Front Final Drive: Other Nissan Armada I

PRECAUTIONS

SPECIAL SERVICE TOOLS

The actual shapes of Kent-Moore tools may differ from those of special service tools (Scheme 20).

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DRIVE GEAR TO DRIVE PINION BACKLASH

Check drive gear to drive pinion backlash using a dial gauge at several points.

1. Drive gear to drive pinion backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in)

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1. Fit a dial gauge onto the companion flange face (inner side of the propeller shaft bolt holes).
2. Rotate the companion flange to check for runout. Runout limit: 0.10 mm (0.0039 in)
3. Fit a test indicator to the inner side of the companion flange (socket diameter).
4. Rotate the companion flange to check for runout. Runout limit: 0.13 mm (0.0051 in)
5. If the runout value is outside the repair limit, follow the procedure below to adjust.

1. Check for runout while changing the phase between companion flange and drive pinion gear by 90° step, and search for the point where the runout is the minimum.
2. If the runout value is still outside of the limit after the phase has been changed, replace the companion flange.
3. If the runout value still outside of the limit after the companion flange has been replaced, check pinion bearing and drive pinion assembly.

TOOTH CONTACT

Check tooth contact. Refer to TOOTH CONTACT .

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1. Remove differential side shaft with a soft hammer.
2. Remove differential side flange with a soft hammer.
3. Remove extension tube and O-ring.
4. Place a small hole in seal case, using suitable punch or drill.
5. Assemble Tool (Scheme 31)and remove seal. Tool number: - (SP8P)
6. Remove rear cover from gear carrier.
7. For proper reinstallation, paint matching mark on one side bearing cap. NOTE: Bearing caps are line-board for initial assembly. The matching marks are used to replace them in their original positions.
8. Remove side bearing caps.
9. Remove side bearing adjust nuts.
10. Keep the side bearing outer races together with inner race. Do not mix them up.

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1. Put matching marks on companion flange and drive pinion with paint.
2. Loosen drive pinion nut using Tool. Tool number: KV38108300 (J-44195)
3. Remove companion flange using a suitable puller.
4. Remove drive pinion (together with rear bearing inner race, collapsible spacer.)
5. Remove pinion front bearing inner race.
6. Place a small hole in case, using suitable punch or drill.
7. Assemble Tool (Scheme 41)and remove seal. Tool number: - (SP8P)
8. Turn nose of gear carrier down. Remove drive pinion front bearing outer race using Tool. Locate driver on back edge of outer race, then drive outer race out. CAUTION: Do not nick gear carrier. Tool number A: - (C-4171) B: - (D-103)
9. Turn nose of gear carrier up. Remove drive pinion rear bearing outer race using Tool. Locate driver on back edge of outer race, then drive outer race out. CAUTION: Do not nick gear carrier. Tool number A: - (C-4171) B: - (C-4307)
10. Remove drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool. Tool number: ST30021000 (-)

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1. Remove side bearing inner race. To prevent damage to bearing, engage puller jaws in groove. Tool number A: ST33081000 ( - ) Tool number B: ST30021000 ( - ) CAUTION: To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise. It is not necessary to remove side bearing except it is replaced. Be careful not to confuse left-hand and right-hand parts. Keep bearing and bearing race for each side together.
2. Loosen drive gear bolts in a crisscross fashion.
3. Tap drive gear off the differential case with a soft hammer. Tap evenly all around to keep the drive gear from bending.
4. Drive out pinion mate shaft lock pin using suitable punch from drive gear side.
5. Remove the pinion mate shaft.
6. 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.
7. Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft and thrust washers.

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1. Clean up the disassemble parts. Then, inspect if the parts are wear or damaged. If so, follow the measures below.

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1. Apply gear oil to contact surfaces of each gear, thrust washers and differential case.
2. Install the removed thrust washer or same thickness washer to side gear.
3. Install the side gears, thrust washers, pinion mate gears and thrust washers into differential case.
4. Install pinion mate shaft to differential case so that it meets lock pin holes.
5. Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer. Refer to «SIDE GEAR ADJUSTMENT»(ref-233279-S06046391532006052500000). Use two feeler gauges to prevent leaning of side gear (Scheme 57) Clearance between side gear thrust washer and differential case: 0.20 mm (0.0079 in) or less
6. Make sure lock pin is flush with case, using a suitable punch.
7. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.
8. Install differential case assembly on drive gear. Tighten bolts in a crisscross pattern, lightly tapping bolt head with a hammer.
9. Place differential case on drive gear. Tighten bolts in a crisscross fashion.
10. Press-fit side bearing inner race on differential case using Tools. Tool number A: KV38100300 (J-25523) Tool number B: ST33081000 ( - )

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1. Drive gear and pinions are supplied in matched sets only. Matching numbers on both pinion and drive gear are etched for verification. If a new gear set is being used, verify the numbers of each pinion gear and drive gear before proceeding with assembly.
2. The mounting distance from the centerline of the drive gear to the back face of the pinion gear for the Model 205 axle assembly is 103.5 mm (4.0748 inches). On the button end of each pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0), which indicates the best running position for each particular gear set. This dimension is controlled by a selective shim between the inner pinion bearing race and pinion gear. For example: If a pinion is etched m+8 (+3), it would require 0.08 mm (0.003 inch) less shim than a pinion etched "0". This means decreasing shim thickness; increases the mounting distance of the pinion to 103.6 mm (4.0778 inches). If a pinion is etched m+8 (-3), it would require adding 0.08 mm (0.003 inch) more to the shim than would be required if the pinion were etched "0". By adding 0.08 mm (0.003 inch), the mounting distance of the pinion was decreased to 103.4 mm (4.0718 inches) which is just what m-8 (a-3) etching indicated.
3. To change the pinion adjustment, use different shims which come in different thickness.
4. Use the following charts as a guide for selecting the correct shim thickness to add or subtract from the old shim.

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1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the differential shim selector tool. Tool number A: - (8144) Tool number B: - (6740) Tool number C: - (6741)
3. Install pinion bearing inner race and pinion height adjusting washer to gear carrier using Tool (Scheme 66)
4. Turn the assembly several times to seat the bearings.
5. Measure the turning torque. Tool number: ST3127S000 (J-25765-A) Turning torque specification: 2.98 - 4.76 N.m (0.31 - 0.48 Kg-m, 27 - 42 in-lb)
6. Tighten side-bearing cap to the specified torque installing Tools (Scheme 69) Tool number A: - (6739) Tool number B: - (D-115-2) Tool number C: - TBD Tool number D: - (D-115-3)
7. Put scooter block on pinion height block. Make sure that dial gauge is level adjusting pressure with a hand. Dial gauge indicates "0".
8. Slide dial gauge along arbor. Record the maximum.
9. Adjust pinion height adjusting washer so that the maximum will be "0".

Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive pinion.

Hypoid gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life.

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1. Thoroughly clean drive gear and drive pinion teeth.
2. Lightly apply a mixture of powdered ferric oxide and oil or the equivalent. Apply it to 3 or 4 teeth of drive gear drive side.
3. Hold companion flange steady by hand and rotate the drive gear in both directions.

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1. Press-fit rear bearing outer race with Tools. Tool number A: ST30901000 ( - ) Tool number B: KV40105230 ( - )
2. Press-fit front bearing outer race with Tools. Tool number A: ST35271000 ( - ) Tool number B: KV40104810 ( - )
3. Select drive pinion height adjusting washer. Refer to «DRIVE PINION HEIGHT ADJUSTMENT»(ref-233279-S34648802062006052500000) .
4. Install drive pinion adjusting washer in drive pinion, and press-fit pinion rear bearing inner race in it, using a press and Tool. Tool number: - (C - 4040)
5. Place pinion front bearing inner race in gear carrier.
6. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal, using Tools. Tool number A: KV38100500 (J-25273) Tool number B: KV38102200 ( - )
7. Place collapsible spacer, drive pinion height adjusting washer and drive pinion in gear carrier.
8. Insert companion flange onto drive pinion. Tap the companion flange with a soft hammer until fully seated.
9. Tighten pinion nut until total preload is within specification. The threaded portion of drive pinion and pinion nut should be free from oil or grease. Tool number: KV38108300 (J-44195)
10. Tighten the pinion nut by very small degrees until the specified preload is achieved. When checking the preload, turn the drive pinion in both directions several times to set the bearing rollers. Tool number: ST3127S000 (J-25765-A) Pinion bearing preload: 2.3 - 3.4 N.m (24 - 34 Kg-cm, 21 - 30 in-lb)

This procedure will have to be repeated if

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1. Maximum preload is achieved before the minimum pinion nut torque is reached.
2. Minimum preload is not achieved before maximum pinion nut torque is reached.

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1. Install side bearing adjust nut into gear carrier.
2. Install differential case assembly with side bearing outer races into gear carrier.
3. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier. Do not tighten at this point. This allows further tightening of side bearing adjusters.
4. Tighten each side bearing adjust nuts alternately turning drive gear.
5. Measure backlash of drive gear and drive pinion using a dial gauge. Drive gear to drive pinion back lash: 0.13 - 0.18 mm (0.0051 - 0.0071 in)
6. Use each adjust nut to adjust backlash.
7. In case of lots of backlash, loosen adjust nut A and tighten adjust nut B. In case of less backlash, loosen adjust nut B and tighten adjust nut A.
8. After adjusting backlash, fix adjuster with screws and tighten cap bolt to the specified torque. Refer to «COMPONENTS»(ref-233279-S22228894182006052500000) .
9. Check total preload with tool. Tool number: ST3127S000 (J-25765-A) Total preload (With oil seal): 2.98 - 4.76 N.m (0.31 - 0.48 Kg-m, 27 - 42 in-lb)
10. Check tooth contact. Refer to «TOOTH CONTACT»(ref-233279-S35909349792006052500000) .
11. Install rear cover. Apply liquid sealant to rear cover side and install gear carrier.
12. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install side oil seal.
13. Install O-ring and extension tube.
14. Install sides haft and side flange.