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A/T: Assembly

  1. Install circular clip to side gear.
    CAUTION: Never damage side gear.
  2. 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
    G04876378Courtesy of NISSAN NORTH AMERICA, INC.
  3. Install side gears and thrust washers into differential case.
    CAUTION:
    • Make sure that the circular clip is installed to side gears.
    • Never reuse circular clip.
  4. 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: Rotating Pinion Mate Gears In Differential Case
    G04876379Courtesy of NISSAN NORTH AMERICA, INC.
  5. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
    Fig 3: Aligning Lock Pin Holes On Differential Case With Shaft
    G04876380Courtesy of NISSAN NORTH AMERICA, INC.
  6. Measure side gear end play. If necessary, select the appropriate side gear thrust washers.
    1. Place differential case straight up so that side gear to be measured comes upward.
      Fig 4: Measuring Side Gear End Play
      G05729145Courtesy of NISSAN NORTH AMERICA, INC.
    2. 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 clearance of the other side as well.

      Standard 

      Side gear back clearance: Refer to  "DIFFERENTIAL SIDE GEAR CLEARANCE ".

      CAUTION: To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.
    3. If the back clearance is outside the specification, use a thicker/thinner side gear thrust washer to adjust. For selecting thrust washer, refer to the latest parts information.

      When the back clearance is large: Use a thicker thrust washer. 

      When the back clearance is small: Use a thinner thrust washer. 

      Fig 5: Measuring Clearance Between Side Gear Back And Differential Case Using Feeler Gauge
      G04876353Courtesy of NISSAN NORTH AMERICA, INC.
      CAUTION: Select a side gear thrust washer for right and left individually.
  7. Drive a lock pin into pinion mate shaft, using a punch.

    Make sure lock pin is flush with differential case.

    CAUTION: Never reuse lock pin.
    Fig 6: Driving Lock Pin Into Pinion Mate Shaft Using Punch
    G04876381Courtesy of NISSAN NORTH AMERICA, INC.
  8. Apply thread locking sealant into the thread hole of drive gear. Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
    CAUTION: Clean and degrease drive gear back and threaded holes sufficiently.
  9. Install the drive gear to differential case.
    CAUTION: Align the matching marks of differential case and drive gear.
    Fig 7: Applying Thread Locking Sealant Into Thread Hole Of Drive Gear
    G04876383Courtesy of NISSAN NORTH AMERICA, INC.
  10. Tighten the mounting bolts with the following procedure.
    CAUTION: Apply anti-corrosin oil to the thread and seat of mounting bolts.
    1. Tighten the bolts in a crisscross fashion to the specified torque.

      Drive gear mounting bolts tightening torque: 78.5 N.m (8.0 kg-m, 58 ft-lb) 

    2. Tighten the bolts additionally at the specified angle.

      Drive gear mounting bolts tightening angle: 31 to 36 degree 

      Fig 8: Tightening Mounting Bolts Using Tool
      G04876384Courtesy of NISSAN NORTH AMERICA, INC.
      CAUTION: Check the tightening angle using the angle wrench [SST: KV10112100 (BT-8653-A)]. Never make judgment by visual inspection.
  11. Press side bearing inner races to differential case, using the drift (A) and the base (B).
    Fig 9: Pressing Side Bearing Inner Races To Differential Case Using Drift
    G09463422Courtesy of NISSAN NORTH AMERICA, INC.
    CAUTION: Never reuse side bearing inner race.
  12. Set bearing outer races to differential case assembly, and install it with removed side bearing adjusting washer or same thickness washer into gear carrier.
    CAUTION:
    • Apply differential gear oil to the side bearings.
    • Install side bearing and side bearing adjusting washer in correct location. (drive gear tooth side or drive gear back side)
  13. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting washers. Refer to "A/T: ADJUSTMENT ".
    Fig 10: Adjusting Washers Together With Bearings
    G04876340Courtesy of NISSAN NORTH AMERICA, INC.
  14. Align matching marks on bearing cap with that on gear carrier.
  15. Install bearing caps and tighten bearing cap mounting bolts.
    Fig 11: Aligning Matching Mark On Bearing Cap And Gear Carrier
    G04876337Courtesy of NISSAN NORTH AMERICA, INC.
  16. Using the drift [SST: KV38100200 (J-26233)], drive side oil seals until it becomes flush with the case end.
    CAUTION:
    • Never reuse oil seal.
    • When installing, never incline oil seal.
    • Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
  17. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to "A/T: ADJUSTMENT ".

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

    Fig 12: Installing Side Oil Seal Using Drift
    G04876389Courtesy of NISSAN NORTH AMERICA, INC.
  18. Apply sealant to mating surface of rear cover.

    Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

    CAUTION: Remove old sealant on mounting surfaces. Also remove any moisture, oil, or foreign material on application and mounting surfaces.
  19. Install rear cover on gear carrier and tighten mounting bolts.
    Fig 13: Applying Sealant To Mating Surface Of Rear Cover
    G04876390Courtesy of NISSAN NORTH AMERICA, INC.
  20. Install side flange with the following procedure.
    1. Attach the protector [SST: KV38107900 (J-39352)] to side oil seal.
    2. After the side flanges is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the protector.
    3. Put a suitable drift on the center of side flange, then drive it until sound changes.
      NOTE: When installation is completed, driving sound of the side flange turns into a sound that seems to affect the whole final drive.
      Fig 14: Attaching Special Tool To Side Oil Seal
      G04876299Courtesy of NISSAN NORTH AMERICA, INC.
    4. Confirm that the dimension of the side flanges (1) installation measurement (A) in the figure comes into the following.

      Standard 

      A: 326 - 328 mm (12.83 - 12.91 in) 

      Fig 15: Identifying Side Flanges Dimension
      G05219277Courtesy of NISSAN NORTH AMERICA, INC.
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