Nissan Rogue manuals

Nissan Rogue Service Manual: Unit disassembly and assembly

ELECTRIC CONTROLLED COUPLING

Exploded View

Exploded View

  1. Stud bolt
  2. Connector bracket
  3. Reamer bolt
  4. Electric controlled coupling assembly
  5. Wave spring
  6. Drive pinion oil seal
  7. Drive pinion lock nut
  8. Pinion front bearing
  9. Gear carrier
  10. Collapsible spacer
  11. Drive pinion adjusting shim
  12. Pinion rear bearing
  13. Drive pinion
  14. Drive gear
  15. Differential case
  16. Side bearing
  17. Side bearing adjusting shim
  18. Side oil seal
  19. Rear cover
  20. Stud bolt
  21. Gasket
  22. Drain plug
  23. Filler plug
  24. Pinion mate thrust washer
  25. Pinion mate gear
  26. Side gear thrust washer
  27. Side gear
  28. Pinion mate shaft
  29. Lock pin
  1. Oil seal lip
  2. Screw hole

: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Select with proper thickness.
: Apply gear oil.
*: Apply anti-corrosion oil.
: Apply multi purpose grease.
: Apply Genuine Silicone RTV or equivalent. Refer to GI-22, "Recommended Chemical Products and Sealants".
: Apply Genuine High Strength Thread Locking Sealant or equivalent. Refer to GI-22, "Recommended Chemical Products and Sealants".

Disassembly and Assembly

DISASSEMBLY

  1.  Remove stud bolts .

Disassembly

  1. Remove electric controlled coupling assembly from final drive assembly.
  2.  Remove wave spring.
  3.  Remove drive pinion oil seal from the inside of gear carrier.

    Refer to DLN-136, "Disassembly and Assembly".

CAUTION: When removing electric controlled coupling, replace drive pinion oil seal.

Disassembly

  1. Remove connector bracket 1 from electric controlled coupling.

Disassembly

  1. Separate band clip and connector clip from connector bracket.

Disassembly

ASSEMBLY

  1. Install connector bracket to electric controlled coupling.
  1.  Fix AWD solenoid harness with band clip and connector clip.
  2.  Install drive pinion oil seal to the inside of gear carrier. Refer to DLN-136, "Disassembly and Assembly".

CAUTION: When removing electric controlled coupling, replace drive pinion oil seal.

Assembly

  1. Install wave spring 1 to the inside of gear carrier.

Assembly

  1. Apply liquid gasket to mating surface of electric controlled coupling assembly.

CAUTION:

Assembly

  1. Match electric controlled coupling assembly 1 to spline of drive pinion, then install it to final drive assembly 2.

    CAUTION: Be careful not to damage drive pinion oil seal.

Assembly

  1. Temporarily tighten reamer bolts 1 to the positions shown in the figure.
  2.  Tighten reamer bolts and electric controlled coupling assembly mounting bolts to the specified torque.

Assembly

  1. Install stud bolts 1.

Assembly

: Electric controlled coupling side

Thread length
A : Long
B : Short

CAUTION:

DIFFERENTIAL ASSEMBLY

Exploded View

Exploded View

  1. Stud bolt
  2. Connector bracket
  3. Reamer bolt
  4. Electric controlled coupling assembly
  5. Wave spring
  6. Drive pinion oil seal
  7. Drive pinion lock nut
  8. Pinion front bearing
  9. Gear carrier
  10. Collapsible spacer
  11. Drive pinion adjusting shim
  12. Pinion rear bearing
  13. Drive pinion
  14. Drive gear
  15. Differential case
  16. Side bearing
  17. Side bearing adjusting shim
  18. Side oil seal
  19. Rear cover
  20. Stud bolt
  21. Gasket
  22. Drain plug
  23. Filler plug
  24. Pinion mate thrust washer
  25. Pinion mate gear
  26. Side gear thrust washer
  27. Side gear
  28. Pinion mate shaft
  29. Lock pin
  1. Oil seal lip
  2. Screw hole

: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Select with proper thickness.
: Apply gear oil.
*: Apply anti-corrosion oil.
: Apply multi purpose grease.

Apply Genuine Silicone RTV or equivalent. Refer to GI-22, "Recommended Chemical Products and Sealants".
: Apply Genuine High Strength Thread Locking Sealant or equivalent. Refer to GI-22, "Recommended Chemical Products

Disassembly and Assembly

DISASSEMBLY

  1.  Remove drain plug, filler plug and gaskets.
  2.  Remove the side oil seal, using oil seal remover (commercial service tool).

    CAUTION: Never damage gear carrier and rear cover.

  3.  Remove rear cover mounting bolts.

Disassembly

  1. Set drifts (A and B) to the right and left side bearing adjusting shims individually. Press differential assembly with side bearing to remove gear carrier assembly and rear cover assembly.

Disassembly

A : Drift [SST: KV40100610 (J-26089)]
B : Drift [SST: KV40100610 (J-26089)]

CAUTION: The pressure shall be as low as possible to remove gear carrier assembly and rear cover assembly. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton).

NOTE: Differential assembly, side bearings, and adjusting washers are compressed and integrated in gear carrier and rear cover.

  1.  Remove stud bolt from rear cover.

    NOTE: It is not necessary to remove stud bolt except when it is replaced.

  2.  Remove side bearing adjusting shims and side bearing outer races.

    CAUTION: Mark the side bearing adjusting shims so that the original mounting positions (right/left) can be identified later.

  3.  Remove side bearing inner races, using adaptor (A), separator (B) and puller (C).

Disassembly

A : Adaptor [ST33052000 ( — )]
B : Separator (commercial service tool)
C : Puller (commercial service tool)

CAUTION:

  1. For proper reinstallation, paint matching marks A on one differential assembly and drive gear.

    CAUTION: For matching marks, use paint. Never damage differential assembly and drive gear.

  2.  Remove drive gear mounting bolts and then remove drive gear from differential assembly.

Disassembly

  1. Remove lock pin of pinion mate shaft, using the pin punch (commercial service tool).

Disassembly

  1. Remove pinion mate shaft.

Disassembly

  1. Remove pinion mate gears, pinion mate thrust washers, side gears, side gear thrust washers from differential case.
  2.  Perform inspection after disassembly. Refer to DLN-134, "Inspection".

Disassembly

ASSEMBLY

  1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.
  2. Install side gears and side gear thrust washers into differential case.

Assembly

  1. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.

Assembly

  1. Align the lock pin holes on differential case with pinion mate shaft, and install pinion mate shaft.

  1. Measure side gear end play. If necessary, select the appropriate side gear thrust washers.
  1.  Place differential assembly straight up so that side gear to be measured comes upward.

Assembly

  1. Using feeler gauge, measure the clearance between side gear back and differential case at 3 different points, while rotating side gear. Average the 3 readings, and then measure the clearance of the other side as well.

Assembly

Side gear back clearance : Refer to DLN-141, "Differential Side Gear Clearance".

CAUTION: To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.

When the back clearance is large : Use a thicker thrust washer.
When the back clearance is small: Use a thinner thrust washer.

CAUTION: Select a side gear thrust washer for right and left individually.

  1.  Drive a lock pin into pinion mate shaft, using the pin punch (commercial service tool).

CAUTION: Never reuse lock pin.

Assembly

  1. Press side bearing inner races to differential assembly, using the drifts (A and B).

Assembly

A : Drift [SST: KV40105020 ( — )]
B : Drift [SST: KV40105020 ( — )]

CAUTION:

  1. Apply thread locking sealant into the thread hole of drive gear.

    CAUTION: Clean and degrees drive gear back and threaded holes sufficiently.

  2. Install the drive gear to differential assembly.

    CAUTION: Align the matching mark of differential assembly and drive gear.

Assembly

  1. Tighten the bolts in a crisscross fashion to the specified torque.

CAUTION: Apply anti-corrosion oil to the thread and seat of mounting bolts.

  1.  Assemble side bearing outer races to inner races.

CAUTION:

  1.  Install new side bearing adjusting shims (2 pieces for one side) with the same thickness as the ones installed prior to disassembly or re-install the old ones, on side bearing outer race of differential assembly.

If side bearing adjusting shims have been already selected, use them.

Assembly

  1. Set the drifts (A and B) to the right and left side bearing adjusting shims individually. Compress differential assembly and side bearing to gear carrier assembly to install differential assembly.

Assembly

A : Drift [KV40100610 (J-26089)]
B : Drift [KV40100610 (J-26089)]

CAUTION:

  1.  Install dummy cover set [SST: KV381086S1 ( — )], check and adjust drive gear runout, tooth contact, backlash, and total preload torque. Refer to DLN-130, "Adjustment".
  2.  Remove dummy cover set.
  3.  Install stud bolt to rear cover.

    CAUTION: Screw the stud bolt until the thread becomes invisible by applying a torque of 20 N·m (2.0 kg-m, 15 ft-lb) or less.

  4.  Apply liquid gasket to mating surface of rear cover.

CAUTION:

Assembly

  1. Set the drifts (A and B) to the right and left side bearing adjusting shims individually. Compress differential assembly and side bearing to install rear cover.

Assembly

A : Drift [KV40100610 (J-26089)]
B : Drift [KV40100610 (J-26089)]

CAUTION:

  1. Tighten rear cover mounting bolts to the specified torque.
  1.  Using the drift (A) [SST: KV38100200 (J-26233)], drive side oil seals until it becomes flush with the gear carrier end.

CAUTION:

  1.  Check total preload torque. Refer to DLN-130, "Adjustment".

Assembly

Adjustment

TOTAL PRELOAD TORQUE

  1. Remove electric controlled coupling assembly. Refer to DLN-121, "Disassembly and Assembly".
  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 operation of the bearing.
  4.  Fit drive pinion socket onto drive pinion spline. Measure the total preload, using the preload gauge and drive pinion socket.

Total preload torque

A : Preload gauge [SST: ST3127S000 (J-25765-A)]
B : Drive pinion socket [SST: KV38109500 ( — )]

Standard
Total preload torque : Refer to DLN-141, "Preload Torque".

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

When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting shims. For selecting adjusting shim, refer to the latest parts information.

When the preload is small
On pinion bearings: Tighten the drive pinion nut.
On side bearings: Use thicker side bearing adjusting shims. For selecting adjusting shim, refer to the latest parts information.

DRIVE GEAR RUNOUT

  1.  Remove rear cover. Refer to DLN-125, "Disassembly and Assembly".
  2.  Following the procedure below, install a dummy cover set [SST: KV381086S1 ( — )] to gear carrier.
  1. Set dummy cover shims [SST: KV38108630 ( — )] to the right and left side bearing adjusting shims.
  2.  Temporarily tighten dummy cover [SST: KV38108610 ( — )] to gear carrier.
  3. Position dummy cover spacers [SST: KV38108621 ( — )] to dummy cover [SST: KV38108610 ( — )].
  4.  Tighten rear cover mounting bolts to the specified torque. Refer to DLN-124, "Exploded View".
  5.  Tighten dummy cover spacer mounting bolts evenly to the specified torque.

: 5.9 N·m (0.6 kg-m, 52 in-lb)

  1. Fit a dial indicator to the drive gear back face.
  2.  Rotate the drive gear to measure runout.

Drive gear runout

Limit
Drive gear back face runout : Refer to DLN-141, "Drive Gear Runout".

CAUTION: Replace drive gear and drive pinion as a set.

TOOTH CONTACT

  1.  Remove rear cover. Refer to DLN-125, "Disassembly and Assembly".
  2. Following the procedure below, install a dummy cover set [SST: KV381086S1 ( — )] to gear carrier.
  1.  Set dummy cover shims [SST: KV38108630 ( — )] to the right and left side bearing adjusting shims.
  2.  Temporarily tighten dummy cover [SST: KV38108610 ( — )] to gear carrier.
  3.  Position dummy cover spacers [SST: KV38108621 ( — )] to dummy cover [SST: KV38108610 ( — )].
  4.  Tighten rear cover mounting bolts to the specified torque. Refer to DLN-124, "Exploded View".
  5. Tighten dummy cover spacer mounting bolts evenly to the specified torque.

: 5.9 N·m (0.6 kg-m, 52 in-lb)

  1. Apply red lead to drive gear.

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

Drive gear runout

  1. Rotate drive gear back and forth several times, check drive pinion gear to drive gear tooth contact.

CAUTION: Check tooth contact on drive side and reverse side.

Drive gear runout

Tooth Contact Judgment Guide
Tooth Contact Judgment Guide

  1. If tooth contact is improperly adjusted, follow the procedure below to adjust the pinion height (dimension X).

Drive gear runout

Drive gear runout

Drive gear runout

BACKLASH

  1.  Remove rear cover. Refer to DLN-125, "Disassembly and Assembly".
  2.  Following the procedure below, install a dummy cover set [SST: KV381086S1 ( — )] to gear carrier.
  1.  Set dummy cover shims [SST: KV38108630 ( — )] to the right and left side bearing adjusting shims.
  2.  Temporarily tighten dummy cover [SST: KV38108610 ( — )] to gear carrier.
  3.  Position dummy cover spacers [SST: KV38108621 ( — )] to dummy cover [SST: KV38108610 ( — )].
  4.  Tighten rear cover mounting bolts to the specified torque. Refer to DLN-124, "Exploded View".
  5.  Tighten dummy cover spacer mounting bolts evenly to the specified torque.

: 5.9 N·m (0.6 kg-m, 52 in-lb)

  1. Fit a dial indicator to the drive gear face to measure the backlash.

Backlash

Standard
Backlash : Refer to DLN-141, "Backlash".

When the backlash is large: Make drive gear back adjusting shims thicker, and drive gear front adjusting shims thinner. For selecting adjusting shim, refer to the latest parts information.

When the backlash is small: Make drive gear back adjusting shims thinner, and drive gear front adjusting shims thicker. For selecting adjusting shim, refer to the latest parts information.

Inspection

INSPECTION AFTER DISASSEMBLY

Drive Gear and Drive Pinion

Bearing

Oil Seal

Differential Assembly

DIFFERENTIAL CASE

SIDE GEAR AND PINION MATE GEAR

SIDE GEAR THRUST WASHER AND PINION MATE THRUST WASHER

DRIVE PINION

Exploded View

Exploded View

  1. Stud bolt
  2. Connector bracket
  3. Reamer bolt
  4. Electric controlled coupling assembly
  5. Wave spring
  6. Drive pinion oil seal
  7. Drive pinion lock nut
  8. Pinion front bearing
  9. Gear carrier
  10. Collapsible spacer
  11. Drive pinion adjusting shim
  12. Pinion rear bearing
  13. Drive pinion
  14. Drive gear
  15. Differential case
  16. Side bearing
  17. Side bearing adjusting shim
  18. Side oil seal
  19. Rear cover
  20. Stud bolt
  21. Gasket
  22. Drain plug
  23. Filler plug
  24. Pinion mate thrust washer
  25. Pinion mate gear
  26. Side gear thrust washer
  27. Side gear
  28. Pinion mate shaft
  29. Lock pin
  1. Oil seal lip
  2. Screw hole

: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Select with proper thickness.
: Apply gear oil.
*: Apply anti-corrosion oil.
: Apply multi purpose grease.
: Apply Genuine Silicone RTV or equivalent. Refer to GI-22, "Recommended Chemical Products and Sealants".
: Apply Genuine High Strength Thread Locking Sealant or equivalent. Refer to GI-22, "Recommended Chemical Products

Disassembly and Assembly

DISASSEMBLY

  1.  Remove electric controlled coupling assembly. Refer to DLN-121, "Disassembly and Assembly".
  2.  Remove differential assembly. Refer to DLN-125, "Disassembly and Assembly".
  3.  Remove drive pinion oil seal, using oil seal remover (commercial service tool).
  4.  Fit drive pinion socket (A) onto drive pinion spline. Remove drive pinion lock nut, using the pinion nut wrench (B).

Disassembly

A : Drive pinion socket [SST: KV38109500 ( — )]
B : Pinion nut wrench [SST: KV38109400 ( — )]

  1. Press drive pinion assembly out of gear carrier.

    CAUTION: Never drop drive pinion assembly.

  2.  Remove pinion front bearing inner race.
  3.  Remove collapsible spacer.

Disassembly

  1. Remove pinion rear bearing inner race from drive pinion, using the separator (A) and the puller (B).

A : Separator (commercial service tool)
B : Puller (commercial service tool)

Disassembly

  1. Using a brass rod or equivalent (A), tap pinion front bearing outer race evenly from the 2 cutouts on gear carrier and remove pinion front bearing outer race.

CAUTION: Be careful not to damage gear carrier.

Disassembly

  1. Using a brass rod or equivalent (A), tap drive pinion adjusting shim evenly from the 2 cutouts on gear carrier and remove drive pinion adjusting shim and pinion rear bearing outer race.

    CAUTION: Be careful not to damage gear carrier.

  2.  Perform inspection after disassembly. Refer to DLN-140, "Inspection".

Disassembly

ASSEMBLY

  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 drift (A) [SST: ST17130000 ( — )].

CAUTION:

Assembly

  1. Press pinion front bearing outer race into gear carrier, using the drift (A) [SST: ST33230000 (J-25805-01)].

CAUTION:

Assembly

  1. Press pinion rear bearing inner race to drive pinion, using the drift (A) [SST: ST23860000 ( — )].

CAUTION: Never reuse pinion rear bearing inner race.

Assembly

  1. Check and adjust the tooth contact and back lash of drive gear and drive pinion following the procedure below.
  1.  Assemble drive pinion into gear carrier.

CAUTION:

  1.  Assemble pinion front bearing inner race to drive pinion assembly.

CAUTION:

  1. Using the drifts (A and C) and press stand (B), press pinion front bearing inner race to drive pinion as far as drive pinion lock nut can be tightened.

Assembly

A : Drift [SST: KV40100610 (J-26089)]
B : Press stand [SST: ST38220000 ( — )]
C : Drift [SST: ST23860000 ( — )]

  1. Temporarily tighten removed drive pinion lock nut to drive pinion.

    NOTE: Use removed drive pinion lock nut only for the preload measurement.

  2.  Rotate drive pinion more than 20 times to adjust bearing.
  3.  Fit the drive pinion socket (A) onto the drive pinion. Using the pinion nut wrench (B), tighten drive pinion lock nut holding drive pinion, while adjusting pinion bearing preload torque using preload gauge (C).

Assembly

A: Drive pinion socket [SST: KV38109500 ( — )]
B : Pinion nut wrench [SST: KV38109400 ( — )]
C : Preload gauge [SST: ST3127S000 (J-25765-A)]

Pinion bearing preload : Refer to DLN-141, "Preload Torque".

CAUTION: Drive pinion lock nut is tightened with no collapsible spacer. Be careful not to overtighten it. While measuring the preload, tighten it by 5° to 10°.

  1. Install new side bearing adjusting shims (2 pieces for one side) with the same thickness or re-install the old ones to the same mounting position they were in prior to disassembly. Install differential assembly to gear carrier. Refer to DLN-125, "Disassembly and Assembly".

    CAUTION: Apply differential gear oil to the side bearings.

  2.  Check and adjust tooth contact, drive gear to drive pinion backlash. Refer to DLN-130, "Adjustment".
  3.  Remove differential assembly.
  4.  Remove drive pinion assembly from gear carrier
  5.  Remove drive pinion nut and press drive pinion assembly out of gear carrier.
  6.  Remove pinion front bearing inner race.
  1. Assemble collapsible spacer 1 to drive pinion 2.

CAUTION:

Assembly

  1. Assemble drive pinion into gear carrier.

    CAUTION: Apply gear oil to pinion rear bearing.

  2.  Assemble pinion front bearing inner race to drive pinion assembly.

CAUTION:

  1. Using the drifts (A and C) and press stand (B), press pinion front bearing inner race to drive pinion as far as drive pinion lock nut can be tightened.

Assembly

A : Drift [SST: KV40100610 (J-26089)]
B : Press stand [SST: ST38220000 ( — )]
C : Drift [SST: ST23860000 ( — )]

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

    CAUTION: Never reuse drive pinion lock nut.

  2.  Fit the drive pinion socket (A) onto the drive pinion. While holding drive pinion, tighten drive pinion lock nut within the limits of specified torque so as to keep the pinion bearing preload within a standard values, using the pinion nut wrench (B) and the preload gauge (C).

Assembly

A : Drive pinion socket [SST: KV38109500 ( — )]
B : Pinion nut wrench [SST: KV38109400 ( — )]
C : Preload gauge [SST: ST3127S000 (J-25765-A)]

Drive pinion lock nut tightening torque : Refer to DLN-135, "Exploded View".
Pinion bearing preload : Refer to DLN-141, "Preload Torque".

CAUTION:

  1.  Install differential assembly. Refer to DLN-125, "Disassembly and Assembly".

CAUTION: Never install rear cover at this timing.

  1. Check and adjust drive gear runout, tooth contact, and drive gear to drive pinion backlash. Refer to DLN- 130, "Adjustment".
  2.  Remove dummy cover set [SST: KV381086S1 ( — )], then install rear cover, and side oil seal. Refer to DLN-125, "Disassembly and Assembly".
  3.  Check total preload torque. Refer to DLN-130, "Adjustment".
  4.  Using the drift (A) [SST: ST35271000 (J-26091)], install drive pinion oil seal 1 within the dimension (D) shown as follows.

Assembly

D : 0.8 – 1.2 mm (0.031 – 0.047 in)

CAUTION:

  1.  Install electric controlled coupling assembly. Refer to DLN-121, "Disassembly and Assembly".

Inspection

INSPECTION AFTER DISASSEMBLY

Drive Gear and Drive Pinion

Bearing

Oil Seal

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