Content .. 258 259 260 261 ..

Nissan Pathfinder (2005 year). Manual - part 260

FRONT FINAL DRIVE ASSEMBLY

FFD-23

FFD

2005 Pathfinder

12. Remove lock pin of pinion mate shaft from drive gear side using

suitable tool.

13. Remove pinion mate shaft.

14. Turn pinion mate gear, then remove pinion mate gear, pinion

mate thrust washer, side gear and side gear thrust washer from
differential case.

Drive Pinion Assembly

Remove side shaft assembly. Refer to

FFD-20, "Side Shaft"

Remove differential assembly. Refer to

FFD-21, "Differential Assembly"

Remove drive pinion lock nut using Tool.

SPD025

SDIA0031J

SDIA0032J

Tool number

: KV38108300 (J-44195)

PDIA0702E

FFD-24

FRONT FINAL DRIVE ASSEMBLY

2005 Pathfinder

Put matching mark on the end of drive pinion. The matching
mark should be in line with the matching mark A on companion
flange.

CAUTION:

Use paint for matching mark. Do not damage companion
flange or drive pinion.

NOTE:
The matching mark A on the final drive companion flange indi-
cates the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.

Remove companion flange using suitable tool.

Press drive pinion assembly out of gear carrier. (Together with
collapsible spacer.)

CAUTION:

Do not drop drive pinion assembly.

Remove pinion rear bearing inner race and drive pinion height
adjusting washer using Tool.

Remove front oil seal using suitable tool.

CAUTION:

Do not damage gear carrier.

Remove pinion front bearing inner race.

10. Remove collapsible spacer.

PDIA0675E

PDIA0703E

PDIA0704E

Tool number

: ST30031000 (J-22912-01)

S-PD179

PDIA0716E

FRONT FINAL DRIVE ASSEMBLY

FFD-25

FFD

2005 Pathfinder

11. Tap pinion front/rear bearing outer races uniformly to remove

them, using suitable tool.

CAUTION:

Do not damage gear carrier.

INSPECTION AFTER DISASSEMBLY

Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If parts are worn or dam-
aged, follow the measures below.

PDIA0705E

Content

Conditions and Measures

Hypoid gear

●

If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.

●

If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.

Bearing

●

If any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing
is observed, replace as a bearing assembly (as a new set).

Side gear and Pinion mate
gear

●

If any cracks or damage on the surface of the tooth is found, replace.

●

If any worn or chipped mark on the contact sides of the thrust washer is found, replace.

Side gear thrust washer and
pinion mate thrust washer

●

If it is chipped (by friction), damaged, or unusually worn, replace.

Oil seal

●

Whenever disassembled, replace.

●

If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.

Differential case

●

If any wear or crack on the contact sides of the differential case is found, replace.

Companion flange

●

If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the
companion flange is found, replace.

FFD-26

FRONT FINAL DRIVE ASSEMBLY

2005 Pathfinder

ADJUSTMENT AND SELECTION ADJUSTING WASHERS
Differential Side Gear Clearance

●

Assemble the differential parts if they are disassembled. Refer to

FFD-32, "Differential Assembly"

Place differential case straight up so that side gear to be mea-
sured comes upward.

Using feeler gauge, measure the clearance between side gear
back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance. (Measure the clearance of the other side as well.)

CAUTION:

To prevent side gear from tilting, insert feeler gauges with
the same thickness from both sides.

If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. Refer to

FFD-36, "Side

Gear Thrust Washer"

CAUTION:

Select a side gear thrust washer for right and left individu-
ally.

Pinion Gear Height

Make sure all parts are clean and that the bearings are well
lubricated.

Assemble the pinion gear bearings into the Tool.

PDIA0460E

Side gear back clearance specification:

0.1 mm (0.004 in) or less.
(Each gear should rotate smoothly without excessive
resistance during differential motion.)

When the back clearance is greater than specification:

Use a thicker thrust washer.

When the back clearance is less than specification:

Use a thinner thrust washer.

PDIA0576E

Tool number

—

(J-34309)

SPD769

FRONT FINAL DRIVE ASSEMBLY

FFD-27

FFD

2005 Pathfinder

●

Pinion front bearing; make sure the J-34309-3 pinion front
bearing seat is secured tightly against the J-34309-2 gauge
anvil. Then turn the pinion front bearing pilot, J-34309-7, to
secure the bearing in its proper position.

●

Pinion rear bearing; the pinion rear bearing pilot, J-34309-8,
is used to center the pinion rear bearing only. The pinion rear
bearing locking seat, J-34309-4, is used to lock the bearing to
the assembly.

●

Installation of J-34309-9 and J-34309-16; place a suitable
2.5 mm (0.098 in) thick plain washer between J-34309-9 and
J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must
be parallel with a clearance of 2.5 mm (0.098 in).

Install the pinion rear bearing inner race into gear carrier. Then
place the pinion preload shim selector tool, J-34309-1, gauge
screw assembly.

Assemble the pinion front bearing inner race and the J-34309-2
gauge anvil. Assemble them together with the J-34309-1 gauge
screw in gear carrier. Make sure that the pinion height gauge
plate, J-34309-16, will turn a full 360 degrees. Tighten the two
sections together by hand.

Turn the assembly several times to seat the bearings.

Measure the turning torque at the end of the J-34309-2 gauge
anvil using Tool.

SPD197A

SPD893

SPD199A

SPD770

Tool number

: ST3127S000 (J-25765- A)

Turning torque specification:

1.0 - 1.6 N·m (0.11 - 0.16 kg-m, 9 - 14 in-lb)

PDIA0566E

FFD-28

FRONT FINAL DRIVE ASSEMBLY

2005 Pathfinder

Place the J-34309-10 “R180A” pinion height adapter onto the
gauge plate and tighten it by hand.

CAUTION:

Make sure all machined surfaces are clean.

Position the side bearing discs, Tool, and arbor firmly into the
side bearing bores. Install the bearing caps and tighten bearing
cap bolts to the specified torque. Refer to

FFD-16, "COMPO-

NENTS"

Select the correct standard pinion height adjusting washer thick-
ness. Select by using a standard gauge of 3 mm (0.12 in) and
your J-34309-101 feeler gauge. Measure the distance between
the J-34309-10 pinion height adapter including the standard
gauge and the arbor.

10. Write down exact measurement (the value of feeler gauge).

11. Correct the pinion height washer size by referring to the “pinion

head number”.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and drive gear as a matched
set. This number should be the same as the number on the
drive gear. The second number is the “pinion head height
number”. It refers to the ideal pinion height from standard
for quietest operation. Use the following chart to determine
the correct pinion height washer.

SPD208A

Tool number

—

(J-25269-18)

SPD211A

SPD204A

SPD775

SPD542

FRONT FINAL DRIVE ASSEMBLY

FFD-29

FFD

2005 Pathfinder

12. Select the correct pinion height adjusting washer. Refer to

FFD-37, "Pinion Height Adjusting Washer"

13. Remove the J-34309 differential shim selector tool from the final

drive housing. Then disassemble to retrieve the pinion bearings.

ASSEMBLY
Drive Pinion Assembly

Install front and rear bearing outer races using Tools.

CAUTION:

●

First tap the bearing outer race until it becomes flat to the
gear carrier.

●

Do not reuse pinion front and rear bearing outer race.

Select drive pinion height adjusting washer. Refer to

FFD-26,

"Pinion Gear Height"

Pinion head height number

Add or remove from the standard pinion height

adjusting washer thickness measurement

- 6
- 5
- 4
- 3
- 2
- 1

+1
+2
+3
+4
+5
+6

Add 0.06 mm (0.0024 in)
Add 0.05 mm (0.0020 in)
Add 0.04 mm (0.0016 in)
Add 0.03 mm (0.0012 in)
Add 0.02 mm (0.0008 in)
Add 0.01 mm (0.0004 in)

Use the selected washer thickness

Subtract 0.01 mm (0.0004 in)
Subtract 0.02 mm (0.0008 in)
Subtract 0.03 mm (0.0012 in)
Subtract 0.04 mm (0.0016 in)
Subtract 0.05 mm (0.0020 in)
Subtract 0.06 mm (0.0024 in)

SPD205A

Tool number

A: ST30611000 (J-25742-1)

B: ST30613000 (J-25742-3)

C: KV38100200 (J-26233)

PDIA0707E

FFD-30

FRONT FINAL DRIVE ASSEMBLY

2005 Pathfinder

Install selected drive pinion height adjusting washer to drive pin-
ion. Press pinion rear bearing inner race to it using Tool.

CAUTION:

●

Install the pinion height adjusting washer in the proper
direction as shown.

●

Do not reuse pinion rear bearing inner race.

Assemble collapsible spacer to drive pinion.

CAUTION:

Do not reuse collapsible spacer.

Apply gear oil to pinion rear bearing, and assemble drive pinion
into gear carrier.

Apply gear oil to pinion front bearing, and assemble pinion front
bearing inner race to drive pinion assembly.

CAUTION:

Do not reuse pinion front bearing inner race.

Press the pinion front bearing inner race to drive pinon as far as
drive pinion lock nut can be tightened using Tool.

Install front oil seal until it becomes flush with the case end using
Tools.

CAUTION:

●

Do not reuse oil seal.

●

Do not incline oil seal when installing.

●

Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.

Tool number

: ST30901000 (J-26010-01)

SDIA0048E

PDIA0708E

SPD581

Tool number

: ST33200000 (J-26082)

PDIA0709E

Tool number

A: ST30720000 (J-25405)

B: ST27863000 (

—

)

PDIA0717E

Content .. 258 259 260 261 ..