Front Final Drive: Adjustments Nissan Frontier D40

ASSEMBLY INSPECTION AND ADJUSTMENT

1. Drain the differential gear oil before inspection and adjustment. Refer to " «DIFFERENTIAL GEAR OIL»(ref-272355-S29755496582007111800000) ".
2. Remove and install the carrier cover as necessary for inspection and adjustment. Refer to " «CARRIER COVER»(ref-272355-S04436434232007111800000) ".

Scheme 1

1. Install the differential side shaft if necessary. Refer to " «DIFFERENTIAL SIDE SHAFT»(ref-272355-S17544233482007111800000) ". CAUTION: The differential side shaft must be installed in order to measure total preload torque.
2. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.
4. Measure total preload torque using Tool. Tool number: ST3127S000 (J-25765-A) Total preload torque: 1.67-2.74 N.m (0.17-0.27 kg-m, 15-24 in-lb) NOTE: Total preload torque = Drive pinion bearing preload torque + Side bearing preload torque see scheme 18: Checking Smooth Operation Of Bearing If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion bearing preload torque first, then adjust the side bearing preload torque. If the total preload torque is greater than specification On drive pinion bearings: Replace the collapsible spacer. On side bearings: Use thinner side bearing adjusting washers by the same amount on each side. Refer to " «SIDE BEARING ADJUSTING WASHER»(ref-272355-S10228969172007111800000) ". If the total preload torque is less than specification On drive pinion bearings: Tighten the drive pinion lock nut. On side bearings: Use thicker side bearing adjusting washers by the same amount on each side. Refer to " «SIDE BEARING ADJUSTING WASHER»(ref-272355-S10228969172007111800000) ". CAUTION: Select a side bearing adjusting washer for right and left individually.

Scheme 2

1. Fit a dial indicator to the drive gear back face.
2. Rotate the drive gear to measure runout. Runout limit: 0.08 mm (0.0031 in) or less If the runout is outside of the limit, check the condition of the drive gear assembly. Foreign material may be caught between the drive gear and differential case, or the differential case or drive gear may be deformed. CAUTION: Replace drive gear and drive pinion as a set. see scheme 19: Checking Drive Gear Runout

Scheme 3

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Scheme 7

1. Apply red lead to the drive gear. NOTE: Apply red lead to both faces of three to four gears, at four locations evenly spaced on the drive gear. see scheme 20: Applying Red Lead To 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. see scheme 21: Checking Drive Pinion Gear To Drive Gear Tooth Contact If the tooth contact is improperly adjusted, adjust the drive pinion height (dimension X). see scheme 22: Adjusting Pinion Height 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. Refer to " «DRIVE PINION HEIGHT ADJUSTING WASHER»(ref-272355-S40745085032007111800000) ". see scheme 23: Identifying Face Contact 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. Refer to " «DRIVE PINION HEIGHT ADJUSTING WASHER»(ref-272355-S40745085032007111800000) ". see scheme 24: Identifying Flank Contact

Scheme 8

1. Fit a dial indicator to the drive gear face to measure the backlash. Backlash: 0.10-0.15 mm (0.0039-0.0059 in) If the backlash is outside of the specification, change the thickness of the side bearing adjusting washers. If the backlash is greater than specification: Make side bearing adjusting washer thicker on drive gear back side, and side bearing adjusting washer thinner on drive gear tooth side by the same amount. Refer to " «SIDE BEARING ADJUSTING WASHER»(ref-272355-S10228969172007111800000) ". If the backlash is less than specification: Make side bearing adjusting washer thinner on drive gear back side, and side bearing adjusting washer thicker on drive gear tooth side by the same amount. Refer to " «SIDE BEARING ADJUSTING WASHER»(ref-272355-S10228969172007111800000) ". see scheme 25: Checking Drive Gear To Drive Pinion Backlash Using Dial Gauge CAUTION: Do not change the total thickness of side bearing adjusting washers as it will change the side bearing preload torque.

Scheme 9

1. Rotate companion flange and check for runout on the companion flange face (inner side of the bolt holes) and companion flange inner side (socket diameter) using suitable tool. Runout limit: 0.1 mm (0.004 in) or less
2. If the runout is outside the runout limit, follow the procedure below to adjust. Rotate the companion flange on the drive pinion by 90°, 180° and 270° while checking for the position where the runout is minimum. see scheme 26: Checking Companion Flange Runout If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a malfunctioning drive pinion bearing. 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.

Scheme 10

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Scheme 13

1. Drain the differential gear oil if necessary.
2. Remove the carrier cover bolts and separate the carrier cover from the gear carrier using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage the mating surface. Do not insert flat-bladed screwdriver, this will damage the mating surface. see scheme 27: Identifying Rear Cover To Insert Seal Cutter Between Gear Carrier And Rear Cover
3. Remove side oil seal. CAUTION: Do not damage gear carrier. see scheme 28: Identifying Side Oil Seal
4. Remove snap ring (hole side) using suitable tool. see scheme 29: Identifying Snap Ring (Hole Side)
5. Remove differential side shaft assembly out of gear carrier using suitable tool. NOTE: Tap on differential side shaft assembly from side gear side.
6. Remove snap ring (differential side shaft side). see scheme 30: Identifying Side Shaft Assembly
7. Press differential side shaft out of differential side shaft bearing. CAUTION: Do not drop differential side shaft. see scheme 31: Pressing Side Shaft Out Of Side Shaft Bearing

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Scheme 22

1. Remove differential side shaft assembly. Refer to " «DIFFERENTIAL SIDE SHAFT»(ref-272355-S04528782342007111800000) ".
2. Remove side seal from gear carrier using suitable tool.
3. 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 bearing cap or gear carrier. Side bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions. see scheme 32: Aligning Matching Mark On Bearing Cap With Gear Carrier
4. Remove the side bearing caps. (Scheme 1): Identifying Bearing Caps
5. 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. Keep side bearing adjusting washers together with side bearings. (Scheme 2): Adjusting Side Bearing Washers
6. Remove housing spacer.
7. Remove side bearing inner race using Tools as shown. Tool number A: ST33051001 (J-22888-20) B: ST33061000 (J-8107-2) 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. (Scheme 3): Identifying Side Bearing Inner Races Keep side bearing outer races together with side bearing inner races. Do not mix them up. (Scheme 4): Identifying Left And Right Side Parts Label
8. 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.
9. Remove the drive gear bolts.
10. Tap the drive gear off the differential case using suitable tool. CAUTION: Tap evenly all around to keep drive gear from bending. (Scheme 5): Identifying Matching Mark
11. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool. (Scheme 6): Driving Out Pinion Mate Shaft Lock Pin
12. Remove the pinion mate shaft. (Scheme 7): Identifying Pinion Mate Shaft
13. 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. (Scheme 8): Identifying Pinion Mate Gear

Scheme 23

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Scheme 28

1. Remove the differential assembly. Refer to " «DIFFERENTIAL ASSEMBLY»(ref-272355-S35280562672007111800000) ".
2. Remove the drive pinion lock nut using Tool. Tool number: KV38108300 (J-44195)
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. (Scheme 9): Identifying Drive Pinion Lock Nut
4. Remove the companion flange using suitable tool. see scheme 42: Identifying Companion Flange
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. (Scheme 10): Pressing Drive Pinion Assembly Of Gear Carrier
6. Remove the drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool. Tool number: ST30031000 (J-22912-01) (Scheme 11): Identifying Drive Pinion Rear Bearing Inner Race And Drive Pinion Height Adjusting Washer
7. Remove the front oil seal using suitable tool. CAUTION: Do not damage gear carrier. (Scheme 12): Identifying Collapsible Spacer
8. Remove the drive pinion front bearing inner race.
9. Remove the drive pinion front and rear bearing outer races by tapping them uniformly using suitable tool. CAUTION: Do not damage gear carrier. (Scheme 13): Taping Pinion Front/Rear Bearing Outer Races