2009 INFINITI QX56 differential

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DISASSEMBLY AND ASSEMBLY
FRONT FINAL DRIVE
Disassembly and AssemblyINFOID:0000000005875038
COMPONENTS
1. Side bearing adjuster 2. Side bearing 3. Side gear thrust washer
4. Side gear 5. Lock pin 6. Pinion mate thrust washer
7. Pinion mate gear 8. Pinion mate shaft 9. Drive pinion
10. Drive pinion height adjusting washer 11. Drive pinion rear bearing 12. Collapsible spacer
13. Breather tube 14. Differential side flange 15. Dust shield
16. Circular clip 17. Side oil seal 18. Drive pinion front bearing
19. Front oil seal 20. Companion flange 21. Drive pinion lock nut
22. Drain plug 23. Differential side shaft 24. Differential side shaft bearing
25. Extension tube 26. O-ring 27. Gear carrier
AWDIA0707GB
Revision: December 20092009 QX56

DLN-218
< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
ASSEMBLY INSPECTION AND ADJUSTMENT
 Drain the differential gear oil before inspection and adjustment. Refer to
DLN-209, "Changing Differential
Gear Oil".
 Remove and install the carrier cover as neces sary for inspection and adjustment. Refer to DLN-214,
"Removal and Installation".
Total Preload Torque
1. Install the differential side shaft and differential side flange if necessary.
CAUTION:
The differential side shaft and differential side flan ge must be installed in order to measure total
preload torque.
2. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.
4. Measure total preload torque using Tool.
NOTE:
Total preload torque = Drive pinion bearing preload torque +
Side bearing preload torque
 If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion
bearing preload torque first, then adjust the side bearing preload torque.
Drive Gear Runout
1. Fit a dial indicator to the drive gear back face.
2. Rotate the drive gear to measure runout.
 If the runout is outside of the limit , check the condition of the drive
gear assembly. Foreign material may be caught between the drive
gear and differential case, or the differential case or drive gear may
be deformed.
CAUTION:
Replace drive gear and drive pinion as a set.
Tooth Contact
28. Plate 29. Differential case 30. Drive gear
31. Side bearing cap 32. Filler plug 33. Carrier cover
34. Bushing 35. Bearing 36 Screw
37 Dowel pin
Tool number : ST3127S000 (J-25765-A)
Total preload torque
: Refer to DLN-234, "Inspection and Adjust-
ment"
PDIA0697E
If the total preload torque is greater than specification
On drive pinion bearings: R eplace the collapsible spacer.
On side bearings: Loosen the side bearin g adjuster by the same amount on each
side.
If the total preload torque is less than specification On drive pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Tighten the side bear ing adjuster by the same amount on each
side.
Runout limit: 0.08 mm (0.0031 in) or less
SPD886
Revision: December 20092009 QX56

DLN-220
< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
Backlash
1. Fit a dial indicator to the drive gear face to measure the back-
lash.
 If the backlash is outside of t he specification, adjust each side
bearing adjuster.
CAUTION:
Do not change the side bearing adjusters by different
amounts as it will change the side bearing preload torque.
Companion Flange Runout
1. Rotate companion flange and check for runout on the compan-
ion flange face (inner side of the bolt holes) and companion
flange inner side (socket diameter) using suitable tool.
2. If the runout is outside the runout limit, follow the procedure below to adjust.
a. Rotate the companion flange on the drive pinion by 90 °, 180 ° and 270 ° while checking for the position
where the runout is minimum.
b. If the runout is still outside of the runout limit af ter the companion flange has been rotated on the drive pin-
ion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a mal-
functioning drive pinion bearing.
c. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion
bearing or drive pinion bearing, replace the companion flange.
DISASSEMBLY
Differential Assembly
1. Drain the differential gear oil if necessary. Backlash : Refer to
DLN-234, "Inspection and Ad-
justment"
SPD513
If the backlash is greater than specification:
Loosen side bearing adjuster A and tighten side bear-
ing adjuster B by the same amount.
If the backlash is less than specification: Loosen side bearing adjuster B and tighten side bear-
ing adjuster A by the same amount.
SDIA2262E
Runout limit
Companion flange face : Refer to DLN-234, "Inspec-
tion and Adjustment"
Companion flange inner
side: Refer to
DLN-234, "Inspec-
tion and Adjustment"
SDIA2078E
Revision: December 20092009 QX56

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2. Remove the differential side shaft and differential side flange using suitable tool.
3. Remove the extension tube and O-ring from the gear carrier.
4. Place a small hole in the side oil seal case using suitable tool.
5. Remove the side oil seal using Tool as shown.
6. Remove the carrier cover bolts and separate the carrier cover from the gear carrier using Tool.
CAUTION:
 Do not damage the mating surface.
 Do not insert flat-bladed screw driver, this will damage the
mating surface.
BDIA0006E
SDIA3205E
LDIA0129E
Tool number : SP8P
LDIA0130E
Tool number : KV10111100 (J-37228)
PDIA0699E
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DLN-222
< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
7. For proper reinstallation, paint matching marks on one side of
the side bearing cap and gear carrier.
CAUTION:
 For matching marks, use paint. Do not damage side bear-
ing cap or gear carrier.
 Side bearing caps are line-board during manufacture. The
matching marks are used to re install them in their original
positions.
8. Remove the side bearing caps.
9. Remove the side bearing adjuster.
10. Lift the differential case assembly out of the gear carrier. CAUTION:
Keep side bearing outer races together with side bearing
inner races. Do not mix them up.
11. Remove side bearing inner race using Tools as shown. CAUTION:
 Do not remove side bearing inner race unless it is beingreplaced.
 Place copper plates between th e vise and the side bearing
inner race and drive gear to prevent damage.
 Engage puller jaws in groo ve to prevent damage to bear-
ing.
PDIA0700E
PDIA0701E
SDIA2230E
SPD527
Tool number A: ST33081000 ( — )
B: ST30021000 ( — )
SDIA2237E
Revision: December 20092009 QX56

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 Keep side bearing outer races together with si de bearing inner races. Do not mix them up.
12. For proper reinstallation, paint matching marks on the differential case and drive gear.
CAUTION:
Use paint for matching marks. Do not damage differential
case or drive gear.
13. Remove the drive gear bolts.
14. Tap the drive gear off the differential case using suitable tool. CAUTION:
Tap evenly all around to keep drive gear from bending.
15. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool.
16. Remove the pinion mate shaft.
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.
PDIA0496E
SPD025
SDIA0031J
SDIA0032J
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DLN-226
< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
 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 num-
bers of each drive pinion and drive gear before proceeding with assembly.
Bearing
 If bearings are chipped (by friction), pitted, worn, rust ed, scratched, or unusual noise is coming from bearing,
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 surf ace 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 unus ual wear are found, replace with new one.
Gear Carrier
 If any wear or cracks are found on the contac t 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.
1. Place the differential case straight up so that the side gear to be measured is upward.
PDIA0460E
Revision: December 20092009 QX56

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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 clearanc e 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 DLN-234, "Inspection and Adjustment"
.
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 individually.
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 assem-
bly.
 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 partic ular gear set. This dimension is controlled by a
selective drive pinion height adjusting washer between t he drive pinion rear bearing inner race and drive pin-
ion.
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 adjusting
washer thickness; increases the m ounting 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 0.08 mm (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 different 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
: Refer to
DLN-234, "Inspection
and Adjustment"
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 spec-
ification: Use a thinner side gear thrust washer.
PDIA0576E
SDIA2241E
Revision: December 20092009 QX56