Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 2003-2005 Approved Nissan Frontier 2005 FFD
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D DRIVELINE/AXLE
A
SECTION
FRONT FINAL DRIVE
FFD B
C
FFD
E
CONTENTS
PRECAUTIONS ......................................................... 2
. REAR COVER GASKET .......................................... 13 . F
Service Notice or Precautions ................................. 2 . Removal and Installation ....................................... 13
.
PREPARATION .......................................................... 3
. REMOVAL .......................................................... 13
.
Special Service Tools .............................................. 3
. INSTALLATION .................................................. 13
. G
Commercial Service Tools ....................................... 5 . FRONT FINAL DRIVE ASSEMBLY ......................... 14 .
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ....................................... 14
.
TROUBLESHOOTING ............................................... 6 . REMOVAL .......................................................... 14
.
H
NVH Troubleshooting Chart .................................... 6 . INSTALLATION .................................................. 15
.
DESCRIPTION ........................................................... 7
. Disassembly and Assembly ................................... 16 .
Cross-Sectional View .............................................. 7
. COMPONENTS .................................................. 16
.
DIFFERENTIAL GEAR OIL ....................................... 8 . ASSEMBLY INSPECTION AND ADJUSTMENT 17 ... I
Changing Differential Gear Oil ................................ 8 . DISASSEMBLY .................................................. 20
.
DRAINING ............................................................ 8
. INSPECTION AFTER DISASSEMBLY ............... 25 .
FILLING ................................................................ 8
. ADJUSTMENT AND SELECTION ADJUSTING J
Checking Differential Gear Oil ................................. 8 . WASHERS ......................................................... 26
.
OIL LEAKAGE AND OIL LEVEL .......................... 8 . ASSEMBLY ........................................................ 29
.
FRONT OIL SEAL ..................................................... 9. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 36 .
K
Removal and Installation ......................................... 9. General Specifications ........................................... 36
.
REMOVAL ............................................................ 9
. Inspection and Adjustment .................................... 36.
INSTALLATION .................................................. 10 . DRIVE GEAR RUNOUT ..................................... 36 .
SIDE OIL SEAL ....................................................... 12
. DIFFERENTIAL SIDE GEAR CLEARANCE ...... 36 . L
Removal and Installation ....................................... 12 . PRELOAD TORQUE .......................................... 36 .
REMOVAL .......................................................... 12
. BACKLASH ........................................................ 36
.
INSTALLATION .................................................. 12 . COMPANION FLANGE RUNOUT ...................... 36 . M
SELECTIVE PARTS ........................................... 36 .
Revision: November 2005 FFD-1 2005 Frontier
PRECAUTIONS
PRECAUTIONS PFP:00001
Service Notice or Precautions UDS000WI
G Check for the correct installation status prior to removal or disassembly. If matching marks are required,
be certain they do not interfere with the function of the parts when applied.
G Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
G Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
G Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.
G Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
G In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
G Clean and flush the parts sufficiently and blow-dry them.
G Be careful not to damage sliding surfaces and mating surfaces.
G 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.
G Always use shop paper for cleaning the inside of components.
G Avoid using cotton gloves or shop rags to prevent entering of lint.
G During assembly, observe the specified tightening torque, and apply new gear oil, petroleum jelly, or multi-
purpose grease as specified for each vehicle, if necessary.
Revision: November 2005 FFD-2 2005 Frontier
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools UDS000WJ
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name
ST29020001 Separating the upper link ball joint stud
(J-24319-01) C
Puller
FFD
NT143
KV38108300 Removing and installing drive pinion lock nut E
(J-44195)
Flange wrench
F
NT771
G
KV381054S0 Removing front oil seal
(J-34286)
Puller
H
ZZA0601D I
ST30720000 G Installing front oil seal
(J-25405) G Installing side oil seal
Drift J
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
K
ZZA0811D
ST27863000 G Installing front oil seal
( -- ) G Installing side oil seal L
Drift
a: 74.5 mm (2.933 in) dia.
b: 62.5 mm (2.461 in) dia.
M
ZZA1003D
ST3127S000 Measuring pinion bearing preload and total
(J-25765-A) preload
Preload gauge
1: GG91030000
(J-25765)
Torque wrench
2: HT62940000
( -- )
Socket adapter (1/2)
3: HT62900000 NT124
( -- )
Socket adapter (3/8)
Revision: November 2005 FFD-3 2005 Frontier
PREPARATION
Tool number
(Kent-Moore No.) Description
Tool name
KV10111100 Removing rear cover
(J-37228)
Seal cutter
S-NT046
ST3306S001 Removing and installing side bearing inner
( -- ) race
Differential side bearing puller set a: 28.5 mm (1.122 in) dia.
1: ST33051001 b: 38 mm (1.50 in) dia.
(J-22888-20)
Puller
2: ST33061000
(J-8107-2)
NT072
Base
ST30031000 Removing pinion rear bearing inner race
(J-22912-01)
Replacer
ZZA0700D
KV38100600 Installing side bearing adjusting shim
(J-25267)
Drift
SDIA0429J
ST30613000 Installing pinion rear bearing outer race
(J-25742-3) a: 72 mm (2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.
ZZA1000D
ST30611000 Installing pinion rear bearing outer race (Use
(J-25742-1) with ST30613000)
Drift bar
S-NT090
KV38100200 Installing pinion front bearing outer race
(J-26233) a: 65 mm (2.56 in) dia.
Drift b: 49 mm (1.93 in) dia.
ZZA1143D
Revision: November 2005 FFD-4 2005 Frontier
PREPARATION
Tool number
(Kent-Moore No.) Description A
Tool name
ST30901000 Installing pinion rear bearing inner race
(J-26010-01) a: 79 mm (3.11 in) dia. B
Drift b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
C
ZZA0978D
ST33200000 Installing pinion front bearing inner race FFD
(J-26082) a: 60 mm (2.36 in) dia.
Drift b: 44.5 mm (1.752 in) dia.
E
ZZA1002D
ST33230000 Installing side bearing inner race F
(J-35867) a: 51 mm (2.01 in) dia.
Drift b: 41 mm (1.61 in) dia.
c: 28 mm (1.10 in) dia. G
ZZA1046D H
(J-34309) Adjusting bearing preload and pinion gear
Differential shim selector tool height
I
J
NT134
(J-25269-18) Selecting pinion height adjusting washer
Side bearing disc (2 Req'd)
K
L
NT135
Commercial Service Tools UDS000WK M
Tool name Description
Power tool Loosening nuts and bolts
PBIC0190E
Revision: November 2005 FFD-5 2005 Frontier
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