2004 INFINITI QX56 Back up

FRONT FINAL DRIVE ASSEMBLY
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Revision: August 20072004 QX56
ASSEMBLY INSPECTION AND ADJUSTMENT

Before inspection and adjustment, drain gear oil.
Total Preload Torque
1. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
2. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
3. Measure total preload with preload gauge.

If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload
and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bear-
ing preload.
Tooth Contact
1. Remove rear cover. Refer to FFD-11, "REMOVAL" .
2. Thoroughly clean drive gear and drive pinion teeth.
3. Lightly apply a mixture of powdered ferric oxide and oil or the
equivalent. Apply it to 3 or 4 teeth of drive gear drive side.
4. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
34. Bushing 35. Bearing 36 Screw
37 Dowel pin
Tool number : ST3127S000 (J-25765-A)
Total preload (with oil seal):
2.98 - 4.76 N·m (0.31 - 0.48 kg-m, 27 - 42 in-lb)
SDIA2220E
When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Loosen the side bearing adjust nuts at the same force on each side.
When the preload is small
On pinion bearings: Tighten the drive pinion nut.
On side bearings: Tighten the side bearing adjust nuts at the same force on each side.
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FRONT FINAL DRIVE ASSEMBLY
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Backlash
1. Remove carrier cover. Refer to FFD-11, "REMOVAL" .
2. Fit a dial indicator to the drive gear face to measure the back-
lash.

If the backlash is outside of the specified value, use each side
bearing adjust nut.
Companion Flange Runout
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
3. Fit a test indicator to the inner side of companion flange (socket
diameter).
4. Rotate companion flange to check for runout.
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Backlash: 0.12 - 0.20 mm (0.0050 - 0.0079 in)
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When the backlash is large:
Loosen adjust nut A and tighten adjust nut B.
When the backlash is small:
Loosen adjust nut B and tighten adjust nut A.
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Runout limit: 0.10 mm (0.0039 in)
Runout limit: 0.13 mm (0.0051 in)
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FRONT FINAL DRIVE ASSEMBLY
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5. Remove drive pinion (together with rear bearing inner race, col-
lapsible spacer.)
6. Remove pinion front bearing inner race.
7. Place a small hole in seal case, using a suitable punch or drill.
8. Install slide hammer tool as shown and remove seal.
9. Turn nose of gear carrier down. Remove drive pinion front bear-
ing outer race using Tool. Locate driver on back edge of outer
race, then drive outer race out.
CAUTION:
Do not nick gear carrier.
10. Turn nose of gear carrier up. Remove drive pinion rear bearing
outer race using Tool. Locate driver on back edge of outer race,
then drive outer race out.
CAUTION:
Do not nick gear carrier.
SDIA2234E
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LDIA0130E
Tool number A: — C-4171
B: — D-103
LDIA0131E
Tool number A: — C-4171
B: — C-4307
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FRONT FINAL DRIVE ASSEMBLY
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ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS
Differential Side Gear Clearance

Assemble the differential parts if they are disassembled. Refer to FFD-28, "Differential Assembly" .
1. Place differential case straight up so that side gear to be mea-
sured comes upward.
2. Using feeler gauge, measure the clearance between side gear
back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance of the other side as well.
CAUTION:
To prevent side gear from tilting, insert feeler gauges with
the same thickness from both sides.
3. If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. Refer to FFD-32, "
Side
Gear Thrust Washer" .
CAUTION:
Select a side gear thrust washer for right and left individually.
Pinion Gear Height

Drive gear and pinions are supplied in matched sets only.
Matching numbers on both pinion and drive gear are etched for
verification. If a new gear set is being used, verify the numbers
of each pinion gear and drive gear before proceeding with
assembly.

The mounting distance from the center line of the drive gear to the back face of the pinion gear for the
M205 final drive is 103.5 mm (4.0748 inches).
On the button end of each pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0),
which indicates the best running position for each particular gear set. This dimension is controlled by a
selective shim between the inner pinion bearing race and pinion gear.
For example: If a pinion is etched m+8 (+3), it would require 0.08 mm (0.003 inch) less shim than a pinion
etched “0”. This means decreasing shim thickness; increases the mounting distance of the pinion to 103.6
mm (4.0778 inches). If a pinion is etched m+8 (-3), it would require adding 0.08mm (0.003 inch) more to
the shim than would be required if the pinion were etched “0”. By adding 0.08 mm (0.003 inch), the mount-
PDIA0460E
Side gear back clearance specification
: 0.20 mm (0.0079 in) or less
When the back clearance is large:
Use a thicker thrust washer.
When the back clearance is small:
Use a thinner thrust washer.
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FRONT FINAL DRIVE ASSEMBLY
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Revision: August 20072004 QX56
2. Press-fit front bearing outer race with Tools.
3. Temporarily install drive pinion height adjusting washer.
When hypoid gear set has been replaced

Select drive pinion height adjusting washer. Refer to FFD-33,
"Pinion Height Adjusting Washer" .
When hypoid gear set has been reused

Temporarily install the removed drive pinion height adjusting
washer or same thickness washer to drive pinion.
4. Install selected drive pinion height adjusting washer to drive pin-
ion, and press-fit pinion rear bearing inner race in it, using a
press and Tool.
5. Place pinion front bearing inner race in gear carrier.
6. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Install front oil seal, using Tools.
7. Perform checking and adjusting the tooth contact and backlash
of the hypoid gear following the procedure below.
a. Assemble the drive pinion to the gear carrier.
CAUTION:
Do not assemble a collapsible spacer.Tool number A: ST35271000 ( — )
B: KV40104810 ( — )
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Tool number : — C-4040
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Tool number A: KV38100500 (J-25273)
B: KV38102200 ( — )
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b. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated.
c. Temporarily tighten removed drive pinon nut to drive pinion.
NOTE:
Use removed drive pinon nut only for the preload measurement.
d. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
e. Tighten to drive pinon nut, while adjust pinion bearing preload
torque.
CAUTION:

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

Drive pinon nut is tightened with no collapsible spacer. Be careful not to overtighten it. While
measuring the preload, tighten it by 5° to 10°.

After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rota-
tion malfunction, and other malfunctions.
f. Install side bearing adjust nut into gear carrier.
g. Install differential case assembly with side bearing outer races
into gear carrier.
SDIA2266E
Tool number : KV38108300 (J-44195)
PDIA0182E
Tool number : ST3127S000 (J-25765-A)
Drive pinion nut tightening torque:
298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
Pinion bearing preload:
2.3 - 3.4 N·m (24 - 34 kg-cm, 21 - 30 in-lb)
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FRONT FINAL DRIVE ASSEMBLY
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h. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.

Do not tighten at this step. This allows further tightening of
side bearing adjusters.
i. Check and adjust the tooth contact and backlash. Refer to FFD-
15, "Tooth Contact" and FFD-16, "Backlash" .
j. Remove differential case assembly.
k. Remove companion flange.
l. Remove drive pinion (together with rear bearing inner race.)
8. Assemble collapsible spacer to drive pinion.
CAUTION:
Do not reuse collapsible spacer.
9. Place collapsible spacer, drive pinion height adjusting washer
and drive pinion in gear carrier.
10. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated.
11. Apply anti-corrosive oil to the thread and seat of drive pinion nut,
and temporarily tighten drive pinion nut to drive pinion.
CAUTION:
Do not reuse drive pinion nut.
12. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
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Tool number : KV38108300 (J-44195)
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FRONT FINAL DRIVE ASSEMBLY
Revision: August 20072004 QX56
13. Tighten to drive pinon nut, while adjust pinion bearing preload
torque.
CAUTION:

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

If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again
to adjust. Never loosen drive pinion nut to adjust the preload torque.

After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rota-
tion malfunction, and other malfunctions.
14. Install differential case assembly. Refer to FFD-28, "
Differential Assembly" .
CAUTION:
Do not install rear cover yet.
15. Check and adjust tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer
to FFD-15, "
Tooth Contact" , FFD-16, "Backlash" , FFD-16, "Companion Flange Runout" .
Recheck above items. Readjust the above description, if necessary.
16. Check total preload torque. Refer to FFD-15, "
Total Preload Torque" .
17. Install rear cover. Refer toFFD-11, "
INSTALLATION" .
Differential Assembly
1. Apply gear oil to contact surfaces of each gear, thrust washers
and differential case.
2. Install the removed thrust washer or same thickness washer to
side gear.
3. Install the side gears, thrust washers, pinion mate gears and
thrust washers into differential case.Tool number : ST3127S000 (J-25765-A)
Drive pinion nut tightening torque:
298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
Pinion bearing preload:
2.3 - 3.4 N·m (24 - 34 kg-cm, 21 - 30 in-lb)
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