Nissan Pathfinder (2012 year). Instruction — part 234

REAR FINAL DRIVE

DLN-437

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

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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 0.1 mm, 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. Refer to

DLN-429, "Exploded View"

.

Tool number

: ST30031000 (J-22912-01)

S-PD179

SDIA0817E

August 2012

2012 Pathfinder

DLN-438

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR 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-447, "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-447, "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

August 2012

2012 Pathfinder

REAR FINAL DRIVE

DLN-439

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

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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-429, "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-447, "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-

447, "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.

Drive Pinion Height

If the hypoid gear has been replaced, select the drive pinion height adjusting washer.

SPD924

SDIA1795E

Tool number

:

—

(J-8129)

Specification

Refer to

DLN-447, "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

August 2012

2012 Pathfinder

DLN-440

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

1. Use the formula below to calculate drive pinion height adjusting

washer thickness.

2. Select the proper drive pinion height adjusting washer. For selecting adjusting washer, refer to

DLN-447,

"Inspection and Adjustment"

.

CAUTION:

If unable to find a washer of desired thickness, use a washer with thickness closest to the calcu-

lated value.

ASSEMBLY

Drive Pinion Assembly

1. Install drive pinion front bearing outer race (1) and rear bearing

outer race (2) 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.

Washer selection equation:
T = T

0

+ (t

1

−

t2

)

T:

Correct washer thickness

T

0:

Removed washer thickness

t

1:

Old drive pinion head letter “H

×

0.01”

(“H”: machined tolerance 1/100 mm

×

100)

t

2

:

New drive pinion head letter “H

×

0.01”

(“H”: machined tolerance 1/100 mm

×

100)

Example:
T = 3.21 + [(2

×

0.01)

−

(–1

×

0.01)] = 3.24

T

0:

3.21

t

1:

+2

t

2

:

–1

Example:

Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm

SDIA0249J

Tool number

(A): ST30720000 (J-25405)
(B): KV40105230 ( — )
(C): ST30611000 (J-25742-1)
(D): ST30613000 (J-25742-3)

PDIA0761J

August 2012

2012 Pathfinder

REAR FINAL DRIVE

DLN-441

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

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2. Temporarily install drive pinion height adjusting washer (1).
a. When hypoid gear set has been replaced.

• Select drive pinion height adjusting washer. Refer to

DLN-430,

"Disassembly and Assembly"

.

b. When hypoid gear set has been reused.

• Temporarily install the removed drive pinion height adjusting

washer or same thickness washer to drive pinion.

CAUTION:

Pay attention to the direction of drive pinion height adjust-

ing washer. (Assemble as shown in the figure.)

3. Install drive pinion rear bearing inner race (1) to drive pinion

using Tool (A).

CAUTION:

Do not reuse drive pinion rear bearing inner race.

4. Check and adjust the tooth contact and back lash of drive gear

and drive pinion following the procedure below.

a. Assemble drive pinion into gear carrier.

CAUTION:

• Do not install collapsible spacer at this time.

• Apply gear oil to drive pinion rear bearing.

b. Assemble drive pinion front bearing inner race to drive pinion assembly.

CAUTION:

• Do not reuse drive pinion front bearing inner race.

• Apply gear oil to drive pinion front bearing.

c. Press the drive pinion front bearing inner race to drive pinion as

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

spacer (A).

d. Install companion flange.

CAUTION:

Do not install front oil seal at this time.

NOTE:

When reusing drive pinion, align the matching mark (B) of drive

pinion with the matching mark (A) of companion flange, and then

install companion flange (1).

JSDIA0760ZZ

Tool number

(A): ST30901000 (J-26010-01)

JSDIA0761ZZ

PDIA0762J

JSDIA0038ZZ

August 2012

2012 Pathfinder

DLN-442

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR FINAL DRIVE

e. Temporarily tighten removed drive pinion lock nut to drive pinion

using suitable tool (A).

NOTE:

Use removed drive pinion nut only for the preload measurement.

f.

Rotate drive pinion more than 20 times to adjust bearing.

g. Tighten to drive pinion lock nut using suitable tool (A), while

adjusting drive pinion bearing preload torque using Tool (B).

CAUTION:

Drive pinion lock nut is tightened with no collapsible

spacer. Be careful not to overtighten it. While measuring the

preload, tighten drive pinion lock nut in 5

°

to 10

°

incre-

ments.

h. Assemble removed drive side bearing adjusting washer or same

thickness of it and install differential case assembly. Refer to

DLN-430, "Disassembly and Assembly"

.

CAUTION:

• Apply differential gear oil to the side bearings.

• Install side bearing and side bearing adjusting washer in correct. (drive gear tooth side or drive

gear back side)

i.

Install bearing caps.

j.

Check and adjust tooth contact and drive gear to drive pinion backlash. Refer to

DLN-430, "Disassembly

and Assembly"

.

k.

Remove bearing caps and differential case assembly.

l.

Remove companion flange.

m. Remove drive pinion assembly from gear carrier.

CAUTION:

Do not drop the drive pinion assembly.

n. Remove drive pinion front bearing inner race.
5. Assemble collapsible spacer.

CAUTION:

Do not reuse collapsible spacer.

6. Assemble drive pinion into gear carrier.

CAUTION:

Apply gear oil to drive pinion rear bearing.

7. Assemble drive pinion front bearing inner race to drive pinion

assembly.

CAUTION:

• Do not reuse drive pinion front bearing inner race.

• Apply gear oil to drive pinion front bearing.

8. Press the drive pinion front bearing inner race to drive pinion as

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

spacer (A).

Tool number

(B): ST3127S000 (J-25765-A)

Drive pinion bearing
preload torque (without
oil seal)

: 1.0 - 1.3 N·m (0.11 -
0.13 kg-m, 9 - 11 in-lb)

WDIA0379E

PDIA0760J

PDIA0762J

August 2012

2012 Pathfinder

REAR FINAL DRIVE

DLN-443

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

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9. Install front oil seal as shown in figure using Tool (A).

CAUTION:

• Do not reuse oil seal.

• When installing, do not incline oil seal.

• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

10. Install companion flange.

NOTE:

When reusing drive pinion, align the matching mark (B) of drive

pinion with the matching mark (A) of companion flange, and then

install companion flange (1).

11. Apply anti-corrosion oil to the thread and seat of drive pinion

lock nut, and temporarily tighten drive pinion lock nut to drive

pinion using suitable tool (A).

CAUTION:

Do not reuse drive pinion lock nut.

12. Adjust to the drive pinion lock nut tightening torque and drive

pinion bearing preload torque using Tool (B).

CAUTION:

• Adjust to the lower limit of the drive pinion lock nut tight-

ening torque fist.

• If the 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 preload torque.

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

times to check for unusual noise, rotation malfunction,

and other malfunctions.

13. Install differential case assembly. Refer to

DLN-430, "Disassem-

bly and Assembly"

.

CAUTION:

Do not install rear cover at this time.

14. Check and adjust drive gear runout, tooth contact and drive gear to drive pinion backlash, and companion

flange runout. Refer to

DLN-430, "Disassembly and Assembly"

.

Recheck above items. Readjust the above description, if necessary.

15. Check total preload torque. Refer to

DLN-430, "Disassembly and Assembly"

.

16. Install rear cover. Refer to

DLN-430, "Disassembly and Assembly"

.

Differential Assembly

Tool number

(A): ST30720000 (J-25405)

PDIA0764J

JSDIA0038ZZ

Tool number

(B): ST3127S000 (J-25765-A)

Drive pinion bearing
preload torque

: Refer to

DLN-447, "Inspec-

tion and Adjustment"

.

WDIA0379E

August 2012

2012 Pathfinder

DLN-444

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R200]

REAR 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.

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-447, "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

August 2012

2012 Pathfinder