Nissan Frontier D40. Manual - part 303

REAR FINAL DRIVE

DLN-233

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NOTE:
Side gear back clearance is clearance between side gear and differential case for adjusting side gear
backlash.

Side Bearing Preload Torque

• A selection of side bearing adjusting washers is required for successful completion of this procedure.

1.

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).

2.

Insert the left and right original side bearing adjusting washers in
place between side bearings and gear carrier using Tool.

3.

Align the matching mark on the side bearing cap with the match-
ing mark on the gear carrier.

4.

Install the side bearing caps and tighten the side bearing cap
bolts to the specified torque. Refer to 

DLN-224, "Disassembly

and Assembly"

.

5.

Turn the differential assembly several times to seat the side
bearings.

6.

To determine side bearing preload torque, measure the pulling
force of the differential assembly at the drive gear bolt using
Tool.

NOTE:
If pulling force of the differential assembly at the drive gear bolt
is within specification, side bearing preload torque will also be
within specification. Refer to 

DLN-224, "Disassembly and Assembly"

.

SPD527

Tool number

: KV38100600 (J-25267)

SPD709

SDIA1795E

Tool number

: 

—

 (J-8129)

Specification

Refer to 

DLN-243, "Inspection and Ad-

justment"

SPD194A

DLN-234

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REAR FINAL DRIVE

7.

If the pulling force is outside the specification, use a thicker or
thinner side bearing adjusting washer to adjust. Refer to 

DLN-

224, "Disassembly and Assembly"

.

CAUTION:

Select a side bearing adjusting washer for right and left
individually.

8.

Record the total amount of washer thickness required for the correct side bearing preload torque.

Drive Pinion Height

1.

Make sure all parts are clean and that the bearings are well
lubricated.

2.

Assemble the drive pinion bearings onto the Tool.

• Drive pinion front bearing; make sure the J-34309-3 drive

pinion front bearing seat is secured tightly against the J-
34309-2 gauge anvil. Then turn the J-34309-5 drive pinion
front bearing pilot to secure the drive pinion bearing in its
proper position.

• Drive pinion rear bearing; the J-34309-8 drive pinion rear

bearing pilot is used to center the drive pinion rear bearing
only. The J-34309-4 drive pinion rear bearing locking seat is
used to lock the drive pinion rear 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 drive pinion rear bearing inner race into the gear car-
rier. Then insert the drive pinion height adjusting washer selec-
tor tool, J-34309-1, gauge screw assembly.

If the pulling force is less than the specification:

Use a thicker side bearing adjusting washer.

If the pulling force is greater than the specification:

Use a thinner side bearing adjusting washer.

SPD772

Tool number

: 

—

 (J-34309)

SPD769

SPD197A

SPD893

REAR FINAL DRIVE

DLN-235

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4.

Assemble the drive pinion front bearing inner race and the J-
34309-2 gauge anvil. Assemble them together with the J-34309-
1 gauge screw in the gear carrier. Make sure that the drive pin-
ion height gauge plate, J-34309-16, will turn a full 360

°

. Tighten

the two sections together by hand.

5.

Turn the assembly several times to seat the drive pinion bear-
ings.

6.

Measure the turning torque at the end of the J-34309-2 gauge
anvil using Tool.

7.

Place the J-34309-11 drive 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, Tool, and arbor firmly into the
side bearing bores. Install the side bearing caps and tighten the
side bearing cap bolts to the specified torque. Refer to "

DLN-

224, "Disassembly and Assembly"

.

SPD199A

SPD770

Tool number

: ST3127S000 (J-25765- A)

Turning torque:

1.0 - 1.3 N·m (0.11 - 0.13 kg-m, 
9 - 11 in-lb)

PDIA0566E

SPD208A

Tool number

: 

—

 (J-25269-4)

SPD211A

DLN-236

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REAR FINAL DRIVE

9.

Select the correct standard drive pinion height adjusting washer
thickness. 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 drive pinion height adapter, including
the standard gauge and the arbor.

10. Write down the exact measurement (the value of feeler gauge).

11. Correct the drive pinion height adjusting washer size by referring

to the drive 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 drive pinion “head
number”. It refers to the ideal drive pinion height from stan-
dard for quietest operation. Use the following chart to
determine the correct drive pinion height adjusting washer.

12. Select the correct drive pinion height adjusting washer. Refer to 

DLN-224, "Disassembly and Assembly"

.

SPD204A

SPD775

Head number

Add or remove from the standard drive pinion 

height adjusting washer thickness measurement

- 6
- 5
- 4
- 3
- 2
- 1

0

+1
+2
+3
+4
+5 
+6

Add 0.06 mm (0.0024 in)
Add 0.05 mm (0.0020 in)
Add 0.04 mm (0.0016 in)
Add 0.03 mm (0.0012 in)
Add 0.02 mm (0.0008 in)
Add 0.01 mm (0.0004 in)

Use the selected washer thickness

Subtract 0.01 mm (0.0004 in)
Subtract 0.02 mm (0.0008 in)
Subtract 0.03 mm (0.0012 in)
Subtract 0.04 mm (0.0016 in)
Subtract 0.05 mm (0.0020 in)
Subtract 0.06 mm (0.0024 in)

SPD542