Adjusting And Selecting Washers

WARNING: This page is about a different car, the 2011 Nissan Xterra. However, it is still accessible from the selected car via links, so may be relevant.

Side Gear Back Clearance

Assemble the differential parts if they are disassembled. Refer to "DISASSEMBLY AND ASSEMBLY ".

Place the differential case straight up so that the side gear to be measured is upward.

Fig 1: Identifying Differential Center Line And Measuring Points
Using feeler gauges, measure the clearance between the side gear back and differential case at three different points, while rotating the side gear. Average the three readings to calculate the clearance. (Measure the clearance of the other side as well.)
Side gear back clearance: Refer to "INSPECTION AND ADJUSTMENT "
- If the side gear back clearance is outside of the specification, use a thicker or thinner side gear thrust washer to adjust. Refer to "INSPECTION AND ADJUSTMENT ".
  If the side gear back clearance is greater than specification:
  
  Use a thicker side gear thrust washer.
  
  If the side gear back clearance is less than specification:
  
  Use a thinner side gear thrust washer.
  
  Fig 2: Measuring Clearance Between Side Gear Back And Differential Case Using Feeler Gauge
  CAUTION:
  - Insert feeler gauges with the same thickness on both sides to prevent side gear from tilting.
  - Each gear should rotate smoothly without excessive resistance during differential motion.
  - Select a side gear thrust washer for right and left individually.
  NOTE: Side gear back clearance is clearance between side gear and differential case for adjusting side gear backlash.

Drive Pinion Height

Make sure all parts are clean and that the bearings are well lubricated.
Assemble the drive pinion bearings onto the Tool.
Tool number : - (J-34309)

Fig 3: Identifying Drive Pinion Gear Bearings Parts
- Drive pinion front bearing; make sure the J-34309-3 drive pinion front bearing seat is secured tightly against the J-34309-2 gauge anvil. Then turn the J-34309-7 drive pinion front bearing pilot to secure the drive pinon front bearing in its proper position.
- Drive pinion rear bearing; the J-34309-8 drive pinion rear bearing pilot is used to center the drive pinion rear bearing only. The J-34309-4 drive pinion rear bearing locking seat is used to lock the drive pinion rear bearing to the assembly.
- Installation of J-34309-9 and J-34309-16; place a suitable 2.5 mm (0.098 in) thick plain washer between J-34309-9 and J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must be parallel with a clearance of 2.5 mm (0.098 in).
  
  Fig 4: Identifying Drive Pinion Front And Rear Bearings
Install the drive pinion rear bearing inner race into the gear carrier. Then insert the drive pinion height adjusting washer selector tool, J-34309-1, gauge screw assembly.

Fig 5: Installing Drive Pinion Rear Bearing Inner Race Onto Gear Carrier
Assemble the drive pinion front bearing inner race and the J-34309-2 gauge anvil. Assemble them together with the J-34309- 1 gauge screw in the gear carrier. Make sure that the drive pinion height gauge plate, J-34309-16, will turn a full 360°. Tighten the two sections together by hand.

Fig 6: Installing Drive Pinion Front Bearing Inner Race
Turn the assembly several times to seat the drive pinon bearings.

Fig 7: Turning Assembly For Seating Drive Pinon Bearings
Measure the turning torque at the end of the J-34309-2 gauge anvil using Tool.
Tool number : ST3127S000 (J-25765- A)

Turning torque specification:

1.0 - 1.6 N.m (0.11 - 0.16 kg-m, 9 - 14 in-lb)

Fig 8: Measuring Turning Torque
Place the J-34309-10 "R180A" drive pinion height adapter onto the gauge plate and tighten it by hand.
CAUTION: Make sure all machined surfaces are clean.

Fig 9: Identifying Pinion Height Adapter
Position the side bearing discs, Tool, and arbor firmly into the side bearing bores. Install the side bearing caps and tighten the side bearing cap bolts to the specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ".
Tool number : - (J-25269-18)

Fig 10: Identifying Side Bearing Discs
Select the correct standard drive pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 in) and your J-34309-101 feeler gauge. Measure the distance between the J-34309-10 drive pinion height adapter, including the standard gauge and the arbor.

Fig 11: Identifying Drive Pinion Height Adjusting Washer
Write down the exact measurement (the value of feeler gauge).

Fig 12: Identifying Exact Pinion Height Adjusting Washer Thickness

Correct the drive pinion height adjusting washer size by referring to the drive pinion "head number".

There are two numbers painted on the drive pinion. The first one refers to the drive pinion and drive gear as a matched set. This number should be the same as the number on the drive gear. The second number is the drive pinion "head number". It refers to the ideal drive pinion height from standard for quietest operation. Use the following chart to determine the correct drive pinion height adjusting washer.

Fig 13: Identifying Drive Pinion Head Number

STANDARD DRIVE PINION HEIGHT ADJUSTING WASHER THICKNESS MEASUREMENT

Head number	Add or remove from the standard drive pinion height adjusting washer thickness measurement
- 6 Add	0.06 mm (0.0024 in)
- 5 Add	0.05 mm (0.0020 in)
- 4 Add	0.04 mm (0.0016 in)
- 3 Add	0.03 mm (0.0012 in)
- 2 Add	0.02 mm (0.0008 in)
- 1 Add	0.01 mm (0.0004 in)
0	Use the selected washer thickness
+1	Subtract 0.01 mm (0.0004 in)
+2	Subtract 0.02 mm (0.0008 in)
+3	Subtract 0.03 mm (0.0012 in)
+4	Subtract 0.04 mm (0.0016 in)
+5	Subtract 0.05 mm (0.0020 in)
+6	Subtract 0.06 mm (0.0024 in)

Select the correct drive pinion height adjusting washer. Refer to "INSPECTION AND ADJUSTMENT ".
Remove the Tool from the gear carrier and disassemble to retrieve the drive pinion bearings.
Tool number : - (J-34309)

Fig 14: Removing Tool From Gear Carrier