Nissan Pathfinder (2011 year). Instruction — part 242

DLN-474

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230]

REAR FINAL DRIVE

8. Remove the drive pinion rear bearing inner race and drive pinion

height adjusting washer using Tool.

9. Remove the drive pinion front and rear bearing outer races by

tapping them uniformly using suitable tool.

CAUTION:

Do not damage gear carrier.

INSPECTION AFTER DISASSEMBLY

Clean the disassembled parts. Then inspect the parts for wear or damage. If wear or damage are found, follow

the measures below.

Drive Pinion and Drive Gear

• If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust,

repair, or replace as necessary.

• If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably,

replace with new drive pinion and drive gear.

• Drive pinion and drive gear are supplied in matched sets only. Matching numbers on both drive pinion and

drive gear are etched for verification. If a new drive pinion and drive gear set are being used, verify the num-

bers of each drive pinion and drive gear before proceeding with assembly.

Bearing

• If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bearing,

replace with new bearing assembly (as a new set).

• Bearing must be replaced with a new one whenever disassembled.

Side Gear and Pinion Mate Gear

• If any cracks or damage are found on the surface of the teeth, replace with new one.

• If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact the

thrust washer, replace with new one.

• Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.

Side Gear Thrust Washer and Pinion Mate Thrust Washer

• If any chips (by friction), damage, or unusual wear are found, replace with new one.

Gear Carrier

• If any wear or cracks are found on the contact sides of gear carrier, replace with new one.

Companion Flange

• If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the

front oil seal lips are found, replace with new one.

ADJUSTING AND SELECTING WASHERS

Side Gear Back Clearance

• Assemble the differential parts if they are disassembled.

Tool number:

: ST30031000 (J-22912-01)

S-PD179

SDIA0817E

2011 Pathfinder

REAR FINAL DRIVE

DLN-475

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230]

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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-483, "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 individually.

NOTE:

Side gear back clearance is clearance between side gear and differential case for adjusting side gear

backlash.

Side Bearing Preload Torque

• A selection of side bearing adjusting washers is required for successful completion of this procedure.
1. 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).

PDIA0460E

Side gear back clearance: Refer to

DLN-483, "Inspec-

tion and Adjustment"

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

SPD527

2011 Pathfinder

DLN-476

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230]

REAR FINAL DRIVE

2. Insert the left and right original side bearing adjusting washers in

place between side bearings and gear carrier.

3. Align the matching mark on the side bearing cap with the match-

ing mark on the gear carrier.

4. Install the side bearing caps and tighten the side bearing cap

bolts to the specified torque. Refer to

DLN-466, "Exploded

View"

.

5. Turn the differential assembly several times to seat the side

bearings.

6. To determine side bearing preload torque, measure the pulling

force of the differential assembly at the drive gear bolt using

Tool.

NOTE:

If pulling force of the differential assembly at the drive gear bolt

is within specification, side bearing preload torque will also be

within specification. Refer to

DLN-483, "Inspection and Adjustment"

.

7. If the pulling force is outside the specification, use a thicker or

thinner side bearing adjusting washer to adjust. Refer to

DLN-

483, "Inspection and Adjustment"

.

CAUTION:

Select a side bearing adjusting washer for right and left

individually.

8. Record the total amount of washer thickness required for the correct side bearing preload torque.

ASSEMBLY

Drive Pinion Assembly

SPD924

SDIA1795E

Tool number

:

—

(J-8129)

Specification

Refer to

DLN-483, "Inspection and Ad-

justment"

SPD194A

If the pulling force is less than the specification:

Use a thicker side bearing adjusting washer.

If the pulling force is greater than the specification:

Use a thinner side bearing adjusting washer.

SPD772

2011 Pathfinder

REAR FINAL DRIVE

DLN-477

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230]

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1. Install the drive pinion front and rear bearing outer races using

Tools.

CAUTION:

Do not reuse drive pinion front and rear bearing outer race.

2. Select a drive pinion height adjusting washer. Refer to

DLN-483, "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. Assemble 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: ST15310000 ( — )
B: ST35325000 ( — )
C: ST30621000 (J-25742-5)

SPD992

Tool number

: ST30022000 ( — )

SPD377

PDIA0492E

2011 Pathfinder

DLN-478

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230]

REAR FINAL DRIVE

7. Press the drive pinion front bearing inner race to the drive pinion

as far as drive pinion lock nut can be tightened using suitable

spacer.

8. Apply multi-purpose grease to the lips of the new front oil seal.

Then drive the new front oil seal in evenly until it becomes flush

with the gear carrier using Tool.

CAUTION:

• Do not reuse front oil seal.

• Do not incline the new front oil seal when installing.

• Apply multi-purpose grease to the lips 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 suitable 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-466, "Exploded View"

.

• 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-483, "Inspection and Adjustment"

.

12. Install the differential case assembly. Refer to

DLN-466, "Exploded View"

.

Differential Assembly

SPD896

Tool number

: ST15310000 ( — )

PDIA0563E

Tool number

B: ST3127S000 (J-25765-A)

Drive pinion bearing
preload torque:

Refer to

DLN-483, "Inspection

and Adjustment"

WDIA0379E

2011 Pathfinder

REAR FINAL DRIVE

DLN-479

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230]

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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.

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.

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 appro-

priate side gear thrust washers. Refer to

DLN-483, "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

WDIA0131E

SDIA2593E

2011 Pathfinder

DLN-480

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230]

REAR FINAL DRIVE

8. Apply thread locking sealant into the threaded holes of the drive

gear and install the bolts.

• Use Genuine Medium Strength Thread Locking Sealant or

equivalent. Refer to

GI-14, "Recommended Chemical Prod-

ucts and Sealants"

.

CAUTION:

Make sure the drive gear back and threaded holes are

clean.

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

DLN-466, "Exploded View"

. After tightening the drive gear bolts

to the specified torque, tighten an additional 34

°

using Tool.

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.

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. Refer to

DLN-

483, "Inspection and Adjustment"

.

13. Insert the selected left and right side bearing adjusting washers

in place between the side bearings and gear carrier.

SDIA2594E

Tool number

A: KV10112100 (BT-8653-A)

AWBIA0722ZZ

Tool number

A: KV38100200 (J-26233)
B: ST33081000 ( — )

SPD353

SPD919

SPD924

2011 Pathfinder

REAR FINAL DRIVE

DLN-481

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R230]

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14. Install the side bearing caps with the matching marks aligned

and tighten the side bearing cap bolts to the specified torque.

Refer to

DLN-466, "Exploded View"

.

15. Check and adjust the drive gear runout, tooth contact, drive gear to drive pinion backlash, and total pre-

load torque. Refer to

DLN-483, "Inspection and Adjustment"

.

Recheck the above items.

16. Install the side flanges. Refer to

DLN-460, "Removal and Installation"

.

17. Apply a 3.2mm (0.126 in) bead of sealant to the mating surface

of the carrier cover.

• Use Genuine Silicone RTV or equivalent. Refer to

GI-14,

"Recommended Chemical Products and Sealants"

.

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

DLN-466, "Exploded View"

.

19. Install the side flange. Refer to

DLN-460, "Removal and Installa-

tion"

Side Flange

1. Apply multi-purpose grease to the lips of the new side oil seal.

Then drive the new side oil seal in evenly until it becomes flush

with the gear carrier using 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.

2. Install the side flange using Tool.
a. Install the Tool to the side oil seal as shown.

b. Insert the side flange until the serrated part of the side flange

has engaged the serrated part of the side gear and remove the

Tool.

c. Drive in the side flange using suitable tool.

NOTE:

Installation is completed when the driving sound of the side

flange turns into a sound which seems to affect the whole rear

final drive assembly.

SPD889

WDIA0282E

Tool number

: ST35271000 ( — )

SPD560

Tool number

: KV38107900 (J-39352)

SDIA0822E

2011 Pathfinder