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Differential Assembly

WARNING: This page is about a different car, the 2008 Infiniti M45 and 2008 Infiniti M35. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.
    Fig 1: Assembling Side Gear Thrust Washers
    G04876378Courtesy of NISSAN MOTOR CO., U.S.A.
  2. Install side gears and thrust washers into differential case.
    CAUTION:
    • Do not reuse circular clip.
    • Make sure that the circular clip is installed to side gear (side retainer side).
  3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.
    Fig 2: Identifying Pinion Mate Gears Into Differential Case
    G04876379Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
  5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "DIFFERENTIAL SIDE GEAR CLEARANCE ".
    Fig 3: Aligning Lock Pin Holes On Differential Case With Shaft
    G04876380Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Drive a lock pin into pinion mate shaft, using a punch. Make sure lock pin is flush with differential case.
    CAUTION: Do not reuse lock pin.
    Fig 4: Driving Lock Pin Into Pinion Mate Shaft
    G04876381Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Align the matching mark of drive gear with the mark of differential case, then place drive gear.
    Fig 5: Aligning Matching Mark Of Differential Case
    G04876382Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Apply thread locking sealant into the thread hole of drive gear.
    • Use Genuine Medium Strength Thread Locking Sealant or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Drive gear back and threaded holes shall be cleaned and degreased sufficiently.
      Fig 6: Applying Thread Locking Sealant Into Thread Hole Of Drive Gear
      G04876383Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install drive gear on the mounting bolts, and then tighten to the specified torque. Refer to "COMPONENTS ".
    CAUTION: Tighten bolts in a crisscross fashion.
    Fig 7: Identifying Drive Gear Bolts
    G04876384Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Press side bearing inner races to differential case, using the drift and the base.

    Tool number A: ST33230000 (J-25805-01) 

    B: ST33061000 (J-8107-2) 

    CAUTION: Never reuse side bearing inner race.
    Fig 8: Pressing Side Bearing Inner Races To Differential Case
    G05225538Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Press-fit side bearing outer race into side retainer with the drift and the drift bar.

    Tool number A: ST30611000 (J-25742-1) 

    B: KV31103000 (J-38982) 

    CAUTION:
    • At first, using a hammer, tap bearing outer race until it becomes flat to side retainer.
    • Do not reuse side bearing outer race.
      Fig 9: Pressing Side Bearing Outer Race Into Side Retainer
      G05225513Courtesy of NISSAN MOTOR CO., U.S.A.
  12. Press-fit side bearing outer race into gear carrier with the drift and the drift bar.

    Tool number A: ST30611000 (J-25742-1) 

    B: KV31103000 (J-38982) 

    CAUTION:
    • At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
    • Do not reuse side bearing outer race.
      Fig 10: Pressing Side Bearing Outer Race Into Gear Carrier
      G05225514Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Place the differential case assembly into gear carrier.
  14. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting shim. Refer to "SIDE BEARING PRELOAD ".
    Fig 11: Identifying Differential Case Assembly Into Gear Carrier
    G05225496Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Install selected side bearing adjusting shim (1).
  16. Apply multi-purpose grease to O-ring (2), and install it to side retainer.
    CAUTION: Do not reuse O-ring.
  17. Install side retainer assembly to gear carrier.
    Fig 12: Applying Multi-Purpose Grease To O-Ring
    G05225542Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Install side retainer mounting bolts to the specified torque. Refer to "COMPONENTS ".
    Fig 13: Locating Retainer Mounting Bolts
    G05225517Courtesy of NISSAN MOTOR CO., U.S.A.
  19. Using the drift, press-fit side oil seal so that its surface comes face to face with the end surface of the side retainer.

    Tool number A: ST33400001 (J-26082) 

    CAUTION:
    • Do not reuse oil seal.
    • When installing, do not incline oil seal.
    • Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
      Fig 14: Pressing Side Oil Seal
      G05225469Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Using the drift, press-fit side oil seal so that its surface comes face to face with the end surface of gear carrier.

    Tool number A: KV38102100 (J-25803-01) 

    CAUTION:
    • Do not reuse oil seal.
    • When installing, do not incline oil seal.
    • Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
      Fig 15: Pressing Side Oil Seal
      G05225470Courtesy of NISSAN MOTOR CO., U.S.A.
  21. Apply multi-purpose grease to O-ring, and install it to gear carrier.
    CAUTION: Do not reuse O-ring.
  22. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to "DRIVE GEAR RUNOUT ", "TOOTH CONTACT ", "BACKLASH ", "TOTAL PRELOAD TORQUE ".

    Recheck above items. Readjust the above description, if necessary.

  23. Apply sealant to mating surface of carrier cover.
    • Use Genuine Silicone RTV or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
      Fig 16: Applying Sealant To Mating Surface Of Carrier Cover
      G05225546Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Install carrier cover on gear carrier and tighten mounting bolts with the specified torque. Refer to "COMPONENTS ".
    Fig 17: Locating Carrier Cover Mounting Bolts
    G05225547Courtesy of NISSAN MOTOR CO., U.S.A.
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