Qashqai J11. Driveline – part 4

DLN-26

< ECU DIAGNOSIS INFORMATION >

[TRANSFER: TY21C]

4WD CONTROL UNIT

Protection Function

INFOID:0000000010755243

4WD system activates its protection function (shuts down 4WD system temporarily) if 4WD system detects
high load continuously or the front wheel tire size differs from the rear tire size. (4WD system is automatically
restored if 4WD system no longer detects any overload or the tire size difference is eliminated.)

NOTE:
• If the 4WD warning displays during driving but remains not displayed after the engine is restarted, the syste-

mis normal. If it again displays after driving for some time, vehicle must be inspected.

• When there is a difference of revolution speed between the front and rear wheel the shift occasionally

changes to direct 4-wheel driving conditions automatically. This is not a malfunction.

DTC Inspection Priority Chart

INFOID:0000000010755244

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.

DTC Index

INFOID:0000000010755245

•C1203
•C1210
•P1808

•P181D

•U1000
•U1010

4WD control changes to front-wheel drive gradually (rear-wheels still have some driving torque),
then 4WD control stops, and the vehicle becomes front-wheel drive.

•P181B

No impact to vehicle behavior.

DTC

Vehicle condition

DTC

4WD warning (on infor-

mation display)

Error area and root cause

Contents of protection

function

—

Refer to

DLN-18, “IN-

FORMATION DISPLAY

(COMBINATION

METER) : 4WD Warn-

ing”

.

Rear final drive assembly in protection mode. It is not malfunction.
(Internal temperature rise of electronic controlled coupling)

Shuts down 4WD sys-

tem temporarily

(Front wheel drive)

—

Malfunction in each tire or different tire diameter

Priority

Detected items (DTC)

1

• C1201 CONTROLLER FAILURE

2

• U1000 CAN COMM CIRCUIT
• U1010 CONTROL UNIT (CAN)

3

• C1203 ABS SYSTEM
• C1210 ENGINE SIGNAL 1
• P1808 VHCL SPEED SEN-ABS
• P181D ENGINE SYSTEM

4

• P1809 CONTROL UNIT

5

• C1204 4WD SOLENOID
• P1811 BATTERY VOLTAGE

6

• C1209 MODE SW

7

• P1804 CONTROL UNIT

8

• P181B INCOMP SELFSHUT
• P181F INCOMP CALIBRATION

DTC

Display Item

Reference

C1201

CONTROLLER FAILURE

DLN-38, “DTC Description”

C1203

ABS SYSTEM

DLN-39, “DTC Description”

C1204

4WD SOLENOID

DLN-40, “DTC Description”

4WD CONTROL UNIT

DLN-27

< ECU DIAGNOSIS INFORMATION >

[TRANSFER: TY21C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

NOTE:
If some DTCs are displayed at the same time, refer to

DLN-26, “DTC Inspection Priority Chart”

.

C1209

MODE SW

DLN-43, “DTC Description”

C1210

ENGINE SIGNAL 1

DLN-46, “DTC Description”

P1804

CONTROL UNIT

DLN-47, “DTC Description”

P1808

VHCL SPEED SEN-ABS

DLN-48, “DTC Description”

P1809

CONTROL UNIT

DLN-49, “DTC Description”

P1811

BATTERY VOLTAGE

DLN-50, “DTC Description”

P181B

INCOMP SELF SHUT

DLN-53, “DTC Description”

P181D

ENGINE SYSTEM

DLN-56, “DTC Description”

P181F

INCOMP CALIBRATION

DLN-57, “DTC Description”

U1000

CAN COMM CIRCUIT

DLN-58, “DTC Description”

U1010

CONTROL UNIT (CAN)

DLN-59, “DTC Description”

DTC

Display Item

Reference

DLN-26

< ECU DIAGNOSIS INFORMATION >

[TRANSFER: TY21C]

4WD CONTROL UNIT

Protection Function

INFOID:0000000010755243

4WD system activates its protection function (shuts down 4WD system temporarily) if 4WD system detects
high load continuously or the front wheel tire size differs from the rear tire size. (4WD system is automatically
restored if 4WD system no longer detects any overload or the tire size difference is eliminated.)

NOTE:
• If the 4WD warning displays during driving but remains not displayed after the engine is restarted, the syste-

mis normal. If it again displays after driving for some time, vehicle must be inspected.

• When there is a difference of revolution speed between the front and rear wheel the shift occasionally

changes to direct 4-wheel driving conditions automatically. This is not a malfunction.

DTC Inspection Priority Chart

INFOID:0000000010755244

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.

DTC Index

INFOID:0000000010755245

•C1203
•C1210
•P1808

•P181D

•U1000
•U1010

4WD control changes to front-wheel drive gradually (rear-wheels still have some driving torque),
then 4WD control stops, and the vehicle becomes front-wheel drive.

•P181B

No impact to vehicle behavior.

DTC

Vehicle condition

DTC

4WD warning (on infor-

mation display)

Error area and root cause

Contents of protection

function

—

Refer to

DLN-18, “IN-

FORMATION DISPLAY

(COMBINATION

METER) : 4WD Warn-

ing”

.

Rear final drive assembly in protection mode. It is not malfunction.
(Internal temperature rise of electronic controlled coupling)

Shuts down 4WD sys-

tem temporarily

(Front wheel drive)

—

Malfunction in each tire or different tire diameter

Priority

Detected items (DTC)

1

• C1201 CONTROLLER FAILURE

2

• U1000 CAN COMM CIRCUIT
• U1010 CONTROL UNIT (CAN)

3

• C1203 ABS SYSTEM
• C1210 ENGINE SIGNAL 1
• P1808 VHCL SPEED SEN-ABS
• P181D ENGINE SYSTEM

4

• P1809 CONTROL UNIT

5

• C1204 4WD SOLENOID
• P1811 BATTERY VOLTAGE

6

• C1209 MODE SW

7

• P1804 CONTROL UNIT

8

• P181B INCOMP SELFSHUT
• P181F INCOMP CALIBRATION

DTC

Display Item

Reference

C1201

CONTROLLER FAILURE

DLN-38, “DTC Description”

C1203

ABS SYSTEM

DLN-39, “DTC Description”

C1204

4WD SOLENOID

DLN-40, “DTC Description”

4WD CONTROL UNIT

DLN-27

< ECU DIAGNOSIS INFORMATION >

[TRANSFER: TY21C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

NOTE:
If some DTCs are displayed at the same time, refer to

DLN-26, “DTC Inspection Priority Chart”

.

C1209

MODE SW

DLN-43, “DTC Description”

C1210

ENGINE SIGNAL 1

DLN-46, “DTC Description”

P1804

CONTROL UNIT

DLN-47, “DTC Description”

P1808

VHCL SPEED SEN-ABS

DLN-48, “DTC Description”

P1809

CONTROL UNIT

DLN-49, “DTC Description”

P1811

BATTERY VOLTAGE

DLN-50, “DTC Description”

P181B

INCOMP SELF SHUT

DLN-53, “DTC Description”

P181D

ENGINE SYSTEM

DLN-56, “DTC Description”

P181F

INCOMP CALIBRATION

DLN-57, “DTC Description”

U1000

CAN COMM CIRCUIT

DLN-58, “DTC Description”

U1010

CONTROL UNIT (CAN)

DLN-59, “DTC Description”

DTC

Display Item

Reference

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

DLN-69

< SYMPTOM DIAGNOSIS >

[TRANSFER: TY21C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

INFOID:0000000010755295

Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec-
essary, repair or replace these parts.

Reference

DLN-7

0

, “Ins

pe

c

tio

n”

—

DLN-78, “Exploded

V

iew”

DLN-78, “Exploded

V

iew”

DLN-8

5

, “Ins

pe

c

tio

n”

,

DLN-93

, “I

ns

pe

ct

ion

“

DLN-8

5

, “Ins

pe

c

tio

n”

,

DLN-93

, “I

ns

pe

ct

ion

“

SUSPECTED PARTS
(Possible cause)

T

R

ANSFER OIL (Level

low)

T

R

ANSFER OIL (W

rong)

T

R

ANSFER OIL (Level

too high)

LI

QUI

D

GASKET

(Dam

ag

ed

)

O-RING (W

o

rn o

r da

m

age

d)

OIL

SEA

L (W

o

rn o

r da

m

age

d)

GEAR

(W

orn

o

r

da

ma

ge

d)

B

EARING (W

orn

or

da

ma

ge

d)

Symptom

Noise

1

2

3

3

3

Transfer oil leakage

3

1

2

2

2

DLN-70

< PERIODIC MAINTENANCE >

[TRANSFER: TY21C]

TRANSFER OIL

PERIODIC MAINTENANCE

TRANSFER OIL

Inspection

INFOID:0000000010590215

OIL LEAKS

Check that oil is not leaking from transfer assembly or around it.

OIL LEVEL

CAUTION:

Do not start engine while checking oil level.

1.

Remove filler plug (1).

2.

Oil level (A) should be level with bottom of filler plug hole. Add
oil if necessary. Refer to

MA-59, “Fluids and Lubricants”

.

3.

Clean threads of filler plug (1) and transfer case.

4.

Apply sealant to the threads of the filler plug (1) and install it.
Tighten to specified torque. Refer to

DLN-76, “Exploded View”

.

Use Genuine Silicone RTV Sealant or equivalent. Refer to

MA-59, “Fluids and Lubricants”

.

Draining

INFOID:0000000010590216

CAUTION:

Do not start engine while checking oil level.

1.

Run the vehicle to warm up the transfer unit sufficiently.

2.

Stop the engine and remove drain plug (1) and drain the transfer
oil.

3.

Clean threads of drain plug (1) and transfer case.

4.

Apply sealant to the threads of the drain plug (1) and install it.
Tighten to specified torque. Refer to

DLN-76, “Exploded View”

.

Use Genuine Silicone RTV Sealant or equivalent. Refer to

MA-59, “Fluids and Lubricants”

.

Refilling

INFOID:0000000010590217

CAUTION:

Do not start engine while checking oil level.

1.

Remove filler plug (1).

2.

Fill with new oil to the specified level (A) near the filler plug hole.

3.

Clean threads of filler plug (1) and transfer case.

4.

Apply sealant to the threads of the filler plug (1), and install it. Tighten to specified torque. Refer to

DLN-

76, “Exploded View”

.

: Front

ALDIA0383ZZ

: Front

ALDIA0382ZZ

: Front

Oil grade and viscosity

: Refer to

MA-59, “Fluids

and Lubricants”

.

Oil capacity

: Refer to

MA-59, “Fluids

and Lubricants”

.

ALDIA0383ZZ

DLN-74

< REMOVAL AND INSTALLATION >

[TRANSFER: TY21C]

TRANSFER COVER OIL SEAL

TRANSFER COVER OIL SEAL

Exploded View

INFOID:0000000010755221

MR20DD

QR25DE

NOTE:
• Replacement on vehicle may cause damage to transfer cover, and may cause a transfer oil leak.
• If transfer cover oil seal requires replacement, remove transfer assembly from the vehicle before replacing

transfer cover oil seal. Refer to

DLN-79, “Disassembly”

.

Removal and Installation

INFOID:0000000010755222

NOTE:

For QR25DE models only:

• Replacement on vehicle may cause damage to transfer cover, and may cause a transfer oil leak.
• If transfer cover oil seal requires replacement, remove transfer assembly from the vehicle before replacing

transfer cover oil seal. Refer to

DLN-79, “Disassembly”

.

REMOVAL

MR20DD

1.

Drain the transfer oil. Refer to

DLN-70, “Draining”

.

2.

Remove front drive shaft (right side). Refer to

FAX-22, “Exploded View (LH)”

.

CAUTION:

Oil may leak from the opening. Use cap and/or plug to prevent leakage.

3.

Remove transfer cover oil seal (outer/inner), using oil seal remover (commercial service tool).

CAUTION:

Never damage transfer cover.

INSTALLATION

MR20DD

Transfer assembly

Transfer cover oil seal (inner)

Transfer cover oil seal (outer)

Oil seal lip

: Always replace after every disassembly.

: Apply transfer oil.

: Apply multi-purpose grease.

JSDIA5360ZZ

TRANSFER ASSEMBLY

DLN-77

< UNIT REMOVAL AND INSTALLATION >

[TRANSFER: TY21C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

• When installing the transfer to the transaxle, install the mounting

bolts following the standard below, tighten bolts to the specified
torque. For each tightening torque, refer to

DLN-76, “Exploded

View”

.

CAUTION:

• Apply anti-corrosion oil to the thread and seat of mounting bolts.
• Never damage O-ring of transfer.

• For mounting bolts of transfer gusset, temporarily tightening the engine side bolt first. After this, tighten bolts

to the specified torque in the order from transfer side bolt to engine side bolt. For tightening torque, refer to

DLN-76, “Exploded View”

. (MR20DD)

• Perform inspection after installation. Refer to

DLN-77, “Inspection”

.

Inspection

INFOID:0000000010755193

INSPECTION AFTER INSTALLATION

When oil leaks while removing/installing transfer assembly, check oil level after the installation. Refer to

DLN-

70, “Inspection”

.

Bolt symbol

Quantity

4

2

Bolt length
“L” mm (in)

40 (1.57)

40 (1.57)

Insertion direction

Transfer to transaxle

Transaxle to transfer

JSDIA5355ZZ

DLN-80

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

TRANSFER COVER

Assembly

INFOID:0000000010755196

1.

Select the ring gear bearing adjusting shim (transfer cover side). Refer to

DLN-88, “Adjustment”

.

2.

Install the selected ring gear bearing adjusting shim (transfer
cover side)

and ring gear bearing outer race (transfer cover

side)

using suitable tool.

CAUTION:

• Never reuse ring gear bearing.
• Apply transfer oil to the ring gear bearing.

3.

Install gasket onto drain plug and install them to transfer cover.

CAUTION:

Never reuse gasket.

4.

Install the transfer cover to the transfer case, and apply anti-cor-
rosive oil onto thread and seats on the mounting bolts. Then
tighten mounting bolts to the specified torque.

NOTE:
At this timing, O-ring installing to transfer cover is not necessary.
Install O-ring after tooth contact is checked.

5.

Check backlash, tooth contact, total preload and companion
flange runout. Refer to

DLN-88, “Adjustment”

.

CAUTION:

Measure the total preload without oil seals of transfer cover and transfer case.

6.

Remove transfer cover to install O-ring.

7.

Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the transfer cover.

CAUTION:

• Never reuse O-ring.
• When installing O-ring, never use a suitable tool.
• Never damage O-ring.

8.

Install the transfer cover to the transfer case, and apply anti-cor-
rosive oil onto thread and seats on the mounting bolts. Then
tighten mounting bolts to the specified torque.

9.

Using drift (commercial service tool), install transfer cover oil
seal (outer/inner) with the directions below.

CAUTION:

• When checking the total preload torque, measure it with-

out the oil seal, then install the oil seal.

JSDIA3992ZZ

A

: M10 bolt

B

: M8 bolt

A

: M10 bolt

B

: M8 bolt

AWDIA1140ZZ

AWDIA1140ZZ

A

: Installation dimension for transfer cover oil seal (inner)

B

: Installation dimension for transfer cover oil seal (outer)

A

: 10.3 0.6/-0 mm (0.406 0.024/-0 in)

B

: 0 0.6/-0 mm (0 0.024/-0 in)

JSDIA3993ZZ

RING GEAR SHAFT

DLN-85

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

7.

Install the ring gear bearing inner race (transfer case side) to
ring gear shaft with suitable tool (A).

CAUTION:

• Never reuse ring gear bearing.
• Apply transfer oil to the ring gear bearing.

8.

Install the ring gear shaft assembly to the transfer case.

CAUTION:

Protect transfer case oil seals beforehand from being dam-
aged by the spline of ring gear shaft below method follow-
ing.

a.

Apply multi-purpose grease to spline part indicated in the figure.

b.

Wrap piece of vinyl to spline part only indicated in the figure.
[(A): limit line]

CAUTION:

Never wrap sliding surfaces on oil seal.

9.

Install transfer cover to check and adjust each part. Refer to

DLN-80, “Assembly”

.

NOTE:
At this timing, O-ring installing to transfer cover is not necessary.
Install O-ring after backlash and tooth contact are checked.

10. Check backlash, tooth contact, total preload and companion

flange runout. Refer to

DLN-88, “Adjustment”

.

CAUTION:

Measure the total preload without oil seals of transfer cover and transfer case.

11. Reinstall transfer cover for installing O-ring. Refer to

DLN-80, “Assembly”

.

12. After installing transfer case oil seals, remove wrapped vinyl from the spline of ring gear shaft.

Inspection

INFOID:0000000010755201

INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones.

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.

CAUTION:

If malfunction is detected on the ring gear or drive pinion, replace the ring gear and drive pinion as a
set.

Bearing

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.

CAUTION:

When replacing the bearing, always replace the inner race and outer race as a pair.

Shim

Check for seizure, damage, and unusual wear.

JSDIA1055ZZ

JSDIA4195ZZ

JSDIA4196ZZ

DLN-88

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

DRIVE PINION

4.

Install oil seal to pinion bearing assembly using suitable tool (A).

CAUTION:

• Never reuse the oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and transfer

oil onto the circumference of the oil seal.

5.

Install dust cover.
NOTE:
Tighten dust cover together with pinion bearing assembly.

6.

Install companion flange

to pinion bearing using suitable tool

(A).

7.

Apply anti-corrosive oil to the thread and seat of the lock nut,
and adjust the pinion lock nut tightening torque and pinion bear-
ing preload torque, using a preload gauge.

a.

Install pinion lock nut, and then tighten to the specified torque.

CAUTION:

• Never reuse pinion lock nut.
• Check that pinion lock nut is seated on the companion flange.

b.

After tightening pinion lock nut to the specified torque, retighten the pinion lock nut by 25 degrees.

c.

Measure the pinion bearing preload.

8.

Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion bearing assembly.

CAUTION:

• Never reuse O-ring.
• When installing O-ring, never use a suitable tool.
• Never damage O-ring.

9.

Install drive pinion assembly, and apply anti-corrosive oil onto
thread and seats on the mounting bolts. Tighten to the specified
torque.
NOTE:
Tighten dust cover together with pinion bearing assembly.

10. Check backlash, tooth contact, total preload and companion

flange runout. Refer to

DLN-88, “Adjustment”

.

CAUTION:

Measure the total preload without oil seals of transfer cover
and transfer case.

Adjustment

INFOID:0000000010755205

ADJUSTING SHIM SELECTION

JSDIA3996ZZ

Pinion lock nut
tightening torque

: 90

±

9 N·m (9.2

±

0.92kg-m, 66

±

7 ft-lb)

Pinion bearing preload

: Refer to

DLN-97, “Preload Torque”

.

JSDIA3997ZZ

JSDIA3951ZZ

DLN-90

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

DRIVE PINION

• Check dimension (M) on the ring gear side face.

NOTE:
Dimension “M” indicates the difference between the optimum
engagement and standard dimensions in increments of 0.01 mm
(0.0004 in) written on the ring gear side face.

• Check dimension (O) on the gear end of drive pinion.

NOTE:
Dimension “O” indicates the difference between the optimum
engagement and the standard dimensions in increments of 0.01
mm (0.0004 in) written on the gear end of drive pinion.

PINION BEARING PRELOAD

CAUTION:

When measuring preload, the rotating speed must be set to 30 rpm.
1.

Remove ring gear shaft assembly from the transfer case. Refer to

DLN-83, “Disassembly”

.

2.

Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking,
and so on.

3.

Rotate the companion flange at least 20 times to check for smooth operation of the bearing.

4.

Measure the pinion bearing preload using Tool (A).

CAUTION:

Each rotational part should rotate smoothly with the speci-
fied transfer oil.
• If outside the standard, disassemble the drive pinion assembly

to check and adjust each part.

TOTAL PRELOAD

CAUTION:

When measuring preload, the rotating speed must be set to 30 rpm.
1.

Measure pinion bearing preload.

CAUTION:

Check that the pinion bearing preload is within the standard.

2.

Assemble the ring gear shaft assembly to the transfer case. Refer to

DLN-84, “Assembly”

3.

Install transfer cover to check and adjust each part. Refer to

DLN-80, “Assembly”

.

4.

Rotate the companion flange at least 20 times to check for smooth operation of the bearing.

JSDIA2495ZZ

JSDIA2496ZZ

Pinion bearing preload

: Refer to

DLN-97, “Preload

Torque”

.

Tool number

: ST3127S000

JSDIA2500ZZ

DRIVE PINION

DLN-91

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

5.

Measure the total preload using Tool (A).

CAUTION:

Each rotational part should rotate smoothly with the speci-
fied transfer oil.
• If outside the standard, disassemble the transfer assembly to

check and adjust each part. Measure it with the transfer case
oil seal and transfer cover oil seal removed when measuring
total preload after disassembly. Then install transfer case oil seals and transfer cover oil seal.

BACKLASH

1.

Install the bolt to the companion flange.

2.

Fit a dial indicator onto the bolt

.

3.

Measure the circumference backlash of the companion flange.

• If outside the standard, disassemble the transfer assembly to

check and adjust each part.

TOOTH CONTACT

1.

Remove transfer cover. Refer to

DLN-79, “Disassembly”

.

2.

Remove ring gear shaft assembly from transfer case. Refer to

DLN-83, “Disassembly”

.

3.

Apply red lead onto the ring gear.

CAUTION:

Apply red lead to both faces of 3 to 4 gears at 4 locations
evenly spaced on the ring gear.

4.

Assemble the ring gear shaft assembly to the transfer case.
Refer to

DLN-84, “Assembly”

.

5.

Install transfer cover to check and adjust each part. Refer to

DLN-80, “Assembly”

.

NOTE:
At this timing, O-ring installing to transfer cover is not necessary.
Install O-ring after backlash and tooth contact are checked.

6.

Remove the plug from the transfer case.

7.

Rotate the companion flange back and forth several times, and check the drive pinion gear to ring gear
tooth contact by viewing from the plug hole.

Total preload

: Refer to

DLN-97, “Preload

Torque”

.

Tool number

: ST3127S000

JSDIA2500ZZ

Backlash

: Refer to

DLN-97, “Backlash”

.

JSDIA2501ZZ

JSDIA2188ZZ

DRIVE PINION

DLN-93

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

• Thin the drive pinion adjusting shim to move the drive pinion

farther from the ring gear in case of flank contact or toe con-
tact.

CAUTION:

Only one adjusting shim can be selected.

COMPANION FLANGE RUNOUT

1.

Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).

2.

Rotate the companion flange to check for runout.

3.

Fit suitable tool to the inner side of the companion flange (socket
diameter).

4.

Rotate the companion flange to check for runout.

5.

Follow the procedure below to adjust if runout value is outside
the repair limit.

a.

Check for runout while changing the phase between companion
flange and drive pinion in 90

°

steps. Then search for the mini-

mum point.

b.

Replace companion flange if runout value is still outside the limit
after the phase has been changed.

c.

Adjust assembly status of the pinion bearing and drive pinion, or
replace pinion bearing assembly if runout is outside the standard
after the companion flange is replaced.

Inspection

INFOID:0000000010755206

INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones.

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.

CAUTION:

Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring
gear or drive pinion.

Bearing

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.

Shim

Check for seizure, damage, and unusual wear.

PDIA0441E

Companion flange runout

: Refer to

DLN-97, “Com-

panion Flange Runout”

.

Companion flange runout

: Refer to

DLN-97, “Com-

panion Flange Runout”

.

JSDIA3981ZZ

DLN-96

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY21C]

TRANSFER CASE

2.

Install the selected ring gear bearing adjusting shim (transfer
case side) and ring gear bearing outer race (transfer case side)
using suitable tool (A).

CAUTION:

• Never reuse ring gear bearing.
• Apply transfer oil to the ring gear bearing.

3.

Install baffle plate

.

4.

Install ring gear shaft assembly. Refer to

DLN-84, “Assembly”

.

CAUTION:

Protect transfer case oil seals beforehand from being dam-
aged by the spline of ring gear shaft.

5.

Install drive pinion assembly. Refer to

DLN-87, “Assembly”

.

6.

Install transfer cover to check and adjust each part. Refer to

DLN-80, “Assembly”

.

NOTE:
At this timing, O-ring installing to transfer cover is not necessary.
Install O-ring after backlash and tooth contact are checked.

7.

Check backlash, tooth contact, total preload and companion flange runout. Refer to

DLN-88, “Adjust-

ment”

.

CAUTION:

Measure the total preload without oil seals of transfer cover and transfer case.

8.

Reinstall transfer cover for installing O-ring. Refer to

DLN-80, “Assembly”

.

9.

Install oil seals using suitable tool.

CAUTION:

• When checking the total preload torque, measure it with-

out the oil seal, then install the oil seal.

• Never reuse the oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and transfer

oil onto the circumference of the oil seal.

• Never damage oil seals by spline of ring gear shaft.

10. After installing oil seals to transfer case, remove wrapped vinyl from the spline of ring gear shaft.

11. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the transfer case.

CAUTION:

• Never reuse O-ring.
• When installing O-ring, never use a suitable tool.
• Never damage O-ring.

Inspection

INFOID:0000000010755210

INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones.

Case

Check the bearing mounting surface for wear, cracks and damages.

JSDIA3998ZZ

A

: 24.8 mm (0.976 in)

B

: 10.3 mm (0.406 in)

JSDIA3982ZZ

JSDIA4047ZZ

DLN-98

< PRECAUTION >

[TRANSFER: TY30A]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Precautions for Removing Battery Terminal

INFOID:0000000010508557

• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key

or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.

• When disconnecting the 12V battery terminal, turn off the ACC

power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.

• For vehicles with the 2-batteries, be sure to connect the main bat-

tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.

• After installing the 12V battery, always check “Self Diagnosis Result” of all ECUs and erase DTC.

NOTE:
The removal of 12V battery may cause a DTC detection error.

HOW TO DISCONNECT 12V BATTERY TERMINAL

Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.

INSTRUCTION 1

1.

Open the hood.

2.

Turn key switch to the OFF position with the driver side door opened.

3.

Get out of the vehicle and close the driver side door.

4.

Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.

CAUTION:

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

5.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)

1.

Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied.

2.

Open the driver side door.

3.

Open the hood.

4.

Close the driver side door.

5.

Wait at least 3 minutes.

SEF289H

D4D engine

: 20 minutes

HRA2DDT

: 12 minutes

K9K engine

: 4 minutes

M9R engine

: 4 minutes

R9M engine

: 4 minutes

V9X engine

: 4 minutes

PRECAUTIONS

DLN-99

< PRECAUTION >

[TRANSFER: TY30A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

CAUTION:

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

6.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

Precaution for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT
PRE-TENSIONER”

INFOID:0000000010505230

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.

WARNING:

Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in

the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.

• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal

injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.

• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-

vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the

ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.

• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the

battery, and wait at least 3 minutes before performing any service.

Precaution for Procedure without Cowl Top Cover

INFOID:0000000010505229

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.

Service Notice or Precautions for Transfer

INFOID:0000000010288327

CAUTION:

• After overhaul refill the transfer with new transfer oil.
• Check the oil level or replace the oil only with the vehicle parked on level surface.
• During removal or installation, keep inside of transfer clear of dust or dirt.
• Replace all tires at the same time. Always use tires of the proper size and the same brand and pat-

tern. Fitting improper size and unusual wear tires applies excessive force to vehicle mechanism and
can cause longitudinal vibration.

• Disassembly should be done in a clean work area.

PIIB3706J

DLN-100

< PRECAUTION >

[TRANSFER: TY30A]

PRECAUTIONS

• Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the

internal parts from becoming contaminated by dirt or other foreign matter.

• Check for the correct installation status prior to removal or disassembly. If matching marks are

required, be certain they do not interfere with the function of the parts when applied.

• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspec-

tion or reassembly.

• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace

them with a new one if necessary.

• Gaskets, seals, O-rings and lock nuts should be replaced any time when the transfer is disassem-

bled.

• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to out-

side. If tightening sequence is specified, use it.

• Observe the specified torque when assembling.
• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.
• Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could

interfere with the operation of the transfer.

DLN-108

< SYSTEM DESCRIPTION >

[TRANSFER: TY30A]

AWD SYSTEM

Component Parts Location

INFOID:0000000010288265

Component Description

INFOID:0000000010288266

1.

Combination meter

2.

Steering angle sensor

3.

ABS actuator and electric control unit

4.

ECM

5.

AWD lock switch

6.

AWD control unit

7.

Electric controled coupling

8.

AWD solenoid

A.

Instrument lower panel LH

B.

Rear wheel house outer panel in lug-
gage room of teh left side

C.

Rear final drive assembly

E1DIA0342ZZ

Component parts

Reference/Function

AWD control unit

DLN-111, “Description”

Wheel sensors

BRC-9, “Wheel Sensor and Sensor Rotor”

AWD solenoid

DLN-113, “Description”

Electric controlled coupling

Transmits driving force to rear final drive.

AWD warning lamp

DLN-126, “Description”

AWD indicator lamp

DLN-127, “Description”

LOCK indicator lamp

DLN-128, “Description”

AWD mode switch

DLN-116, “Description”

ABS actuator and electric unit (control unit)

DLN-112, “Description”

ECM

DLN-119, “Description”

Combination meter

DLN-127, “Description”

AWD SYSTEM SYMPTOMS

DLN-143

< SYMPTOM DIAGNOSIS >

[TRANSFER: TY30A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

SYMPTOM DIAGNOSIS

AWD SYSTEM SYMPTOMS

Symptom Table

INFOID:0000000010288311

If AWD warning lamp turns ON, perform self-diagnosis.

NOTE:

Light tight-corner braking symptom may occur depending on driving conditions. This is not malfunction.

Symptom

Condition

Check item

Reference

AWD warning lamp does not turn ON when
the ignition switch is turned to ON.
(AWD warning lamp check)

Ignition switch: ON

Power supply and ground for AWD con-
trol unit

DLN-144, “De-

scription”

CAN communication line

AWD control unit

Combination meter

AWD warning lamp does not turn OFF sev-
eral seconds after engine started.

Engine running

AWD control unit self-diagnosis

DLN-145, “De-

scription”

AWD warning lamp

Power supply and ground for AWD con-
trol unit

Heavy tight-corner braking symptom occurs
when the vehicle is driven and the steering
wheel is turned fully to either side after the
engine is started. (See NOTE.)

• While driving
• Steering wheel is

turned fully to either
sides

ECM self-diagnosis

DLN-146, “De-

scription”

AWD control unit self-diagnosis

AWD solenoid

Mechanical malfunction of electric con-
trolled coupling (clutch sticking etc.)

Vehicle does not enter AWD mode even
though AWD warning lamp turned to OFF.

While driving

CAN communication line

DLN-147, “De-

scription”

AWD solenoid

Mechanical malfunction of electric con-
trolled coupling (Mechanical engage-
ment of clutch is not possible.)

While driving, AWD warning lamp blinks
quickly. (When blinking in approx. 1 minute
and then turning OFF.)
Quick blinking: 2 times/second

While driving

Protection function is activated due to
heavy load to electric controlled cou-
pling. (AWD system is not malfunction-
ing. Also, optional distribution of torque
sometimes becomes rigid before lamp
blinks quickly, but it is not malfunction.)

DLN-148, “De-

scription”

While driving, AWD warning lamp blinks
slowly. (When continuing to blink until turn-
ing ignition switch OFF)
Slow blinking: 1 time/2 seconds

• While driving
• Vehicle speed: 20 km/h

(12 MPH) or more

Tire size is different between front and
rear of vehicle.

DLN-149, “De-

scription”

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

DLN-151

< SYMPTOM DIAGNOSIS >

[TRANSFER: TY30A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

INFOID:0000000010288324

M/T MODELS

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.

Reference

DL

N-15

2,

“In

s

p

e

c

tio

n”

DL

N-15

7,

“Ex

p

lo

de

d

V

iew”

DL

N-15

7,

“Ex

p

lo

de

d

V

iew”

DL

N-15

7,

“Ex

p

lo

de

d

V

iew”

D

L

N-1

6

3

, “I

ns

pe

ct

io

n

Af

te

r Di

sa

ss

em

bl

y”

D

L

N-1

6

3

, “I

ns

pe

ct

io

n

Af

te

r Di

sa

ss

em

bl

y”

SUSPECTED PARTS
(Possible cause)

TRANSF

ER OIL (Level l

o

w)

TRANSF

ER OIL (W

rong)

T

R

ANSFER OI

L (L

ev

el

to

o h

ig

h

)

LIQUID GASKET

(Damaged)

O-RING (W

orn

or

da

ma

ge

d)

OIL SEAL (W

orn or

damaged)

GEAR (W

o

rn o

r da

m

a

g

ed)

BEAR

ING

(W

orn

o

r

da

ma

ge

d)

Symptom

Noise

1

2

3

3

3

Transfer oil leakage

3

1

2

2

2

DLN-152

< PERIODIC MAINTENANCE >

[TRANSFER: TY30A]

TRANSFER OIL

PERIODIC MAINTENANCE

TRANSFER OIL

Inspection

INFOID:0000000010288332

OIL LEAKAGE

Check transfer surrounding area (oil seal, drain plug, filler plug, and transfer case, etc.) for oil leakage.

OIL LEVEL

1.

Remove filler plug (1) and gasket. Then check that oil is filled up
(A) from mounting hole for the filler plug.

2.

Before installing filler plug, set a new gasket. Install filler plug on
transfer and tighten to the specified torque. Refer to

DLN-157,

“Exploded View”

.

CAUTION:

Never reuse gaskets.

Draining

INFOID:0000000010288333

1.

Run the vehicle to warm up the transfer unit sufficiently.

2.

Stop the engine and remove drain plug (1) and gaskets to drain
the transfer oil.

CAUTION:

Never remove tooth contact test hole plug (2).

3.

Before installing drain plug, set a new gasket. Install drain plug
on transfer and tighten to the specified torque. Refer to

DLN-

157, “Exploded View”

.

CAUTION:

Never reuse gaskets.

Refilling

INFOID:0000000010288334

1.

Remove filler plug (1) and gasket. Then fill oil up to mounting
hole (A) for the filler plug.

CAUTION:

Carefully fill the oil. (Fill up for approximately 3 minutes.)

2.

Leave the vehicle for 3 minutes. Then check oil level again.

3.

Before installing filler plug, set a new gasket. Install filler plug on
transfer and tighten to the specified torque. Refer to

DLN-157, “Exploded View”

.

CAUTION:

Never reuse gasket.

SDIA3060J

SDIA3059J

Oil grade and viscosity

: Refer to

MA-59, “Fluids

and Lubricants”

.

Oil capacity

: Refer to

DLN-97, “General

Specifications”

.

SDIA3060J

RING GEAR SHAFT

DLN-163

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY30A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

8.

Apply anti-corrosive oil to threads and seats of ring gear nut.
Tighten the ring gear nut with the specified torque by using a
torque wrench.

CAUTION:

• Never reuse ring gear nut.
• Never damage ring gear shaft.

9.

Install inner race of ring gear shaft bearing (transfer case side)
to the ring gear shaft with a drift (A) (SST: KV10111400).

CAUTION:

• Never reuse ring gear shaft bearing (transfer case side).
• Apply gear oil to the ring gear shaft bearing (transfer race

side).

10. Assemble the ring gear shaft assembly to the transfer case.
11. Install adapter case. Refer to

DLN-158, “Assembly”

.

12. Check backlash, tooth contact, total preload and companion

flange runout. Refer to

DLN-167, “Adjustment”

.

CAUTION:

Measure the total preload without the adapter case oil seal.

13. Install adapter case oil seal (outer/inner) to the adapter case. Refer to

DLN-158, “Assembly”

.

Inspection After Disassembly

INFOID:0000000010288358

Check items below. If necessary, replace them with new ones.

GEAR AND SHAFT

Check gear face and shaft for wear, cracks, damage, and seizure.

CAUTION:

Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring
gear or drive pinion.

BEARING

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.

CAUTION:

Always replace inner race and outer race as a pair when replacing the bearing.

SHIM

Check for seizure, damage, and unusual wear.

CASE

Check the bearing mounting surface for wear, cracks and damages.

SDIA3100J

JSDIA0254ZZ

DRIVE PINION

DLN-167

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY30A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

8.

Tap the companion flange with a plastic hammer as far as the
lock nut can be tightened.

CAUTION:

Never damage drive pinion oil seal.

9.

Apply anti-corrosive oil to the thread and seat of the lock nut,
and temporarily tighten lock nut to the drive pinion.

CAUTION:

Never reuse lock nut.

10. Tighten lock nut within the specified torque range with a preload

gauge (A) (SST: ST3127S000) so that the drive pinion bearing
preload is within standard.

CAUTION:

• Start the tightening of lock nut from lower limit of the

specified torque. Check the preload every 5

°

to 10

°

while

tightening the lock nut.

• Replace the collapsible spacer and tighten it again to adjust if preload exceeds the specified

value. Never loosen lock nut to adjust preload.

• After adjustment, rotate the drive pinion back and forth from 2 to 3 times to check for unusual

noise, sticking, binding, and so on.

11. Install ring gear shaft assembly. Refer to

DLN-162, “Assembly”

.

12. Install adapter case. Refer to

DLN-158, “Assembly”

.

13. Check backlash, tooth contact, total preload and companion flange runout. Refer to

DLN-167, “Adjust-

ment”

.

CAUTION:

Measure the total preload without the adapter case oil seal.

Adjustment

INFOID:0000000010288366

BACKLASH

1.

Install the bolt (A) to the companion flange.

2.

Fit a dial indicator onto the bolt.

3.

Measure the circumference backlash of the companion flange.

Disassemble the transfer assembly to check and adjust each
part if outside the standard.

TOOTH CONTACT

1.

Remove adapter case. Refer to

DLN-158, “Disassembly”

.

SDIA3095J

Standard

Drive pinion bearing preload

: Refer to

DLN-180, “Pre-

load Torque”

.

SDIA3072J

Standard

Backlash

: Refer to

DLN-180, “Backlash”

.

JSDIA0321ZZ

DRIVE PINION

DLN-169

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY30A]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

7.

Follow the procedure below to adjust pinion height (dimension
X) if tooth contact is improper.

CAUTION:

If no adjusting shim with the calculated value is available,
select the thicker and closest one.

• Thicken the drive pinion adjusting shim to move the drive pin-

ion closer to the ring gear in case of face contact or heel con-
tact.

CAUTION:

Only one adjusting shim can be selected.

• Thin the drive pinion adjusting shim to move the drive pinion

farther from the ring gear in case of flank contact or toe con-
tact.

CAUTION:

Only one adjusting shim can be selected.

8.

Assemble the plug to the transfer case.

CAUTION:

• Remove old gasket on mounting surface, then remove

any moisture, oil, and foreign material on the application
and mounting surfaces.

• Apply liquid gasket to the thread, and tighten to the speci-

fied torque when installing plug.

DRIVE PINION BEARING PRELOAD

1.

Remove adapter case. Refer to

DLN-158, “Disassembly”

.

2.

Remove ring gear shaft assembly from the transfer case.

3.

Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking,
and so on.

4.

Rotate the companion flange at least 20 times to check for smooth operation of the bearing.

5.

Measure the drive pinion bearing preload with a preload gauge
(A) (SST: ST3127S000).

CAUTION:

Each rotational part should rotate smoothly with the speci-
fied gear oil.
• Disassemble the drive pinion assembly to check and adjust

each part if outside the standard.

TOTAL PRELOAD

1.

Measure drive pinion bearing preload (P

1

). Refer to “DRIVE PINION BEARING PRELOAD”.

SDIA3158J

PDIA0440E

PDIA0441E

Standard

Drive pinion bearing preload

: Refer to

DLN-180, “Pre-

load Torque”

.

SDIA3072J

DLN-176

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY30A]

DRIVE PINION

CAUTION:

• Only one adjusting shim can be selected.
• Select the closest one, if no adjusting shim with the calculated value is available.

Inspection After Disassembly

INFOID:0000000010288367

Check items below. If necessary, replace them with new ones.

GEAR AND SHAFT

Check gear face and shaft for wear, cracks, damage, and seizure.

CAUTION:

Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring
gear or drive pinion.

BEARING

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.

CAUTION:

Always replace inner race and outer race as a pair when replacing the bearing.

SHIM

Check for seizure, damage, and unusual wear.

CASE

Check the bearing mounting surface for wear, cracks and damages.

DLN-178

< UNIT DISASSEMBLY AND ASSEMBLY >

[TRANSFER: TY30A]

TRANSFER CASE

Disassembly

INFOID:0000000010288374

1.

Remove adapter case. Refer to

DLN-158, “Disassembly”

.

2.

Remove ring gear shaft assembly. Refer to

DLN-161, “Disassembly”

.

3.

Remove drive pinion assembly. Refer to

DLN-165, “Disassembly”

.

4.

Tap the outer race of drive pinion bearing from transfer case with
a brass rod to remove outer race of drive pinion bearing (front
side and rear side).

CAUTION:

Never damage transfer case.

5.

Remove air breather hose from transfer case.

CAUTION:

Never damage air breather hose.

6.

Remove air breather tube from transfer case.

7.

Remove the filler plug and drain plug from the transfer case, and
then remove each gasket.

8.

Remove plug from transfer case.

Assembly

INFOID:0000000010288375

1.

Install outer race of drive pinion bearing (front side) to the trans-
fer case with drifts and bushing remover.

CAUTION:

• Never reuse drive pinion bearing (front side).
• Apply gear oil to the drive pinion bearing (front side)

2.

Install outer race of drive pinion bearing (rear side) to transfer
case with a drift (A) (SST: ST33230000).

CAUTION:

• Never reuse drive pinion bearing (rear side).
• Apply gear oil to the drive pinion bearing (rear side).

3.

Install drive pinion assembly. Refer to

DLN-166, “Assembly”

.

4.

Install ring gear shaft assembly. Refer to

DLN-162, “Assembly”

.

5.

Install adapter case. Refer to

DLN-158, “Assembly”

.

: Apply Genuine Liquid Gasket, Three Bond 1215 or equivalent.

Refer to

GI-4, “Components”

for symbols not described on the above.

SDIA3088J

A : Drift (commercial service tool)

B : Drift (SST: ST35272000)

C : Bushing remover (SST: ST38280000)

SDIA3091J

SDIA3092J

PRECAUTIONS

DLN-181

< PRECAUTION >

[REAR PROPELLER SHAFT: C-CVJ-C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

PRECAUTION

PRECAUTIONS

Precautions for Removing Battery Terminal

INFOID:0000000010763741

• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key

or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.

• When disconnecting the 12V battery terminal, turn off the ACC

power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.

• For vehicles with the 2-batteries, be sure to connect the main bat-

tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.

• After installing the 12V battery, always check “Self Diagnosis Result” of all ECUs and erase DTC.

NOTE:
The removal of 12V battery may cause a DTC detection error.

HOW TO DISCONNECT 12V BATTERY TERMINAL

Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.

INSTRUCTION 1

1.

Open the hood.

2.

Turn key switch to the OFF position with the driver side door opened.

3.

Get out of the vehicle and close the driver side door.

4.

Wait at least 3 minutes.

CAUTION:

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

5.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)

1.

Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied.

2.

Open the driver side door.

3.

Open the hood.

4.

Close the driver side door.

5.

Wait at least 3 minutes.

CAUTION:

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

6.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

Service Notice or Precautions for Propeller Shaft

INFOID:0000000010763742

• Replace the propeller shaft assembly if there is a breakage or deflection on tube.

SEF289H

DLN-184

< SYMPTOM DIAGNOSIS >

[REAR PROPELLER SHAFT: C-CVJ-C]

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

INFOID:0000000010763744

Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.

×

: Applicable

Reference

DL

N-18

5,

“I

ns

pe

ct

io

n”

DL

N-18

6,

“Exp

lo

de

d V

ie

w

“

DL

N-18

5,

“I

ns

pe

ct

io

n”

DL

N-18

9,

“I

ns

pe

ct

io

n”

DL

N-18

5,

“I

ns

pe

ct

io

n”

DL

N-18

5,

“I

ns

pe

ct

io

n”

DL

N-18

5,

“I

ns

pe

ct

io

n”

NVH of REAR FINAL

DR

IVE in this section.

NVH in F

AX, RAX

, FS

U,

an

d RS

U

se

ct

ion

.

NVH in WT

se

ct

io

n.

NVH in WT

se

ct

io

n.

NVH in F

AX and RAX section.

NVH in BR section.

NVH in ST

section.

Possible cause and SUSPECTED PARTS

Un

ev

en

rot

a

ti

ng

to

rq

ue

Ce

nt

e

r be

ari

n

g

im

pro

p

e

r

in

st

al

la

ti

on

Exc

e

s

s

ive

c

e

n

ter

be

arin

g

ax

ia

l e

n

d

pl

ay

Ce

nt

e

r be

ari

n

g

mou

n

ti

n

g

(in

s

u

lat

or) c

rack

s

, da

ma

ge

or de

te

ri

ora

tio

n

Ex

ce

ssi

v

e

jo

in

t an

gl

e

Ro

ta

ti

on

i

m

ba

la

nc

e

Ex

ce

ssi

v

e

run

o

u

t

DIFFERENTIAL

AXLE

AND SUSPE

N

S

ION

TIRE

ROA

D

WHEEL

DR

IVE SHAF

T

BRAKE

STEERING

Symptom

Noise

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Shake

×

×

×

×

×

×

×

×

Vibration

×

×

×

×

×

×

×

×

×

×

×

REAR PROPELLER SHAFT

DLN-185

< PERIODIC MAINTENANCE >

[REAR PROPELLER SHAFT: C-CVJ-C]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

PERIODIC MAINTENANCE

REAR PROPELLER SHAFT

Inspection

INFOID:0000000010763745

LOOSENESS OF CONNECTED PART

Check each fixing bolt and nut for looseness using torque wrench. For each tightening torque, refer to

DLN-

186, “Exploded View”

.

BACKLASH OF JOINT PART

Move the joint of propeller shaft up and down and from side to side
(axial direction of shaft and right angle to shaft) to check that the joint
has no backlash. If the joint has a malfunction, remove propeller
shaft and perform inspection.

BACKLASH OF CENTER BEARING

Move the shaft near center bearing up and down and from side to
side (axial direction of shaft and right angle to shaft) to check that the
bearing has no backlash. If the bearing has a malfunction, remove
propeller shaft and perform inspection.

APPEARANCE AND NOISE

• Check the propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft

assembly.

• If center bearing is noisy or damaged, replace propeller shaft assembly.

VIBRATION

If vibration is present at high speed, adjust the propeller shaft phase first.
1.

Check the propeller shaft for bend and damage. If damaged, replace propeller shaft assembly.

2.

Perform a cruise test drive to check the propeller shaft for runout. If vibration occurs, separate propeller
shaft at final drive companion flange; then change the phase between electric controlled coupling stud bolt
and propeller shaft by the one bolt hole at a time and install propeller shaft.

3.

If vibration is still detected, measure propeller shaft runout after removing it. Refer to

DLN-189, “Inspec-

tion”

.

MAA0555D

MAA0005D

DLN-188

< REMOVAL AND INSTALLATION >

[REAR PROPELLER SHAFT: C-CVJ-C]

REAR PROPELLER SHAFT

8.

Remove propeller shaft assembly fixing nuts, and separate pro-
peller shaft assembly from electric controlled coupling of final
drive.

9.

Remove center bearing mounting bracket mounting nuts.

10. Remove propeller shaft assembly.

11. Remove clips and then remove center bearing mounting bracket

(upper/lower).

12. Perform inspection after removal. Refer to

DLN-189, “Inspec-

tion”

.

INSTALLATION

Note the following, and install in the reverse order of removal.
• For non-reusable parts, refer to

DLN-186, “Exploded View”

.

• For each tightening torque, refer to

DLN-186, “Exploded View”

.

• After removing propeller shaft, replace stud bolts on electric controlled coupling. Refer to

DLN-76, “Exploded

View”

.

• Remove any moisture, oil, or foreign material from matching surface on transfer companion flange, electric

controlled coupling and propeller shaft flange.

• Install center bearing mounting bracket (upper) with its arrow mark

facing forward.

• Adjust position of center bearing mounting bracket (upper)

, cen-

ter bearing mounting bracket (lower)

sliding back and forth to

prevent play in thrust direction of center bearing insulator

. Install

center bearing mounting bracket (upper/lower) to vehicle.

• Center bearing mounting bracket fixing nuts must be tightened in

the order from left to right.

JSDIA5330ZZ

JSDIA4492ZZ

JSDIA4491ZZ

JSDIA5331ZZ

DLN-192

< SYMPTOM DIAGNOSIS >

[REAR FINAL DRIVE: R145]

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

INFOID:0000000010288393

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×

: Applicable

Reference

DL

N-2

2

7

, “I

ns

pe

ct

ion

Af

ter Di

sa

ss

em

bl

y”

DLN

-22

4,

“Ad

just

m

en

t”

DL

N-2

2

7

, “I

ns

pe

ct

ion

Af

ter Di

sa

ss

em

bl

y”

DLN

-22

4,

“Ad

just

m

en

t”

DLN

-22

4,

“Ad

just

m

en

t”

DLN

-19

9,

“In

s

p

e

c

ti

o

n”

NVH in DLN section

NVH in F

AX,

RAX, FSU and

R

S

U sections

NVH in WT section

NVH in WT section

NVH i

n

F

AX and RAX

secti

o

n

NVH in B

R

section

NVH in S

T

section

Possible cause and SUSPECTED PARTS

Gea

r to

ot

h ro

ug

h

Ge

ar co

nt

a

c

t im

pro

p

e

r

T

o

o

th su

rfac

es

wo

rn

Ba

ck

la

sh

in

co

rrec

t

Com

p

ani

on

fl

an

ge

ex

ce

ss

iv

e

run

o

u

t

Ge

ar oi

l im

pro

p

e

r

PROPELLER S

H

AFT

AXLE AND S

U

S

PENSION

TI

RE

ROAD WHEE

L

DRIVE SHAFT

BRAKE

STE

E

RING

Symptom

Noise

×

×

×

×

×

×

×

×

×

×

×

×

×

PRECAUTIONS

DLN-193

< PRECAUTION >

[REAR FINAL DRIVE: R145]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

PRECAUTION

PRECAUTIONS

Service Notice or Precautions for Rear Final Drive

INFOID:0000000010288394

CAUTION:

• Check for the correct installation status prior to removal or disassembly. If matching marks are

required, be certain they do not interfere with the function of the parts when applied.

• Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
• Before disassembly, using steam or white gasoline, completely remove sand and mud from the exte-

rior of the unit, preventing them from entering into the unit during disassembly or assembly.

• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace

them with a new one if necessary.

• Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to out-

side. If tightening sequence is specified, observe it.

• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.
• When applying sealant, remove the old sealant from the mounting surface; then remove any mois-

ture, oil, and foreign materials from the application and mounting surfaces.

• Always use shop paper for cleaning the inside of components.
• Avoid using cotton gloves or shop rags to prevent entering of lint.
• During assembly, observe the specified tightening torque, and apply new gear oil, petroleum jelly, or

multi-purpose grease as specified for each vehicle, if necessary.

Precautions for Removing Battery Terminal

INFOID:0000000010508560

• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key

or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.

• When disconnecting the 12V battery terminal, turn off the ACC

power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.

• For vehicles with the 2-batteries, be sure to connect the main bat-

tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.

• After installing the 12V battery, always check “Self Diagnosis Result” of all ECUs and erase DTC.

NOTE:
The removal of 12V battery may cause a DTC detection error.

HOW TO DISCONNECT 12V BATTERY TERMINAL

Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.

INSTRUCTION 1

1.

Open the hood.

2.

Turn key switch to the OFF position with the driver side door opened.

3.

Get out of the vehicle and close the driver side door.

4.

Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.

SEF289H

D4D engine

: 20 minutes

HRA2DDT

: 12 minutes

DLN-194

< PRECAUTION >

[REAR FINAL DRIVE: R145]

PRECAUTIONS

CAUTION:

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

5.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)

1.

Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied.

2.

Open the driver side door.

3.

Open the hood.

4.

Close the driver side door.

5.

Wait at least 3 minutes.

CAUTION:

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

6.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

K9K engine

: 4 minutes

M9R engine

: 4 minutes

R9M engine

: 4 minutes

V9X engine

: 4 minutes

FRONT OIL SEAL

DLN-201

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: R145]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

3.

Remove companion flange lock nut, using a flange wrench
(commercial service tool). Then remove companion flange.

4.

Remove front oil seal from coupling cover, using a flat-bladed
screwdriver.

CAUTION:

Be careful not to damage coupling cover.

INSTALLATION

1.

Install front oil seal until it becomes flush with the coupling cover
end, using the drifts.

CAUTION:

• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

2.

Align the matching mark of electric controlled coupling with the
matching mark of companion flange, then install the companion
flange.

3.

Install companion flange lock nut with a flange wrench (commer-
cial service tool), tighten to the specified torque.

CAUTION:

Never reuse companion flange lock nut.

4.

Install rear propeller shaft. Refer to

DLN-186, “Exploded View”

.

5.

When oil leaks while removing, check oil level after the installa-
tion. Refer to

DLN-199, “Inspection”

.

JSDIA0199ZZ

JSDIA0200ZZ

A

: Drift (SST: KV38100200)

B

: Drift (SST: ST27861000)

PDIA0038E

PDIA0455E

DLN-202

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: R145]

SIDE OIL SEAL

SIDE OIL SEAL

Exploded View

INFOID:0000000010288403

Removal and Installation

INFOID:0000000010288404

REMOVAL

1.

Remove rear drive shafts. Refer to

RAX-14, “Exploded View”

.

2.

Remove side oil seals, using a flat-bladed screwdriver.

CAUTION:

Be careful not to damage gear carrier and rear cover.

INSTALLATION

1.

Install side oil seals until it becomes flush with the carrier end,
using the drift (A) (SST: KV38100200).

CAUTION:

• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

2.

Install rear drive shafts. Refer to

RAX-14, “Exploded View”

.

3.

When oil leaks while removing, check oil level after the installa-
tion. Refer to

DLN-199, “Inspection”

.

1.

Final drive assembly

2.

Side oil seal

A: Oil seal lip

: Vehicle front

: Apply gear oil.

Refer to

GI-4, “Components”

for symbols not described on the above.

JSDIA0232ZZ

PDIA0431E

JSDIA0201ZZ

ELECTRIC CONTROLLED COUPLING

DLN-205

< REMOVAL AND INSTALLATION >

[REAR FINAL DRIVE: R145]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

3.

Install electric controlled coupling to spline of drive pinion inside
gear carrier.

CAUTION:

• Align the pin on electric controlled coupling with the

groove of gear carrier.

• Be careful not to damage center oil seal.

4.

Set 4WD solenoid harness guide to gear carrier.

5.

Using the drifts, drive front oil seal until it becomes flush with the
coupling cover end.

CAUTION:

• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

6.

Apply liquid gasket to mating surface of coupling cover. Overlap
both ends of the bead for at least 3 mm (0.12 in).

CAUTION:

Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces.

7.

Install coupling cover to final drive assembly with arrow facing
upward, temporarily tighten reamer bolts to the positions shown
in the figure.

8.

Tighten reamer bolts and coupling cover mounting bolts to the
specified torque.

9.

Install electric controlled coupling breather hose to coupling
cover.

10. Install connector bracket, and tighten bolts to the specified

torque.

11. Connect 4WD solenoid harness connector.

12. Install companion flange.

NOTE:
When reusing electric controlled coupling, align the matching
mark of electric controlled coupling with the matching mark of
companion flange, then install companion flange.

13. Install companion flange lock nut with flange wrench (commer-

cial service tool), tighten to the specified torque.

CAUTION:

Never reuse companion flange lock nut.

14. Check companion flange runout. Refer to

DLN-212, “Adjust-

ment”

.

PDIA0463E

A

: Drift (SST: KV38100200)

B

: Drift (SST: ST27861000)

PDIA0449E

PDIA0613E

SDIA0587E

PDIA0455E

DLN-210

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R145]

ELECTRIC CONTROLLED COUPLING

Disassembly

INFOID:0000000010288410

1.

Remove connector bracket.

2.

Put matching mark on the thread edge of electric controlled cou-
pling. The matching mark should be in line with the matching
mark on companion flange.

CAUTION:

For matching mark, use paint. Never damage electric con-
trolled coupling.
NOTE:
When replacing electric controlled coupling, matching mark is
not necessary.

3.

Remove companion flange lock nut, using a flange wrench
(commercial service tool).

4.

Remove companion flange.

5.

Remove coupling cover.

6.

Remove front oil seal from coupling cover, using flat-bladed
screwdriver.

CAUTION:

Be careful not to damage coupling cover.

7.

Remove electric controlled coupling.

8.

Remove 4WD solenoid harness.

9.

Remove center oil seal from gear carrier.

Assembly

INFOID:0000000010288411

1.

Using the drift (A) (SST: ST35271000), install center oil seal (1)
as shown in the figure.

CAUTION:

• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

2.

Connect 4WD solenoid harness to electric controlled coupling.

: Apply Genuine Medium Strength Thread Locking Sealant, Three Bond 1322B or equivalent.

Refer to

GI-4, “Components”

for symbols not described on the above.

PDIA0455E

PDIA0442E

PDG0213D

Dimension “D”

: 0.8 – 1.2 mm (0.031 – 0.047 in)

JSDIA0260ZZ

ELECTRIC CONTROLLED COUPLING

DLN-211

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R145]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

3.

Install electric controlled coupling to spline of drive pinion inside
gear carrier.

CAUTION:

• Align the pin on electric controlled coupling with the

groove of gear carrier.

• Be careful not to damage center oil seal.

4.

Set 4WD solenoid harness guide to gear carrier.

5.

Using the drifts, drive front oil seal until it becomes flush with the
coupling cover end.

CAUTION:

• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

6.

Apply liquid gasket to mating surface of coupling cover. Overlap
both ends of the bead for at least 3 mm (0.12 in).

CAUTION:

Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces.

7.

Install coupling cover to gear carrier with arrow facing upward,
temporarily tighten reamer bolts to the positions shown in the
figure.

8.

Tighten reamer bolts and coupling cover mounting bolts to the
specified torque.

9.

Install connector bracket, and tighten bolts to the specified
torque.

10. Install companion flange.

NOTE:
When reusing electric controlled coupling, align the matching
mark of electric controlled coupling with the matching mark of
companion flange, then install companion flange.

11. Install companion flange lock nut with flange wrench (commer-

cial service tool), tighten to the specified torque.

CAUTION:

Never reuse companion flange lock nut.

12. Check companion flange runout. Refer to

DLN-212, “Adjust-

ment”

.

PDIA0463E

A

: Drift (SST: KV38100200)

B

: Drift (SST: ST27861000)

PDIA0449E

PDIA0613E

SDIA0587E

PDIA0455E

DLN-212

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R145]

ELECTRIC CONTROLLED COUPLING

Adjustment

INFOID:0000000010288412

COMPANION FLANGE RUNOUT

1.

Fit a dial indicator onto the companion flange face (inner side of
the rear propeller shaft mounting bolt holes).

2.

Rotate companion flange to check for runout.

3.

Fit a test indicator to the inner side of companion flange (socket
diameter).

4.

Rotate companion flange to check for runout.

5.

If the runout value is outside the runout limit, follow the procedure below to adjust.

a.

Check for runout while changing the phase between companion flange and drive pinion by 90

°

step, and

search for the position where the runout is the minimum.

b.

If the runout value is still outside of the limit after the phase has been changed, replace companion flange.

c.

If the runout value is still outside of the limit after companion flange has been replaced, possible cause will
be an assembly malfunction of drive pinion and electric controlled coupling, malfunctioning coupling bear-
ing, or malfunctioning of electric controlled coupling.

Inspection After Disassembly

INFOID:0000000010288413

Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.

Limit

Companion flange runout

: Refer to

DLN-229, “Com-

panion Flange Runout”

.

Limit

Companion flange runout

: Refer to

DLN-229, “Com-

panion Flange Runout”

.

PDIA0439E

Content

Conditions and Measures

Hypoid gear

• If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-

essary.

• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new

drive gear and drive pinion as a set.

Bearing

If any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).

Side gear and Pinion mate
gear

• If any cracks or damage on the surface of the tooth is found, replace.
• If any worn or chipped mark on the contact sides of the thrust washer is found, replace.

Side gear thrust washer and
pinion mate thrust washer

If it is chipped (by friction), damaged, or unusually worn, replace.

Differential case

If any wear or crack on the contact sides of the differential case is found, replace.

Companion flange

If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the com-
panion flange is found, replace.

DLN-218

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R145]

DIFFERENTIAL ASSEMBLY

12. Install dummy cover set, check and adjust drive gear runout, tooth contact, backlash, and total preload

torque. Refer to

DLN-224, “Adjustment”

.

13. Remove dummy cover set.

14. Apply liquid gasket to mating surface of rear cover. Overlap both

ends of the bead for at least 3 mm (0.12 in).

CAUTION:

Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces.

15. Set the drifts (commercial service tool) to the right and left side

bearing adjusting shims individually. Compress differential case
assembly and side bearing to install rear cover.

CAUTION:

• The drift shall be placed on the center of the adjusting

shims.

• The pressure shall be as low as possible to install the rear

cover. The maximum pressure shall be 10 kN (1 ton, 1.0
Imp ton).

• If rear cover is forced in by tapping, rear cover may be

damaged by adjusting shims. Avoid tapping.

16. Tighten rear cover mounting bolts to the specified torque.

17. Using the drift (SST: KV38100200), drive side oil seals until it

becomes flush with the carrier end.

CAUTION:

• Never reuse oil seals.
• When installing, do not incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil

onto the circumference of oil seal.

18. Check total preload torque. Refer to

DLN-224, “Adjustment”

.

Inspection After Disassembly

INFOID:0000000010288417

Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.

PDIA0447E

PDIA0065E

PDIA0448E

Content

Conditions and Measures

Hypoid gear

• If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-

essary.

• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new

drive gear and drive pinion as a set.

Bearing

If any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).

Side gear and Pinion mate
gear

• If any cracks or damage on the surface of the tooth is found, replace.
• If any worn or chipped mark on the contact sides of the thrust washer is found, replace.

Side gear thrust washer and
pinion mate thrust washer

If it is chipped (by friction), damaged, or unusually worn, replace.

Differential case

If any wear or crack on the contact sides of the differential case is found, replace.

Companion flange

If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the com-
panion flange is found, replace.

DRIVE PINION

DLN-221

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R145]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

Assembly

INFOID:0000000010288420

1.

Install a drive pinion adjusting shim of the same thickness as
was installed prior to disassembly. Press pinion rear bearing
outer race into gear carrier, using the suitable drift.

CAUTION:

• At first, using a hammer, tap bearing outer race until it

becomes flush to gear carrier.

• Never reuse pinion rear bearing outer race.

2.

Press pinion front bearing outer race into gear carrier, using the
drift (SST: 33230000).

CAUTION:

• At first, using a hammer, tap bearing outer race until it

becomes flush to gear carrier.

• Never reuse pinion front bearing outer race.

3.

Press pinion rear bearing inner race to drive pinion, using the
drift (SST: ST23860000).

CAUTION:

Never reuse pinion rear bearing inner race.

4.

After checking and adjusting the tooth contact and backlash of the hypoid gear following the procedure
below.

a.

Apply gear oil to the pinion rear bearing, and assemble the drive pinion to the gear carrier.

CAUTION:

Never assemble a collapsible spacer.

b.

Apply gear oil to pinion front bearing, and assemble pinion front
bearing inner race to drive pinion. Using the drifts and stand,
press pinion front bearing inner race to drive pinion as far as
drive pinion nut can be tightened.

CAUTION:

Never reuse pinion front bearing inner race.

c.

Temporarily tighten removed drive pinion nut to drive pinion.
NOTE:
Use removed drive pinion nut only for the preload measurement.

PDIA0898E

PDIA0067E

PDIA0068E

A

: Drift (SST: ST23860000)

B

: Drift (commercial service tool)

JPDID0012ZZ

DLN-222

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R145]

DRIVE PINION

d.

Fit the drive pinion socket (A) (SST: KV38109500) onto the drive
pinion spline. Using the pinion nut wrench (B) (SST:
KV38108400), tighten drive pinion nut to the specified preload
torque.

CAUTION:

Drive pinion nut is tightened with no collapsible spacer. Be
careful not to over tighten it. While measuring the preload,
tighten it by 5

°

to 10

°

.

e.

Apply gear oil to side bearings, and install new side bearing
adjusting shims with the same thickness or re-install the old
ones to the same mounting position they were in prior to disas-
sembly. Set the drifts (commercial service tool) to the right and
left. Install differential case assembly to gear carrier.

CAUTION:

• The drifts shall be placed on the center of the adjusting

shims.

• The pressure shall be as low as possible to install gear

carrier assembly to differential assembly. The maximum
pressure shall be 10 kN (1 ton, 1.0 Imp ton).

• If adjusting shims are installed by tapping, gear carrier

may be damaged. Avoid tapping.

f.

Check and adjust the tooth contact. Refer to

DLN-224, “Adjustment”

.

g.

Check and adjust the backlash. Refer to

DLN-224, “Adjustment”

.

h.

Remove dummy cover set, and remove differential case assembly.

i.

Remove drive pinion nut and press drive pinion assembly out of
gear carrier.

CAUTION:

Never drop drive pinion assembly.

j.

Remove pinion front bearing inner race.

C

: Preload gauge (SST: ST3127S000)

Standard

Pinion bearing preload

: Refer to

DLN-229,

“Preload Torque”

.

JSDIA0266ZZ

PDIA0064E

PDIA0445E

DRIVE PINION

DLN-223

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R145]

C

E

F

G

H

I

J

K

L

M

A

B

DLN

N

O

P

5.

Assemble collapsible spacer to drive pinion.

CAUTION:

• Be careful of the mounting direction of collapsible spacer.
• Never reuse collapsible spacer.

6.

Apply gear oil to pinion front bearing, and assemble pinion front
bearing inner race to drive pinion. Using the drifts and stand,
press pinion front bearing inner race to drive pinion as far as
drive pinion nut can be tightened.

CAUTION:

Never reuse pinion front bearing inner race.

7.

Apply anti-corrosive oil to the thread and seat of drive pinion nut,
and temporarily tighten drive pinion nut to drive pinion.

CAUTION:

Never reuse drive pinion nut.

8.

Fit the drive pinion socket (A) (SST: KV38109500) onto the drive
pinion spline. Using the pinion nut wrench (B) (SST:
KV38108400), adjust the drive pinion nut tightening torque and
pinion bearing preload torque.

CAUTION:

• Adjust the lower limit of the drive pinion nut tightening

torque first.

• If the preload torque exceeds the specified value, replace

collapsible spacer and tighten it again to adjust. Never
loosen drive pinion nut to adjust the preload torque.

• After adjustment, rotate drive pinion back and forth 2 to 3

times to check for unusual noise, rotation malfunction,
and other malfunctions.

9.

Install differential case assembly. Refer to

DLN-215, “Assem-

bly”

.

CAUTION:

Never install rear cover.

10. Install dummy cover set, and check drive gear runout, tooth contact, and backlash. Refer to

DLN-224,

“Adjustment”

.

11. Remove dummy cover set, then install rear cover, and side oil seal. Refer to

DLN-215, “Assembly”

.

12. Check total preload torque. Refer to

DLN-224, “Adjustment”

.

13. Install electric controlled coupling assembly. Refer to

DLN-210, “Assembly”

.

14. Check companion flange runout. Refer to

DLN-212, “Adjustment”

.

SDIA2525E

A

: Drift (SST: ST23860000)

B

: Drift (commercial service tool)

C

: Preload gauge (SST: ST3127S000)

Drive pinion tightening
torque

:Refer to

DLN-219, “Ex-

ploded View”

.

Standard

Pinion bearing preload

: Refer to

DLN-229, “Pre-

load Torque”

.

JPDID0012ZZ

JSDIA0266ZZ

DLN-224

< UNIT DISASSEMBLY AND ASSEMBLY >

[REAR FINAL DRIVE: R145]

DRIVE PINION

Adjustment

INFOID:0000000010288421

TOTAL PRELOAD TORQUE

1.

Remove electric controlled coupling assembly. Refer to

DLN-210, “Disassembly”

.

2.

Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.

3.

Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.

4.

Fit drive pinion socket onto drive pinion spline. Measure the total
preload, using the preload gauge (A) (SST: 3127S000) and drive
pinion socket (B) (SST: KV38109500).

NOTE:
Total preload torque = Pinion bearing torque Side bearing
torque

• If measured value is out of the specification, disassemble it to check and adjust each part. Adjust the pinion

bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.

DRIVE GEAR RUNOUT

1.

Remove rear cover. Refer to

DLN-214, “Disassembly”

.

2.

Following the procedure below, install a dummy cover set (SST: KV389L0010) to gear carrier.

a.

Set dummy cover shims to the right and left side bearing adjusting shims.

b.

Temporarily tighten dummy cover to gear carrier.

c.

Position dummy cover spacers to dummy cover.

d.

Tighten rear cover mounting bolts to the specified torque. Refer to

DLN-219, “Exploded View”

.

e.

Tighten dummy cover spacer mounting bolts evenly to the specified torque.

3.

Fit a dial indicator to the drive gear back face.

4.

Rotate the drive gear to measure runout.

• If the runout is outside of the repair limit, check drive gear

assembly condition; foreign material may be caught between
drive gear and differential case, or differential case or drive
gear may be deformed, etc.

CAUTION:

Replace drive gear and drive pinion as a set.

Standard

Total preload torque

: Refer to

DLN-229, “Pre-

load Torque”

.

When the preload torque is large

On pinion bearings:

Replace the collapsible spacer.

On side bearings:

Use thinner side bearing adjusting shims.

When the preload is small

On pinion bearings:

Tighten the drive pinion nut.

On side bearings:

Use thicker side bearing adjusting shims.

PDIA0048E

: 5.9 N·m (0.6 kg-m, 52 in-lb)

Limit

Drive gear back face
runout

: Refer to

DLN-229, “Drive

Gear Runout”

.

PDIA0050E