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Disassembly and Assembly: Assembly

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.

Drive Pinion Assembly

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

    Tool number (A): ST15310000 (-) 

    (B): ST35325000 (-) 

    (C): ST30621000 (J-25742-5) 

    CAUTION: Do not reuse drive pinion front and rear bearing outer race.
    Fig 1: Pressing Pinion Front And Rear Bearing Outer Races Using Tools
    G04901968Courtesy of NISSAN NORTH AMERICA, INC.
  2. Select a drive pinion height adjusting washer. Refer to "INSPECTION AND ADJUSTMENT ".
  3. Install the selected drive pinion height adjusting washer to the drive pinion. Press the drive pinion rear bearing inner race to it using Tool.

    Tool number: ST30022000 (-) 

    Fig 2: Installing Selected Drive Pinion Height Adjusting Washer
    G04901969Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Install the drive pinion height adjusting washer in the proper direction as shown.
    • Do not reuse drive pinion rear bearing inner race.
  4. Assemble the collapsible spacer to the drive pinion.
    CAUTION: Do not reuse collapsible spacer.
  5. Apply differential gear oil to the drive pinion rear bearing, and install the drive pinion assembly to the gear carrier.
  6. 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.
    Fig 3: Identifying Pinion Front And Rear Bearing Inner Race, Collapsible Spacer And Drive Pinion
    G04876373Courtesy of NISSAN NORTH AMERICA, INC.
  7. 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.
    Fig 4: Pressing Drive Pinion Front Bearing Inner Race To Drive Pinion Using Spacer
    G04876374Courtesy of NISSAN NORTH AMERICA, INC.
  8. Apply multi-purpose grease to the lips 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.

    Tool number: ST15310000 (-) 

    CAUTION:
    • Do not reuse front oil seal.
    • Do not incline the new front oil seal when installing.
    • Apply multi-purpose grease to the lips of the new front oil seal.
      Fig 5: Installing Front Oil Seal In Gear Carrier Using Tool
      G04876375Courtesy of NISSAN NORTH AMERICA, INC.
  9. 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).

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

    Drive pinion bearing preload torque: Refer to  "INSPECTION AND ADJUSTMENT "

    Fig 6: Adjusting Drive Pinion Lock Nut Tightening Torque Using Tool
    G05941075Courtesy of NISSAN NORTH AMERICA, INC.
    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 "EXPLODED VIEW ".
    • 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.
      Fig 7: Installing Side Gear Thrust Washers
      G07016678Courtesy of NISSAN NORTH AMERICA, INC.
  11. Check companion flange runout. Refer to "INSPECTION AND ADJUSTMENT ".
  12. Install the differential case assembly. Refer to "EXPLODED VIEW ".

Differential Assembly

  1. 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.
    Fig 8: Installing Side Gears And Side Gear Thrust Washers In Differential Case
    G07016679Courtesy of NISSAN NORTH AMERICA, INC.
  2. Install the side gears and side gear thrust washers into the differential case.
    CAUTION: Make sure that the circular clip is installed to side gears.
  3. 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.
  4. 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.
  5. Measure the side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "INSPECTION AND ADJUSTMENT ".
    Fig 9: Locating Differential Case
    G07016680Courtesy of NISSAN NORTH AMERICA, INC.
  6. 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.
    Fig 10: Installing Lock Pin Into Pinion Mate Shaft
    G04901977Courtesy of NISSAN NORTH AMERICA, INC.
  7. Align the matching mark of the differential case with the mark of the drive gear, then place the drive gear onto the differential case.
    Fig 11: Identifying Matching Mark Of Differential Case With Drive Gear Mark
    G07016684Courtesy of NISSAN NORTH AMERICA, INC.
  8. 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 "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Make sure the drive gear back and threaded holes are clean.
      Fig 12: Applying Thread Locking Sealant Into Drive Gear Thread Hole
      G07016685Courtesy of NISSAN NORTH AMERICA, INC.
  9. Tighten the drive gear bolts to the specified torque. Refer to "EXPLODED VIEW ". After tightening the drive gear bolts to the specified torque, tighten an additional 34° using Tool.

    Tool number (A): KV10112100 (BT-8653-A) 

    Fig 13: Tightening Of Drive Gear Bolt Using Tool
    G05883388Courtesy of NISSAN NORTH AMERICA, INC.
    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.

    Tool number (A): KV38100200 (J-26233) 

    (B): ST33081000 (-) 

    Fig 14: Pressing Side Bearing Inner Races Into Differential Case Using Tools
    G07017190Courtesy of NISSAN NORTH AMERICA, INC.
    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 "INSPECTION AND ADJUSTMENT ".
    Fig 15: Installing Differential Case Assembly Into Gear Carrier
    G04876422Courtesy of NISSAN NORTH AMERICA, INC.
  13. Insert the selected left and right side bearing adjusting washers in place between the side bearings and gear carrier.
    Fig 16: Inserting Left And Right Side Bearing Adjusting Washers
    G04876436Courtesy of NISSAN NORTH AMERICA, INC.
  14. Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to the specified torque. Refer to "EXPLODED VIEW ".
    Fig 17: Identifying Matching Mark On Bearing Cap And Gear Carrier
    G04901984Courtesy of NISSAN NORTH AMERICA, INC.
  15. Check and adjust the drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to "INSPECTION AND ADJUSTMENT ". Recheck the above items.
  16. Install the side flanges. Refer to "REMOVAL AND INSTALLATION ".
  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 "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      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 "EXPLODED VIEW ".
  19. Install the side flange. Refer to "REMOVAL AND INSTALLATION "
    Fig 18: Identifying Carrier Cover Sealant Applying Surface
    G04901931Courtesy of NISSAN NORTH AMERICA, INC.

Side Flange

  1. Apply multi-purpose grease to the lips 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.

    Tool number: ST35271000 (-) 

    Fig 19: Installing Side Oil Seal Using Drift
    G07016815Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Do not reuse side oil seal.
    • Do not incline the new side oil seal when installing.
    • Apply multi-purpose grease to the lips of the new side oil seal.
  2. Install the side flange using Tool.
    1. Install the Tool to the side oil seal as shown.

      Tool number: KV38107900 (J-39352) 

    2. 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.
    3. 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.
      Fig 20: Installing Side Flange Using Tool
      G07016777Courtesy of NISSAN NORTH AMERICA, INC.
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