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Disassembly and Assembly: Assembly

WARNING: This page is about a different car, the 2019 Nissan NV3500 HD, 2019 Nissan NV2500 HD, and 2019 Nissan NV1500. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: If assembly is being done on-vehicle, perform the following after assembly:
  • Connect the propeller shaft to the rear final drive. Refer to Exploded View 3S1355 (VQ40DE), or Exploded View 3S1415 (VK56VD).
  • Install the spare tire.

Drive Pinion Assembly 

Note: 

  1. Install the new drive pinion front bearing outer race (2) and the new drive pinion rear bearing outer race (1), using Tools (A, B, C,).
    GNSAWDIA1007Z-007Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-8092)

    (B):--(J-51040)

    (C):--(J-51041)
    CAUTION: Do not reuse drive pinion front and rear bearing outer race. Replace with bearing as a set.
  2. Install the drive pinion washer (2) to the drive pinion (1). Press on the new drive pinion rear bearing (3) using Tool (A) and suitable tool.
    GNSDB119225Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-44412)
    CAUTION:
    • Install the drive pinion washer in the proper direction as shown.
    • Do not reuse drive pinion rear bearing.
    • Be sure that drive pinion rear bearing is properly seated to the drive pinion.
  3. Assemble the new collapsible spacer to the drive pinion.
    CAUTION: Do not reuse collapsible spacer.
  4. Apply differential gear oil to the drive pinion rear bearing, and install the drive pinion assembly into the gear carrier.
  5. Apply differential gear oil to the new drive pinion front bearing and install it onto the pinion assembly.
    CAUTION: Do not reuse drive pinion front bearing.
  6. Install the companion flange and washer onto the drive pinion.
  7. Seat the drive pinion bearing.
    • If using Tool (A) to seat the drive pinion bearing, perform the following:
      GNSAWDIA1011Z-011Courtesy of NISSAN NORTH AMERICA, INC.

      a. Thread the Tool (A) onto the drive pinion.

      b. Hold Tool and tighten draw-nut (B) to seat the drive pinion bearing.

      Tool number

      (A):--(J-51048)

      c. Remove Tool and remove the companion flange using suitable tools.

    • If no Tool is available to seat the drive pinion bearing, perform the following.
      GNSAWDIA1005Z-005Courtesy of NISSAN NORTH AMERICA, INC.

      a. Using the old washer and drive pinion lock nut, tighten the drive pinion lock nut using Tool (A) until the hand-felt lash has been removed.

      Tool number

      (A):--(J-45012)
      CAUTION: Do not use power tool to seat the drive pinion bearing.

      b. Remove the drive pinion lock nut, washer and companion flange using suitable tools.

  8. Install the new front oil seal in evenly until it becomes flush with the gear carrier using Tool (A).
    GNSALDIA0337Z-337Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-50982)
    CAUTION:
    • Do not reuse front oil seal.
    • Do not incline the new front oil seal when installing.
  9. Apply spline sealant 1.5 mm (0.059 in) diameter bead 360 degrees around splines inside of the pinion flange and install the companion flange to the drive pinion, aligning the matching marks.
    GNSDB120463Courtesy of NISSAN NORTH AMERICA, INC.
  10. Install the new drive pinion lock nut and washer and temporarily tighten using Tool (A).
    GNSAWDIA1005Z-005Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-45012)
    CAUTION:
    • Do not use power tool to install drive pinion lock nut.
    • Do not reuse drive pinion lock nut or washer.
  11. Adjust the drive pinion preload torque using suitable tool (A).
    GNSAWDIA1004Z-004Courtesy of NISSAN NORTH AMERICA, INC.

    Drive pinion bearing preload torque:

    Refer to Inspection 
    1. Tighten drive pinion lock nut in small increments and measure drive pinion bearing preload torque several times to prevent overtightening.
    2. Rotate the drive pinion several times, each time the drive pinion lock nut is tightened to seat the drive pinion bearings.
      CAUTION:
      • Do not loosen drive pinion lock nut to adjust the drive pinion bearing preload torque. If the drive pinion bearing preload torque exceeds specification, disassemble and replace the collapsible spacer and the drive pinion front bearing. Then tighten it again to adjust. Refer to Disassembly and Assembly .
      • After adjustment, rotate drive pinion back and forth two to three times to check for unusual noise, rotation malfunction, and other malfunctions.
  12. Check companion flange runout. Refer to Disassembly and Assembly .
  13. Install differential case assembly. Refer to Disassembly and Assembly .

Differential Assembly 

NOTE: Do not disassemble the differential case assembly, it is not serviceable. Replace it as an assembly.
  1. Secure the differential case in a vise using Tool.

    Tool number

    :--(J-51044)
  2. Apply thread locking sealant the point (A) into the thread hole for the drive gear (1).
    GNSJPDIE0038Z-038Courtesy of NISSAN NORTH AMERICA, INC.

    Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to Recommended Chemical Products and Sealants .

    CAUTION:
    • Completely clean and degrease the drive gear back face, thread holes.
    • Apply thread locking sealant onto the first and second threads under the thread hole chamfering of the drive gear on three or more different points.
    • Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to Recommended Chemical Products and Sealants .
  3. Align the matching mark of the differential case with the mark of the drive gear (if reusing drive gear), then hand thread all the drive gear bolts to the drive gear.
    GNSDB123742Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Drive gear bolts are left hand threaded.

    Do not reuse drive gear bolts.

  4. Draw the gear onto the differential case by tightening drive gear bolts evenly in a crisscross pattern.
    CAUTION: Do not use power tool to tighten drive gear bolts.
  5. Tighten the drive gear bolts to specification.

    Drive gear torque specification:

    Refer to Disassembly and Assembly 
    CAUTION:
    • Do not reuse drive gear bolts.
    • Tighten drive gear bolts in a crisscross pattern.
  6. Press the new side bearings (1) onto the differential case (2) using Tools (A, B).
    GNSAWDIA1010Z-010Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-51045 or J-51046)

    (B):--(J-51047)
    CAUTION: Do not reuse side bearing inner race if removed.

    Be sure that the side bearings are properly seated onto the differential case.

  7. If Tool was removed after dissassembly reinstall Tools (A, B, C).
    GNSAWDIA1056Z-056Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-51043)

    (B):--(J-24385-C)

    (C):--(J-45101)
  8. Install the differential case assembly with the side bearing outer races into the gear carrier.
    GNSALDIA0392Z-392Courtesy of NISSAN NORTH AMERICA, INC.
  9. Insert the left and right side bearing adjusting shims (2) in place between the side bearing outer race (3) and gear carrier (1) using Tool (A).
    GNSAWDIA1009Z-009Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-51042)
    CAUTION:
    • Install the side bearing adjusting shims in the proper direction as shown.
    • Do not strike the side bearing adjusting shims with a hammer.
    NOTE: Use axle housing spreader tool if necessary.
  10. Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to specification.
    GNSALDIA0338Z-338Courtesy of NISSAN NORTH AMERICA, INC.

    Side bearing cap bolt torque specification:

    Refer to Disassembly and Assembly 
    CAUTION: Tighten side bearing cap bolts in a crisscross pattern.
  11. Check and adjust backlash, tooth contact and total preload torque. Refer to Disassembly and Assembly .
  12. Install the carrier cover. Refer to Removal and Installation .
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