2005 NISSAN NAVARA lock

RFD-16
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
ASSEMBLY INSPECTION AND ADJUSTMENT
lBefore 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. Turn drive pinion in both directions several times to set bearing
rollers.
4. Measure total preload with preload gauge.
NOTE:
Total preload torque = Pinion bearing preload torque + Side bearing preload torque
lIf measured value is out of the specification, disassemble it to check and adjust each part. Adjust pinion
bearing preload and side bearing preload.
Adjust pinion bearing preload first, then adjust side bearing preload.
Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive
pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check
gear tooth contact pattern to obtain the best contact for low noise and long life.
1. Remove carrier cover. Refer toRFD-13, "
Removal and Installation".
2. Thoroughly clean drive gear and drive pinion teeth.
3. Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.Tool number : ST3127S000
To ta l p r e l o a d
Gear ratio 3.357 Type:
2.38 - 4.46 N·m (0.25 - 0.45 kg-m, 21- 39 in-lb)
Gear ratio 3.538 Type:
2.34 - 4.34 N·m (0.24 - 0.44 kg-m, 21- 38 in-lb)
Gear ratio 3.692 Type:
2.32 - 4.34 N·m (0.24 - 0.44 kg-m, 21 - 38 in-lb)
When the preload torque is greater than specification
On pinion bearings: Replace collapsible spacer.
On side bearings: Loosen side bearing adjuster.
When the preload torque is less than specification
On pinion bearings: Tighten drive pinion lock nut.
On side bearings: Tighten side bearing adjuster.
PDIA0309E
PDIA0321E

REAR FINAL DRIVE ASSEMBLY
RFD-17
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
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MA
B
RFD
4. Hold companion flange steady by hand and rotate drive gear in
both directions.
5. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer toRFD-23, "
Drive
Pinion Height Adjusting Washer"andRFD-17, "Backlash".
Backlash
1. Remove carrier cover. Refer toRFD-19, "Differential Assembly".
2. Check drive gear to drive pinion backlash using a dial indicator
at several points.
3. If outside the standard, adjust side bearing adjusters.
CAUTION:
Check tooth contact and total preload after adjusting side
bearing adjusters. Refer toRFD-16, "
Total Preload Torque",
RFD-16, "
Tooth Contact".
a. Remove adjuster lock plates.
b. Loosen side bearing cap bolts.
PDIA0322E
SDIA2591E
Drive gear to drive pinion backlash:
0.08 - 0.13 mm (0.0031 - 0.0051 in)
SDIA2640E

RFD-18
[WITH LIMITED SLIP DIFFERENTIAL]
REAR FINAL DRIVE ASSEMBLY
c. Tighten or loosen each side bearing adjusters using Tool.
d. In case of excessive backlash, loosen side bearing adjuster A
and tighten side bearing adjuster B. In case of insufficient back-
lash, loosen side bearing adjuster B and tighten side bearing
adjuster A.
e. After adjusting backlash, tighten side bearing cap bolts to the
specified torque. Refer toRFD-15, "
COMPONENTS".
f. Install adjuster lock plates and tighten to the specified torque.
Refer toRFD-15, "
COMPONENTS".
Companion Flange Runout
1. Fit a dial indicator onto companion flange face (inner side of pro-
peller shaft 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 repair limit, follow the procedure
below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90°,180°and
270°and search for the point where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.
c. If the runout value is still outside of the limit after companion flange has been replaced, check drive pinion
front bearing, drive pinion rear bearing and drive pinion assembly.Tool number : KV38108800
PDIA1044E
PDIA0330E
PDIA0331E
Runout limit : 0.10 mm (0.0039 in) or less
Runout limit : 0.13 mm (0.0051 in) or less
SDIA2078E

REAR FINAL DRIVE ASSEMBLY
RFD-19
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
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B
RFD
DISASSEMBLY
Differential Assembly
1. Remove carrier cover bolts and bracket.
2. Separate carrier cover from axle housing using Tool.
CAUTION:
lBe careful not to damage the mating surface.
lDo not insert flat-bladed screwdriver, this will damage the
mating surface.
3. For proper reinstallation, paint matching mark on one side of
side bearing cap and axle housing.
CAUTION:
lSide bearing caps are line-board for initial assembly. The
matching marks are used to reinstall them in their origi-
nal positions.
lFor matching mark, use paint. Do not damage side bear-
ing cap and axle housing.
4. Remove adjuster lock plates.
5. Remove side bearing caps.
PDIA1066E
Tool number : KV10111100
PDIA1041E
PDIA0310E
PDIA0311E

REAR FINAL DRIVE ASSEMBLY
RFD-21
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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MA
B
RFD
Drive Pinion Assembly
1. Remove differential case assembly. Refer toRFD-19, "Differential Assembly".
2. Remove drive pinion lock nut and washer using Tool.
3. Put a matching mark on the thread edge of drive pinion. The
mark should be in line with the mark on companion flange.
CAUTION:
For matching mark, use paint. Do not damage drive pinion
and companion flange.
4. Remove companion flange using suitable tool.
5. Remove front oil seal using Tool.
CAUTION:
Be careful not to damage axle housing.
6. Remove front bearing thrust washer.Tool number : KV40104000
PDIA0314E
SDIA2590E
PDIA0315E
Tool number : KV381054S0
SDIA2586E

REAR FINAL DRIVE ASSEMBLY
RFD-25
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
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MA
B
RFD
b. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated.
CAUTION:
Do not assemble a front oil seal.
c. Temporarily tighten removed drive pinion lock nut and washer to
drive pinion.
NOTE:
Use removed drive pinion lock nut and washer only for the pre-
load measurement.
d. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
e. Tighten to drive pinion lock nut, while adjust pinion bearing pre-
load torque.
CAUTION:
lAdjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
lDrive pinion lock nut is tightened with no collapsible spacer. Be careful not to overtighten it.
While measuring the preload, tighten it by 5°to 10°.
lAfter 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 adjusters into axle housing.
PDIA0328E
Tool number : KV40104000
PDIA0313E
Tool number : ST3127S000
Drive pinion lock nut tightening torque:
298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
Pinion bearing preload:
1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb)
PDIA0309E
PDIA0381E

REAR FINAL DRIVE ASSEMBLY
RFD-27
[WITH LIMITED SLIP DIFFERENTIAL]
C
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B
RFD
12. Align the matching mark of the drive pinion with the mark of the
companion flange, then install the companion flange.
13. Insert companion flange onto drive pinion. Tap the companion
flange with a soft hammer until fully seated.
CAUTION:
Be careful not to damage companion flange and front oil
seal.
14. Apply anti-corrosive oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut and
washer to drive pinion.
CAUTION:
Do not reuse drive pinion lock nut and washer.
15. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
16. Tighten to drive pinion lock nut, while adjust pinion bearing pre-
load torque.
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. Never 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, rota-
tion malfunction, and other malfunctions.
17. Install differential case assembly. Refer toRFD-28, "
Differential Assembly".
CAUTION:
Do not install carrier cover yet.
18. Check and adjust backlash, tooth contact and companion flange runout. Refer toRFD-17, "
Backlash",
RFD-16, "
Tooth Contact"andRFD-18, "Companion Flange Runout". Recheck above items. Readjust the
above description, if necessary.
SDIA2590E
PDIA0328E
Tool number : KV40104000
PDIA0313E
Tool number : ST3127S000
Drive pinion lock nut tightening torque:
298 - 678 N·m (31 - 69 kg-m, 220 - 500 ft-lb)
Pinion bearing preload:
1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb)
PDIA0309E

REAR FINAL DRIVE ASSEMBLY
RFD-29
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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MA
B
RFD
3. Apply thread locking sealant into the thread hole of drive gear.
Refer toRFD-15, "
COMPONENTS".
CAUTION:
Make sure threaded holes are clean.
4. Install the drive gear bolts, and then tighten to the specified
torque. Refer toRFD-15, "
COMPONENTS".
CAUTION:
lDo not reuse the bolts.
lTighten bolts in a crisscross fashion.
5. Press side bearing inner races to differential case assembly
using suitable tool and Tool.
CAUTION:
Do not reuse side bearings.
6. Install side bearing adjusters into axle housing.
7. Apply gear oil to side bearings. Install differential case assembly
with side bearing outer races into axle housing.
SDIA2594E
SDIA0247J
Tool number : KV38100300
PDIA1060E
PDIA0381E
PDIA0312E