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Nissan Pathfinder (2008 year). Manual - part 229

DLN-416

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

Backlash

Fit a dial indicator to the drive gear face to measure the back-
lash.

• If the backlash is outside of the specification, change the thickness

of the side bearing adjusting washers.

CAUTION:

Do not change the total thickness of side bearing adjusting washers as it will change the side bearing
preload torque.

Companion Flange Runout

Rotate companion flange and check for runout on the outer face
of the companion flange using suitable tool.

If the runout is outside of the runout limit, follow the procedure
below to adjust.

Rotate the companion flange on the drive pinion by 90

, 180

and 270

while checking for the position where the runout is

minimum.

If the runout is still outside of the runout limit after the companion
flange has been rotated on the drive pinion, possible cause
could be an assembly malfunction of drive pinion and drive pinion bearing or a malfunctioning drive pinion
bearing.

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

Side Flange

Drain the differential gear oil if necessary.

Remove the side flange using Tools.

NOTE:
Circular clip installation position: Rear final drive side

Remove the side oil seal using suitable tool.

CAUTION:

Do not to damage gear carrier.

Differential Assembly

Remove the side flanges. Refer to

DLN-407, "Removal and Installation"

Backlash:

0.10 - 0.15 mm (0.0039 - 0.0059 in)

If the backlash is greater than specification:

Make side bearing adjusting washer thicker on drive
gear back side, and side bearing adjusting washer
thinner on drive gear tooth side by the same amount.
Refer to

DLN-413, "Disassembly and Assembly"

If the backlash is less than specification:

Make side bearing adjusting washer thinner on drive
gear back side, and side bearing adjusting washer
thicker on drive gear tooth side by the same amount.
Refer to

DLN-413, "Disassembly and Assembly"

SPD513

Runout limit

: 0.08 mm (0.0031 in) or less

WDIA0231E

Tool numbers

A: KV40104100 (

—

)

B: ST36230000 (J-25840-A)

REAR FINAL DRIVE

DLN-417

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

Remove the carrier cover bolts.

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 screwdriver, this will damage the

mating surface.

Mount the carrier on the Tool using two 45 mm (1.77 in) spacers.

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 reinstall them in their original
positions.

Remove the side bearing caps.

Tool number

: KV10111100 (J-37228)

WDIA0123E

Tool number

: KV38100800 (J-25604-01)

SPD888

SDIA1795E

S-PD343

DLN-418

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

Lift the differential case assembly out using Tool.

CAUTION:

• Keep side bearing outer races together with inner race.

Do not mix them up.

• Keep side bearing adjusting washers together with side

bearings.

Remove the side bearing inner races 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.

Tool number

: HT72400000 (

—

)

S-PD344

SPD919

Tool number

A: ST33051001 (J-22888-20)

B: ST33061000 (J-8107-2)

SPD920

REAR FINAL DRIVE

DLN-419

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

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.

10. Remove the drive gear bolts.

11. Tap the drive gear off the differential case using suitable tool.

CAUTION:

Tap evenly all around to keep drive gear from bending.

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

side using suitable tool.

13. Remove the pinion mate shaft.

14. 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

DLN-410, "Removal and Installation"

PDIA0496E

WDIA0132E

SDIA0031J

SDIA0032J

DLN-420

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

Remove the drive pinion lock nut using Tool.

Put matching marks on the companion flange and drive pinion
using paint.

CAUTION:

Use paint to make the matching marks. Do not damage the
companion flange or drive pinion.

Remove the companion flange using suitable tool.

Press the drive pinion assembly (with rear inner bearing race
and collapsible spacer) out of the gear carrier.

CAUTION:

Do not drop drive pinion assembly.

Remove the front oil seal.

CAUTION:

Do not damage gear carrier.

Remove the drive pinion front bearing inner race.

Remove the drive pinion rear bearing inner race and drive pinion
height adjusting washer using Tool.

Remove the drive pinion front and rear bearing outer races by
tapping them uniformly using suitable tool.

CAUTION:

Do not damage gear carrier.

Tool number

: KV40104000 (

—

)

SDIA1144E

SDIA1132E

SPD892

Tool number

: ST30031000 (J-22912-01)

S-PD179

SDIA0817E

REAR FINAL DRIVE

DLN-421

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

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.

Drive Pinion and Drive Gear

• If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust,

repair, or replace as necessary.

• If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably,

replace with new drive pinion and drive gear.

• 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, rusted, 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 unusual 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. Refer to

DLN-413, "Disassembly and Assembly"

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

PDIA0460E

DLN-422

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

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-432, "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 individu-

ally.

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).

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

Side gear back clearance:

0.2 mm (0.008 in) or less.

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

SPD527

SPD924

REAR FINAL DRIVE

DLN-423

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

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

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

DLN-413, "Disassembly

and Assembly"

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

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-432, "Inspection and Adjustment"

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

DLN-

432, "Inspection and Adjustment"

CAUTION:

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

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

Drive Pinion Height

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

Assemble the drive pinion bearings onto the Tool.

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 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

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