NISSAN NAVARA 2005 Repair Workshop Manual

RFD-18
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
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-15, "
COMPONENTS".
f. Install adjuster lock plates and tighten to the specified torque.
Refer toRFD-15, "
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
PDIA0331E
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-19
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
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MA
B
RFD
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. 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.
4. Remove adjuster lock plates.
5. Remove side bearing caps.
PDIA1066E
Tool number : KV10111100
PDIA1041E
PDIA0310E
PDIA0311E

RFD-20
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
6. Loosen side bearing adjusters using Tool.
7. Keep side bearing outer races together with inner races. Do not
mix them up. Also, keep side bearing adjusters together with
bearing.
8. Remove side bearing adjusters from axle housing.
9. Remove side bearing inner races using suitable tools.
CAUTION:
Be careful not to damage differential case assembly.
10. 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.
11. Remove drive gear bolts.
12. Tap drive gear off differential case assembly using suitable tool.
CAUTION:
Tap evenly all around to keep drive gear from binding.Tool number : KV38108800
PDIA1044E
PDIA0312E
PDIA1072E
SDIA2238E

REAR FINAL DRIVE ASSEMBLY
RFD-21
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
MA
B
RFD
Drive Pinion Assembly
1. Remove differential case assembly. Refer toRFD-19, "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.
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.Tool number : KV40104000
PDIA0314E
SDIA2590E
PDIA0315E
Tool number : KV381054S0
SDIA2586E

RFD-22
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
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.
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.
PDIA0316E
SDIA2641E
Tool number : ST30021000
SDIA2236E

REAR FINAL DRIVE ASSEMBLY
RFD-23
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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MA
B
RFD
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.
Unit: mm (in)
SDIA2241E
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)

RFD-24
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
ASSEMBLY
Drive Pinion Assembly
1. Install the breather and then tighten to the specified torque. Refer toRFD-15, "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.
4. Temporarily install drive pinion height adjusting washer.
When hypoid gear set has been replaced
lSelect drive pinion height adjusting washer. Refer toRFD-23,
"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.Tool number : ST30022000
PDIA1051E
PDIA1052E
SDIA1666E
PDIA1053E

REAR FINAL DRIVE ASSEMBLY
RFD-25
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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MA
B
RFD
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.
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.
PDIA0328E
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
PDIA0381E

RFD-26
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
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-
17, "Backlash"andRFD-16, "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.
m. Press the drive pinion assembly from axle housing.
CAUTION:
Do not drop drive pinion assembly.
10. Install front oil seal into axle housing using suitable tool.
CAUTION:
lDo not reuse oil seal.
lDo not incline oil seal when installing.
lApply multi-purpose grease onto oil seal lip, and gear oil
onto the circumference of oil seal.
11. Install collapsible spacer to drive pinion. And then install drive
pinion assembly in axle housing.
CAUTION:
lDo not reuse collapsible spacer.
lBe careful not to damage front oil seal.
PDIA0312E
SDIA3446E
PDIA0316E
PDIA1054E
SDIA2595E

REAR FINAL DRIVE ASSEMBLY
RFD-27
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
I
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K
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MA
B
RFD
12. Align the matching mark of the drive pinion with the mark of the
companion flange, then install the companion flange.
13. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated.
CAUTION:
Be careful not to damage companion flange and front oil
seal.
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-28, "
Differential Assembly".
CAUTION:
Do not install carrier cover yet.
18. Check and adjust backlash, tooth contact and companion flange runout. Refer toRFD-17, "
Backlash",
RFD-16, "
Tooth Contact"andRFD-18, "Companion Flange Runout". Recheck above items. Readjust the
above description, if necessary.
SDIA2590E
PDIA0328E
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