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Differential Assembly

WARNING: This page is about a different car, the 2013 Nissan Armada. However, it is still accessible from the selected car via links, so may be relevant.
  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 1: Installing Side Gear Thrust Washers
    G04876378Courtesy of NISSAN NORTH AMERICA, INC.
  2. Install the side gears and side gear thrust washers into the differential case.
  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.
    Fig 2: Installing Side Gears And Side Gear Thrust Washers Into Differential Case
    G04876379Courtesy of NISSAN NORTH AMERICA, INC.
  4. 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.
  5. Measure the side gear end play. If necessary, select the appropriate side gear thrust washers.
    Fig 3: Aligning Lock Pin Hole On Pinion Mate Shaft With Lock Pin Hole On Differential Case
    G04876380Courtesy 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 4: Driving Lock Pin Into Pinion Mate Shaft With Differential Case Using Suitable Tool
    G04876381Courtesy 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 5: Identifying Matching Mark On Differential Case And Drive Gear
    G04876382Courtesy of NISSAN NORTH AMERICA, INC.
  8. Install and tighten the new drive gear bolts to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    CAUTION:
    • Make sure the drive gear back and threaded holes are clean.
    • Do not reuse drive gear bolts.
    • Tighten new drive gear bolts in a crisscross pattern.
    Fig 6: Identifying Drive Gear With Mounting Bolts
    G04901888Courtesy of NISSAN NORTH AMERICA, INC.
  9. Press the new side bearing inner races to the differential case using tools.

    Tool number (A): KV38100300 (J-25523) 

    (B): ST33081000 (-) 

    CAUTION: Do not reuse side bearing inner races.
    Fig 7: Pressing Side Bearing Inner Races To Differential Case Using Tool
    G04876385Courtesy of NISSAN NORTH AMERICA, INC.
  10. Install side bearing adjusters into gear carrier.
  11. Apply differential gear oil to the side bearings, and install the differential 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).
    Fig 8: Installing Side Bearing Adjusters Into Gear Carrier
    G04876340Courtesy of NISSAN NORTH AMERICA, INC.
  12. Install the side bearing caps with the matching marks aligned.
    NOTE: Do not tighten at this step. This allows further tightening of side bearing adjusters.
    Fig 9: Identifying Matching Marks On Side Bearing Caps
    G04901855Courtesy of NISSAN NORTH AMERICA, INC.
  13. Tighten each side bearing adjuster alternately turning drive gear.
    Fig 10: Tightening Side Bearing Adjuster Alternately Turning Drive Gear
    G04901892Courtesy of NISSAN NORTH AMERICA, INC.
  14. Check and adjust tooth contact, backlash, drive gear runout and total preload torque.

    Recheck above items.

    • After adjusting tooth contact and backlash secure side bearing adjuster with screws and tighten side bearing cap bolt to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
      Fig 11: Tightening Side Bearing Cap Bolt
      G04901893Courtesy of NISSAN NORTH AMERICA, INC.
  15. Apply multi-purpose grease to the lips of the new side oil seal. Then drive the new side oil seal in evenly to the gear carrier using suitable tool.
    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.
  16. Install the extension tube with a new O-ring.
    CAUTION:
    • Do not reuse O-ring.
    • If the extension tube is being replaced, install a new axle shaft bearing.
    Fig 12: Front Final Drive Replacement Components With Torque Specifications
    G08696887Courtesy of NISSAN NORTH AMERICA, INC.
  17. Apply 3 mm (0.12 in) bead of sealant to the mating surface of the carrier cover as shown below.
    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 "REMOVAL AND INSTALLATION ".
  19. Install side shaft and side flange.
    Fig 13: Applying Bead Of Sealant To Mating Surface Of Carrier Cover
    G04901895Courtesy of NISSAN NORTH AMERICA, INC.
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