2004 INFINITI QX56 service

PREPARATION
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PREPARATIONPFP:00002
Special service toolEIS002WE
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolEIS002WF
Tool number
(Kent-Moore No.)
Tool nameDescription
—
(J-39570)
Chassis earLocating the noise
—
(J-43980)
NISSAN Squeak and
Rattle KitRepairing the cause of noise
SIIA0993E
SIIA0994E
Tool name
(Kent-Moore No.)Description
Engine ear
(J-39565)Locating the noise
SIIA0995E

RF-4
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Revision: August 20072004 QX56
SQUEAK AND RATTLE TROUBLE DIAGNOSESPFP:00000
Work FlowEIS002WG
CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any
customer comments; refer to RF-8, "
Diagnostic Worksheet" . This information is necessary to duplicate the
conditions that exist when the noise occurs.

The customer may not be able to provide a detailed description or the location of the noise. Attempt to
obtain all the facts and conditions that exist when the noise occurs (or does not occur).

If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer
is concerned about. This can be accomplished by test driving the vehicle with the customer.

After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.

Squeak —(Like tennis shoes on a clean floor)
Squeak characteristics include the light contact/fast movement/brought on by road conditions. Hard sur-
faces = higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping.

Creak—(Like walking on an old wooden floor)
Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch
dependent on materials/often brought on by activity.

Rattle—(Like shaking a baby rattle)
Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing
clip or fastener/incorrect clearance.

Knock —(Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.

Tick—(Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action or road conditions.

Thump—(Heavy, muffled knock noise)
Thump characteristics include softer knock/dead sound often drought on by activity.

Buzz—(Like a bumble bee)
Buzz characteristics include high frequency rattle/firm contact.

Often the degree of acceptable noise level will vary depending upon the person. A noise that you may
judge as acceptable may be irritating to the customer.

Weather conditions, especially humidity and temperature, may have a great effect on noise level.
SBT 8 42

SQUEAK AND RATTLE TROUBLE DIAGNOSES
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DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions when you confirm the repair.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following:
1) Close a door.
2) Tap or push/pull around the area where the noise appears to be coming from.
3) Rev the engine.
4) Use a floor jack to recreate vehicle "twist".
5) At idle, apply engine load (electrical load, half-clutch on M/T model, drive position on A/T model).
6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.

Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.

If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
CHECK RELATED SERVICE BULLETINS
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to that concern or symptom.
If a TSB relates to the symptom, follow the procedure to repair the noise.
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool
(Chassis Ear: J-39570, Engine Ear: J-39565 and mechanic's stethoscope).
2. Narrow down the noise to a more specific area and identify the cause of the noise by:

Removing the components in the area that you suspect the noise is coming from.
Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be broken
or lost during the repair, resulting in the creation of new noise.

Tapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only
temporarily.

Feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
noise.

Placing a piece of paper between components that you suspect are causing the noise.

Looking for loose components and contact marks.
Refer to RF-6, "
Generic Squeak and Rattle Troubleshooting" .
REPAIR THE CAUSE

If the cause is a loose component, tighten the component securely.

If the cause is insufficient clearance between components:
–Separate components by repositioning or loosening and retightening the component, if possible.
–Insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-
thane tape. A NISSAN Squeak and Rattle Kit (J-43980) is available through your authorized NISSAN
Parts Department.
CAUTION:
Do not use excessive force as many components are constructed of plastic and may be damaged.
Always check with the Parts Department for the latest parts information.
The following materials are contained in the NISSAN Squeak and Rattle Kit (J-43980). Each item can be
ordered separately as needed.
URETHANE PADS [1.5 mm (0.059 in) thick]
Insulates connectors, harness, etc.
76268-9E005: 100×135 mm (3.94×5.31 in)
76884-71L01: 60×85 mm (2.36×3.35 in)
76884-71L02: 15×25 mm (0.59×0.98 in)
INSULATOR (Foam blocks)
Insulates components from contact. Can be used to fill space behind a panel.
73982-9E000: 45 mm (1.77 in) thick, 50×50 mm (1.97×1.97 in)
73982-50Y00: 10 mm (0.39 in) thick, 50×50 mm (1.97×1.97 in)

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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SECTION RFD
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B
RFD
Revision: August 20072004 QX56 PREPARATION ........................................................... 2
Special Service Tools ............................................... 2
Commercial Service Tools ........................................ 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 5
NVH Troubleshooting Chart ..................................... 5
FRONT OIL SEAL ...................................................... 6
Removal and Installation .......................................... 6
REMOVAL ............................................................. 6
INSTALLATION ..................................................... 7
SIDE OIL SEAL .......................................................... 8
Removal and Installation .......................................... 8
REMOVAL ............................................................. 8
INSTALLATION ..................................................... 8
REAR FINAL DRIVE ASSEMBLY ............................ 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ....................................................11
Components ............................................................11
Pre-Inspection ........................................................ 12
TOTAL PRELOAD ............................................... 12
DRIVE GEAR TO DRIVE PINION BACKLASH ... 12
DRIVE GEAR RUNOUT ...................................... 12
COMPANION FLANGE RUNOUT ...................... 13
TOOTH CONTACT .............................................. 13
Disassembly and Assembly ................................... 13
REMOVAL OF DIFFERENTIAL CASE ASSEM-BLY ...................................................................... 13
REMOVAL OF DRIVE PINION ASSEMBLY ........ 14
DISASSEMBLY OF DIFFERENTIAL CASE
ASSEMBLY ......................................................... 16
INSPECTION ...................................................... 17
ADJUSTMENT OF DIFFERENTIAL CASE ......... 17
SIDE BEARING PRELOAD ................................. 18
TOOTH CONTACT .............................................. 19
ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
BLY ...................................................................... 20
INSTALLATION OF DRIVE PINION ASSEMBLY ... 21
INSTALLATION OF DIFFERENTIAL CASE
ASSEMBLY ......................................................... 23
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 26
General Specifications ............................................ 26
Drive Gear Runout .................................................. 26
Side Gear Adjustment ............................................ 26
AVAILABLE SIDE GEAR THRUST WASHERS ... 26
Drive Pinion Height Adjustment .............................. 26
AVAILABLE PINION HEIGHT ADJUSTING
WASHERS .......................................................... 26
Drive Pinion Preload Adjustment ............................ 26
Side Bearing Preload Adjustment ........................... 27
SIDE BEARING ADJUSTING WASHERS .......... 27
Total Preload Adjustment ........................................ 27

RFD-2
PREPARATION
Revision: August 20072004 QX56
PREPARATIONPFP:00002
Special Service ToolsEDS0 02 JH
The actual shapes of the Kent-Moore tools may differ from those of the special service tools illustrated here.
Tool name
Tool number
(Kent-Moore No.)Description
Drift
ST15310000
(—)

Installing front oil seal

Installing drive pinion rear bearing outer
race.
a: 96 mm (3.77 in) dia.
b: 84 mm (3.30 in) dia.
Drift
ST35271000
(—)Installing side oil seal
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.
Protector
KV38107900
(J-39352)Installing side flange
Attachment
KV38100800
(J-25604-01) Fixing unit assembly
a: 541 mm (21.30 in) dia.
b: 200 mm (7.87 in) dia.
Differential side bearing puller set
ST3306S001
(—)
1.ST33051001
(—)
2.ST33061000
(J-8107-2)Removing side bearing inner race
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
Drift
ST30621000
(—)Installing drive pinion front bearing outer race
a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.
ZZA0811D
ZZA1143D
S-NT129
SDIA0267E
NT072
ZZA0810D

RFD-4
PREPARATION
Revision: August 20072004 QX56
Commercial Service ToolsEDS002JI
Side bearing outer race puller
ST33290001
(J-34286)Removing front oil seal
Drift
ST33081000
(—)Installing side bearing
a: 43 mm (1.69 in) dia.
b: 33.5 mm (1.31 in) dia.
Bearing puller
ST30021000
(—)Removing drive pinion rear bearing inner
race
Drift
ST30022000
(—)Installing drive pinion rear bearing inner race
a: 110 mm (4.33 in) dia.
b: 46 mm (1.81 in) dia. Tool name
Tool number
(Kent-Moore No.)Description
ZZA0601D
ZZA0810D
ZZA0700D
ZZA0920D
Tool nameDescription
Power toolRemoving bolts and nuts
PBIC0190E

REAR FINAL DRIVE ASSEMBLY
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4. Install the side bearing caps in their original locations marked
during disassembly, and tighten the bearing cap bolts to specifi-
cation.
5. Turn the carrier several times to seat the bearings.
6. Measure the turning force of the carrier at the drive gear retain-
ing bolts using a suitable spring gauge.
7. If the turning force is not within the specification, adjust the turn-
ing force.

If the turning force is less than specification, install thicker
washers.

If the turning force is greater than specification, install thinner
washers.

Select the correct washer size to adjust the turning force.
Refer to RFD-27, "
SIDE BEARING ADJUSTING WASH-
ERS" .
8. Record the selected washer thickness required for the correct
carrier side bearing preload.
9. Remove the differential case assembly from the gear carrier
using Tool. Save the selected side bearing adjusting washers for
assembly.
TOOTH CONTACT
NOTE:
Checking the gear tooth contact pattern is necessary to verify that there is the correct tooth contact between
the drive gear and the drive pinion.
Hypoid gears which are not positioned properly may be noisy or have a short service life. Check the gear tooth
contact pattern to obtain the best contact for low noise and long service life.Bearing cap bolts : 93 N·m (9.5 kg-m, 69 ft.-lb)
SPD5 26
Drive gear bolt pulling force : 29.4 - 147 N (3 - 15 kg-f,
22 - 108 lb-f)
SPD1 94 A
SPD7 72
Tool number : HT72400000 ( — )
S-PD3 44

RFD-26
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: August 20072004 QX56
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS002JQ
Drive Gear RunoutEDS0 02 JR
Unit: mm (in)
Side Gear Adjustment EDS002JS
Unit: mm (in)
AVAILABLE SIDE GEAR THRUST WASHERS
Unit: mm (in)
Drive Pinion Height AdjustmentEDS002JT
AVAILABLE PINION HEIGHT ADJUSTING WASHERS
Unit: mm (in)
Drive Pinion Preload AdjustmentEDS0 02 JU
Grade2WD 4WD
Final drive modelR230 (2 - pinion)
Gear ratio2.937 : 1 3.357 : 1
Number of teeth (drive gear / drive pinion) 47 / 16 47 / 14
Oil capacity (approx.)
1.75 (3 3/4 US pt, 3 1/8 Imp pt)
Final drive modelR230 (2 - pinion)
Drive gear runout limit 0.05 (0.0020) or less
Final drive modelR230 (2 - pinion)
Clearance limit between side gear and differential case 0.20 (0.0079) or less
Final drive modelR230 (2 - pinion)
Thrust washerThickness Part number
1.75 (0.0688) 38424 7S000
1.80 (0.0708) 38424 7S001
1.85 (0.0728) 38424 7S002
Final drive model R230 (2 - pinion)
Adjusting washerThickness Part number Thickness Part number
2.59 (0.1020) 38154 40P00 2.79 (0.1098) 38154 40P10
2.61 (0.1028) 38154 40P01 2.81 (0.1106) 38154 40P11
2.63 (0.1035) 38154 40P02 2.83 (0.1114) 38154 40P12
2.65 (0.1043) 38154 40P03 2.85 (0.1122) 38154 40P13
2.67 (0.1051) 38154 40P04 2.87 (0.1130) 38154 40P14
2.69 (0.1059) 38154 40P05 2.89 (0.1138) 38154 40P15
2.71 (0.1067) 38154 40P06 2.91 (0.1146) 38154 40P16
2.73 (0.1075) 38154 40P07 2.93 (0.1154) 38154 40P17
2.75 (0.1083) 38154 40P08 2.95 (0.1161) 38154 40P18
2.77 (0.1091) 38154 40P09 2.97 (0.1169) 38154 40P19
Final drive modelR230 (2 - pinion)
Drive pinion preload 1.77 − 2.64 N·m (0.18 − 0.26 kg−m, 16 − 23 in-lb)