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Nissan Pathfinder (2005 year). Manual - part 390

REAR FINAL DRIVE ASSEMBLY

RFD-21

RFD

2005 Pathfinder

Remove the bearing caps.

Lift the differential case assembly out, using suitable tool.

CAUTION:

●

Keep side bearing outer races together with inner race.
Do not mix them up.

●

Keep side bearing adjusting washers together with bear-
ings.

S-PD343

PDIA0547E

SPD919

RFD-22

REAR FINAL DRIVE ASSEMBLY

2005 Pathfinder

Remove the side bearing inner race, using Tools.

CAUTION:

●

Engage Tool jaws in bearing groove to prevent damage.

●

Place copper plates between the side bearing and drive
gear and the vise to prevent damage.

●

Do not remove side bearing inner race unless it is being
replaced.

10. For proper reinstallation, paint a matching mark on one side of

the differential case assembly.

CAUTION:

Use paint for matching mark. Do not damage differential
case or drive gear.

11. Remove the drive gear bolts.

12. Tap the drive gear off the differential case assembly.

CAUTION:

Tap evenly all around to keep drive gear from bending.

13. Remove the lock pin of the pinion mate shaft from the drive gear

side.

14. Remove the pinion mate shaft.

Tool number

A: ST33051001 (J-22888-20)

B: ST33061000 (J-8107-2)

SPD920

PDIA0496E

WDIA0132E

SDIA0031J

REAR FINAL DRIVE ASSEMBLY

RFD-23

RFD

2005 Pathfinder

15. 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

Remove the differential assembly. Refer to

RFD-20, "Differential Assembly"

Remove the drive pinion lock nut, using Tool.

Put a matching mark on the end of the drive pinion in line with
the matching mark B on the companion flange.

CAUTION:

Use paint for matching mark. Do not damage companion
flange or drive pinion.

NOTE:
The matching mark B on the final drive companion flange indi-
cates the maximum vertical runout position.
When replacing the companion flange, a matching mark is not
necessary.

Remove the companion flange, using suitable tool.

SDIA0032J

Tool number

: KV40104000 (

—

)

SDIA1144E

SDIA0270E

SDIA1132E

RFD-24

REAR FINAL DRIVE ASSEMBLY

2005 Pathfinder

Press the drive pinion assembly out of the gear carrier.

CAUTION:

Do not drop drive pinion assembly.

Remove the front oil seal.

Remove the side oil seal.

Remove the pinion front bearing inner race.

Remove the collapsible spacer.

10. Remove the pinion rear bearing inner race and drive pinion

height adjusting washer, using Tool.

11. Remove the pinion front/rear bearing outer races by tapping

them uniformly.

CAUTION:

Do not damage gear carrier.

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.

SPD892

Tool number

: ST30031000 (J-22912-01)

S-PD179

SDIA0817E

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.

REAR FINAL DRIVE ASSEMBLY

RFD-25

RFD

2005 Pathfinder

ADJUSTMENT AND SELECTION ADJUSTING WASHERS
Differential Side Gear Clearance

●

Assemble the differential parts if they are disassembled. Refer to

RFD-32, "Differential Assembly"

Place the differential case straight up so that the side gear to be
measured is upward.

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.)

CAUTION:

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

If the back clearance is outside of the specification, use a
thicker/thinner side gear thrust washer to adjust. Refer to

RFD-

36, "Side Gear Thrust Washer"

CAUTION:

Select a side gear thrust washer for right and left individu-
ally.

Side Bearing Preload

●

A selection of carrier side bearing adjusting washers is required for successful completion of this proce-
dure.

Make sure all parts are clean and the bearings are well lubri-
cated with gear oil.

Place the differential case, with the side bearings and bearing
races installed, into the gear carrier.

PDIA0460E

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 greater than specification:

Use a thicker thrust washer.

When the back clearance is less than specification:

Use a thinner thrust washer.

PDIA0576E

SPD527

RFD-26

REAR FINAL DRIVE ASSEMBLY

2005 Pathfinder

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

Install the bearing caps in their correct locations. Tighten the
bearing cap bolts to the specified torque. Refer to

RFD-16,

"COMPONENTS"

Turn the carrier several times to seat the bearings.

Measure the turning torque of the carrier at the drive gear bolts,
using Tool.

If the turning torque is outside the specification, use a thicker/
thinner side bearing adjusting washer to adjust. Refer to

RFD-

37, "Side Bearing Adjusting Washer"

CAUTION:

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

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

SPD924

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 specification:

Use a thicker thrust washer.

If the turning torque is greater than the specification:

Use a thinner thrust washer.

SPD772

REAR FINAL DRIVE ASSEMBLY

RFD-27

RFD

2005 Pathfinder

Pinion Gear Height

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

Assemble the pinion gear bearings into the Tool.

●

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 bear-
ing 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).

Install the pinion rear bearing inner race into the gear carrier.
Then insert the pinion preload shim selector tool, J-34309-1
gauge screw assembly.

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 the 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.

Tool number

—

(J-34309)

SPD769

SPD197A

SPD893

SPD199A

RFD-28

REAR FINAL DRIVE ASSEMBLY

2005 Pathfinder

Turn the assembly several times to seat the bearings.

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

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.

Position the side bearing discs, Tool, and arbor firmly into the
side bearing bores. Install the bearing caps and tighten the bear-
ing cap bolts to the specified torque. Refer to

RFD-16, "COM-

PONENTS"

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.

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

SPD208A

Tool number

—

(J-25269-4)

SPD211A

SPD204A

Content .. 388 389 390 391 ..