Nissan Pathfinder (2005 year). Manual - part 391

REAR FINAL DRIVE ASSEMBLY

RFD-29

RFD

2005 Pathfinder

10. Write down the 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.

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

RFD-37, "Pinion Height Adjusting Washer"

13. Remove the J-34309 differential shim selector tool from the final

drive housing. Then disassemble it to retrieve the pinion bear-
ings.

SPD775

Pinion head height number

Add or remove from the standard pinion height

adjusting washer thickness measurement

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

+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

SPD205A

RFD-30

REAR FINAL DRIVE ASSEMBLY

2005 Pathfinder

ASSEMBLY
Drive Pinion Assembly

Install the front and rear bearing outer races, using Tools.

CAUTION:

●

First tap the bearing outer race until it becomes flat to the
gear carrier.

●

Do not reuse pinion front and rear bearing outer race.

Select a drive pinion height adjusting washer. Refer to

RFD-27,

"Pinion Gear Height"

Install the selected drive pinion height adjusting washer to the
drive pinion. Press the pinion rear bearing inner race to it, using
Tool.

CAUTION:

●

Install the pinion height adjusting washer in the proper
direction as shown.

●

Do not reuse pinion rear bearing inner race.

Assemble the collapsible spacer to the drive pinion.

CAUTION:

Do not reuse collapsible spacer.

Apply gear oil to the pinion rear bearing, and assemble the drive
pinion into the gear carrier.

Apply gear oil to the pinon front bearing, and assemble the pin-
ion front bearing inner race to the drive pinion assembly.

CAUTION:

Do not reuse pinion front bearing inner race.

Tool number

A: ST30720000 (J-25405)

B: KV40105230 (

—

)

C: ST30611000 (J-25742-1)

D: ST30613000 (J-25742-3)

PDIA0562E

Tool number

: ST30901000 (J-26010-01)

SDIA0048E

PDIA0492E

REAR FINAL DRIVE ASSEMBLY

RFD-31

RFD

2005 Pathfinder

Press the pinion front bearing inner race to the drive pinion,
using suitable spacer. Press the pinion front bearing as far as
the drive pinion nut can be tightened.

Install the front oil seal, using Tool.

CAUTION:

●

Do not reuse oil seal.

●

Do not incline oil seal when installing.

●

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.

Install the companion flange.

NOTE:
When reusing the drive pinion, align the matching mark of the
drive pinion with the matching mark B of the companion flange,
then install the companion flange.

10. Apply anti-corrosive oil to the thread and seat of the drive pinion

lock nut. Temporarily tighten the drive pinion lock nut to the drive
pinion.

CAUTION:

Do not reuse drive pinion lock nut.

SPD896

Tool number

: ST30720000 (J-25405)

PDIA0563E

SDIA0270E

SDIA1144E

RFD-32

REAR FINAL DRIVE ASSEMBLY

2005 Pathfinder

11. Adjust the drive pinion lock nut tightening torque and pinion

bearing preload torque, using Tools.

CAUTION:

●

Adjust the lower limit of the drive pinion lock nut tightening torque first.

●

If the preload torque exceeds the specified value, replace the collapsible spacer and tighten it
again to adjust. Do not loosen the drive pinion lock nut to adjust the preload torque.

●

After adjustment, rotate the drive pinion back and forth 2 to 3 times to check for unusual noise,
rotation malfunction, and other malfunctions.

12. Install the differential case assembly. Refer to

RFD-32, "Differential Assembly"

CAUTION:

Do not install rear cover yet.

13. Check and adjust the drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion

flange runout. Refer to

RFD-17, "Drive Gear Runout"

RFD-18, "Tooth Contact"

RFD-19, "Backlash"

RFD-20, "Companion Flange Runout"

Recheck the above items.

14. Install the rear cover. Refer to

RFD-32, "Differential Assembly"

15. Check the total preload torque. Refer to

RFD-17, "Total Preload Torque"

Differential Assembly

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.

Install the side gears and thrust washers into the differential
case.

CAUTION:

Make sure that the circlip is installed to side gears.

Install the thrust washers to the two pinion mate gears. Then
install the pinion mate gears with the thrust washers by aligning
them in diagonally opposite positions and rotating them into the
differential case.

Tool number

A: KV40104000 (

—

)

B: ST3127S000 (J-25765-A)

Drive pinion lock nut tightening torque:

147 - 323 N·m (15 - 32 kg-m, 109 - 238 ft-lb)

Drive pinion bearing preload:

2.65 - 3.23 N·m (0.27 - 0.32 kg-m, 24 - 28 in-lb)

SPD884

SDIA0193J

SDIA2025E

REAR FINAL DRIVE ASSEMBLY

RFD-33

RFD

2005 Pathfinder

Align the lock pin holes on the differential case with the shaft,
and install the pinion mate shaft.

Measure the side gear end play. If necessary, select the appro-
priate side gear thrust washers. Refer to

RFD-25, "Differential

Side Gear Clearance"

Drive a lock pin into the pinion mate shaft. Make sure the lock
pin is flush with the differential case.

CAUTION:

Do not reuse lock pin.

Align the matching mark of the differential case with the mark of
the drive gear, then place the drive gear onto the differential
case.

Apply thread locking sealant into the threaded holes of the drive
gear, and install the bolts.

●

Use Genuine Medium Strength Thread Locking Sealant or
equivalent. Refer to

GI-45, "Recommended Chemical

Products and Sealants"

CAUTION:

Make sure the drive gear back and threaded holes are
clean.

Tighten the drive gear bolts to the specified torque. Refer to

RFD-16, "COMPONENTS"

CAUTION:

●

Tighten bolts in a crisscross pattern.

●

After tightening the bolts to the specified torque, tighten
the bolts an additional 31 to 36 degrees.

SDIA0195J

WDIA0131E

SDIA2593E

SDIA2594E

SDIA0247J

RFD-34

REAR FINAL DRIVE ASSEMBLY

2005 Pathfinder

10. Press the side bearing inner races into the differential case,

using Tools.

CAUTION:

Do not reuse side bearing inner race.

11. Install the differential case assembly with the side bearing outer

races into the gear carrier.

12. Measure the side bearing preload. If necessary, select the

appropriate side bearing adjusting washers. Refer to

RFD-25,

"Side Bearing Preload"

13. Insert the selected left and right side bearing adjusting washers

in place between the side bearings and gear carrier.

14. Align the matching mark on the bearing cap with the matching

mark on the gear carrier.

15. Install the bearing caps. Tighten the bearing cap bolts to the

specified torque. Refer to

RFD-16, "COMPONENTS"

16. Drive in the side oil seals until they become flush with the case

end, using Tool.

CAUTION:

●

Do not reuse oil seal.

●

Do not incline oil seal when installing.

●

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.

Tool number

A: KV38100300 (J-25523)

B: ST33061000 (J-8107-2)

SPD353

SPD919

SPD924

SDIA1795E

Tool number

: KV38100200 (J-26233)

SPD560

REAR FINAL DRIVE ASSEMBLY

RFD-35

RFD

2005 Pathfinder

17. Check and adjust the drive gear runout, tooth contact, drive gear to drive pinion backlash, and total pre-

load torque. Refer to

RFD-17, "Drive Gear Runout"

RFD-18, "Tooth Contact"

RFD-19, "Backlash"

RFD-17, "Total Preload Torque"

Recheck the above items.

18. Apply a 3.2mm (0.126 in) bead of sealant to the mating surface

of the rear cover. Use Genuine Silicone RTV or equivalent.
Refer to

GI-45, "RECOMMENDED CHEMICAL PRODUCTS

AND SEALANTS"

CAUTION:

Remove any old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the application and mounting surfaces.

19. Install the rear cover onto the gear carrier. Tighten the bolts to

the specified torque. Refer to

RFD-16, "COMPONENTS"

20. Install the side flanges using the following procedure.

Attach the Tool to the side oil seal.

After the side flange is inserted and the serrated part of the side
flange has engaged the serrated part of the side gear, remove
the Tool.

Drive in the side flange.

NOTE:
Installation is completed when the driving sound of the side
flange turns into a sound which seems to affect the whole final
drive.

SDIA0970E

Tool number

: KV38107900 (J-39352)

SDIA0822E

RFD-36

SERVICE DATA AND SPECIFICATIONS (SDS)

2005 Pathfinder

SERVICE DATA AND SPECIFICATIONS (SDS)

PFP:00030

General Specifications

EDS001MD

Inspection and Adjustment

EDS001ME

DRIVE GEAR RUNOUT

Unit: mm (in)

DIFFERENTIAL SIDE GEAR CLEARANCE

Unit: mm (in)

PRELOAD TORQUE

Unit: N·m (kg-m, in-lb)

BACKLASH

Unit: mm (in)

COMPANION FLANGE RUNOUT

Unit: mm (in)

SELECTIVE PARTS
Side Gear Thrust Washer

Unit: mm (in)

*: Always check with the Parts Department for the latest parts information.

Engine

VQ40DE

Axle type

2WD

4WD

Final drive model

R200

Gear ratio

3.133

3.357

Number of teeth (Drive gear/Drive pinion)

47/15

47/14

Oil capacity (Approx.)

(US pt, lmp pt)

1.4 (3, 2-1/2)

Number of pinion gears

Drive pinion adjustment spacer type

Collapsible

Item

Runout limit

Drive gear back face

0.05 (0.0020) or less

Item

Specification

Side gear backlash (Clearance between side gear and differential
case)

0.2 (0.008) or less

(Each gear should rotate smoothly without excessive resistance

during differential motion.)

Item

Specification

Pinion bearing (P

)

2.65 - 3.23 (0.27 - 0.32, 24 - 28)

Side bearing (P

)

0.20 - 0.52 (0.02 - 0.05, 2 - 4)

Side bearing to pinion bearing (Total preload)
(Total preload = P

+ P

)

2.84 - 3.75 (0.29 - 0.38, 26 - 33)

Item

Specification

Drive gear to drive pinion gear

0.10 - 0.15 (0.0039 - 0.0059)

Item

Runout limit

Outer side of the companion flange

0.08 (0.0031) or less

Thickness

Part number*

Thickness

Part number*

0.75 (0.0295)
0.78 (0.0307)
0.81 (0.0319)
0.84 (0.0331)

38424 0C000
38424 0C001
38424 0C002
38424 0C003

0.87 (0.0343)
0.90 (0.0350)
0.93 (0.0366)

38424 0C004
38424 0C005
38424 0C006

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