differential NISSAN TERRANO 2004 Service Owner's Manual

PROPELLER SHAFT &
DIFFERENTIAL CARRIER
SECTION
PD
CONTENTS
PREPARATION ................................................................2
PROPELLER SHAFT ......................................................5
On-Vehicle Service ......................................................6
Removal and Installation .............................................7
Inspection.....................................................................7
Disassembly.................................................................7
Assembly .....................................................................8
ON-VEHICLE SERVICE ................................................10
Front Oil Seal Replacement
(Front final drive: R180A) ..........................................10
Front Oil Seal Replacement
(Rear final drive: C200) .............................................10
REMOVAL AND INSTALLATION (Front final drive
- R180A) ........................................................................\
.12
Removal .....................................................................12
Installation ..................................................................12
REMOVAL AND INSTALLATION (Rear final drive
- C200) ........................................................................\
...13
Removal .....................................................................13
Installation ..................................................................13
FRONT FINAL DRIVE (R180A) ....................................14
DISASSEMBLY (R180A) ...............................................15
Pre-inspection ............................................................15
Final Drive Housing ...................................................15
Differential Case ........................................................18
Extension Tube and Differential Side Shaft ..............19
INSPECTION (R180A) ...................................................20
Ring Gear and Drive Pinion ......................................20
Differential Case Assembly........................................20
Bearing.......................................................................20
ADJUSTMENT (R180A) ................................................21 Drive Pinion Height ....................................................21
Side Bearing Preload.................................................24
Tooth Contact.............................................................27
ASSEMBLY (R180A) .....................................................28
Extension Tube and Differential Side Shaft ..............28
Differential Case ........................................................29
Final Drive Housing ...................................................30
REAR FINAL DRIVE (C200) .........................................35
Air Breather................................................................36
DISASSEMBLY (C200) ..................................................37
Pre-inspection ............................................................37
Differential Carrier......................................................38
Differential Case ........................................................40
INSPECTION (C200) .....................................................42
Ring Gear and Drive Pinion ......................................42
Differential Case Assembly........................................42
Bearing.......................................................................42
LIMITED SLIP DIFFERENTIAL (C200) .........................43
Preparation for Disassembly .....................................43
Disassembly...............................................................44
Inspection...................................................................44
Adjustment .................................................................45
Assembly ...................................................................47
ADJUSTMENT (C200) ...................................................49
Drive Pinion Height ....................................................49
Tooth Contact.............................................................52
ASSEMBLY (C200) ........................................................53
Differential Carrier......................................................53
SERVICE DATA AND SPECIFICATIONS (SDS) ..........57
Propeller Shaft ...........................................................57
Final Drive..................................................................58
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SPECIAL SERVICE TOOLS
*: Special tool or commercial equivalent
Tool number
Tool nameDescription Unit application
R180A H233B
ST31211000
Height gauge
Selecting pinion height adjusting washer
XÐ
ST31212000
Dummy shaft
Selecting pinion height adjusting washer XÐ
ST31852000
Stopper
Selecting pinion height adjusting washer XÐ
ST3125S000
Drive pinion height
setting gauge set
q
1ST31251000
Drive pinion
height gauge
q
2ST31181001
Dummy shaft
Selecting pinion height adjusting washer
ÐX
ST32501000
Weight block
Selecting side bearing adjusting shim XÐ
KV38101900
Master gauge
[20.0 mm (0.787 in)]
Selecting side bearing adjusting shim XÐ
ST0501S000
Engine stand
q
1ST05011000
Engine stand
q
2ST05012000
Base
Mounting differential attachment
XX
KV38100800
Differential attach-
ment
Mounting final drive XÐ
ST06340000
Differential attach-
ment
Mounting final drive ÐX
PREPARATION
PD-2
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*: Special tool or commercial equivalent
Tool number
Tool nameDescription Unit application
R180A H233B
ST32580000
Diff. side bearing
adjusting nut wrench
Adjusting side bearing preload and back-
lash (ring gear drive pinion) ÐX
KV381052S0
Rear axle shaft
dummy
q
1KV38105210
Torque wrench
side
q
2KV38105220
Vice side
Checking differential torque on limited slip
differential
ÐX
ST33290001*
Side bearing outer
race puller
Removing side bearing outer race and
side oil seal XÐ
ST38060002*
Drive pinion flange
wrench
Removing and installing propeller shaft
lock nut, and drive pinion lock nut XÐ
KV38104700*
Drive pinion flange
wrench
Removing and installing propeller shaft
lock nut, and drive pinion lock nut ÐX
ST3090S000*
Drive pinion rear inner
race puller set
q
1ST30031000
Puller
q
2ST30901000*
Base
Removing and installing drive pinion rear
inner cone
A: 79 mm (3.11 in) dia.
B: 45 mm (1.77 in) dia.
C: 35 mm (1.38 in) dia. XX
ST3306S001
Diff. side bearing
puller set
q
1ST33051001*
Body
q
2ST33061000*
Adapter
Removing and installing differential side
bearing inner cone
A: 28.5 mm (1.122 in) dia.
B: 38 mm (1.50 in) dia. XX
ST33230000*
Diff. side bearing drift
Installing side bearing inner cone
A: 51 mm (2.01 in) dia.
B: 28.5 mm (1.122 in) dia. XÐ
PREPARATION
PD-3
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Removal
1. Remove front propeller shaft.
2. Remove drive shaft. Refer to FA section.
3. Remove engine mounting bolts and raise up engine.
4. Remove front final drive together with differential mountingmember.
Installation
1. Install front final drive assembly together with differentialmounting member.
2. Tighten the front final drive securing bolts and nuts following the procedures below to prevent drive train vibration.
(1) Temporarily tighten nut q
A.
(2) Temporarily tighten nut q
B.
(3) Tighten bolts q
Cto the torque of 68 to 87 N
×m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
(4) Tighten bolts q
Dto the torque of 68 to 87 N
×m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
(5) Tighten nut q
Ato the torque of 68 to 87 N
×m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
(6) Tighten nut q
Bto the torque of 68 to 87 N
×m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
(7) Tighten nuts q
Eto the torque of 68 to 87 N
×m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
3. Install drive shaft. Refer to FA section.
4. Install front propeller shaft.
SPD741
SPD742
SPD743
REMOVAL AND INSTALLATION (Front final drive Ð R180A)
PD-12
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2. Remove extension tube and differential side shaft assembly.
3. Remove differential side flange.
4. Mark side retainers for identification. Remove side retainers.
Be careful not to confuse right and left side retainers and
shims.
5. Extract differential case from final drive housing.
6. Remove side outer races.Tool number:ST33290001
Be careful to keep the side bearing outer races together with
their respective inner cones Ð do not mix them up.
7. Remove side oil seal.
NPD005
SPD713
SPD639
SPD309
PD243
DISASSEMBLY (R180A)
Final Drive Housing (Cont'd)
PD-16
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Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in grooves.Assembly:ST33065001
Tool number: q
AST33051001
q
BST33061000
Be careful not to confuse the right and left 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.
4. Separate L.H. and R.H. differential cases.
Put match marks on both L.H. and R.H. differential cases.
SPD642
SPD022
SPD024
SPD643
DISASSEMBLY (R180A)
PD-18
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Extension Tube and Differential Side Shaft
1. Remove differential side shaft assembly from extension tube.
2. Cut rear axle bearing collar with cold chisel. Be careful not todamage differential side shaft.
3. Install differential side shaft into extension tube and secure with bolts. Remove extension tube retainer from differential side
shaft.
4. Remove grease seal.
SPD644
SPD645
SPD646
SPD647
DISASSEMBLY (R180A)
PD-19
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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.
SPD648
SPD715
INSPECTION (R180A)
PD-20
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Side Bearing Preload
1. To simplify the job, make a chart like the one below to organizeyour calculations.
LETTERS HUNDREDTHS OF
A MILLIMETER
A þ Left housing
B þ Right housing
C þ Differential case
D þ Differential case
E þ Left side bearing
F þ Right side bearing
G
1þ Left side retainer
G
2þ Right side retainer
2. Write the following numbers down in the chart. A & B: Figures marked on final drive housing.
C & D: Figures marked on differential case.
G
1&G2: Figures marked on side retainer.
SPD650
SPD651
SPD652
ADJUSTMENT (R180A)
PD-24
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Extension Tube and Differential Side Shaft
1. Measure rear axle bearing end play.Rear axle bearing end play (A þ B):0.1 mm (0.0039 in) or less
The end play can be adjusted with bearing adjusting shim.
(Refer to PD-57.)
2. Install oil seal.
3. Install the spacer, grease seal, extension tube retainer, adjust- ing shim, shim and shim collar onto the differential side shaft.
4. Install differential side shaft assembly into extension tube.
SPD699
SPD654
SPD655
ASSEMBLY (R180A)
PD-28
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