2005 INFINITI FX35 Companion Flange Runout

FFD-1
FRONT FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
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Revision: 2005 July 2005 FX
FRONT FINAL DRIVE
PRECAUTIONS .......................................................... 2
Service Notice or Precautions ............................. ..... 2
PREPARATION ...................................................... ..... 3
Special Service Tools .......................................... ..... 3
Commercial Service Tools ................................... ..... 5
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... ..... 6
NVH Troubleshooting Chart ................................ ..... 6
DESCRIPTION ....................................................... ..... 7
Cross-Sectional View .......................................... ..... 7
DIFFERENTIAL GEAR OIL ................................... ..... 8
Changing Differential Gear Oil ............................ ..... 8
DRAINING ........................................................ ..... 8
FILLING ............................................................ ..... 8
Checking Differential Gear Oil ............................. ..... 8
OIL LEAKAGE AND OIL LEVEL ...................... ..... 8
FRONT OIL SEAL ................................................. ..... 9
Removal and Installation ..................................... ..... 9
REMOVAL ........................................................ ..... 9
INSTALLATION ................................................ ... 10
SIDE OIL SEAL ..................................................... ....11
Removal and Installation ..................................... .... 11
REMOVAL ........................................................ .... 11
INSTALLATION ................................................ .... 11
FRONT FINAL DRIVE ASSEMBLY ....................... ... 12
Removal and Installation (VQ35DE Models) ....... ... 12 COMPONENTS ................................................
... 12
REMOVAL ........................................................ ... 12
INSTALLATION ................................................ ... 12
Removal and Installation (VK45DE Models) ....... ... 14
COMPONENTS ................................................ ... 14
REMOVAL ........................................................ ... 14
INSTALLATION ................................................ ... 14
Disassembly and Assembly ................................. ... 16
COMPONENTS (VQ35DE MODELS) .............. ... 16
COMPONENTS (VK45DE MODELS) .............. ... 18
ASSEMBLY INSPECTION AND ADJUSTMENT ... 20
DISASSEMBLY ................................................ ... 24
INSPECTION AFTER DISASSEMBLY ............. ... 28
ADJUSTMENT AND SELECTION OF ADJUST-
ING WASHERS (SHIMS) ................................. ... 29
ASSEMBLY ...................................................... ... 32
SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 39
General Specifications ......................................... ... 39
Inspection and Adjustment .................................. ... 39
DRIVE GEAR RUNOUT ................................... ... 39
DIFFERENTIAL SIDE GEAR CLEARANCE .... ... 39
PRELOAD TORQUE ........................................ ... 39
BACKLASH ...................................................... ... 39
COMPANION FLANGE RUNOUT .................... ... 39
SELECTIVE PARTS ......................................... ... 39

FFD-6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: 2005 July 2005 FX
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartADS00196
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×: Applicable Reference page
Refer to
FFD-28, "
INSPECTION AFTER DISASSEMBLY
" .
Refer to FFD-21, "
Tooth Contact
" .
Refer to FFD-28, "
INSPECTION AFTER DISASSEMBLY
" .
Refer to FFD-23, "
Backlash
" .
Refer to FFD-23, "
Companion Flange Runout
" .
Refer to MA-32, "
Checking Differential Gear Oil
" .
NVH in PR section.
NVH in FAX, RAX, FSU and RSU sections.
NVH in WT section.
NVH in WT section.
NVH in FAX and RAX section.
NVH in BR section.
NVH in PS section.
Possible cause and SUSPECTED PARTS
Gear tooth rough
Gear contact improper
Tooth surfaces worn
Backlash incorrect
Companion flange excessive runout
Gear oil improper
PROPELLER SHAFT
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
DRIVE SHAFT
BRAKES
STEERING
Symptom Noise ×××××××××××××

FRONT OIL SEAL FFD-9
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Revision: 2005 July 2005 FX
FRONT OIL SEALPFP:38189
Removal and InstallationADS0019N
REMOVAL
1. Remove front propeller shaft. Refer to PR-5, "Removal and Installation" .
2. Remove drive pinion lock nut using a flange wrench.
3. Put matching mark on the end of the drive pinion. The matching mark should be in line with the matching mark A on companion
flange.
CAUTION:
For matching mark, use paint. Do not damage drive pinion.
NOTE:
The matching mark A on the final drive companion flange indi-
cates the maximum vertical runout position.
4. Remove companion flange using a puller.
5. Remove front oil seal using the puller.
PDIA0651E
PDIA0650E
PDIA0652E
Tool number : KV381054S0 (J-34286)
PDIA0653E

FRONT FINAL DRIVE ASSEMBLY FFD-23
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Revision: 2005 July 2005 FX

If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken pinon height adjusting washers to
move drive pinion closer to drive gear.
Refer to FFD-40, "
Pinion Height Adjusting Washer" .

If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin pinion height adjusting washers to move
drive pinion farther from drive gear.
Refer to FFD-40, "
Pinion Height Adjusting Washer" .
Backlash
1. Remove carrier cover. Refer to FFD-24, "Differential Assembly" .
2. Fit a dial indicator to the drive gear face to measure the back- lash.

If the backlash is outside of the specified value, change the
thickness of side bearing adjusting washer.
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.
5. If the runout value is outside the runout limit, follow the proce- dure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90 ° step, and
search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for
these items and repair if necessary.
PDIA0440E
PDIA0441E
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
When the backlash is large: Decrease side bearing adjusting washer thickness.
Refer to FFD-40, "
Side Bearing Adjusting Washer" .
When the backlash is small: Increase side bearing adjusting washer thickness.
Refer to FFD-40, "
Side Bearing Adjusting Washer" .
SDIA0009J
Runout limit: 0.18 mm (0.0070 in) or less
Runout limit: 0.13 mm (0.0051 in) or less
PDIA0646E

FFD-24
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.
DISASSEMBLY
Side Shaft Assembly
1. Hold extension tube retainer with puller, then press out side shaft using a press.
2. Remove side shaft oil seal from extension tube retainer with a flat- blade screwdriver.
3. Remove side shaft bearing from extension tube retainer.
4. Remove O-ring from extension tube retainer.
5. Remove dust sealed from side shaft.
Differential Assembly
1. Drain gear oil, if necessary.
2. Remove carrier cover mounting bolts.
3. Remove carrier cover to insert the seal cutter between gear car- rier and carrier cover.
CAUTION:

Be careful not to damage the mating surface.

Do not insert flat-bladed screwdriver, this way damage
the mating surface.
4. Remove side retainer mounting bolts.
SDIA1628E
PDIA0664E
Tool number : KV10111100 (J-37228)
PDIA0668E
PDIA0669E

FRONT FINAL DRIVE ASSEMBLY FFD-27
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20. Turn pinion mate gear, then remove pinion mate gears, pinion
mate thrust washers, side gears and side gear thrust washers
from differential case.
Drive Pinion Assembly
1. Remove differential assembly. Refer to FFD-24, "Differential Assembly" .
2. Remove drive pinion lock nut with a flange wrench.
3. Put matching mark on the end of drive pinion. The matching mark should be in line with the matching mark A on companion
flange.
CAUTION:
For matching mark, use paint. Do not damage companion
flange and drive pinion.
NOTE:
The matching mark A on the final drive companion flange indi-
cates the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
4. Remove companion flange using the suitable puller.
SDIA0032J
PDIA0741E
PDIA0675E
SDIA1132E

FFD-34
FRONT FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
10. Install companion flange.
NOTE:
When reusing drive pinion, align the matching mark of drive pin-
ion with the matching mark A of companion flange, then install
companion flange.
11. Apply gear oil to the thread and seat of new drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.
CAUTION:
Do not reuse drive pinion lock nut.
12. Tighten to drive pinon lock nut, while adjust pinion bearing pre- load torque.
CAUTION:

Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.

After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
13. Install differential case assembly. Refer to FFD-34, "
Differential
Assembly" .
CAUTION:
Do not install carrier cover yet.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer to FFD-20, "
Drive Gear Runout" , FFD-21, "Tooth Contact" , FFD-23, "Backlash" ,
FFD-23, "
Companion Flange Runout" .
Recheck above items. Readjust the above description, if necessary.
15. Check total preload torque. Refer to FFD-20, "
Total Preload Torque" .
16. Install carrier cover. Refer to FFD-34, "
Differential Assembly" .
Differential Assembly
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
the side gears.
PDIA0675E
Tool number : ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 127.4 - 245.0 N·m (13 - 25 kg-m, 94 - 181 ft-lb)
Pinion bearing preload: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
PDIA0778E
SDIA0193J

SERVICE DATA AND SPECIFICATIONS (SDS) FFD-39
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Revision: 2005 July 2005 FX
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsADS0019Z
Inspection and AdjustmentADS001A0
DRIVE GEAR RUNOUT
Unit: mm (in)
DIFFERENTIAL SIDE GEAR CLEARANCE
Unit: mm (in)
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in)
SELECTIVE PARTS
Side Gear Thrust Washer
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information. Applied model VQ35DE VK45DE
Final drive model F160A
Gear ratio 3.692
Number of teeth (Drive gear/Drive pinion) 48/13
Oil capacity (Approx.) (US pt, lmp pt) 0.65 (1-3/8, 1-1/8)
Number of pinion gears 2
Drive pinion adjustment spacer type Solid
Item Runout limit
Drive gear back face 0.05 (0.0020) or less
Item Specification
Side gear backlash (Clearance between side gear and differential
case) 0.2 (0.008) or less
(Each gear should rotate smoothly without excessive resistance
during differential motion.)
Item Specification
Pinion bearing (P
1 ) 0.78 - 1.57 (0.08 - 0.16, 7 - 13)
Side bearing (P
2 ) 0.78 - 1.08 (0.08 - 0.11, 7 - 9)
Side bearing to pinion bearing (Total preload)
(Total preload = P
1 + P2 ) 1.56 - 2.65 (0.16 - 0.27, 14 - 23)
Item Specification
Drive gear to drive pinion gear 0.10 - 0.15 (0.0039 - 0.0059)
Item Runout limit
Companion flange face 0.18 (0.0070) or less
Inner side of the companion flange 0.13 (0.0051) or less
Thickness Part number* Thickness Part number*
0.68 (0.0268)
0.71 (0.0280)
0.74 (0.0291)
0.77 (0.0303)
0.80 (0.0315)
0.83 (0.0327) 38424 W1010
38424 W1011
38424 W1012
38424 W1013
38424 W1014
38424 W1015 0.86 (0.0339)
0.89 (0.0350)
0.92 (0.0362)
0.95 (0.0374)
0.98 (0.0386)
1.01 (0.0398) 38424 W1016
38424 W1017
38424 W1018
38424 W1019
38424 W1020
38424 W1021