Drive Pinion 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 front and rear bearing outer races using drifts.
Tool number A: ST30611000 (J-25742-1)

B: ST30613000 (J-25742-3)

C: KV38100200 (J-26233)
CAUTION:
- At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
- Do not reuse pinion front and rear bearing outer race.
  
  Fig 1: Installing Front And Rear Bearing Outer Races
  Courtesy of NISSAN MOTOR CO., U.S.A.
Select drive pinion height adjusting washer. Refer to "PINION GEAR HEIGHT ".
Install selected drive pinion height adjusting washer to drive pinion. Press pinion rear bearing inner race to it, using drift.
Tool number: ST30901000 (J-26010-01)
CAUTION:
- Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
- Do not reuse pinion rear bearing inner race.
  
  Fig 2: Pressing Pinion Height Adjusting Washer To Drive Pinion
  Courtesy of NISSAN MOTOR CO., U.S.A.
Assemble collapsible spacer to drive pinion.
CAUTION: Do not reuse collapsible spacer.
Apply gear oil to pinion rear bearing, and assemble drive pinion into gear carrier.

Fig 3: Installing Drive Pinion Into Gear Carrier
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion assembly.
CAUTION: Do not reuse pinion front bearing inner race.

Fig 4: Installing Pinion Front Bearing Inner Race To Drive Pinion Assembly
Courtesy of NISSAN MOTOR CO., U.S.A.
Using the drift, press the pinion front bearing inner race to drive pinion as far as drive pinion lock nut can be tightened.
Tool number: ST33200000 (J-26082)

Fig 5: Pressing Pinion Front Bearing Inner Race To Drive Pinion
Courtesy of NISSAN MOTOR CO., U.S.A.
Using the drift, install front oil seal until it becomes flush with the case end.
Tool number A: ST30720000 (J-25405)

B: ST27863000 ( - )
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 6: Installing Front Oil Seal
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install companion flange.
NOTE: When reusing drive pinion, align the matching mark of drive pinion with the matching mark A of companion flange, then install companion flange.

Fig 7: Installing Companion Flange
Courtesy of NISSAN MOTOR CO., U.S.A.
Apply gear oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.
CAUTION: Do not reuse drive pinion lock nut.
Adjust the drive pinion lock nut tightening torque and pinion bearing preload torque.
Tool number A: KV38108300 (J-44195)

B: ST3127S000 (J-25765-A)

Drive pinion lock nut tightening torque:

186 - 294 N.m (19 - 29 kg-m, 138 - 216 ft-lb)

Drive pinion bearing preload:

1.08 - 1.66 N.m (0.11 - 0.16 kg-m, 10 - 14 in-lb)
CAUTION:
- Adjust the lower limit of the drive pinion lock nut tightening torque first.
- If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the preload torque.
- After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
  
  Fig 8: Adjusting Tightening Torque Of Drive Pinion Lock Nut
  Courtesy of NISSAN MOTOR CO., U.S.A.
Install differential case assembly. Refer to "DIFFERENTIAL ASSEMBLY ".
CAUTION: Do not install rear cover yet.
Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer to "DRIVE GEAR RUNOUT ", "TOOTH CONTACT ", "BACKLASH ", "COMPANION FLANGE RUNOUT ".
Recheck above items. Readjust the above description, if necessary.
Check total preload torque. Refer to "TOTAL PRELOAD TORQUE ".
Install rear cover. Refer to "DIFFERENTIAL ASSEMBLY ".
Install side shaft assembly. Refer to "SIDE SHAFT ".