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

6. Install drive pinion bearing spacer, pinion bearing adjusting
shim and drive pinion in gear carrier.
7. Insert companion ¯ange into drive pinion by tapping the com-
panion ¯ange with a soft hammer.
8. Tighten pinion nut to the speci®ed torque.
The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number: KV38104700
9. Turn drive pinion in both directions several times, and measure
pinion bearing preload.
Tool number: ST3127S000
Pinion bearing preload (with front oil seal):
1.4 - 1.7 Nzm (14 - 17 kg-cm, 12 - 15 in-lb)
If preload is out of speci®cation, adjust the thickness of spacer and
shim combination by replacing shim and spacer with thinner one.
+Start from the combination of thickest spacer and shim.
+Combine each spacer and shim thickness one by one until the
correct speci®cation are achieved.
Drive pinion bearing preload adjusting spacer and
shim:
Refer to SDS (PD-51).
SPD935-A
SPD697
SPD040
SPD149
ASSEMBLY
Differential Carrier (Cont'd)
PD-34

10. Install differential case assembly with side bearing outer races
into gear carrier.
11. Position side bearing adjusters on gear carrier with threads
properly engaged; screw in adjusters lightly at this stage of
assembly.
Tool number:
ST32580000
12. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
+Do not tighten at this point to allow further tightening of side
bearing adjusters.
13. Tighten both right and left side bearing adjusters alternately and
measure ring gear backlash and total preload at the same time.
Adjust right and left side bearing adjusters by tightening them
alternately so that proper ring gear backlash and total preload
can be obtained.
Ring gear-to-drive pinion backlash:
0.15 - 0.20 mm (0.0059 - 0.0079 in)
+When checking preload, turn drive pinion in both direc-
tions several times to set bearing rollers.
Tool number: ST3127S000
Total preload (with front oil seal):
Drive pinion bearing
New parts
1.7 - 2.5 Nzm (17 - 25 kg-cm, 15 - 22 in-lb)
Used parts
1.5 - 1.7 Nzm (15 - 17 kg-cm, 13 - 15 in-lb)
PD383
SPD684
SPD265
SPD246
SPD149
ASSEMBLY
Differential Carrier (Cont'd)
PD-35

14. Tighten side bearing cap bolts.
15. Install side lock ®nger in place to prevent rotation during opera-
tion.
16. Check runout of ring gear with a dial indicator.
Runout limit: 0.08 mm (0.0031 in)
+If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case.
+If the backlash varies greatly when the runout of the ring gear
is within a speci®ed range, the hypoid gear set or differential
case should be replaced.
17. Check tooth contact. Refer to ADJUSTMENT (PD-27).
SPD698
SPD247
ASSEMBLY
Differential Carrier (Cont'd)
PD-36

Actuator and Fork
SPD441A
SPD835-A
DIFFERENTIAL LOCK
PD-37

Disassembly
1. Remove side bearing inner cone with Tool. For removal
procedure, refer to ordinary differential case.
2. Loosen ring gear bolts in a criss-cross pattern.
3. Tap ring gear off the gear with a soft hammer.
4. Put marks on both differential cases.
5. Loosen screws on differential cases A and B using a press.
Tool number: ST33081000
6. Separate differential cases A and B.
7. Drive out pinion mate shaft lock pin with Tool.
Draw out component parts.
SPD839
SPD449A
SPD841
DIFFERENTIAL LOCK
PD-38

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
V3Side gear thrust washer
V4Side gear
V5Pinion mate thrust washer
V6Pinion mate gear
V7Pinion mate shaft
ACTUATOR OPERATION
Apply a vacuum pressure of 66.7 kPa (667 mbar, 500 mmHg, 19.69
inHg) and check its operation and leakage within 10 seconds.
SPD842
SPD906
DIFFERENTIAL LOCK
PD-39

Assembly
DIFFERENTIAL CASE
1. Install side gears, pinion mate gears and thrust washers into
differential case B.
2. Fit pinion mate shaft to differential case so that it meets lock pin
holes.
3. Adjust backlash between side gear and pinion mate gear.
+Opposite side of ring gear:
Select side gear thrust washer by measuring gap with feeler
gauge. Refer to SDS.
+Ring gear side:
Measure height H
1.
Measure height H
2.
H
2þH1= Clearance between the side gear end face and dif-
ferential case B
Select side gear thrust washer. Refer to SDS.
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and dif-
ferential case):
0.10 - 0.20 mm (0.0039 - 0.0079 in)
4. Install pinion mate shaft lock pin with a punch. Make sure lock
pin is ¯ush with case.
5. Install differential case A.
6. Place ring gear on differential case and install it by tightening
bolt. Use locking sealant.
7. Install side bearing inner cone.
SPD844
SPD845
SPD846
SPD847
DIFFERENTIAL LOCK
PD-40

ACTUATOR
+If same differential carrier is used again, reuse actuator shim or
use a shim of the same thickness when used shim is damaged.
+When differential carrier is replaced with a new one, select
actuator shim to keep differential lock mechanism functioning.
+When installing the differential lock fork, make sure it is facing
the correct direction.
1. Standard length ``A'' is between speci®ed mounting surface of
actuator and differential case B surface ``P''. Refer to SDS.
2. Install differential carrier on axle case.
3. Rotate ring gear until surface ``P'' is seen through actuator
mounting hole in axle case.
Measure dimension ``L'' between actual mounting surface of
actuator on axle case and surface ``P'', using suitable gauge
tool.
+Put gauge as shown on drawing.
+Put mark on gauge at actuator mounting surface.
+Measure dimension ``L''.
SPD848
SPD930
SPD931
DIFFERENTIAL LOCK
Assembly (Cont'd)
PD-41

4. If shim thickness determined by equation is assumed as ``T'',
``T'' will be expressed by equation ``A'' - ``L''. Select a combina-
tion of shims from those shown in SDS so that shim thickness
is within ``T'' range. Install actuator using selected shims.
SPD932
DIFFERENTIAL LOCK
Assembly (Cont'd)
PD-42

System Description
The differential lock operates only in 4WD.
The differential lock control unit interrupts current ¯owing through
differential lock solenoid-2 when vehicle speed exceeds 7 km/h (4
MPH). If the differential lock switch is accidentally turned on when
vehicle speed is greater than 7 km/h (4 MPH), the control unit will
prevent the differential lock from sustaining impact damage.
A warning buzzer will sound when the vehicle is driven over 20
km/h (12 MPH) with the differential lock engaged.
SPD446A
DIFFERENTIAL LOCK
PD-43