2005 NISSAN NAVARA lock

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)
PDIA1005E
PDIA0700E
PDIA0704E

FRONT FINAL DRIVE ASSEMBLY
FFD-31
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FFD
5. Assemble collapsible spacer to drive pinion.
CAUTION:
Do not reuse collapsible spacer.
6. Apply gear oil to pinion rear bearing, and assemble drive pinion
into gear carrier.
7. Apply gear oil to pinion front bearing, and assemble pinion front
bearing inner race to drive pinion assembly.
CAUTION:
Do not reuse pinion front bearing inner race.
8. Press the pinion front bearing inner race to drive pinion as far as
drive pinion lock nut can be tightened using Tool.
9. Install front oil seal until it becomes flush with the case end using
Tools.
CAUTION:
lDo not reuse oil seal.
lDo not incline oil seal when installing.
lApply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
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.
PDIA0708E
SPD581
Tool number : ST33200000
PDIA0709E
Tool number A: ST30720000
B: ST27863000
PDIA0717E
PDIA0675E

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)
PDIA1005E
SDIA0193J

FRONT FINAL DRIVE ASSEMBLY
FFD-33
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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.
SDIA2025E
SDIA0195J
WDIA0131E
SDIA2593E
SDIA2594E

FL-2
PREPARATION
PREPARATION
PFP:00002
Commercial Service ToolsEBS01E70
Tool nameDescription
Fuel filter wrench Removing fuel filter
Fuel tank lock ring wrench Removing and installing fuel tank lock ring
PBIC0519E
ZZA0122D

FL-14
FUEL LEVEL SENSOR UNIT
FUEL LEVEL SENSOR UNIT
PFP:17042
ComponentsEBS01F6N
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E76
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Remove fuel tank from the vehicle. Refer toFL-9, "
FUEL TANK".
2. Using a fuel tank lock ring wrench (commercial service tool),
remove the lock ring.
3. Remove fuel level sensor unit.
CAUTION:
lDo not bend the float arm during removal.
lAvoid impacts such as falling when handling components.
INSPECTION AFTER REMOVAL
Make sure fuel level sensor unit is free from foreign materials. If any are found, remove them.
1. Lock ring 2. Fuel level sensor unit 3. Seal packing
4. Fuel tank
A. Refer to text.
PBIC3374E
PBIC0240E

FUEL LEVEL SENSOR UNIT
FL-15
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INSTALLATION
Note the following, and install in the reverse order of removal.
lInstall fuel level sensor unit (1) with aligning mating marks (A) on
fuel tank and fuel level sensor unit as shown in the figure.
lInstall lock ring (1), and tighten lock ring by hand. Then tighten
lock ring with a fuel tank lock ring wrench (commercial service
tool), aligning mating marks (A) on fuel tank and lock ring as
showninthefigure.
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
lStart engine and rev it up and make sure there is no fuel leakage at connections.
: Vehicle front
PBIC3506E
: Vehicle front
PBIC3632E

FSU-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
PrecautionsEES002KG
lWhen installing the rubber bushings, the final tightening must be done under unladen condition and with
the tires on level ground. Oil will shorten the life of the rubber bushings, so wipe off any spilled oil immedi-
ately.
lUnladen condition means the fuel tank, engine coolant and lubricants are at the full specification. The
spare tire, jack, hand tools, and mats are in their designated positions.
lAfter installing suspension components, check the wheel alignment.
lLock nuts are not reusable. Always use new lock nuts for installation. New lock nuts are pre-oiled, do not
apply any additional lubrication.