differential NISSAN NAVARA 2005 Repair Manual PDF

CARRIER COVER
RFD-13
[WITH LIMITED SLIP DIFFERENTIAL]
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RFD
CARRIER COVERPFP:38351
Removal and InstallationEDS00397
REMOVAL
1. Remove the drain plug and drain the gear oil. Refer toRFD-9, "DRAINING".
2. Disconnect the rear cable (LH) from the carrier cover. Refer toPB-3, "
Components".
3. Remove bracket from the axle housing.
4. Remove the carrier cover bolts. Then separate carrier cover
from the 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.
INSTALLATION
1. Apply sealant to mating surface of carrier cover. Refer toRFD-
15, "COMPONENTS".
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
2. Install carrier cover and bracket on axle housing. Then tighten
carrier cover bolts to the specified torque. Refer toRFD-15,
"COMPONENTS".
3. Connect the rear cable (LH) to the carrier cover and tighten to
the specified torque. Refer toPB-3, "
Components".
4. Fill with new gear oil until oil level reaches the specified limit
near filler plug hole. Refer toRFD-9, "
Checking Differential Gear
Oil".
PDIA1066E
Tool number : KV10111100
PDIA1041E
PDIA1042E
PDIA1066E

RFD-14
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
REAR FINAL DRIVE ASSEMBLY
PFP:38300
Removal and InstallationEDS00398
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
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-9, "
Checking Differential Gear Oil".
lRefill brake fluid and bleed the air from the brake system. Refer toBR-11, "Bleeding Brake System".

REAR FINAL DRIVE ASSEMBLY
RFD-15
[WITH LIMITED SLIP DIFFERENTIAL]
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RFD
Disassembly and AssemblyEDS00399
COMPONENTS
1. Drive pinion lock nut 2. Washer 3. Companion flange
4. Front oil seal 5. Front bearing thrust washer 6. Drive pinion front bearing
7. Axle housing 8. Breather 9. Drain plug
10. Side bearing cap 11. Adjuster lock plate 12. Carrier cover
13. Filler plug 14. Bracket 15. Drive pinion
16. Drive pinion height adjusting washer 17. Drive pinion rear bearing 18. Collapsible spacer
19. Side bearing adjuster 20. Side bearing 21. Differential case assembly
22. Drive gear
PDIA1083E

RFD-16
[WITH LIMITED SLIP DIFFERENTIAL]
REAR 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 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-13, "
Removal and Installation".
2. Thoroughly clean drive gear and drive pinion teeth.
3. Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.Tool number : ST3127S000
To ta l p r e l o a d
Gear ratio 3.357 Type:
2.38 - 4.46 N·m (0.25 - 0.45 kg-m, 21- 39 in-lb)
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
PDIA0321E

REAR FINAL DRIVE ASSEMBLY
RFD-17
[WITH LIMITED SLIP DIFFERENTIAL]
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RFD
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-23, "
Drive
Pinion Height Adjusting Washer"andRFD-17, "Backlash".
Backlash
1. Remove carrier cover. Refer toRFD-19, "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-16, "
Total Preload Torque",
RFD-16, "
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)
SDIA2640E

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]
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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]
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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