Diff NISSAN PATROL 2006 Manual PDF

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

Differential Case Ð 4-pinion type Ð
1. Measure clearance between side gear thrust washer and dif-
ferential case.
Clearance between side gear thrust washer
and differential case (A Ð B):
0.15 - 0.20 mm (0.0059 - 0.0079 in)
The clearance can be adjusted with side gear thrust washer.
Refer to SDS.
2. Apply oil to gear tooth surfaces and thrust surfaces and check
that they turn properly.
3. Install differential case LH and RH.
4. Place differential case on ring gear.
5. Apply locking sealer to ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.
6. Press-®t side bearing inner races on differential case with Tool.
Tool number:
j
AST33190000
j
BST02371000
SPD656
SPD643
SPD746
PD353
ASSEMBLY
PD-31

Differential Case Ð 2-pinion type Ð
1. Install side gears, pinion mate gears and thrust washers into
differential case.
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 by
selecting 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):
0.15 - 0.20 mm (0.0059 - 0.0079 in)
4. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is ¯ush with case.
5. Apply gear oil to gear tooth surfaces and thrust surfaces and
make sure they turn properly.
6. Install differential case assembly on ring gear.
Tighten bolts in a criss-cross pattern, lightly tapping bolt head
with a hammer.
7. Press-®t side bearing inner cones on differential case with Tool.
Tool number:
j
AST33190000
j
BST02371000
SPD552
SPD258
SPD030
SPD322
PD353
ASSEMBLY
PD-32

Differential Carrier
1. Press-®t front and rear bearing outer races with Tools.
Tool number:
j
AST30611000
j
BST30621000 (front differential)
or suitable pipe
j
CST30701000
CAUTION:
Do not damage roller side face.
2. Select drive pinion height adjusting washer. Refer to ADJUST-
MENT (PD-27).
3. Install drive pinion height adjusting washer in drive pinion, and
press-®t pinion rear bearing inner cone in it, with press and
Tool.
Tool number: ST30911000
4. Place pinion front bearing inner cone in gear carrier.
5. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Install front oil seal.
Tool number:
j
AST30720000
j
BKV38102510
SPD580
SPD377
SPD581
SPD451A
ASSEMBLY
PD-33

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