2010 INFINITI QX56 differential

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
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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 groove to prevent damage to bear- ing.
PDIA0700E
PDIA0701E
SDIA2230E
SPD527
Tool number A: ST33081000 ( — )
B: ST30021000 ( — )
SDIA2237E
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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 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 unus ual 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.
1. Place the differential case straight up so that the side gear to be measured is upward.
PDIA0460E
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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 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 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 center line 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 the 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 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 0.08 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
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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 fron t 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
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DLN-230
< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
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 suitable 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 pinionand 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 DLN-217, "
Disassembly and
Assembly".
• If the drive pinion bearin g preload torque exceeds the
specified value, replace collap sible 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 fo rth 2 to 3 times to check for unusual noise, rota-
tion malfunction, and other malfunctions.
11. Check companion flange runout.
12. Install the differential case 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 B: ST3127S000 (J-25765-A)
Drive pinion bearing preload torque
: Refer to DLN-234, "
Inspection and Adjust-
ment"
WDIA0382E
SDIA0193J
SDIA2025E
Revision: April 20092010 QX56