NISSAN NAVARA 2005 Repair Workshop Manual

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
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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
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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

REAR FINAL DRIVE ASSEMBLY
RFD-93
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
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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

RFD-94
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
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.
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.
PDIA0316E
PDIA1054E
SDIA2595E
SDIA2590E
PDIA0328E

REAR FINAL DRIVE ASSEMBLY
RFD-95
[WITH ELECTRONIC LOCKING DIFFERENTIAL]
C
E
F
G
H
I
J
K
L
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