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Disassembly and Assembly: Disassembly

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 disassembly is being done on-vehicle, perform the following prior to disassembly:
  • Disconnect the propeller shaft from the rear final drive and support the propeller shaft using suitable wire. Refer to Exploded View 3S1355 (VQ40DE), or Exploded View 3S1415 (VK56VD).
  • Remove the spare tire.

Differential Case Assembly 

  1. Remove the carrier cover bolts, carrier cover and gasket.
    NOTE: The carrier cover gasket is reusable. Only replace the carrier cover gasket if it is damaged.
    CAUTION:
    • Do not damage the mating surface.
    • Do not insert flat-bladed screwdriver, this will damage the mating surface.
    NOTE: Do not disassemble the differential case assembly, it is not serviceable.

    Replace it as an assembly if necessary.

  2. For proper reinstallation, paint matching marks on side of the side bearing caps.
    GNSALDIA0338Z-338Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions.
    • For matching mark, use paint. Do not damage side bearing cap.
  3. Remove side bearing caps using suitable tool.
    GNSALDIA0339Z-339Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Do not use power tool to remove side bearing caps.
  4. Remove differential case assembly.
    GNSALDIA0390Z-390Courtesy of NISSAN NORTH AMERICA, INC.
    1. Attach Tool (A) to gear carrier.

      Tool number

      (A):--(J-51043)
    2. Attach Tool (B) to Tool (A) and position Tool (C) in the proper orientation to measure the axle housing spread.
      GNSAWDIA1056Z-056Courtesy of NISSAN NORTH AMERICA, INC.

      Tool number

      (A):--(J-51043)

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

      (C):--(J-45101)
      WARNING: Be cautious when using Tool (A, B), the differential case assembly is heavy and could cause serious injury.
      CAUTION:
      • Using a dial indicator (C) do not exceed a spread of 0.381mm (0.015 in) when using axle housing spreader.
      • Remove Tool from gear carrier immediately after differential case removal, to avoid damage to gear carrier.
  5. Remove side bearing outer races and side bearing adjusting shims. Keep side bearing and outer races together. Do not mix them up. Also, keep side bearing adjusting shims together with bearings.
    CAUTION: If reusing side bearing outer races and side bearing adjusting shims:
    • Do not mix them up.
    • Tag the side bearing outer races and the side bearing adjusting shims so they are installed in the same position they were removed from.
  6. Remove side bearing using Tool (A) and suitable tool.
    GNSDB121835Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-8433)
    CAUTION:
    • Engage puller jaws in groove (SYMBOL ) to prevent damage.
    • To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
    • Do not reuse side bearing if removed. Replace side bearing and bearing outer race as a set.
    NOTE: It is not necessary to remove side bearing except if it needs to be replaced.
  7. For proper reinstallation, paint matching mark on differential case assembly and drive gear.
    CAUTION: Use paint for matching marks. Do not damage differential case or drive gear.
    GNSALDIA0391Z-391Courtesy of NISSAN NORTH AMERICA, INC.
  8. Remove drive gear bolts.

    Tool number (A)

    :--(J-51044)
    CAUTION:
    • Secure the differential assembly in a vise using Tool (A).
    • Drive gear bolts are left hand threaded.
    • Do not damage drive gear by removing bolts improperly.
  9. Tap the drive gear off the differential case assembly uniformly with a brass bar or equivalent.
    CAUTION:
    • Tap evenly all around to keep drive gear from binding.
    • Do not pry.
    • Do not strike top of drive gear bolts to remove the drive gear.

Drive Pinion Assembly 

NOTE: If assembly is being done on-vehicle, perform the following prior to after assembly:
  • Install the propeller shaft to the rear final drive. Refer to Exploded View 3S1355 (VQ40DE), or Exploded View 3S1415 (VK56VD).
  • Install the spare tire.
  1. Remove differential case assembly. Refer to Disassembly and Assembly .
  2. Remove drive pinion lock nut and washer using Tool (A).
    GNSAWDIA1005Z-005Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-45012)
  3. Put matching marks on the companion flange and drive pinion using paint.
    GNSDB120463Courtesy of NISSAN NORTH AMERICA, INC.
    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.
    GNSAWDIA1006Z-006Courtesy of NISSAN NORTH AMERICA, INC.
  5. Remove front oil seal using Tool (A).
    GNSAWDIA1067Z-067Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-26941)
    CAUTION: Do not reuse front oil seal.
  6. Remove drive pinion assembly from gear carrier using Tool (A).
    GNSDB116609Courtesy of NISSAN NORTH AMERICA, INC.

    Tool number

    (A):--(J-44421)
    CAUTION: Do not drop drive pinion assembly.
  7. Remove drive pinion front bearing.
    CAUTION: Do not reuse drive pinion front bearing.
  8. Remove collapsible spacer from drive pinion assembly.
    CAUTION: Do not reuse the collapsible spacer.
  9. Remove drive pinion rear bearing and drive pinion washer using suitable tool.
    GNSALDIA0340Z-340Courtesy of NISSAN NORTH AMERICA, INC.
    NOTE:
    • The drive pinion washer is matched to the carrier for proper drive pinion height. No drive pinion height adjustment is necessary if reusing original drive pinion washer.
    CAUTION:
    • Do not reuse drive pinion rear bearing.
    • Do not discard drive pinion washer, reuse if not damaged.
  10. Clean threads and splines of the drive pinion, if reusing drive pinion.
  11. Tap drive pinion front and rear bearing outer races uniformly with a brass bar or equivalent to remove.
    G04076373Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Do not reuse bearing outer races. Replace bearing and outer races as a set.
    • Do not damage gear carrier.
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