Assembly
Reverse ``Disassembly'' procedure to assemble and note the following:
GEAR CASE ASSEMBLY
1. Assemble pinion mates, side gears and thrust washers in differential case.
2. Install pinion shaft to differential case.
3. Adjust side gear-to-pinion mate backlash by selecting side gear thrust washers. Backlash should be .0039-.0079 inch (less than .0059 inch on models).
4. Lock pinion shaft lock pin using a punch after secured into place.
5. Apply oil to gear tooth surfaces and thrust surfaces and check if they turn properly.
6. Place ring gear on differential case and torque bolts to 65-72 ft. lbs.
7. On 1984 Maxima, press side bearing cone onto differential case.
DRIVE BEARING HEIGHT & PRELOAD
1. Before adjusting pinion height and drive pinion bearing preload, set up each tool, rear pinion bearing and front pinion bearing as follows:
Fig. 18 Installing Rear Pinion Bearing Pilot & Gauge Plate On Hex Head Long Bolt:
a. Install rear pinion bearing pilot into gauge plate and slide over hex head long bolt, Fig. 18.
Fig. 19 Installing bearing preload adapter & pinion bearing adjusting spacer on hex head long bolt:
b. Slide pinion rear bearing inner race, bearing preload adapter and pinion bearing adjusting spacer over hex head long bolt, Fig. 19.
c. Install hex head long bolt assembly into gear carrier.
Fig. 20 Assembling front bearing pilot support assembly:
d. Stand front bearing pilot support on workbench with appropriate side up and assemble front pinion bearing pilot, front pinion bearing inner race and lead preload washer, ensuring that all parts are seated, Fig. 20.
e. Install assembly, Fig. 20, over hex head long bolt into gear carrier. Install and finger tighten support nut, ensuring that all parts turn freely and that they are properly aligned.
f. Carefully tighten support nut to obtain preload of 5.2-8.7 inch lbs.
Fig. 21 Arbor assembly w/side bearing discs:
2. Install two side bearing discs with arbor assembly, ensuring that arbor turns freely, Fig. 21.
Fig. 22 Installing Arbor Assembly With Discs Into Differential Carrier:
3. Place side bearing discs with arbor assembly into differential carrier, lifting spring loaded plunger and placing it on face of gauge plate, Fig. 22.
4. Install bearing caps.
Fig. 23 Installing Dial Indicator:
5. Install dial indicator and tighten hold down clamp, Fig. 23.
6. Zero dial indicator by rotating arbor and plunger back and forth while noting highest deflection, then set indicator at zero.
7. Rotate gauge plate until plunger falls off gauge plate and record reading of dial indicator.
Fig. 17 Drive pinion marking:
8. Note head number on drive pinion head, Fig. 17.
9. Calculate washer thickness as follows:
a. Add dial indicator reading to 3 mm.
b. Using drive pinion head number, subtract it from sum obtained in step 9a if head number is plus (+) or add if head number is minus (-).
c. Select proper replacement washer equal to total obtained in step 9b. If washer is not available in calculated thickness, use washer whose thickness is closest to calculated thickness.
10. To determine pinion bearing preload, disassemble pinion height/bearing preload tools and measure thickness of lead washer. This is correct size pinion bearing adjusting washer required.
11. If shims are not available in determined thickness, use shims so that total thickness is closest to calculated value. Sometimes the correct dimension cannot be set with washers only. If this is the case, washers may be used in combination with drive pinion bearing adjusting spacers.
SIDE BEARING RETAINER SHIMS
Fig. 12 Location Of ``A'' & ``B'' Values:
Fig. 13 Location Of ``C'' & ``D'' Values:
Fig. 11 Side bearing thickness measuring tools:
1. The required thicknesses of the left and right adjusting shims can be obtained from the following formulas: T1 = A + C - G1 - D - E + H + .76 mm; T2 = B + G2 + D - F - G + .76 mm; where, T1 = required thickness of left side shim pack in millimeters, T2 = required thickness of right side shim pack in millimeters, A & B = figures marked on gear carrier, Fig. 8, C & D = figures marked on differential case, Fig. 9, E & F = side bearing measurements as determined in step 2, G1 & G2 = figures marked on left or right side retainer and H = figure marked on ring gear.
2. Calculate how far under standard thickness of .79 inch (20 mm) the side bearings are using tool J25407-1, J25407-2 and J25407-3 or equivalents, Fig. 11, as follows:
a. Set weight block, 4 step gauge block and dial indicator on base plate.
b. Adjust dial indicator to zero.
c. Carefully slide 4 step gauge block and weight block out from under dial indicator.
d. Lubricate side bearing and place side bearing on base plate, ensuring base plate has recess in it and bearing turns freely when positioned over recess.
e. Place weight block on side bearing.
f. Slide dial indicator onto weight block.
g. Rotate weight block several times to ensure bearing is properly seated.
h. Read dial indicator. Indicator should read .0039-.0118 inch (.10-.30 mm). If needle fluctuates erratically, bearing is either dirty or defective and should be cleaned or replaced as necessary.
i. Measurement obtained for left side bearing is measurement E, step 1 and measurement obtained for right side bearing is measurement F.
DIFFERENTIAL CARRIER
1. Press in front and rear bearing outer races.
2. Install selected pinion height adjusting washer in drive pinion and press in rear bearing inner race.
3. Set drive pinion assembly in differential carrier and install drive pinion with suitable tool.
4. Apply suitable lubricant to cavity at sealing lips of oil seal, then install front oil seal.
5. Install companion flange and torque pinion nut to 123-145 ft. lbs.
6. Turn drive pinion in both directions several times, then measure pinion bearing preload. If preload is not 7.8-14.8 inch lbs., replace pinion bearing adjusting washer and spacer with a different thickness.
7. Select side retainer adjusting washer, then press fit side bearing outer race into side retainer.
8. Install side oil seal, then the differential case assembly.
Fig. 12 Side retainer installation:
9. Position selected side retainer adjusting shims and O-rings in side retainers, then install retainers in carrier with arrow marks on retainers properly positioned, Fig. 12.