Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 1998-2002 Approved Nissan Frontier 2000 KA24DE PD
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PROPELLER SHAFT & GI
DIFFERENTIAL CARRIER
MA
SECTION PD EM
LC
EC
CONTENTS FE
PREPARATION................................................................3 Extension Tube and Differential Side Shaft ..............21
CL
Special Service Tools ..................................................3 INSPECTION..................................................................23
NOISE, VIBRATION AND HARSHNESS (NVH) Ring Gear and Drive Pinion ......................................23
TROUBLESHOOTING .....................................................7 Differential Case Assembly........................................23 MT
NVH Troubleshooting Chart.........................................7 Bearing.......................................................................23
ADJUSTMENT ...............................................................24
PROPELLER SHAFT Side Bearing Preload.................................................24 AT
Pinion Gear Height and Pinion Bearing Preload.......25
PROPELLER SHAFT ......................................................8 Tooth Contact.............................................................29
On-vehicle Service.....................................................10 ASSEMBLY....................................................................30 TF
Removal and Installation............................................10 Extension Tube and Differential Side Shaft ..............30
Inspection...................................................................10 Differential Case ........................................................30
Final Drive Housing ...................................................31 PD
Disassembly...............................................................11
Assembly ...................................................................12
H190A FA
FINAL DRIVE
REAR FINAL DRIVE .....................................................35
ON-VEHICLE SERVICE ................................................14 DISASSEMBLY..............................................................36 RA
Front Oil Seal Replacement Pre-inspection ............................................................36
(Front final drive: Model R180A) ...............................14 Differential Carrier......................................................36
Differential Case ........................................................38 BR
Rear Cover Gasket Replacement
(Rear final drive: Model C200) ..................................14 INSPECTION..................................................................40
REMOVAL AND INSTALLATION (Front final Ring Gear and Drive Pinion ......................................40
Differential Case Assembly........................................40
ST
drive)..............................................................................15
Removal.....................................................................15 Bearing.......................................................................40
Installation..................................................................15 ADJUSTMENT ...............................................................41 RS
REMOVAL AND INSTALLATION (Rear final drive) ....16 Side Bearing Preload.................................................41
Removal.....................................................................16 Pinion Gear Height ....................................................42
Installation..................................................................16 Tooth Contact.............................................................46 BT
ASSEMBLY....................................................................47
Differential Case ........................................................47
R180A
Differential Carrier......................................................48 HA
FRONT FINAL DRIVE ...................................................17
C200
DISASSEMBLY..............................................................18 EL
Pre-inspection ............................................................18
Final Drive Housing ...................................................18 REAR FINAL DRIVE .....................................................52
Differential Case ........................................................20 2WD models .....................................................52 IDX
CONTENTS (Cont'd.)
4WD models .....................................................53 Tooth Contact.............................................................64
DISASSEMBLY..............................................................54 ASSEMBLY....................................................................65
Pre-inspection ............................................................54 Differential Case ........................................................65
Differential Carrier......................................................54 Differential Carrier......................................................66
Differential Case ........................................................56 SERVICE DATA AND SPECIFICATIONS (SDS) ..........70
INSPECTION..................................................................58 Propeller Shaft ...........................................................70
Ring Gear and Drive Pinion ......................................58 Final Drive..................................................................71
Differential Case Assembly........................................58 General Specifications ..........................................71
Bearing.......................................................................58 Inspection And Adjustment (R180A) .....................72
ADJUSTMENT ...............................................................59 Inspection And Adjustment (H190A) .....................73
Side Bearing Preload..................................................59 Inspection And Adjustment (C200) .......................74
Pinion Gear Height ....................................................60
PD-2
PREPARATION
Special Service Tools GI
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Unit application MA
(Kent-Moore No.) Description
Tool name R180A H190A C200
EM
ST3127S000 Measuring pinion bearing preload
(See J25765-A) and total preload
Preload gauge
1 GG91030000
LC
(J25765)
Torque wrench
2 HT62940000
X X X EC
( -- )
Socket adapter
3 HT62900000
FE
( -- )
Socket adapter NT124
CL
KV38100800 Mounting final drive
(J25604-01), (J34310) (To use, make a new hole.)
Differential attachment MT
X -- --
NT119 a: 152 mm (5.98 in) AT
ST06310000 Mounting final drive
(J25602-01) TF
Differential attachment
-- X --
PD
NT140
ST33290001 Removing side bearing outer race FA
(J25810-A) and side oil seal
Side bearing outer race
X -- --
puller RA
NT076
BR
ST38060002 Removing and installing propeller
(J34311) shaft lock nut and drive pinion lock
Drive pinion flange nut
X X X ST
wrench
NT113
RS
ST3090S000 Removing and installing drive pinion
( -- ) rear inner cone
Drive pinion rear inner BT
race puller set
1 ST30031000
(J22912-01) HA
Puller X X X
2 ST30901000
(J26010-01) EL
Base
a: 79 mm (3.11 in) dia. IDX
b: 45 mm (1.77 in) dia.
NT527 c: 35 mm (1.38 in) dia.
PD-3
PREPARATION
Special Service Tools (Cont'd)
Tool number Unit application
(Kent-Moore No.) Description
Tool name R180A H190A C200
ST3306S001 Removing and installing differential
Differential side bearing side bearing inner cone
puller set
1 ST33051001
(J22888-20)
Body
X X X
2 ST33061000
(J8107-2)
Adapter
a: 28.5 mm (1.122 in) dia.
NT072 b: 38 mm (1.50 in) dia.
ST33230000 Installing side bearing inner cone
(J25805-01)
Differential side bearing
drift X X X
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
NT085 c: 28.5 mm (1.122 in) dia.
ST33081000 Installing side bearing inner cone
( -- )
Side bearing puller
adapter -- -- X
a: 43 mm (1.69 in) dia.
NT431 b: 33.5 mm (1.319 in) dia.
KV38100600 Installing side bearing spacer
(J25267)
Side bearing spacer drift -- -- X
a: 8 mm (0.31 in)
NT528 b: R42.5 mm (1.673 in)
ST30611000 Installing pinion rear
(J25742-1) bearing outer race
Drift
X X X
NT090
ST30621000 Installing pinion rear bearing outer
(J25742-5) race
Drift
X X X
a: 79 mm (3.11 in) dia.
NT073 b: 59 mm (2.32 in) dia.
ST30701000 Installing pinion front bearing outer
(J25742-2) race
Drift
X -- --
a: 61.5 mm (2.421 in) dia.
NT073 b: 41 mm (1.61 in) dia.
PD-4
PREPARATION
Special Service Tools (Cont'd)
GI
Tool number Unit application
(Kent-Moore No.) Description
Tool name R180A H190A C200
MA
ST30613000 Installing pinion front bearing outer
(J25742-3) race
Drift EM
-- X X
a: 72 mm (2.83 in) dia.
NT073 b: 48 mm (1.89 in) dia.
LC
KV381025S0 Installing front oil seal
( -- ) EC
Oil seal fitting tool
1 ST30720000
(J25405) FE
Drift bar X X --
2 KV38102510
( -- ) CL
Drift
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
c: 71 mm (2.80 in) dia. MT
NT525 d: 65 mm (2.56 in) dia.
KV38100500 Installing front oil seal
(J25273)
AT
Gear carrier front oil seal
-- -- X
drift
TF
a: 85 mm (3.35 in) dia.
NT115 b: 60 mm (2.36 in) dia.
ST33720000 Installing side retainer PD
(J25817)
Differential side retainer X -- --
guide FA
NT138
ST33270000 Installing side oil seal
RA
(J25809)
Side oil seal drift
X -- -- BR
a: 62 mm (2.44 in) dia. ST
NT526 b: 28 mm (1.10 in) dia.
(J34309) Adjusting bearing pre-load and gear
Differential shim height RS
selector
BT
X X X
HA
NT134
EL
(J25269-4) Selecting pinion height adjusting
Side bearing discs washer
(2 req'd) X -- X IDX
NT136
PD-5
PREPARATION
Special Service Tools (Cont'd)
Tool number Unit application
(Kent-Moore No.) Description
Tool name R180A H190A C200
(J25269-18) Selecting pinion height adjusting
Side bearing discs washer
(2 req'd) -- X --
NT135
(J8129)
Spring gauge
X X X
Measuring carrier turning torque
NT127
(J35764) Installing side oil seal
Gear carrier side oil seal
drift
X -- --
NT120
KV381051S0 Checking differential torque on lim-
( -- ) ited slip differential
Rear axle shaft dummy
1 KV38105110
( -- ) -- X X
Torque wrench side
2 KV38105120
( -- )
Vice side
NT142
PD-6
Symptom
X : Applicable
Reference page
Possible cause and
SHAFT
SUSPECTED PARTS
PROPELLER
DIFFERENTIAL
Noise
Noise
Shake
Vibration
X
X
Uneven rotation torque --
X
X
X
Center bearing improper installlation PD-9, 12
X
X
Excessive center bearing axial end play --
X
X
Center bearing mounting (insulator) cracks, damage or deterioration --
X
X
X
Excessive joint angle --
PD-7
X
X
Rotation imbalance PD-10
X
X
Excessive runout PD-10
X
Rough gear tooth PD-23, 40, 58
X
Improper gear contact PD-29, 46, 64
X
Tooth surfaces worn PD-23, 40, 58
X
Incorrect backlash PD-33, 50, 68
X
Companion flange excessive runout --
NVH Troubleshooting Chart
X
Improper gear oil Refer to MA section
X
PROPELLER SHAFT Refer to PROPELLER SHAFT in this chart
X
DIFFERENTIAL Refer to DIFFERENTIAL in this chart
X
X
X
X
DRIVE SHAFT NVH in FA section
X
X
X
X
AXLE AND SUSPENSION NVH in FA, RA section
X
X
X
X
TIRES NVH in FA section
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
X
X
X
ROAD WHEEL NVH in FA section
X
X
X
BRAKES NVH in BR section
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
X
X
X
X
STEERING NVH in ST section
GI
TF
AT
EL
FE
ST
FA
BT
CL
LC
RS
EC
RA
HA
BR
MT
PD
EM
MA
IDX
PROPELLER SHAFT PROPELLER SHAFT
Front propeller shaft (Model 2F1310)
APD025
Rear propeller shaft (Model 2S1310)
APD024
PD-8
PROPELLER SHAFT PROPELLER SHAFT
Rear propeller shaft (Model 3S1310) GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
WPD017
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
PD-9
PROPELLER SHAFT PROPELLER SHAFT
On-vehicle Service
PROPELLER SHAFT VIBRATION
If vibration is present at high speed, inspect propeller shaft runout
first.
1. Raise rear end of vehicle until wheels are clear of the ground.
2. Measure propeller shaft runout at several points along propel-
ler shaft by rotating final drive companion flange using hands.
3. If runout exceeds specifications, disconnect propeller shaft at
final drive companion flange. Rotate companion flange 180
SPD728
degrees, then reconnect propeller shaft.
Runout limit: 0.6 mm (0.024 in)
4. Check runout again. If runout still exceeds the limit, replace
propeller shaft assembly.
5. Perform road test.
APPEARANCE CHECKING
q Inspect propeller shaft tube surface for dents or cracks and
replace as necessary.
q Check center bearing for noise or damage and replace as
necessary.
SPD102
Removal and Installation
1. Place matching marks on flanges, then separate propeller
shaft from final drive.
SPD103
2. Remove propeller shaft.
q Insert plug into rear oil seal after removing rear propeller
shaft.
SPD359
Inspection
q Inspect propeller shaft runout. If runout exceeds the limit,
replace propeller shaft assembly.
Runout limit: 0.6 mm (0.024 in)
SPD106
PD-10
PROPELLER SHAFT PROPELLER SHAFT
Inspection (Cont'd)
q Inspect journal axial play. GI
If play exceeds the limit, replace propeller shaft assembly.
Journal axial play:
0.02 mm (0.0008 in) or less MA
EM
LC
SPD874
Disassembly EC
CENTER BEARING
1. Place matching marks on flanges, then separate 2nd tube from FE
1st tube.
CL
MT
SPD109
2. Place matching marks on the flange and shaft. AT
TF
PD
FA
SPD110
3. Remove locking nut using Tool. RA
Tool number:
ST38060002 (J34311)
4. Remove companion flange using puller. BR
ST
RS
SPD170A
5. Remove center bearing using Tool and press.
BT
Tool number: ST30031000 (J22912-01)
HA
EL
IDX
SPD113
PD-11
PROPELLER SHAFT PROPELLER SHAFT
Disassembly (Cont'd)
JOURNAL
NOTE:
1. Place matching marks on propeller shaft and flange or yoke.
SPD128
2. Remove snap ring.
APD011
3. Remove pushed out journal bearing by lightly tapping yoke
with a hammer, taking care not to damage journal and yoke
hole.
SPD732
4. Remove bearing at opposite side in above operation.
Put marks on disassembled parts so that they can be
reinstalled in their original positions.
SPD131
Assembly
CENTER BEARING
q When installing center bearing, position the ``F'' mark on cen-
ter bearing toward front of vehicle.
q Apply a coat of multi-purpose lithium grease containing
molybdenum disulfide to the end face of the center bearing
and both sides of the washer.
SPD114
PD-12
PROPELLER SHAFT PROPELLER SHAFT
Assembly (Cont'd)
q Stake the nut. Always use new one. GI
q Align match marks when assembling tubes.
MA
EM
LC
SPD117
JOURNAL EC
1. Assemble journal bearing. Apply recommended multi-purpose
grease on bearing inner surface.
FE
When assembling, be careful that needle bearing does not fall
down.
CL
MT
SPD133
2. Select snap ring that will provide specified play in axial direction AT
of journal, and install them.
Refer to SDS, PD-70.
Select snap rings with a difference in thickness at both sides TF
within 0.06 mm (0.0024 in).
PD
FA
APD012
3. Adjust thrust clearance between bearing and snap ring to zero RA
by tapping yoke.
BR
ST
RS
SPD732
4. Check to see that journal moves smoothly and check for axial
BT
play.
Axial play: 0.02 mm (0.0008 in) or less
HA
EL
IDX
SPD874
PD-13
ON-VEHICLE SERVICE FINAL DRIVE
Front Oil Seal Replacement
(Front final drive: Model R180A)
1. Remove front propeller shaft.
2. Loosen drive pinion nut.
Tool number: ST38060002 (J34311)
SPD733
3. Remove companion flange using puller.
SPD734
4. Remove front oil seal.
SPD735
5. Apply multi-purpose grease to cavity at sealing lips of oil seal.
Press front oil seal into carrier.
Tool number:
ST30720000 (J25405)
6. Install companion flange and drive pinion nut.
7. Install propeller shaft.
SPD736
Rear Cover Gasket Replacement
(Rear final drive: Model C200)
1. Drain gear oil.
2. Remove rear cover and rear cover gasket.
3. Install new rear cover gasket and rear cover.
4. Fill final drive with recommended gear oil.
SPD740-A
PD-14
REMOVAL AND INSTALLATION (Front final drive) FINAL DRIVE
Removal GI
1. Remove front propeller shaft.
2. Separate drive shaft from front final drive. Refer to FA section MA
[``Drive Shaft'', ``FRONT AXLE (4WD)''].
3. Remove engine mounting bolts and raise up engine.
4. Remove front final drive together with differential mounting EM
member.
LC
SPD741
Installation EC
1. Install front final drive assembly together with differential
mounting member. FE
CL
MT
SPD742
2. Tighten front final drive securing bolts and nuts by following the AT
procedure to prevent drive train vibration.
a. Temporarily tighten nut A .
b. Temporarily tighten nut B . TF
c. Tighten bolt C to the torque of 68 to 87 N m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
d. Tighten bolt D to the torque of 68 to 87 N m (6.9 to 8.9 kg-m, PD
50 to 64 ft-lb).
e. Tighten nut A to the torque of 68 to 87 N m (6.9 to 8.9 kg-m,
50 to 64 ft-lb). FA
f. Tighten nut B to the torque of 68 to 87 N m (6.9 to 8.9 kg-m,
50 to 64 ft-lb).
g. Tighten nut E to the torque of 68 to 87 N m (6.9 to 8.9 kg-m, RA
50 to 64 ft-lb).
3. Install drive shaft. Refer to FA section [``Drive Shaft'', ``FRONT
AXLE (4WD)'']. BR
4. Install front propeller shaft.
ST
RS
SPD743
BT
HA
EL
IDX
PD-15
REMOVAL AND INSTALLATION (Rear final drive) FINAL DRIVE
Removal
q Remove propeller shaft.
Plug front end of transfer.
q Remove axle shaft.
Refer to RA section (``REAR AXLE'').
CAUTION:
q Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shaft.
q Before removing the final drive assembly or rear axle
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
q Fill final drive with recommended gear oil.
SPD123
PD-16
FRONT FINAL DRIVE R180A
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
IDX
APD026
PD-17
DISASSEMBLY R180A
Pre-inspection
Before disassembling final drive, perform the following inspection.
q Total preload
a. Turn drive pinion in both directions several times to set bearing
rollers.
b. Check total preload with Tool.
Tool number: ST3127S000 (J25765-A)
Total preload:
1.2 - 2.3 N m
(12 - 23 kg-cm, 10 - 20 in-lb)
SPD634
q Ring gear-to-drive pinion backlash
Check backlash of ring gear with a dial indicator at several
points.
Ring gear-to-drive pinion backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 in)
SPD635
q Ring gear runout
Check runout of ring gear with a dial indicator.
Runout limit:
0.05 mm (0.0020 in)
q Tooth contact
Check tooth contact. Refer to ``ADJUSTMENT'', PD-29.
SPD636
Final Drive Housing
1. Using three spacers [20 mm (0.79 in)], mount final drive
assembly on Tool.
Tool number:
KV38100800 (J34310), (J25604-01)
SPD637
2. Remove extension tube and differential side shaft assembly.
SPD638
PD-18
DISASSEMBLY R180A
Final Drive Housing (Cont'd)
3. Remove differential side flange. GI
MA
EM
LC
SPD713
4. Mark side retainers for identification. Remove side retainers. EC
Be careful not to confuse right and left side retainers and
shims.
FE
CL
MT
SPD639
5. Extract differential case from final drive housing. AT
TF
PD
FA
SPD309
6. Remove side outer races. RA
Tool number: ST33290001 (J25810-A)
Keep the side bearing outer races together with their respec-
tive inner cones -- do not mix them up. BR
7. Remove side oil seal.
ST
RS
PD243
8. Loosen drive pinion nut.
BT
Tool number: ST38060002 (J34311)
9. Remove companion flange with puller.
HA
EL
IDX
SPD171A
PD-19
DISASSEMBLY R180A
Final Drive Housing (Cont'd)
10. Take out drive pinion together with pinion rear bearing inner
cone, drive pinion bearing spacer and pinion bearing adjusting
washer.
11. Remove front oil seal and pinion front bearing inner cone.
SPD641
12. Remove pinion front and rear bearing outer races with brass
drift.
PD349
13. Remove pinion rear bearing inner cone and drive pinion
adjusting washer.
Tool number: ST30031000 (J22912-01)
SPD209
Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in grooves.
Tool numbers:
A ST33051001 (J22888-20)
B ST33061000 (J8107-2)
SPD642
PD-20
DISASSEMBLY R180A
Differential Case (Cont'd)
Be careful not to confuse the right and left hand parts. GI
MA
EM
LC
SPD022
2. Loosen ring gear bolts in a criss-cross fashion. EC
3. Tap ring gear off differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.
FE
CL
MT
SPD024
4. Separate differential case LH and RH. AT
Put match marks on both differential case LH and RH sides
prior to separating them.
TF
PD
FA
SPD643
RA
Extension Tube and Differential Side Shaft
1. Remove differential side shaft assembly from extension tube.
BR
ST
RS
SPD644
2. Cut rear axle bearing collar with cold chisel. Be careful not to
BT
damage differential side shaft.
HA
EL
IDX
SPD236A
PD-21
DISASSEMBLY R180A
Extension Tube and Differential Side Shaft
(Cont'd)
3. Reinstall differential side shaft into extension tube and secure
with bolts. Remove rear axle bearing by drawing out differential
side shaft from rear axle bearing with puller.
SPD646
4. Remove grease seal.
SPD647
PD-22
INSPECTION R180A
Ring Gear and Drive Pinion GI
Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive pinion MA
as a set (hypoid gear set).
EM
LC
Differential Case Assembly EC
Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft and thrust washers. FE
CL
MT
AT
TF
PD
FA
SPD648
RA
Bearing
1. Thoroughly clean bearing.
2. Check bearing for wear, scratches, pitting or flaking. BR
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner cone as a set.
ST
RS
SPD715
BT
HA
EL
IDX
PD-23
ADJUSTMENT R180A
For quiet and reliable final drive operation, the following five
adjustments must be made correctly:
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear-to-pinion backlash. Refer to ``ASSEMBLY'', PD-33.
5. Ring and pinion gear tooth contact pattern.
Side Bearing Preload
A selection of carrier side retainer adjusting shims is required
for successful completion of this procedure.
1. Make sure all parts are clean. Also make sure the bearings are
well lubricated with light oil or type ``DEXRONTM'' automatic
transmission fluid.
2. Install differential carrier and side bearing assembly into the
final drive housing.
SPD191A
3. Place all of the original side retainer adjusting shims onto the
side bearing retainer that goes at the ring gear end of the
carrier.
SPD192A
4. Install both bearing retainers onto the final drive housing and
torque the retainer bolts.
Bolt torque specification:
: 9 - 12 N m (0.9 - 1.2 kg-m, 78 - 104 in-lb)
SPD193A
5. Turn the carrier several times to seat the bearings.
6. Measure the carrier turning torque with a spring gauge, J8129,
at the ring gear retainer bolt.
Turning torque specification:
34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb)
of pulling force at the ring gear bolt
SPD194A
PD-24
ADJUSTMENT R180A
Side Bearing Preload (Cont'd)
7. If the turning torque measured is incorrect, establish the cor- GI
rect bearing preload by adding to or subtracting from the total
amount of shim thickness.
q Increase shim thickness to decrease turning torque on the MA
carrier.
q Decrease shim thickness to increase turning torque on the
carrier. EM
LC
8. Record the correct, selected total thickness of the side retainer EC
adjusting shims, and remove the carrier and bearings from the
final drive housing. Save all shims for later re-use.
FE
CL
MT
SPD195A
Pinion Gear Height and Pinion Bearing Preload AT
1. Make sure all parts are clean and that the bearings are well
lubricated. TF
2. Assemble the pinion gear bearings into the pinion pre-load
shim selector tool, J34309.
q Front Pinion Bearing -- make sure the J34309-3 front pinion PD
bearing seat is secured tightly against the J34309-2 gauge
anvil. Then turn the front pinion bearing pilot, J34309-7, to
secure the bearing in its proper position. FA
SPD769
RA
q Rear Pinion Bearing -- the rear pinion bearing pilot,
J34309-8, is used to center the rear pinion bearing only. The
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