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RFD-25
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8. Lift differential case assembly out with a suitable tool.
Keep side bearing outer races together with inner race. Do
not mix them up.
Also, keep side bearing adjusting washers together with bear-
ings.
9. Remove side bearing inner race.
To prevent damage to bearing, engage puller jaws in groove.
CAUTION:
To prevent damage to the side bearing and drive gear,
place copper plates between these parts and vise.
It is not necessary to remove side bearing inner race
except it is replaced.
10. For proper reinstallation, paint matching marks on one differen-
tial case assembly.
CAUTION:
For matching marks, use paint. Do not damage differential
case and drive gear.
11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer.
CAUTION:
Tap evenly all around to keep drive gear from bending.
PDIA0547E
SPD527
Tool number A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)
SPD920
PDIA0496E
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RFD-26
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Revision: 2006 November2007 350Z
13. Remove lock pin of pinion mate shaft with a punch from drive
gear side.
14. Remove pinion mate shaft.
15. 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 differential assembly. Refer to RFD-24, "Differential Assembly" .
2. Remove drive pinion lock nut with the flange wrench.
SPD025
SDIA0031J
SDIA0032J
Tool number : KV40104000 ( — )
SDIA1144E
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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.
5. Press drive pinion assembly out of gear carrier.
CAUTION:
Do not drop drive pinion assembly.
6. Remove front oil seal.
7. Remove side oil seal.
8. Remove pinion front bearing inner race.
9. Remove collapsible spacer.
10. Remove pinion rear bearing inner race and drive pinion height
adjusting washer with the replacer.
11. Tap pinion front/rear bearing outer races uniformly a brass rod or
equivalent to removed.
CAUTION:
Be careful not to damage gear carrier.
PDIA0629E
SDIA1132E
SPD892
Tool number : ST30031000 (J-22912-01)
S-PD179
SDIA0817E
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INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.
ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS
Differential Side Gear Clearance
Assemble the differential parts if they are disassembled. Refer to RFD-24, "Differential Assembly" .
1. Place differential case straight up so that side gear to be mea-
sured comes upward.
Content Conditions and Measures
Hypoid gear
If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.
If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
Bearing
If 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
If any cracks or damage on the surface of the tooth is found, replace.
If 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
If it is chipped (by friction), damaged, or unusually worn, replace.
Oil seal
Whenever disassembled, replace.
If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case
If any wear or crack on the contact sides of the differential case is found, replace.
Companion flange
If 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.
PDIA0460E
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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 of the other side as well.
CAUTION:
To prevent side gear from tilting, insert feeler gauges with
the same thickness from both sides.
3. If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. Refer to RFD-60,
"Side Gear Thrust Washer" .
CAUTION:
Select a side gear thrust washer for right and left individu-
ally.
Side Bearing Preload
Selecting carrier side bearing adjusting washers is required for successful completion of this procedure.
1. Make sure all parts are clean. Also, make sure the bearings are
well lubricated with gear oil.
2. Place the differential case, with side bearings and bearing races
installed, into gear carrier.
3. Insert left and right original side bearing adjusting washers in
place between side bearings and gear carrier.Side gear back clearance specification:
0.2 mm (0.008 in) or less.
(Each gear should rotate smoothly without excessive
resistance during differential motion.)
When the back clearance is large:
Use a thicker thrust washer.
When the back clearance is small:
Use a thinner thrust washer.
PDIA0576E
SPD527
SPD558
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4. Install bearing caps in their correct locations and tighten bearing
cap mounting bolts to the specified torque. Refer to RFD-19,
"COMPONENTS" .
5. Turn the carrier several times to seat the bearings.
6. Measure the turning torque of the carrier at the drive gear
mounting bolts with a spring gauge.
7. If the turning torque is outside the specification, use a thicker/
thinner side bearing adjusting washer to adjust. Refer to RFD-
60, "Side Gear Thrust Washer" .
CAUTION:
Select a side bearing adjusting washer for right and left
individually.
8. Record the total amount of washer thickness required for the correct carrier side bearing preload.
Pinion Gear Height
1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion gear bearings into the differential shim
selector tool.
SDIA1795E
Tool number : — (J-8129)
Specification:
34.2 – 39.2 N (3.5 – 4.0 kg, 7.7 – 8.8 lb) of pulling
force at the drive gear bolt
SPD194A
If the turning torque is less than the specified range:
Use a thicker thrust washer.
If the turning torque is greater than the specification:
Use a thinner thrust washer.
SPD772
Tool number : — (J-34309)
SPD769
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Pinion front bearing; make sure the J-34309-3 pinion front
bearing seat is secured tightly against the J-34309-2 gauge
anvil. Then turn the pinion front bearing pilot, J-34309-5, to
secure the bearing in its proper position.
Pinion rear bearing; the pinion rear bearing pilot, J-34309-8,
is used to center the pinion rear bearing only. The pinion rear
bearing locking seat, J-34309-4, is used to lock the bearing to
the assembly.
Installation of J-34309-9 and J-34309-16; place a suitable
2.5 mm (0.098 in) thick plain washer between J-34309-9 and
J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must
be parallel with a clearance of 2.5 mm (0.098 in).
3. Install the pinion rear bearing inner race into gear carrier. Then
place the pinion preload shim selector tool, J-34309-1, gauge
screw assembly.
4. Assemble the pinion front bearing inner race and the J-34309-2
gauge anvil. Assemble them together with the J-34309-1 gauge
screw in gear carrier. Make sure that the pinion height gauge
plate, J-34309-16, will turn a full 360 degrees. Tighten the two
sections together by hand.
5. Turn the assembly several times to seat the bearings.
6. Measure the turning torque at the end of the J-34309-2 gauge
anvil using preload gauge.
SPD197A
SPD893
SPD199A
SPD770
Tool number : ST3127S000 (J-25765- A)
Turning torque specification:
1.0 – 1.3 N·m (0.11 – 0.13 kg-m, 9 – 11 in-lb)
PDIA0566E
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7. Place the J-34309-11 “R200A” pinion height adapter onto the
gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.
8. Position the side bearing discs, J-25269-4, and arbor firmly into
the side bearing bores. Install the bearing caps and tighten bear-
ing cap mounting bolts to the specified torque. Refer to RFD-19,
"COMPONENTS" .
9. Select the correct standard pinion height adjusting washer thick-
ness. Select by using a standard gauge of 3 mm (0.12 in) and
your J-34309-101 feeler gauge. Measure the distance between
the J-34309-11 pinion height adapter including the standard
gauge and the arbor.
10. Write down exact measurement (the value of feeler gauge).
11. Correct the pinion height washer size by referring to the “pinion
head number”.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and drive gear as a matched
set. This number should be the same as the number on the
drive gear. The second number is the “pinion head height
number”. It refers to the ideal pinion height from standard
for quietest operation. Use the following chart to determine
the correct pinion height washer.
SPD208A
SPD211A
SPD204A
SPD775
SPD542
