DRIVELINE/AXLE

SECTION
FRONT FINAL DRIVE
FFD B

FFD

E
CONTENTS
SERVICE INFORMATION ............................ 2 REAR COVER GASKET .................................... 9 F
Removal and Installation .......................................... 9
PRECAUTIONS ................................................... 2
Precaution for Supplemental Restraint System FRONT FINAL DRIVE ASSEMBLY .................. 10 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal and Installation .........................................10
SIONER" ................................................................... 2 Component ..............................................................11
Precaution for Servicing Front Final Drive ................ 2 Pre-Inspection .........................................................11
Disassembly and Assembly .....................................13 H
PREPARATION ................................................... 3 Inspection and Adjustment ......................................23
Special Service Tool ................................................. 3
SERVICE DATA AND SPECIFICATIONS I
NOISE, VIBRATION AND HARSHNESS (SDS) ................................................................. 30
(NVH) TROUBLESHOOTING ............................. 6 General Specification ..............................................30
NVH Troubleshooting Chart ...................................... 6 Ring Gear Runout ....................................................30
J
Axle bearing adjustment ..........................................30
DIFFERENTIAL GEAR OIL ................................. 7 Side Gear Adjustment .............................................30
Changing Differential Gear Oil .................................. 7
Side Bearing Adjustment .........................................30
Checking Differential Gear Oil ................................... 7 K
Total Preload Adjustment ........................................31
FRONT OIL SEAL ............................................... 8 Drive Pinion Height Adjustment ...............................31
Removal and Installation ........................................... 8 Drive Pinion Preload Adjustment .............................31
L

Revision: September 2009 FFD-1 2010 D22 LCV

 PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000005783020

The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precaution for Servicing Front Final Drive INFOID:0000000005783021

Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic
operations.
Check for the correct installation status prior to removal or disassembly. When matching marks are required,
be certain they do not interfere with the function of the parts they are applied to.
Overhaul should be done in a clean work area, a dust proof area is recommended.
Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
Always use shop paper for cleaning the inside of components.
Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them
with new ones if necessary.
Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
Clean and flush the parts sufficiently and blow them dry.
Be careful not to damage sliding surfaces and mating surfaces.
When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil, and
foreign materials from the application and mating surfaces.
In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a
tightening sequence is specified, observe it.
During assembly, observe the specified tightening torque.
Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.

Revision: September 2009 FFD-2 2010 D22 LCV

 PREPARATION
< SERVICE INFORMATION >
PREPARATION
A
Special Service Tool INFOID:0000000005471275

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. B
Tool number
(Kent-Moore No.) Description
Tool name
C
ST3127S000 Measuring pinion bearing preload and total
(See J-25765-A) preload
Preload gauge
1 GG91030000 FFD
(J-25765)
Torque wrench
2 HT62940000
( ) E
Socket adapter
3 HT62900000 NT124
( )
Socket adapter F
KV38100800 Mounting final drive housing
(J-25604-01) (To use, make a new hole.)
Differential attachment a: 152 mm (5.98 in) G

H
NT119

ST3090S000 Removing and installing drive pinion rear in-

( ) ner cone I
Drive pinion rear inner race puller set a: 79 mm (3.11 in) dia.
1 ST30031000 b: 45 mm (1.77 in) dia.
(J-22912-01) c: 35 mm (1.38 in) dia.
J
Puller
2 ST30901000
(J-26010-01)
Base NT527
K
ST3306S001 Removing and installing differential side bear-
Differential side bearing puller set ing inner cone
1 ST33051001 a: 28.5 mm (1.122 in) dia.
L
(J-22888-20) b: 38 mm (1.50 in) dia.
Body
2 ST33061000
(J-8107-2) M
Adapter
NT072

KV3323000 Installing side bearing inner cone

(J-25801-1) a: 51 mm (2.01 in) dia. N
Differential side bearing drift b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.

NT085

ST3806002 Removing and Installing companion flange P

(J-34311)
Drive pinion flange wrench

NT113

Revision: September 2009 FFD-3 2010 D22 LCV

 PREPARATION
< SERVICE INFORMATION >
Tool number
(Kent-Moore No.) Description
Tool name
ST30611000 Installing drive pinion rear bearing outer race
(J-25742-1) and drive pinion front bearing outer race
Drift (Use with ST30621000 or ST30613000)

NT090

ST30621000 Installing drive pinion rear bearing outer race

(J-25742-5) (Use with ST30611000)
Drift a: 79 mm (3.11 in) dia.
b: 59 mm (2.32 in) dia.

NT073

ST30701000 Installing drive pinion front bearing outer race

(J-25742-2) (Use with ST30611000)
Drift a: 61.5 mm (2.421 in) dia.
b: 41 mm (1.61 in) dia.

NT073

KV38100500 Installing front oil seal and side flange oil seal
(J-25273) a: 85 mm (3.35 in) dia.
Gear carrier front oil seal drift b: 60 mm (2.36 in) dia.

NT115

ST30720000 Installing side oil seal

(J-25405)
Gear carrier side oil seal drift

NT120

(J-34309) Adjusting bearing pre-load and gear height

Differential shim selector

NT134

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 PREPARATION
< SERVICE INFORMATION >
Tool number
(Kent-Moore No.) Description A
Tool name
KV381001S0 Selecting pinion height adjusting washer
Drive pinion setting guage set B
1: KV38100110
Dummy shaft
2: KV38100120
Height gauge C
3: KV38100130
Collar
4: KV38100140 NT512
Stopper FFD
ST3372000 Installing side retainer
( )
Differential side retainer guide E

F
NT138

(J-44372) Measuring differential case assembly turning

Spring gauge resistance G

NT127
I

Revision: September 2009 FFD-5 2010 D22 LCV

 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION >
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000005471276

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

FAX-4, FSU-5, FSU-27

PS-5, MS-5,
FFD-11

FFD-11

FFD-11

FFD-11

FFD-7

FAX-4
WT-3
PR-4

BR-4

Reference page

Companion flange excessive runout

AXLE AND SUSPENSION

Improper gear contact

PROPELLER SHAFT
Tooth surface worn
Possible cause and SUSPECTED PARTS

Incorrect backlash
Rough gear tooth

Improper gear oil

ROAD WHEEL

DRIVESHAFT

STEERING
BRAKES
TIRES
Symptom DIFFERENTIAL Noise
: Applicable

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 DIFFERENTIAL GEAR OIL
< SERVICE INFORMATION >
DIFFERENTIAL GEAR OIL
A
Changing Differential Gear Oil INFOID:0000000005471277

DRAINING B
1. Stop the engine.
2. Remove the drain plug and gasket from the front final drive
assembly to drain the differential gear oil. C
3. Install the drain plug with a new gasket to the front final drive
assembly. Tighten to the specified torque. Refer to FFD-11,
"Component". FFD
CAUTION:
Do not reuse gasket.
E

SMA632C
F
FILLING
1. Remove the filler plug and gasket from the front final drive
assembly. G
2. Fill the front final drive assembly with new differential gear oil
until the level reaches the specified level near the filler plug hole.
H
Differential gear oil : Refer to MA-14, "Fluids
grade and capacity and Lubricants".
3. Install the filler plug with a new gasket on it to the front final drive I
assembly. Tighten to the specified torque. Refer to FFD-11,
"Component". SMA632C
CAUTION: J
Do not reuse gasket.
Checking Differential Gear Oil INFOID:0000000005471278

K
DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL
1. Make sure that differential gear oil is not leaking from the front final drive assembly or around it.
2. Check the differential gear oil level from the filler plug hole as L
shown.
CAUTION:
Do not start engine while checking differential gear oil level. M
3. Install the filler plug with a new gasket on it to the front final drive
assembly. Tighten to the specified torque. Refer to FFD-11,
"Component". N
CAUTION:
Do not reuse gasket.
O
SMA632C

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 FRONT OIL SEAL
< SERVICE INFORMATION >
FRONT OIL SEAL
Removal and Installation INFOID:0000000005471279

REMOVAL
1. Remove front propeller shaft. Refer to PR-9, "Removal and Installation".
2. Remove drive pinion nut using suitable tool.

PD466

3. Remove companion flange using a suitable puller.

SPD413A

4. Remove front oil seal using suitable tool.

INSTALLATION
1. Apply multi-purpose grease to cavity at sealing lips of front oil
seal. Press front oil seal into final drive housing using Tool.

Tool number : KV38100500 (J-25273)

2. Installation is in the reverse order of removal.

SPD414A

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 REAR COVER GASKET
< SERVICE INFORMATION >
REAR COVER GASKET
A
Removal and Installation INFOID:0000000005471280

REMOVAL B
1. Drain gear oil. Refer to MA-41, "Changing Front Final Drive Oil (Front Differential Gear Oil)".
2. Remove rear cover and rear cover gasket.
C
INSTALLATION
1. Install new rear cover gasket and rear cover. Refer to FFD-11, "Component".
2. Fill final drive with recommended gear oil. Refer to MA-14, "Fluids and Lubricants". FFD

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 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
FRONT FINAL DRIVE ASSEMBLY
Removal and Installation INFOID:0000000005471281

REMOVAL
1. Remove front propeller shaft. Refer to PR-9, "Removal and
Installation".
CAUTION:
Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shaft.
2. Separate drive shaft from front final drive. Refer to FAX-20,
"Removal".
3. Remove engine bolts and raise up engine. Refer to EM-176,
"Removal and Installation".
4. Remove front final drive with differential member as an assem-
bly. SPD741

CAUTION:
Before removing the final drive assembly, disconnect the ABS sensor harness connector from the
assembly and move it away from the final drive/rear axle assembly area. Failure to do so may
result in the sensor wires being damaged and the sensor becoming inoperative.
INSTALLATION
1. Install front final drive assembly with differential member as an
assembly.

SPD417A

2. Tighten front final drive bolts and nuts in the alpha order shown
to prevent drive train vibration.

Front final drive bolts

Step 1 : Temporarily tighten nut A
Step 2 : Temporarily tighten nut B
Step 3 : 68 to 87 Nm (6.9 to 8.9 kg-m, 50 to 64 ft-lb)
(bolt C)
Step 4 : 68 to 87 Nm (6.9 to 8.9 kg-m, 50 to 64 ft-lb)
(bolt D)
Step 5 : 68 to 87 Nm (6.9 to 8.9 kg-m, 50 to 64 ft-lb)
(nut A)
Step 6 : 68 to 87 Nm (6.9 to 8.9 kg-m, 50 to 64 ft-lb)
(nut B)
Step 7 : 68 to 87 Nm (6.9 to 8.9 kg-m, 50 to 64 ft-lb)
(bolt E)

SPD743

3. Lower engine and install engine bolts. Refer to EM-176, "Removal and Installation".
Revision: September 2009 FFD-10 2010 D22 LCV
 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
4. Install drive shaft. Refer to FAX-24, "Installation".
5. Install front propeller shaft. Refer to PR-9, "Removal and Installation". A

Component INFOID:0000000005471282

FFD

SPD429A

Pre-Inspection INFOID:0000000005471283

Before disassembling final drive, perform the following inspections.

Revision: September 2009 FFD-11 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
TOTAL PRELOAD
Turn drive pinion in both directions several times to set bearing roll-
ers.
Check total preload with Tool. Refer to FFD-31, "Total Preload
Adjustment".

Tool number : ST3127S000 (J-25765-A)

SPD634

RING GEAR TO DRIVE PINION BACKLASH

Check backlash of ring gear with a dial indicator at several points.
Refer to FFD-31, "Total Preload Adjustment".

SPD635

RING GEAR RUNOUT

Check runout of ring gear with a dial indicator. Refer to FFD-30,
"Ring Gear Runout".

SPD636

TOOTH CONTACT
Check tooth contact. Refer to FFD-13, "Disassembly and Assembly".
SIDE GEAR TO DRIVE PINION GEAR BACKLASH
Measure clearance between side gear thrust washer and differen-
tial case using a feeler gauge. Refer to FFD-30, "Side Gear Adjust-
ment".

SPD665

Revision: September 2009 FFD-12 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
Disassembly and Assembly INFOID:0000000005471284

A
REMOVAL OF DIFFERENTIAL CASE ASSEMBLY
1. Using three spacers [20 mm (0.79 in)], mount final drive assem-
bly on Tool. B

Tool number : KV38100800 (J-25604-01)

C

FFD

SPD637
E
2. Remove extension tube and differential side shaft assembly.

H
SPD638

3. Remove differential side flange while holding the differential side I

flange with a suitable tool.

SPD667 L
4. Mark side retainers for identification. Remove side retainers.
CAUTION:
Be careful not to confuse LH and RH side retainers and shims. M
5. Put match marks on one side of side bearing cap with paint or
punch to ensure that it is replaced in proper position during
assembly. N
NOTE:
Bearing caps are line-bored during manufacture and should be
put back in their original places.
O

P
SPD526

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 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
6. Remove side bearing caps.

PD343

7. Remove differential case assembly.

SPD309

8. Remove side outer races using Tool.

CAUTION:
Be careful to keep the side bearing outer races together
with their respective inner cones do not mix them up.
Side bearing spacer is placed on either the left or right
depending upon final drive gear ratio. It should be labeled
so that it may be replaced correctly.

Tool number : ST38060002 (J-34311)

PD243

REMOVAL OF DRIVE PINION ASSEMLBY

1. Loosen drive pinion nut while holding companion flange using a
suitable tool.
2. Remove companion flange with suitable puller.

SPD477A

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 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
3. Take out drive pinion together with drive pinion rear bearing
inner cone, drive pinion bearing spacer and drive pinion bearing A
preload adjusting washer.
CAUTION:
Use a brass drift to prevent damage to the drive pinion
B
threads.

SPD641

FFD
4. Remove front oil seal and drive pinion front bearing inner cone.
5. Remove drive pinion bearing outer races with a brass drift.
E

PD349

H
6. Remove drive pinion rear bearing inner cone and drive pinion height adjusting washer using Tool.

Tool number : ST30031000 (J-22912-01) I

DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY
1. Remove side bearing inner cones using Tool.
J
CAUTION:
To prevent damage to bearing, engage puller jaws in grooves.

Tool numbers K
A : ST33051001 (J-22888-20)
B : ST33061000 (J-8107-2)
L

SPD642

NOTE:

Revision: September 2009 FFD-15 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
Be careful not to confuse the right-hand and left-hand parts.
Keep bearing and bearing race for each side together.

SPD022

2. Loosen ring gear bolts in a crisscross pattern.

3. Tap ring gear off the differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.

SPD024

4. Separate differential case LH and RH.

SPD643

DISASSEMBLY OF DIFFERENTIAL SIDE SHAFT

1. Remove differential side shaft from extension tube.

SPD644

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 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
2. Cut front axle bearing collar with cold chisel.
CAUTION: A
Be careful not to damage differential side shaft.

SPD236A

FFD
3. Reinstall differential side shaft into extension tube and secure
with bolts. Remove front axle bearing by drawing out differential
side shaft from front axle bearing with puller.
E

SPD672
K
4. Remove grease seal.

N
SPD647

EXTENSION TUBE AND DIFFERENTIAL SIDE SHAFT O

1. Measure front axle bearing end play. Refer to FFD-30, "Axle bearing adjustment".

Revision: September 2009 FFD-17 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >

Rear axle bearing end play : 0.1 mm (0.0039 in) or less

(A - B)
NOTE:
Front axle end play can be adjusted with adjustment shims.
Refer to FFD-30, "Axle bearing adjustment".

SPD433A

2. Install grease seal using suitable tool.

SPD654-A

3. Install extension tube retainer, front axle bearing and front axle
bearing collar on differential side shaft using a suitable tool.

WDIA0018E

4. Install differential side shaft assembly into extension housing.

ASSEMBLY OF DIFFERENTIAL CASE ASSEMLBY

1. Measure Clarence between side gear thrust washer and differential case. Refer to FFD-30, "Side Gear
Adjustment".

Revision: September 2009 FFD-18 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >

Clarence between side : 0.1 mm (0.0039 in) or less A

gear thrust washer and dif-
ferential case (A - B)
B

FFD

G
SPD656

Adjust backlash between side gear and drive pinion mate gear by selecting side gear thrust washer. Refer
to FFD-30, "Side Gear Adjustment". H

2. Install differential case LH and RH. Refer to FFD-11, "Compo-

nent". I

SPD643

L
3. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.

4. Install differential case assembly on ring gear.

M
5. Apply Genuine Medium Strength Thread Locking Sealant or
equivalent to ring gear bolts, and install them.
Tighten ring gear bolts in a crisscross pattern.
Refer to FFD-11, "Component". N

SPD746
P

Revision: September 2009 FFD-19 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
6. Press-fit side bearing inner cones on differential case with Tool.

Tool numbers
A : ST33230000 (J-25801-05)
B : ST33061000 (J-8107-2)

PD353

INSTALLATION OF DRIVE PINION ASSEMBLY

1. Press-fit front and rear bearing outer races using Tools.

Tool number
A : ST30611000 (J-25742-1)
B : ST30621000 (J-25742-5)
C : ST30701000 (J-25742-2)

SPD679

2. Select drive pinion height adjusting washer and drive pinion

bearing preload adjusting washer. Refer to FFD-31, "Drive Pin-
ion Height Adjustment" and FFD-31, "Drive Pinion Preload
Adjustment".
3. Install drive pinion height adjusting washer on drive pinion, and
press-fit drive pinion rear bearing inner cone in it, using press
and Tool.

Tool number : ST30901000 (J-26010-01)

SPD377

4. Place drive pinion front bearing inner cone in final drive housing.

SPD581

Revision: September 2009 FFD-20 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
5. Apply multi-purpose grease to cavity at sealing lips of front oil
seal. Install front oil seal using Tool. A

Tool number : ST30720000 (J-25405)

B

SPD657
FFD
6. Place drive pinion bearing preload adjusting spacer, drive pinion
bearing preload adjusting washer and drive pinion in final drive
housing.
E

G
WDIA0020E

7. Insert companion flange into drive pinion by tapping the com-

H
panion flange with a soft hammer.

SPD659
K
8. Tighten drive pinion nut while holding companion flange using a
suitable tool. Refer to FFD-11, "Component".
NOTE: L
The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
M

N
PD466

9. Turn drive pinion in both directions several revolutions, and O

measure drive pinion bearing preload with front oil seal resis-
tance using Tool. Refer to FFD-31, "Drive Pinion Preload Adjust-
ment". P

Tool number : ST3127S000 (J-25765-A)

When drive pinion bearing preload with front oil seal resis-
tance is outside the specifications, replace drive pinion bearing
preload adjusting washer and spacer with a different thick-
ness.
SPD634

Revision: September 2009 FFD-21 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
10. Press fit side bearing outer race to the side retainer.

Tool numbers A: ST30611000 (J-25742-1)

B: ST30621000 (J-25742-5)
11. Install side oil seal to side retainer using suitable tool.
12. Install differential case assembly.

SPD332

13. Install side retainer adjusting shims, o-ring and side retainer
onto final drive housing, using Tool.

Tool number : ST33720000 ( )

NOTE:
Be sure to align arrows stamped on side retainer and final drive
housing.

SPD660

14. Measure ring gear to drive pinion backlash using a dial indicator.
Refer to FFD-31, "Total Preload Adjustment".
If backlash is too small, decrease thickness of RH shim and
increase LH shim by the same amount. If backlash is too
great, reverse this process.
NOTE:
Never change the total amount of shims as it will change
the bearing preload.

SPD635

15. Check total preload using Tool. Refer to FFD-31, "Total Preload
Adjustment".

Tool number : ST3127S000 (J-25765-A)

SPD634

16. Recheck ring gear to drive pinion backlash either because increase or decrease in thickness of shims will
cause change of ring gear to pinion backlash.
NOTE:
If the backlash varies greatly and the ring gear runout is with in specifications the hypoid gear set or dif-
ferential case should be replaced.
17. Check ring gear runout using a dial indicator. Refer to FFD-30, "Ring Gear Runout".
NOTE:
If runout varies excessively in different places, the variance may have to do with foreign material caught
between the ring gear and the differential case
18. Check tooth contact. Refer to FFD-23, "Inspection and Adjustment".
19. Install rear cover with a new gasket and tighten to specifications. Refer to FFD-11, "Component".

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 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
20. Install differential side flange, extension tube and differential
side shaft assembly and tighten to specifications. Refer to FFD- A
11, "Component".

SPD661

FFD
Inspection and Adjustment INFOID:0000000005471285

INSPECTION E
Ring gear and drive pinion
Check gear teeth for scoring, cracking or chipping. If any damaged part is evident, replace ring gear and drive
pinion as a set (hypoid gear set). F
Differential case assembly
Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft and thrust washers. G

M
SPD648

Bearing
1. Thoroughly clean bearing. N
2. Check bearing for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set. O

SPD715

ADJUSTMENT OF DIFFERENTIAL CASE ASSEMBLY

For quiet and reliable final drive operation, the following five adjustments must be made correctly:

Revision: September 2009 FFD-23 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
1. Side bearing preload. Refer to FFD-30, "Side Bearing Adjustment".
2. Pinion gear height. Refer to FFD-31, "Drive Pinion Height Adjustment".
3. Pinion bearing preload. Refer to FFD-31, "Drive Pinion Preload Adjustment".
4. Ring gear to drive pinion backlash. Refer to FFD-31, "Total Preload Adjustment".
5. Ring and pinion gear tooth contact pattern. Refer to FFD-13, "Disassembly and Assembly".

SIDE BEARING PRELOAD

NOTE:
A selection of carrier side bearing adjusting washers are required for
successful completion of this procedure.
1. Make sure all parts are clean and that the bearings are well
lubricated with light oil or DEXRONTM automatic transmission
fluid or equivalent. Refer to MA-14, "Fluids and Lubricants".
2. Place the differential carrier assembly, with side bearings and
bearing races installed, into the final drive housing.

SPD527

3. Place all of the original side gear retainer adjusting shims onto the side bearing retainers that goes at the
ring gear end of the carrier.

4. Install both bearing retainers onto the final drive housing and tighten to the specified torque. Refer to FFD-
11, "Component".

5. Install the side bearing caps in their correct locations and tighten
the bearing cap bolts to specification. Refer to FFD-11, "Compo-
nent".
6. Turn the differential case assembly several times to seat the
bearings.

SPD526

7. Measure the differential case assembly turning resistance at the

ring gear bolts using Tool. Refer to FFD-30, "Side Bearing
Adjustment".

Tool number : (J-44372)

WDIA0013E

8. If the differential case assembly turning resistance is not within the specification range, increase or
decrease the total thickness of the side bearing adjusting shims until the turning resistance is correct. If
the turning resistance is less than the specified range, install side bearing adjusting shims of greater thick-
ness; if the turning resistance is greater than the specification, install thinner side bearing adjusting shims.
Refer to FFD-30, "Side Bearing Adjustment".

9. Record the total amount of side bearing adjusting shim thickness required for the correct side bearing pre-
load.

Revision: September 2009 FFD-24 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
10. Remove the differential case assembly from the final drive hous-
ing, saving the selected side bearing adjusting shims for later A
use during the assembly of the final drive unit.

SPD309

FFD
DRIVE PINION GEAR HEIGHT AND PINION BEARING PRELOAD
1. Make sure all parts are clean and that the bearings are well
lubricated.
E
2. Assemble the pinion gear bearings into Tool.

Tool number : (J-34309)

F

SPD769

H
Drive Pinion Front Bearing make sure the J-34309-3 front
pinion bearing seat is secured tightly against the J-34309-2
gauge anvil. Then turn the front pinion bearing pilot, J-34309-
5, to secure the bearing in its proper position. I
Drive Pinion Rear Bearing the rear pinion bearing pilot, J-
34309-15, is used to center the rear pinion bearing only. The
rear pinion bearing locking seat, J-34309-4, is used to lock the J
bearing to the assembly.

K
SPD197A

3. Place the differential shim selector tool, J-34309, gauge screw

assembly with the pinion rear bearing inner cone installed into L
the final drive housing.

SPD893
O

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 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
4. Assemble the drive pinion front bearing inner cone and the J-
34309-2 gauge anvil together with the J-34309-1 gauge screw in
the final drive housing. Make sure that the pinion height gauge
plate, J-34309-16, will turn a full 360 degrees, and tighten the
two sections together by hand.

SPD199A

5. Turn the assembly several times to seat the bearings.

SPD770

6. Measure the drive pinion preload without front oil seal resistance
at the end of the J-34309-2 gauge anvil using Tool. Refer to
FFD-31, "Drive Pinion Preload Adjustment".

Tool number ST3127S000 (J-25765-A)

SPD234A

7. Place the Tool R180A pinion height adapter onto the gauge plate and tighten it by hand.

Tool number : (J-34309-1)

SPD208A

DRIVE PINION BEARING PRELOAD WASHER SELECTION

CAUTION:
Make sure all machined surfaces are clean.

SPD209A

Revision: September 2009 FFD-26 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >

8. Place the solid pinion bearing spacer, small end first, over the J- A
34309-2 gauge anvil and seat the small end squarely against
the tip of the J-34309-1 gauge screw in the tool recessed por-
tion.
B

SPD773
FFD
9. Select the correct thickness of drive pinion bearing preload adjusting washer using a standard gauge of 6
mm (0.24 in) and J-34309-101 feeler gauge. The exact measure is the thickness of the drive pinion
adjusting washer required. Select the correct drive pinion bearing preload adjusting washer. E

Drive pinion bearing : Refer to FFD-31, "Drive

preload adjusting Pinion Preload Adjust- F
washer ment".

H
SPD210A

SPD774
L
10. Set the selected, correct drive pinion bearing preload adjusting washer aside for use when assembling the
drive pinion and bearings into the final drive.
DRIVE PINION HEIGHT ADJUSTING WASHER SELECTION M
11. Position the side bearing discs and Tool firmly into the side bear-
ing bores.
N
Tool number : KV38100120 ( )

SPD211A

Revision: September 2009 FFD-27 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
12. Install the side bearing caps and tighten the side bearing cap
bolts.

Side bearing : 88 - 98 Nm (9 - 10 kg-m, 65 - 72 ft-lb)

cap bolts

SPD212A

13. Select the correct drive pinion height adjusting washer thickness
by using a standard gauge of 3.0 mm (0.118 in) and J-34309-
101 feeler gauge. Measure the gap between the J-34309-11
R180A pinion height adapter and the arbor.
14. Write down the exact total measurement.

SPD204A

15. Correct the drive pinion height adjusting washer size by referring
to the drive pinion head number.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and ring gear as a matched set
and should be the same as the number on the ring gear. The
second number is the drive pinion head height number, and
it refers to the ideal drive pinion height for quietest operation.
Use the following chart to determine the correct drive pinion
height adjusting washer.

Add or Remove from the Drive Pinion SPD542

Drive Pinion Head Height Number Height Adjusting Washer Thickness

Measurement
6 Add 0.06 mm (0.0024 in)
5 Add 0.05 mm (0.0020 in)
4 Add 0.04 mm (0.0016 in)
3 Add 0.03 mm (0.0012 in)
2 Add 0.02 mm (0.0008 in)
1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
16. Select the correct drive pinion height adjusting washer.

Drive pinion height : Refer to FFD-31, "Drive Pinion

adjusting washer Height Adjustment".

Revision: September 2009 FFD-28 2010 D22 LCV

 FRONT FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION >
17. Remove the J-34309 pinion preload shim selector tool from the
final drive housing and disassemble to retrieve the pinion bear- A
ings.

SPD205A

FFD
TOOTH CONTACT
Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly in relation to one another may be noisy, or have short life,
or both. With a pattern check, the most desirable contact for low noise level and long life can be assured. E
1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or
equivalent to 3 or 4 teeth of ring gear drive side. F

H
SPD357

3. Hold companion flange steady by hand and rotate the ring gear I
in both directions.

SPD653
L

SPD007-B

Revision: September 2009 FFD-29 2010 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000005471286

Engine YD25DDTi
R180A
Front final drive
4-pinion
Gear ratio 4.625
Number of teeth (Ring gear/drive pinion) 37/8

Oil capacity (Approx.) (US pt, lmp pt) 1.3 (2 3/4, 2 1/4)

Ring Gear Runout INFOID:0000000005471287

Ring gear runout limit mm (in) 0.05 (0.0020)

Axle bearing adjustment INFOID:0000000005471288

Axle bearing end play mm (in) 0 - 0.1 (0 - 0.004)

Thickness mm (in) Part number*
Available
axle bearing 0.10 (0.0039) 38233 - 01G11
adjusting 0.20 (0.0079) 38233 - 01G12
shims 0.30 (0.0118) 38233 - 01G13
0.40 (0.0157) 38233 - 01G14
*Always check with the Parts Department for the latest parts information.

Side Gear Adjustment INFOID:0000000005471289

Side gear to pinion mate gear backlash (Clearance between side gear
Less than 0.15 (0.0059)
thrust washer and differential case) mm (in)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-W2010
0.78 (0.0307) 38424-W2011
Available 0.81 (0.0319) 38424-W2012
side gear 0.84 (0.0331) 38424-W2013
thrust shims 0.87 (0.0343) 38424-W2014
0.90 (0.0354) 38424-W2015
0.93 (0.0366) 38424-W2016
0.96 (0.0378) 38424 W2017
*Always check with the Parts Department for the latest parts information.

Side Bearing Adjustment INFOID:0000000005471290

Differential carrier assembly turning resistance N (kg, lb) 34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)
Thickness mm (in) Part number*
Available 0.20 (0.0079) 38453-01G00
side bearing 0.25 (0.0098) 38453-01G01
adjusting 0.30 (0.0118) 38453-01G02
washers 0.40 (0.0157) 38453-01G03
0.50 (0.0197) 38453-01G04
*Always check with the Parts Department for the latest parts information.

Revision: September 2009 FFD-30 2010 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
Total Preload Adjustment INFOID:0000000005471291

Total preload Nm (kg-cm, in-lb) 1.2 - 2.3 (12 - 23, 10 - 20)

Ring gear to drive pinion backlash mm (in) 0.13 - 0.18 (0.0051 - 0.0071) B

Drive Pinion Height Adjustment INFOID:0000000005471292

C
Thickness mm (in) Part number*
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018 FFD
3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020
3.21 (0.1264) 38154-P6021
E
3.24 (0.1276) 38154-P6022
3.27 (0.1287) 38154-P6023
Available 3.30 (0.1299) 38154-P6024
drive pinion 3.33 (0.1311) 38154-P6025
height ad-
F
3.36 (0.1323) 38154-P6026
justing 3.39 (0.1335) 38154-P6027
washers 3.42 (0.1346) 38154-P6028
3.45 (0.1358) 38154-P6029 G
3.48 (0.1370) 38154-P6030
3.51 (0.1382) 38154-P6031
3.54 (0.1394) 38154-P6032
3.57 (0.1406) 38154-P6033 H
3.60 (0.1417) 38154-P6034
3.63 (0.1429) 38154-P6035
3.66 (0.1441) 38154-P6036
I
*Always check with the Parts Department for the latest parts information.

Drive Pinion Preload Adjustment INFOID:0000000005471293

Drive pinion bearing preload adjusting method Adjusting washer and spacer
Drive pinion preload with front oil seal Nm (kg-cm, in-lb) 1.1 - 1.7 (11 - 17, 9.5 - 14.8) K
Drive pinion preload without front oil seal Nm (kg-cm, in-lb) 1.0 - 1.6 (10 - 16, 8.7 - 13.9)
Thickness mm (in) Part number*
L
3.81 (0.1500) 38125-61001
3.83 (0.1508) 38126-61001
3.85 (0.1516) 38127-61001
3.87 (0.1524) 38128-61001 M
Available 3.89 (0.1531) 38129-61001
drive pinion 3.91 (0.1539) 38130-61001
bearing pre- 3.93 (0.1547) 38131-61001
load adjust- 3.95 (0.1555) 38132-61001 N
ing washers 3.97 (0.1563) 38133-61001
3.99 (0.1571) 38134-61001
4.01 (0.1579) 38135-61001
4.03 (0.1587) 38136-61001 O
4.05 (0.1594) 38137-61001
4.07 (0.1602) 38138-61001
4.09 (0.1610) 38139-61001
P
Length mm (in) Part number*
Available 54.50 (2.1457) 38165-B4000
drive pinion 54.80 (2.1575) 38165-B4001
bearing pre- 55.10 (2.1693) 38165-B4002
load adjust- 55.40 (2.1811) 38165-B4003
ing spacers 55.70 (2.1929) 38165-B4004
56.00 (2.2047) 38165-61001

Revision: September 2009 FFD-31 2010 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
*Always check with the Parts Department for the latest parts information.

Revision: September 2009 FFD-32 2010 D22 LCV