Nissan Pathfinder (2009 year). Manual - part 233

DLN-346

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

ASSEMBLY INSPECTION AND ADJUSTMENT

• Drain the differential gear oil before inspection and adjustment. Refer to 

DLN-338

.

• Remove and install the carrier cover as necessary for inspection and adjustment. Refer to 

DLN-342

.

Total Preload Torque

1.

Install the differential side shaft if necessary. Refer to 

DLN-341, "Removal and Installation"

.

CAUTION:

The differential side shaft must be installed in order to measure total preload torque. 

2.

Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.

3.

Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.

4.

Measure total preload torque using Tool.

NOTE:
Total preload torque = Drive pinion bearing preload torque +
Side bearing preload torque

• If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion

bearing preload torque first, then adjust the side bearing preload torque.

CAUTION:

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

Drive Gear Runout

1.

Fit a dial indicator to the drive gear back face.

2.

Rotate the drive gear to measure runout.

• If the runout is outside of the limit, check the condition of the drive

gear assembly. Foreign material may be caught between the drive
gear and differential case, or the differential case or drive gear may
be deformed.

CAUTION:

Replace drive gear and drive pinion as a set.

Tooth Contact

28. Housing spacer

29. Side bearing cap

30. Filler plug

31. Carrier cover

Tool number

: ST3127S000 (J-25765-A)

Total preload torque:

1.67 - 2.74 N·m (0.17 - 0.27 kg-m, 15 - 24 in-lb)

PDIA0697E

If the total preload torque is greater than specification

On drive pinion bearings:

Replace the collapsible spacer.

On side bearings:

Use thinner side bearing adjusting washers by the same 
amount on each side. Refer to 

DLN-364, "Inspection and Adjust-

ment"

.

If the total preload torque is less than specification

On drive pinion bearings:

Tighten the drive pinion lock nut.

On side bearings:

Use thicker side bearing adjusting washers by the same 
amount on each side. Refer to 

DLN-364, "Inspection and Adjust-

ment"

.

Runout limit:

0.08 mm (0.0031 in) or less

SPD886

2009 Pathfinder

FRONT FINAL DRIVE

DLN-347

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

1.

Apply red lead to the drive gear.
NOTE:
Apply red lead to both faces of three to four gears, at four loca-
tions evenly spaced on the drive gear.

2.

Rotate the drive gear back and forth several times. Then check
for correct drive pinion to drive gear tooth contact as shown.

CAUTION:

Check tooth contact on drive side and reverse side.

• If the tooth contact is improperly adjusted, adjust the drive pin-

ion height (dimension X).

- If the tooth contact is near the face (face contact), or near the

heel (heel contact), use a thicker drive pinion height adjusting
washer to move drive pinion closer to the drive gear.
Refer to 

DLN-364, "Inspection and Adjustment"

.

SPD357

SDIA0570E

SDIA0517E

PDIA0440E

2009 Pathfinder

DLN-348

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

- If the tooth contact is near the flank (flank contact), or near the

toe (toe contact), use a thinner drive pinion height adjusting
washer to move the drive pinion farther from the drive gear.
Refer to 

DLN-364, "Inspection and Adjustment"

.

Backlash

1.

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

• If the backlash is outside of the specification, change the thick-

ness 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

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 after the companion
flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pin-
ion and drive pinion bearing or a malfunctioning 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 side shaft

1.

Drain the differential gear oil if necessary.

PDIA0441E

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-364, "Inspection and Adjustment"

.

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-364, "Inspection and Adjustment"

.

SPD513

Runout limit:

0.1 mm (0.004 in) or less

SDIA2078E

2009 Pathfinder

FRONT FINAL DRIVE

DLN-349

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

2.

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.

3.

Remove side oil seal.

CAUTION:

Do not damage gear carrier.

4.

Remove snap ring (hole side) using suitable tool.

5.

Remove differential side shaft assembly out of gear carrier using
suitable tool.
NOTE:
Tap on differential side shaft assembly from side gear side.

6.

Remove snap ring (differential side shaft side).

7.

Press differential side shaft out of differential side shaft bearing.

CAUTION:

Do not drop differential side shaft.

Tool number

: KV10111100 (J-37228)

PDIA0699E

PDIA0713E

PDIA0714E

PDIA0715E

PDIA0718E

2009 Pathfinder

DLN-350

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

Differential Assembly

1.

Remove differential side shaft assembly. Refer to 

DLN-341, "Removal and Installation"

.

2.

Remove side seal from gear carrier using suitable tool.

3.

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.

4.

Remove the side bearing caps.

5.

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.

• Keep side bearing adjusting washers together with side

bearings.

6.

Remove housing spacer.

7.

Remove side bearing inner race using Tools as shown.

CAUTION:

• Do not remove side bearing inner race unless it is being

replaced.

• Place copper plates between the vise and the side bearing

inner race and drive gear to prevent damage.

PDIA0700E

PDIA0701E

SPD919

Tool number

 A: ST33051001 (J-22888-20)

 B: ST33061000 (J-8107-2)

PDIA0827E

2009 Pathfinder

FRONT FINAL DRIVE

DLN-351

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

• Keep side bearing outer races together with side bearing

inner races. Do not mix them up.

8.

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.

9.

Remove the drive gear bolts.

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

CAUTION:

Tap evenly all around to keep drive gear from bending.

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

side using suitable tool.

12. Remove the pinion mate shaft.

13. 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.

SPD022

PDIA0496E

SPD025

SDIA0031J

SDIA0032J

2009 Pathfinder

DLN-352

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

Drive Pinion Assembly

1.

Remove the differential assembly. Refer to 

DLN-345, "Disassembly and Assembly"

.

2.

Remove the drive pinion lock nut using Tool.

3.

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.

4.

Remove the companion flange using suitable tool.

5.

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.

6.

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

Tool number

: KV38108300 (J-44195)

PDIA0702E

PDIA0703E

PDIA0704E

Tool number

: ST30031000 (J-22912-01)

S-PD179

2009 Pathfinder

FRONT FINAL DRIVE

DLN-353

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

7.

Remove the front oil seal using suitable tool.

CAUTION:

Do not damage gear carrier.

8.

Remove the drive pinion front bearing inner race.

9.

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

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.

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-345, "Disassembly and Assembly"

.

PDIA0716E

PDIA0705E

2009 Pathfinder