Nissan Pathfinder (2009 year). Instruction — part 234

DLN-354

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

1.

Place the differential case straight up so that the side gear to be
measured is upward.

2.

Using feeler gauges, measure the clearance between the side
gear back and differential case at three different points, while
rotating the side gear. Average the three readings to calculate
the clearance. (Measure the clearance of the other side as well.)

• If the side gear back clearance is outside of the specification,

use a thicker or thinner side gear thrust washer to adjust.
Refer to

DLN-364, "Inspection and Adjustment"

.

CAUTION:

• Insert feeler gauges with the same thickness on both

sides to prevent side gear from tilting.

• Each gear should rotate smoothly without excessive

resistance during differential motion.

• Select a side gear thrust washer for right and left individu-

ally.

NOTE:
Side gear back clearance is clearance between side gear and differential case for adjusting side gear
backlash.

Drive Pinion Height

1.

Make sure all parts are clean and that the bearings are well lubricated.

2.

Assemble the drive pinion bearings onto the Tool.

PDIA0460E

Side gear back clearance:

0.1 mm (0.004 in) or less.

If the side gear back clearance is greater than
specification:

Use a thicker side gear thrust washer.

If the side gear back clearance is less than spec-
ification:

Use a thinner side gear thrust washer.

PDIA0576E

Tool number

:

—

(J-34309)

SPD769

2009 Pathfinder

FRONT FINAL DRIVE

DLN-355

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

• Drive pinion front bearing; make sure the J-34309-3 drive

pinion front bearing seat is secured tightly against the J-
34309-2 gauge anvil. Then turn the J-34309-7 drive pinion
front bearing pilot to secure the drive pinon front bearing in its
proper position.

• Drive pinion rear bearing; the J-34309-8 drive pinion rear

bearing pilot is used to center the drive pinion rear bearing
only. The J-34309-4 drive pinion rear bearing locking seat is
used to lock the drive pinion rear bearing to the assembly.

• Installation of J-34309-9 and J-34309-16; place a suitable

2.5 mm (0.098 in) thick plain washer between J-34309-9 and
J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must
be parallel with a clearance of 2.5 mm (0.098 in).

3.

Install the drive pinion rear bearing inner race into the gear car-
rier. Then insert the drive pinion height adjusting washer selec-
tor tool, J-34309-1, gauge screw assembly.

4.

Assemble the drive pinion front bearing inner race and the J-
34309-2 gauge anvil. Assemble them together with the J-34309-
1 gauge screw in the gear carrier. Make sure that the drive pin-
ion height gauge plate, J-34309-16, will turn a full 360

°

. Tighten

the two sections together by hand.

5.

Turn the assembly several times to seat the drive pinon bear-
ings.

SPD197A

SPD893

SPD199A

SPD770

2009 Pathfinder

DLN-356

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

6.

Measure the turning torque at the end of the J-34309-2 gauge
anvil using Tool.

7.

Place the J-34309-10 “R180A” drive pinion height adapter onto
the gauge plate and tighten it by hand.

CAUTION:

Make sure all machined surfaces are clean.

8.

Position the side bearing discs, Tool, and arbor firmly into the
side bearing bores. Install the side bearing caps and tighten the
side bearing cap bolts to the specified torque. Refer to

DLN-345,

"Disassembly and Assembly"

.

9.

Select the correct standard drive pinion height adjusting washer
thickness. Select by using a standard gauge of 3 mm (0.12 in)
and your J-34309-101 feeler gauge. Measure the distance
between the J-34309-10 drive pinion height adapter, including
the standard gauge and the arbor.

10. Write down the exact measurement (the value of feeler gauge).

Tool number

: ST3127S000 (J-25765- A)

Turning torque specification:

1.0 - 1.6 N·m (0.11 - 0.16 kg-m, 9 - 14 in-lb)

PDIA0566E

SPD208A

Tool number

:

—

(J-25269-18)

SPD211A

SPD204A

SPD775

2009 Pathfinder

FRONT FINAL DRIVE

DLN-357

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

11. Correct the drive pinion height adjusting washer size by referring

to the drive pinion “head number”.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and drive gear as a matched
set. This number should be the same as the number on the
drive gear. The second number is the drive pinion “head
number”. It refers to the ideal drive pinion height from stan-
dard for quietest operation. Use the following chart to
determine the correct drive pinion height adjusting washer.

12. Select the correct drive pinion height adjusting washer. Refer to

DLN-364, "Inspection and Adjustment"

.

13. Remove the Tool from the gear carrier and disassemble to

retrieve the drive pinion bearings.

ASSEMBLY

Drive Pinion Assembly

Head number

Add or remove from the standard drive pinion

height adjusting washer thickness measurement

- 6
- 5
- 4
- 3
- 2
- 1

0

+1
+2
+3
+4
+5
+6

Add 0.06 mm (0.0024 in)
Add 0.05 mm (0.0020 in)
Add 0.04 mm (0.0016 in)
Add 0.03 mm (0.0012 in)
Add 0.02 mm (0.0008 in)
Add 0.01 mm (0.0004 in)

Use the selected washer thickness

Subtract 0.01 mm (0.0004 in)
Subtract 0.02 mm (0.0008 in)
Subtract 0.03 mm (0.0012 in)
Subtract 0.04 mm (0.0016 in)
Subtract 0.05 mm (0.0020 in)
Subtract 0.06 mm (0.0024 in)

Tool number

:

—

(J-34309)

SPD542

SPD205A

2009 Pathfinder

DLN-358

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

1.

Install drive pinion rear bearing outer race and drive pinion front
bearing outer race using Tools.

CAUTION:

• First tap the drive pinion bearing outer race until it

becomes flush with the gear carrier.

• Do not reuse drive pinion front and rear bearing outer

race.

2.

Select drive pinion height adjusting washer. Refer to

DLN-364, "Inspection and Adjustment"

.

3.

Install the selected drive pinion height adjusting washer to the
drive pinion. Press the drive pinion rear bearing inner race to it
using Tool.

CAUTION:

• Install the drive pinion height adjusting washer in the

proper direction as shown.

• Do not reuse drive pinion rear bearing inner race.

4.

Install the collapsible spacer to the drive pinion.

CAUTION:

Do not reuse collapsible spacer.

5.

Apply differential gear oil to the drive pinion rear bearing, and
install the drive pinion assembly to the gear carrier.

6.

Apply differential gear oil to the drive pinion front bearing, and
install the drive pinion front bearing inner race to the drive pinion
assembly.

CAUTION:

Do not reuse drive pinion front bearing inner race.

Tool number

A: ST30611000 (J-25742-1)

B: ST30613000 (J-25742-3)

C: KV38100200 (J-26233)

PDIA0707E

Tool number

: ST30901000 (J-26010-01)

SDIA0048E

PDIA0708E

2009 Pathfinder

FRONT FINAL DRIVE

DLN-359

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

7.

Press the drive pinion front bearing inner race to the drive pinion
as far as drive pinion lock nut can be tightened using Tool.

8.

Apply multi-purpose grease to the lips and differential gear oil to
the circumference of the new front oil seal. Then drive the new
front oil seal in evenly until it becomes flush with the gear carrier
using Tools.

CAUTION:

• Do not reuse front oil seal.
• Do not incline the new front oil seal when installing.
• Apply multi-purpose grease to the lips and differential

gear oil to the circumference of the new front oil seal.

9.

Install the companion flange to the drive pinion while aligning the matching marks.

10. Apply anti-corrosive oil to the threads of the drive pinion and the

seating surface of the new drive pinion lock nut. Then adjust the
drive pinion lock nut tightening torque using Tool A, and check
the drive pinion bearing preload torque using Tool B.

CAUTION:

• Do not reuse drive pinion lock nut.
• Apply anti-corrosive oil to the threads of the drive pinion

and the seating surface of the new drive pinion lock nut.

• Adjust the drive pinion lock nut tightening torque to the

lower limit first. Do not exceed the drive pinion lock nut
specified torque. Refer to

DLN-345, "Disassembly and

Assembly"

.

• If the drive pinion bearing preload torque exceeds the

specified value, replace collapsible spacer and tighten it
again to adjust. Do not loosen drive pinion lock nut to
adjust the drive pinion bearing preload torque.

• After adjustment, rotate drive pinion back and forth 2 to 3

times to check for unusual noise, rotation malfunction, and other malfunctions.

11. Check companion flange runout. Refer to

DLN-364, "Inspection and Adjustment"

.

12. Install the differential case assembly. Refer to

DLN-345, "Disassembly and Assembly"

.

Differential Assembly

Tool number

: ST33200000 (J-26082)

PDIA0709E

Tool number

A: ST30720000 (J-25405)

B: ST27863000 (

—

)

PDIA0717E

Tool number

A: KV38108300 (J-44195)

B: ST3127S000 (J-25765-A)

Drive pinion bearing preload torque:

1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)

WDIA0382E

2009 Pathfinder

DLN-360

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE

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.

2.

Install the side gears and side gear thrust washers into the dif-
ferential 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.

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 appro-
priate side gear thrust washers. Refer to

DLN-364, "Inspection

and Adjustment"

.

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.

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.

SDIA0193J

SDIA2025E

SDIA0195J

SPD030

SDIA2593E

2009 Pathfinder

FRONT FINAL DRIVE

DLN-361

< DISASSEMBLY AND ASSEMBLY >

[FRONT FINAL DRIVE: R180A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

8.

Apply thread locking sealant into the threaded holes of the drive
gear and install the new drive gear bolts.
• Use Genuine High Strength Thread Locking Sealant or equiv-

alent. Refer to

GI-26, "Recommended Chemical Products and

Sealants"

.

CAUTION:

Make sure the drive gear back and threaded holes are
clean.

9.

Tighten the new drive gear bolts to the specified torque. Refer to

DLN-345, "Disassembly and Assembly"

. After tightening the

new drive gear bolts to the specified torque, tighten an additional
34

°

to 39

°

using Tool.

CAUTION:

• Always use Tool. Avoid tightening based on visual check

alone.

• Tighten new drive gear bolts in a crisscross pattern.

10. Press the new side bearing inner races to the differential case

using Tools.

CAUTION:

Do not reuse side bearing inner races.

11. Install housing spacer into gear carrier.

12. Apply differential gear oil to the side bearings, and install the dif-

ferential 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).

SDIA2594E

Tool number

: KV10112100-A (BT-8653-A)

AWBIA0722ZZ

Tool number

A: ST33230000 (J-35867)

B: ST33061000 (J-8107-2)

SPD353

SPD527

2009 Pathfinder