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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 Washer
    G04876378Courtesy 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.
    Fig 2: Installing Pinion Mate Thrust Washers To Two Pinion Mate Gears
    G04876379Courtesy of NISSAN NORTH AMERICA, INC.
  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 3: Installing Pinion Mate Shaft
    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 Using Tool
    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 5: Identifying Matching Marks On Differential Case And Drive Gear
    G04876382Courtesy of NISSAN NORTH AMERICA, INC.
  8. Apply thread locking sealant into the threaded holes of the drive gear and install the bolts.
    CAUTION: Make sure the drive gear back and threaded holes are clean.
    Fig 6: Applying Thread Locking Sealant Into Threaded Holes Of Drive Gear
    G04876383Courtesy of NISSAN NORTH AMERICA, INC.
  9. Tighten the drive gear bolts to the specified torque. After tightening the drive gear bolts to the specified torque, tighten an additional 34° using Tool (A).

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

    Fig 7: Tightening Drive Gear Bolts To Specified Torque Using Suitable 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 8: Pressing Side Bearing Inner Races Into Differential Case Using Tools
    G04876385Courtesy 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.
    Fig 9: Installing Side Bearing Adjusting Washers With Bearings
    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 10: Inserting Adjusting Washers Between Side Bearings And Gear Carrier
    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.
    Fig 11: Identifying Matching Marks On Side Bearing Caps
    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.

    Recheck the above items.

  16. Install the side flanges.
  17. Apply a 3.2mm (0.126 in) bead of sealant to the mating surface of the carrier cover.
    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 the side flange. Refer to "REMOVAL AND INSTALLATION ".
    Fig 12: Applying Sealant To Mating Surface Of Carrier Cover
    G04901931Courtesy of NISSAN NORTH AMERICA, INC.
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