2006 INFINITI QX56 differential

FRONT FINAL DRIVE ASSEMBLYFFD-21
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Revision: November 2009 2006 QX56
17. Turn the pinion mate gear, then remove the pinion mate gear,
pinion mate thrust washer, side gear and side gear thrust
washer from the differential case.
Drive Pinion Assembly
1. Remove the differential assembly. Refer to FFD-18, "Differential Assembly" .
2. Remove the drive pinion lock nut using Tool.
3. Put matching marks on the companion flange and drive pinion using paint.
CAUTION:
Use paint to make the matching marks. Do not damage the
companion flange or drive pinion.
4. Remove the companion flange using suitable tool.
5. Press the drive pinion assembly (with rear inner bearing race and collapsible spacer) out of the gear carrier.
CAUTION:
Do not drop drive pinion assembly.
SDIA0032J
Tool number : KV38108300 (J-44195)
PDIA0702E
PDIA0703E
SDIA2234E

FRONT FINAL DRIVE ASSEMBLYFFD-23
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INSPECTION AFTER DISASSEMBLY
Clean the disassembled parts. Then inspect the parts for wear or damage. If wear or damage are found, follow
the measures below.
Drive Pinion and Drive Gear

If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust,
repair, or replace as necessary.

If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably,
replace with new drive pinion and drive gear.

Drive pinion and drive gear are supplied in matched sets only. Matching numbers on both drive pinion and
drive gear are etched for verification. If a new drive pinion and drive gear set are being used, verify the
numbers of each drive pinion and drive gear before proceeding with assembly.
Bearing

If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bear-
ing, replace with new bearing assembly (as a new set).

Bearing must be replaced with a new one whenever disassembled.
Side Gear and Pinion Mate Gear

If any cracks or damage are found on the surface of the teeth, replace with new one.

If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact
the thrust washer, replace with new one.

Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.
Side Gear Thrust Washer and Pinion Mate Thrust Washer

If any chips (by friction), damage, or unusual wear are found, replace with new one.
Gear Carrier

If any wear or cracks are found on the contact sides of gear carrier, replace with new one.
Companion Flange

If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the
front oil seal lips are found, replace with new one.
ADJUSTING AND SELECTING WASHERS
Side Gear Back Clearance

Assemble the differential parts if they are disassembled. Refer to FFD-27, "Differential Assembly" .
1. Place the differential case straight up so that the side gear to be measured is upward.
PDIA0460E

FFD-24
FRONT FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
2. Using feeler gauges, measure the clearance between the side
gear back and differential case at three different points, while
rotating the side gear. Average the three readings to calculate
the clearance. (Measure the clearance of the other side as well.)

If the side gear back clearance is outside of the specification,
use a thicker or thinner side gear thrust washer to adjust.
Refer to FFD-32, "
Side Gear Thrust Washer" .
CAUTION:

Insert feeler gauges with the same thickness on both
sides to prevent side gear from tilting.

Each gear should rotate smoothly without excessive
resistance during differential motion.

Select a side gear thrust washer for right and left individ-
ually.
NOTE:
Side gear back clearance is clearance between side gear and differential case for adjusting side gear
backlash.
Drive Pinion Height

Drive gear and drive pinion are supplied in matched sets only.
Matching numbers on both drive pinion and drive gear are
etched for verification. If a new gear set is being used, verify the
numbers of each drive pinion and drive gear before proceeding
with assembly.

The mounting distance from the centerline of the drive gear to the back face of the drive pinion for the
M205 final drive assembly is 103.5 mm (4.0748 inches).
On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero
(0), which indicates the best running position for each particular gear set. This dimension is controlled by
a selective drive pinion height adjusting washer between the drive pinion rear bearing inner race and drive
pinion.
For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 inch) less drive pinion
height adjusting washer than a drive pinion etched “0”. This means decreasing drive pinion height adjust-
ing washer thickness; increases the mounting distance of the drive pinion to 103.6 mm (4.0778 inches). If
a drive pinion is etched m-8 (-3), it would require adding 0.08mm (0.003 inch) more to the drive pinion
height adjusting washer than would be required if the drive pinion were etched “0”. By adding 0.08 mm
(0.003 inch), the mounting distance of the drive pinion was decreased to 103.4 mm (4.0718 inches) which
is just what a m-8 (-3) etching indicated.

To change the drive pinion height, use different drive pinion height adjusting washers which come in differ-
ent thickness.

Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness
to add or subtract from the old drive pinion height adjusting washer. Side gear back clearance: 0.20 mm (0.0079 in) or less
If the side gear back clearance is greater than
specification:
Use a thicker side gear thrust washer.
If the side gear back clearance is less than
specification: Use a thinner side gear thrust washer.
PDIA0576E
SDIA2241E

FFD-26
FRONT FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
4. Install the selected drive pinion height adjusting washer to the
drive pinion. Press the drive pinion rear bearing inner race to it
using Tool.
CAUTION:
Do not reuse drive pinion rear bearing inner race.
5. Install the collapsible spacer to the drive pinion. CAUTION:
Do not reuse collapsible spacer.
6. Apply differential gear oil to the drive pinion rear bearing, and install the drive pinion assembly to the gear carrier.
7. Apply differential gear oil to the drive pinion front bearing, and install the drive pinion front bearing inner race to the drive pinion
assembly.
CAUTION:
Do not reuse drive pinion front bearing inner race.
8. Apply multi-purpose grease to the lips of the new front oil seal. Then drive the new front oil seal in evenly using Tools.
CAUTION:

Do not reuse front oil seal.

Do not incline the new front oil seal when installing.

Apply multi-purpose grease to the lips of the new front oil
seal.
9. Install the companion flange to the drive pinion while aligning the matching marks. Tap the companion flange until fully seated
using suitable tool.Tool number : C-4040
SDIA2253E
PDIA0708E
Tool number A: KV38100500 (J-25273)
B: KV38102200 ( — )
PDIA0717E
SDIA2266E

FRONT FINAL DRIVE ASSEMBLYFFD-27
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10. Apply anti-corrosive oil to the threads of the drive pinion and the
seating surface of the new drive pinion lock nut. Then adjust the
drive pinion lock nut tightening torque using Tool A, and check
the drive pinion bearing preload torque using Tool B.
CAUTION:

Do not reuse drive pinion lock nut.

Apply anti-corrosive oil to the threads of the drive pinion
and the seating surface of the new drive pinion lock nut.

Adjust the drive pinion lock nut tightening torque to the
lower limit first. Do not exceed the drive pinion lock nut
specified torque. Refer to FFD-14, "
COMPONENTS" .

If the drive pinion bearing 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 drive pinion bearing preload torque.

After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
11. Check companion flange runout. Refer to FFD-17, "
Companion Flange Runout" .
12. Install the differential case assembly. Refer to FFD-27, "
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.
2. Install the side gears and side gear thrust washers into the dif- ferential case.
3. Install the pinion mate thrust washers to the two pinion mate gears. Then install the pinion mate gears with the pinion mate
thrust washers by aligning them in diagonally opposite positions
and rotating them into the differential case.Tool number A: KV38108300 (J-44195)
B: ST3127S000 (J-25765-A)
Drive pinion bearing preload torque: 2.3 - 3.4 N·m (24 - 34 kg-cm, 21 - 30 in-lb)
WDIA0382E
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FFD-28
FRONT FINAL DRIVE ASSEMBLY
Revision: November 20092006 QX56
4. Install the pinion mate shaft and align the lock pin hole on the
pinion mate shaft with the lock pin hole on the differential case.
5. Measure the side gear end play. If necessary, select the appro- priate side gear thrust washers. Refer to FFD-23, "
Side Gear
Back Clearance" .
6. Drive a new lock pin into the pinion mate shaft until it is flush with the differential case using suitable tool.
CAUTION:
Do not reuse lock pin.
7. Align the matching mark of the differential case with the mark of the drive gear, then place the drive gear onto the differential
case.
8. Install and tighten the new drive gear bolts to the specified torque. Refer to FFD-14, "
COMPONENTS" .
CAUTION:

Make sure the drive gear back and threaded holes are
clean.

Do not reuse drive gear bolts.

Tighten new drive gear bolts in a crisscross pattern.
9. Press the new side bearing inner races to the differential case using Tools.
CAUTION:
Do not reuse side bearing inner races.
SDIA0195J
SPD030
SDIA2593E
SDIA2239E
Tool number A: KV38100300 (J-25523)
B: ST33081000
SPD353

FRONT FINAL DRIVE ASSEMBLYFFD-29
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10. Install side bearing adjusters into gear carrier.
11. Apply differential gear oil to the side bearings, and install the dif-
ferential case assembly with the side bearing outer races into
the gear carrier.
CAUTION:
Do not reuse side bearing outer race when replacing side
bearing inner race (replace as a set).
12. Install the side bearing caps with the matching marks aligned. NOTE:
Do not tighten at this step. This allows further tightening of side
bearing adjusters.
13. Tighten each side bearing adjuster alternately turning drive gear.
14. Check and adjust tooth contact, backlash, drive gear runout and total preload torque. Refer to FFD-16,
"Tooth Contact" , FFD-17, "Backlash" , FFD-15, "Drive Gear Runout" and FFD-15, "Total Preload Torque"
.
Recheck above items.

After adjusting tooth contact and backlash secure side bear-
ing adjuster with screws and tighten side bearing cap bolt to
the specified torque. Refer to FFD-14, "
COMPONENTS" .
15. Apply multi-purpose grease to the lips of the new side oil seal. Then drive the new side oil seal in evenly to the gear carrier using suitable tool.
CAUTION:

Do not reuse side oil seal.

Do not incline the new side oil seal when installing.
SPD527
PDIA0700E
SDIA2265E
SDIA2263E

SERVICE DATA AND SPECIFICATIONS (SDS)FFD-31
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS00458
Inspection and AdjustmentEDS00459
DRIVE GEAR RUNOUT
Unit: mm (in)
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)
Applied model
VK56E
Final drive model M205
Gear ratio 3.357
Number of teeth (Drive gear/Drive pinion) 47/14
Differential gear oil capacity (Approx.) 1.6 (3 3/8 US pt, 2 7/8 Imp pt)
Number of pinion gears 2
Drive pinion adjustment spacer type Collapsible
ItemRunout limit
Drive gear back face 0.08 (0.0031) or less
ItemSpecification
Side gear back clearance (Clearance between side gear and dif-
ferential case for adjusting side gear backlash) 0.20 (0.0079) or less
(Each gear should rotate smoothly without excessive resistance during differential motion.)
Item Specification
Drive pinion bearing preload torque 2.3 - 3.4 (0.23 - 0.35, 21 - 31)
Total preload torque
(Total preload torque = drive pinion bearing preload torque + side
bearing preload torque). 2.98 - 4.76 (0.31 - 0.48, 27 - 42)
Item
Specification
Drive gear to drive pinion backlash 0.12 - 0.20 (0.0050 - 0.0079)
ItemRunout limit
Companion flange face 0.10 (0.0039) or less
Companion flange inner side 0.13 (0.0051) or less