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Differential Assembly

WARNING: This page is about a different car, the 2013 Nissan Xterra. 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: Installing Side Gear Thrust Washers
    G08711184Courtesy of NISSAN NORTH AMERICA, INC.
  2. Install the side gears and side gear thrust washers into the differential case.
  3. Install the pinion mate thrust washers to the two pinion mate gears. Then install the pinion mate gears with the pinion mate thrust washers by aligning them in diagonally opposite positions and rotating them into the differential case.
    Fig 2: Installing Pinion Mate Gears
    G08711185Courtesy of NISSAN NORTH AMERICA, INC.
  4. Install the pinion mate shaft and align the lock pin hole on the pinion mate shaft with the lock pin hole on the differential case.
  5. Measure the side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "INSPECTION AND ADJUSTMENT ".
    Fig 3: Installing Pinion Mate Shaft
    G08711186Courtesy of NISSAN NORTH AMERICA, INC.
  6. Drive a new lock pin into the pinion mate shaft until it is flush with the differential case using suitable tool.
    CAUTION: Do not reuse lock pin.
    Fig 4: Driving Lock Pin Into Pinion Mate Shaft
    G08711187Courtesy of NISSAN NORTH AMERICA, INC.
  7. Align the matching mark of the differential case with the mark of the drive gear, then place the drive gear onto the differential case.
    Fig 5: Identifying Matching Marks
    G08711188Courtesy of NISSAN NORTH AMERICA, INC.
  8. Apply thread locking sealant into the threaded holes of the drive gear and install the new drive gear bolts.
    CAUTION: Make sure the drive gear back and threaded holes are clean.
    Fig 6: Applying Thread Locking Sealant Into Threaded Holes Of Drive Gear
    G08711189Courtesy of NISSAN NORTH AMERICA, INC.
  9. Tighten the new drive gear bolts to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ". After tightening the new drive gear bolts to the specified torque, tighten an additional 34° to 39° using Tool (A).

    Tool number: KV10112100 (BT-8653-A) 

    Fig 7: Tightening Drive Gear Bolts To Specified Torque
    G08711190Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Always use Tool. Avoid tightening based on visual check alone.
    • Tighten new drive gear bolts in a crisscross pattern.
  10. Press the new side bearing inner races to the differential case using Tools.

    Tool number (A): ST33230000 (J-35867) 

    (B): ST33061000 (J-8107-2) 

    Fig 8: Pressing Side Bearing Inner Races To Differential Case
    G08711191Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Do not reuse side bearing inner races.
  11. Install housing spacer into gear carrier.
  12. Apply differential gear oil to the side bearings, and install the differential case assembly with the side bearing outer races into the gear carrier.
    CAUTION: Do not reuse side bearing outer race when replacing side bearing inner race (replace as a set).
    Fig 9: Installing Housing Spacer Into Gear Carrier
    G08711192Courtesy of NISSAN NORTH AMERICA, INC.
  13. Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier using Tool.

    Tool number: KV38100600 (J-25267) 

    Fig 10: Inserting Left And Right Original Side Bearing Adjusting Washers In Place Between Side Bearings And Gear Carrier Using Tool
    G08711193Courtesy of NISSAN NORTH AMERICA, INC.
  14. Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
    Fig 11: Identifying Matching Marks
    G08711194Courtesy of NISSAN NORTH AMERICA, INC.
  15. Apply multipurpose grease to the lips and differential gear oil to the circumference of the new side oil seal. Then drive the new side oil seal in evenly until it becomes flush with the gear carrier using Tools.

    Tool number (A): ST30720000 (J-25405) 

    (B): ST27863000 (-) 

    Fig 12: Installing Side Oil Seal
    G08711195Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION:
    • Do not reuse side oil seal.
    • Do not incline the new side oil seal when installing.
    • Apply multipurpose grease to the lips and differential gear oil to the circumference of the new side oil seal.
  16. Check and adjust tooth contact, backlash, drive gear runout and total preload torque. Refer to "INSPECTION AND ADJUSTMENT ".

    Recheck above items.

  17. Apply a 3 mm (0.12 in) bead of sealant to the mating surface of the carrier cover as shown below.
    CAUTION: Remove any old sealant stuck to the mating surfaces. Also remove any moisture, oil, or foreign material stuck to the application and mating surfaces.
    Fig 13: Identifying Sealant
    G08711196Courtesy of NISSAN NORTH AMERICA, INC.
  18. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
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