDIA2633E
PDIA0381E

RFD-98
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
11. Apply gear oil to side bearings. Install differential case assembly
with side bearing outer races into axle housing.
12. Apply multi-purpose grease to sensor connector.
CAUTION:
Do not reuse sensor connector.
13. Connect differential lock solenoid harness and sensor connec-
tor. Then install it to axle housing, tighten to the specified torque.
Refer toRFD-82, "
COMPONENTS".
14. Align paint matching mark on side bearing cap with that on axle
housing and install side bearing caps on axle housing.
CAUTION:
Do not tighten at this point. This allows further tightening of
side bearing adjusters.
15. Tighten each side bearing adjusters using Tool.
16. Adjust backlash of drive gear and drive pinion. Refer toRFD-84,
"Backlash".
17. Check tooth contact. Refer toRFD-83, "
To o t h C o n t a c t".
18. Check total preload. Refer toRFD-83, "
Total Preload Torque".
19. Apply sealant to mating surface of carrier cover. Refer toRFD-
82, "COMPONENTS".
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
SDIA2588E
SDIA3456E
SDIA2632E
Tool number : KV38108800
PDIA1044E
PDIA1061E

REAR FINAL DRIVE ASSEMBLY
RFD-99
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
20. Install carrier cover and bracket on axle housing. Then tighten
carrier cover bolts to the specified torque. Refer toRFD-82,
"COMPONENTS".
PDIA1066E