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 PINION PRELOAD
Exc. 1985-88 200SX
Adjust preload of drive pinion with spacer and washer between front and rear bearing cones, regardless of thickness of pinion height adjusting washer. This adjustment must be performed without oil seal inserted.
1. Press front and rear bearing outer races into gear carrier.
Fig. 3 Pinion height & preload adjusting tools:
2. Insert pinion height adjusting washer of .1217 inch thickness and rear bearing cone into Dummy Shaft ST31212000 to make convenient to adjust pinion height, Fig. 3.
Fig. 4 Torquing pinion nut:
Fig. 5 Measuring pinion preload:
3. Install drive pinion bearing spacer, washer, front bearing cone, Drive Pinion Dummy Collar ST31214000 and companion flange on dummy shaft and tighten drive pinion nut using Stopper ST31852000, Fig. 4. Measure pinion bearing preload using Preload Gauge ST3127S000, and select washer and spacer that will provide required preload, Fig. 5.
Fig. 6 Measuring drive pinion height:
DRIVE PINION HEIGHT
Exc. 1985-88 200SX
On 1984 Maxima, perform steps 1 through 3.
Adjust pinion height with washer provided between rear bearing cone and back of pinion gear.
1. Install height gauge ST31211000 on carrier with dummy shaft mounted, Fig. 6.
2. Measure the clearance (N) between the tip end of height gauge and the end surface of dummy shaft, using a thickness gauge, Fig. 6.
3. The thickness of drive pinion height adjusting washer can be obtained from the following formula: T= W + N - ((H - D' - S) 0.01 - 0.20 where T = required thickness of rear bearing adjusting washers in millimeters, W = thickness of washers temporarily inserted in millimeters, N = measured value with thickness gauge in millimeters, H = figure marked on the drive pinion head, D' = figure marked on the dummy shaft, S = figure marked on the height gauge and figures for H, D' and S are dimensional variations in a unit 1/100 mm against each standard measurement. If values signifying H, D' and S are not given, regard them as zero and compute.
4. Install determined pinion height adjusting washer in drive pinion, and press rear bearing cone in, using Base ST30901000.
5. Lubricate pinion front and rear bearings. Install drive pinion in gear carrier and the drive pinion bearing spacer and washer, front bearing cone and front bearing pilot spacer, pilot bearing and the front oil seal.
6. Install companion flange on drive pinion and torque nut to 123-145 ft. lbs.
SIDE BEARING RETAINER SHIMS
Fig. 7 Side bearing retainer shim thickness:
Fig. 12 Location Of ``A'' & ``B'' Values:
Fig. 13 Location Of ``C'' & ``D'' Values:
Fig. 14 Location Of ``G1'' & ``G2'' Values:
1. If the hypoid gear set, carrier, differential case, side bearing or side bearing retainer has been replaced with a new part, adjust the side bearing preload with adjusting shim. The required thickness of the right and left retainer shims can be obtained from the following formulas: T1= (A + C + G1 - D) 0.01 + 0.76 - E; T2= (B + D + G2) 0.01 + 0.76 - F; where, T1 = required thickness of left side retainer shim in millimeters, Fig. 7, T2 = required thickness of right side retainer shim in millimeters, Fig. 7, A & B = figures marked on the gear carrier, Fig. 8, C & D = figures marked on the differential case, Fig. 9, E & F = differences in width of left or right side bearing against the standard width (20 mm) in millimeters, Fig. 10 (measure bearing width using master gauge KV38101900 and weight block ST32501000), G1 & G2 = figure marked on the left or right side retainer and figures for A, B, C, D, G1 and G2 are dimensional variations in a unit of 1/100 mm against each standard measurement. If values signifying A, B, C, D, G1 and G2 are not given, regard value as zero and compute.