2005 NISSAN NAVARA differential

FFD-22
FRONT FINAL DRIVE ASSEMBLY
6. Press side shaft out of side shaft bearing.
CAUTION:
Do not drop side shaft.
Differential Assembly
1. Remove side shaft assembly. Refer toFFD-35, "Side Shaft".
2. Remove rear cover bolts.
3. Separate the rear cover from the gear carrier using Tool.
CAUTION:
lDo not damage the mating surface.
lDo not insert flat-bladed screwdriver, this will damage the
mating surface.
4. For proper reinstallation, paint matching marks on one side of
the bearing cap.
CAUTION:
lFor matching mark, use paint. Do not damage bearing
caps and gear carrier.
lBearing caps are line-board during manufacture. The
matching marks are used to reinstall them in their origi-
nal positions.
5. Remove bearing caps.
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Tool number : KV10111100
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FRONT FINAL DRIVE ASSEMBLY
FFD-23
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FFD
6. Lift differential case assembly out using suitable tool.
CAUTION:
lKeep side bearing outer races together with inner race.
Do not mix them up.
lKeep side bearing adjusting washers together with bear-
ings.
7. Remove housing spacer.
8. Remove side bearing inner races, using Tools.
CAUTION:
lPlace copper plates between the side bearing and drive
gear and the vise to prevent damage.
lDo not remove side bearing inner race unless it is being
replaced.
9. For proper reinstallation, paint matching mark on one side of dif-
ferential case assembly.
CAUTION:
Use paint for matching mark. Do not damage differential
case or drive gear.
10. Remove drive gear bolts.
11. Tap drive gear off differential case assembly using suitable tool.
CAUTION:
Tap evenly all around to keep drive gear from bending.
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SPD527
Tool number A: ST33051001
B: ST33061000
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FFD-24
FRONT FINAL DRIVE ASSEMBLY
12. Remove lock pin of pinion mate shaft from drive gear side using
suitable tool.
13. Removepinionmateshaft.
14. Turn pinion mate gear, then remove pinion mate gear, pinion
mate thrust washer, side gear and side gear thrust washer from
differential case.
Drive Pinion Assembly
1. Remove side shaft assembly. Refer toFFD-21, "Side Shaft".
2. Remove differential assembly. Refer toFFD-22, "
Differential Assembly".
3. Remove drive pinion lock nut using flange wrench.
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FFD-26
FRONT FINAL DRIVE ASSEMBLY
11. Tap pinion front/rear bearing outer races uniformly to remove
them, using suitable tool.
CAUTION:
Do not damage gear carrier.
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If parts are worn or dam-
aged, follow the measures below.
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Content Conditions and Measures
Hypoid gear
lIf the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.
lIf the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
Bearing
lIf any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing
is observed, replace as a bearing assembly (as a new set).
Side gear and Pinion mate
gear
lIf any cracks or damage on the surface of the tooth is found, replace.
lIf any worn or chipped mark on the contact sides of the thrust washer is found, replace.
Side gear thrust washer and
pinion mate thrust washer
lIf it is chipped (by friction), damaged, or unusually worn, replace.
Oil seal
lWhenever disassembled, replace.
lIf wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case
lIf any wear or crack on the contact sides of the differential case is found, replace.
Companion flange
lIf any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the
companion flange is found, replace.

FRONT FINAL DRIVE ASSEMBLY
FFD-27
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FFD
ADJUSTMENT AND SELECTION ADJUSTING WASHERS
Differential Side Gear Clearance
lAssemble the differential parts if they are disassembled. Refer toFFD-32, "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. (Measure the clearance of the other side as well.)
CAUTION:
To prevent side gear from tilting, insert feeler gauges with
thesamethicknessfrombothsides.
3. If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. Refer toFFD-37, "
Side
Gear Thrust Washer".
CAUTION:
Select a side gear thrust washer for right and left individu-
ally.
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Side gear back clearance specification:
0.1 mm (0.004 in) or less.
(Each gear should rotate smoothly without excessive
resistance during differential motion.)
When the back clearance is greater than specification:
Use a thicker thrust washer.
When the back clearance is less than specification:
Use a thinner thrust washer.
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FFD-30
FRONT FINAL DRIVE ASSEMBLY
e. Temporarily tighten removed drive pinon nut to drive pinion.
NOTE:
Use removed drive pinon nut only for the preload measurement.
f. Adjust the drive pinion lock nut tightening torque and pinion
bearing preload torque using Tool.
CAUTION:
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°.
g. Apply gear oil to side bearings, and install new side bearing
adjusting washer with the same thickness or re-install the old
ones to the same mounting position they were in prior to disas-
sembly. Install differential case assembly to gear carrier.
h. Align matching mark on bearing cap with that on gear carrier.
i. Check and adjust the tooth contact. Refer toFFD-19, "
To o t h
Contact".
j. Check and adjust the backlash. Refer toFFD-20, "
Backlash".
k. Remove bearing caps.
l. Lift differential case assembly out using suitable tool.
CAUTION:
lKeep side bearing outer races together with inner race.
Do not mix them up.
lKeep side bearing adjusting washers together with bear-
ings.
m. Remove companion flange.
n. Press drive pinion assembly out of gear carrier. (Together with
collapsible spacer.)
CAUTION:
Do not drop drive pinion assembly.
o. Remove pinion front bearing inner race.Tool number A: ST3127S000
Drive pinion bearing preload:
1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)
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FFD-32
FRONT FINAL DRIVE ASSEMBLY
11. Apply anti-corrosive oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Do not reuse drive pinion lock nut.
12. Adjust the drive pinion lock nut tightening torque and pinion
bearing preload torque using Tool.
CAUTION:
lAdjust the lower limit of the drive pinion lock nut tighten-
ing torque first.
lIf the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Do not
loosen drive pinion lock nut to adjust the preload torque.
lAfter 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 toFFD-32, "
Differential Assembly".
CAUTION:
Do not install rear cover yet.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer toFFD-18, "
Drive Gear Runout",FFD-19, "To o t h C o n t a c t",FFD-20, "Backlash",
FFD-21, "
Companion Flange Runout".
Recheck above items. Readjust the above description, if necessary.
15. Check total preload torque. Refer toFFD-18, "
Total Preload Torque".
16. Install rear cover. Refer toFFD-32, "
Differential Assembly".
17. Install side shaft assembly. Refer toFFD-35, "
Side Shaft".
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.Tool number A: ST3127S000
Drive pinion lock nut tightening torque:
186 - 294 N·m (19 - 29 kg-m, 138 - 216 ft-lb)
Drive pinion bearing preload:
1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)
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FRONT FINAL DRIVE ASSEMBLY
FFD-33
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FFD
2. Install side gears and thrust washers into differential case.
3. Align 2 pinion mate gears in diagonally opposite positions, then
rotate and install them into differential case after installing thrust
washer to pinion mate gear.
4. Align the lock pin holes on differential case with shaft, and install
pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate
side gear thrust washers. Refer toFFD-27, "
Differential Side
Gear Clearance".
6. Drive a lock pin into pinion mate shaft, using suitable tool.
Make sure lock pin is flush with differential case.
CAUTION:
Do not reuse lock pin.
7. Align the matching mark of differential case with the mark of
drive gear, then place drive gear.
8. Apply recommended thread locking sealant into the thread hole
of drive gear. Refer toFFD-17, "
COMPONENTS".
CAUTION:
Make sure the drive gear back and threaded holes are
clean.
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