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Nissan Frontier D40. Manual - part 296

FRONT FINAL DRIVE

DLN-205

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

DLN

Install drive pinion rear bearing outer race and drive pinion front
bearing outer race 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 drive pinion height adjusting washer. Refer to

DLN-211, "Inspection and Adjustment"

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.

Install 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: ST30611000 (J-25742-1)

B: ST30613000 (J-25742-3)

C: KV38100200 (J-26233)

PDIA0707E

Tool number

: ST30901000 (J-26010-01)

SDIA0048E

PDIA0708E

DLN-206

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT 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 Tool.

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 Tools.

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 suitable 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-192, "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-211, "Inspection and Adjustment"

12. Install the differential case assembly. Refer to

DLN-192, "Disassembly and Assembly"

Differential Assembly

Tool number

: ST33200000 (J-26082)

PDIA0709E

Tool number

A: ST30720000 (J-25405)

B: ST27863000 (

—

)

PDIA0717E

Tool number

B: ST3127S000 (J-25765-A)

Drive pinion bearing preload torque:

1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)

WDIA0382E

FRONT FINAL DRIVE

DLN-207

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

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.

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.

Install the pinion mate shaft and align the lock pin hole on the
pinion mate shaft with the lock pin hole on the differential case.

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

DLN-211, "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

SPD030

SDIA2593E

DLN-208

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

Apply thread locking sealant into the threaded holes of the drive
gear and install the new drive gear bolts.
• Use Genuine High Strength Thread Locking Sealant or equiv-

alent. Refer to

Sealants"

CAUTION:

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

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

DLN-192, "Disassembly and Assembly"

. After tightening the

new drive gear bolts to the specified torque, tighten an additional
34

to 39

using Tool (A).

CAUTION:

• Always use Tool. Avoid tightening based on visual check

alone.

• Tighten new drive gear bolts in a crisscross pattern.

10. Press the new side bearing inner races to the differential case

using Tools.

CAUTION:

Do not reuse side bearing inner races.

11. Install housing spacer into gear carrier.

12. 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).

SDIA2594E

Tool number

: KV10112100-A (BT-8653-A)

AWBIA0722ZZ

Tool number

A: ST33230000 (J-35867)

B: ST33061000 (J-8107-2)

SPD353

SPD527

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