Nissan Frontier D22. Manual — part 721

FFD-1

FRONT FINAL DRIVE

D DRIVELINE/AXLE

CONTENTS

C

E

F

G

H

I

J

K

L

M

SECTION

A

B

FFD

PREPARATION . . . . . . . . . . . . . . ... 2

Special Service Tools . . . . . . . . . . . ... 2

NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . . 5

NVH Troubleshooting Chart . . . . . . . . . . 5

FRONT OIL SEAL . . . . . . . . . . . . . .. 6

Removal and Installation . . . . . . . . . . .. 6

REMOVAL . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . 6

REAR COVER GASKET . . . . . . . . . . . 8

Removal and Installation . . . . . . . . . . .. 8

REMOVAL . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . 8

FRONT FINAL DRIVE ASSEMBLY . . . . . . . 9

Removal and Installation . . . . . . . . . . .. 9

REMOVAL . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . 9

Components . . . . . . . . . . . . . . . 11
Pre-Inspection . . . . . . . . . . . . . . 12

TOTAL PRELOAD . . . . . . . . . . . ... 12
RING GEAR TO DRIVE PINION BACKLASH . 12
RING GEAR RUNOUT . . . . . . . . . . 13
TOOTH CONTACT . . . . . . . . . . . .. 13
SIDE GEAR TO DRIVE PINION GEAR BACK-
LASH . . . . . . . . . . . . . . . . ... 13

Disassembly and Assembly . . . . . . . . ... 13

REMOVAL OF DIFFERENTIAL CASE ASSEM-

BLY . . . . . . . . . . . . . . . . . .. 13
REMOVAL OF DRIVE PINION ASSEMLBY . ... 15
DISASSEMBLY OF DIFFERENTIAL CASE
ASSEMBLY . . . . . . . . . . . . . . . 16
DISASSEMBLY OF DIFFERENTIAL SIDE
SHAFT . . . . . . . . . . . . . . . . . 17
INSPECTION . . . . . . . . . . . . . .. 18
ADJUSTMENT OF DIFFERENTIAL CASE
ASSEMBLY . . . . . . . . . . . . . . . 19
SIDE BEARING PRELOAD . . . . . . . . . 19
DRIVE PINION GEAR HEIGHT AND PINION
BEARING PRELOAD . . . . . . . . . . .. 21
TOOTH CONTACT . . . . . . . . . . . .. 25
INSTALLATION OF DRIVE PINION ASSEMBLY ... 26
ASSEMBLY OF DIFFERENTIAL SIDE SHAFT ... 28
ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
LBY . . . . . . . . . . . . . . . . . .. 28
INSTALLATION OF DIFFERENTIAL CASE
ASSEMBLY . . . . . . . . . . . . . . . 30

SERVICE DATA AND SPECIFICATIONS (SDS) . .. 33

General Specifications . . . . . . . . . . . 33
Ring Gear Runout . . . . . . . . . . . . ... 33
Side Gear Adjustment . . . . . . . . . . . 33
Side Bearing Adjustment . . . . . . . . . . 33
Total Preload Adjustment . . . . . . . . . . 33
Drive Pinion Height Adjustment . . . . . . . .. 34
Drive Pinion Preload Adjustment . . . . . . . 34

FFD-2

PREPARATION

PREPARATION

PFP:00002

Special Service Tools

EDS0012A

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.)
Tool name

Description

ST3127S000
(See J25765-A)
Preload gauge
1 GG91030000
(J25765)
Torque wrench
2 HT62940000
(

—

)

Socket adapter
3 HT62900000
(

—

)

Socket adapter

Measuring pinion bearing preload and total
preload

KV38100800
(J34310, J25604-01)
Differential attachment

Mounting final drive housing
(To use, make a new hole.)
a: 152 mm (5.98 in)

KV38108300
(J-44195)
Companion flange wrench

Removing and installing propeller shaft lock
nut, and drive pinion nut

ST3090S000
(

—

)

Drive pinion rear inner race puller set
1 ST30031000
(J22912-01)
Puller
2 ST30901000
(J26010-01)
Base

Removing and installing drive pinion rear in-
ner cone
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35 mm (1.38 in) dia.

ST3306S001
Differential side bearing puller set
1 ST33051001
(J22888-20)
Body
2 ST33061000
(J8107-2)
Adapter

Removing and installing differential side bear-
ing inner cone
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.

KV38100300
(J25523)
Differential side bearing drift

Installing side bearing inner cone
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.

NT124

NT119

NT771

NT527

NT072

NT085

PREPARATION

FFD-3

C

E

F

G

H

I

J

K

L

M

A

B

FFD

KV38100600
(J25267)
Side bearing spacer drift

Installing side bearing spacer
a: 8 mm (0.31 in)
b: R42.5 mm (1.673 in)

ST30611000
(J25742-1)
Drift

Installing drive pinion rear bearing outer race
and drive pinion front bearing outer race
(Use with ST30621000 or ST30613000)

ST30621000
(J25742-5)
Drift

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

ST30613000
(J25742-3)
Drift

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

KV38100500
(J25273)
Gear carrier front oil seal drift

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

KV38100200
(J26233)
Gear carrier side oil seal drift

Installing side oil seal

(J34309)
Differential shim selector

Adjusting bearing pre-load and gear height

Tool number
(Kent-Moore No.)
Tool name

Description

NT528

NT090

NT073

NT073

NT115

NT120

NT134

FFD-4

PREPARATION

(J25269-4)
Side bearing discs
(2 Req'd)

Selecting drive pinion height adjusting washer

(J8129)
Spring gauge

Measuring differential case assembly turning
resistance

Tool number
(Kent-Moore No.)
Tool name

Description

NT136

NT127