Disassembly And Assembly

Removal of Drive Gear and Differential Case Assembly 

1. Remove the side retainer mounting bolt.
2. Remove the retainer by pulling it and tapping carrier case using a plastic hammer.
3. Remove the differential case assembly from the carrier case.
   CAUTION: Be careful not to damage the carrier cover mating surface.
4. Remove the side bearing outer race using puller.
5. Keep the side bearing outer races together with inner race. Do not mix them up. Also, keep adjusting washers together with bearings.
   Fig 1: Identifying Drive Gear (Back Of Teeth Side, Teeth Side)

   Courtesy of NISSAN MOTOR CO., U.S.A.
6. Drive out the side oil seals from the carrier case.
   Fig 2: Driving Out Side Oil Seals From Carrier Case

   Courtesy of NISSAN MOTOR CO., U.S.A.

Removal of Drive Pinion Assembly 

1. Hold the companion flange using cam sprocket wrench or flange wrench, remove the pinion lock nut.
   Fig 3: Holding Companion Flange Using Cam Sprocket Wrench Or Flange Wrench

   Courtesy of NISSAN MOTOR CO., U.S.A.

   Tool number: KV40104000 (-) 

2. Remove the companion flange using puller.
3. Temporarily install drive pinion lock nut.
   CAUTION: Install the drive pinion lock nut until it flash with the drive pinion end.
4. Remove the drive pinion from the carrier case.
5. Remove the bearing outer race by tapping the race evenly.
6. On companion flange side, remove the bearing outer race with bearing and oil seal.
7. Press out the drive pinion bearing from the drive pinion using puller.

   Tool number: ST30031000 (J22912-01) 

   Fig 4: Pressing Out Drive Pinion Bearing From Drive Pinion Using Puller

   Courtesy of NISSAN MOTOR CO., U.S.A.

Differential Case Disassembly 

1. Remove side bearing inner race.

   To prevent damage to bearing, engage puller jaws in groove.

   Tool number 

   A: ST3305S001 (J22888-20) 

   B: ST33061000(J8107-2) 

   CAUTION:

   • To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
   • If is not necessary to remove side bearing except it is replaced.
     Fig 5: Engaging Puller Jaws In Groove

     Courtesy of NISSAN MOTOR CO., U.S.A.
   • Be careful not to confuse left-hand and right-hand parts. Keep bearing and bearing race for each side together.
     Fig 6: Identifying Bearings (LH And RH)

     Courtesy of NISSAN MOTOR CO., U.S.A.
2. Loosen drive gear mounting bolt in a crisscross fashion.
3. Tap drive gear off the differential case with a soft hammer.
   • Tap evenly all around to keep the drive gear from binding.
     Fig 7: Tapping Drive Gear Off Differential Case With A Soft Hammer

     Courtesy of NISSAN MOTOR CO., U.S.A.
4. Disassembly the differential case.
   1. Drive out the pinion mate shaft lock pin using punch.

      Tool number: KV31100300 (-) 

      Fig 8: Driving Out Pinion Mate Shaft Lock Pin Using Punch

      Courtesy of NISSAN MOTOR CO., U.S.A.
   2. Remove the pinion mate shaft.
      Fig 9: Removing Pinion Mate Shaft

      Courtesy of NISSAN MOTOR CO., U.S.A.
   3. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from the differential case.
      Fig 10: Turning Pinion Mate Gear

      Courtesy of NISSAN MOTOR CO., U.S.A.
   4. Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft and thrust washers.
      Fig 11: Identifying Differential Case, Side Gears, Pinion Mate Gears, Pinion Mate Shaft And Thrust Washers

      Courtesy of NISSAN MOTOR CO., U.S.A.

Inspection 

• Clean up the disassemble parts. Then, inspect if the parts are wear or damaged. If so, follow the measures below.
  INSPECTING MEASURES OF CONTENT
  
  

  Content	Measures
  Drive gear and drive pinion	If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as necessary. If the gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new gears.
  Bearing	If found any chipped (by friction), pitted, worn, rusted, scratched mark, or unusual noise from the bearing, replace with new bearing assembly (as a new set).
  Side gear and pinion mate gear	Replace with a new one if found any cracks or damage on the surface of the tooth. Replace with a new one if found any worn or chipped mark on the contact sides of the thrust washer.
  Side gear thrust washer and pinion mate thrust washer	Replace with a new one if found that it is chipped (by friction), damaged, or unusual worn.
  Oil seal	Oil seals must be replaced with a new one whenever disassembled.
  Differential case	Replace with a new one if found any wear or cracks on the contact sides of the differential case.
  Companion flange	Replace with a new one if found any chipped marks (about 0.10 mm, 0.0038 in) or other damage on the contact sides of the lip of the companion flange.