ADJUSTMENT (Model R200)
Contents
1. 00004 in against a standard measurement 5 To zero dial indicator rotate arbor and plunger back and forth and note highest deflection the point where needle changes direction Set dial indicator at zero Head number H SPD542 SPO540 PD 16 ADJUSTMENT Model R200 Drive Pinion Height Cont d Drive Pinion Preload 8 Calculate washer thickness following the chart 1 To determine pinion bearing preload disas below semble pinion height bearing preload tools and measure thickness of lead washer This ts the correct size pinion bearing adjusting washer required If a lead washer is not available use a piece of thick roll solder to obtain preload washer size H factor from drive pinion Step 7 H factor sign O PLUS SIGN line 5 SUBTRACT line 4 from 3 Enter difference on line 6 N MINUS SIGN line 5 ADD lines 3 S and 4 Enter sum on line 6 MJ i Washer size Ore Example Dial Indicator Reading O3mm SPD543 Number on Pinion Head 2 2 Select the proper washer Refer to S D S 3 00 standard measure e If you cannot find shims with the desired 03 indicator reading thickness use shims so that the total thickness 33 Pinion head is plus so you is the closest to the calculated value 0 02 SUBTRACT it e Sometimes the correct dimension cannot be set 3 28 mm total pinion washer you with washers alone In these cases washers may will need be used in combination2. A mi det p gt WA Ex Too Biz SS Mb A PD179 Too number ST30031000 J22912 01 SPD529 Tool number ST33051001 ST33061000 J8107 2 Be careful not to confuse the right and left hand parts SPD022 PD 11 DISASSEMBLY Model R200 Differential Case Cont d 2 Loosen ring gear bolts in a criss cross fashion 3 Tap ring gear off the gear case with a soft hammer Tap evenly all around to keep ring gear from binding SPD024 4 Punch off pinion mate shaft lock pin from ring gear side Lock pin ts calked at pin hole mouth on differen tial case SP D025 PD 12 INSPECTION Model R200 Ring Gear and Drive Pinion Bearing Check gear teeth for scoring cracking or chipping 1 Thoroughly clean bearing and dry with com If any damaged part is evident replace ring gear pressed air and drive pinion as a set hypoid gear set 2 Check bearings for wear scratches pitching or flaking Check tapered roller bearing for a burned out portion as shown in the figure below If dam aged replace outer and inner races as a set Differential Case Assembly _ _ Check mating surfaces of differential case side gears pinion mate gears pinion mate shaft thrust block and thrust washers Particular point tube checked SPD458 SPD584 PD 13 ADJUSTMENT Model R200 To avoid any confusion while calculating bearing shims tt is absolutely necessary
3. Engine stand 1 STO5011000 Engine stand 2 ST05012000 Base ST3090S000 Drive pinion rear Inner race puller set 1 T30031000 J22912 01 Puller 2 ST30901000 Base ST33065001 Diff side bearing puller set D ST33051001 Body 2 ST33061000 J8107 2 Adapter SPECIAL SERVICE TOOLS Tool number Kent Moore No Tool name ST30611000 J25742 1 Drift Tool T306 13000 J25742 3 Drift ST30621000 Drift KV38100200 Gear carrier side o seal drift KV38100500 Gear carrier front oil seal drift ST33290001 J25810 A Side bearing outer race puller KV38100300 J25523 Diff side bearing drift KV38100401 Pilot bearing drift KV38100600 J25267 Side bearing spacer drift HT72400000 Slide hammer Tool SPECIAL SERVICE TOOLS Tool number Tool number Kent Moore No Tool Kent Moore No Tool name Tool name T3127S000 See J25765 A Preload gauge D GG91030000 J25765 A Torque wrench 2 HT62940000 Socket adapter HT62900000 Socket adapter J8001 M Q Metric dial indicator set BIG J8001 6 dial indicator S esto only J25269 B Pinion height amp preload gauge set 1 J25269 23 Bolt amp nut J23597 1 Arbor Long plunger Use with J23597 1 J25269 25 Lead preload
4. Part No 38154 P6017 38154 P6018 38154 P6019 38154 P6020 38154 P6021 38154 P6022 38154 P6023 38154 P6024 38154 P6025 38154 P6026 38154 P6027 38154 P6028 38154 P6029 38154 P6030 38154 P6031 38154 P6032 38154 P6033 38154 P6034 38154 P6035 38154 P6036 38453 28500 38454 28500 Side bearing adjusting washer Differential Carrier Cont d Thickness mm in 2 00 0 0787 2 05 0 0807 2 10 0 0827 2 15 0 0846 2 20 0 0866 2 25 0 0886 2 30 0 0906 2 35 0 0925 2 40 0 0945 2 45 0 0965 2 50 0 0984 2 55 0 1004 2 60 0 1024 Part No 38453 N3100 38453 N3101 38453 N3102 38453 N3103 38453 N3104 38453 N3105 38453 N3106 38453 N3107 38453 N3108 38453 N3109 38453 N3110 38453 N3111 38453 N3112 Side gear thrust washer Thickness mm in 0 75 0 80 0 0295 0 0315 0 80 0 85 0 0315 0 0335 0 85 0 90 0 0335 0 0354 0 90 0 95 0 0354 0 0374 Part No 38424 N3100 38424 N3101 38424 N3102 38424 N3103 Drive pinion bearing preload adjusting washer Thickness mm lin 3 80 3 82 0 1496 0 1504 3 82 3 84 0 1504 0 1512 3 84 3 86 0 1512 0 1520 3 86 3 88 0 1520 0 1528 3 88 3 90 0 1528 0 1535 3 90 3 92 0 1535 0 1543 3 92 394 0 1543 0 1551 3 94 3 96 0 1551 0 1559 3 96 3 98 0 1559 0 1567 3 98 4 00 0 1567 0 1575 4 00 4 02 0 1575 0 1583 402 404 0 1583 0 1591 404 406 0 1591 0 1598 4 06 4 08 0 1598
5. 4 step gauge block J25407 1 8 Place weight block on side bearing Base plate J25407 2 9 Slide dial indicator on weight block O Weight block J25407 3 4 Set weight block 4 step gauge block 21 mm 0 83 in and dial indicator on base plate 5 Adjust dial indicator scale to zero SPD548 SPD546 6 Carefully slide 4 step gauge block and weight block out from under dial indicator 7 Lubricate side bearing and place side bearing on base plate PD 19 ADJUSTMENT Model R200 10 Turn weight block a few times to ensure that bearing is properly seated 11 Read dial indicator e Normal indication 0 10 0 30 mm 0 0039 0 0118 in e If the needle fluctuates erratically then bearing is either dirty or defective and should be cleaned or replaced SPD549 12 Measure both bearings in the same way and write the left side bearing measurement next to E and the right side bearing measurement next to F Side Bearing Preload Cont d 13 Calculate washer thickness following the charts below Left ring gear side OPERATION Left side standard number 2 05mm Enter A factor gear carrier BE Enter OD factor differential case Enter E factor left bearing SEN LINE 2 3 4 5 1L L L L S En rm 7 on C ng Th 4 may D m ec 2 m Z b e o 3 UT m re mp L 8L 9L Enter H factor s sign D PLUS SIGN Line
6. SL SUBTRACT Line 8L from 7L Enter difference on Line 10L MINUS SIGN Line SL ADD Lines 7L and BL Enter sum on Line 10L 10L Left side shim size T Enter H factor ring gear PD 20 ADJUSTMENT Model R200 Side Bearing Preload Cont d Right side The formulas are as follows T A C D E H 205 mm T B D F G H 1 95 mm OPERATION Right side standard number 195mm Enter B factor gear carrier mM Enter F factor right bearing Example Enter G factor R 200 only See Chart Below ADD Lines 1R 2R 3R and 4R Enter SUM Left Side T1 Right Side T2 Enter D factor differential case 7R SUBTRACT Line 6R from 5R Enter DIFFERENCE Enter H factor ring gear Line 8R from 7R Enter difference on line 10R Enter H factor s sign O PLUS SIGN Line 9R ADD Lines 7R and 8R Enter sum on Line 10H MINUS SIGN Line 9R SUBTRACT 214 The measurement for the shim pack on the left G FACTOR CALCULATION R200 ONLY G FACTOR CALCULATION R200 ONLY T1 should be 2 28 mm and for the right T2 2 14 mm To check the accuracy of your work in the previous step the side bearing shim measure ment should be figured with a Si SUBTRACT Line B from Line A and enter g Side Bearing Shim DIFFERENCE on Line 4R of right side of Calculator chart PD 21 ADJUSTMENT Model R200 Side Bearing Preload Cont d Follow the instructions for the
7. sample given below EXAMPLE CALCULATOR Left Side ature aa ale PI ra _ Red pi 9 E o Step 1 Move slide 1 to place C 3 in line with an arrow Step 2 Move slide 2 to place D 3 in line with C3 Step 3 Move slide 3 to place E 18 in line with H yes tee nese cl Washer O ei Siandard ol B 1D mm pe ple Washa 1e6 4 810 O41G x 4i eM Step 4 Read answer at left side arrow 2 28mm or close to 087 in SPD550 Right Side Step 1 Move slide 1 to place B 3 in line with an arrow Step 2 Move slide 2 to place G 7 in line with D 3 Step 3 Move slide 3 to place F 14 in line with H 2 red scale for right side Step 4 Read answer at right side arrow 2 14mm or closer to 086 in SPD551 14 Compare these answers with the answers on the previous page f both answers agree pro ceed to the next step 15 Select the proper washer Refer toS DS If you cannot find the desired thickness of washer use washer so that thickness is the closest to the calculated value PD 22 ADJUSTMENT Model R200 Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion Hypoid gear set which are not positioned properly may be noisy or have short life or both With a pattern check the most desirable contact for low noise level and long life can be assured 1 Thoroughly clean ring gear and drive pinion teeth 2 Sparingly apply a mixture of powdered ferric oxide and oil o
8. to stay with the metric system If you measure anything in inches the results MUST be converted to the metric system You can use a conversion chart or a calculator as illustrated 3 3 a 9 US METRIC CONVERTER _ think metric a 1 w ia ull ii sari Lal iim Y SPD531 _ Setting Up Each Tool Set up each tool rear pinion bearing and front pinion bearing before adjusting pinion height and drive pinion bearing preload 1 Install rear pinion beartng pilot into gauge plate and slide over hex head long bolt SPD532 Tool number Hex head long bolt J25269 23 Gauge plate J25269 1 Rear pinion bearing pilot J25269 2 2 Slide pinion rear bearing inner race bearing preload adapter and pinion bearing adjusting spacer over hex head long bolt Tool Pinton rear bearing inner race Pinion bearing adjusting spacer SPD533 Tool number Bearing preload adapter J25269 26 3 Install these parts into gear carrier 4 Stand front bearing pilot support on the bench with the appropriate side up and as semble front pinion bearing pilot front pinion bearing inner race and lead preload washer Ensure that all parts are seated OM Pinion front bearing inner race WAN SS SPD534 Tool number Lead preload washer J25269 25 Front pinion bearing pilot J25269 3 Front bearing pilot support J25269 29 PD 14 ADJUSTMENT Model R2
9. washers Pkg of 5 J25269 26 Bearing preload adapter J25269 29 Front bearing pilot support J25269 32 Instructions J25407 01 Side bearing measuring set consists of D J25407 1 4 step gauge block J25407 2 Base plate 3 J25407 3 Weight block wrench J25269 1 cs B J26099 A Gauge plate Differential shim organizer J25269 2 J26335 Rear pinion bearing pilot Differential filler pluq J25269 3 Front pinion bearing pilot J25269 44 Side bearing discs 2 Req d BL PD 33 Tool Courtesy Nissan 1777 North Central Expressway Richardson TX 75080 800 527 1909 NISSAN FACTORY SERVICE MANUAL CDROM END USER LICENSE AGREEMENT NOTICE TO USER THIS IS A CONTRACT BY PURCHASING AND USING THE SERVICE MANUAL ON CDROM YOU ACCEPT ALL THE TERMS AND CONDITIONS OF THIS AGREEMENT This End User License Agreement accompanies the Service Manual on CDROM product and related explanatory materials Please read this Agreement carefully By purchasing and using the Service Manual on CDROM you are implying that you have carefully read agree with and will adhere to the conditions set forth in this agreement If you do not wish to accept the terms of this End User Agreement please do not use the Service Manual on CDROM You will not be permitted to use the Service Manual on CDROM without consenting to this end user agreement Upon your acceptance of this
10. 0 1606 4 08 4 10 0 1606 0 1614 Part No 38125 61001 38126 61001 38127 61001 38128 61001 38129 61001 38130 61001 38131 61001 38132 61001 38133 61001 38134 61001 38135 61001 38136 61001 38137 61001 38138 61001 38139 61001 TIGHTENING TORQUE Drive pinion bearing preload adjusting spacer Length mm in 55 10 2 1693 55 40 2 1811 55 70 2 1929 56 00 2 2047 56 25 2 2146 Part No 38165 B4002 38165 B4003 38165 B4004 38165 61001 38166 61001 Type R200 Unit Nm kg m ft ib Final drive installation Drive shaft to rear axle VG30E without 39 49 4 5 29 36 turbo VG30E turbo 59 69 6 7 43 51 Rear cover to 88 118 90 120 65 87 mounting insulator Mounting insulator to body Bolt 29 39 3 4 22 29 Nut 59 78 6 8 43 58 Differential carrier to 59 78 6 8 43 58 suspension member Final drive assembly Drive pinion nut 186 294 19 30 137 217 Ring gear bolt using Locktite stud lock or equivalent VG30E without 69 78 70 80 51 58 turbo VG30E turbo 132 152 135 155 98 112 Side bearing cap bolt 88 98 90 100 65 72 Rear cover fixing bolt 16 24 16 24 12 17 Companion flange to 39 44 40 45 29 33 propeller shaft fixing bo t Filler and drain plug 59 98 6 10 43 72 PD 31 Tool number Kent Moore No Tool name T31520000 4 Drive pinion flange wrench KV38100800 Differential attachment Equivalent tool J25604 01 T0501S000 J26023
11. 00 Drive Pinion Height Setting Up Each Tool Cont d 5 Holding these parts together slide the as 1 Install two side bearing discs with arbor sembly over hex head long bolt into gear assembly Ensure that arbor turns freely carrier Install support nut Finger tighten the nut and ensure that all parts turn freely and are properly aligned SPD537 Tool number A Arbor assembly J23597 1 Side bearing disc J25269 4 SPD535 6 Tighten support nut carefully to correct pre load of 0 6 to 10 N m 6 to 10 kg cm 5 2 to 8 7 in Ib 2 Place side bearing discs with arbor assembly into differential carrier Lift spring loaded plunger and place it on the face of gauge plate Tool SPD536 Tool number J25765 A SPD538 PD 15 ADJUSTMENT Model R200 Drive Pinion Height Cont d 3 Install bearing caps 6 Rotate gauge plate until the plunger falls off 4 Install dial indicator and tighten hold down gauge plate and read dial indicator Read the clamp dial indicator diectly Repeat to ensure accuracy Spring loaded plunger Spring compressed loaded plunger o extended I GE BARI 7 UU NE Gauge plate NN rotated 180 PIA YP O R SPDS41 Tool number A Hold down clamp J8001 1 7 Read head number H on drive pinion head rclam 001 2 see elis a The figure for H is a dimensional variation in units ndicator tar of 0 01 mm
12. 0E turbo Final drive model R200 Ring gear pitch mm in 200 7 87 diameter Gear ratio 3 700 3 545 Number of teeth Ring gear Drive pinion 37 10 39 11 Oil capacity approx US pt Imp pt 1 3 2 3 4 2 1 4 Differential Carrier 75 2 95 TIGHTENING TORQUE Unit Nm kg m ft Ib Shaft to companion 39 44 40 45 29 33 flange boits SERVICE DATA Finat drive model R200 Drive pinion bearing preload Adjustin acer and washer adjusting method justing sp Drive pinion preload With front oil seal N m kg cm in Ib 113 172 115 175 100 15 2 Drive pinion preioad Without front oil seal N m kg cm in Ib 10 13 10 13 87 11 3 Total preload 123 230 N m kg em in Ib 125 235 109 20 4 Side bearing adjusting method Shim Backlash Drive pinion to ring gear 013 0 18 0 0051 0 0071 mm in Side gear to pinton mate gear Clearance between side gear to differential case mm in Less than 0 15 0 0059 Ring gear runout limit mm in O 05 0 0020 PD 30 SERVICE DATA AND SPECIFICATIONS S D S Pinion height adjusting washer Thickness mm in 3 09 0 1217 3 12 0 1228 3 15 0 1240 3 18 0 1252 3 21 0 1264 3 24 0 1276 3 27 0 1287 3 30 0 1299 333 0 1311 3 36 0 1323 3 39 0 1335 3 42 0 1346 3 45 0 1358 3 48 0 1370 3 51 0 1382 3 54 0 1394 3 57 0 1406 3 60 0 1417 3 63 0 1429 3 66 0 1441 0 05 O 0020 0 07 0 0028
13. Agreement Courtesy Nissan grants to you a nonexclusive license to use the Service Manual on CDROM provided that you agree to the following USE OF SOFTWARE You may install the contents of the CD on a hard disk or other storage device for personal use only Each Service Manual on CDROM comes with a single user license Under no circumstances should the contents of the Service Manual CDROM be placed on a server for purposes of distributing or allowing access to the material over a network COPYRIGHT AND TRADEMARK RIGHTS The Service Manual CDROM is owned by Courtesy Nissan and its structure and organization all graphics and coding are considered intellectual property of Courtesy Nissan The Service Manual on CDROM 1s also protected by United States Copyright Law and International Treaty provisions This Agreement does not grant you any intellectual property or resale rights to the Service Manual CDROM RESTRICTIONS You agree not to modify adapt translate reverse engineer decompile or disassemble the PDF file on the Service Manual CDROM The Service Manual on CDROM is licensed and distributed by Courtesy Nissan for single user utilization of its contents only Licensed users will be permitted to use the contents of the Service Manual CDROM for multimedia presentation to an audience from a single machine using a large display or projection device but the Service Manual CDROM may not otherwise be distributed sold to or made accessible to multipl
14. J8USEM Gunsnipe Buiig q epis 49USEM LIAS 4ayjyeosg Jayeds Buliseaq apis soeyins dij Bujjees o L 48 S9 0 ZL 0 6 SLL 88 O y ees io apis EB PD 4 ON VEHICLE SERVICE Model R200 Front Oil Seal Replacement 1 Remove propeller shaft 2 Loosen drive pinion nut Tool number ST31520000 3 Remove companion flange Tool number ST33290001 J25810 A SPD517 SPD518 SPD519 5 Apply multi purpose grease to cavity at sealing lips of oid seal Press front oil seal into carrier SPD520 Tool number KV38100500 6 Install companion flange and drive pinion nut 7 Install propeller shaft PD 5 ON VEHICLE SERVICE Model R200 Side Oil Seal Replacement Ring Gear to Drive Pinion Backlash_ 1 Remove drive shafts 1 Support carrier with a jack Refer to section RA 2 Remove rear cover 2 Remove oil seal 3 Check ring gear to drive pinion backlash with a dial indicator at several points If it is not within specifications adjust it after re moving final drive assembly SPD521 3 Apply multi purpose grease to cavity at sealing lips of oil seal Press fit oil seal into carrier SPD523 SPDS22 Tool number KV38100200 4 Install drive shafts PD 6 REMOVAL AND INSTALLATION Model R200 Removal Installation e Remove propeller shaft e Full final drive with recommended gear oil Refer to Propeller Shaft Refer to section Gl e Remove drive shaft
15. PROPELLER SHAFT amp DIFFERENTIAL CARRIER SECTION PD CONTENTS PROPELLER SHAFT PD 2 FINAL DRIVE Model R200 T PD 4 ON VEHICLE SERVICE Model R200 PD 5 REMOVAL AND INSTALLATION Model R200 I PD 7 DISASSEMBLY Model R200 TP PD 8 INSPECTION Mode R200 PD 13 ADJUSTMENT Model R200 PD 14 ASSEMBLY Model R200 PD 24 SERVICE DATA AND SPECIFICATIONS SDS PD 30 SPECIAL SERVICE TOOLS PD 32 PROPELLER SHAFT Companion flange 39 44Nm 40 45 kg m 29 33 ft lb Propeller shaft Sleeve yoke PD427 General Inspection e Inspect propeller shaft tube surface for dents or cracks If damaged replace propeller shaft assembly e f center bearing ss noisy or damaged replace center bearing PROPELLER SHAFT VIBRATION To check and correct an unbalanced propeller shaft proceed as follows 1 Remove undercoating and other foreign material which could upset shaft balance and SPD102 check shaft vibration by road test 2 If shaft vibration ts noted during road test disconnect propeller shaft at differential 3 Again check shaft vibration if vibration carrier companion flange rotate companion still persists replace propeller shaft assembly flange 180 degrees and reconnect propeller shaft PD 2 PROPELLER SHAFT Removal and Installation _ _____nspection e Put match marks on flanges and separate e Inspect propeller shaft runout f runout propeller shaft from differential c
16. arrier exceeds specifications replace propeller shaft assembly SPD106 SPD103 Runout limit 0 6 mm 0 024 in e Inspect journal axial play If the play exceeds specifications replace propeller shaft assembly e Draw out propeller shaft from transmission and plug up rear end of transmission rear extension housing Journal axial play 0 mm 0 in Transmission SPD359 PD 3 FINAL DRIVE Model R200 ary w ByyuwN i 1uajJea nba 40 4901 pn s 81114907 juabe 6U Y90J Bus pas nba si 3ueunsn py x pajgquiassesip uauM aoejdes sAemiy O SPD516 LZ LEL OE GL VEZ 981 o aBue j UOLUBJWO a3ejans dij Butjees o L x E95 po 30014 ETRE Buiig q yofId 1uoij 1e2eds Buileag lopd 1uoij3 Buiig q UOJ uoluid T 82561 DL 131n0 Jeuu ZLL 86 S SL SEL ZGL ZEL oqan 30 5A 885 15 08 0 Z 82 69 oqin INOYNM 30 9A onl 4 Qs op or rt Jaysem Buusnipe uiseag uciuld x J928ds Bunsnipe Burijeeq uolutd ae ro aL SS f 0 OL 0 6 E v d 86 88 si aseo Ee11u9J8441 Q 185 1026 saysem Bunsnipe 146194 uorulg x M A11p BUI uoiutd aug L L v Z L vE 9L o SU I A JBUSEM 15n4u JEL UOIUI JeaD 838u1 uoluld 909 Bulseag apis Buiueaq Je81 uOlutg fe ZL Eb 4e 86 GUIY sauu BILI OL 9 18A02 282 08 ie i H yap WS 86 6S D 1 n2419 OS Jea6 apis Leys m JBYSBA ISMIUI 1836 apis Cd ayeu Hemd y
17. bearing adjusting washer Refer to Adjustment 9 Install differential case assembly with side bearing outer races into gear carrier SPD559 Tool number KV38100600 J25267 SPD527 PD 27 ASSEMBLY Model R200 12 Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier SPD526 13 Apply multi purpose grease to cavity at sealing lips of oil seal Install side oil seal SENT Tool SPD560 Tool number KV38100200 Differential Carrier Cont d 14 Measure ring gear to drive pinion backlash with a dial indicator SPD513 Ring gear to drive pinion backlash 0 13 0 18 mm 0 0051 0 0071 in e If backlash is too small decrease thickness of right shim and increase thickness of left shim by the same amount If backlash is too great reverse the above pro cedure Never change the total amount of shims as it will change the bearing preload 15 Check total preload with Tool When checking preload turn drive pinion in both directions several times to set bearing rollers PO340 Tool number ST3127S000 See J25765 A Total preload 1 23 2 30 N m 12 5 23 5 kg cm 10 9 20 4 in Ib PD 28 ASSEMBLY Model R200 Differential Carrier Cont d e f preload is too great add the same amount of e if the backlash varies greatly when the runout shim to each side of the ring gear is within a specified range the e f preload is too small remove
18. e users NO WARRANTY The software is being delivered to you AS IS and Courtesy Nissan makes no warranty as to its use or performance COURTESY NISSAN DOES NOT AND CANNOT WARRANT THE PERFORMANCE OR RESULTS YOU MAY OBTAIN BY USING THE SERVICE MANUAL CDROM OR DOCUMENTATION NOR MAKES ANY WARRANTIES EXPRESS OR IMPLIED AS TO NONINFRINGEMENT OF THIRD PARTY RIGHTS MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE IN NO EVENT WILL COURTESY NISSAN BE LIABLE TO YOU FOR ANY CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES FOR ANY REASON Courtesy Nissan 1777 North Central Expressway Richardson TX 75080 800 527 1909 GOVERNING LAW AND GENERAL PROVISIONS This Agreement will be governed by the laws of the State of Texas USA excluding the application of its conflicts of law rules This Agreement will not be governed by the United Nations Convention on Contracts for the International Sale of Goods the application of which is expressly excluded If any part of this Agreement is found void and unenforceable it will not affect the validity of the balance of the Agreement which shall remain valid and enforceable according to its terms You agree that the Service Manual on CDROM will not be shipped transferred or exported into any country or used in any manner prohibited by the United States Export Administration act or any other export laws restrictions or regulations This Agreement shall automatically terminate upon failure by you to comply with it
19. figure below in differential carrier and install drive pinion with press and suitable tool Stop when drive T touches T n E ii N Suitable spacer I Il 7 YY Drive pinion Pinion bearing adjusting spacer Pinion bearing adjusting Qi m da oe ms Pac front bearing inner race Front pilot bearing spacer S Front pilot bearing SPD556 Differential Carrier Cont d 5 Apply multi purpose grease to cavity at sealing lips of oil seal Install front oil seal SPD557 Tool number KV38100500 6 Install companion flange and tighten pinion nut to specified torque Ascertain that threaded portion of drive pinion and pinion nut are free from oil or grease PD466 Tool number ST31520000 PD 26 ASSEMBLY Model R200 Differential Carrier Cont d 7 Turn drive pinion in both directions several 10 Insert left and right side bearing adjusting times and measure pinion bearing preload washers in place between side bearings and carrier 4 E A C we Too PD340 SPD558 Tool number T3127S000 See J25765 A 11 Drive in side bearing spacer with Tool Pinion bearing preload With front oil seal Side bearing 1 13 1 72 N m 11 5 17 5 kg cm 10 0 15 2 in Ib spacer When pinion bearing preload is outside the specifications replace pinion bearing adjusting washer and spacer with a different thickness 8 Select side
20. n mate shaft lock pin with a punch punch Make sure lock pin ss flush with case SPDO30 5 Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly JA TA gt gt SPD322 PD 24 ASSEMBLY Model R200 Differential Case Cont d Differential Carrier 6 Apply locking agent Locktite stud lock or 1 Press fit front and rear bearing outer races equivalent to contacting surfaces of ring gear with Tools and differential case then place differential case on ring gear Pinion rear bearing outer race ELA Ra Pinion front bearing outer race SPD600 x 7 Apply locking agent Locktite stud lock or equivalent to ring gear bolts and install them d m Tighten bolts in a criss cross fashion lightly tap ping bolt head with a hammer SPD555 8 Press fit side bearing inner races on differential Tool number case with Tool ST30611000 J25742 1 ST30621000 ST30613000 J25742 3 PD353 Tool number KV38100300 J25523 ST33061000 J8107 2 PD 25 ASSEMBLY Model R200 2 Select pinion height adjusting washer and pinion bearing adjusting washer spacer refer ring to Adjustment 3 Install pinion height adjusting washer in drive pinion and press fit rear bearing inner race in it with press and Tool Press i Adiusting SPD377 Tool number ST30901000 4 Set drive pinion assembly as shown in
21. nt 3 Remove side bearing caps carrier on Tool PD343 sPD529 4 Using Tool lift differential case assembly Tool number KV38100800 J25604 1 out 2 Put match marks on one side of side bearing cap and gear carrier with paint or punch to en sure that it is replaced in proper position during reassembly Bearing caps are line board during manufacture and should be put back in their original places PD344 Tool number HT72400000 Be careful to keep the side bearing outer races together with inner race do not mix them up SPD526 SPD527 PD 9 DISASSEMBLY Model R200 Differential Carrier Cont d 7 Remove oil seal panion flange 8 Remove pilot bearing together with pilot bearing spacer and front bearing inner race with Tool 5 Loosen drive pinion nut and pull off com PD345 PD346 6 Take out drive pinion together with rear Posa bearing inner race bearing spacer and ad Tool number KV38100401 justing washer 9 Remove side oil seal 10 Remove pinion bearing outer races with a brass drift SPD528 PD349 PD 10 DISASSEMBLY Model R200 Differential Carrier Cont d Differential Case 11 Remove pinion rear bearing inner race and 1 Remove side bearing inner races pinion height adjusting washer To prevent damage to bearing engage puller paws with grooves lea pe A C rtm TE ci fy 2 QA iN di 3 ga
22. r equivalent to 3 or 4 teeth of ring gear drive side As lt M SV SPD357 Face contact Heel contact lt To correct increase thickness of pinion height adjusting washer in order to bring drive pinion close to ring gear Tooth Contact 3 Hold companion flange steady by hand and rotate the ring gear in both directions SPD308 Usually the pattern will be correct if you have calculated the shims correctly and the backlash Is correct However in extremely rare cases you will have to use trial and error processes until you get a good tooth contact pattern The tooth pattern is the best indication of how well a differential has been set up Toe contact Flank contact NON To correct reduce thickness of pinion height adjusting washer in order to make drive pinion go away from ring gear Correct tooth contact S AE LS le si SPD007 PD 23 ASSEMBLY Model R200 1 Install side gears pinion mate gears thrust washers and thrust block into differential case SPD552 2 Fit pinion mate shaft to differential case so that it meets lock pin holes gt la SPD553 3 Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer Refer to S DS SPD029 Differential Case Clearance between side gear thrust washer and differential case Less than 0 15 mm 0 0059 in 4 Install pinio
23. s Refer to RA section e Pull off differential carrier backward to gether with Jack Oil level Filler opening SPD348 SPD511 CAUTION e Be careful not to damage spline and sleeve yoke when removing propeller shaft e After carrier assembly ts removed support suspension member on a stand to prevent its insulators being twisted or damaged PD 7 DISASSEMBLY Model R200 Before disassembling final drive perform the following inspection e Total preload 1 Turn drive pinion in both directions several times to set bearing rollers 2 Check total preload with Tool PD245 Tool number ST3127S000 See J25765 A Total preload 1 23 2 30 N m 12 5 23 5 kg cm 10 9 20 4 in Ib e Ring gear to drive pinion backlash Check backlash of ring gear with a dial indi cator at several points SPD513 Ring gear to drive pinton backlash 0 13 0 18 mm 0 0051 0 0071 in Pre inspection e Ring gear runout Check runout of ring gear with a dial indi cator SPD524 Runout limit 0 05 mm 0 0020 in e Tooth contact Check tooth contact referring to Adjustment e Side gear to pinion mate gear backlash Measure clearance between side gear thrust washer and differential case with thickness gauge SPD370 Clearance between side gear thrust washer and differential case Less than 0 15 mm 0 0059 in PD 8 DISASSEMBLY Model R200 Differential Carrier 1 Using three spacers 45 mm 1 77 in mou
24. s terms This Agreement may only be modified in writing signed by and authorized officer for Courtesy Nissan Courtesy Nissan 1777 North Central Expressway Richardson TX 75080 USA YOUR ACCEPTANCE OF THE FOREGOING AGREEMENT IS IMPLIED UPON PURCHASING AND USING THE SERVICE MANUAL CDROM
25. the same hypoid gear set or differential case should be amount of shim to each side replaced Never add or remove a different number of shims 18 Check tooth contact for each side as it will change ring gear to drive Refer to Adjustment pinion backlash 19 Install rear cover and gasket SPD561 16 Recheck ring gear to drive pinion backlash because increase or decrease in thickness of shims wil cause change of ring gear to pinion backlash 17 Check runout of ring gear with a dial indicator SPD524 Runout limit 0 05 mm 0 0020 in e f backlash varies excessively in different places the variance may have resulted from foreign matter caught between the ring gear and the differential case PD 29 SERVICE DATA AND SPECIFICATIONS S D S GENERAL SPECIFICATIONS 2 seater Apphed model VG30E without turbo M T AIT Propeller shaft model Number of joints Coupling method with transmission Distance between yokes Type of journal bearing Propeller Shaft Unit mm in 2 2 seater VG30E turbo VG30E without turbo VG30E turbo 2871A 2 Sleeve type 71 2 80 Shell type non disassembly type Shaft length Spider to spider 665 26 18 1685 26 97 665 26 18 685 26 97 1865 34 06 885 34 84 885 34 84 Shaft outer diameter SERVICE DATA Un t mm in Model 2571A Propeller shaft runout limit 06 0 024 Journal axial play O 0 GENERAL SPECIFICATIONS VG30E Applied model VG3
26. with drive pinion bearing adjusting spacers Refer to S D S 9 Select the proper washer Refer to S D S If you cannot find the desired thickness of washer use washer so that thickness is the closest to the calculated value Example 3 28 mm Calculated total pinion washer in step 8 The correct washer is 3 27 mm Part number 38154 P6023 PD 17 ADJUSTMENT Model R200 1 To simplify the job make a chart like the one below to organize your calculations Cum Pon e emm sopes eoe H 2 or ring gear G Spacer measurement 2 Write the following numbers down in the chart A amp B Figures marked on gear carrier PD358 Side Bearing Preload C amp D Figures marked on differential case PD359 SPD576 G Thisis the difference n thickness of side spacer against standard width B 10 mm 0 3189 in G Standard spacer Measured spacer SPD544 PD 18 ADJUSTMENT Model R200 Side Bearing Preload Cont d 3 Measure how far under the standard thickness Make sure that base plate has a recess in it and 21 mm 083 in the side bearings are It that bearing will turn freely when positioned over will require the tools shown below the recess as shown Side bearing inner race Side bearing outer race 7 thickness A 3 J measurement A Recessed surface plate L SPD545 SPD547 Tool number amp
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