DRIVELINE/AXLE

RFD
A

B
SECTION
REAR FINAL DRIVE C

RFD

E
CONTENTS
C200 Checking Differential Gear Oil .................................. 7 F

SERVICE INFORMATION ............................ 2 FRONT OIL SEAL .............................................. 8

PRECAUTIONS ................................................... 2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 2
Precaution for Servicing Rear Final Drive ................. 2
PREPARATION ................................................... 3
Special Service Tool ................................................. 3
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 6
NVH Troubleshooting Chart ...................................... 6
DIFFERENTIAL GEAR OIL ................................. 7
Changing Differential Gear Oil .................................. 7
Removal and Installation .......................................... 8
G
REAR COVER GASKET ................................... 10
Removal and Installation .........................................10
H
REAR FINAL DRIVE ASSEMBLY .................... 11
Removal and Installation .........................................11
Component ..............................................................12
Pre-Inspection .........................................................14 I
Disassembly and Assembly .....................................15
SERVICE DATA AND SPECIFICATIONS J
(SDS) ................................................................. 30
General Specifications .............................................30
Inspection and Adjustments ....................................30 K

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 PRECAUTIONS
< SERVICE INFORMATION > [C200]

SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000008945323

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 and SB section of
this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which 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 the SRS section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT 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 Servicing Rear Final Drive INFOID:0000000008945324

• Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic
operations.
• Check for the correct installation status prior to removal or disassembly. When matching marks are required,
be certain they do not interfere with the function of the parts they are applied to.
• Overhaul should be done in a clean work area, a dust proof area is recommended.
• Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
• Always use shop paper for cleaning the inside of components.
• Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
• Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them
with new ones if necessary.
• Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
• Clean and flush the parts sufficiently and blow them dry.
• Be careful not to damage sliding surfaces and mating surfaces.
• When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil, and
foreign materials from the application and mating surfaces.
• In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a
tightening sequence is specified, observe it.
• During assembly, observe the specified tightening torque.
• Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.

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 PREPARATION
< SERVICE INFORMATION > [C200]
PREPARATION
A
Special Service Tool INFOID:0000000008945325

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. B
Tool number Description
(Kent-Moore No.)
Tool name
C
ST3127S000 Measuring pinion bearing preload and total
(See J-25765-A) preload
Preload gauge
1 GG91030000 RFD
(J-25765)
Torque wrench
2 HT62940000
( — ) E
Socket adapter
3 HT62900000 NT124
( — )
Socket adapter F
ST3090S000 Removing and installing drive pinion rear in-
( — ) ner cone
Drive pinion rear inner race puller set a: 79 mm (3.11 in) dia. G
1 ST30031000 b: 45 mm (1.77 in) dia.
(J-22912-01) c: 35 mm (1.38 in) dia.
Puller
2 ST30901000 H
(J-26010-01)
Base NT527

ST3306S001 Removing and installing differential side bear- I

( — ) ing inner cone
Differential side bearing puller set a: 28.5 mm (1.122 in) dia.
1 ST33051001 b: 38 mm (1.50 in) dia.
(J-22888-20) J
Body
2 ST33061000
(J-8107-2)
Adapter NT072 K
ST33230000 Installing side bearing inner cone
(J-25805-01) a: 51 mm (2.01 in) dia.
Differential side bearing drift b: 41 mm (1.61 in) dia. L
c: 28.5 mm (1.122 in) dia.

M
NT085

KV38100600 Installing side bearing spacer

(J-25267) a: 8 mm (0.31 in)
N
Side bearing spacer drift b: R42.5 mm (1.673 in)

NT528
P

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 PREPARATION
< SERVICE INFORMATION > [C200]
Tool number Description
(Kent-Moore No.)
Tool name
ST30611000 Installing pinion rear bearing outer race
(J-25742-1)
Drift

NT090

ST30621000 Installing pinion rear bearing outer race

(J-25742-5) a: 79 mm (3.11 in) dia.
Drift b: 59 mm (2.32 in) dia.

NT073

ST30613000 Installing pinion front bearing outer race

(J-25742-3) a: 72 mm (2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.

NT073

KV38100500 Installing front oil seal

(J-25273) a: 85 mm (3.35 in) dia.
Gear carrier front oil seal drift b: 60 mm (2.36 in) dia.

NT115

— Adjusting bearing pre-load and gear height

(J-34309)
Differential shim selector

NT134

— Selecting pinion height adjusting washer

(J-25269-4)
Side bearing discs
(2 Req'd)

NT136

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 PREPARATION
< SERVICE INFORMATION > [C200]
Tool number Description
(Kent-Moore No.) A
Tool name
— Measuring carrier turning torque
(J-8129) B
Spring gauge

NT127

KV10112100 Tightening side bearing cap bolts RFD

(BT-8653-A)
Angle wrench
E

S-NT014 F

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 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION > [C200]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000008945326

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

FAX-4,RAX-6, FSU-5, RSU-4

RFD-15, RFD-15

RFD-15

RFD-15

RFD-14

RAX-6
MA-9

WT-4
PR-4

BR-4

PS-5
Reference page

—
Companion flange excessive runout

AXLE AND SUSPENSION

Improper gear contact

PROPELLER SHAFT
Possible cause and SUSPECTED PARTS

Tooth surface worn

Incorrect backlash
Rough gear tooth

Improper gear oil

ROAD WHEEL

DRIVESHAFT

STEERING
BRAKES
TIRES
Symptom DIFFERENTIAL Noise × × × × × × × × × × × × ×
×: Applicable

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 DIFFERENTIAL GEAR OIL
< SERVICE INFORMATION > [C200]
DIFFERENTIAL GEAR OIL
A
Changing Differential Gear Oil INFOID:0000000008945327

DRAINING B
1. Stop engine.
2. Remove the drain plug from the rear final drive assembly to
drain the differential gear oil. C
3. Install the drain plug with a new gasket to the rear final drive
assembly. Tighten to the specified torque. Refer to RFD-12,
"Component". RFD
CAUTION:
Do not reuse gasket.
E

LDIA0187E
F
FILLING
1. Remove the filler plug from the rear final drive assembly.
2. Fill the rear final drive assembly with new differential gear oil G
until the level reaches the specified level near the filler plug hole.

Differential gear oil : Refer to MA-9, "Fluids and H

grade and capacity Lubricants".
3. Install the filler plug with sealant applied on the threads to the
rear final drive assembly. Tighten to the specified torque. Refer I
to RFD-12, "Component".
• Use High Performance Thread Sealant or equivalent. Refer to
GI-45, "Recommended Chemical Product and Sealant". J
LDIA0127E

Checking Differential Gear Oil INFOID:0000000008945328

K
DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL
1. Make sure that differential gear oil is not leaking from the rear final drive assembly or around it.
2. Check the differential gear oil level from the filler plug hole as L
shown.
CAUTION:
Do not start engine while checking differential gear oil level.
M
3. Install the filler plug with sealant applied on the threads to the
rear final drive assembly. Tighten to the specified torque. Refer
to FFD-11, "Component".
• Use High Performance Thread Sealant or equivalent. Refer to N
GI-45, "Recommended Chemical Product and Sealant".

LDIA0127E O

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 FRONT OIL SEAL
< SERVICE INFORMATION > [C200]
FRONT OIL SEAL
Removal and Installation INFOID:0000000008945329

1. Remove propeller shaft. Refer to PR-8, "Removal and Installation".

2. Loosen drive pinion nut while holding companion flange using a
suitable tool.

APD032

3. Remove companion flange using a suitable tool.

4. Remove wheel sensor and rear wheel sensor rotor.

SPD737

5. Remove front oil seal.

WPD013

6. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Press front oil seal into carrier using Tool.

Tool number : KV38100500 (J25273)

7. Install wheel sensor and rear wheel sensor rotor. Refer to RFD-
12.
8. Install companion flange.

WPD014

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 FRONT OIL SEAL
< SERVICE INFORMATION > [C200]
9. Hold the companion flange using a suitable tool and tighten
drive pinion nut. Refer to RFD-12. A

APD032

RFD
10. Install rear propeller shaft. Refer to PR-8, "Removal and Installation".

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 REAR COVER GASKET
< SERVICE INFORMATION > [C200]
REAR COVER GASKET
Removal and Installation INFOID:0000000008945330

1. Drain gear oil. Refer to MA-22, "Changing Rear Final Drive Oil - C200 (Rear Differential Gear Oil)".
2. Remove rear cover and rear cover gasket.
3. Install new rear cover gasket and rear cover.
4. Tighten rear cover bolts. Refer to RFD-12.
5. Fill final drive with recommended gear oil. Refer to MA-9, "Fluids and Lubricants".

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
REAR FINAL DRIVE ASSEMBLY
A
Removal and Installation INFOID:0000000008945331

REMOVAL B
CAUTION:
• Do not damage spline, companion flange and front oil seal when removing propeller shaft.
• Before removing final drive assembly or rear axle assembly, disconnect wheel sensor harness con- C
nector from the assembly and move it away from final drive/rear axle assembly area. Failure to do so
may result in sensor wires being damaged and sensor becoming inoperative.
1. Drain the differential gear oil. Refer to MA-22, "Changing Rear Final Drive Oil - C200 (Rear Differential
RFD
Gear Oil)".
2. Remove the rear propeller shaft. Refer to PR-8, "Removal and Installation".
3. Remove the axle shaft. Refer to RAX-8, "Removal". E
4. Disconnect the following components from the rear final drive assembly.
• Brake tube block connectors. Refer to BR-10, "Front and Rear Brake Piping and Hose".
• Wheel sensor harness (if equipped). Refer to BRC-34, "Rear Wheel Sensor and Sensor Rotor" (2WD),
or BRC-70, "Rear Wheel Sensor" (4WD). F
• Parking brake cables. Refer to PB-3, "Removal and Installation".
• Remove LSV. Refer to BR-15, "2WD : Removal and Installation" (2WD), or BR-17, "4WD : Removal and
Installation" (4WD). G
5. Disconnect brake hose from brake tube at the clip on top of rear final drive assembly. Then remove the
metal clip to disconnect brake line from the clip on the rear final drive assembly.
6. Support rear final drive assembly using a suitable jack. H
7. Remove rear shock absorber lower bolts. Refer to RSU-8, "Removal and Installation".
8. Remove leaf spring U-bolt nuts. Refer to RSU-9, "Removal".
9. Remove rear final drive assembly. I
CAUTION:
Secure rear final drive assembly to the jack while removing it.
J
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Fill the rear final drive assembly with differential gear oil after installation. Refer to MA-22, "Changing K
Rear Final Drive Oil - C200 (Rear Differential Gear Oil)".
• Bleed the air from brake system. Refer to BR-7, "Bleeding Brake System".
L

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Component INFOID:0000000008945332

LDIA0019E

1. Axle case 2. Front oil seal 3. Wheel sensor unit

4. Rear wheel sensor rotor 5. Companion flange 6. Inner cone
7. Outer race 8. Drive pinion front bearing 9. Drain plug
10. Collapsible spacer 11. Washer 12. Pinion height adjusting washer
13. Pinion mate thrust washer 14. Thrust block 15. Side gear
16. Side gear thrust washer 17. Side bearing adjusting shim 18. Side bearing spacer

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
19. Outer race 20. Inner cone 21. Side bearing
22. Lock pin 23. Pinion mate shaft 24. Pinion mate gear A
25. Drive pinion 26. Ring gear 27. Hypoid gear set
28. Filler plug 29. Carrier cover bolt 30. Carrier cover
31. Carrier cover gasket 32. Differential case 33. Inner cone B
34. Outer race 35. Drive pinion rear bearing 36. Side bearing cap

RFD

LDIA0020E

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]

1. Axle case 2. Front oil seal 3. Companion flange

4. Inner cone 5. Outer race 6. Drive pinion front bearing
7. Drain plug 8. Collapsible spacer 9. Washer
10. Pinion height adjusting washer 11. Pinion mate thrust washer 12. Pinion mate gear
13. Pinion mate thrust washer 14. Side gear 15. Side bearing adjusting shim
16. Outer race 17. Inner cone 18. Side bearing
19. Differential case A 20. Side gear thrust washer 21. Pinion mate shaft
22. Drive pinion 23. Ring gear 24. Hypoid gear set
25. Filler plug 26. Carrier cover bolt 27. Carrier cover
28. Carrier cover gasket 29. Side bearing spacer 30. Differential case B
31. Inner cone 32. Outer race 33. Drive pinion rear bearing
34. Side bearing cap

Pre-Inspection INFOID:0000000008945333

Before disassembling final drive, perform the following inspections.

TOTAL PRELOAD
1. Turn drive pinion in both directions several times to set bearing rollers.
2. Check total preload using Tool. Refer to RFD-30, "Inspection
and Adjustments".

Tool number : ST3127S000 (J-25765-A)

PD245

RING GEAR-TO-DRIVE PINION BACKLASH

Check backlash of ring gear with a dial indicator at several points.
Refer to RFD-30, "Inspection and Adjustments".

SPD196

RING GEAR RUNOUT

Check runout of ring gear with a dial indicator. Refer to RFD-30,
"Inspection and Adjustments".

SPD702

TOOTH CONTACT

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Check tooth contact. Refer to RFD-15, "Disassembly and Assembly".
A
SIDE GEAR-TO-PINION MATE GEAR BACKLASH
Measure clearance between side gear thrust washer and differential
case with a feeler gauge. Refer to RFD-30, "Inspection and Adjust-
ments". B

RFD

SPD198

Disassembly and Assembly INFOID:0000000008945334 E

REMOVAL OF DIFFERENTIAL CASE

1. Remove rear cover and rear cover gasket. F
2. Put match marks on one side of side bearing cap with paint or
punch to ensure that it is replaced in proper position during reas-
sembly. G
• Bearing caps are line-bored during manufacture and
should be put back in their original places.
H

SPD714
I

3. Remove side bearing caps.

J

SPD202
M
4. Remove differential case assembly with pry bar.

P
SPD193

NOTE:

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Keep the side bearing outer races together with their respective
inner cones — do not mix them up.

SPD745

REMOVAL OF DRIVE PINION ASSEMBLY

1. Remove pinion nut while holding the companion flange using a
suitable tool.

APD032

2. Remove companion flange with puller.

3. Remove wheel sensor and sensor rotor.

SPD014

4. Remove drive pinion with soft hammer.

5. Remove front oil seal and pinion front bearing inner cone.

SPD206

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
6. Remove pinion bearing outer races with a brass drift.
A

PD349

RFD
7. Remove pinion rear bearing inner cone and pinion height adjust-
ing washer.
E
Tool number : ST30031000 (J-22912-01)

G
PD179

DISASSEMBLY OF DIFFERENTIAL CASE

H
1. Remove side gears, pinion mate gears and thrust washers into differential case
2. Remove side bearing inner cones using Tool.
• To prevent damage to bearing, engage puller jaws in
grooves. I

Tool number (A) : ST33051001 (J-22888-20)

J
Tool number (B) : ST33061000 (J-8107-2)

O
SPD529

NOTE: P

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Be careful not to confuse the right-hand and left-hand parts.

SPD022

3. Loosen ring gear bolts in a crisscross fashion.

4. Tap ring gear off the differential case with a soft hammer.
• Tap evenly all around to keep ring gear from binding.

SPD024

5. Punch off pinion mate shaft lock pin from differential case.
• Lock pin is caulked at pinhole mouth on differential case.

SPD025

6. Disassemble the LH and RH differential case (4WD models).

SPD643

INSPECTION
Ring Gear and Drive Pinion
Check gear teeth for scoring, cracking or chipping. If any damaged part is evident, replace ring gear and drive
pinion as a set (hypoid gear set).
Differential Case Assembly

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Check mating surfaces of differential case, side gears, pinion mate
gears, pinion mate shaft, thrust block and thrust washers. A

SPD584

RFD
Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking. E
Check tapered roller bearing for smooth rotation. If damaged,
replace outer race and inner race as a set.

SPD715

SIDE BEARING PRELOAD H

A selection of side bearing adjusting shims is required for successful completion of this procedure.
1. Make sure all parts are clean. Also make sure the bearings are
well lubricated with light oil or “DEXRONTM” automatic transmis- I
sion fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing. J

SPD919

L
3. Put the side bearing adjusting shim in place.
CAUTION:
Side bearing adjusting shim is placed on either the right or
M
left depending upon final drive gear ratio. Be sure to place it
on the correct side.

O
SPD894

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
4. Use Tool to place original carrier side bearing adjusting shims on
the carrier end, opposite the ring gear.

Tool number : KV38100600 (J-25267)

SPD986

5. Install the side bearing caps in their correct locations using the
matchmarks made during removal, and tighten the bearing cap
bolts to specification. Refer to RFD-12, "Component".
6. Turn the carrier several times to seat the bearings.

SPD526

7. Measure the turning resistance of the differential carrier assem-

bly at the ring gear retaining bolts with Tool. Refer to RFD-30,
"Inspection and Adjustments".

Tool number : — (J-8129)

WDIA0013E

8. If the turning resistance is not within the specification, correct as

follows:
• If the turning resistance is less than the specified range, install
thicker side bearing adjusting shims.
• If the turning resistance is greater than the specification, install
thinner side bearing adjusting shims.

Side bearing adjustment Refer to RFD-30, "Inspection

and Adjustments".
9. Record the total amount of shim thickness required for the cor-
rect carrier side bearing preload.
SPD772

10. Remove the carrier from the final drive housing. Save the
selected adjusting shims for later use during the assembly of the
final drive unit.

PD344

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
PINION GEAR HEIGHT
1. Make sure all parts are clean and that the bearings are well A
lubricated.

RFD
SPD769

2. Assemble the pinion gear bearings into the pinion preload shim selector Tool, J-34309.
• Front pinion bearing— make sure the J-34309-3 front pinion E
bearing seat is secured tightly against the J-34309-2 gauge
anvil. Then turn the front pinion bearing pilot, J34309-5, to
secure the bearing in its proper position.
• Rear pinion bearing— the rear pinion bearing pilot, J-34309- F
8, is used to center the rear pinion bearing only. The rear pin-
ion bearing locking seat, J-34309-4, is used to lock the bearing
to the assembly. G

SPD197A H

3. Install the pinion rear bearing inner cone into the final drive
housing. Then place the pinion preload shim selector Tool, J-
I
34309-1, on gauge screw assembly.

SPD893

L
4. Assemble the front pinion bearing inner cone and the J-34309-2
gauge anvil. Assemble them together with the J-34309-1 gauge
screw in the final drive housing. Make sure that the pinion height
gauge plate, J-34309-16, will turn a full 360 degrees. Tighten the M
two sections together by hand.

O
SPD199A

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
5. Turn the assembly several times to seat the bearings.

SPD770

6. Measure the turning torque at the end of the J-34309-2 gauge

anvil using Tool. Refer to RFD-30, "Inspection and Adjust-
ments".

Tool number : ST3127S000 (J-25765-A)

SPD234A

7. Place the J-34309-11 pinion height adapter onto the gauge plate
and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.

SPD208A

Pinion Height Adjusting Washer Selection

1. Now, position the side bearing discs, J-25269-4, and arbor firmly
into the side bearing bores.

SPD211A

2. Install the side bearing caps and tighten the side bearing cap bolts to proper torque. Refer to RFD-12,
"Component".

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
3. Select the correct standard pinion height adjusting washer thick-
ness. Select by using a standard gauge of 3 mm (0.12 in) and J- A
34309-101 feeler gauge. Measure the distance between the J-
34309-11 pinion height adapter including the standard gauge
and the arbor.
B
4. Write down the exact measurement (the value of feeler gauge).

SPD204A

RFD
5. Correct the pinion height adjusting washer size by referring to
the “pinion head number”.
• There are two numbers painted on the pinion gear. The
E
first one refers to the pinion and ring gear as a matched
set. This number should be the same as the number on
the ring gear. The second number is the “pinion head
height number”. It refers to the ideal pinion height from F
standard for quietest operation.
• Use the following chart to determine the correct pinion
height adjusting washer:
G
SPD542

Add or remove from the standard pin-

Pinion head height number ion height adjusting washer thick-
H
ness measurement
−6 Add 0.06 mm (0.0024 in)
−5 Add 0.05 mm (0.0020 in)
I
−4 Add 0.04 mm (0.0016 in)
−3 Add 0.03 mm (0.0012 in)
−2 Add 0.02 mm (0.0008 in) J
−1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
K
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in) L
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
M
+6 Subtract 0.06 mm (0.0024 in)
6. Select the correct pinion height adjusting washer. Refer to RFD-30, "Inspection and Adjustments".
7. Remove the J-34309 pinion preload shim selector Tool from the N
final drive housing. Then disassemble to retrieve the pinion
bearings.
O

SPD205A

TOOTH CONTACT
Checking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pin-
ion.

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
Hypoid gear set which is not positioned properly may be noisy, or have short life or both. With the checking or
gear tooth contact pattern, 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 or
equivalent to 3 or 4 teeth of ring gear drive side.

SPD199

3. Hold companion flange steady and rotate the ring gear in both
directions.

SPD200

SPD007-B

ASSEMBLY OF DIFFERENTIAL CASE

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 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
1. Measure clearance between side gear thrust washer and differ-
ential case (4WD models). Refer to RFD-30, "Inspection and A
Adjustments".
The clearance can be adjusted with side gear thrust washer.
Refer to RFD-30, "Inspection and Adjustments".
B
2. Install side gears, pinion mate gears and thrust washers into dif-
ferential case
3. Apply gear oil to gear tooth surfaces and thrust surfaces and
C
check to see that they turn properly.

RFD

G
SPD656

4. Install differential case LH and RH (4WD models).

H

SPD643
K
5. Place differential case on ring gear.
6. Apply Genuine Medium Strength Locking Sealant or equivalent
to ring gear bolts, and install them. L
• Refer to MA-9, "Fluids and Lubricants", RFD-12, "Compo-
nent".
• Tighten bolts in a crisscross pattern. M
Tool number KV10112100 (BT-8653-A)
N
SPD746

7. Press-fit side bearing inner cones on differential case with Tool.

O

Tool number (A) : ST33230000 (J-25805-01)

Tool number (B) : ST33061000 (J-8107-2) P

PD353

Revision: April 2013 RFD-25 2013 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
INSTALLATION OF DRIVE PINION ASSEMBLY
1. Press-fit front and rear bearing outer races with Tools.

Tool number (A) : ST30611000 (J-25742-1)

Tool number (B) : ST30621000 (J-25742-5)
Tool number (C) : ST30613000 (J-25742-3)

SPD679

2. Select pinion height adjusting washer. Refer to RFD-15, "Disas-

sembly and Assembly".
3. Install pinion height adjusting washer in drive pinion, and press-
fit rear bearing inner cone in it, with press and Tool.

Tool number : ST30901000 (J-26010-01)

SPD377

4. Place pinion front bearing inner cone in gear carrier.

SPD581

5. Apply multi-purpose grease to cavity at sealing lips of oil seal.

Install front oil seal.

Tool number : KV38100500 (J-25273)

SPD557

Revision: April 2013 RFD-26 2013 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
6. Place drive pinion bearing spacer, drive pinion bearing adjusting
washer and drive pinion in gear carrier. A

SPD222
RFD
7. Install wheel sensor unit and sensor rotor. Refer to RFD-12,
"Component".
E

G
SPD708

8. Insert companion flange onto drive pinion by tapping the companion flange with a soft hammer until fully H
seated.
9. Hold companion flange using a suitable tool and tighten the pin-
ion nut. Refer to RFD-12, "Component". I
The threaded portion of drive pinion and pinion nut should
be free from oil or grease.

APD032

L
10. Tighten the pinion nut by very small degrees until the specified
preload is achieved. When checking the preload, turn the drive
pinion in both directions several times to set the bearing rollers.
Refer to RFD-30, "Inspection and Adjustments". M

Tool number : ST3127S000 (J-25765-A)

N

O
SPD241

INSTALLATION OF DIFFERENTIAL CASE

P

Revision: April 2013 RFD-27 2013 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
This procedure will have to be repeated if:
• Maximum preload is achieved before the minimum pinion nut
torque is reached.
• Minimum preload is not achieved before maximum pinion nut
torque is reached.
1. Select side bearing adjusting shim. Refer to RFD-15, "Disas-
sembly and Assembly".
2. Install differential case assembly with side bearing outer races
into gear carrier.

SPD203

3. Insert left and right side bearing adjusting shims in place

between side bearing outer races and differential carrier asse-
bly.

SPD558

4. Drive in side bearing spacer with Tool.

Tool number : KV38100600 (J-25267)

SPD709

5. Align matchmark on bearing cap with that on differential gear

carrier and install side bearing cap on gear carrier with soft ham-
mer. Refer to RFD-12, "Component".

SPD226

6. Measure ring gear-to-drive pinion backlash with a dial indicator.

Refer to RFD-30, "Inspection and Adjustments".
• 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 procedure.
• Never change the total amount of shims as it will change
the bearing preload.

SPD196

Revision: April 2013 RFD-28 2013 D22 LCV

 REAR FINAL DRIVE ASSEMBLY
< SERVICE INFORMATION > [C200]
7. Check total preload with Tool. Refer to RFD-30, "Inspection and
Adjustments". A
• When checking preload, turn drive pinion in both direc-
tions several times to seat bearing rollers correctly.
B
Tool number : ST3127S000 (J-25765-A)

SPD241

RFD
• If preload is too great, remove the same amount of shim from
each side.
• If preload is too small, add the same amount of shim to each E
side.
• Never add or remove a different number of shims for each
side as it will change ring gear-to-drive pinion backlash.
8. Recheck ring gear-to-drive pinion backlash because increase or F
decrease in thickness of shims will cause change of ring gear-
to-pinion backlash.
G
SPD561

9. Check runout of ring gear with a dial indicator. Refer to RFD-30, H

"Inspection and Adjustments".
• If backlash varies excessively in different places, the variance
may have resulted from foreign matter caught between the
ring gear and the differential case. I
• If the backlash varies greatly when the runout of the ring gear
is within a specified range, the hypoid gear set or differential
case should be replaced. J
10. Check tooth contact. Refer to RFD-15, "Disassembly and
Assembly".
11. Install new rear cover gasket and rear cover. SPD702 K
12. Tighten rear cover bolts. Refer to RFD-12, "Component".

Revision: April 2013 RFD-29 2013 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [C200]
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications INFOID:0000000008945335

GENERAL SPECIFICATIONS
2WD Models
M/T
Rear final drive C200
Standard Optional
Gear ratio 4.875 4.375
Number of teeth (Ring gear drive pinion) 37/9

Oil capacity (Approx.) (US pt., Imp pt) 1.3 (2 3/4, 2 1/4)

4WD Model
Transmission M/T
Rear final drive C200
Gear ratio 4.625
Number of teeth (Ring gear/drive pinion) 37/8

Oil capacity (Approx.) (US pt, lmp pt) 1.3 (2-3/4, 2-1/4)

Inspection and Adjustments INFOID:0000000008945336

RING GEAR RUNOUT

Ring gear runout limit mm (in) 0.05 (0.0020)

SIDE GEAR ADJUSTMENT

Side gear backlash (Clearance between side gear thrust washer

Less than 0.15 (0.0059)
and differential case) mm (in)
Available side gear thrust washers (2wd)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-N3110
0.78 (0.0307) 38424-N3111
0.81 (0.0319) 38424-N3112
0.84 (0.0331) 38424-N3113
0.87 (0.0343) 38424-N3114
0.90 (0.0354) 38424-N3115
0.93 (0.0366) 38424-N3116
Available side gear thrust washers (4wd)
Thickness mm (in) Part number*
0.75 (0.0295) 38424-0C000
0.78 (0.0307) 38424-0C001
0.81 (0.0319) 38424-0C002
0.84 (0.0331) 38424-0C003
0.87 (0.0343) 38424-0C004
0.90 (0.0354) 38424-0C005
0.93 (0.0366) 38424-0C006

*Always check with the Parts Department for the latest parts information.

SIDE BEARING ADJUSTMENT

Differential carrier assembly turning resistance N (kg, lb) 34.3 - 39.2 (3.5 - 4.0, 7.7 - 8.8)

Revision: April 2013 RFD-30 2013 D22 LCV

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [C200]
Thickness mm (in) Part number*
A
2.00 (0.0787) 38453-N3100
2.05 (0.0807) 38453-N3101
2.10 (0.0827) 38453-N3102
2.15 (0.0846) 38453-N3103 B
Available 2.20 (0.0866) 38453-N3104
side bearing 2.25 (0.0886) 38453-N3105
adjusting 2.30 (0.0906) 38453-N3106
shims 2.35 (0.0925) 38453-N3107 C
2.40 (0.0945) 38453-N3108
2.45 (0.0965) 38453-N3109
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111 RFD
2.60 (0.1024) 38453-N3112
*Always check with the Parts Department for the latest parts information.
E
TOTAL PRELOAD ADJUSTMENT

Total preload N·m (kg-cm, in-lb) 1.4 - 2.9 (15 - 29, 13 - 25)
F
Gear ratio 3.700, 4.625 0.13 - 0.18 (0.0051 - 0.0071)
Ring gear-to-drive pinion backlash mm (in)
Gear ratio 4.111 0.10 - 0.15 (0.0041 - 0.0059)
G
DRIVE PINION HEIGHT ADJUSTMENT

Thickness mm (in) Part number*

H
3.09 (0.1217) 38154-P6017
3.12 (0.1228) 38154-P6018
3.15 (0.1240) 38154-P6019
3.18 (0.1252) 38154-P6020 I
3.21 (0.1264) 38154-P6021
3.24 (0.1276) 38154-P6022
3.27 (0.1287) 38154-P6023
Available 3.30 (0.1299) 38154-P6024 J
drive pinion 3.33 (0.1311) 38154-P6025
height ad- 3.36 (0.1323) 38154-P6026
justing 3.39 (0.1335) 38154-P6027
washers 3.42 (0.1346) 38154-P6028 K
3.45 (0.1358) 38154-P6029
3.48 (0.1370) 38154-P6030
3.51 (0.1382) 38154-P6031 L
3.54 (0.1394) 38154-P6032
3.57 (0.1406) 38154-P6033
3.60 (0.1417) 38154-P6034
3.63 (0.1429) 38154-P6035 M
3.66 (0.1441) 38154-P6036
*Always check with the Parts Department for the latest parts information.

DRIVE PINION PRELOAD ADJUSTMENT N

Drive pinion bearing preload adjusting method Collapsible spacer

Drive pinion preload with front oil seal N·m (kg-cm, in-lb) 1.1 - 1.4 (12 - 14, 10 - 12)
O
Drive pinion preload without front oil seal N·m (kg-cm, in-lb) 1.0 - 1.3 (11 - 13, 9 - 11)

Revision: April 2013 RFD-31 2013 D22 LCV