2003 NISSAN X-TRAIL differential

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

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
C
E
F
G
H
I
J
K
L
MA
B
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

FAX-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS00127
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
—
FAX-14—
FAX-7, FA X -11

—
NVH in PR section.
NVH in RFD section.
NVH in RAX and RSU sections.
Refer to FRONT AXLE in this chart.
NVH in WT section.
NVH in WT section.
Refer to DRIVE SHAFT in this chart.
NVH in BR section.
NVH in PS section.
Possible cause and SUSPECTED PARTS
Excessive joint angle
Joint sliding resistance
Imbalance
Improper installation, looseness
Parts interference
PROPELLER SHAFT
DIFFERENTIAL
REAR AXLE AND REAR SUSPENSION
FRONT AXLE
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
SymptomDRIVE
SHAFTNoise×× ×××××× ××
Shake×× ×××××××
FRONT
AXLENoise×× ××× ×××××
Shake×××××××××
Vibration×××××××
Shimmy×× ×××××
Judder× × ×× ××
Poor quality ride or handling×× × ××

FAX-12
FRONT DRIVE SHAFT

×: Applicable
–: Not applicable

Remove installation bolts from right-side drive shaft support bearing bracket. Then remove bracket from
engine.

Remove installation bolts from right-side drive shaft and remove drive shaft from side shaft.
INSPECTION AFTER REMOVAL

Move joint in up/down, left/right, and axial directions. Check for
motion that is not smooth and for significant looseness.

Check for cracking and damage of boots, and for grease leak-
age.
INSTALLATION

Install support bearing bracket onto engine and tighten installation bolts to specified torque. Refer to FA X -
11 , "Removal and Installation" .

Install drive shaft to side shaft and tighten installation bolts to specified torque. Refer to FA X - 11 , "Removal
and Installation" .
1. In order to prevent damage to differential side oil seal, first fit a
protector onto oil seal before inserting drive shaft. Slide drive
shaft slide joint and tap with a hammer to install securely.
CAUTION:
Be sure to check that circular clip is securely fastened.
2. Insert drive shaft into steering knuckle. Install lock nut and then
temporarily tighten lock nut. Refer to FA X - 11 , "
Removal and
Installation" .
3. Install installation bolts for steering knuckle and strut.
4. Use lock plate to fix brake hose to strut.
5. Install tie rod to steering knuckle.
6. Install wheel sensor.
7. Tighten lock nuts to specified torque. Refer to FAX-11, "
Removal
and Installation" .
8. Install cotter pin.
CAUTION:
Discard the old cotter pin; replace with a new one.
Engine typeDrive shaft with circular clip
Right Left
QR20DE and QR25DE –×
YD22DDTi –×
RAA0030D
Model type Protector SST No.
RH KV38107800
LH KV38105500
SDIA0593E
SDIA0603E

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
RAX-5
C
E
F
G
H
I
J
K
L
MA
B
RAX

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS000FK
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
—
RAX-12—
RAX-6, RAX-10—
NVH in PR section.
NVH in RFD section.
NVH in FAX and FSU sections.
Refer to REAR AXLE in this chart.
NVH in WT section.
NVH in WT section.
Refer to DRIVE SHAFT in this chart.
NVH in BR section.
NVH in PS section.
Possible cause and SUSPECTED PARTS
Excessive joint angle
Joint sliding resistance
Imbalance
Improper installation, looseness
Parts interference
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE AND FRONT SUSPENSION
REAR AXLE
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
SymptomDRIVE
SHAFTNoise×× ×××××× ××
Shake×× ×××××××
REAR
AXLENoise×× ××× ×××××
Shake×× × × ×××××
Vibration×××××××
Shimmy×× × × × × ×
Judder××××××
Poor quality ride or handling×× × ××

FSU-4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEES000ID
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: ApplicableReference page
FSU-5 FSU-8—
—
—
FSU-5 FSU-6 FSU-11
NVH in PR section
NVH in RFD section.
NVH in RAX and RSU section.
NVH in WT section.
NVH in WT section.
NVH in RAX section.
NVH in BR section.
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 bar fatigue
PROPELLER SHAFT
DIFFERENTIAL
REAR AXLE AND REAR SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom FRONT SUSPENSIONNoise××××× × ××× ×××××
Shake×××× × × × ×××××
Vibration××××× × ×× × ×
Shimmy×××× × ××× ××
Judder××× ××× ××
Poor quality ride or han-
dling×× × × × ×× × × ×