Nissan Pathfinder (2011 year). Manual — part 232
DLN-394
< UNIT DISASSEMBLY AND ASSEMBLY >
[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
1. Apply red lead to the drive gear.
NOTE:
Apply red lead to both faces of three to four gears, at four loca-
tions evenly spaced on the drive gear.
2. Rotate the drive gear back and forth several times. Then check
for correct drive pinion to drive gear tooth contact as shown.
CAUTION:
Check tooth contact on drive side and reverse side.
3. If the tooth contact is improperly adjusted, follow the procedure
below to adjust the drive pinion height (dimension X).
• If the tooth contact is near the face (face contact), or near the heel
(heel contact), use a thicker drive pinion height adjusting washer to
move drive pinion closer to the drive gear.
DLN-409, "Inspection and Adjustment"
• If the tooth contact is near the flank (flank contact), or near the toe
(toe contact), use a thinner drive pinion height adjusting washer to
move the drive pinion farther from the drive gear.
DLN-409, "Inspection and Adjustment"
SPD357
SDIA0570E
SDIA0517E
PDIA0440E
PDIA0441E
2011 Pathfinder
FRONT FINAL DRIVE
DLN-395
< UNIT DISASSEMBLY AND ASSEMBLY >
[FRONT FINAL DRIVE: M205]
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Backlash
1. Fit a dial indicator to the drive gear face to measure the back-
lash.
• If the backlash is outside of the specification, adjust each side
bearing adjuster.
CAUTION:
Do not change the side bearing adjusters by different
amounts as it will change the side bearing preload torque.
Companion Flange Runout
1. Rotate companion flange and check for runout on the compan-
ion flange face (inner side of the bolt holes) and companion
flange inner side (socket diameter) using suitable tool.
2. If the runout is outside the runout limit, follow the procedure
below to adjust.
a. Rotate the companion flange on the drive pinion by 90
°
, 180
°
and 270
°
while checking for the position
where the runout is minimum.
b. If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pin-
ion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a mal-
functioning drive pinion bearing.
c. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion
bearing or drive pinion bearing, replace the companion flange.
DISASSEMBLY
Differential Assembly
1. Drain the differential gear oil if necessary.
Backlash:
SPD513
If the backlash is greater than specification:
Loosen side bearing adjuster A and tighten side bear-
ing adjuster B by the same amount.
If the backlash is less than specification:
Loosen side bearing adjuster B and tighten side bear-
ing adjuster A by the same amount.
SDIA2262E
Runout limit
Companion
flange face:
Refer to
Companion
flange inner side:
Refer to
SDIA2078E
2011 Pathfinder
DLN-396
< UNIT DISASSEMBLY AND ASSEMBLY >
[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
2. Remove the differential side shaft and differential side flange
using suitable tool.
3. Remove the extension tube and O-ring from the gear carrier.
4. Place a small hole in the side oil seal case using suitable tool.
5. Remove the side oil seal using Tool as shown.
6. Remove the carrier cover bolts and separate the carrier cover
from the gear carrier using Tool.
CAUTION:
• Do not damage the mating surface.
• Do not insert flat-bladed screwdriver, this will damage the
mating surface.
BDIA0006E
SDIA3205E
LDIA0129E
Tool number
: —
SP8P
LDIA0130E
Tool number
: KV10111100 (J-37228)
PDIA0699E
2011 Pathfinder
FRONT FINAL DRIVE
DLN-397
< UNIT DISASSEMBLY AND ASSEMBLY >
[FRONT FINAL DRIVE: M205]
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7. For proper reinstallation, paint matching marks on one side of
the side bearing cap and gear carrier.
CAUTION:
• For matching marks, use paint. Do not damage side bear-
ing cap or gear carrier.
• Side bearing caps are line-board during manufacture. The
matching marks are used to reinstall them in their original
positions.
8. Remove the side bearing caps.
9. Remove the side bearing adjuster.
10. Lift the differential case assembly out of the gear carrier.
CAUTION:
Keep side bearing outer races together with side bearing
inner races. Do not mix them up.
11. Remove side bearing inner race using Tools as shown.
CAUTION:
• Do not remove side bearing inner race unless it is being
replaced.
• Place copper plates between the vise and the side bearing
inner race and drive gear to prevent damage.
• Engage puller jaws in groove to prevent damage to bear-
ing.
PDIA0700E
PDIA0701E
SDIA2230E
SPD527
Tool number
A: ST33081000 ( — )
B: ST30021000 ( — )
SDIA2237E
2011 Pathfinder
DLN-398
< UNIT DISASSEMBLY AND ASSEMBLY >
[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
• Keep side bearing outer races together with side bearing
inner races. Do not mix them up.
12. For proper reinstallation, paint matching marks on the differential
case and drive gear.
CAUTION:
Use paint for matching marks. Do not damage differential
case or drive gear.
13. Remove the drive gear bolts.
14. Tap the drive gear off the differential case using suitable tool.
CAUTION:
Tap evenly all around to keep drive gear from bending.
15. Remove the lock pin of the pinion mate shaft from the drive gear
side using suitable tool.
16. Remove the pinion mate shaft.
17. Turn the pinion mate gear, then remove the pinion mate gear,
pinion mate thrust washer, side gear and side gear thrust
washer from the differential case.
SPD022
PDIA0496E
SPD025
SDIA0031J
SDIA0032J
2011 Pathfinder
FRONT FINAL DRIVE
DLN-399
< UNIT DISASSEMBLY AND ASSEMBLY >
[FRONT FINAL DRIVE: M205]
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Drive Pinion Assembly
1. Remove the differential assembly.
2. Remove the drive pinion lock nut using suitable tool.
3. Put matching marks on the companion flange and drive pinion
using paint.
CAUTION:
Use paint to make the matching marks. Do not damage the
companion flange or drive pinion.
4. Remove the companion flange using suitable tool.
5. Press the drive pinion assembly (with rear inner bearing race
and collapsible spacer) out of the gear carrier.
CAUTION:
Do not drop drive pinion assembly.
6. Remove the drive pinion rear bearing inner race and drive pinion
height adjusting washer using Tool.
PDIA0702E
PDIA0703E
SDIA2234E
Tool number
: ST30021000 ( — )
S-PD179
2011 Pathfinder
DLN-400
< UNIT DISASSEMBLY AND ASSEMBLY >
[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
7. Place a small hole in the front oil seal case using suitable tool.
8. Remove the front oil seal using Tool as shown.
9. Remove the drive pinion front bearing inner race.
10. Remove the drive pinion front bearing outer race using Tool as
shown. Locate the driver on the back edge of the drive pinion
front bearing outer race, then drive the drive pinion front bearing
outer race out.
CAUTION:
Do not damage gear carrier.
11. Remove the drive pinion rear bearing outer race using Tool as
shown. Locate the driver on the back edge of the drive pinion
rear bearing outer race, then drive the drive pinion rear bearing
outer race out.
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.
LDIA0129E
Tool number
: —
SP8P
LDIA0130E
Tool number
A: —
C-4171
B: —
D-103
LDIA0131E
Tool number
A: —
C-4171
B: —
C-4307
LDIA0132E
2011 Pathfinder
FRONT FINAL DRIVE
DLN-401
< UNIT DISASSEMBLY AND ASSEMBLY >
[FRONT FINAL DRIVE: M205]
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• 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. Refer to
1. Place the differential case straight up so that the side gear to be
measured is upward.
PDIA0460E
2011 Pathfinder
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