NISSAN PATROL 1998 Y61 / 5.G Propeller Shaft And Differential Carrier Owner's Manual

CAUTION:
Do not run engine when one wheel (rear) is off the ground.
Preparation for Disassembly
CHECKING DIFFERENTIAL TORQUE
Measure differential torque with Tool.
If it is not within the speci®cations, inspect components of limited
slip differential.
Differential torque:
108 - 137 Nzm (11 - 14 kg-m, 80 - 101 ft-lb)
Tool number: KV38106400
SPD439A
SPD508
LIMITED SLIP DIFFERENTIAL
PD-20

Disassembly
1. Remove side bearing inner cone with Tool.
2. Loosen ring gear bolts in a criss-cross pattern.
3. Tap ring gear off gear case with a soft hammer.
Tap evenly all around to keep ring gear from binding.
4. Loosen screws on differential cases A and B using a press.
5. Separate differential cases A and B. Draw out component parts
(discs and plates, etc.).
Put marks on gears, discs and plates so that they can be rein-
stalled in their original positions from which they were
removed.
Inspection
CONTACT SURFACES
1. Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
2. If following surfaces are found with burrs or scratches, smooth
with oil stone.
V1Differential case A
V2Differential case B
V3Pressure ring
V4Thrust washer
V5Pinion mate shaft
V6Thrust block
V7Pinion mate gear
V8Side gear
SPD476
SPD507
SPD503
LIMITED SLIP DIFFERENTIAL
PD-21

DISC AND PLATE
1. Clean the discs and plates in suitable solvent and blow dry with
compressed air.
2. Inspect discs and plates for wear, nicks and burrs.
3. To test if friction disc or plate is not distorted, place it on a sur-
face plate and rotate it by hand with indicating ®nger of dial
gauge resting against disc or plate surface.
Allowable warpage:
0.08 mm (0.0031 in)
If it exceeds limits, replace with a new plate to eliminate possi-
bility of clutch slippage or sticking.
4. Measure frictional surfaces and projected portions of friction
disc, friction plate, spring plate, and determine each part's dif-
ferences to see if the speci®ed wear limit has been exceeded.
If any part has worn beyond the wear limit, and deformed or
fatigued, replace it with a new one that is the same thickness
as the projected portion.
Wear limit:
0.1 mm (0.004 in) or less
SPD478
SPD279
SPD403
LIMITED SLIP DIFFERENTIAL
Inspection (Cont'd)
PD-22

Adjustment
FRICTION DISC AND FRICTION PLATE END PLAY
End play of friction disc and friction plate can be calculated by using
following equation and should be adjusted within following range.
Adjustment can be made by selecting friction disc having two dif-
ferent thicknesses.
End play E:
0.05 - 0.15 mm (0.0020 - 0.0059 in)
E=Aþ(B+C)
A: Length of differential case contact surface to differen-
tial case inner bottom.
B: Total thickness of friction discs, friction plates, spring
disc and spring plate in differential case on one side.
C: Length of differential case contact surface to back side
of side gear.
1. Measure values of ``A''.
Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in)
2. Measure thickness of each disc and plate.
Total thickness ``B'':
19.24 - 20.26 mm (0.7575 - 0.7976 in)
3. Measure values of ``C''.
(1) Attach a dial indicator to the base plate.
(2) Place differential case B on the base plate, and install a mas-
ter gauge on case B.
Then adjust the dial indicator scale to zero with its tip on the
master gauge.
SPD761
SPD417
SPD420
SPD418
LIMITED SLIP DIFFERENTIAL
PD-23

(3) Install pinion mate gears, side gears and pinion mate shaft in
differential case B.
(4) Set dial indicator's tip on the side gear, and read the indication.
Example:
E = A þ D = A þ (B + C) = 0.05 to 0.15 mm
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D=B+C E=AþD
B .... 19.45 A ..... 49.52
+C .... 29.7 þD .... 49.15
49.150.37
From the above equation, end play of 0.37 mm exceeds the speci-
®ed range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.
Assembly
Assemble differential case in the reverse order of disassembly,
observing the following.
1. As an aid to installation, apply sufficient amounts of recom-
mended limited slip differential gear oil (refer to MA section) to
the faces of pressure rings, discs and plates to be assembled
together.
2. Place differential case B on a level surface, then install thrust
washer.
3. Install spring plates, friction plates and friction discs.
Pay particular attention to the direction of clutch plates and
their assembly sequence.
SPD419
SPD479
SPD406
SPD504
LIMITED SLIP DIFFERENTIAL
Adjustment (Cont'd)
PD-24

4. Install pressure ring.
5. Install side gear by inserting projected portion of disc.
6. Install pinion mate gears and shaft.
Always attach pinion mate shaft to ``V'' groove in pressure ring
with ¯at surfaces facing up and down.
7. Install thrust block.
8. Install differential case A side components in the opposite way
of differential case B components.
9. Apply gear oil to differential case A, and attach thrust washer
to it.
SPD481
SPD482
SPD483
SPD505
SPD506
LIMITED SLIP DIFFERENTIAL
Assembly (Cont'd)
PD-25

10. Install differential case A on differential case B. Align the match-
ing marks on the cases, then install screws while pushing dif-
ferential case down using a press.
Press force:
7,846 N (800 kg, 1,764 lb)
11. After all parts have been assembled, check and adjust the fol-
lowing:
DIFFERENTIAL TORQUE INSPECTION
a. Place side gear in a vise with Tool into the gear splines.
b. Turn side gear several times, then measure the differential
torque after side gear begins to rotate in order to determine
whether it is within the speci®ed range. If it is not, adjust it by
selecting a friction disc. (Refer to SDS for adjustment parts.)
Differential torque:
108 - 137 Nzm (11 - 14 kg-m, 80 - 101 ft-lb)
Tool number: KV38106400
SIDE GEAR BACKLASH INSPECTION
Check backlash of side gear on both sides. Using a feeler gauge,
measure clearance between side gear and thrust washer. If it is not
within speci®cations, adjust it by selecting a thrust washer. (Refer
to SDS.)
Side gear backlash:
Differential case A side
0.05 - 0.20 mm (0.0020 - 0.0079 in)
Differential case B side
0.05 - 0.20 mm (0.0020 - 0.0079 in)
12. After checking and adjusting, tighten ring gear bolts in a criss-
cross fashion.
13. Bend up lock straps to lock bolts in place.
14. Install side bearing inner race with Tool.
SPD507
SPD508
SPD411
LIMITED SLIP DIFFERENTIAL
Assembly (Cont'd)
PD-26

To avoid confusion while calculating bearing shims, it is absolutely
necessary to stay with the metric system. If you measure anything
in inches,the results must be converted to the metric system.
Drive Pinion Height
1. First prepare Tools for pinion height adjustment.
:
V1Height gauge (ST31251000)
V2Dummy shaft (ST31181001)
V3Spacer [thickness: 2.50 mm (0.0984 in)]
V4Feeler gauge
2. To simplify the job, make a chart, like the one below, to orga-
nize your calculations.
LETTERSHUNDREDTHS OF
A MILLIMETER
H: Head number
D¢: Figure marked on dummy shaft
S: Figure marked on height gauge
N: Measuring clearance
3. Write the following numbers down the chart.
H: Head number
D¢: Figure marked on dummy shaft.
SPD758
SPD542
SPD759
ADJUSTMENT
PD-27

S: Figure marked on height gauge.
4. Place pinion rear bearing inner cone and Tools on gear carrier.
Tool number:
ST31181001
5. Attach Tool (Height gauge) to gear carrier, and measure the
clearance between the height gauge tip and the dummy shaft
face.
Tool number:
ST31251000
6. Substitute these values into the equation to calculate the thick-
ness of the washer.
If values signifying H, D¢and S are not given, regard them as
zero and calculate.
T (Thickness of washer)
=Nþ[(HþD¢þ S) x 0.01] + 3.05
SPD760
SPD271-A
SPD272-A
PD444-A
PD029
ADJUSTMENT
Drive Pinion Height (Cont'd)
PD-28

Example (H233B):
N = 0.30
H=2
D¢=þ1
S=0
T=Nþ[(HþD¢þ S) x 0.01] + 3.05
= 0.30 þ [{2 þ (þ1) þ 0} x 0.01] + 3.05
(1) H ........................................................................ 2
þD¢................................................................. þ(þ1)
3
þS ...................................................................... þ0
3
(2) 3
x 0.01
0.03
(3) N ................................................................... 0.30
þ0.03
0.27
(4) 0.27
+3.05
3.32
\T = 3.32
7. Select the proper pinion height washer.
Drive pinion height adjusting washer:
Refer to SDS (PD-0, 53).
If you cannot ®nd the desired thickness of washer, use washer
with thickness closest to the calculated value.
Example (H233B):
Calculated value ... T = 3.32 mm
Used washer ... T = 3.33 mm
Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly in relation to
one another may be noisy, or have short life or both. With a pat-
tern check, the most desirable contact for low noise level and long
life can be assured.
1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.
SPD005
ADJUSTMENT
Drive Pinion Height (Cont'd)
PD-29