differential NISSAN NAVARA 2005 Repair Manual Online

REAR FINAL DRIVE ASSEMBLY
RFD-23
[WITH LIMITED SLIP DIFFERENTIAL]
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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]
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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]
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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

RFD-28
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
19. Check total preload torque. Refer toRFD-16, "Total Preload Torque".
20. 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.
21. Install carrier cover and bracket on axle housing. Then tighten
carrier cover bolts to the specified torque. Refer toRFD-15,
"COMPONENTS".
Differential Assembly
1. Apply sealant to back face of drive gear. 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. Align the matching mark of differential case assembly with the
mark of drive gear, then install drive gear.
PDIA1042E
PDIA1066E
PDIA1059E
SDIA2593E

REAR FINAL DRIVE ASSEMBLY
RFD-29
[WITH LIMITED SLIP DIFFERENTIAL]
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RFD
3. Apply thread locking sealant into the thread hole of drive gear.
Refer toRFD-15, "
COMPONENTS".
CAUTION:
Make sure threaded holes are clean.
4. Install the drive gear bolts, and then tighten to the specified
torque. Refer toRFD-15, "
COMPONENTS".
CAUTION:
lDo not reuse the bolts.
lTighten bolts in a crisscross fashion.
5. Press side bearing inner races to differential case assembly
using suitable tool and Tool.
CAUTION:
Do not reuse side bearings.
6. Install side bearing adjusters into axle housing.
7. Apply gear oil to side bearings. Install differential case assembly
with side bearing outer races into axle housing.
SDIA2594E
SDIA0247J
Tool number : KV38100300
PDIA1060E
PDIA0381E
PDIA0312E

RFD-30
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
8. 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.
9. Tighten each side bearing adjusters using Tool.
10. Adjust backlash of drive gear and drive pinion. Refer toRFD-17,
"Backlash".
11. Check tooth contact. Refer toRFD-16, "
To o t h C o n t a c t".
12. Check total preload. Refer toRFD-16, "
Total Preload Torque".
13. 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.
14. Install carrier cover and bracket on axle housing. Then tighten
carrier cover bolts to the specified torque. Refer toRFD-15,
"COMPONENTS".
SDIA3446E
Tool number : KV38108800
PDIA1044E
PDIA1042E
PDIA1066E

SERVICE DATA AND SPECIFICATIONS (SDS)
RFD-31
[WITH LIMITED SLIP DIFFERENTIAL]
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RFD
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS0039A
*: Option
Inspection and AdjustmentEDS0039B
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in) Applied modelYD25DDTi
2WD 4WD
6M/T 5A/T 6M/T 5A/T
Grade SE, XE SE SE, XE* XE SE
Final drive modelM226
Gear ratio 3.538 3.357 3.692 3.538
Number of pinion gears 2
Number of teeth (Drive gear / drive pinion) 46/13 47/14 48/13 46/13
Oil capacity (Approx.)
(lmp pt)2.01 (3-1/2)
Drive pinion adjustment spacer type Collapsible
ItemSpecification
Gear ratio 3.357 type Gear ratio 3.538 type Gear ratio 3.692 type
To t a l p r e l o a d2.38 - 4.46
(0.25-0.45,21-39)2.34 - 4.34
(0.24 - 0.44, 21 - 38)2.32 - 4.34
(0.24 - 0.44, 21 - 38)
Pinion bearing preload 1.7 - 3.1 (0.18 - 0.31, 15 - 27)
Item Standard
Drive gear to drive pinion gear 0.08 - 0.13 (0.0031 - 0.0051)
Item Runout limit
Companion flange face 0.10 (0.0039) or less
Inner side of companion flange 0.13 (0.0051) or less

RFD-32
[WITH LIMITED SLIP DIFFERENTIAL]
SERVICE DATA AND SPECIFICATIONS (SDS)
SELECTIVE PARTS
Drive Pinion Height Adjusting Washer
Unit: mm (in)
*Always check with the Parts Department for the latest parts information.Thickness Package part number*
0.076 (0.030)
0.079 (0.031)
0.081 (0.032)
0.084 (0.033)
0.086 (0.034)38151 8S101
0.089 (0.035)
0.091 (0.036)
0.094 (0.037)
0.097 (0.038)
0.099 (0.039)38151 8S102
0.102 (0.040)
0.104 (0.041)
0.107 (0.042)
0.109 (0.043)
0.112 (0.044)38151 8S103
0.114 (0.045)
0.117 (0.046)
0.119 (0.047)
0.122 (0.048)
0.124 (0.049)38151 8S104
0.127 (0.050)
0.130 (0.051)
0.132 (0.052)
0.135 (0.053)
0.137 (0.054)38151 8S105