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DIFF LOCK Indicator Lamp Sometimes Flashes Nissan Frontier D40

Rear Final Drive 7 illustrations ~1523 words

DIFF LOCK Indicator Lamp Sometimes Flashes

SYMPTOM

DIFF LOCK indicator lamp sometimes flashes when it turns ON or OFF during driving.

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

Scheme 284

Scheme 284: Tooth Contact
Scheme 284: Tooth Contact
  1. Thoroughly clean drive gear and drive pinion teeth.
  2. 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 211: Applying Red Lead To Drive Gear
  3. Hold companion flange steady by hand and rotate drive gear in both directions. (Scheme 274): Holding Companion Flange Steady By Hand (Scheme 275): Identifying Tooth Contact Pattern
  4. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to " «DRIVE PINION HEIGHT ADJUSTING WASHER»(ref-272368-S28035362072007111800000) " and " «BACKLASH»(ref-272368-S28518323252007111800000) ".
  1. Fit a dial indicator to the drive gear face to measure the backlash. Backlash: 0.08-0.13 mm (0.0031-0.0051 in)
  2. If the backlash is outside of the specification, adjust each side bearing side bearing adjuster. Remove adjuster lock plate. Loosen side bearing cap bolts. (Scheme 276): Checking Drive Pinion Backlash Tighten or loosen each side bearing adjusters using Tool. Tool number: - (C-4164) (Scheme 277): Adjusting Side Bearing Adjuster If the backlash is greater than specification: Loosen side bearing adjuster A and tighten side bearing adjuster B by the same amount. If the backlash is less than specification: Loosen side bearing adjuster B and tighten side bearing adjuster A by the same amount. (Scheme 278): Identifying Bearing Adjuster Position CAUTION: Do not change the side bearing side bearing adjusters by different amounts as it will change the side bearing preload torque. Tighten side bearing cap bolts to the specified torque. Refer to " «COMPONENTS»(ref-272368-S41561754442007111800000) ". Install adjuster lock plate and tighten to the specified torque. Refer to " «COMPONENTS»(ref-272368-S41561754442007111800000) ". CAUTION: Check tooth contact and total preload torque after adjusting side bearing adjuster. Refer to " «TOOTH CONTACT»(ref-272368-S19778887442007111800000) " and " «TOTAL PRELOAD TORQUE»(ref-272368-S17064013162007111800000) ". (Scheme 279): Tightening Adjuster Lock Plate
  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 Companion flange face: 0.10 mm (0.0039 in) Companion flange inner side: 0.13 mm (0.0051 in)
  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. 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 280): Checking Companion Flange Runout

Scheme 285

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Scheme 290
Scheme 290
  1. Remove carrier cover bolts.
  2. Remove carrier cover 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 219: Separating Carrier Cover Using Tool
  3. Remove differential sensor connector bolt and differential lock solenoid connector. see scheme 220: Identifying Differential Sensor Connector Bolt
  4. For proper reinstallation, paint matching mark on one side of side bearing cap. CAUTION: Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions. For matching mark, use paint. Do not damage side bearing cap.
  5. Remove adjuster lock plates. see scheme 221: Identifying Matching Marks
  6. Remove side bearing caps. see scheme 222: Identifying Side Bearing Caps
  7. Remove side bearing adjusters using Tool. Tool number: - (C-4164) see scheme 223: Adjusting Side Bearing Adjuster
  8. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.
  9. Remove side bearing adjusters from gear carrier. see scheme 224: Applying Tag On Side Bearing Outer Races
  10. Remove bracket of differential lock position switch connector and bolts.
  11. Remove differential lock position switch.
  12. Remove side bearing inner race and washer using Tool. Tool number: ST33081000 ( - ) CAUTION: Do not damage differential case assembly and differential lock solenoid.
  13. Remove differential lock solenoid and solenoid washer. see scheme 225: Identifying Differential Lock Solenoid And Solenoid Washer
  14. Remove side bearing inner race using Tool. Tool number: ST33081000 ( - ) CAUTION: Do not damage differential case assembly. see scheme 226: Identifying Side Bearing Inner Race
  15. For proper reinstallation, paint matching mark on differential case and drive gear. CAUTION: Use paint for matching marks. Do not damage differential case or drive gear.
  16. Remove drive gear bolts.
  17. Tap the drive gear off the differential case using suitable tool. CAUTION: Tap evenly all around to keep drive gear from binding. see scheme 227: Loosening Drive Gear Bolts In Crisscross Pattern
  1. If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as necessary.
  2. If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new gears.
  3. Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive 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.
  1. If found any chipped (by friction), pitted, worn, rusted, scratched mark, or unusual noise from the bearing, replace with new bearing assembly (as a new set).
  2. Bearing must be replaced with a new one whenever disassembled.
  1. If the operating part of differential lock solenoid is not smooth, perform component inspection. Refer to " «COMPONENT INSPECTION»(ref-272368-S30412653172007111800000) ".
  1. Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive pinion and drive gear are etched for verification. If a new gear set is being used, verify the numbers of each drive pinion and drive gear before proceeding with assembly. see scheme 234: Identifying Drive Pinion Matching Gear Set Number
  2. The mounting distance from the center line of drive gear to the back face of drive pinion for the Model 226 final drive assembly is 109.5 mm (4.312 in). On the button end of each drive 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 drive pinion height adjusting washer between drive pinion inner bearing race and drive pinion. For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 in) less drive pinion height adjusting washer than a drive pinion etched "0". This means decreasing drive pinion height adjusting washer thickness; increases the mounting distance of drive pinion to 109.6 mm (4.315 in). If a drive pinion is etched m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting washer than would be required if drive pinion were etched "0". By adding 0.08 mm (0.003 in), the mounting distance of drive pinion was decreased to 109.4 mm (4.309 in) which is just what m-8 (a-3) etching indicated.
  3. To change drive pinion adjustment, use different drive pinion height adjusting washers which come in different thickness.
  4. Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to add or subtract from the old drive pinion height adjusting washer.
OLD DRIVE PINION MARKINGNEW DRIVE PINION MARKING mm (in)
10 (-4)8 (-3)5 (-2)3 (-1)0 (0)+3 (+1)+5 (+2)+8 (+3)+10 (+4)
+10 (+4)+0.20 (+0.008)+0.18 (+0.007)+0.15 (+0.006)+0.13 (+0.005)+0.10 (+0.004)+0.08 (+0.003)+0.05 (+0.002)+0.02 (+0.001)0 (0)
+8 (+3)+0.18 (+0.007)+0.15 (+0.006)+0.13 (+0.005)+0.10 (+0.004)+0.08 (+0.003)+0.05 (+0.002)+0.02 (+0.001)0 (0)0.02 (-0.001)
+5 (+2)+0.15 (+0.006)+0.13 (+0.005)+0.10 (+0.004)+0.08 (+0.003)+0.05 (+0.002)+0.02 (+0.001)0 (0)0.02 (-0.001)0.05 (-0.002)
+3 (+1)+0.13 (+0.005)+0.10 (+0.004)+0.08 (+0.003)+0.05 (+0.002)+0.02 (+0.001)0 (0)0.02 (-0.001)0.05 (-0.002)0.08 (-0.003)
0 (0)+0.10 (+0.004)+0.08 (+0.003)+0.05 (+0.002)+0.02 (+0.001)0 (0)0.02 (-0.001)0.05 (-0.002)0.08 (-0.003)0.10 (-0.004)
3 (-1)+0.08 (+0.003)+0.05 (+0.002)+0.02 (+0.001)0 (0)0.02 (-0.001)0.05 (-0.002)0.08 (-0.003)0.10 (-0.004)0.13 (-0.005)
5 (-2)+0.05 (+0.002)+0.02 (+0.001)0 (0)0.02 (-0.001)0.05 (-0.002)0.08 (-0.003)0.10 (-0.004)0.13 (-0.005)0.15 (-0.006)
8 (-3)+0.02 (+0.001)0 (0)0.02 (-0.001)0.05 (-0.002)0.08 (-0.003)0.10 (-0.004)0.13 (-0.005)0.15 (-0.006)0.18 (-0.007)
10 (-4)0 (0)0.02 (-0.001)0.05 (-0.002)0.08 (-0.003)0.10 (-0.004)0.13 (-0.005)0.15 (-0.006)0.18 (-0.007)0.20 (-0.008)

DRIVE PINION MARKING

  1. Make sure all parts are clean and that drive pinion bearings are well lubricated.
  2. Assemble drive pinion bearings into the tools. Tool number A: - (8144) B: - (6740) C: - (6741) see scheme 235: Assembling Drive Pinion Bearings Into Tool
  3. Install drive pinion bearing inner race and drive pinion height adjusting washer to gear carrier using tool as shown. see scheme 236: Identifying Drive Pinion Bearing Inner Race And Drive Pinion Height Adjusting Washer
  4. Turn the assembly several times to seat drive pinion bearings. see scheme 237: Seating Drive Pinion Bearings
  5. Measure the turning torque, using Tool. Tool number: ST3127S000 (J-25765-A) Turning torque specification: 1.2-2.8 N-m (0.13-0.28 kg-m, 11-24 in-lb) see scheme 238: Measuring Turning Torque
  6. Tighten side bearing caps to the specified torque installing Tools as shown. Tool number A: - (6739) B: - (D-115-2) C: - (8541A-1) D: - (D-115-3) see scheme 239: Tightening Side Bearing Caps
  7. Put scooter block on pinion height block. Make sure that dial indicator is level adjusting pressure with a hand. Dial indicator indicates "0".
  8. Slide dial indicator along arbor. Record the maximum.
  9. Adjust drive pinion height adjusting washer so that the maximum will be "0". see scheme 240: Adjusting Drive Pinion Height
Unit: mm (in)
ItemStandard
Drive gear to drive pinion gear0.08-0.13 (0.0031-0.0051)

BACKLASH SPECIFICATION

Unit: mm (in)
ItemRunout limit
Companion flange face0.10 (0.0039) or less
Companion flange inner side0.13 (0.0051) or less

COMPANION FLANGE RUNOUT CHART

Unit: mm (in)
ThicknessPackage part number (1)
0.076 (0.030) 0.079 (0.031) 0.081 (0.032) 0.084 (0.033) 0.086 (0.034)38151 8S101
0.089 (0.035) 0.091 (0.036) 0.094 (0.037) 0.097 (0.038) 0.099 (0.039)38151 8S102
0.102 (0.040) 0.104 (0.041) 0.107 (0.042) 0.109 (0.043) 0.112 (0.044)38151 8S103
0.114 (0.045) 0.117 (0.046) 0.119 (0.047) 0.122 (0.048) 0.124 (0.049)38151 8S104
0.127 (0.050) 0.130 (0.051) 0.132 (0.052) 0.135 (0.053) 0.137 (0.054)38151 8S105
(1) Always check with the Parts Department for the latest parts information.
(1)Always check with the Parts Department for the latest parts information.

DRIVE PINION HEIGHT ADJUSTING WASHER THICKNESS