2003 NISSAN X-TRAIL differential

REAR FINAL DRIVE ASSEMBLY
RFD-15
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RFD

INSTALLATION
Note the following, and install in the reverse order of removal.

Refer to RFD-16, "Components" about each tightening torque.

When installing breather hoses, refer to the figure and following.
CAUTION:
Make sure there are no pinched or restricted areas on the
breather hose caused by bending or winding when install-
ing it.
–For installation of rear final drive breather hose, the vehicle side
end shall be inserted to cross member. Install metal connector
side of this hose to rear cover by inserting it with aiming painted
marking to the front of vehicle.
–For installation of electric controlled coupling breather hose, the
vehicle side end shall be inserted to cross member. Install its
metal tube to rear final drive assembly and direct the metal tube
hose side end to the front of vehicle.

When oil leaks while removing final drive assembly, check oil
level after the installation. Refer to RFD-8, "
Checking Differential
Gear Oil" .
PDIA0436E
PDIA0437E

RFD-16
REAR FINAL DRIVE ASSEMBLY

ComponentsEDS001ZB
PDIA0196E
1. Drive pinion 2. Pinion rear bearing 3. Drive pinion adjusting shim
4. Collapsible spacer 5. Gear carrier 6. Pinion front bearing
7. Drive pinion nut 8. Electric controlled coupling connec-
tor bracket9. Companion flange lock nut
10. Companion flange 11. Front oil seal 12. Coupling cover
13. Coupling front bearing 14. Electric controlled coupling 15. Center oil seal
16. Electric controlled coupling connec-
tor17. Side gear 18. Pinion mate shaft
19. Side gear thrust washer 20. Pinion mate thrust washer 21. Pinion mate gear
22. Lock pin 23. Side oil seal 24. Side bearing adjusting shim
25. Side bearing 26. Differential case 27. Drive gear

RFD-18
REAR FINAL DRIVE ASSEMBLY

DRIVE GEAR TO DRIVE PINION BACKLASH
1. Drain the oil.
2. Remove the rear cover. Refer to RFD-22, "
Removal of Differential Assembly" .
3. Following the procedure below, install a dummy cover set to the
gear carrier.
a. Fit dummy cover shims to the right and left side bearing adjust-
ing shims.
b. Temporarily tighten a dummy cover to the gear carrier.
c. Position a dummy cover spacer to the dummy cover.
d. Tighten rear cover mounting bolts to the specified torque. Refer to RFD-16, "
Components" .
e. Tighten dummy cover spacer mounting bolts evenly to the specified torque.
4. Fit a dial gauge to the drive gear face to measure the backlash.

If outside the standard, change the thickness of the side bearing
adjusting shims.
Side bearing adjusting shimsTool Number : KV381086S1
PDIA0474E
: 5.9 N·m (0.6 kg-m, 52 in-lb)
Backlash : 0.10 - 0.15 mm (0.0039 - 0.0059 in)
Tool number : KV381086S1
PDIA0049E
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

REAR FINAL DRIVE ASSEMBLY
RFD-19
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RFD

DRIVE GEAR RUNOUT
1. Drain the oil.
2. Remove the rear cover.Refer to RFD-22, "
Removal of Differential Assembly" .
3. Attach dummy cover set. Refer to RFD-18, "
DRIVE GEAR TO
DRIVE PINION BACKLASH" .
4. Fit a dial gauge to the drive gear back face.
5. Rotate the drive gear to measure runout.

If 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 of electronically controlled coupling.
TOOTH CONTACT
1. Drain the oil.
2. Remove the rear cover. Refer to RFD-22, "
Removal of Differential Assembly" .
3. Attach dummy cover set. Refer to RFD-18, "
DRIVE GEAR TO
DRIVE PINION BACKLASH" .
4. Thoroughly clean drive gear and drive pinion teeth.
5. Lightly apply a mixture of powdered ferric oxide and oil or the
equivalent. Apply it to 3 to 4 teeth of drive gear drive side.Tool Number : KV381086S1
Runout limit : 0.05 mm (0.0020 in)
PDIA0050E
Runout limit : 0.13 mm (0.0051 in)
Runout limit : 0.19 mm (0.0075 in)
PDIA0439E
Tool Number : KV381086S1
PDIA0051E

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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RFD

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