differential NISSAN X-TRAIL 2003 Electronic Manual PDF

RFD-8
FRONT OIL SEAL
FRONT OIL SEAL
PFP:38189
Removal and InstallationEDS0005B
REMOVAL
1. Remove propeller shaft. Refer toPR-3, "REMOVAL".
2. Paint mating marks on the final drive companion flange and the thread edge of the electronically con-
trolled coupling.
CAUTION:
Use paint to avoid scratching the surface.
3. Using a differential flange tool, remove companion flange nut to remove companion flange.
4. Using a screwdriver or similar tool, remove oil seal.
INSTALLATION
1. Apply multi-purpose grease to oil seal lips. Using a drift as
shown, install oil seal. It should become flush with case end sur-
face.
CAUTION:
lWhen installing, do not incline the oil seal.
lOil seals are not reusable. Never reuse them.
2. Align the mating marks on the companion flange and on the electronically controlled coupling, and install
the companion flange.
3. Install a companion flange nut. Using a differential flange tool, tighten the nut to the specified torque.
CAUTION:
Do not reuse the companion flange nut.
4. Connect propeller shaft. Refer toPR-3, "
Removal and Installation".
SDIA0142J
: 100 - 122 N-m (11 - 12 kg-m,74 - 89 ft-lb)

RFD-16
REAR FINAL DRIVE ASSEMBLY
4. Fit a dial gauge to the drive gear face to measure the backlash.
lIf outside the standard, change the thickness of the side bearing adjusting shims.
Side bearing adjusting shims
DRIVE GEAR BACK RUNOUT
1. Drain the oil.
2. Remove the rear cover.Refer toRFD-20, "
Removal of differen-
tial assembly".
3. Attach dummy cover set. Refer toRFD-15, "
HYPOID GEAR
BACKLASH".
4. Fit a dial gauge to the drive gear back face.
5. Rotate the drive gear to measure runout.
lIf outside the repair limit, check drive gear assembly condition;
foreign material may be caught between drive gear and differen-
tial case, or differential case or drive gear may be deformed, etc.
CAUTION:
Replace the drive gear and drive pinion gear as a set.
COMPANION FLANGE RUNOUT
1. Fit a dial gauge onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate the companion flange to check for runout.
3. Fit a test indicator to the inner side of the companion flange
(socket diameter).
4. Rotate the companion flange to check for runout.
5. If the runout value is outside the repair limit, follow the procedure
below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion gear by 90°step,
and search for the point where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, replace the companion
flange.
c. If the runout value is still outside of the limit after the companion flange has been replaced, possible cause
will be an assembly malfunction of the drive pinion gear and the electronically controlled coupling, mal-
functioning coupling bearing, or malfunctioning electronically controlled coupling.Backlash : 0.10 - 0.15 mm (0.0039 - 0.0059 in)
When the backlash is large:
Make the drive gear back adjusting shims thicker, and the drive gear front adjusting
shims thinner.
When the backlash is small:
Make the drive gear back adjusting shims thinner, and the drive gear front adjusting
shims thicker.
Thickness Part No. Thickness Part No. Thickness Part No.
1.85 mm (0.0728 in)
1.90 mm (0.0748 in)
1.95 mm (0.0768 in)
2.00 mm (0.0787 in)38453 4N200
38453 4N201
38453 4N202
38453 4N2032.05 mm (0.0807 in)
2.10 mm (0.0827 in)
2.15 mm (0.0854 in)
2.20 mm (0.0866 in)38453 4N204
38453 4N205
38453 4N206
38453 4N2072.25 mm (0.0886 in)
2.30 mm (0.0906 in)
2.35 mm (0.0925 in)38453 4N208
38453 4N209
38453 4N210
Runout limit : 0.05 mm (0.0020 in)
PDG0210D
Runout limit : 0.13 mm (0.0051 in)
Runout limit : 0.19 mm (0.0075 in)
SDIA0569E

RFD-20
REAR FINAL DRIVE ASSEMBLY
6. Using a puller, remove coupling front bearing from the electroni-
cally controlled coupling.
CAUTION:
When the bearing is replaced with new one, reassemble the
shim between bearing and the coupling.
Removal of differential assembly
1. Using a slotted screwdriver, remove side oil seal from the carrier
case assembly.
CAUTION:
Be careful not to damage the carrier case and rear cover.
2. Remove rear cover mounting bolts.
3. Fit a drift to the right and left side bearing adjusting shims indi-
vidually. Compress differential case ASSY and side bearing to
remove carrier case ASSY and rear cover.
CAUTION:
The pressure shall be as low as possible to remove carrier
case assembly and rear cover. The maximum pressure shall
be 1 ton.
NOTE:
The differential case assembly, side bearings, and adjusting
shims are compressed and integrated in the carrier case and
rear cover.
4. Remove side bearing adjusting shims and side bearing outer
race.
CAUTION:
Mark the side bearing adjusting shims so that the original
mounting positions (right/left) can be identified later.
5. Remove drive gear mounting bolts, and remove drive gear from
the differential case.
6. Using a puller and a drift, remove side bearing inner race.
7. Using a pin punch, pull the lock pin out of the pinion mating
shaft.
8. Remove pinion mating shaft, pinion mating gears, pinion mating
thrust washers, side gears, side gear thrust washers from the
differential case.
SDIA0574E
PDG0216D
SDIA0575E
SDIA0620E
PDG0219D

REAR FINAL DRIVE ASSEMBLY
RFD-21
C
E
F
G
H
I
J
K
L
MA
B
RFD
Removing drive pinion gear assembly
1. Remove electronically controlled coupling assembly. Refer to
RFD-19, "
Removal of electronically controlled coupling assem-
bly".
2. Remove differential case assembly. Refer toRFD-20, "
Removal
of differential assembly".
3. Fit a drive pinion gear socket onto the drive pinion gear spline.
Using a pinion nut wrench, remove pinion nut.
4. Remove center oil seal.
5. Press the drive pinion gear assembly out of the carrier case.
6. Remove pinion front bearing inner race.
7. Remove collapsible spacer.
8. Using a puller, remove pinion rear bearing inner race from the
drive pinion gear.
9. Using a brass rod, tap the pinion front bearing outer race evenly
from the 2 cutouts on the carrier case, and remove pinion front
bearing outer race.
CAUTION:
Be careful not to damage the carrier case.
10. Using a brass rod, tap the drive pinion gear adjusting shim
evenly from the 2 cutouts on the carrier case, and remove drive
pinion gear adjusting shims and pinion rear bearing outer race.
CAUTION:
Be careful not to damage the carrier case.
PDG0220D
SDIA0576E
SDIA0577E
SDIA0564E

RFD-22
REAR FINAL DRIVE ASSEMBLY
ASSEMBLY
Assembly of drive pinion gear assembly
1. Assemble with a drive pinion gear adjusting shim of the same
thickness as was installed prior to disassembly. Using a drift,
press a pinion rear bearing outer race into the carrier case.
CAUTION:
lAt first, using a hammer, tap the bearing outer race until it
becomes square to the carrier case.
lDo not reuse the pinion rear bearing outer race.
2. Using a drift, press a pinion front bearing outer race into the car-
rier case.
CAUTION:
lAt first, using a hammer, tap the bearing outer race until it
becomes square to the carrier case.
lDo not reuse the pinion front bearing outer race.
3. Using a drift, press a pinion rear bearing inner race into the drive
pinion gear.
CAUTION:
Do not reuse the pinion rear bearing inner race.
4. After checking and adjusting the tooth contact and backlash of
the hypoid gear following the procedure below, assemble a col-
lapsible spacer to the drive pinion gear.
CAUTION:
lBe careful of the mounting orientation of the collapsible
spacer.
lDo not reuse the collapsible spacer.
a. Apply differential oil to the pinion bearing, and assemble the
drive pinion gear to the carrier case.
CAUTION:
Do not assemble a collapsible spacer.
SDIA0578E
SDIA0579E
SDIA0580E
SDIA0581E

REAR FINAL DRIVE ASSEMBLY
RFD-23
C
E
F
G
H
I
J
K
L
MA
B
RFD
b. Assemble a pinion front bearing inner race to the drive pinion
gear. Using a drift and press stand, press the pinion nut as far as
it can be tightened.
c. Temporarily tighten the removed pinion nut and pinion washer to
the drive pinion gear.
NOTE:
Use the removed pinion nut only for the preload torque mea-
surement.
d. Fit the drive pinion gear socket onto the drive pinion gear spline.
Using a pinion nut wrench, tighten the pinion nut to the specified
preload torque.
CAUTION:
The pinion nut is tightened with no collapsible spacer. Be careful not to overtighten it. While mea-
suring the preload, tighten it by 5°to 10°.
e. Apply differential oil to the side bearings, and install new side
bearing adjusting shims with the same thickness or re-install the
old ones to the same mounting position they were in prior to dis-
assembly. Install the differential case assembly to the carrier
case. Refer toRFD-24, "
Installation of differential assembly".
f. Install a dummy cover set to check and adjust the tooth contact.
Refer toRFD-17, "
TOOTH CONTACT".
g. Check and adjust the backlash. Refer toRFD-15, "
HYPOID
GEAR BACKLASH".
h. Remove dummy cover set, and remove differential case assem-
bly.
i. Remove pinion nut, pinion washer, and pinion front bearing
inner race, and remove drive pinion gear.
5. Install the drive pinion gear with a collapsible spacer to the car-
rier case.
6. Using a drift and press stand, press the pinion front bearing
inner race to the drive pinion gear as far as a pinion nut can be
tightened.
7. Apply anti-corrosive oil to the thread and seat of the pinion nut,
and temporarily tighten the pinion nut and washer to the drive
pinion gear.
CAUTION:
Do not reuse the pinion nut.
SDIA0582E
PDG0229D
SDIA0582E

RFD-24
REAR FINAL DRIVE ASSEMBLY
8. Fit a drive pinion gear socket onto the drive pinion gear spline.
Using a pinion nut wrench, adjust the pinion nut tightening
torque and pinion bearing preload torque.
CAUTION:
lDo not reuse the pinion nut.
lAdjust the lower limit of the pinion nut tightening torque
first.
lIf the preload torque exceeds the specified value, replace
the collapsible spacer and tighten it again to adjust. Never
loosen the pinion nut to adjust the preload torque.
lAfter adjustment, rotate the drive pinion gear back and forth
2 - 3 times to check for abnormal noise, rotation malfunc-
tion, and other malfunctions.
9. Install center oil seal.
10. Install the differential case assembly. Refer toRFD-24, "
Installa-
tion of differential assembly".
CAUTION:
Do not install the rear cover.
11. Install a dummy cover set, and check backlash, drive gear back
runout, and tooth contact. Refer toRFD-17, "
TOOTH CON-
TA C T".
12. Install the rear cover, and drive in the oil seal.RFD-24, "
Installa-
tion of differential assembly"Refer to
13. Check overall preload torque. Refer toRFD-15, "
OVERALL
PRELOAD TORQUE".
14. Connect electronically controlled coupling assembly. Refer toRFD-27, "
Installation of electronically con-
trolled coupling assembly".
15. Check companion flange runout. Refer toRFD-16, "
COMPANION FLANGE RUNOUT".
Installation of differential assembly
1. Assemble new side gear thrust washers with the same thickness as the ones installed prior to disassem-
bly or reinstall the old ones on the side gears.
2. Assemble the side gears, side gear thrust washers, pinion mating gears, and pinion mating thrust wash-
ers to the differential case, and temporarily assemble the pinion mating shaft.Pinion nut tightening torque:
99 - 431 N·m (10 - 43 kg-m,73 - 317 ft-lb)
Pinion bearing preload torque:
0.69 - 1.17 N·m (0.07 - 0.11 kg-m,7 - 10 in-lb)
PDG0229D
SDIA0146E

REAR FINAL DRIVE ASSEMBLY
RFD-25
C
E
F
G
H
I
J
K
L
MA
B
RFD
3. Measure the side gear endplay following the procedure below,
and select the appropriate side gear thrust washers.
lUsing a thickness gauge, measure the clearance between
side gear back and the differential case at 3 different points,
while rotating the side gear. Average the 3 readings, and
select the appropriate side gear thrust washer so that the
mean value is within specifications below. (Measure the clear-
ance of the other side as well.)
CAUTION:
lBefore measurement, place differential case straight up
so that side gear to be measured comes upward. To pre-
vent the side gear from tilting, insert thickness gauges
with the same thickness from both sides.
lSelect a side gear thrust washer for right and left individ-
ually.
4. Assemble the selected side gear thrust washer to the differential
case.
5. Using a pin punch, drive a lock pin into the pinion mating shaft.
CAUTION:
Do not reuse the lock pin.
6. Using a drift, press a side bearing inner race into the differential
case.
7. Apply locking sealant (Thread lock super 1303 or equivalent) onto the thread of the drive gear.
CAUTION:
The drive gear back, threaded holes, and drive gear bolts shall be cleaned and decreased suffi-
ciently.
8. Assemble the drive gear to the differential case. Apply anti-corrosive oil onto threads and seats of the
drive gear bolts, and tighten to the specified torque.Side gear endplay standard:
0.2 mm (0.008 in) or less. Every gear shall rotate
smoothly with no abnormal feeling of drag.
Thickness Part No. Thickness Part No.
0.74 mm (0.0291 in)
0.77 mm (0.0303 in)
0.80 mm (0.0315 in)38424 4N200
38424 4N201
38424 4N2020.83 mm (0.0327 in)
0.86 mm (0.0339 in)38424 4N203
38424 4N204
SDIA0583E
PDG0219D
SDIA0584E
:94-112N·m(9.6-11kg-m,70-82ft-lb)

RFD-26
REAR FINAL DRIVE ASSEMBLY
9. Apply differential oil to the side bearings, and assemble new side bearing adjusting shims (2 pieces for
one side) with the same thickness as the ones installed prior to disassembly or re-install the old ones, with
a side bearing outer race to the differential case.
If the side bearing adjusting shims have been already selected, use them.
10. Fit a drift to the right and left side bearing adjusting shims indi-
vidually. Compress differential case ASSY and side bearing to
install the carrier case ASSY to differential case ASSY.
CAUTION:
lA drift shall be placed on the center of the adjusting
shims.
lThepressureshallbeaslowaspossibletoinstallthe
carrier case assembly into the differential assembly. The
maximum pressure shall be 1 ton.
lIf the adjusting shims are installed by tapping, the carrier
case may be damaged. Avoid tapping.
11. Install a dummy cover set, check and adjust the backlash, drive gear back runout, tooth contact, and over-
all preload torque. Refer toRFD-15, "
Inspection Before Disassembly".
12. Remove dummy cover set.
13. Apply sealant (Three bond 1217 or the equivalent) around the carrier case mounting surface on the rear
cover.
CAUTION:
Remove old sealant on the mounting surface, then remove any moisture, oil, and foreign material
on the application and mounting surfaces.
14. Fit a drift to the right and left side bearing adjusting shims indi-
vidually. Compress differential case ASSY and side bearing to
install the rear cover.
CAUTION:
lA drift shall be placed on the center of the adjusting
shims.
lThepressureshallbeaslowaspossibletoinstallthe
rear cover. The maximum pressure shall be 1 ton.
lIf the rear cover is forced in by tapping, the rear cover
may be damaged by the adjusting shims. Avoid tapping.
15. Tighten rear cover mounting bolts to the specified torque.
16. Using a drift, drive the oil seal until it becomes flush with the
case end.
CAUTION:
lOil seals are not reusable. Never reuse them.
lApply multi-purpose grease onto the oil seal lips, and dif-
ferential oil onto the circumference of the oil seal.
17. Check overall preload torque. Refer toRFD-15, "
OVERALL PRELOAD TORQUE".
SDIA0585E
SDIA0575E
Tightening torque
M8-bolt : 14 - 17 N·m (1.5 - 1.7 kg-m,11 - 12 ft-lb)
M10-bolt : 31 - 36 N·m (3.2 - 3.6kg·m,23 - 26 ft-lb)
PDG0234D

RSU-4
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting ChartEES000IE
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
´: ApplicableReference page
Refer toRSU-5Refer toRSU-8
—
—
—
Refer toRSU-5
Refer toRSU-6Refer toRSU-5NVHinPRsection.
NVH in RFD section.
NVH in FAX and FSU sections.
NVH in WT section.
NVH in WT section.
NVH in RAX section.
NVHinBRsection.
NVH in PS section.
Possible cause and SUSPECTED PARTS
Improper installation, looseness
Shock absorber deformation, damage or deflection
Bushing or mounting deterioration
Parts interference
Spring fatigue
Suspension looseness
Incorrect wheel alignment
Stabilizer fatigue
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE AND FRONT SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom REAR SUSPENSIONNoise´´´´´´ ´´´´´´´´
Shake´´´´ ´ ´ ´´´´´´
Vibration´´´´´ ´ ´´ ´ ´
Shimmy´´´´ ´ ´´´ ´´
Judder´´´ ´´´ ´´
Poor quality ride or
handling´´´´´ ´´ ´´´