Qashqai J11. Driveline — part 6
TRANSFER COVER
DLN-81
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[TRANSFER: TY21C]
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• Never reuse the oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and transfer oil onto the circumference of the oil
seal.
10. Install gasket onto filler plug and install them to transfer cover.
CAUTION:
• Never reuse gasket.
• Install filler plug after oil is filled.
Inspection
INFOID:0000000010755197
INSPECTION AFTER DISASSEMBLY
Check items below. If necessary, replace them with new ones.
Transfer cover
Check the bearing mounting surface for wear, cracks and damages.
DLN-82
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
RING GEAR SHAFT
RING GEAR SHAFT
Exploded View
INFOID:0000000010755198
MR20DD models
JSDIA5341GB
Pinion lock nut
Companion flange
Dust cover
Oil seal
Pinion bearing assembly
O-ring
Drive pinion adjusting shim
Drive pinion
O-ring
Oil seal
Dowel pin
Plug
Gasket
Transfer case
Baffle plate
Ring gear bearing adjusting shim
(transfer case side)
Ring gear bearing (transfer case
side)
Ring gear
Ring gear shaft
Ring gear shaft oil seal
Ring gear bearing (transfer cover
side)
Ring gear bearing adjusting shim
(transfer cover side)
Oil seal
O-ring
Transfer cover
Oil seal
Filler plug
Drain plug
Oil seal lip
Comply with the assembly procedure
when tightening. Refer to
.
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Select with proper thickness.
RING GEAR SHAFT
DLN-83
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Disassembly
INFOID:0000000010755199
1.
Remove transfer cover assembly. Refer to
.
2.
Remove ring gear bearing outer race (transfer cover side) and ring gear bearing adjusting shim (transfer
cover side) from the transfer cover. Refer to
.
3.
Remove ring gear shaft assembly from the transfer case.
4.
Remove ring gear bearing outer race (transfer case side) and ring gear bearing adjusting shim (transfer
case side) from the transfer case. Refer to
.
5.
Remove ring gear bearing inner race (transfer cover side) from
ring gear shaft using suitable tool (A) and suitable tool.
6.
Remove ring gear bearing inner race (transfer case side) from
ring gear shaft with suitable tool (A) and Tool.
7.
Remove the ring gear mounting bolts.
8.
Lightly tap ring gear with a plastic hammer to remove ring gear
from the ring gear shaft.
: Apply transfer oil.
*
: Apply anti-corrosive oil.
: Apply multi-purpose grease.
JPDIE0030ZZ
Tool number
: ST33061000
JPDIE0031ZZ
SDIA1807J
DLN-84
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
RING GEAR SHAFT
9.
Remove ring gear shaft oil seal from the ring gear shaft with the
Tool (A).
10. Perform inspection after disassembly. Refer to
Assembly
INFOID:0000000010755200
1.
Using suitable tool (A), install ring gear shaft oil seal
within the
dimension (L) shown as follows.
CAUTION:
• Never reuse the oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and transfer
oil onto the circumference of the oil seal.
2.
Select ring gear bearing adjusting shim (transfer case side) and
ring gear bearing adjusting shim (transfer cover side). Refer to
.
3.
Assemble the selected ring gear bearing adjusting shim (transfer case side) and ring gear bearing outer
race (transfer case side) to transfer case. Refer to
CAUTION:
• Never reuse ring gear bearing.
• Apply transfer oil to the ring gear bearing.
4.
Assemble the selected ring gear bearing adjusting shim (transfer cover side) and ring gear bearing outer
race (transfer cover side) to transfer cover. Refer to
.
CAUTION:
• Never reuse ring gear bearing.
• Apply transfer oil to the ring gear bearing.
5.
Install the ring gear to ring gear shaft, and tighten mounting bolts to the specified torque.
6.
Install ring gear bearing inner race (transfer cover side) with drift
(A) (commercial service tool).
CAUTION:
• Never reuse ring gear bearing.
• Apply transfer oil to the ring gear bearing.
Tool number
: KV381054S0
JPDIE0032ZZ
L
: 2.0 +0.6/
−
0 mm (0.079 +0.024/
−
0 in)
JSDIA2492ZZ
JSDIA1056ZZ
RING GEAR SHAFT
DLN-85
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7.
Install the ring gear bearing inner race (transfer case side) to
ring gear shaft with suitable tool (A).
CAUTION:
• Never reuse ring gear bearing.
• Apply transfer oil to the ring gear bearing.
8.
Install the ring gear shaft assembly to the transfer case.
CAUTION:
Protect transfer case oil seals beforehand from being dam-
aged by the spline of ring gear shaft below method follow-
ing.
a.
Apply multi-purpose grease to spline part indicated in the figure.
b.
Wrap piece of vinyl to spline part only indicated in the figure.
[(A): limit line]
CAUTION:
Never wrap sliding surfaces on oil seal.
9.
Install transfer cover to check and adjust each part. Refer to
NOTE:
At this timing, O-ring installing to transfer cover is not necessary.
Install O-ring after backlash and tooth contact are checked.
10. Check backlash, tooth contact, total preload and companion
flange runout. Refer to
.
CAUTION:
Measure the total preload without oil seals of transfer cover and transfer case.
11. Reinstall transfer cover for installing O-ring. Refer to
.
12. After installing transfer case oil seals, remove wrapped vinyl from the spline of ring gear shaft.
Inspection
INFOID:0000000010755201
INSPECTION AFTER DISASSEMBLY
Check items below. If necessary, replace them with new ones.
Gear and Shaft
Check gear face and shaft for wear, cracks, damage, and seizure.
CAUTION:
If malfunction is detected on the ring gear or drive pinion, replace the ring gear and drive pinion as a
set.
Bearing
Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.
CAUTION:
When replacing the bearing, always replace the inner race and outer race as a pair.
Shim
Check for seizure, damage, and unusual wear.
JSDIA1055ZZ
JSDIA4195ZZ
JSDIA4196ZZ
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DRIVE PINION
DRIVE PINION
Exploded View
INFOID:0000000010755202
MR20DD models
JSDIA5341GB
Pinion lock nut
Companion flange
Dust cover
Oil seal
Pinion bearing assembly
O-ring
Drive pinion adjusting shim
Drive pinion
O-ring
Oil seal
Dowel pin
Plug
Gasket
Transfer case
Baffle plate
Ring gear bearing adjusting shim
(transfer case side)
Ring gear bearing (transfer case
side)
Ring gear
Ring gear shaft
Ring gear shaft oil seal
Ring gear bearing (transfer cover
side)
Ring gear bearing adjusting shim
(transfer cover side)
Oil seal
O-ring
Transfer cover
Oil seal
Filler plug
Drain plug
Oil seal lip
Comply with the assembly procedure
when tightening. Refer to
.
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Select with proper thickness.
DRIVE PINION
DLN-87
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[TRANSFER: TY21C]
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Disassembly
INFOID:0000000010755203
1.
Remove pinion bearing assembly mounting bolts.
2.
Lightly tap companion flange with a plastic hammer to remove
drive pinion assembly
.
3.
Remove the O-ring from pinion bearing.
4.
Remove the pinion lock nut.
5.
Remove drive pinion from pinion bearing assembly using suit-
able tool (A) and suitable tool (B).
6.
Remove adjusting shim.
7.
Remove companion flange.
8.
Remove the dust cover.
9.
Remove the oil seal.
10. Perform inspection after disassembly. Refer to
Assembly
INFOID:0000000010755204
1.
Select drive pinion adjusting shim. Refer to
.
2.
Assemble the selected drive pinion adjusting shim to drive pinion.
3.
Install the drive pinion to pinion bearing assembly using suitable tool.
CAUTION:
• Never reuse pinion bearing assembly.
• Apply transfer oil to pinion bearing part.
: Apply transfer oil.
*
: Apply anti-corrosive oil.
: Apply multi-purpose grease.
JSDIA3951ZZ
JSDIA3952ZZ
JSDIA3953ZZ
DLN-88
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
DRIVE PINION
4.
Install oil seal to pinion bearing assembly using suitable tool (A).
CAUTION:
• Never reuse the oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and transfer
oil onto the circumference of the oil seal.
5.
Install dust cover.
NOTE:
Tighten dust cover together with pinion bearing assembly.
6.
Install companion flange
to pinion bearing using suitable tool
(A).
7.
Apply anti-corrosive oil to the thread and seat of the lock nut,
and adjust the pinion lock nut tightening torque and pinion bear-
ing preload torque, using a preload gauge.
a.
Install pinion lock nut, and then tighten to the specified torque.
CAUTION:
• Never reuse pinion lock nut.
• Check that pinion lock nut is seated on the companion flange.
b.
After tightening pinion lock nut to the specified torque, retighten the pinion lock nut by 25 degrees.
c.
Measure the pinion bearing preload.
8.
Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion bearing assembly.
CAUTION:
• Never reuse O-ring.
• When installing O-ring, never use a suitable tool.
• Never damage O-ring.
9.
Install drive pinion assembly, and apply anti-corrosive oil onto
thread and seats on the mounting bolts. Tighten to the specified
torque.
NOTE:
Tighten dust cover together with pinion bearing assembly.
10. Check backlash, tooth contact, total preload and companion
flange runout. Refer to
.
CAUTION:
Measure the total preload without oil seals of transfer cover
and transfer case.
Adjustment
INFOID:0000000010755205
ADJUSTING SHIM SELECTION
JSDIA3996ZZ
Pinion lock nut
tightening torque
: 90
±
9 N·m (9.2
±
0.92kg-m, 66
±
7 ft-lb)
Pinion bearing preload
: Refer to
.
JSDIA3997ZZ
JSDIA3951ZZ
DRIVE PINION
DLN-89
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
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Measurement point
Select adjusting shim of T1, T2, and T3, respectively, by using the following equation.
T1 [Ring gear bearing adjusting shim (transfer case side)]
• T1 = A
−
(B +X/2) +C +W
−
V
−
F
−
(M/100) +0.071 mm (0.0028 in)
T2 [Ring gear bearing adjusting shim (transfer cover side)]
• T2 =
−
Y +Z +(B +X/2)
−
C
−
D
−
H +(M/100) +0.071 mm (0.0028 in)
T3 (Drive pinion adjusting shim)
• T3 =
−
Q +(R +S/2)
−
K +(O/100)
JSDIA4034ZZ
DLN-90
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
DRIVE PINION
• Check dimension (M) on the ring gear side face.
NOTE:
Dimension “M” indicates the difference between the optimum
engagement and standard dimensions in increments of 0.01 mm
(0.0004 in) written on the ring gear side face.
• Check dimension (O) on the gear end of drive pinion.
NOTE:
Dimension “O” indicates the difference between the optimum
engagement and the standard dimensions in increments of 0.01
mm (0.0004 in) written on the gear end of drive pinion.
PINION BEARING PRELOAD
CAUTION:
When measuring preload, the rotating speed must be set to 30 rpm.
1.
Remove ring gear shaft assembly from the transfer case. Refer to
2.
Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking,
and so on.
3.
Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4.
Measure the pinion bearing preload using Tool (A).
CAUTION:
Each rotational part should rotate smoothly with the speci-
fied transfer oil.
• If outside the standard, disassemble the drive pinion assembly
to check and adjust each part.
TOTAL PRELOAD
CAUTION:
When measuring preload, the rotating speed must be set to 30 rpm.
1.
Measure pinion bearing preload.
CAUTION:
Check that the pinion bearing preload is within the standard.
2.
Assemble the ring gear shaft assembly to the transfer case. Refer to
3.
Install transfer cover to check and adjust each part. Refer to
.
4.
Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
JSDIA2495ZZ
JSDIA2496ZZ
Pinion bearing preload
: Refer to
.
Tool number
: ST3127S000
JSDIA2500ZZ
DRIVE PINION
DLN-91
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
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5.
Measure the total preload using Tool (A).
CAUTION:
Each rotational part should rotate smoothly with the speci-
fied transfer oil.
• If outside the standard, disassemble the transfer assembly to
check and adjust each part. Measure it with the transfer case
oil seal and transfer cover oil seal removed when measuring
total preload after disassembly. Then install transfer case oil seals and transfer cover oil seal.
BACKLASH
1.
Install the bolt to the companion flange.
2.
Fit a dial indicator onto the bolt
.
3.
Measure the circumference backlash of the companion flange.
• If outside the standard, disassemble the transfer assembly to
check and adjust each part.
TOOTH CONTACT
1.
Remove transfer cover. Refer to
2.
Remove ring gear shaft assembly from transfer case. Refer to
.
3.
Apply red lead onto the ring gear.
CAUTION:
Apply red lead to both faces of 3 to 4 gears at 4 locations
evenly spaced on the ring gear.
4.
Assemble the ring gear shaft assembly to the transfer case.
Refer to
.
5.
Install transfer cover to check and adjust each part. Refer to
NOTE:
At this timing, O-ring installing to transfer cover is not necessary.
Install O-ring after backlash and tooth contact are checked.
6.
Remove the plug from the transfer case.
7.
Rotate the companion flange back and forth several times, and check the drive pinion gear to ring gear
tooth contact by viewing from the plug hole.
Total preload
: Refer to
Tool number
: ST3127S000
JSDIA2500ZZ
Backlash
: Refer to
.
JSDIA2501ZZ
JSDIA2188ZZ
DLN-92
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
DRIVE PINION
Tooth Contact Judgment Guide
8.
Follow the procedure below to adjust pinion height (dimension
X) if tooth contact is improper. For selecting adjusting shim, refer
to the latest parts information.
CAUTION:
If no adjusting shim with the calculated value is available,
select the thicker and closest one.
• Thicken the drive pinion adjusting shim to move the drive pin-
ion closer to the ring gear in case of face contact or heel con-
tact.
CAUTION:
Only one adjusting shim can be selected.
JSDIA4035GB
JSDIA1221ZZ
PDIA0440E
DRIVE PINION
DLN-93
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
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• Thin the drive pinion adjusting shim to move the drive pinion
farther from the ring gear in case of flank contact or toe con-
tact.
CAUTION:
Only one adjusting shim can be selected.
COMPANION FLANGE RUNOUT
1.
Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2.
Rotate the companion flange to check for runout.
3.
Fit suitable tool to the inner side of the companion flange (socket
diameter).
4.
Rotate the companion flange to check for runout.
5.
Follow the procedure below to adjust if runout value is outside
the repair limit.
a.
Check for runout while changing the phase between companion
flange and drive pinion in 90
°
steps. Then search for the mini-
mum point.
b.
Replace companion flange if runout value is still outside the limit
after the phase has been changed.
c.
Adjust assembly status of the pinion bearing and drive pinion, or
replace pinion bearing assembly if runout is outside the standard
after the companion flange is replaced.
Inspection
INFOID:0000000010755206
INSPECTION AFTER DISASSEMBLY
Check items below. If necessary, replace them with new ones.
Gear and Shaft
Check gear face and shaft for wear, cracks, damage, and seizure.
CAUTION:
Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring
gear or drive pinion.
Bearing
Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.
Shim
Check for seizure, damage, and unusual wear.
PDIA0441E
Companion flange runout
: Refer to
.
Companion flange runout
: Refer to
.
JSDIA3981ZZ
DLN-94
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
TRANSFER CASE
TRANSFER CASE
Exploded View
INFOID:0000000010755207
MR20DD models
JSDIA5341GB
Pinion lock nut
Companion flange
Dust cover
Oil seal
Pinion bearing assembly
O-ring
Drive pinion adjusting shim
Drive pinion
O-ring
Oil seal
Dowel pin
Plug
Gasket
Transfer case
Baffle plate
Ring gear bearing adjusting shim
(transfer case side)
Ring gear bearing (transfer case
side)
Ring gear
Ring gear shaft
Ring gear shaft oil seal
Ring gear bearing (transfer cover
side)
Ring gear bearing adjusting shim
(transfer cover side)
Oil seal
O-ring
Transfer cover
Oil seal
Filler plug
Drain plug
Oil seal lip
Comply with the assembly procedure
when tightening. Refer to
.
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Select with proper thickness.
TRANSFER CASE
DLN-95
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
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Disassembly
INFOID:0000000010755208
1.
Remove transfer cover. Refer to
2.
Remove ring gear shaft assembly. Refer to
.
3.
Remove drive pinion assembly. Refer to
.
4.
Remove O-ring from transfer case.
CAUTION:
• Never use a suitable tool.
• Never damage transfer case.
5.
Remove oil seals
.
CAUTION:
Never damage transfer case.
6.
Remove baffle plate
.
7.
Remove the ring gear bearing adjusting shim (transfer case
side)
and ring gear bearing outer race (transfer case side)
by tapping from the 2 cutouts (
) on the transfer case.
CAUTION:
Never damage transfer case.
8.
Remove plug and gasket.
9.
Perform inspection after disassembly. Refer to
Assembly
INFOID:0000000010755209
1.
Select the ring gear bearing adjusting shim (transfer case side). Refer to
: Apply transfer oil.
*
: Apply anti-corrosive oil.
: Apply multi-purpose grease.
JSDIA3983ZZ
JSDIA3982ZZ
JSDIA3984ZZ
DLN-96
< UNIT DISASSEMBLY AND ASSEMBLY >
[TRANSFER: TY21C]
TRANSFER CASE
2.
Install the selected ring gear bearing adjusting shim (transfer
case side) and ring gear bearing outer race (transfer case side)
using suitable tool (A).
CAUTION:
• Never reuse ring gear bearing.
• Apply transfer oil to the ring gear bearing.
3.
Install baffle plate
.
4.
Install ring gear shaft assembly. Refer to
CAUTION:
Protect transfer case oil seals beforehand from being dam-
aged by the spline of ring gear shaft.
5.
Install drive pinion assembly. Refer to
6.
Install transfer cover to check and adjust each part. Refer to
.
NOTE:
At this timing, O-ring installing to transfer cover is not necessary.
Install O-ring after backlash and tooth contact are checked.
7.
Check backlash, tooth contact, total preload and companion flange runout. Refer to
CAUTION:
Measure the total preload without oil seals of transfer cover and transfer case.
8.
Reinstall transfer cover for installing O-ring. Refer to
.
9.
Install oil seals using suitable tool.
CAUTION:
• When checking the total preload torque, measure it with-
out the oil seal, then install the oil seal.
• Never reuse the oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and transfer
oil onto the circumference of the oil seal.
• Never damage oil seals by spline of ring gear shaft.
10. After installing oil seals to transfer case, remove wrapped vinyl from the spline of ring gear shaft.
11. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the transfer case.
CAUTION:
• Never reuse O-ring.
• When installing O-ring, never use a suitable tool.
• Never damage O-ring.
Inspection
INFOID:0000000010755210
INSPECTION AFTER DISASSEMBLY
Check items below. If necessary, replace them with new ones.
Case
Check the bearing mounting surface for wear, cracks and damages.
JSDIA3998ZZ
A
: 24.8 mm (0.976 in)
B
: 10.3 mm (0.406 in)
JSDIA3982ZZ
JSDIA4047ZZ
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