Differential Assembly

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: Identifying Side Gear Thrust Washers

   Courtesy of NISSAN MOTOR CO., U.S.A.
2. Install side gears and thrust washers into differential case.
   CAUTION: Make sure that the circular clip is installed to side gears.
3. 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.
4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to , "DIFFERENTIAL SIDE GEAR CLEARANCE "
   Fig 3: Identifying Pinion Mate Shaft

   Courtesy of NISSAN MOTOR CO., U.S.A.
6. Drive a lock pin into pinion mate shaft, using suitable tool. Make sure lock pin is flush with differential case.
   CAUTION: Do not reuse lock pin.
   Fig 4: Driving Lock Pin Into Pinion Mate Shaft

   Courtesy of NISSAN MOTOR CO., U.S.A.
7. 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.
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: Make sure the drive gear back and threaded holes are clean.
     Fig 6: Applying Thread Locking Sealant Into Thread Hole Of Drive Gear

     Courtesy of NISSAN MOTOR CO., U.S.A.
9. Install drive gear bolts, and then tighten to the specified torque. Refer to , "COMPONENTS ". After tightening the bolts to the specified torque, tighten the bolts an additional 31 to 36 degrees using Tool.

   Tool number : KV10112100-A (BT-8653-A) 

   Fig 7: Tightening Drive Gear Bolts

   Courtesy of NISSAN MOTOR CO., U.S.A.
   CAUTION:

   • Always use Tool. Avoid tightening based on visual check alone.
   • Tighten bolts in a crisscross pattern.
10. Press side bearing inner races to 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

    Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION: Do not reuse side bearing inner race.
11. Install housing spacer.
12. Apply gear oil to side bearings, and install differential case assembly with side bearing outer races into gear carrier.
    Fig 9: View Of Differential Case And Bearing Races

    Courtesy of NISSAN MOTOR CO., U.S.A.
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

    Courtesy of NISSAN MOTOR CO., U.S.A.
14. Align matching mark on bearing cap with that on gear carrier.
15. Install bearing caps and tighten bearing cap bolts to the specified torque. Refer to , "COMPONENTS "
    Fig 11: Aligning Matching Mark On Bearing Cap With That On Gear Carrier

    Courtesy of NISSAN MOTOR CO., U.S.A.
16. Drive side oil seal until it becomes flush with the case end using Tools.

    Tool number A: ST30720000 (J-25405) 

    B: ST27863000 ( - ) 

    Fig 12: Driving Side Oil Seal

    Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:

    • Do not reuse oil seal.
    • Do not incline oil seal when installing.
    • 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 , "DRIVE GEAR RUNOUT ", , "TOOTH CONTACT ", , "BACKLASH ", , "TOTAL PRELOAD TORQUE "

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

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 adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.
19. Install rear cover on gear carrier and tighten bolts with the specified torque. Refer to , "COMPONENTS "
20. Install side shaft assembly. Refer to , "SIDE SHAFT "
    Fig 13: Applying Sealant To Mating Surface Of Rear Cover

    Courtesy of NISSAN MOTOR CO., U.S.A.

Side Shaft 

1. Press side shaft bearing to side shaft.
   CAUTION: Do not reuse bearing.
2. Install snap ring (shaft side).
3. Install side shaft assembly into gear carrier.
4. Install snap ring (hole side).
   Fig 14: Pressing Side Shaft Bearing To Side Shaft

   Courtesy of NISSAN MOTOR CO., U.S.A.
5. Drive side oil seal until it becomes flush with the case end using Tools.

   Tool number A: ST30720000 (J-25405) 

   B: ST27863000 ( - ) 

   Fig 15: Driving Side Oil Seal

   Courtesy of NISSAN MOTOR CO., U.S.A.
   CAUTION:

   • Do not reuse oil seal.
   • Do not incline oil seal when installing.
   • Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.