differential NISSAN TERRANO 2004 Service Service Manual

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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Differential Carrier
1. Press-fit front and rear bearing outer races with Tools.Tool number: q
AST30611000
q
BST30621000
q
CST30613000
2. Select drive pinion height adjusting washer, referring to Adjust- ment.
3. Install drive pinion adjusting washer in drive pinion, and press- fit pinion rear bearing inner cone in it with press and Tool.Tool number: ST30901000
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: q
AST30720000
q
BKV38102510
SPD580
SPD377
SPD581
YPD009
ASSEMBLY (C200)
PD-53
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6. Install drive pinion bearing spacer, pinion bearing adjustingshim and drive pinion in gear carrier.
7. Insert companion flange into drive pinion by tapping the com- panion flange with a soft hammer.
8. Tighten pinion nut to specified 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: 1.1 - 1.6 N ×m (11.2 - 16.3 kg-cm, 9.7 - 14.1 in-lb)
10. Install differential case assembly with side bearing outer races into gear carrier.
SPD712
SPD697
SPD040
SPD149
PD383
ASSEMBLY (C200)
Differential Carrier (Cont'd)
PD-54
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11. Position side bearing on gear carrier with threads properlyengaged; 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.
I 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: 0.10 - 0.20 mm (0.0039 - 0.0079 in)
I When checking preload, turn drive pinion in both direc-
tions several times to set bearing rollers.
Tool number: ST3127S000
The total pinion bearing preload value with the differential case
assembly should be in accordance with the same value measured
without the differential case assembly. (See point 9.)
The relationship between both is:
Pinion bearing preload
With differential case assembly Without differential case assembly kg-cm N×m kg-cmN×m
14 1.417 - 23 1.7 - 2.3
15 1.518 - 24 1.8 - 2.4
16 1.619 - 25 1.9 - 2.5
17 1.720 - 26 2.0 - 2.6
SPD684
SPD265
SPD246
SPD149
ASSEMBLY (C200)
Differential Carrier (Cont'd)
PD-55
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14. Tighten side bearing cap bolts.
:88-98N×m (9.0 - 9.9 kg-m, 65 - 72 ft-lb)
15. Install side lock finger 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)
I If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case.
I If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced.
17. Check tooth contact. (Refer to PD-49.)
SPD698
SPD247
ASSEMBLY (C200)
Differential Carrier (Cont'd)
PD-56
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Final Drive
GENERAL SPECIFICATIONS
Front final driveR180A
4-pinion
Oil capacity (Approx.) (Imp pt) 1.3 (2-1/4)
Rear final drive H233B LSD* 4-pinion
Oil capacity (Approx.) (Imp pt) 2.8 (4-7/8)
Model TD27Ti ZD30DDTi
Gear ratio 4.375 4.111
Number of teeth Ring gear 35 37
Drive pinion 8 9
* Limited Slip Differential
INSPECTION AND ADJUSTMENT (R180A)
Ring gear runout
Ring gear runout limit mm (in) 0.05 (0.0020)
Axle bearing adjustment
Axle bearing end play mm (in) 0 - 0.1 (0 - 0.004)
Available axle bearing adjusting shims
Thickness mm (in) Part number0.10 (0.0039) 38233-01G11
0.20 (0.0079) 38233-01G12
0.30 (0.0118) 38233-01G13
0.40 (0.0157) 38233-01G14
Side gear adjustment
Side gear backlash
(Clearance between side gear to
differential case) mm (in)0.10 - 0.20
(0.0039 - 0.0079)
Available side gear thrust washers
Thickness mm (in) Part number 0.75 (0.0295) 38424-W2010
0.78 (0.0307) 38424-W2011
0.81 (0.0319) 38424-W2012
0.84 (0.0331) 38424-W2013
0.87 (0.0343) 38424-W2014
0.90 (0.0354) 38424-W2015
0.93 (0.0366) 38424-W2016
0.96 (0.0378) 38424-W2017
Drive pinion height adjustment
Available pinion height adjusting washers
Thickness mm (in) Part number
3.09 (0.1217) 38154-G2317
3.12 (0.1228) 38154-G2318
3.15 (0.1240) 38154-G2319
3.18 (0.1252) 38154-G2320
3.21 (0.1264) 38154-G2321
3.24 (0.1276) 38154-G2322
3.27 (0.1287) 38154-G2323
3.30 (0.1299) 38154-G2324 3.33 (0.1311) 38154-G2360
3.36 (0.1323) 38154-G2361
3.39 (0.1335) 38154-G2362
3.42 (0.1346) 38154-G2363
3.45 (0.1358) 38154-G2364
3.48 (0.1370) 38154-G2365
3.51 (0.1382) 38154-G2366
3.54 (0.1394) 38154-G2367
3.57 (0.1406) 38154-G2368
3.60 (0.1417) 38154-G2369
3.63 (0.1429) 38154-G2370
3.66 (0.1441) 38154-G2371
Drive pinion preload adjustment
Drive pinion bearing preload
adjusting method Adjusting washer and spacer
Drive pinion preload N×m (kg-cm, in-lb)
With front oil seal 1.2 - 1.6 (12 - 16, 10 - 14) Available drive pinion preload adjusting washers
Thickness mm (in) Part number6.59 (0.2594) 38127-01G00
6.57 (0.2587) 38127-01G01
6.55 (0.2579) 38127-01G02
6.53 (0.2571) 38127-01G03
6.51 (0.2563) 38127-01G04
6.49 (0.2555) 38127-01G05
6.47 (0.2547) 38127-01G06
6.45 (0.2539) 38127-01G07
6.43 (0.2531) 38127-01G08
6.41 (0.2524) 38127-01G09
6.39 (0.2516) 38127-01G10
6.37 (0.2508) 38127-01G11
6.35 (0.2500) 38127-01G12
6.33 (0.2492) 38127-01G13
6.31 (0.2484) 38127-01G14
Available drive pinion preload adjusting spacers
Length mm (in) Part number 52.20 (2.0551) 38130-G2300
52.40 (2.0630) 38131-G2301
52.60 (2.0709) 38132-G2302
52.80 (2.0787) 38133-G2303
53.00 (2.0866) 38134-G2304
53.20 (2.0945) 38135-G2305
SERVICE DATA AND SPECIFICATIONS (SDS)
PD-58
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