NISSAN X-TRAIL 2003 Service Repair Manual

REAR FINAL DRIVE ASSEMBLY
RFD-21
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RFD

Drive pinion adjusting shim

In case of face contact or heel contact, thicken the drive pinion
gear adjusting shims to move the drive pinion gear closer to the
drive gear.

In case of flank contact or toe contact, thin the drive pinion gear
adjusting shims to move the drive pinion gear farther from the
drive gear.
Thickness Part No. Thickness Part No.
1.70 mm (0.0669 in)
1.73 mm (0.0681 in)
1.76 mm (0.0693 in)
1.79 mm (0.0705 in)
1.82 mm (0.0717 in)
1.85 mm (0.0728 in)
1.88 mm (0.0740 in)
1.91 mm (0.0752 in)
1.94 mm (0.0764 in)
1.97 mm (0.0776 in)38154 4N200
38154 4N201
38154 4N202
38154 4N203
38154 4N204
38154 4N205
38154 4N206
38154 4N207
38154 4N208
38154 4N2092.00 mm (0.0787 in)
2.03 mm (0.0799 in)
2.06 mm (0.0811 in)
2.09 mm (0.0823 in)
2.12 mm (0.0835 in)
2.15 mm (0.0846 in)
2.18 mm (0.0858 in)
2.21 mm (0.0870 in)
2.24 mm (0.0882 in)38154 4N210
38154 4N211
38154 4N212
38154 4N213
38154 4N214
38154 4N215
38154 4N216
38154 4N217
38154 4N218
SDIA0571E
SDIA0572E

RFD-22
REAR FINAL DRIVE ASSEMBLY

Disassembly and AssemblyEDS001ZD
DISASSEMBLY
Removal of Electric Controlled Coupling Assembly
1. Using a drive pinion flange wrench, remove companion flange lock nut.
2. Using a puller, remove the companion flange.
3. Remove coupling cover.
4. Using flat tip screwdriver, remove front oil seal from the coupling
cover.
CAUTION:
Be careful not to damage the coupling cover.
5. Remove electric controlled coupling assembly from the gear carrier.
6. Using a puller, remove coupling front bearing from the electroni-
cally controlled coupling.
CAUTION:
When the bearing is replaced with new one, readjust the
shim between bearing and the coupling.
Removal of Differential Assembly
1. Using flat tip screwdriver, remove side oil seal from the gear car-
rier assembly.
CAUTION:
Be careful not to damage the gear carrier and rear cover.
2. Remove rear cover mounting bolts.
3. Fit a drift to the right and left side bearing adjusting shims indi-
vidually. Press differential case assembly and side bearing to
remove gear carrier assembly and rear cover.
CAUTION:
The pressure shall be as low as possible to remove gear
carrier assembly and rear cover. The maximum pressure
shall be 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
Differential case assembly, side bearings, and adjusting shims
are compressed and integrated in the gear carrier and rear
cover.
4. Remove side bearing adjusting shims and side bearing outer race.
PDG0213D
PDIA0177E
PDG0216D
Tool number : KV40100610
PDIA0065E

REAR FINAL DRIVE ASSEMBLY
RFD-23
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RFD

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 the drift below, remove side bearing inner
race.
7. Using the pin punch below, pull the lock pin out of the pinion
mate shaft.
8. Remove pinion mate shaft, pinion mate gears, pinion mate
thrust washers, side gears, side gear thrust washers from the
differential case.
Removing Drive Pinion Assembly
1. Remove Electric controlled coupling assembly. Refer to RFD-22, "Removal of Electric Controlled Coupling
Assembly" .
2. Remove differential case assembly. Refer to RFD-22, "
Removal of Differential Assembly" .
3. Fit the drive pinion socket onto the drive pinion spline. Using the
pinion nut wrench, remove drive pinion nut.
4. Remove center oil seal.
5. Press the drive pinion gear assembly out of the gear carrier.
6. Remove pinion front bearing inner race.
7. Remove collapsible spacer.Tool number : ST33052000
PDIA0178E
Tool number : ST23550000
PDIA0062E
Tool number A: KV38108400
B: KV38108500
PDIA0054E
SDIA0576E

RFD-24
REAR FINAL DRIVE ASSEMBLY

8. Using a puller, remove pinion rear bearing inner race from the
drive pinion.
9. Using a brass rod, tap the pinion front bearing outer race evenly
from the 2 cutouts on the gear carrier and remove pinion front
bearing outer race.
CAUTION:
Be careful not to damage the gear carrier.
10. Using a brass rod, tap the drive pinion adjusting shim evenly
from the 2 cutouts on the gear carrier and remove drive pinion
adjusting shims and pinion rear bearing outer race.
CAUTION:
Be careful not to damage the gear carrier.
INSPECTION

Clean up the disassembled parts. Then, inspect if the parts are wear or damaged. If so, follow the mea-
sures below.
PDIA0179E
SDIA0564E
Content Measures
Hypoid gear

If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace
as necessary.

If the gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with a
new gears.
Bearing

If found any chipped (by friction), pitted, worn, rusted, scratched mark, or unusual noise from the
bearing, replace with a new bearing ASSY (as new set).
Side gear thrust washer and
Pinion mate thrust washer

Replace with a new one if found any cracks or damage on the surface of the tooth.

Replace with a new one if found any worn or chipped mark on the contact sides of the thrust
washer.
Side gear and Pinion mate
thrust washer

Replace with a new one if found that it chipped (by friction), damaged, or unusual worn.
Oil seal

Oil seals must be replaced with a new one whenever disassembled.
Differential case

Replace with a new one if found any wear or cracks on the contact sides of the Differential case.
Companion flange

Replace with a new one if found any chipped marks (about 0.10mm, 0.0039in) or other damage on
the contact sides of the lips of the companion flange.

REAR FINAL DRIVE ASSEMBLY
RFD-25
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ASSEMBLY
Assembly of Drive Pinion Assembly
1. Assemble with a drive pinion adjusting shim of the same thick-
ness as was installed prior to disassembly. Using the drift below,
press a pinion rear bearing outer race into the gear carrier.
CAUTION:

At first, using a hammer, tap the bearing outer race until it
becomes square to the gear carrier.

Do not reuse the pinion rear bearing outer race.
2. Using the drift below, press a pinion front bearing outer race into
the gear carrier.
CAUTION:

At first, using a hammer, tap the bearing outer race until it
becomes square to the gear carrier.

Do not reuse the pinion front bearing outer race.
3. Using the drift below, press a pinion rear bearing inner race into
the drive pinion.
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.
CAUTION:

Be careful of the mounting direction of the collapsible
spacer.

Do not reuse the collapsible spacer.
a. Apply differential oil to the pinion rear bearing, and assemble the
drive pinion to the gear carrier.Tool number : ST17130000
PDIA0056E
Tool number : ST33230000
PDIA0067E
Tool number : ST23860000
PDIA0068E
PDIA0239E

RFD-26
REAR FINAL DRIVE ASSEMBLY

b. Assemble a pinion front bearing inner race to the drive pinion.
Using the drifts and press stand, press the pinion nut as far as it
can be tightened.
c. Temporarily tighten the removed pinion nut to the drive pinion.
NOTE:
Use the removed pinion nut only for the preload measurement.
d. Fit the drive pinion gear socket onto the drive pinion spline.
Using the pinion nut wrench, tighten the pinion nut to the speci-
fied preload torque.
CAUTION:
The pinion nut is tightened with no collapsible spacer. Be
careful not to overtighten it. While measuring 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 gear car-
rier. Refer to RFD-28, "
Installation of Differential Assembly" .
f. Install a dummy cover set to check and adjust the tooth contact.
Refer to RFD-19, "
TOOTH CONTACT" .
g. Check and adjust the backlash. Refer to RFD-18, "
DRIVE
GEAR TO DRIVE PINION BACKLASH" .
h. Remove dummy cover set, and remove differential case assembly.
i. Remove pinion nut, pinion front bearing inner race, and remove
drive pinion gear.
5. Install the drive pinion gear with a collapsible spacer to the gear
carrier.Tool number A: KV40100610
B: ST38220000
C: ST23860000
PDIA0057E
Tool number A: KV38108400
B: KV38108500
C: ST3127S000
PDIA0058E
SDIA0576E

REAR FINAL DRIVE ASSEMBLY
RFD-27
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RFD

6. Using the drifts and press stand, press the pinion front bearing
inner race to the drive pinion as far as a pinion nut can be tight-
ened.
7. Apply anti-corrosive oil to the thread and seat of the pinion nut,
and temporarily tighten the pinion nut to the drive pinion.
CAUTION:
Do not reuse the pinion nut.
8. Fit the drive pinion gear socket onto the drive pinion gear spline.
Using the pinion nut wrench, adjust the pinion nut tightening
torque and pinion bearing preload torque.
CAUTION:

Do not reuse the pinion nut.

Adjust the lower limit of the pinion nut tightening torque
first.

If 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.

After adjustment, rotate the drive pinion gear back and forth
2 to 3 times to check for abnormal noise, rotation malfunc-
tion, and other malfunctions.Tool number A: KV40100610
B: ST38220000
C: ST23860000
PDIA0057E
Tool number A: KV38108400
B: KV38108500
C: ST3127S000
Pinion nut tightening torque
: 98 - 431 N·m (10 - 43 kg-m, 73 - 317 ft-lb)
Pinion bearing preload
: 0.69 - 1.17 N·m (0.07 - 0.11 kg-m, 7 - 10 in-lb)
PDIA0058E

RFD-28
REAR FINAL DRIVE ASSEMBLY

9. Install center oil seal as shown in the right figure.
10. Install the differential case assembly. Refer to RFD-28, "
Installa-
tion of Differential Assembly" .
CAUTION:
Do not install the rear cover.
11. Install the dummy cover set, and check backlash, drive gear
back runout, and tooth contact. Refer to RFD-19, "
TOOTH CON-
TA C T" .
12. Remove the dummy cover, then install the rear cover, and drive
in the oil seal. Refer to.RFD-28, "
Installation of Differential
Assembly" .
13. Check overall preload torque. Refer to RFD-17, "
TOTAL PRE-
LOAD" .
14. Connect electric controlled coupling assembly. Refer to RFD-30,
"Installation of Electric Controlled Coupling Assembly" .
15. Check companion flange runout. Refer to RFD-19, "
COMPAN-
ION 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 mate gears, and pinion mate thrust washers to
the differential case, and temporarily assemble the pinion mate shaft.
3. Measure the side gear end play following the procedure below,
and select the appropriate side gear thrust washers.

Using 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:

Before 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.

Select a side gear thrust washer for right and left individ-
ually.
4. Assemble the selected side gear thrust washer to the differential case.Tool number : ST35271000
PDIA0464E
Side gear end play 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

REAR FINAL DRIVE ASSEMBLY
RFD-29
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RFD

5. Using the pin punch below, drive a lock pin into the pinion mat-
ing shaft.
CAUTION:
Do not reuse the lock pin.
6. Using the drift below, press a side bearing inner race into the dif-
ferential case.
7. Apply locking sealant 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, and tighten it with drive gear bolt. Refer to RFD-16,
"Components" .
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 the drift below to the right and left side bearing adjusting shims individually. Compress differential case
assembly and side bearing to install the gear carrier assembly to differential case assembly.
CAUTION:

The drift shall be placed on the center of the adjusting
shims.

The pressure shall be as low as possible to install the
gear carrier assembly into the differential assembly. The
maximum pressure shall be 1 ton.

If the adjusting shims are installed by tapping, the gear
carrier may be damaged. Avoid tapping.
11. Install a dummy cover set, check and adjust the backlash, drive
gear back runout, tooth contact, and overall preload torque.
Refer to RFD-17, "
Pre-inspection" .
12. Remove dummy cover set.Tool number : ST23550000
PDIA0062E
Tool number : KV40105020
PDIA0052E
Tool number : KV40100610
PDIA0064E

RFD-30
REAR FINAL DRIVE ASSEMBLY

13. Apply a continuos bead of sealant around the gear carrier mat-
ing surface on the rear cover as shown in the figure. Overlap
both ends of the bead for at least 3 mm (0.12 in).
CAUTION:
Remove old sealant on the mounting surface, then remove
any moisture, oil, and foreign material on the application
and mounting surfaces.
14. Fit the drift below to the right and left side bearing adjusting
shims individually. Compress differential case assembly and
side bearing to install the rear cover.
CAUTION:

The drift shall be placed on the center of the adjusting
shims.

The pressure shall be as low as possible to install the
rear cover. The maximum pressure shall be 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton)

If 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. Refer to RFD-16, "
Components" .
16. Using both drift, drive the oil seal until it becomes flush with the
case end.
CAUTION:

Do not reuse oil seals.

Apply 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 to RFD-17, "
TOTAL PRE-
LOAD" .
Installation of Electric Controlled Coupling Assembly
1. Using the drift below, install the coupling front bearing to the
electric controlled coupling.
CAUTION:
At disassembly, be sure to install shim between electric
controlled coupling and bearing. Chamfering side of shim
should be coupled to install.
2. Assemble the electric controlled coupling assembly to the drive pinion gear.
PDIA0240E
Tool number : KV40100610
PDIA0065E
Tool number : KV38100200
PDIA0448E
Tool number : ST22360002
PDIA0060E