Nissan Pathfinder (2009 year). Manual - part 243

DLN-426

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

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-432, "Inspection and Adjustment"

13. Remove the Tool from the gear carrier and disassemble to

retrieve the drive pinion bearings.

ASSEMBLY

Drive Pinion Assembly

SPD775

Head number

Add or remove from the standard drive 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)

Tool number

—

(J-34309)

SPD542

SPD205A

2009 Pathfinder

REAR FINAL DRIVE

DLN-427

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

Install the drive pinion front and rear bearing outer races using
Tools.

CAUTION:

• First tap the drive pinion bearing outer race until it

becomes flush with the gear carrier.

• Do not reuse drive pinion front and rear bearing outer

race.

Select a drive pinion height adjusting washer. Refer to

DLN-413, "Disassembly and Assembly"

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

CAUTION:

• Install the drive pinion height adjusting washer in the

proper direction as shown.

• Do not reuse drive pinion rear bearing inner race.

Assemble the collapsible spacer to the drive pinion.

CAUTION:

Do not reuse collapsible spacer.

Apply differential gear oil to the drive pinion rear bearing, and
install the drive pinion assembly to the gear carrier.

Apply differential gear oil to the drive pinion front bearing, and
install the drive pinion front bearing inner race to the drive pinion
assembly.

CAUTION:

Do not reuse drive 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

2009 Pathfinder

DLN-428

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

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

Apply multi-purpose grease to the lips and differential gear oil to
the circumference of the new front oil seal. Then drive the new
front oil seal in evenly until it becomes flush with the gear carrier
using Tool.

CAUTION:

• Do not reuse front oil seal.
• Do not incline the new front oil seal when installing.
• Apply multi-purpose grease to the lips and differential

gear oil to the circumference of the new front oil seal.

Install the companion flange to the drive pinion while aligning the matching marks.

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

seating surface of the new drive pinion lock nut. Then adjust the
drive pinion lock nut tightening torque using Tool A, and check
the drive pinion bearing preload torque using Tool B.

CAUTION:

• Do not reuse drive pinion lock nut.
• Apply anti-corrosive oil to the threads of the drive pinion

and the seating surface of the new drive pinion lock nut.

• Adjust the drive pinion lock nut tightening torque to the

lower limit first. Do not exceed the drive pinion lock nut
specified torque. Refer to

DLN-413, "Disassembly and

Assembly"

• If the drive pinion bearing preload torque exceeds the

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

• After adjustment, rotate drive pinion back and forth 2 to 3

times to check for unusual noise, rotation malfunction, and other malfunctions.

11. Check companion flange runout. Refer to

DLN-413, "Disassembly and Assembly"

12. Install the differential case assembly. Refer to

DLN-410, "Removal and Installation"

Differential Assembly

SPD896

Tool number

: ST30720000 (J-25405)

PDIA0563E

Tool number

A: KV40104000 (

—

)

B: ST3127S000 (J-25765-A)

Drive pinion bearing preload torque:

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

WDIA0379E

2009 Pathfinder

REAR FINAL DRIVE

DLN-429

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

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 side gear thrust washers into the dif-
ferential case.

CAUTION:

Make sure that the circular clip is installed to side gears.

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

Align the lock pin hole on the differential case with the lock pin
hole on the pinion mate 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

DLN-432, "Inspection

and Adjustment"

Drive a new lock pin into the pinion mate shaft until it is flush
with the differential case using suitable tool.

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.

SDIA0193J

SDIA2025E

SDIA0195J

WDIA0131E

SDIA2593E

2009 Pathfinder

DLN-430

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

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-26, "Recommended Chemical Prod-

ucts 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

DLN-413, "Disassembly and Assembly"

. After tightening the

drive gear bolts to the specified torque, tighten an additional 31

to 36

using Tool.

CAUTION:

• Always use Tool. Avoid tightening based on visual check

alone.

• Tighten drive gear bolts in a crisscross pattern.

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 torque. If necessary, select

the appropriate side bearing adjusting washers. Refer to

DLN-

413, "Disassembly and Assembly"

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

in place between the side bearings and gear carrier.

SDIA2594E

Tool number

: KV10112100-A (BT-8653-A)

AWBIA0722ZZ

Tool number

A: KV38100300 (J-25523)

B: ST33061000 (J-8107-2)

SPD353

SPD919

SPD924

2009 Pathfinder

REAR FINAL DRIVE

DLN-431

< DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

DLN

14. Install the side bearing caps with the matching marks aligned

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

DLN-413, "Disassembly and Assembly"

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

load torque. Refer to

DLN-432, "Inspection and Adjustment"

Recheck the above items.

16. Install the side flanges. Refer to

DLN-413, "Disassembly and Assembly"

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

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

GI-26,

CAUTION:

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

18. Install the carrier cover to the gear carrier. Tighten the bolts to

the specified torque. Refer to

DLN-413, "Disassembly and

Assembly"

19. Install the side flange. Refer to

DLN-413, "Disassembly and

Assembly"

Side Flange

Apply multi-purpose grease to the lips and differential gear oil to
the circumference of the new side oil seal. Then drive the new
side oil seal in evenly until it becomes flush with the gear carrier
using Tool.

CAUTION:

• Do not reuse side oil seal.
• Do not incline the new side oil seal when installing.
• Apply multi-purpose grease to the lips and differential

gear oil to the circumference of the new side oil seal.

Install the side flange using Tool.

Install the Tool to the side oil seal as shown.

Insert the side flange until the serrated part of the side flange
has engaged the serrated part of the side gear and remove the
Tool.

Drive in the side flange using suitable tool.
NOTE:
Installation is completed when the driving sound of the side
flange turns into a sound which seems to affect the whole rear
final drive assembly.

SPD889

WDIA0282E

Tool number

: KV38100200 (J-26233)

SPD560

Tool number

: KV38107900 (J-39352)

SDIA0822E

2009 Pathfinder

DLN-432

< SERVICE DATA AND SPECIFICATIONS (SDS)

[REAR FINAL DRIVE: R200]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specification

INFOID:0000000003937463

Inspection and Adjustment

INFOID:0000000003937464

DRIVE GEAR RUNOUT

Unit: mm (in)

SIDE GEAR CLEARANCE

Unit: mm (in)

PRELOAD TORQUE

BACKLASH

Unit: mm (in)

COMPANION FLANGE RUNOUT

Unit: mm (in)

SELECTIVE PARTS

Side Gear Thrust Washer

Applied model

VQ40DE

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.)

1.4

(3 US pt, 2-1/2 lmp pt)

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 back clearance
(Clearance between side gear and differential case for adjusting
side gear backlash)

0.2 (0.008) or less

(Each gear should rotate smoothly without excessive resistance

during differential motion.)

Item

Specification

Drive pinion bearing preload torque

2.65 - 3.23 N·m (0.27 - 0.32 kg

−

m, 24 - 28 in-lb)

Side bearing preload torque (reference value determined by drive
gear bolt pulling force)

0.20 - 0.52 N·m (0.02 - 0.05 kg

−

m, 2 - 4 in-lb)

Drive gear bolt pulling force (by spring gauge)

34.2

−

39.2 N (3.5

−

4 kg, 7.7

−

8.8 lb)

Total preload torque
(Total preload torque = drive pinion bearing preload torque + Side
bearing preload torque)

2.84 - 3.75 N·m (0.29 - 0.38 kg

−

m, 26 - 33 in-lb)

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

2009 Pathfinder

SERVICE DATA AND SPECIFICATIONS (SDS)

DLN-433

< SERVICE DATA AND SPECIFICATIONS (SDS)

[REAR FINAL DRIVE: R200]

DLN

Unit: mm (in)

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

Drive Pinion Height Adjusting Washer

Unit: mm (in)

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

Side Bearing Adjusting Washer

Unit: mm (in)

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

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

Thickness Part

number*

Thickness Part

number*

3.05 (0.1201)
3.08 (0.1213)

3.11 (0.1224)

3.14 (0.1236)

38154 0C000
38154 0C001
38154 0C002
38154 0C003

3.17 (0.1248)
3.20 (0.1260)
3.23 (0.1272)
3.26 (0.1283)

38154 0C004
38154 0C005
38154 0C006
38154 0C007

Thickness

Part number*

Thickness

Part number*

2.00 (0.0787)
2.05 (0.0807)
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
2.25 (0.0886)
2.30 (0.0906)

38453 N3100
38453 N3101
38453 N3102
38453 N3103
38453 N3104
38453 N3105
38453 N3106

2.35 (0.0925)
2.40 (0.0945)
2.45 (0.0965)
2.50 (0.0984)
2.55 (0.1004)
2.60 (0.1024)
2.65 (0.1043)

38453 N3107
38453 N3108
38453 N3109

38453 N3110

38453 N3111

38453 N3112
38453 N3113

2009 Pathfinder

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