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Disassembly and Assembly: Disassembly

WARNING: This page is about a different car, the 2012 Nissan Pathfinder. However, it is still accessible from the selected car via links, so may be relevant.

Side Flange

  1. Drain the differential gear oil if necessary.
  2. Remove the side flange using Tools.

    Tool numbers (A): KV40104100 (-) 

    (B): ST36230000 (J-25840-A) 

    Fig 1: Inspecting Companion Flange Runout Using Tool
    G04901944Courtesy of NISSAN NORTH AMERICA, INC.
    Fig 2: Removing Side Flange Using Tools
    G04901926Courtesy of NISSAN NORTH AMERICA, INC.
  3. Remove the side oil seal using suitable tool.
    CAUTION: Do not to damage gear carrier.
    Fig 3: Removing Side Oil Seal Using Tool
    G04910765Courtesy of NISSAN NORTH AMERICA, INC.

Differential Assembly

  1. Remove the side flanges. Refer to "REMOVAL AND INSTALLATION ".
  2. Remove the carrier cover bolts.
  3. Remove the carrier cover bolts and separate the carrier cover from the gear carrier using Tool.

    Tool number: KV10111100 (J-37228) 

    CAUTION:
    • Do not damage the mating surface.
    • Do not insert flat-bladed screwdriver, this will damage the mating surface.
      Fig 4: Separating Carrier Cover From Gear Carrier Using Tool
      G04901930Courtesy of NISSAN NORTH AMERICA, INC.
  4. Mount the carrier on the Tool using two 45 mm (1.77 in) spacers.

    Tool number: KV38100800 (J-25604-01) 

    Fig 5: Mounting Carrier On Tool Using Spacers
    G04876336Courtesy of NISSAN NORTH AMERICA, INC.
  5. 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 bearing cap or gear carrier.
    • Side bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.
      Fig 6: Identifying Matching Mark On Bearing Cap And Gear Carrier
      G07016846Courtesy of NISSAN NORTH AMERICA, INC.
  6. Remove the side bearing caps.
    Fig 7: Removing Bearing Caps
    G07016847Courtesy of NISSAN NORTH AMERICA, INC.
  7. Lift the differential case assembly out using Tool.

    Tool number: HT72400000 (-) 

    Fig 8: Removing Differential Case Assembly Using Tool
    G04901949Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Keep side bearing outer races together with inner race. Do not mix them up.
    • Keep side bearing adjusting washers together with side bearings.
      Fig 9: Removing Side Bearing Inner Races Using Tools
      G08166784Courtesy of NISSAN NORTH AMERICA, INC.
  8. Remove the side bearing inner races using Tools.

    Tool number (A): ST3306S001 (-) 

    (B): ST33061000 (J-8107-2) 

    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.
      Fig 10: Locating Drive Gear Bolts
      G08166785Courtesy of NISSAN NORTH AMERICA, INC.
  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.
    Fig 11: Removing Pinion Mate Shaft Lock Pin Using Tool
    G08166786Courtesy of NISSAN NORTH AMERICA, INC.
  12. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool.
    Fig 12: Removing Differential Assembly
    G08166787Courtesy of NISSAN NORTH AMERICA, INC.
  13. Remove the pinion mate shaft.
    Fig 13: Removing Pinion Mate Shaft
    G07016676Courtesy of NISSAN NORTH AMERICA, INC.
  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.
    Fig 14: Turning Pinion Mate Gear
    G07016677Courtesy of NISSAN NORTH AMERICA, INC.

Drive Pinion Assembly

  1. Remove the differential assembly. Refer to "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.
    Fig 15: Removing Drive Pinion Lock Nut Using Tool
    G04876346Courtesy of NISSAN NORTH AMERICA, INC.
  4. Remove the companion flange using suitable tool.
    Fig 16: Removing Companion Flange Using Puller
    G07016715Courtesy of NISSAN NORTH AMERICA, INC.
  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.
    Fig 17: Pressing Drive Pinion Assembly Out Of Gear Carrier
    G04876349Courtesy of NISSAN NORTH AMERICA, INC.
  8. Remove the drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.

    Tool number:: ST30031000 (J-22912-01) 

    Fig 18: Removing Drive Pinion Rear Bearing Inner Race And Height Adjusting Washer Using Tool
    G07023708Courtesy of NISSAN NORTH AMERICA, INC.
  9. Remove the drive pinion front and rear bearing outer races by tapping them uniformly using suitable tool.
    CAUTION: Do not damage gear carrier.
    Fig 19: Taping Drive Pinion Front And Rear Bearing Outer Races Using Tool
    G05219646Courtesy of NISSAN NORTH AMERICA, INC.
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