Differential Assembly

WARNING: This page is about a different car, the 2005 Nissan Frontier. However, it is still accessible from the selected car via links, so may be relevant.

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: Identifying Side Gears And Thrust Washers
Courtesy of NISSAN MOTOR CO., U.S.A.
Install side gears and thrust washers into differential case.
CAUTION: Make sure that the circular clip is installed to side gears.
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: Installing Side Gears And Thrust Washers Into Differential Case
Courtesy of NISSAN MOTOR CO., U.S.A.
Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
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
Courtesy of NISSAN MOTOR CO., U.S.A.
Drive a lock pin into pinion mate shaft, using punch.
Make sure lock pin is flush with differential case.

CAUTION: Do not reuse lock pin.

Fig 4: Installing Lock Pin Into Pinion Mate Shaft
Courtesy of NISSAN MOTOR CO., U.S.A.
Align the matching mark of differential case with the mark of drive gear, then place drive gear.

Fig 5: Aligning Matching Mark Of Differential Case With Mark Of Drive Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
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: Drive gear back and threaded holes shall be cleaned and decreased sufficiently.

Fig 6: Applying Thread Locking Sealant Into Thread Hole Of Drive Gear
Courtesy of NISSAN MOTOR CO., U.S.A.
Install drive gear on the bolts, and then tighten to the specified torque. Refer to "COMPONENTS ".
CAUTION:
- Tighten bolts in a crisscross fashion.
- After tightening the bolt to the specified torque, tighten the bolts additionally by turning the bolts 31 to 36 degrees.
  
  Fig 7: Installing Drive Gear On The Bolts
  Courtesy of NISSAN MOTOR CO., U.S.A.
Press side bearing inner races to differential case, using drift and base.
Tool number A: ST33230000 (J-35867)

B: ST33061000 (J-8107-2)

CAUTION: Do not reuse side bearing inner race.

Fig 8: Pressing Side Bearing Inner Races To Differential Case, Using Drift And Base
Courtesy of NISSAN MOTOR CO., U.S.A.
Install housing spacer.
Apply gear oil to side bearings, and install differential case assembly with side bearing outer races into gear carrier.

Fig 9: Identifying Correct Side Bearing Outer Races According To Label
Courtesy of NISSAN MOTOR CO., U.S.A.
Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier, with tool.
Tool number: KV38100600 (J-25267)

Fig 10: Adjusting Washers In Place Between Side Bearings And Gear Carrier, With Tool
Courtesy of NISSAN MOTOR CO., U.S.A.
Align matching mark on bearing cap with that on gear carrier.
Install bearing caps and tighten bearing cap bolts to the specified torque. Refer to "COMPONENTS ".

Fig 11: Aligning Bearing Cap Matching Mark With Gear Carrier
Courtesy of NISSAN MOTOR CO., U.S.A.
Using the drift, drive side oil seals until it becomes flush with the case end.
Tool number A: ST30720000 (J-25405)

B: ST27863000 ( - )

Fig 12: Driving Side Oil Seals Until It Becomes Flush With The Case End
Courtesy of NISSAN MOTOR CO., U.S.A.
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.
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.
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 adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
Install rear cover on gear carrier and tighten bolts with the specified torque. Refer to "COMPONENTS ".
Install side shaft assembly. Refer to "SIDE SHAFT ".

Fig 13: Applying Sealant On Rear Cover
Courtesy of NISSAN MOTOR CO., U.S.A.