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FRONT FINAL DRIVE


D DRIVELINE/AXLE

                                                                                                                                                           A




                                                                                    SECTION
                                                                                           FRONT FINAL DRIVE
                                                                                                             FFD                                           B



                                                                                                                                                           C


                                                                                                                                                           FFD


                                                                                                                                                           E
                                                                CONTENTS
PRECAUTIONS ......................................................... 2
                                                                      .         FRONT FINAL DRIVE ASSEMBLY ......................... 12           .        F
  Service Notice or Precautions ................................. 2   .          Removal and Installation ....................................... 12
                                                                                                                                                  .
PREPARATION .......................................................... 3
                                                                      .            COMPONENTS .................................................. 12
                                                                                                                                                  .
  Special Service Tools .............................................. 3
                                                                      .            REMOVAL .......................................................... 12
                                                                                                                                                  .        G
  Commercial Service Tools ....................................... 5  .            INSTALLATION .................................................. 12
                                                                                                                                                  .
NOISE, VIBRATION AND HARSHNESS (NVH)                                             Disassembly and Assembly ................................... 14  .
TROUBLESHOOTING ............................................... 6     .            COMPONENTS .................................................. 14
                                                                                                                                                  .
                                                                                                                                                           H
  NVH Troubleshooting Chart .................................... 6    .            ASSEMBLY INSPECTION AND ADJUSTMENT 16                          ...
DESCRIPTION ........................................................... 7
                                                                      .            DISASSEMBLY .................................................. 20
                                                                                                                                                  .
  Cross-Sectional View .............................................. 7
                                                                      .            INSPECTION AFTER DISASSEMBLY ............... 24                .
DIFFERENTIAL GEAR OIL ....................................... 8       .            ADJUSTMENT AND SELECTION OF ADJUST-                                      I
  Changing Differential Gear Oil ................................ 8   .            ING WASHERS (SHIMS) ................................... 25     .
   DRAINING ............................................................ 8
                                                                      .            ASSEMBLY ........................................................ 28
                                                                                                                                                  .
   FILLING ................................................................ 8
                                                                      .         SERVICE DATA AND SPECIFICATIONS (SDS) ..... 35                    .         J
  Checking Differential Gear Oil ................................. 8  .          General Specifications ........................................... 35
                                                                                                                                                  .
   OIL LEAKAGE AND OIL LEVEL .......................... 8             .          Inspection and Adjustment .................................... 35.
FRONT OIL SEAL ..................................................... 9.            DRIVE GEAR RUNOUT ..................................... 35     .
                                                                                                                                                           K
  Removal and Installation ......................................... 9.            DIFFERENTIAL SIDE GEAR CLEARANCE ...... 35                     .
   REMOVAL ............................................................ 9
                                                                      .            PRELOAD TORQUE .......................................... 35   .
   INSTALLATION .................................................. 10 .            BACKLASH ........................................................ 35
                                                                                                                                                  .
SIDE OIL SEAL ........................................................11
                                                                      .            COMPANION FLANGE RUNOUT ...................... 35              .         L
  Removal and Installation ........................................11 .            SELECTIVE PARTS ........................................... 35 .
   REMOVAL ...........................................................11
                                                                      .
   INSTALLATION ...................................................11 .                                                                                    M




Edition; 2004 September                                                  FFD-1                                                    2005 G35 Sedan
                                            PRECAUTIONS

PRECAUTIONS                                                                                            PFP:00001

Service Notice or Precautions                                                                             ADS001C7


q   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.
q   Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
q   Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
    the unit, preventing them from entering into the unit during disassembly or assembly.
q   Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
    with a new ones if necessary.
q   Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
q   In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
    tightening sequence is specified, observe it.
q   Clean and flush the parts sufficiently and blow-dry them.
q   Be careful not to damage sliding surfaces and mating surfaces.
q   When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
    and foreign materials from the application and mounting surfaces.
q   Always use shop paper for cleaning the inside of components.
q   Avoid using cotton gloves or shop rags to prevent entering of lint.
q   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.




Edition; 2004 September                            FFD-2                                       2005 G35 Sedan
                                                       PREPARATION

PREPARATION                                                                                                                          PFP:00002
                                                                                                                                                   A
Special Service Tools                                                                                                                   ADS001C8

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

  KV381054S0                                                                             q   Removing front oil seal
                                                                                                                                                   C
  (J-34286)                                                                              q   Removing side bearing outer race
  Puller
                                                                                         q   Removing side oil seal
                                                                                                                                                   FFD

                                                                        ZZA0601D


  ST33400001                                                                             q   Installing front oil seal
                                                                                                                                                   E
  (J-26082)                                                                              q   Installing side oil seal (right side)
  Drift
  a: 60 mm (2.36 in) dia.
                                                                                                                                                   F
  b: 47 mm (1.85 in) dia.


                                                                        ZZA0702D
                                                                                                                                                   G
  KV38102510                                                                             Installing front oil seal
  (     --   )
  Drift
                                                                                                                                                   H
  a: 71 mm (2.80 in) dia.
  b: 65 mm (2.56 in) dia.

                                                                                                                                                    I
                                                                        ZZA0838D


  KV38102100                                                                             Installing side oil seal (left side)
  (J-25803-01)
  Drift                                                                                                                                             J
  a: 44 mm (1.73 in) dia.
  b: 36 mm (1.42 in) dia.
  c: 24.5 mm (0.965 in) dia.
                                                                                                                                                   K
                                                                        ZZA1046D


  KV38100200                                                                             Installing side shaft oil seal
  (     --   )                                                                                                                                      L
  Drift
  a: 65 mm (2.56 in) dia.
  b: 49 mm (1.93 in) dia.
                                                                                                                                                   M

                                                                        ZZA1143D


  ST30032000                                                                             q   Installing drive pinion rear bearing inner
  (J-26010-01)                                                                               race
  Drift                                                                                  q   Installing side shaft
  a: 80 mm (3.15 in) dia.
  b: 38 mm (1.50 in) dia.
  c: 31 mm (1.22 in) dia.

                                                                        S-NT107




Edition; 2004 September                                        FFD-3                                                      2005 G35 Sedan
                                         PREPARATION

  Tool number
  (Kent-Moore No.)                                         Description
  Tool name

  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)
  KV10111100                                               Removing carrier cover
  (J-37228)
  Seal cutter




                                                S-NT046


  ST3306S001                                               Removing and installing side bearing inner
  (J-22888-D)                                              race
  Differential side bearing puller set
  1: ST33051001
     (J-22888-20)
     Puller
  2: ST33061000
     (J-8107-2)
     Base
                                                NT072
     a: 28.5 mm (1.122 in) dia.
     b: 38 mm (1.50 in) dia.
  ST30031000                                               Removing pinion rear bearing inner race
  (J-22912-01)
  Replacer




                                                ZZA0700D


  KV31103000                                               Installing side bearing outer race
  (J-38982)
  Drift
  a: 49 mm (1.93 in) dia.
  b: 70 mm (2.76 in) dia.


                                                ZZA1113D


  ST30611000                                               Installing side bearing outer race (Use with
  (J-25742-1)                                              KV31103000)
  Drift bar




                                                S-NT090




Edition; 2004 September                     FFD-4                                      2005 G35 Sedan
                               PREPARATION

  Tool number
  (Kent-Moore No.)                                Description                                             A
  Tool name

  ST37820000                                      Installing drive pinion front and rear bearing
  (     --   )                                    outer race                                              B
  Drift
  a: 39 mm (1.54 in) dia.
  b: 72 mm (2.83 in) dia.
                                                                                                          C

                                      ZZA0836D


  ST33230000                                      Installing side bearing inner race                      FFD
  (J-25805-01)
  Drift
  a: 51 mm (2.01 in) dia.
  b: 41 mm (1.61 in) dia.                                                                                 E
  c: 28.5 mm (1.122 in) dia.

                                      ZZA1046D
                                                                                                          F
  (J-8129)                                        Measuring turning torque
  Spring gauge

                                                                                                          G



                                      NT127
                                                                                                          H

Commercial Service Tools                                                                       ADS001C9


  Tool name                                       Description                                              I
  Flange wrench                                   Removing and installing drive pinion lock nut

                                                                                                           J



                                                                                                          K
                                      NT771


  Spacer                                          Installing pinion front bearing inner race
  a: 60 mm (2.36 in) dia.                                                                                  L
  b: 36 mm (1.42 in) dia.
  c: 30 mm (1.18 in)

                                                                                                          M

                                      ZZA1133D


  Power tool                                      Loosening bolts and nuts




                                      PBIC0190E




Edition; 2004 September           FFD-5                                        2005 G35 Sedan
                                          Symptom
                          



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