Nissan Pathfinder (2011 year). Manual - part 237

DLN-434

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

8. 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.

9. 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.

Tool number  A: ST33051001 (J-22888-20)

 B: ST33061000 (J-8107-2)

SPD920

PDIA0496E

WDIA0132E

SDIA0031J

2011 Pathfinder

REAR FINAL DRIVE

DLN-435

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

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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

1. Remove the differential assembly. Refer to 

DLN-425, "Removal and Installation"

.

2. Remove the drive pinion lock nut using suitable 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 front oil seal.

CAUTION:

Do not damage gear carrier.

7. Remove the drive pinion front bearing inner race.

SDIA0032J

SDIA1144E

SDIA1132E

SPD892

2011 Pathfinder

DLN-436

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

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

height adjusting washer using Tool.

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-428, "Exploded View"

.

Tool number

: ST30031000 (J-22912-01)

S-PD179

SDIA0817E

2011 Pathfinder

REAR FINAL DRIVE

DLN-437

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[REAR FINAL DRIVE: R200]

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1. Place the differential case straight up so that the side gear to be

measured is upward.

2. 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-447, "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 individually.

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).

PDIA0460E

Side gear back clearance: Refer to 

DLN-447, "Inspec-

tion and Adjustment"

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

2011 Pathfinder

DLN-438

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

2. Insert the left and right original side bearing adjusting washers in

place between side bearings and gear carrier.

3. Align the matching mark on the side bearing cap with the match-

ing mark on the gear carrier.

4. Install the side bearing caps and tighten the side bearing cap

bolts to the specified torque. Refer to 

DLN-428, "Exploded

View"

.

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

bearings.

6. 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-447, "Inspection and Adjustment"

.

7. If the pulling force is outside the specification, use a thicker or

thinner side bearing adjusting washer to adjust. Refer to 

DLN-

447, "Inspection and Adjustment"

.

CAUTION:

Select a side bearing adjusting washer for right and left

individually.

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

Drive Pinion Height

If the hypoid gear has been replaced, select the drive pinion height adjusting washer.

SPD924

SDIA1795E

Tool number

: 

—

 (J-8129)

Specification

Refer to 

DLN-447, "Inspection and Ad-

justment"

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

2011 Pathfinder

REAR FINAL DRIVE

DLN-439

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

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1. Use the formula below to calculate drive pinion height adjusting

washer thickness.

2. Select the proper drive pinion height adjusting washer. For selecting adjusting washer, refer to 

DLN-447,

"Inspection and Adjustment"

.

CAUTION:

If unable to find a washer of desired thickness, use a washer with thickness closest to the calcu-

lated value.

ASSEMBLY

Drive Pinion Assembly

1. Install drive pinion front bearing outer race (1) and rear bearing

outer race (2) 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.

Washer selection equation:
T = T

0

 + (t

1 

−

 t2

)

T:

Correct washer thickness

T

0:

Removed washer thickness

t

1:

Old drive pinion head letter “H 

×

 0.01”

(“H”: machined tolerance 1/100 mm 

×

 100)

t

2

:

New drive pinion head letter “H 

×

 0.01”

(“H”: machined tolerance 1/100 mm 

×

 100)

Example:
T = 3.21 + [(2 

×

 0.01) 

−

 (–1 

×

 0.01)] = 3.24

T

0:

3.21

t

1:

+2

t

2

:

–1

Example:

Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm

SDIA0249J

Tool number

(A): ST30720000 (J-25405)
(B): KV40105230 ( — )
(C): ST30611000 (J-25742-1)
(D): ST30613000 (J-25742-3)

PDIA0761J

2011 Pathfinder

DLN-440

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

2. Temporarily install drive pinion height adjusting washer (1).
a. When hypoid gear set has been replaced.

• Select drive pinion height adjusting washer. Refer to 

DLN-429,

"Disassembly and Assembly"

.

b. When hypoid gear set has been reused.

• Temporarily install the removed drive pinion height adjusting

washer or same thickness washer to drive pinion.

CAUTION:

Pay attention to the direction of drive pinion height adjust-

ing washer. (Assemble as shown in the figure.)

3. Install drive pinion rear bearing inner race (1) to drive pinion

using Tool (A).

CAUTION:

Do not reuse drive pinion rear bearing inner race.

4. Check and adjust the tooth contact and back lash of drive gear

and drive pinion following the procedure below.

a. Assemble drive pinion into gear carrier.

CAUTION:

• Do not install collapsible spacer at this time.

• Apply gear oil to drive pinion rear bearing.

b. Assemble drive pinion front bearing inner race to drive pinion assembly.

CAUTION:

• Do not reuse drive pinion front bearing inner race.

• Apply gear oil to drive pinion front bearing.

c.

Press the drive pinion front bearing inner race to drive pinion as

far as drive pinion lock nut can be tightened, using suitable

spacer (A).

d. Install companion flange.

CAUTION:

Do not install front oil seal at this time.

NOTE:

When reusing drive pinion, align the matching mark (B) of drive

pinion with the matching mark (A) of companion flange, and then

install companion flange (1).

JSDIA0760ZZ

Tool number

(A): ST30901000 (J-26010-01)

JSDIA0761ZZ

PDIA0762J

JSDIA0038ZZ

2011 Pathfinder

REAR FINAL DRIVE

DLN-441

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

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e. Temporarily tighten removed drive pinion lock nut to drive pinion

using suitable tool (A).

NOTE:

Use removed drive pinion nut only for the preload measurement.

f.

Rotate drive pinion more than 20 times to adjust bearing.

g. Tighten to drive pinion lock nut using suitable tool (A), while

adjusting drive pinion bearing preload torque using Tool (B).

CAUTION:

Drive pinion lock nut is tightened with no collapsible

spacer. Be careful not to overtighten it. While measuring the

preload, tighten drive pinion lock nut in 5

°

 to 10

°

 incre-

ments.

h. Assemble removed drive side bearing adjusting washer or same

thickness of it and install differential case assembly. Refer to

DLN-429, "Disassembly and Assembly"

.

CAUTION:

• Apply differential gear oil to the side bearings.

• Install side bearing and side bearing adjusting washer in correct. (drive gear tooth side or drive

gear back side)

i.

Install bearing caps.

j.

Check and adjust tooth contact and drive gear to drive pinion backlash. Refer to 

DLN-429, "Disassembly

and Assembly"

.

k. Remove bearing caps and differential case assembly.
l.

Remove companion flange.

m. Remove drive pinion assembly from gear carrier.

CAUTION:

Do not drop the drive pinion assembly.

n. Remove drive pinion front bearing inner race.
5. Assemble collapsible spacer.

CAUTION:

Do not reuse collapsible spacer.

6. Assemble drive pinion into gear carrier.

CAUTION:

Apply gear oil to drive pinion rear bearing.

7. Assemble drive pinion front bearing inner race to drive pinion

assembly.

CAUTION:

• Do not reuse drive pinion front bearing inner race.

• Apply gear oil to drive pinion front bearing.

8. Press the drive pinion front bearing inner race to drive pinion as

far as drive pinion lock nut can be tightened, using suitable

spacer (A).

Tool number

(B): ST3127S000 (J-25765-A)

Drive pinion bearing 
preload torque (without 
oil seal)

: 1.0 - 1.3 N·m (0.11 - 
0.13 kg-m, 9 - 11 in-lb)

WDIA0379E

PDIA0760J

PDIA0762J

2011 Pathfinder