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Installation of Differential Assembly

WARNING: This page is about a different car, the 2004 Nissan Murano. However, it is still accessible from the selected car via links, so may be relevant.
  1. Assemble new side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.
  2. Assemble the side gears, side gear thrust washers, pinion mate gears, and pinion mate thrust washers to the differential case, and temporarily assemble the pinion mate shaft.
  3. Measure the side gear end play following the procedure below, and select the appropriate side gear thrust washers.
    • Using a thickness gauge, measure the clearance between side gear back and the differential case at 3 different points, while rotating the side gear. Average the 3 readings, and select the appropriate side gear thrust washer so that the mean value is within specifications below. (Measure the clearance of the other side as well.)

    Side gear end play standard: 

    0.2 mm (0.008 in) or less. Every gear shall rotate smoothly with no abnormal feeling of drag. 

    Fig 1: Measuring Clearance Between Side Gear Back And Differential Case
    G00768585Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Before measurement, place differential case straight up so that side gear to be measured comes upward. To prevent the side gear from tilting, insert thickness gauges with the same thickness from both sides.
    • Select a side gear thrust washer for right and left individually.
    Fig 2: Side Gear End Play Chart
    G00768586Courtesy of NISSAN MOTOR CO., U.S.A.
  4. Assemble the selected side gear thrust washer to the differential case.
  5. Using a pin punch, drive a lock pin into the pinion mating shaft.

    Tool number: ST23550000 ( - ) 

    CAUTION: Do not reuse the lock pin.
    Fig 3: Driving Lock Pin Into Pinion Mating Shaft
    G00768587Courtesy of NISSAN MOTOR CO., U.S.A.
  6. Using a drift, press a side bearing inner race into the differential case.

    Tool number: KV40105020 ( - ) 

    Fig 4: Pressing Side Bearing Inner Race Into Differential Case
    G00768588Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Apply locking sealant onto the thread of the drive gear.
    CAUTION: The drive gear back, threaded holes, and drive gear bolts shall be cleaned and decreased sufficiently.
  8. Assemble the drive gear to the differential case, and tighten it with drive gear bolt. Refer to "COMPONENTS ".
  9. Apply differential oil to the side bearings, and assemble new side bearing adjusting shims (2 pieces for one side) with the same thickness as the ones installed prior to disassembly or re-install the old ones, with a side bearing outer race to the differential case.

    If the side bearing adjusting shims have been already selected, use them.

  10. Fit a drift to the right and left side bearing adjusting shims individually. Compress differential case assembly and side bearing to install the gear carrier assembly to differential case assembly.

    Tool number: KV40100610 (J26089) 

    CAUTION:
    • A drift shall be placed on the center of the adjusting shims.
    • The pressure shall be as low as possible to install the gear carrier assembly into the differential assembly. The maximum pressure shall be 1 ton.
    • If the adjusting shims are installed by tapping, the gear carrier may be damaged. Avoid tapping.
    Fig 5: Installing Gear Carrier Assembly Into Differential Assembly
    G00768589Courtesy of NISSAN MOTOR CO., U.S.A.
  11. Install a dummy cover set, check and adjust the backlash, drive gear back runout, tooth contact, and overall preload torque. Refer to "PRE-INSPECTION ".
  12. Remove dummy cover set.
  13. Apply a continuous bead of sealant around the gear carrier mating surface on the rear cover as shown in Fig 6 . Overlap both ends of the bead for at least 3 mm (0.12 in).
    CAUTION: Remove old sealant on the mounting surface, then remove any moisture, oil, and foreign material on the application and mounting surfaces.
    Fig 6: Applying Bead Of Sealant Around Gear Carrier Mating Surface
    G00768590Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Fit a drift to the right and left side bearing adjusting shims individually. Compress differential case assembly and side bearing to install the rear cover.

    Tool number: KV40100610 (J26089) 

    CAUTION:
    • A drift shall be placed on the center of the adjusting shims.
    • The pressure shall be as low as possible to install the rear cover. The maximum pressure shall be 10 kN (1 ton, 1.1 US ton, 1.0 lmp ton)
    • If the rear cover is forced in by tapping, the rear cover may be damaged by the adjusting shims. Avoid tapping.
    Fig 7: Compressing Differential Case Assembly And Side Bearing
    G00768591Courtesy of NISSAN MOTOR CO., U.S.A.
  15. Tighten rear cover mounting bolts to the specified torque. Refer to "COMPONENTS ".
  16. Using a drift, drive the oil seal until it becomes flush with the case end.

    Tool number A: KV38100200 (J26233) 

    B: ST27861000 ( - ) 

    CAUTION:
    • Do not reuse oil seals.
    • Apply multi-purpose grease onto the oil seal lips, and differential oil onto the circumference of the oil seal.
  17. Check overall preload torque. Refer to "TOTAL PRELOAD ".
    Fig 8: Installing Oil Seal
    G00768592Courtesy of NISSAN MOTOR CO., U.S.A.
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