Assembly
Reverse ``Disassembly'' procedure to assemble and note the following:
GEAR CASE ASSEMBLY
1. Assemble pinion mates, side gears, thrust washers, and thrust block, if equipped, in differential case.
2. Install pinion shaft to differential case.
3. Adjust side gear-to-pinion mate backlash or adjust the clearance between the rear face of side gear and thrust washer. Backlash or clearance should be .0039-.0079 inch, .0059 inch with tripod type driveshaft.
4. Lock pinion shaft lock pin.
5. Apply oil to gear tooth surfaces and thrust surfaces and check that they turn properly.
6. Place ring gear on differential case and apply a small amount of locking compound to the bolts, then install bolts.
7. Torque bolts to 65-72 ft. lbs. on 1984 200SX with turbocharger, or 51-58 ft. lbs. on all other models.
Fig. 14 Measuring bearing width:
8. Measure bearing width with a standard gauge (21.00 mm thickness) and a weight block, about 5.5 lbs., prior to installation, Fig. 14.
9. Press side bearing inner race on differential case.
DRIVE PINION HEIGHT & PRELOAD, 200SX & 1985-88 300ZX
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.
Fig. 25 Location Of ``A'' & ``B'' Values:
Fig. 26 Location Of ``C'' & ``D'' Values:
SIDE BEARING WASHERS, 200SX & 1985-88 300ZX
1. The required thicknesses of the left and right adjusting washers can be obtained from the following formulas: T1 = A - C + D + E - H + 2.05 mm; T2 = B - D + F + G + H + 1.95 mm; where T1 = required thickness of left side washer in millimeters, T2 = required thickness of right side washer in millimeters, A & B = figure marked on gear carrier, Fig. 25, C & D = figure marked on differential case, Fig. 26, E & F = side bearing measurements as determined in step 2, G = difference between 8.10 mm and measured thickness of side spacer and H = figure marked on ring gear.
Fig. 11 Side bearing thickness measuring tools:
2. Calculate how far under standard thickness of 21 mm the side bearings are using tools 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 that base plate has recess in it and that bearing will turn 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 that bearing is properly seated.
h. Read dial indicator. Indicator should read .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.
3. Press in front and rear bearing outer races.
4. Install selected pinion height adjusting washer in drive pinion and press in rear bearing inner race.
5. Set drive pinion assembly in differential carrier and install drive pinion with suitable tool.
6. Apply suitable lubricant to cavity at sealing lips of oil seal, then install front oil seal.
7. Install companion flange and torque pinion nut to 137-159 ft. lbs.
8. Turn drive pinion in both directions several times, then measure pinion bearing preload. If preload is not 10-15.2 inch lbs., replace pinion bearing adjusting washer and spacer with a different thickness.
9. Install differential case assembly with side bearing outer races into gear carrier.
10. Insert selected left and right side bearing adjusting washers in place between side bearings and carrier.
11. Drive in side bearing spacer with suitable tool.
12. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.
13. Apply suitable lubricant to cavity at sealing lips of oil seal, then install side oil seal.
14. Measure ring gear to drive pinion backlash with a dial indicator. If backlash is less than .0051-.0071 inch, decrease thickness of right shim and increase thickness of left shim by same amount. If backlash exceeds .0051-.0071 inch, increase thickness of right shim and decrease thickness of left shim by same amount. Never change the total amount of shims to prevent changing bearing preload.
15. Check total preload, which should be 10.9-20.4 inch lbs. If preload is too great, add the same amount of shims to each side. If preload is too small, remove the same amount of shims from each side.
16. Recheck ring gear to drive pinion backlash and check run out of ring gear. If backlash varies excessively in different places, foreign matter may be trapped between ring gear and differential case.
17. If backlash varies greatly and ring gear run out is .0031 inch or less on 1984 models or .0020 or less on 1985-88 models. The hypoid gear set or differential case needs to be replaced.
18. Install rear cover with gasket.