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REAR FINAL DRIVE

D DRIVELINE/AXLE

B
SECTION
REAR FINAL DRIVE C

RFD

E
CONTENTS
C200 H233B F

PRECAUTIONS .......................................................... 3 PRECAUTIONS ........................................................ 28


Caution ..................................................................... 3 Caution ................................................................... 28
G
PREPARATION ........................................................... 4 PREPARATION ......................................................... 29
Special Service Tool ................................................. 4 Special Service Tools ............................................. 29
NOISE, VIBRATION, AND HARSHNESS (NVH) NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 6 TROUBLESHOOTING .............................................. 31 H
NVH Troubleshooting Chart ..................................... 6 NVH Troubleshooting Chart ................................... 31
FRONT OIL SEAL ...................................................... 7 FRONT OIL SEAL ..................................................... 32
Removal and Installation .......................................... 7 Removal and Installation ........................................ 32 I
REMOVAL ............................................................. 7 REMOVAL ........................................................... 32
INSTALLATION ..................................................... 7 INSTALLATION ................................................... 32
REAR FINAL DRIVE ASSEMBLY .............................. 8 REAR FINAL DRIVE ASSEMBLY ............................ 33 J
Removal and Installation .......................................... 8 Removal and Installation ........................................ 33
REMOVAL ............................................................. 8 REMOVAL ........................................................... 33
INSTALLATION ..................................................... 8 INSTALLATION ................................................... 33
Disassembled Drawing ............................................ 9 Disassembled Drawing ........................................... 34 K
Inspection before Disassembly .............................. 10 Inspection before Disassembly ............................... 35
TOTAL PRELOAD ............................................... 10 TOTAL PRELOAD ............................................... 35
RING GEAR TO DRIVE PINION BACKLASH ... 10 RING GEAR TO DRIVE PINION BACKLASH ..... 35 L
RING GEAR RUNOUT ........................................ 10 RING GEAR RUNOUT ........................................ 35
TOOTH CONTACT .............................................. 10 TOOTH CONTACT .............................................. 35
Disassembly and Assembly ....................................11 Disassembly and Assembly .................................... 35 M
REMOVING DRIVE GEAR AND DIFFERENTIAL REMOVE DRIVE GEAR AND DIFFERENTIAL
CASE ASSEMBLY ...............................................11 CASE ASSEMBLY ............................................... 35
REMOVING DRIVE PINION GEAR ASSEMBLY....11 REMOVE DRIVE PINION GEAR ASSEMBLY ... 37
DISASSEMBLING DIFFERENTIAL CASE ......... 12 DISASSEMBLY DIFFERENTIAL CASE
PARTS INSPECTION ......................................... 14 (2PINION) ............................................................ 38
ASSEMBLING DIFFERENTIAL CASE ............... 14 PARTS INSPECTION (2PINION) ........................ 39
ADJUSTMENT SIDE BEARING PRELOAD ....... 17 ASSEMBLY DIFFERENTIAL CASE (2PINION)... 39
ADJUSTMENT DRIVE PINION ........................... 19 DISASSEMBLY DIFFERENTIAL CASE (LIM-
ASSEMBLY DIFFERENTIAL CARRIER ............. 22 ITED SLIP DIFFERENTIAL) ................................ 41
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 26 PARTS INSPECTION (LIMITED SLIP DIFFER-
General Specifications ........................................... 26 ENTIAL) ............................................................... 42
Ring gear runout .................................................... 26 ADJUSTMENT DIFFERENTIAL CASE (LIM-
Side gear adjustment ............................................. 26 ITED SLIP DIFFERENTIAL) ................................ 43
Side Bearing Adjustment ........................................ 26 ASSEMBLY DIFFERENTIAL CASE (LIMITED
Total Preload Adjustment ....................................... 26 SLIP DIFFERENTIAL) ......................................... 45
Drive Pinion Height Adjustment ............................. 27 ADJUSTMENT DRIVE PINION ........................... 47
Drive Pinion Preload Adjustment ........................... 27 ASSEMBLY DIFFERENTIAL CARRIER .............. 50

RFD-1
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 54 MODELS) .............................................................54
General Specifications ............................................ 54 Total Preload Adjustment ........................................54
Ring Gear Runout ................................................... 54 DRIVE PINION HEIGHT ADJUSTMENT .............55
Side Gear Clearance Adjustment ........................... 54 DRIVE PINION PRELOAD ADJUSTMENT .........56
DIFFERENTIAL TORQUE ADJUSTMENT (LSD

RFD-2
PRECAUTIONS
[C200]
PRECAUTIONS
[C200] PFP:00001
A
Caution EDS000GN

Before starting diagnosis of vehicle, understand trouble symptoms well. Perform correct and systematic
operations. B
Check for the correct installation status prior to removal or disassembly. When mating marks are required,
be sure they do not interfere with the function of the parts they are applied to.
Perform overhaul in clean place. Using a dustproof room is recommended. C
Before disassembly, using steam or white gasoline, etc., completely remove sand and mud from exterior
of unit, and prevent them from entering into unit during disassembly or assembly.
Check appearance of disassembled parts for damage, deformation, and unusual wear. If a malfunction is RFD
detected, replace it with a new one.
As a rule, replace lock pins, oil seals, and bearings with new ones every time they are removed.
Use Nissan Genuine Parts for replacement. E
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
Clean and flush the parts sufficiently, and blow them dry. F
Be careful not to damage sliding surfaces and mating surfaces.
When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces. G
Always use shop paper for cleaning the inside of components.
Do not use cotton gloves or a shop cloth. Using them may leave lint on the surface of the parts.
H
During assembly, observe the specified tightening torque, and apply new deferential oil, Vaseline, or multi-
purpose grease as specified for each vehicle, when necessary.
Do not reuse drained oil. Discard waste oil after oil changes or treating part in accordance with local laws
and regulations. I

RFD-3
PREPARATION
[C200]
PREPARATION PFP:00002

Special Service Tool EDS000GO

Description Application

Drift
KV38100500
Installing rear final drive oil seal
a: 80 mm (3.35in)dia.
b: 60 mm (2.36in)dia.

ZZA0811D

Drift
ST33061000
Installing side bearing
a: 38 mm dia.
b: 28.5 mm dia.

ZZA0810D

Drift
ST33230000
a: 51 mm Installing side bearing
b: 41 mm
c: 28 mm
ZZA1046D

Spacer drift Installing differential gear case


KV38100600 assembly

SDIA0429J

Drive pinion rear inner race puller set


ST3306S001
Puller
(1)ST30031000
Base Removing drive pinion rear bearing
(2)ST30901000
a: 79 mm(3.11in)dia.
b: 45 mm(1.77in)dia. NT527
c: 35 mm(1.38in)dia.
Differential side bearing puller set
Body
(1)ST33051001
Adapter Removing and installing differential
(2)ST33061000 side bearing
a: 52 mm(2.05in)dia.
b: 45.5 mm(1.791in)dia.
c: 34 mm(1.34in)dia. NT072

Drive pinion height setting gauge set


KV381039S0
Dummy shaft
(1)KV38103910 Selecting pinion height adjusting
height gauge washer
(2)KV38100120
Stopper
(3)KV38100140 NT226

RFD-4
PREPARATION
[C200]
Description Application
A

Drift Installing pinion rear outer race B


ST30611000 (use with ST3062100 on 3061300)

NT090 C

Drift RFD
ST30621000 Installing pinion rear outer race
a: 79 mm(3.11in)dia. (use with ST3061100)
b: 59 mm(2.32in)dia.
E
NT073

F
Drift
ST30621000 Installing pinion rear outer race
a: 72 mm(2.83in)dia. (use with ST3061100)
b: 48 mm(1.89in)dia. G
NT073

H
Drift
ST33710000
Removing drive pinion gear
a: 30 mm dia. I
b: 23 mm dia.

SDIA0082J
J

RFD-5
: Applicable

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
NVH Troubleshooting Chart
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
Symptom

Possible cause and SUSPECTED PARTS

Reference page

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING


DIFFERENTIAL
Noise
Rough gear tooth Refer toRFD-14


RFD-6

Inproper gear contact Refer toRFD-10


Tooth surfaces worn Refer to RFD-14


Incorrect baklash Refer to RFD-10


Companion flange excessive runout

Improper gear oil Refer to MA section.

PROPELLER SHAFT NVH in PR section.


AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.

TIRES NVH in WT sectiont.


ROAD WEEL NVH in WT section.


DRIVE SHAFT NVH in RAX section.


PFP:00003
BRAKES NVH in BR section.

[C200]

EDS000GP
STEERING NVH in PS section.

FRONT OIL SEAL
[C200]
FRONT OIL SEAL PFP:38189
A
Removal and Installation EDS000GQ

REMOVAL
1. Remove Propeller Shaft.
B
2. Put a mark on the end of the drive pinion corresponding to the B
position mark on the final drive companion flange.
CAUTION:
C
When making mating marks, use paint, etc., to avoid
scratching on surface.

RFD

SDIA0270E
E

3. Using a differential flange tool, remove drive pinion gear nut.


4. Using a puller, remove companion flange. F
5. Using a flat-bladed screwdriver, remove oil seal.

WPD013

INSTALLATION I
1. Apply multi-purpose grease to oil seal lips. Using a drift (special
service tool) as shown, install oil seal. It should become flush
with case end surface. J
Tool number :KV38100500
CAUTION:
When installing, be careful not to incline oil seal.
K
Discard old oil seal; replace with a new one.

L
WPD014

2. Align mating marks on companion flange and drive pinion gear, M


then install companion flange.
3. Apply anti-corrosive oil to drive pinion gear thread and pinion nut
seating surface. Then, install pinion nut to companion flange.
4. Install Propeller Shaft.

SDIA0270E

RFD-7
REAR FINAL DRIVE ASSEMBLY
[C200]
REAR FINAL DRIVE ASSEMBLY PFP:38300

Removal and Installation EDS000GR

REMOVAL
1. Remove rear propeller shaft. Refer to PR-3, "REAR PROPELLER SHAFT" .
2. Remove drain plug to drain oil.
3. Remove rear axle shaft.
4. Remove air breather hose.
5. Set a transmission jack, and remove final drive mounting nuts. Then remove final drive assembly.
INSTALLATION
Install in reverse order of removal.
CAUTION:
Install gasket in the correct direction shown in the figure.
After installing, bleed air in brake, adjust parking brake, and
fill oil to final drive.

SDIA0504E

RFD-8
REAR FINAL DRIVE ASSEMBLY
[C200]
Disassembled Drawing EDS000GS

RFD

SDIA0425E

RFD-9
REAR FINAL DRIVE ASSEMBLY
[C200]
Inspection before Disassembly EDS000GT

Before disassembling final drive, perfrom the following inspection.


Remove carrier cover.
CAUTION:
Drain oil.

If carrier case is unusual, replace carrier case assembly.

SDIA0304J

TOTAL PRELOAD
Rotate companion flange several times. Using preload gauge,
measure preload.
Total preload :
1.4 - 2.8 Nm (0.14 - 0.29 kg-m,13-25in-lb)

SPD241

RING GEAR TO DRIVE PINION BACKLASH


Using a dial gauge, measure backlash of drive gear and drive
pinion gear.
Ring gear to drive pinion backlash:
0.13 - 0.18 mm(0.0051-0.0071in)

SDIA0306J

RING GEAR RUNOUT


Set a dial gauge to back of drive gear. Then rotate drive gear,
and measure runout
Runout repair limit:
0.05 mm(0.002in)

SDIA0307J

TOOTH CONTACT
Check tooth contact. Refer to RFD-20, "Tooth Contact" .

RFD-10
REAR FINAL DRIVE ASSEMBLY
[C200]
Disassembly and Assembly EDS000GU

REMOVING DRIVE GEAR AND DIFFERENTIAL CASE ASSEMBLY A


1. Confirm mating marks on side bearing cap and carrier case. If
there are no mating marks, make them.
CAUTION: B
Bearing cap is machined together with carrier case. Be sure
to assemble them properly. When making mating marks,
use paint, etc., to avoid scratch on surface. C
2. Remove mounting bolts. Tap bearing cap, and remove it.

RFD
SDIA0311E

3. Insert a handle of hammer between differential gear case and E


carrier case. Then remove differential gear case assembly.
CAUTION:
Do not drop side bearing outer races, bearing spacer, and F
adjusting washer.
Put different color marks on each side bearing outer race,
or store separately. G

SDIA0312J
H

REMOVING DRIVE PINION GEAR ASSEMBLY


1. Using a flange wrench, remove pinion lock nut. I

SPD204
L

2. Remove drive pinion gear with companion flange.


CAUTION: M
Be careful not to drop drive pinion gear.
Tool number: ST30031000

SDIA0022E

RFD-11
REAR FINAL DRIVE ASSEMBLY
[C200]
3. Using a brass rod, tap bearing outer race evenly to remove.
4. For front, drive out bearing with oil seal.

SDIA0023E

5. Using a bearing replacer, remove drive pinion gear and rear


bearing with a press.
Tool number: ST30031000

SDIA0024J

DISASSEMBLING DIFFERENTIAL CASE


1. Removing side bearing
Fix differential gear case assembly in a vise. Using a puller
set,remove side bearing.
CAUTION:
Be sure to fix the assembly in a vise and make sure to pre-
vent side bearing and drive gear from scratching.
Do not remove side bearing except for replacement.
Tool number:
A ST33051001
SPD207A
B ST3306100

2. Removing drive gear


Put mating marks on differential gear case and drive gear,
and remove mounting bolts.
Using a plastic hammer, tap side of drive gear, and remove
drive gear.
CAUTION:
When making mating marks, use paint, etc., to avoid
scratching drive gear and differential gear case.

SDIA0318E

RFD-12
REAR FINAL DRIVE ASSEMBLY
[C200]
Turn differential gear case upside down, and check side gear
back clearance on other side as well. A

SDIA0319J
RFD
3. Disassembly
Confirm mating marks.

If there are no mating marks, make them. E


Remove bolts.

CAUTION:
When making mating marks, use paint to avoid scratch- F
ing differential gear case.

G
SDIA0321E

Using a plastic hammer, tap differential gear case to separate.


H

SDIA0322E
K

Remove the following parts from differential gear case: side


gear, side gear thrust washer, pinion mating shaft, pinion mat- L
ing gear, pinion, mating thrust washer, and thrust block.

SDIA0323E

RFD-13
REAR FINAL DRIVE ASSEMBLY
[C200]
Follow Parts inspection, check the following parts, and take
action against it: side gear, side gear thrust washer, pinion
mating shaft, pinion mating gear, pinion, pinion mating thrust
washer, thrust block, and differential gear case.

SDIA0324J

PARTS INSPECTION
Item Corrective action
If tooth contact is unusual, determine the possible cause. When assembling, adjust tooth contact
Drive gear properly. If gear is worn out excessively, or cannot be adjusted properly, replace it as a set.
Drive pinion If cracks, damage, and seizure is detected on tooth face, replace it as a set.
If tooth damage is light, repair it using oil stone.
Check for seizure, peeling, wear, and corrosion. Also check for sticking, unusual noise, and
Bearing
roughness while turning bearing. If any, replace it.

Side gear If cracks or damage is detected on tooth face, replace it.


Pinion mating gear If wear or seizure is detected on thrust washer face, replace it.
Side gear thrust washer If seizure, damage, of unusual wear is detected, replace it.
Oil seal Normally, replace it when disassembling. If settling or damage is detected, be sure to replace it.
Differential case If wear or a crack is detected on sliding surface, replace it.
Companion flange If damage, wear, or seizure is detected on lip contact surface of oil seal, replace it.

ASSEMBLING DIFFERENTIAL CASE


1. Assemble thrust washer to side gear.
CAUTION:
When assembling, use the original thrust washer removed
during assembly, or the one of same size.

SDIA0325J

RFD-14
REAR FINAL DRIVE ASSEMBLY
[C200]
2. Assemble side gear to differential gear case.
3. Then, assemble pinion mating assembly (pinion mating shaft A
assembled with pinion mating gear and thrust washer).

SDIA0326J
RFD
4. Assemble side gear and thrust washer to the other side.
CAUTION:
When assembling, use the original thrust washer removed E
during assembly, or the one of same size.

G
SDIA0327J

5. Side gear back clearance adjustment (side gear thrust washer


H
selection)
Measure height B between case contact surface of differential
gear case B and end face of side gear thrust washer.
6. Then, measure depth A (between differential gear case con- I
tact surface and side gear thrust washer contact surface) on dif-
ferential gear case A.
7. Calculate side gear back clearance N. J
N=A-B
Side gear back clearance:
K
0.10 - 0.20 mm(0.004 - 0.008in)
8. Select the same thickness washers on right and left so that the
calculated back clearance becomes within standard. L

SPD656

Thickness mm(in) Part number


0.75 (0.0295) 38424-N3110
0.78 (0.0307) 38424-N3111
0.81 (0.0319) 38424-N3112
0.84 (0.0331) 38424-N3113
0.87 (0.0343) 38424-N3114
0.90 (0.0354) 38424-N3115
0.93 (0.0366) 38424-N3116

RFD-15
REAR FINAL DRIVE ASSEMBLY
[C200]
9. Assemble the selected thrust washer with side gear, and assem-
ble pinion mating assembly.
CAUTION:
Apply gear oil to sliding parts on gear and washer.

SDIA0326J

10. Assemble thrust block.

SDIA0330J

11. Assemble selected thrust washer and side gear on the other
side.

SDIA0327J

12. Align mating marks, and connect differential gear cases.

SDIA0332E

RFD-16
REAR FINAL DRIVE ASSEMBLY
[C200]
13. Evenly tighten bolts diagonally. Then tighten them to specified
torque. A

SDIA0333J
RFD
14. Apply sealant (Locktite) to drive gear mounting bolts and threads
of drive gear.
E

G
SDIA0336J

15. Align mating marks on drive gear and differential gear case, and H
assemble them.
16. Evenly tighten bolts diagonally. Then tighten them to specified
torque. I

SDIA0337J
K

17. Press-fit side bearing inner cones on differential case with tool.
L
Tool number:
ST33230000
ST33061000 M

S-PD244

ADJUSTMENT SIDE BEARING PRELOAD


A selection of carrier side bearing preload shims is required for successful completion of this procedure.

RFD-17
REAR FINAL DRIVE ASSEMBLY
[C200]
1. Make sure all parts are clean. Make sure, also, the bearings are
well lubricated with light oil or type DEXRON automatic trans-
mission fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.

SPD919

3. Put the side bearing spacer in place.


CAUTION:
Side bearing spacer is placed on either the right or left
depending upon final drive gear ratio. Be sure to replace it
on the correct side.

SPD894

4. Use Tool to place original carrier side bearing preload shims on


the carrier end, opposite the ring gear.
Tool number: KV38100600

SPD986

5. Install the side bearing caps in their correct locations and torque
the bearing cap retaining bolts.
Specification:
88 - 98 N-m (9.0 - 10.0 kg-m, 65 - 72 ft-lb)
6. Turn the carrier several times to seat the bearings.

SPD526

7. Measure the turning torque of the carrier at the ring gear retain-
ing bolts with a spring gauge, J8129.
Specification:
34.3 -39.2 N (3.5 - 4.0 kg, 7.7 -8.8 lb) of pulling
force at the ring gear bolt

SPD194A

RFD-18
REAR FINAL DRIVE ASSEMBLY
[C200]
8. If the turning torque is not within the specifications, correct the
torque as follows: A
If the turning torque is less than the specified range, install
washers of greater thickness.
If the turning torque is greater than the specification, install thin- B
ner washers to side bearing.
Side bearing adjustment:
C
Refer to RFD-17, "ADJUSTMENT SIDE BEARING
PRELOAD"
SPD772
9. Record the total amount of washer thickness required for the RFD
correct carrier side bearing preload.
10. Remove the carrier from the final drive housing. Save the
selected preload washers for later use during the assembly of E
the final drive unit.

S-PD344
H
ADJUSTMENT DRIVE PINION
Drive Pinion Height
1. First prepared Tools for pinion height adjustment.
I
1. Dummy shaft (KV38103910)
2. Height Gauge (KV38100120)
3. Stopper (KV38100140) J
4. Feeler gauge
2. To simplify the job, make a chart, like the one below, to organize
your calculations. K
LETTER HUNDREDTHS OF A MILLIMETER
H: Head number SPD233
L
N: Measuring clearance

3. Write the following numbers down the chart.


H: Head number M

SPD542

RFD-19
REAR FINAL DRIVE ASSEMBLY
[C200]
4. Set Tool (Dummy shaft) as shown t left and tighten drive pinion
nut carefully to correct preload of 1.0 to 1.3 N-m (0.1 to 0.13 kg-
m, 8.7 to 11.3 in-lb).
Tool number: KV38103910

SPD756

5. Attach Tool (Height gauge) to gear carrier, and measure the


clearance N between the height gauge and the dummy shaft
face.
Tool number: KV38100120
6. Substitute these values into the equation to calculate the thick-
ness of the washer.
If valve signifying H is not given, regard it as zero and calculate.
T (Thickness of washer) = N (H 0.01) + 3.00
SPD757

SDIA0507E

7. Select the proper washer. Refer to RFD-26, "SERVICE DATA AND SPECIFICATIONS (SDS)" .
If you cannot find the desired thickness of washer, use washer with thickness closest to the calculated
value.
Example:
Calculated value: T = 3.22 mm
Used washer: T = 3.21 mm
Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pin-
ion.
Hypoid gear set which is not positioned properly may be noisy, or have short life or both. With the checking or
gear tooth contact pattern, the most desirable contact for low noise level and long life can be assured.

RFD-20
REAR FINAL DRIVE ASSEMBLY
[C200]
1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or A
equivalent to 3 or 4 teeth of ring gear drive side.

SPD199
RFD
3. Hold companion flange steady and rotate the ring gear in both
directions.
E

G
SPD200

SPD007-B

RFD-21
REAR FINAL DRIVE ASSEMBLY
[C200]
ASSEMBLY DIFFERENTIAL CARRIER
1. Press-fit front and rear bearing outer races with Tools.
Tool numbers:
A ST30611000
B ST30621000
C ST30613000

SPD679

2. Select pinion height adjusting washer. Refer to


3. Install pinion height adjusting washer in drive pinion, and press-
fit rear bearing inner cone in it, with press and Tool.
Tool number: ST30901000

SPD377

4. Place pinion front bearing inner cone in gear carrier.

SPD581

RFD-22
REAR FINAL DRIVE ASSEMBLY
[C200]
5. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Install front oil seal. A
Tool number: KV38100500

SPD557
RFD
6. Place drive pinion bearing spacer, drive pinion bearing adjusting
washer and drive pinion in gear carrier.
E

G
SPD222

7. Insert companion flange into drive pinion by tapping the com-


panion flange with a soft hammer. H

SPD708
K
8. Tighten pinion nut to 127 N-m (13 kg-m, 94 ft-lb).
The threaded portion of drive pinion and pinion nut should be
free from oil or grease. L

SPD204

9. Tighten the pinion nut by very small degrees until the specified
preload is achieved. When checking the preload, turn the drive
pinion in both directions several times to set the bearing rollers.
Pinion bearing preload:
1.1 - 1.7 N-m (0.11 - 0.17 kg-m, 9.5 - 14.8 in-lb)
This procedure will have to be repeated if:
Maximum preload is achieved before the minimum pinion nut
torque is reached.
SPD241

RFD-23
REAR FINAL DRIVE ASSEMBLY
[C200]
Minimum preload is not achieved before maximum pinion ut torque is reached.

10. Select side bearing adjusting washer.


Refer to RFD-17, "ADJUSTMENT SIDE BEARING PRELOAD"
11. Install differential case assembly with side bearing outer races
into gear carrier.

SPD203

12. Insert left and right side bearing adjusting washers in place
between side bearing and carrier.

SPD558

13. Drive in side bearing spacer with Tool.


Tool number: KV38100600

SPD709

14. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.

SPD226

RFD-24
REAR FINAL DRIVE ASSEMBLY
[C200]
15. Measure ring gear-to-drive pinion backlash with a dial indicator.
Ring gear-to-pinion backlash: A
0.13 - 0.18 mm (0.0051 - 0.0071 in)
If backlash is too small, decrease thickness of right shim and B
increase thickness of left shim by the same amount.
If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the C
bearing preload.
SPD196
RFD
16. Check total preload with Tool.
When checking preload, turn drive pinion in both directions sev-
eral times to seat bearing rollers correctly.
E
Total preload:
1.4 - 2.8 N-m (0.14 - 0.29 kg-m, 13 - 25 in-lb)
F

G
SPD241

If preload is too great, remove the same amount of shim from


each side. H
If preload is too small, add the same amount of shim to each
side.
Never add or remove a different number of shims for each side as it I
will change ring gear-to-pinion backlash.
17. Recheck ring gear-to-pinion backlash because increase or
decrease in thickness of shims will cause change of ring gear- J
to-pinion backlash.
SPD561
K
18. Check runout of ring gear with a dial indicator.
Runout limit: 0.05 mm (0.0020 in)
L
If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the
ring gear and the differential case.
M
If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced.
19. Check tooth contact.
Refer toRFD-20, "Tooth Contact" SPD702

20. Install rear cover and gasket.

RFD-25
SERVICE DATA AND SPECIFICATIONS (SDS)
[C200]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications EDS000GV

Rear final drive 4 pinion


Gear ratio 4.875
Number of teeth (Ring gear/drive pinion) 39/8

Oil capacity (Approx.) (Imp pt) 1.3 (2 - 1/4)

Ring gear runout EDS000GW

Ring gear runout limit mm (in) 0.05 (0.0020)

Side gear adjustment EDS000GX

Side gear backlash (Clearance between side gear and differential case) mm (in) Less than 0.15 (0.0020)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-N3110
0.78 (0.0307) 38424-N3111
Available side gear thrust washers 0.81 (0.0319) 38424-N3112
0.84 (0.0331) 38424-N3113
0.87 (0.0343) 38424-N3114
0.90 (0.0354) 38424-N3115
0.93 (0.0366) 38424-N3116
* Always check with the Parts Department for the latest parts information.

Side Bearing Adjustment EDS000GY

Differential carrier assembly turning resistance N (kg, lb) 34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)
Thickness mm (in) Part number*
2.00 (0.0787) 38453-N3100
2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N3102
2.15 (0.0846) 38453-N3103
2.20 (0.0866) 38453-N3104
Available side bearing adjusting wash- 2.25 (0.0886) 38453-N3105
ers 2.30 (0.0906) 38453-N3106
2.35 (0.0925) 38453-N3107
2.40 (0.0945) 38453-N3108
2.45 (0.0965) 38453-N3109
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111
2.60 (0.1024) 38453-N3112
* Always check with the Parts Department for the latest parts information.

Total Preload Adjustment EDS000GZ

Total preload N-m (kg-m, in-lb) 1.4 - 2.8 (0.14 - 0.29, 13 - 25)
Ring gear-to-pinion backlash mm (in) 0.13 - 0.18 (0.0051 - 0.0071)

RFD-26
SERVICE DATA AND SPECIFICATIONS (SDS)
[C200]
Drive Pinion Height Adjustment EDS000H0

A
Thickness mm (in) Part number*
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
B
3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020
3.21 (0.1264) 38154-P6021
3.24 (0.1276) 38154-P6022 C
3.27 (0.1287) 38154-P6023
3.30 (0.1299) 38154-P6024
Available pinion height adjusting 3.33 (0.1311) 38154-P6025
washers 3.36 (0.1323) 38154-P6026 RFD
3.39 (0.1335) 38154-P6027
3.42 (0.1346) 38154-P6028
3.45 (0.1358) 38154-P6029
3.48 (0.1370) 38154-P6030 E
3.51 (0.1382) 38154-P6031
3.54 (0.1394) 38154-P6032
3.57 (0.1406) 38154-P6033
3.60 (0.1417) 38154-P6034 F
3.63 (0.1429) 38154-P6035
3.66 (0.1441) 38154-P6036
* Always check with the Parts Department for the latest parts information. G

Drive Pinion Preload Adjustment EDS000H1

Drive pinion bearing preload adjusting method Collapsible spacer H


Drive pinion preload with front oil seal N-m (kg-m, in-lb) 1.1 - 1.7 (0.11 - 0.17, 9.5 - 15)
Drive pinion preload without front oil seal N-m (kg-m, in-lb) 1.0 - 1.6 (0.10 - 0.16, 8.7 - 14)
I

RFD-27
PRECAUTIONS
[H233B]
PRECAUTIONS
[H233B] PFP:00001

Caution EDS000G5

Before starting diagnosis of vehicle, understand trouble symptoms well. Perform correct and systematic
operations.
Check for the correct installation status prior to removal or disassembly. When mating marks are required,
be sure they do not interfere with the function of the parts they are applied to.
Perform overhaul in clean place. Using a dustproof room is recommended.
Before disassembly, using steam or white gasoline, etc., completely remove sand and mud from exterior
of unit, and prevent them from entering into unit during disassembly or assembly.
Check appearance of disassembled parts for damage, deformation, and unusual wear. If a malfunction is
detected, replace it with a new one.
As a rule, replace lock pins, oil seals, and bearings with new ones every time they are removed.
Use Nissan Genuine Parts for replacement.
In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
Clean and flush the parts sufficiently, and blow them dry.
Be careful not to damage sliding surfaces and mating surfaces.
When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
Always use shop paper for cleaning the inside of components.
Do not use cotton gloves or a shop cloth. Using them may leave lint on the surface of the parts.
During assembly, observe the specified tightening torque, and apply new deferential oil, Vaseline, or multi-
purpose grease as specified for each vehicle, when necessary.
Do not reuse drained oil. Discard waste oil after oil changes or treating part in accordance with local laws
and regulations.

RFD-28
PREPARATION
[H233B]
PREPARATION PFP:00002
A
Special Service Tools EDS000GB

Tool name
Description
Tool number B

Differential attachment C
ST06340000
Mounting final drive

RFD
NT140

E
Differential side bearing adjusting
Adjusting side bearing preload and backlash
nut wrench
(ring gear-drive pinion)
ST32580000
F
NT141

Drive pinion rear inner race puller set


G
ST3306S001
Puller
(1) ST30031000
Removing and installing drive pinion rear
Base H
inner cone.
(2) ST30901000
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia. NT527
c: 35 mm (1.38 in) dia. I

Differential side bearing puller set


Body
(1) ST33051001 J
Removing and installing differential side
Adapter
bearing inner cone.
(2) ST33061000
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
K
NT072

Differential side bearing drift L


ST33190000
a: 52 mm (2.05 in) dia. Installing side bearing inner cone.
b: 45.5 mm (1.791 in) dia.
c: 34 mm (1.34 in) dia. M
NT085

Side bearing puller adapter


ST33081000
Installing side bearing inner cone
a: 43 mm (1.69 in) dia.
b: 33.5 mm (1.319 in) dia.

NT431

Drift Installing pinion rear bearing outer race


ST30611000 (Use with ST30621000 or ST30613000)

NT090

RFD-29
PREPARATION
[H233B]
Tool name
Description
Tool number

Drift
ST30621000 Installing pinion rear bearing outer race
a: 79 mm (3.11 in) dia. (Use with ST30611000)
b: 59 mm (2.32 in) dia.

NT073

Drift
ST30613000 Installing pinion front bearing outer race
a: 72 mm (2.83 in) dia. (Use with ST30611000)
b: 48 mm (1.89 in) dia.

NT073

Oil seal fitting tool


KV381025S0
Drift bar
(1) ST30720000
a: 77 mm (3.03 in) dia.
Installing front oil seal
b: 55 mm (2.17 in) dia.
Drift
(2) KV38102510
c: 71 mm (2.80 in) dia. NT525
d: 65 mm (2.56 in) dia.
Drive pinion height setting gauge set
KV381001S0
Dummy shaft
(1) KV38100110
Height gauge
Selecting pinion height adjusting washer
(2) KV38100120
Collar
(3) KV38100130
Stopper NT512
(4) KV38100140

Drive pinion height setting gauge set


ST3125S000
Height gauge
Selecting pinion height adjusting washer
(1) ST31251000
Dummy shaft
(2) ST31181001
NT524

Rear axle shaft dummy


KV381052S0
Torque wrench side Checking differential torque on limited slip
(1) KV38105210 differential
Vise side
(2) KV38105220
NT142

Gear carrier front oil seal drift


KV38100500
Installing front oil seal
a: 85 mm (3.35 in) dia.
b: 60 mm (2.36 in) dia.

NT115

RFD-30
NVH Troubleshooting Chart
: Applicable

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING


Symptom

Possible cause and SUSPECTED PARTS

Reference page

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING


DIFFERENTIAL
Noise
RFD-31

Rough gear tooth Refer toRFD-42RFD-39


Inproper gear contact Refer toRFD-49


Tooth surfaces worn Refer to RFD-42RFD-39


Incorrect baklash Refer toRFD-35


Companion flange excessive runout

Improper gear oil Refer to MA section.

PROPELLER SHAFT NVH in PR section.


AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.

TIRES NVH in WT sectiont.


ROAD WEEL NVH in WT section.


DRIVE SHAFT NVH in RAX section.


[H233B]
PFP:00003
BRAKES NVH in BR section.

EDS000G4
STEERING NVH in PS section.

RFD
M

G
H

C
K

A
F
L

I
FRONT OIL SEAL
[H233B]
FRONT OIL SEAL PFP:38189

Removal and Installation EDS000G6

REMOVAL
1. Remove Propeller Shaft.
2. Put a mark on the end of the drive pinion corresponding to the B
position mark on the final drive companion flange.
CAUTION:
When making mating marks, use paint, etc., to avoid
scratching on surface.

SDIA0270E

3. Using a differential flange tool, remove drive pinion gear nut.


4. Using a puller, remove companion flange.
5. Using a flat-bladed screwdriver, remove oil seal.

SPD738

INSTALLATION
1. Apply multi-purpose grease to oil seal lips. Using a drift (special
service tool) as shown, install oil seal. It should become flush
with case end surface.
Tool number :KV38100500
CAUTION:
When installing, be careful not to incline oil seal.
Discard old oil seal; replace with a new one.

SPD739

2. Align mating marks on companion flange and drive pinion gear,


then install companion flange.
3. Apply anti-corrosive oil to drive pinion gear thread and pinion nut
seating surface. Then, install pinion nut to companion flange.
4. Install propeller shaft.

SDIA0270E

RFD-32
REAR FINAL DRIVE ASSEMBLY
[H233B]
REAR FINAL DRIVE ASSEMBLY PFP:38300
A
Removal and Installation EDS000G7

REMOVAL
1. Remove rear of propeller shaft.
B
Plug front end of transfer.
2. Remove drain plug to drain oil.
3. Remove axle shaft.
C
Refer to RAX-7, "Removal and Installation"
4. Remove rear final drive mounting bolts.
CAUTION: RFD
Be careful not to damage spline, sleeve yoke and front oil seal when removing propeller shaft.
INSTALLATION
Fill final drive with recommended gear oil. E

SPD123 H

Pay attention to the direction of gasket.


I

SPD767

RFD-33
REAR FINAL DRIVE ASSEMBLY
[H233B]
Disassembled Drawing EDS000GK

SDIA0505E

RFD-34
REAR FINAL DRIVE ASSEMBLY
[H233B]
Inspection before Disassembly EDS000G8

A
Before disassembling final drive, perform the following inspection.
TOTAL PRELOAD
1. Turn drive pinion in both directions several times to seat bearing B
rollers correctly.
2. Check total preload with Tool.
Total preload: C

P1 +[0.3 - 0.4 N-m (0.003 - 0.04 kg-m, 2.6 -3.5 in-lb)]


P1 :Drive pinion preload RFD

SPD149 E
RING GEAR TO DRIVE PINION BACKLASH
Check backlash of ring gear with a dial indicator at several
points. F
Ring gear to drive pinion backlash:
0.13 - 0.18mm (0.0051 - 0.0071 in) G

SPD246
I
RING GEAR RUNOUT
Check runout of ring gear with a dial indicator.
Runout limit: J
0.08mm (0.0031 in)

SPD247

TOOTH CONTACT M
Check tooth contact. Refer to RFD-49, "Tooth Contact"
Disassembly and Assembly EDS000G9

REMOVE DRIVE GEAR AND DIFFERENTIAL CASE ASSEMBLY


1. Mount final drive assembly on tool.
Tool number: ST06340000

SPD683

RFD-35
REAR FINAL DRIVE ASSEMBLY
[H233B]
2. Put match marks on one side of side bearing cap with paint or
punch to ensure that it is replaced in proper position during reas-
sembly.
Bearing caps are line-bored during manufacture and should
be put back in their original places.

SPD249

3. Remove side lock fingers and side bearing caps.

SPD250

4. Remove side bearing adjuster with tool.


Tool number: ST32580000

SPD684

5. Remove differential case assembly with a pry bar.

SPD685

RFD-36
REAR FINAL DRIVE ASSEMBLY
[H233B]
Be careful to keep the side bearing outer races together with
their respective inner cones - do not mix them up. A

SPD011
RFD
REMOVE DRIVE PINION GEAR ASSEMBLY
1. Remove drive pinion nut with tool.
2. Remove companion flange with puller. E

G
SPD480A

3. Take out drive pinion together with pinion rear bearing inner H
cone, drive pinion bearing spacer and pinion bearing adjusting
shim.
I

SPD687 K

4. Remove front oil seal and pinion front bearing inner cone.
5. Remove pinion bearing outer races with a brass drift. L

SPD563

RFD-37
REAR FINAL DRIVE ASSEMBLY
[H233B]
6. Remove pinion rear bearing inner cone and drive pinion adjust-
ing washer.
Tool number: ST30031000

SPD018

DISASSEMBLY DIFFERENTIAL CASE (2PINION)


1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove

Tool number:
A ST33051001
B ST33061000

SPD207A

Be careful not to confuse the left and right hand parts.


Keep bearing and bearing race for each side together.

SPD022

2. Loosen ring gear bolts in a criss-cross pattern.


3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD024

RFD-38
REAR FINAL DRIVE ASSEMBLY
[H233B]
4. Drive out pinion mate shaft lock pin, with punch from ring gear
side. A
Lock pin is calked at pin hole mouth on differential case.

SPD025
RFD
Follow Parts Inspection, check the following parts, and take
action against it: side gear, side gear thrust washer, pinion
mating shaft, pinion mating gear, pinion, pinion mating thrust E
washer, thrust block, and differential gear case.

G
SPD584

PARTS INSPECTION (2PINION) H


Item Corrective action
If tooth contact is unusual, determine the possible cause. When assembling, adjust tooth contact
Drive gear properly. If gear is worn out excessively, or cannot be adjusted properly, replace it as a set. I
Drive pinion If cracks, damage, and seizure is detected on tooth face, replace it as a set.
If tooth damage is light, repair it using oil stone.
Check for seizure, peeling, wear, and corrosion. Also check for sticking, unusual noise, and J
Bearing
roughness while turning bearing. If any, replace it.

Side gear If cracks or damage is detected on tooth face, replace it.


Pinion mating gear If wear or seizure is detected on thrust washer face, replace it. K
Side gear thrust washer If seizure, damage, of unusual wear is detected, replace it.
Oil seal Normally, replace it when disassembling. If settling or damage is detected, be sure to replace it.
L
Differential case If wear or a crack is detected on sliding surface, replace it.
Companion flange If damage, wear, or seizure is detected on lip contact surface of oil seal, replace it.
M
ASSEMBLY DIFFERENTIAL CASE (2PINION)
1. Install side gears, pinion mate gears and thrust washers into dif-
ferential case.

SPD552

RFD-39
REAR FINAL DRIVE ASSEMBLY
[H233B]
2. Fit pinion mate shaft to differential case so that it meets lock pin
holes.
3. Adjust backlash between side gear and pinion mate gear by
selecting side gear thrust washer.
Refer to RFD-54, "SERVICE DATA AND SPECIFICATIONS
(SDS)"
Backlash between side gear and pinion mate gear
(Clearance between side gear thrust washer and dif-
ferential case):
SPD258
0.10 - 0.20 mm (0.0039 - 0.0079 in)
4. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.

SPD030

5. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.
6. Install differential case assembly on ring gear.
Tighten bolts in a criss-cross pattern, lightly tapping bolt head
with a hammer.

SPD322

7. Press-fit side bearing inner cones on differential case with Tool.


Tool number:
A ST33190000
B ST33081000

S-PD244

RFD-40
REAR FINAL DRIVE ASSEMBLY
[H233B]
DISASSEMBLY DIFFERENTIAL CASE (LIMITED SLIP DIFFERENTIAL)
A

RFD

SDIA0506E I
CAUTION:
Do not run engine when one wheel (rear) is off the ground.
1. Measure differential torque with Tool. J
If it is not within the specifications, inspect components of limited
slip differential.
Differential torqu: K
88 - 108 N-m (9 - 11 kg-m, 65 - 80 ft-lb)
Tool number: A KV38105210 L
Tool number: B KV38105220

SPD415 M

2. Remove side bearing inner cone with Tool.


3. Loosen ring gear bolts in a criss-cross pattern.
4. Tap ring gear off gear case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD275

RFD-41
REAR FINAL DRIVE ASSEMBLY
[H233B]
5. Remove couple bolts on differential cases A and B with a press.
Tool number: ST33081000
6. Separate differential case A and B.
Draw out component parts (discs and plates, etc.).
Put marks on gears and pressure rings so that they can be
reinstalled in their original positions from which they were
removed.
Clean the disassembled parts in suitable solvent and blow dry
with compressed air.
SPD363A

If following surfaces are found with burrs or scratches, smooth


with oil stone.
1.Differential case B
2.Differential case A
3.Side gear
4.Pinion mate gear
5.Pinion mate shaft
6.Friction plate guide

SPD359A

PARTS INSPECTION (LIMITED SLIP DIFFERENTIAL)


Item Corrective action
If tooth contact is unusual, determine the possible cause. When assembling, adjust tooth contact
Drive gear properly. If gear is worn out excessively, or cannot be adjusted properly, replace it as a set.
Drive pinion If cracks, damage, and seizure is detected on tooth face, replace it as a set.
If tooth damage is light, repair it using oil stone.
Check for seizure, peeling, wear, and corrosion. Also check for sticking, unusual noise, and
Bearing
roughness while turning bearing. If any, replace it.

Side gear If cracks or damage is detected on tooth face, replace it.


Pinion mating gear If wear or seizure is detected on thrust washer face, replace it.
Side gear thrust washer If seizure, damage, of unusual wear is detected, replace it.
Oil seal Normally, replace it when disassembling. If settling or damage is detected, be sure to replace it.
Differential case If wear or a crack is detected on sliding surface, replace it.
Companion flange If damage, wear, or seizure is detected on lip contact surface of oil seal, replace it.

Disc and Plate


1. Clean the discs and plates in suitable solvent and blow dry with compressed air.
2. Inspect discs and plates for wear, nicks and burrs.

RFD-42
REAR FINAL DRIVE ASSEMBLY
[H233B]
3. To test if friction disc or plate is not distorted, place it on a spur-
face plate and rotate it by hand with indicating finger of dial A
gauge resting against disc or plate surface.
Allowable warpage:
0.08 mm (0.0031 in) B

If it exceeds limits, replace with a new plate to eliminate pos-


sibility of clutch slippage or sticking.
C

SPD279
RFD
4. Measure frictional surfaces and projected portions of friction
disc, friction plate, spring plate, and determine each part's differ-
ences to see if the specified wear limit has been exceeded. E
If any part has worn beyond the wear limit, and deformed or
fatigued, replace it with a new one that is the same thickness
as the projected portion. F
Wear limit:
0.1mm (0.004 in) or less
A B = Wear limit mm (in) G

Measuring points
A: Projected portion
B: Frictional surface H

SPD381A
K
ADJUSTMENT DIFFERENTIAL CASE (LIMITED SLIP DIFFERENTIAL)
Friction Disc and Friction Plate End Play
End play of friction disc and friction plate can be calculated by L
using following equation and should be adjusted within following
range.
Adjustment can be made by selecting friction disc having two M
different thicknesses.
End play E:
0.05 - 0.15 mm (0.0020 - 0.0059 in)
E = A (B + C)
A: Length of differential case contact surface to differential case
SPD383A
inner bottom.

RFD-43
REAR FINAL DRIVE ASSEMBLY
[H233B]
B: Total thickness of friction discs, friction plates, spring disc and
spring plate in differential case on one side.
C: Length of differential case contact surface to back side of side
gear.
1. Measure values of A.
Standard length A:
49.50 - 49.55 mm (1.9488 - 1.9508 in)

SPD417

2. Measure thickness of each disc and plate.


Total thickness B:
19.24 - 20.26 mm (0.7575 - 0.7976 in)

SPD420

3. Measure values of C.
a. Attach a dial indicator to the base plate.
b. Place differential case B on the base plate, and install a master
gauge on case B.
Then adjust the dial indicator scale to zero with its tip on the
master gauge.

SPD418

c. Install pinion mate gears, side gears and pinion mate shaft in dif-
ferential case B.
d. Set dial indicator's tip on the side gear, and read the indication.
Example:
E = A - D = A - (B + C) = 0.05 to 0.15 mm
A = 49.52 mm
B = 19.45 mm
C = 29.7 mm
D =B +C SPD419

49.15 (D) = 19.45 (B) + 29.7 (C)


E=A -D
0.37 (E) = 49.52 (A) - 49.15 (D)
From the above equation, end play of 0.37 mm exceeds the specified range of 0.05 to 0.15 mm.
Select suitable discs and plates to adjust correctly.

RFD-44
REAR FINAL DRIVE ASSEMBLY
[H233B]
ASSEMBLY DIFFERENTIAL CASE (LIMITED SLIP DIFFERENTIAL)
Prior to assembling discs and plates, properly lubricate them by A
dipping them in limited slip differential oil.
1. Alternately position specified number of friction plates and fric-
tion discs on rear of side gear. B
Always position a friction plate first on rear of side gear.

SPD421 RFD

2. Install spring plate.


E

SPD384A
H
3. Install friction plate guides.
Correctly align the raised portions of friction plates, and apply
grease to inner surfaces of friction plate guides to prevent I
them from falling.

K
SPD385A

4. Install differential case B over side gear, discs, plates and fric- L
tion plate guide assembly.
Install differential case B while supporting friction plate guides
with your middle finger inserted through oil hole in differential M
case.
Be careful not to detach spring disc from the hexagonal part of
the side gear.

SPD386A

RFD-45
REAR FINAL DRIVE ASSEMBLY
[H233B]
5. Install pinion mate gears and pinion mate thrust washers on pin-
ion mate shaft, then install pinion mate shaft in differential case
B.

SPD426

6. Install side gear to pinion mate gears.


7. Install each disc and plate.
Use same procedures as outlined in steps 1. through 4.
above.

SPD387A

8. Install differential case A.


Position differential cases A and B by correctly aligning marks
stamped on cases.

SPD388A

9. Tighten differential case couple bolts.


10. Place ring gear on differential case and tighten ring gear bolts.
Tighten bolts in a criss-cross pattern, lightly tapping bolt head
with a hammer.
Then bend up lock straps to lock the bolts in place.

11. Check differential torque.

SPD364A

RFD-46
REAR FINAL DRIVE ASSEMBLY
[H233B]
12. Press-fit side bearing inner cones on differential case with Tool.
A
Tool number:
A ST33190000
B ST33081000 B

S-PD244
RFD
ADJUSTMENT DRIVE PINION
To avoid confusion while calculating bearing shims, it is absolutely necessary to stay with the metric sys-
tem. If you measure anything in inches, the results must be converted to the metric system.
E
Drive Pinion Height
1. First prepare Tools for pinion height adjustment.
1. Height Gauge (ST31251000) F
2. Dummy Shaft (ST31181001)
3. Spacer [thickness: 2.50 mm (0.0984 in)]
4. Feeler Gauge G
2. To simplify the job, make a chart, like the one below, to organize
your calculations.
H
LETTERS HUNDREDTHS OF A MILLIMETER
H: Head number SPD758

D: Figure marked on dummy shaft I


S: Figure marked on height gauge
N: Measuring clearance
J
3. Write the following numbers down in the chart.
H: Head number
K

M
SPD542

D: Figure marked on dummy shaft

SPD759

RFD-47
REAR FINAL DRIVE ASSEMBLY
[H233B]
S: Figure marked on height gauge

SPD760

4. Place pinion rear bearing inner race and Tools on gear carrier.

SPD271

5. Attach Tool (Height gauge) to gear carrier, and measure the


clearance between the height gauge tip and the dummy shaft
face.

SPD365A

6. Substitute these values into the equation to calculate the thickness of the washer.

RFD-48
REAR FINAL DRIVE ASSEMBLY
[H233B]
If values signifying H, D and S are not given, regard them as zero and calculate.
A

RFD

SPD541A I
7. Select the proper pinion height washer.
Drive pinion height adjusting washer:
J
Refer to RFD-54, "SERVICE DATA AND SPECI-
FICATIONS (SDS)"
If you cannot find the desired thickness of washer, use washer with thickness closest to the calculated K
value.
Example:
L
Calculated value T = 3.32 mm
Used washer T = 3.33 mm
Tooth Contact M
Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive
pinion.
Hypoid gear sets which are not positioned properly in relation to one another may be noisy, or have short
life or both. With a pattern check, the most desirable contact for low noise level and long life can be
assured.
1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD005

RFD-49
REAR FINAL DRIVE ASSEMBLY
[H233B]
3. Hold companion flange steady by hand and rotate the ring gear
in both directions.

SPD695

SPD007-B

ASSEMBLY DIFFERENTIAL CARRIER


1. Press-fit front and rear bearing outer races with Tools.
Tool number
A ST30611000
B ST30621000
C ST30613000

SPD580

RFD-50
REAR FINAL DRIVE ASSEMBLY
[H233B]
2. Select drive pinion height adjusting washer. Refer to
3. Install drive pinion adjusting washer in drive pinion, and press fit A
pinion rear bearing inner cone in it, with press and Tool.
Tool number:
B
ST30901000

SPD377
RFD
4. Place pinion front bearing inner cone in gear carrier.

G
SPD581

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.


Install front oil seal. H
Tool number:
A ST30720000 I
B KV38102510

SPD291A
K
6. Install drive pinion bearing spacer, pinion bearing adjusting shim
and drive pinion in gear carrier.
L

SPD935-A

7. Insert companion flange into drive pinion by tapping the com-


panion flange with a soft hammer.

SPD697

RFD-51
REAR FINAL DRIVE ASSEMBLY
[H233B]
8. Tighten pinion nut to the specified torque.
The threaded portion of drive pinion and pinion nut should be
free from oil or grease.

SPD481A

9. Turn drive pinion in both directions several times, and measure


pinion bearing preload.
Pinion bearing preload (Without front oil seal):
1.2 - 2.0 N-m (0.12 - 0.20 kg-m, 10 - 17 in-lb)
If preload is out of specification, adjust the thickness of spacer and
shim combination by replacing shim and spacer with thinner one.
Start from the combination of thickest spacer and shim.
Combine each spacer and shim thickness one by one until the
correct specification are achieved. SPD149

Drive pinion bearing preload adjusting spacer and


shim:
Refer to RFD-54, "SERVICE DATA AND SPECI-
FICATIONS (SDS)"
10. Install differential case assembly with side bearing outer races
into gear carrier.
11. Position side bearing adjusters on gear carrier with threads
properly engaged; screw in adjusters lightly at this stage of
assembly.
Tool number: ST32580000

SPD684

12. Align mark on bearing cap with that on gear carrier and install
bearing cap on gear carrier.
Do not tighten at this point to allow further tightening of side
bearing adjusters.

SPD265

RFD-52
REAR FINAL DRIVE ASSEMBLY
[H233B]
13. Tighten both right and left side bearing adjusters alternately and
measure ring gear backlash and total preload at the same time. A
Adjust right and left side bearing adjusters by tightening them
alternately so that proper ring gear backlash and total preload
can be obtained.
B
Ring gear-to-drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
C

SPD246
RFD
When checking preload, turn drive pinion in both directions sev-
eral times to set bearing rollers.
Tool number: ST3127S000 E
Total preload:
P1 + [0.3 - 0.4 N-m (0.03 - 0.04 kg-m, 2.6 - 3.5 in-lb)]
P1 : Drive pinion preload F

G
SPD149

14. Tighten side bearing cap bolts.


H
15. Install side lock finger in place to prevent rotation during opera-
tion.

SPD698
K
16. Check runout of ring gear with a dial indicator.
Runout limit: 0.08 mm (0.0031 in) L
If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the ring
gear and the differential case. M
If the backlash varies greatly when the runout of the ring gear is
within a specified range, the hypoid gear set or differential case
should be replaced.
17. Check tooth contact. Refer to RFD-49, "Tooth Contact"
SPD247

RFD-53
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications EDS000GF

Stnderd Optional
Rear final drive 2-pinion LSD
Gear retio 4.875 4.900
Number of teeth (Ring gear/drive pinion) 39/8 49/10
Oil capacity(Approx.) (Imp) 2.8(4-7/8)

Ring Gear Runout EDS000GC

Drive gear back runout limit mm(in) 0.08 (0.0031)

Side Gear Clearance Adjustment EDS000GD

Side gear backlash (Clearance bettween side gear and differential case) mm(in) 0.10-0.020(0.0039-0.0079)
Thickness mm(in) Part number
Available side gear thrust washers 1.75(0.0689) 38424-T5000
1.80(0.0709) 38424-T5001
1.85(0.0728) 38424-T5002
*:Always check with the Parts Department for the latest parts information.

DIFFERENTIAL TORQUE ADJUSTMENT (LSD MODELS)


Differential torque Nm(kg-m,ft-lb) 88- 108(9-11,65-80)
Friction disc 5
Friction plate 6
Number of discs and plates(One side)
Spring plate 2
Wear limit of plate and disc mm(in) 0.1(0.004)
Allowable warpage of friction disc and plate mm(in) 0.08(0.0031)
Plate name Thickness mm(in) Part number*
1.48-1.52(0.0583-0.0598) 38433-C6002(Standard type)
Friction disc 1.38-1.42(0.543-0.0559) 38433-C6004(Adjusting type)
Available discs
1.58-1.62(0.0622-0.0638) 38433-C6003(Adjusting type)
and plates
1.48-1.52(0.0583-0.0598) 38432-C6001
Friction plate 1.38-1.42(0.543-0.0559) 38432-C6002
1.58-1.62(0.0622-0.0638) 38432-C6003
*:Always check with the Parts Department for the latest parts information.

Total Preload Adjustment EDS000GE

Total preload Nm (kg-cm,in-lb) P1+[0.3-0.4(3-4,2.6-3.5)]


Ring gear backlash mm (in) 0.13-0.18(0.0051-0.0071)
Side bearing adjusting method Side adjuster

RFD-54
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]
DRIVE PINION HEIGHT ADJUSTMENT
Thickness mm (in) Part number*
A

2.58(0.1016) 38151-01J00
2.61(0.1028) 38151-01J01
2.64(0.1039) 38151-01J02 B
2.67(0.1051) 38151-01J03
2.70(0.1063) 38151-01J04
2.73(0.1075) 38151-01J05
2.76(0.1087) 38151-01J06 C
2.79(0.1098) 38151-01J07
2.82(0.1110) 38151-01J08
2.85(0.1122) 38151-01J09
RFD
2.88(0.1134) 38151-01J10
2.91(0.1146) 38151-01J11
2.94(0.1157) 38151-01J12
2.97(0.1169) 38151-01J13 E
3.00(0.1181) 38151-01J14
3.03(0.1193) 38151-01J15
3.06(0.1205) 38151-01J16
Available pinion height 3.09(0.1217) 38151-01J17 F
adjust washers 3.12(0.1228) 38151-01J18
3.15(0.1240) 38151-01J19
3.18(0.1252) 38151-01J60
3.21(0.1264) 38151-01J61 G
3.24(0.1276) 38151-01J62
3.27(0.1287) 38151-01J63
3.30(0.1299) 38151-01J64
3.33(0.1311) 38151-01J65
H
3.36(0.1323) 38151-01J66
3.39(0.1335) 38151-01J67
3.42(0.1346) 38151-01J68
I
3.45(0.1358) 38151-01J69
3.48(0.1370) 38151-01J70
3.51(0.1382) 38151-01J71
3.54(0.1394) 38151-01J72 J
3.57(0.1406) 38151-01J73
3.60(0.1417) 38151-01J74
3.63(0.1429) 38151-01J75
3.66(0.1441) 38151-01J76 K
*:Always check with the Parts Department for the latest parts information.

RFD-55
SERVICE DATA AND SPECIFICATIONS (SDS)
[H233B]
DRIVE PINION PRELOAD ADJUSTMENT
Drive pinion bearing preload adjusting method Adjusting shim and spacer
Drive pinion preload without front oil seal Nm (kg-cm,in-lb) [P1] 1.2-2.0(12-20,10-17)
Thickness mm (in) Part number*
2.31(0.0909) 38125-82100
2.33(0.0917) 38126-82100
2.35(0.0925) 38127-82100
2.37(0.0933) 38128-82100
Available front 2.39(0.0941) 38129-82100
drive pinion 2.41(0.0949) 38130-82100
bearing adjusting 2.43(0.0957) 38131-82100
shims 2.45(0.0965) 38132-82100
2.47(0.0972) 38133-82100
2.49(0.0980) 38134-82100
2.51(0.0988) 38135-82100
2.53(0.0996) 38136-82100
2.55(0.1004) 38137-82100
2.57(0.1012) 38138-82100
2.59(0.1020) 38139-82100
Thickness mm (in) Part number*
Available 4.50(0.1772) 38165-76000
drive pinion 4.75(0.1870) 38166-76000
bearing adjusting 5.00(0.1969) 38167-76000
spacers 5.25(0.2067) 38166-01J00
5.50(0.2165) 38166-01J10
*:Always check with the Parts Department for the latest parts information.

RFD-56