REAR FINAL DRIVE D DRIVELINE/AXLE RFD A - The Nissan And .

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REAR FINAL DRIVED DRIVELINE/AXLESECTIONRFDREAR FINAL DRIVEABCRFDECONTENTSPREPARATION . 2Special Service Tools . 2Commercial Service Tools . 4NOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING . 5NVH Troubleshooting Chart . 5FRONT OIL SEAL . 6Removal and Installation . 6REMOVAL . 6INSTALLATION . 7SIDE OIL SEAL . 8Removal and Installation . 8REMOVAL . 8INSTALLATION . 8REAR FINAL DRIVE ASSEMBLY . 10Removal and Installation . 10REMOVAL . 10INSTALLATION .11Components . 12R200 2–PINION . 12R200V VISCOUS . 14Pre-Inspection . 15TOTAL PRELOAD . 15RING GEAR TO DRIVE PINION BACKLASH . 15RING GEAR RUNOUT . 15TOOTH CONTACT . 15Disassembly and Assembly . 16REMOVAL OF DIFFERENTIAL CASE ASSEMBLY . 16REMOVAL OF DRIVE PINION ASSEMBLY . 17DISASSEMBLY OF DIFFERENTIAL CASERevision; 2004 AprilASSEMBLY (R200 2–PINION) . 18DISASSEMBLY OF DIFFERENTIAL CASEASSEMBLY(R200V) . 20INSPECTION . 21ADJUSTMENT OF DIFFERENTIAL CASE (R2002–PINION) . 21ADJUSTMENT OF DIFFERENTIAL CASE(R200V) . 22SIDE BEARING PRELOAD . 23PINION GEAR HEIGHT . 24TOOTH CONTACT . 27ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200 2–PINION) . 28ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200V) . 29INSTALLATION OF DRIVE PINION ASSEMBLY. 30INSTALLATION OF DIFFERENTIAL CASEASSEMBLY . 31SERVICE DATA AND SPECIFICATIONS (SDS) . 34General Specifications . 34Ring Gear Runout . 34Side Gear Adjustment . 34AVAILABLE SIDE GEAR THRUST WASHERS. 34Drive Pinion Height Adjustment . 35AVAILABLE PINION HEIGHT ADJUSTINGWASHERS . 35Drive Pinion Preload Adjustment . 35Side Bearing Preload Adjustment . 35SIDE BEARING ADJUSTING WASHERS . 35Total Preload Adjustment . 35RFD-12003 350ZFGHIJKLM

PREPARATIONPREPARATIONSpecial Service ToolsPFP:00002ADS0005UThe actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool nameTool number (Kent-Moore No.)DescriptionDriftST30720000 (J25405)a: 77 mm (3.03 in) dia.b: 55 mm (2.17 in) dia.Installing front oil sealZZA0811DDriftKV38100200 (J26233)a: 65 mm (2.56 in) dia.b: 49 mm (1.93 in) dia.Installing final drive side oil sealZZA1143DProtectorKV38107900 (J39352)Installing final drive side flangeS-NT129AttachmentKV38100800 (J25604-01)a: 541 mm (21.30 in)b: 200 mm (7.87 in)Fixing unit assemblySDIA0267EDifferential side bearing puller setST3306S001 ( – )1.ST3305S001 ( – )2.ST33061000 (J8107–2)a: 28.5 mm (1.122 in) dia.b: 38 mm (1.50 in) dia.Removing and installing side bearingNT072DriftST30613000 (J25742-3)a: 72 mm (2.83 in) dia.b: 48 mm (1.89 in) dia.Installing pinion front and rear bearing outerraceZZA0810DDriftKV38100300 (J25523)a: 54 mm (2.13 in) dia.b: 46 mm (1.81 in) dia.c: 32 mm (1.26 in) dia.Installing side bearingZZA1046DRevision; 2004 AprilRFD-22003 350Z

PREPARATIONTool nameTool number (Kent-Moore No.)DescriptionDrive pinion flange wrenchKV40104000 ( – )a : 85 mm (3.35 in) dia.b : 65 mm (2.56 in) dia.Removing and installing drive pinion locknutABCNT659RFDSliding hammerST36230000 (J25840-A)Removing side flangeEZZA0803DFAxle standKV40104100 ( – )Removing side flangeGZZA0804DSlideing hammerHT72400000 ( – )HRemoving differential case assemblyJS-NT125Drive pinion rear inner race puller setST3090S000 ( – )1. ST30031000 (J22912-01) Puller2. ST30901000 ( – ) BaseEquivalent tool (J26010-01)a : 90 mm (3.54 in) dia.b : 80 mm (3.15 in) dia.c : 50 mm (1.97 in) dia.d : 79 mm (3.11 in) dia.e : 45 mm (1.77 in) dia.f : 35 mm (1.38 in) dia.KRemoving and installing drive pinion rearbearing inner raceLS-NT640MDriftST30611000 (J25742–1)Installing pinion rear bearing outer race(Use with ST30613000)S-NT090Preload gaugeST3127S000 (see J25765-A)1. GG91030000Torque wrench (J25765)2. HT62940000 ( – )Socket adapter (1/2″)3. HT62900000 ( – )Socket adapter (3/8″)Revision; 2004 AprilIMeasuring pinion bearing preload and totalpreloadNT124RFD-32003 350Z

PREPARATIONTool nameTool number (Kent-Moore No.)DescriptionSide bearing outer race pullerST33290001 (J34286)Removing oil sealNT713Differential shim selection (J34309)Adjusting bearing preload gear heightNT134Commercial Service ToolsADS0005VPower toolPBIC0190ERevision; 2004 AprilRFD-42003 350Z

SymptomDIFFERENTIALRevision; 2004 AprilIncorrect backlashCompanion flange excessive runoutImproper gear oilPROPELLER SHAFTAXLE AND SUSPENSIONTIRESROAD WHEELDRIVE SHAFTBRAKESSTEERINGNoiseTooth surfaces wornPossible cause and SUSPECTED PARTSImproper gear contactRFD-5NVH in PS section.NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGNVH Troubleshooting ChartNVH in BR section.NVH in RAX section.NVH in WT section.NVH in WT section.NVH in FAX, RAX, FSU and RSU sections.NVH in PR section.Refer to MA-21, "CHASSIS AND BODY MAINTENANCE"—Refer to RFD-15, "Pre-Inspection"Refer to RFD-21, "Contact Surfaces"Refer to RFD-27, "TOOTH CONTACT"Refer to RFD-21, "Contact Surfaces"Reference pageRough gear toothNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003ADS0005WAUse the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.BCRFDE : Applicable 2003 350ZFGHIJKLM

FRONT OIL SEALFRONT OIL SEALRemoval and InstallationPFP:38189ADS00081REMOVAL1.2.Remove the propeller shaft. Refer to PR-5, "REAR PROPELLER SHAFT" .CAUTION:Do not impact or damage propeller shaft tube.Put a mark on the end of the drive pinion corresponding to the Bposition mark on the final drive companion flange.CAUTION: For matching mark, use paint. Never damage drive pinion. The mark on the final drive companion flange indicatesthe maximum vertical runout position.SDIA0270E3.Using the drive pinion flange wrench, Remove drive pinion nut.Tool number: KV40104000 ( – )SDIA1142E4.Using the puller, remove the companion flange.SDIA1054E5.Using the side bearing outer race puller, remove oil seal.Tool number: ST33290001 (J34286)SDIA1003ERevision; 2004 AprilRFD-62003 350Z

FRONT OIL SEALINSTALLATION1.AApply multi-purpose grease to sealing lips of oil seal. Press frontoil seal into carrier with tool.Tool number: ST30720000 (J25405)BCAUTION: When installing the oil seal, be careful not to get itinclined. Discard the old oil seal. Always replace with new one.CSDIA1004E2.Align the matching mark of drive pinion with the matching markB of companion flange, then install the companion flange.RFDEFGSDIA0270E3.4.HApply oil or grease on the screw part of drive pinion and the seating surface of drive pinion nut.Install drive pinion nut with tool.Tool number: KV4010400 ( - )I: 147 - 323N·m (15.0 - 32.0 kg-m, 109 - 238 ft-lb)JCAUTION:The drive pinion nut is not reusable. Never reuse drive pinion nut.5. Install propeller shaft. Refer to PR-5, "REAR PROPELLER SHAFT" .KLMRevision; 2004 AprilRFD-72003 350Z

SIDE OIL SEALSIDE OIL SEALRemoval and InstallationPFP:33142ADS0006QREMOVAL1.a.b.c.Remove side flange with the following procedure for press-fitting.Remove rear ABS wheel sensor. Refer to BRC-87, "WHEEL SENSORS" .Remove drive shaft. Refer to RAX-10, "REAR DRIVE SHAFT" and RAX-6, "WHEEL HUB" .Install axle stand to side flange.Tool number Ad.: KV40104100 ( – )Using a sliding hammer, pull out the side flange.Tool number B: ST36230000 (J25840–A)SDIA1005ECircular clip installation positionModelRight sideLeft sideR200R200V2.Final drive sideFinal drive sideSide flange sideRemove oil seal using a flat-bladed screwdriver.SDIA1036EINSTALLATIONNOTE:Be sure to install the RH companion flange of the R200V, then install the LH companion flange. If LH companion flange is installed first, the RH companion flange comes out sometimes from the shock of installing the RHcompanion flange.1. Apply multi-purpose grease to sealing lips of oil seal.2.Using the drift, press-fit oil seal so that its surface comes face toface with the end surface of the case.Tool number: KV38100200 (J26233)CAUTION:When installing the oil seal be careful not to get itinclined. Discard the old oil seal. Always replace with new one. SDIA1037ERevision; 2004 AprilRFD-82003 350Z

SIDE OIL SEAL3.a.Install the side flange with the following procedure.Attach the protector to side oil seal.Tool numberb.A: KV38107900 (J39352)After the side flange is inserted and the serrated part of sidegear has engaged the serrated part of flange, remove the protector.BCSDIA0822ERFDc.4.Put suitable drift on the center of side flange, then drive it untilsound changes.NOTE:When installation is completed, driving sound of the side flangeturns into a sound which seems to affect the whole final drive.Confirm that the dimension of the side flange installation (Measurement A) in the illustration comes into the following, theninstall the drive shaft.Measurement A: Approx. 326 - 328 mm (12.83 - 12.91 in)5.EFGSDIA0276EHAlign the installing position of the ABS wheel sensor. Refer to BRC-87, "WHEEL SENSORS" .IJKLMRevision; 2004 AprilRFD-92003 350Z

REAR FINAL DRIVE ASSEMBLYREAR FINAL DRIVE ASSEMBLYRemoval and .4.5.6.7.Remove rear propeller shaft from the final drive. Refer to PR-7, "REMOVAL" .CAUTION:Do not impact or damage propeller shaft tube.Remove rear stabilizer bar with power tool. Refer to RSU-16, "STABILIZER BAR" .Remove drive shaft from final drive. Then suspend it by wire etc.Refer to RAX-10, "REAR DRIVE SHAFT" .Remove breather hose from the final drive.Remove ABS wheel sensor. Refer to BRC-87, "WHEEL SENSORS" .Place a transmission jack on the final drive.CAUTION:Do not place a transmission jack on the rear cover (aluminum case).Remove the mounting bolts and nuts connecting to the suspension member, and remove the rear final drive.Revision; 2004 AprilRFD-10SDIA1094E2003 350Z

REAR FINAL DRIVE ASSEMBLYINSTALLATIONInstall in the reverse order of removal.CAUTION:After installation, check the final drive oil level. Refer to MA-24, "Checking Differential Gear Oil" .ABCRFDEFGHIJKLMRevision; 2004 AprilRFD-112003 350Z

REAR FINAL DRIVE ASSEMBLYComponentsADS0006SR200 2–PINIONSDIA1023ERevision; 2004 AprilRFD-122003 350Z

REAR FINAL DRIVE ASSEMBLY1.Drive pinion nut2.Companion flange3.Front oil seal4.Pinion front bearing5.Pinion bearing adjusting spacer(Collapsible spacer)6.Pinion rear bearing7.Pinion height adjusting washer8.Drive pinion9.Side oil seal10. Ring gear11. Pinion mate shaft12. Look pin13. Pinion mate gear14. Pinion mate thrust washer15. Side gear16. Side gear thrust washer17. Differential case18. Side bearing19. Side bearing adjusting washer20. Bearing cap21. Rear cover22. Filler plug23. Drain plug24. Gear carrier25. Circular clip26. GasketABCRFDEFGHIJKLMRevision; 2004 AprilRFD-132003 350Z

REAR FINAL DRIVE ASSEMBLYR200V VISCOUSSDIA1022ERevision; 2004 AprilRFD-142003 350Z

REAR FINAL DRIVE ASSEMBLY1.Drive pinion nut2.Companion flange3.Front oil seal4.Pinion front bearing5.Pinion bearing adjusting spacer(Collapsible spacer)6.Pinion rear bearing7.Pinion height adjusting washer8.Drive pinion9.Side oil sealAB10. Ring gear11. Pinion mate shaft12. Pinion mate gear13. Pinion mate thrust washer14. Side gear thrust washer15. Side gear16. Viscous coupling17. Side gear thrust washer18. Differential case B19. Differential case A20. Side bearing21. Side bearing adjusting washer22. Bearing cap23. Rear cover24. Filler plug25. Drain plug26. Gear carrier27. Circular clipCRFD28. GasketPre-InspectionADS0006TEBefore disassembling final drive, perform the following inspection.TOTAL PRELOAD1.2.FTurn drive pinion in both directions several times to set bearingrollers.Check total preload with Tool.GTool number: ST3127S000 (see J25765-A)Total preload: 2.84 - 3.75 N·m (0.29 - 0.38 kg-m, 26 - 33 in-lb)HSPD884IRING GEAR TO DRIVE PINION BACKLASHCheck ring gear to drive pinion backlash with a dial indicator at several points.JRing gear backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)KLSPD513RING GEAR RUNOUTCheck runout of ring gear with a dial indicator.Runout limit: 0.05 mm (0.0020 in) lessSPD886TOOTH CONTACTCheck tooth contact. Refer to RFD-27, "TOOTH CONTACT" .Revision; 2004 AprilRFD-152003 350ZM

REAR FINAL DRIVE ASSEMBLYDisassembly and AssemblyADS0006UREMOVAL OF DIFFERENTIAL CASE ASSEMBLY1.Using two 45 mm (1.77 in) spacers, mount carrier on Tool.Tool number: KV38100800 (J25604–01)SPD8882.For proper reinstallation, paint match marks on one side of thebearing cap.Bearing caps are line-board during manufacture. Replace themin their proper positions.SPD8893.Remove bearing caps.S-PD3434.Lift differential case assembly out with Tool.Tool number: HT72400000 (–)S-PD344Revision; 2004 AprilRFD-162003 350Z

REAR FINAL DRIVE ASSEMBLY Keep the side bearing outer races together with inner races.Do not mix them up.Also, keep adjusting washers together with bearings.ABCSPD919RFDREMOVAL OF DRIVE PINION ASSEMBLY1.2.Put match marks on companion flange and drive pinion withpaint.Loosen drive pinion nut with tool.Tool numberE: KV40104000 (–)FGSDIA1144E3.HUsing the puller remove companion flange.IJKSDIA1132E4.5.6.7.Take out drive pinion (together with rear bearing inner race,bearing adjusting spacer).Remove front oil seal. Refer to RFD-6, "FRONT OIL SEAL"Remove pinion front bearing inner race.Remove side oil seal. Refer to RFD-8, "SIDE OIL SEAL"LMSPD892Revision; 2004 AprilRFD-172003 350Z

REAR FINAL DRIVE ASSEMBLY8.Remove pinion bearing outer races with a brass drift.SDIA0817E9.Remove pinion rear bearing inner race and drive pinion heightadjusting washer with Tool.Tool number:: ST30031000 (J22912-01)S-PD179DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200 2–PINION)1.Remove side bearing inner races.To prevent damage to bearing, engage puller jaws in groove.Tool number: A ST3305S001 (–): B ST33061000 (J8107-2)SPD920Revision; 2004 AprilRFD-182003 350Z

REAR FINAL DRIVE ASSEMBLY Be careful not to confuse left- and right-hand parts.ABCSPD022RFD2.3.Loosen ring gear bolts in a criss-cross fashion.Tap ring gear off the differential case with a soft hammer. Tap evenly all around to keep ring gear from binding.EFGSPD0244.Drive out pinion mate shaft lock pin with punch from ring gearside.HIJSPD025KLMRevision; 2004 AprilRFD-192003 350Z

REAR FINAL DRIVE ASSEMBLYDISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY(R200V)1.Remove side bearing inner race.To prevent damage to bearing, engage puller jaws in groove.Tool number: A ST3305S001 (–): B ST33061000 (J8107-2)SDIA0818E Be careful not to confuse left- and right-hand parts.SPD0222.3.Loosen ring gear bolts in a criss-cross fashion.Tap ring gear off the differential case with a soft hammer. Tap evenly all around to keep ring gear from binding.SPD024Revision; 2004 AprilRFD-202003 350Z

REAR FINAL DRIVE ASSEMBLY4.5.6.Put match marks with paintLoosen screws on differential cases A and B.Separate differential cases A and B.ABCSPD862RFDINSPECTIONContact Surfaces1.2.Clean the disassembled parts in suitable solvent and blow dry with compressed air.If following surfaces are found to be burred or scratched, smooth with oil stone. Differential case Side gear Pinion mate gear Pinion mate shaftEFGBearing1.2.Thoroughly clean bearing.Check bearings for wear, scratches, pitting or flaking.Check tapered roller bearing for smooth rotation. If damaged,replace outer race and inner race as a set.HIJSPD715ADJUSTMENT OF DIFFERENTIAL CASE (R200 2–PINION)Thrust Washer Selection1.KInstall side gears, pinion mate gears, thrust washers into differential case.LMSPD552Revision; 2004 AprilRFD-212003 350Z

REAR FINAL DRIVE ASSEMBLY2.Fit pinion mate shaft to differential case so that it meets lock pinholes.SPD5533.Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer.Refer to RFD-34, "AVAILABLE SIDE GEAR THRUST WASHERS" .Use two feeler gauges to prevent leaning of side gear as shown,figure.Clearance between side gear thrust washer and differential case: 0.20 mm (0.0079 in) lessSPD828ADJUSTMENT OF DIFFERENTIAL CASE (R200V)Side gear Thrust Washer SelectionWhenever side gears or pinion mate gears are replaced, select suitable thrust washers as follows:1. Clean side gears and pinion mate gears using white gasoline.2. Before assembling gears, apply hypoid gear oil to frictional surfaces.3. Install the previously removed thrust washer on right side gear.On left side gear, install a suitable thrust washer.Temporarily tighten differential cases using two screws.4. Position differential assembly so that right side gear is on theupper side. Place feeler gauge of 0.03 mm (0.0012 in) thicknessSDIA1146Ebetween right side gear and thrust washer as shown. Do not place feeler gauge at groove side of differential case.5. Also place a 0.03 mm (0.0012 in) additional feeler gauge between right side gear and thrust washer sothat it is positioned diagonal to (180 apart from) the feeler gauge described previously.6. Rotate right side gear with a suitable tool attached to splines. If hard to rotate, replace thrust washer onleft side gear with a thinner one.7. Replace both 0.03 mm (0.0012 in) feeler gauges with 0.15 mm (0.0059 in) gauges. At this point, makesure right side gear does not rotate. If it rotates, replace thrust washer on left side gear with a thicker oneto prevent rotation.8. As explained in above example, select suitable thrust washers to ensure that:a. Both side gears rotate. [0.03 mm (0.0012 in) feeler gauges are used in this case.]b. Side gear is held stationary. [0.15 mm (0.0059 in) feeler gauges are used in this case.]For quiet and reliable final drive operation, the following five adjustments must be made correctly.1. Side bearing preload2. Pinion gear height3. Pinion bearing preload4. Ring gear to pinion backlash.Revision; 2004 AprilRFD-222003 350Z

REAR FINAL DRIVE ASSEMBLY5.Ring and pinion gear tooth contact patternASIDE BEARING PRELOADA selection of carrier side bearing adjusting washers is required for successful completion of this procedure.1. Make sure all parts are clean. Also, make sure the bearings arewell lubricated with light oil or DEXRONTM type automatic transmission fluid.2. Place t

3. Install the side flange with the following procedure. a. Attach the protector to side oil seal. b. After the side flange is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the pro-tector. c. Put suitable drift on the center

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