NISSAN TERRANO 2004 Service Repair Manual

11. Remove pinion rear bearing inner cone and drive pinion adjust-ing washer.Tool number: ST30031000
Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove. Tool number:q
AST33051001
q
BST33061000
Be careful not to confuse left and right hand parts.
2. Loosen ring gear bolts in a criss-cross fashion.
3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.
SPD018
SPD688
SPD022
SPD024
DISASSEMBLY (C200)
Differential Carrier (Cont'd)
PD-40
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4. Separate differential case.
Put match marks on both L.H. and R.H. differential cases.
SPD716
DISASSEMBLY (C200)
Differential Case (Cont'd)PD-41
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Ring Gear and Drive Pinion
Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive pinion
as a set (hypoid gear set).
Differential Case Assembly
Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, and thrust washers.
Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.
EPD009
SPD715
INSPECTION (C200)
PD-42
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CAUTION:
Do not run engine when one rear wheel is off the ground.
Preparation for Disassembly
CHECKING DIFFERENTIAL TORQUE
Measure differential torque with Tool.
If it is not within the specifications, inspect components of limited
slip differential.Differential torque:353 - 392 N×m (36 - 40 kg-m, 260 - 289 ft-lb)
Assembly: KV38105250
Tool number: q
AKV38105210
q
BKV38105220
YPD025
SPD415
LIMITED SLIP DIFFERENTIAL (C200)
PD-43
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Disassembly
1. Spread out lock straps.
2. Remove couple bolts using a press.Tool number: ST33081000
3. Separate differential case A and B. Draw out component parts (discs and plates, etc.)
Put marks on gears and pressure rings so that they can be
reinstalled 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.
q
1Differential case B
q
2Differential case A
q
3Side gear
q
4Pinion mate gear
q
5Pinion mate shaft
q
6Friction plate guide
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 make sure that friction disc or plate is not distorted, place it on a surface plate and rotate it by hand with indicating finger
of dial gauge resting against disc or plate surface. Check the
warpage.Allowable warpage: 0.05 - 0.15 mm (0.0020 - 0.0059 in)
If it exceeds limit, replace with a new plate to eliminate possi-
bility of clutch slippage or sticking.
SPD276
EPD010
SPD279
LIMITED SLIP DIFFERENTIAL (C200)
PD-44
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4. Measure frictional surfaces and projected portions of frictiondisc, friction plate and spring plate.
If any part has worn beyond the wear limit, 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
Adjustment
FRICTION DISC AND FRICTION PLATE END PLAY
End play of friction disc and friction plate can be calculated by using
the following equation and should be adjusted within the 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 differential 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 ªAº. Standard length A:49.50 - 49.55 mm (1.9488 - 1.9508 in)
SPD403
SPD761
SPD417
LIMITED SLIP DIFFERENTIAL (C200)
Inspection (Cont'd)
PD-45
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2. Measure thickness of each disc and plate.Total thickness ªBº:19.24 - 20.26 mm (0.7575 - 0.7976 in)
No. of discs and plates (One side): Friction disc 5
Friction plate 6
Spring disc 1
Spring plate 1
3. Measure values of ªCº.
(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.
(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= AþD = Aþ(B+C)
= 0.05 to 0.15 mm ,Specified range
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D= B+C B .............19.45
+ C .............29.7 49.15
E= AþD A .............49.52
þ D .............49.15 0.37
From the above equation, end play of 0.37 mm exceeds the speci-
fied range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly. (Refer to
PD-57.)
SPD420
YPD007
YPD008
LIMITED SLIP DIFFERENTIAL (C200)
Adjustment (Cont'd)
PD-46
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Assembly
Prior to assembling discs and plates, properly lubricate them by
dipping them in limited slip differential oil.
1. Alternately position specified number of friction plates and fric-tion discs on rear of side gear.
Always position a friction plate first on rear of side gear.
2. Install spring disc.
Align the twelve angular holes in spring disc with the hexago-
nal area of the side gear.
3. Install spring plate.
4. Install friction plate guides.
Correctly align the raised portions of friction plates, and apply
grease to inner surfaces of friction plate guides to prevent
them from falling.
5. Install differential case B over side gear, discs, plates and fric- tion plate guide assembly.
I Install differential case B while supporting friction plate
guides with your middle finger inserted through oil hole in
differential case.
I Be careful not to detach spring disc from the hexagonal
part of the side gear.
SPD421
SPD422
SPD423
SPD424
SPD425
LIMITED SLIP DIFFERENTIAL (C200)
PD-47
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6. Install pinion mate gears and pinion shaft to differential case B.
7. Install side gear to pinion mate gears.
8. Install each disc and plate.
Use same procedures as outlined in steps 1. through 4. above.
9. Install differential case A.
Position differential cases A and B by correctly aligning marks
stamped on cases.
10. Tighten differential case bolts.
:64-69N×m (6.5 - 7.0 kg-m, 47 - 51 ft-lb)
11. Place ring gear on differential case and install new lock straps and bolts.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.
Then bend up lock straps to lock the bolts in place.
12. Install side bearing inner cone.
13. Check differential torque.
SPD426
SPD429
SPD430
SPD288
LIMITED SLIP DIFFERENTIAL (C200)
Assembly (Cont'd)
PD-48
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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.Assembly q
1q2:
ST3125500
q
1Height Gauge (ST31251000)
q
2Dummy Shaft (ST31181001)
q
3Spacer [thickness: 2.50 mm (0.0984 in)]
q
4Feeler Gauge
2. To simplify the job, make a chart, like the one below, to orga- nize your calculations.
LETTERS HUNDREDTHS 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 in the chart. H: Head number
D¢: Figure marked on dummy shaft
SPD758
SPD542
SPD759
ADJUSTMENT (C200)
PD-49
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