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Disassembly and Assembly: Assembly

  1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.
  2. Install side gear thrust washers and side gears into differential case.
    Fig 1: Installing Side Gear Thrust Washers & Side Gears Into Differential Case
    G02886349Courtesy of NISSAN MOTOR CO., U.S.A.
  3. While rotating pinion mate thrust washers and pinion mate gears, aligning them diagonally, install them into differential case.
  4. Insert pinion mate shaft into differential case.
    CAUTION: Be sure not to damage pinion mate thrust washers.
    Fig 2: Inserting Pinion Mate Shaft Into Differential Case
    G02886350Courtesy of NISSAN MOTOR CO., U.S.A.
  5. Measure end play of side gears using the procedure below, then select a side gear thrust washer.
    1. Upright the differential case so that its side gear to be measured face upward.
    2. Place final drive adapter and dial indicator onto side gears.
      Fig 3: Placing Final Drive Adapter & Dial Indicator Onto Side Gears
      G02886351Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Move side gears up and down to measure end play, and select thrust washer so that it satisfies standard.

      End play standard : 0.1 - 0.2 mm (0.004 - 0.008 in) 

      CAUTION:
      • There should be no resistance with the gears rotating freely.
      • Place differential case upside down. Be sure to measure end play for opposite side-gears likewise.
        Fig 4: Placing Differential Case Upside Down
        G02886352Courtesy of NISSAN MOTOR CO., U.S.A.

        Thrust washer 

        THRUST WASHER THICKNESS SPECIFICATION

        Thickness Part number
        0.75 mm (0.0295 in) 38424 81X00
        0.80 mm (0.0315 in) 38424 81X01
        0.85 mm (0.0335 in) 38424 81X02
        0.90 mm (0.0354 in) 38424 81X03
        0.95 mm (0.0374 in) 38424 81X04
        CAUTION: Only one thrust washer can be selected.
  6. Drive a new lock pin into the pinion mate shaft using Tool (pin punch).
    CAUTION: Do not reuse the lock pin.
    Fig 5: Driving A Lock Pin Into Pinion Mate Shaft Using Tool
    G02886353Courtesy of NISSAN MOTOR CO., U.S.A.
  7. Install differential side bearing (transaxle case side) using Tool (drift).
    Fig 6: Installing Differential Side Bearing (Transaxle Case Side) Using Tool
    G02886354Courtesy of NISSAN MOTOR CO., U.S.A.
  8. Align and install speedometer drive gear onto differential case.
    Fig 7: Installing Speedometer Drive Gear Onto Differential Case
    G02886355Courtesy of NISSAN MOTOR CO., U.S.A.
  9. Install differential side bearing (clutch housing side) using Tool (drift).
    Fig 8: Installing Differential Side Bearing (Clutch Housing Side) Using Tool
    G02886356Courtesy of NISSAN MOTOR CO., U.S.A.
  10. Install differential gear into differential case, and tighten final gear bolts.

    Final gear bolts : Refer to "FINAL DRIVE COMPONENTS ".

    Fig 9: Installing Differential Gear Into Differential Case
    G02886357Courtesy of NISSAN MOTOR CO., U.S.A.
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