Differential Assembly

WARNING: This page is about a different car, the 2007 Nissan Pathfinder. 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: Assembling Side Gear Thrust Washers
Install the side gears and side gear thrust washers into the differential case.
Install the pinion mate thrust washers to the two pinion mate gears. Then install the pinion mate gears with the pinion mate thrust washers by aligning them in diagonally opposite positions and rotating them into the differential case.

Fig 2: Identifying Pinion Mate Gears Into Differential Case
Install the pinion mate shaft and align the lock pin hole on the pinion mate shaft with the lock pin hole on the differential case.

Fig 3: Aligning Lock Pin Holes On Differential Case With Shaft
Measure the side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "SIDE GEAR BACK CLEARANCE ".
Drive a new lock pin into the pinion mate shaft until it is flush with the differential case using suitable tool.
CAUTION: Do not reuse lock pin.

Fig 4: Tapping Lock Pin Into Pinion Mate Shaft
Align the matching mark of the differential case with the mark of the drive gear, then place the drive gear onto the differential case.

Fig 5: Aligning Matching Mark Of Differential Case
Apply thread locking sealant into the threaded holes of the drive gear and install the new drive gear bolts.
- 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
Tighten the new drive gear bolts to the specified torque. Refer to "COMPONENTS ". After tightening the new drive gear bolts to the specified torque, tighten an additional 34° to 39° using Tool.
Tool number : KV10112100-A (BT-8653-A)
CAUTION:
- Always use Tool. Avoid tightening based on visual check alone.
- Tighten new drive gear bolts in a crisscross pattern.
  
  Fig 7: Tightening Drive Gear Bolts
Press the new side bearing inner races to the differential case using Tools.
Tool number A: ST33230000 (J-35867)

B: ST33061000 (J-8107-2)

CAUTION: Do not reuse side bearing inner races.

Fig 8: Pressing Side Bearing Inner Races Into Differential Case
Install housing spacer into gear carrier.
Apply differential gear oil to the side bearings, and install the differential case assembly with the side bearing outer races into the gear carrier.
CAUTION: Do not reuse side bearing outer race when replacing side bearing inner race (replace as a set).

Fig 9: Identifying Correct Bearing Races
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: Adjusting Washers In Place Between Side Bearings And Gear Carrier
Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to the specified torque. Refer to "COMPONENTS ".

Fig 11: Aligning Matching Mark On Bearing Cap With Gear Carrier
Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal. Then drive the new side oil seal in evenly until it becomes flush with the gear carrier using Tools.
Tool number A: ST30720000 (J-25405)

B: ST27863000 ( - )
CAUTION:
- Do not reuse side oil seal.
- Do not incline the new side oil seal when installing.
- Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal.
  
  Fig 12: Tapping Side Oil Seal
Check and adjust tooth contact, backlash, drive gear runout and total preload torque. Refer to "TOOTH CONTACT ", "BACKLASH ", "DRIVE GEAR RUNOUT " and "TOTAL PRELOAD TORQUE ".
Recheck above items.
Apply a 3 mm (0.12 in) bead of sealant to the mating surface of the carrier cover as shown.
- Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
CAUTION: Remove any old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.

Fig 13: Applying Bead Of Sealant To Mating Surface Of Rear Cover
Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to "COMPONENTS ".