REAR FINAL DRIVE

D DRIVELINE/AXLE

SECTION RFD
REAR FINAL DRIVE
B

RFD

E
CONTENTS
PRECAUTIONS .......................................................... 2 ELECTRIC CONTROLLED COUPLING ................... 12 F
Service Notice or Precautions .................................. 2 Removal and Installation ........................................ 12
PREPARATION ........................................................... 3 REMOVAL ........................................................... 12
Special Service Tools ............................................... 3 INSTALLATION ................................................... 13 G
Commercial Service Tools ........................................ 5 REAR FINAL DRIVE ASSEMBLY ............................ 14
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ........................................ 14
TROUBLESHOOTING ................................................ 6 COMPONENTS ................................................... 14
H
NVH Troubleshooting Chart ..................................... 6 REMOVAL ........................................................... 14
DESCRIPTION ............................................................ 7 INSTALLATION ................................................... 15
Cross-Sectional View ............................................... 7 Disassembly and Assembly .................................... 16
DIFFERENTIAL GEAR OIL ........................................ 8 COMPONENTS ................................................... 16 I
Changing Differential Gear Oil ................................. 8 ASSEMBLY INSPECTION AND ADJUSTMENT... 17
DRAINING ............................................................. 8 DISASSEMBLY ................................................... 21
FILLING ................................................................. 8 INSPECTION AFTER DISASSEMBLY ................ 24 J
Checking Differential Gear Oil .................................. 8 ASSEMBLY ......................................................... 25
OIL LEAKAGE AND OIL LEVEL ........................... 8 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
FRONT OIL SEAL ...................................................... 9 General Specifications ............................................ 34
K
Removal and Installation .......................................... 9 Inspection and Adjustment ..................................... 34
REMOVAL ............................................................. 9 DRIVE GEAR RUNOUT ...................................... 34
INSTALLATION ..................................................... 9 DIFFERENTIAL SIDE GEAR CLEARANCE ....... 34
SIDE OIL SEAL .........................................................11 PRELOAD TORQUE ........................................... 34 L
Removal and Installation .........................................11 BACKLASH ......................................................... 34
REMOVAL ............................................................11 COMPANION FLANGE RUNOUT ....................... 34
INSTALLATION ....................................................11 SELECTIVE PARTS ............................................ 34 M

Revision: 2005 March RFD-1 2005 X-Trail

 PRECAUTIONS

PRECAUTIONS PFP:00001

Service Notice or Precautions ADS0015Z

● 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 exterior 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 ones 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 outside. 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 moisture, 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 differential oil, petroleum jelly, or
multi-purpose grease as specified for each vehicle, if necessary.

Revision: 2005 March RFD-2 2005 X-Trail

 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools ADS00160

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number B
(Kent-Moore No.) Description
Tool name

ST27861000 Installing final drive front oil seal

C
( — )
Drift
a: 62 mm (2.44 in) dia.
b: 52 mm (2.05 in) dia. RFD

ZZA0832D

KV38100200 ● Installing final drive front oil seal

E
(J-26233) ● Installing final drive side oil seal
Drift
a: 65 mm (2.56 in) dia.
F
b: 49 mm (1.93 in) dia.

ZZA1143D
G
ST3127S000 Measuring preload torque
(J-25765-A)
Preload gauge
H

I
ZZA0503D

ST33052000 Removing side bearing inner race

( — )
Drift J
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
K
ZZA1023D

KV40100610 ● Removing and installing gear carrier and

(J-26089) rear cover (2 pieces are used) L
Drift ● Installing pinion front bearing inner race
a: 63 mm (2.48 in) dia.
b: 54.3 mm (2.138 in) dia.
M

ZZA0810D

ST23550000 Removing and installing lock pin

( — )
Pin punch
a: 4.5 mm (0.177 in) dia.

NT410

ST17130000 Installing pinion rear bearing outer race

( — )
Drift
a: 31.8 mm (1.252 in) dia.
b: 58 mm (2.28 in) dia.

ZZA0836D

Revision: 2005 March RFD-3 2005 X-Trail

 PREPARATION

Tool number
(Kent-Moore No.) Description
Tool name

ST33230000 Installing pinion front bearing outer race

(J-25805-01)
Drift
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.

ZZA1046D

ST23860000 ● Installing pinion rear bearing inner race

( — ) ● Installing pinion front bearing inner race
Drift
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.

ZZA0534D

ST38220000 Installing pinion front bearing inner race

( — )
Press stand
a: 63 mm (2.48 in) dia.
b: 65 mm (2.56 in)

ZZA1058D

KV40105020 Installing side bearing inner race

( — )
Drift
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)

ZZA1133D

ST35271000 Installing center oil seal

(J-26091)
Drift
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.

ZZA0814D

ST22360002 Installing coupling front bearing

(J-25679-01)
Drift
a: 29 mm (1.14 in) dia.
b: 23 mm (0.91 in) dia.
c: 150 mm (5.91 in)

ZZA0546D

Revision: 2005 March RFD-4 2005 X-Trail

 PREPARATION

Tool number
(Kent-Moore No.) Description A
Tool name

KV381086S1 ● Checking backlash

( — ) ● Checking drive gear runout
B
Dummy cover set
● Checking tooth contact
1. KV38108610
( — ) C
Dummy cover
2. KV38108621
( — )
Dummy cover spacer RFD
SDIA2313E
3. KV38108630
( — )
Dummy cover shim E
KV38108500 ● Measuring preload torque
( — ) ● Removing and installing drive pinion nut
Drive pinion socket F

G
ZZA1205D

KV38108400 ● Measuring preload torque

( — ) ● Removing drive pinion nut H
Pinion nut wrench

I
ZZA1206D

Commercial Service Tools ADS0018A J

Tool name Description

Flange wrench Removing and installing companion flange K

lock nut

NT771
M
Power tool Loosening nuts and bolts

PBIC0190E

Revision: 2005 March RFD-5 2005 X-Trail

 Symptom
×: Applicable
Reference page

Revision: 2005 March

Noise
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart

Gear tooth rough Refer to RFD-24, "INSPECTION AFTER DISASSEMBLY" .

×
×
Gear contact improper Refer to RFD-18, "Tooth Contact" .

RFD-6
×
Tooth surfaces worn Refer to RFD-24, "INSPECTION AFTER DISASSEMBLY" .

×
Backlash incorrect Refer to RFD-20, "Backlash" .

Companion flange excessive runout Refer to RFD-20, "Companion Flange Runout" .

×
Gear oil improper Refer to RFD-8, "Checking Differential Gear Oil" .

×
×
PROPELLER SHAFT NVH in PR section.

×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.

×
TIRES NVH in WT section.
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

ROAD WHEEL NVH in WT section.

×
DRIVE SHAFT NVH in FAX and RAX section.

×
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

× BRAKES NVH in BR section.

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

STEERING NVH in PS section.

PFP:00003

2005 X-Trail
ADS00161
 DESCRIPTION

DESCRIPTION PFP:00000
A
Cross-Sectional View ADS0018B

RFD

SDIA0141E

Revision: 2005 March RFD-7 2005 X-Trail

 DIFFERENTIAL GEAR OIL

DIFFERENTIAL GEAR OIL PFP:KLD30

Changing Differential Gear Oil ADS0018C

DRAINING
1. Stop engine.
2. Remove drain plug and drain oil.
3. Set a gasket on drain plug and install it to final drive assembly
and tighten to the specified torque. Refer to RFD-16, "COMPO-
NENTS" .
CAUTION:
Do not reuse gasket.

PDIA0454E

FILLING
1. Remove filler plug. Fill with new oil until oil level reaches the
specified level near filler plug mounting hole.
Oil grade and Viscosity:
Refer to MA-11, "Fluids and Lubricants" .
Oil capacity:
Approx. 0.55 (1-1/8 US pt, 1 Imp pt)
2. After refilling oil, check oil level. Set a gasket to filler plug, then
install it to final drive assembly. Refer to RFD-16, "COMPO-
NENTS" . PDIA0453E

CAUTION:
Do not reuse gasket.
Checking Differential Gear Oil ADS0018D

OIL LEAKAGE AND OIL LEVEL

● Make sure that oil is not leaking from final drive assembly or around it.
● Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Do not start engine while checking oil level.
● Set a gasket on filler plug and install it on final drive assembly.
Refer to RFD-16, "COMPONENTS" .
CAUTION:
Do not reuse gasket.

PDIA0453E

Revision: 2005 March RFD-8 2005 X-Trail

 FRONT OIL SEAL

FRONT OIL SEAL PFP:38189

A
Removal and Installation ADS0016K

REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
B
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.
C
CAUTION:
For matching mark, use paint. Do not damage electric con-
trolled coupling.
RFD

E
PDIA0455E

3. Remove companion flange lock nut, using a flange wrench. F

Then remove companion flange.

PDIA0456E I

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

screwdriver.
J
CAUTION:
Be careful not to damage coupling cover.

PDIA0457E

INSTALLATION M
1. Apply multi-purpose grease to front oil seal lips.
2. Install front oil seal until it becomes flush with the case end,
using the drifts.
Tool number A: KV38100200 (J-26233)
B: ST27861000 ( — )
CAUTION:
● Do not reuse oil seal.

● When installing, do not incline oil seal.

PDIA0038E

Revision: 2005 March RFD-9 2005 X-Trail

 FRONT OIL SEAL

3. Align the matching mark of electric controlled coupling with the

matching mark of companion flange, then install the companion
flange.
4. Install companion flange lock nut with a flange wrench, tighten
the to the specified torque. Refer to RFD-16, "COMPONENTS" .
CAUTION:
Do not reuse companion flange lock nut.
5. Install propeller shaft. Refer to PR-4, "Removal and Installation"
.
PDIA0455E

Revision: 2005 March RFD-10 2005 X-Trail

 SIDE OIL SEAL

SIDE OIL SEAL PFP:38343

A
Removal and Installation ADS0016L

REMOVAL
1. Remove rear drive shaft with power tool. Refer to RAX-20, "REAR DRIVE SHAFT" .
B
2. Remove side oil seal, using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage gear carrier and rear cover.
C

RFD

E
PDIA0431E

INSTALLATION
1. Apply multi-purpose grease to side oil seal lips. F
2. Install side oil seal until it becomes flush with the case end,
using the drift.
Tool number : KV38100200 (J-26233) G

CAUTION:
● Do not reuse oil seal.
H
● When installing, do not incline oil seal.

3. Install rear drive shaft. Refer to RAX-20, "REAR DRIVE

SHAFT" .
I
PDIA0432E

Revision: 2005 March RFD-11 2005 X-Trail

 ELECTRIC CONTROLLED COUPLING

ELECTRIC CONTROLLED COUPLING PFP:38760

Removal and Installation ADS0018E

REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
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 the companion flange.
CAUTION:
For matching mark, use paint. Do not damage electric con-
trolled coupling.
NOTE:
When replacing electric controlled coupling, matching mark is
not necessary.

PDIA0455E

3. Remove companion flange lock nut, using a flange wrench.

4. Remove companion flange.
5. Disconnect AWD solenoid harness connector and remove con-
nector bracket.
6. Remove electric controlled coupling breather hose from cou-
pling cover.

PDIA0456E

7. Remove coupling cover with electric controlled coupling from

gear carrier.
8. Remove electric controlled coupling from coupling cover.

PDIA0458E

Revision: 2005 March RFD-12 2005 X-Trail

 ELECTRIC CONTROLLED COUPLING

INSTALLATION
1. Install electric controlled coupling to spline of drive pinion inside A
gear carrier.
CAUTION:
● Align the pin on electric controlled coupling with the B
groove of gear carrier.
● Be careful not to damage center oil seal.

2. Set AWD solenoid harness guide to gear carrier. C

PDIA0463E
RFD

3. Apply liquid gasket to mating surface of coupling cover. Overlap

both ends of the bead for at least 3 mm (0.12 in). E
● Use Genuine Silicone RTV or equivalent. Refer to GI-48,
"RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS" . F
CAUTION:
Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering G
to the mounting surfaces.

PDIA0451E
H
4. Install coupling cover to gear carrier with arrow facing upward,
temporarily tighten reamer bolts to the positions shown in the
figure. I
5. Tighten reamer bolts and coupling cover mounting bolts to the
specified torque. Refer to RFD-16, "COMPONENTS" .
6. Install electric controlled coupling breather hose to coupling J
cover.
7. Install connector bracket and connect AWD solenoid harness
connector. K
8. Install companion flange. SDIA0587E
NOTE:
When reusing electric controlled coupling, align the matching L
mark of electric controlled coupling with the matching mark of
companion flange, then install companion flange.
9. Install companion flange lock nut with flange wrench, tighten to
M
the specified torque. Refer to RFD-16, "COMPONENTS" .
CAUTION:
Do not reuse companion flange lock nut.
10. Install propeller shaft. Refer to PR-4, "Removal and Installation"
.
PDIA0455E

Revision: 2005 March RFD-13 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

REAR FINAL DRIVE ASSEMBLY PFP:38300

Removal and Installation ADS00166

COMPONENTS

PDIA0433E

1. Rear suspension member 2. Final drive mounting bracket 3. Harness bracket

4. Drive shaft 5. Propeller shaft 6. Rear final drive assembly

REMOVAL
1. Remove propeller shaft. Refer to PR-4, "Removal and Installation" .
2. Remove drive shaft with power tool. Refer to RAX-20, "Removal and Installation" .
3. Disconnect AWD solenoid harness connector.
4. Remove rear final drive breather hose and electric controlled coupling breather hose.
5. Support rear final drive assembly with a suitable jack.
6. Remove rear final drive mounting nut at rear suspension mem-
ber.

PDIA0434E

7. Remove rear final drive mounting bolts at final drive mounting

bracket, and then remove rear final drive assembly.
If necessary, remove final drive mounting bracket.
CAUTION:
Secure rear final drive assembly to a suitable jack while
removing it.

PDIA0435E

Revision: 2005 March RFD-14 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

INSTALLATION
Note the following, and install in the reverse order of removal. A
● Refer to RFD-14, "COMPONENTS" about each tightening torque.
● When installing breather hoses, refer to the figure and following.
B
CAUTION:
Make sure there are no pinched or restricted areas on the
breather hose caused by bending or winding when install-
ing it. C
– For installation of rear final drive breather hose, the vehicle side
end shall be inserted to cross member. Install metal connector
side of this hose to rear cover by inserting it with aiming painted RFD
marking to the front of vehicle.

H
PDIA0436E

– For installation of electric controlled coupling breather hose, the I

vehicle side end shall be inserted to cross member. Install its
metal tube to rear final drive assembly and direct the metal tube
hose side end to the front of vehicle.
J
● When oil leaks while removing final drive assembly, check oil
level after the installation. Refer to RFD-8, "Checking Differential
Gear Oil" .
K

PDIA0437E
L

Revision: 2005 March RFD-15 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

Disassembly and Assembly ADS00169

COMPONENTS

PDIA0438E

1. Companion flange lock nut 2. Companion flange 3. Front oil seal

4. Coupling cover 5. Connector bracket 6. Reamer bolt
7. Coupling front bearing 8. Bearing shim 9. Electric controlled coupling
10. AWD solenoid harness 11. Center oil seal 12. Drive pinion nut
13. Pinion front bearing 14. Gear carrier 15. Collapsible spacer
16. Drive pinion adjusting shim 17. Pinion rear bearing 18. Drive pinion
19. Side oil seal 20. Side bearing adjusting shim 21. Side bearing
22. Drive gear 23. Differential case 24. Side gear thrust washer
25. Side gear 26. Pinion mate thrust washer 27. Pinion mate gear
28. Pinion mate shaft 29. Lock pin 30. Rear cover
31. Filler plug 32. Drain plug 33. Gasket

Revision: 2005 March RFD-16 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

ASSEMBLY INSPECTION AND ADJUSTMENT

Total Preload Torque A
1. Remove electric controlled coupling assembly. Refer to RFD-21, "Electric Controlled Coupling Assembly"
.
2. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction. B
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 C
preload, using the preload gauge.
Tool number A: ST3127S000 (J-25765-A)
RFD
B: KV38108500 ( — )

Total preload torque:

E
1.33 - 2.15 N·m (0.14 - 0.21 kg-m, 12 - 19 in-lb)
PDIA0048E
NOTE:
Total preload torque = Pinion bearing torque + Side bearing torque
F
● If measured value is out of the specification, disassemble it to check and adjust each part. Adjust the pin-
ion bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.
G
When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting shims. Refer to RFD-35, "Side H
Bearing Adjusting Shim" .

When the preload is small I

On pinion bearings: Tighten the drive pinion nut.
On side bearings: Use thicker side bearing adjusting shims. Refer to RFD-35, "Side
Bearing Adjusting Shim" . J

Drive Gear Runout

1. Remove rear cover. Refer to RFD-22, "Differential Assembly" . K
2. Following the procedure below, install a dummy cover set to
gear carrier.
Tool number : KV381086S1 ( — ) L
a. Set dummy cover shims to the right and left side bearing adjust-
ing shims.
b. Temporarily tighten dummy cover to gear carrier. M
c. Position dummy cover spacer to dummy cover.
d. Tighten rear cover mounting bolts to the specified torque. Refer
to RFD-16, "COMPONENTS" .
PDIA0474E
e. Tighten dummy cover spacer mounting bolts evenly to the spec-
ified torque.
: 5.9 N·m (0.6 kg-m, 52 in-lb)

Revision: 2005 March RFD-17 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

3. Fit a dial indicator to the drive gear back face.

4. Rotate the drive gear to measure runout.
Runout limit: 0.05 mm (0.0020 in) or less
● 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 gear as a set.
PDIA0050E

Tooth Contact
1. Remove rear cover. Refer to RFD-22, "Differential Assembly" .
2. Attach dummy cover set. For dummy cover installation, refer to RFD-17, "Drive Gear Runout" .
Tool number : KV381086S1 ( — )
3. Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.

PDIA0051E

4. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.

SDIA0570E

Revision: 2005 March RFD-18 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

RFD

SDIA2549E J
5. If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X).
K

M
SDIA0517E

● If the tooth contact is near the face (face contact), or near the
heal (heel contact), thicken drive pinion gear adjusting shims to
move drive pinion closer to drive gear.
Refer to RFD-35, "Drive Pinion Adjusting Shim" .

PDIA0440E

Revision: 2005 March RFD-19 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

● If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin drive pinion gear adjusting shims to move
drive pinion farther from drive gear.
Refer to RFD-35, "Drive Pinion Adjusting Shim" .

PDIA0441E

Backlash
1. Remove rear cover. Refer to RFD-22, "Differential Assembly" .
2. Attach dummy cover set. For dummy cover installation, refer to RFD-17, "Drive Gear Runout" .
Tool number : KV381086S1 ( — )
3. Fit a dial indicator to the drive gear face to measure the back-
lash.
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
● If the backlash is outside of the specified value, change the
thickness of side bearing adjusting shims.
When the backlash is large:
Make drive gear back adjusting shims thicker, and
drive gear front adjusting shims thinner. Refer to RFD-
35, "Side Bearing Adjusting Shim" . PDIA0049E

When the backlash is small:

Make drive gear back adjusting shims thinner, and
drive gear front adjusting shims thicker. Refer to RFD-
35, "Side Bearing Adjusting Shim" .
Companion Flange Runout
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
Runout limit: 0.13 mm (0.0051 in) or less
3. Fit a test indicator to the inner side of companion flange (socket
diameter).
4. Rotate companion flange to check for runout.
Runout limit: 0.19 mm (0.0075 in) or less
PDIA0439E
5. If the runout value is outside the runout limit, follow the proce-
dure 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.

Revision: 2005 March RFD-20 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

DISASSEMBLY
Electric Controlled Coupling Assembly A
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 B
mark on companion flange.
CAUTION:
For matching mark, use paint. Do not damage electric con- C
trolled coupling.
NOTE:
When replacing electric controlled coupling, matching mark is RFD
not necessary.

PDIA0455E
E
3. Remove companion flange lock nut, using a flange wrench.
4. Remove companion flange.
F
5. Remove coupling cover.

PDIA0442E

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

screwdriver.
CAUTION:
Be careful not to damage coupling cover. J

PDG0213D
L

7. Remove electric controlled coupling assembly from drive pinion

in gear carrier. M
8. Remove AWD solenoid harness.

PDIA0443E

Revision: 2005 March RFD-21 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

9. Remove coupling front bearing, using pullers and then take off
bearing shim from electric controlled coupling.
10. Remove center oil seal from gear carrier.

PDIA0444E

Differential Assembly
1. Remove side oil seal from gear carrier and rear cover, using flat-
bladed screwdriver.
CAUTION:
Be careful not to damage gear carrier and rear cover.
2. Remove rear cover mounting bolts.

PDG0216D

3. Set drifts to the right and left side bearing adjusting shims indi-
vidually. Press differential case assembly with side bearing to
remove gear carrier assembly and rear cover assembly.
Tool number : 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, 1.1 US ton, 1.0 Imp ton).
NOTE:
Differential case assembly, side bearings, and adjusting shims PDIA0065E
are compressed and integrated in gear carrier and rear cover.
4. Remove drain plug and filler plug.
5. 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.
6. Remove drive gear mounting bolts and then remove drive gear
from differential case.

PDIA0446E

Revision: 2005 March RFD-22 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

7. Remove side bearing inner races, using pullers and the drift.
Tool number : ST33052000 ( — ) A

PDIA0459E

RFD
8. Pull the lock pin out of pinion mate shaft, using the pin punch.
Tool number : ST23550000 ( — )
E

G
PDIA0062E

9. Remove pinion mate shaft, pinion mate gears, pinion mate

thrust washers, side gears, side gear thrust washers from differ- H
ential case.

SDIA0032J

K
Drive Pinion Assembly
1. Remove electric controlled coupling assembly. Refer to RFD-21, "Electric Controlled Coupling Assembly"
. L
2. Remove differential case assembly. Refer to RFD-22, "Differential Assembly" .
3. Fit drive pinion socket onto drive pinion spline. Remove drive
pinion nut, using the pinion nut wrench. M
Tool number A: KV38108400 ( — )
B: KV38108500 ( — )

PDIA0054E

Revision: 2005 March RFD-23 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

4. Press drive pinion assembly out of gear carrier.

CAUTION:
Do not drop drive pinion assembly.
5. Remove pinion front bearing inner race.
6. Remove collapsible spacer.

PDIA0445E

7. Remove pinion rear bearing inner race from drive pinion, using
pullers.

PDIA0179E

8. Using a brass rod, tap pinion front bearing outer race evenly
from the 2 cutouts on gear carrier and remove pinion front bear-
ing outer race.
CAUTION:
Be careful not to damage gear carrier.
9. Using a brass rod, tap drive pinion adjusting shim evenly from
the 2 cutouts on gear carrier and remove drive pinion adjusting
shims and pinion rear bearing outer race.
CAUTION:
Be careful not to damage the gear carrier.
SDIA0564E

INSPECTION AFTER DISASSEMBLY

Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.
Content Conditions and Measures
● If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.
Hypoid gear
● If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
● If any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing
Bearing
is observed, replace as a bearing assembly (as a new set).

Side gear and Pinion mate ● If any cracks or damage on the surface of the tooth is found, replace.
gear ● If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
Side gear thrust washer and
● If it is chipped (by friction), damaged, or unusually worn, replace.
pinion mate thrust washer
● Whenever disassembled, replace.
Oil seal ● If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case ● If any wear or crack on the contact sides of the differential case is found, replace.
● If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the
Companion flange
companion flange is found, replace.

Revision: 2005 March RFD-24 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

ASSEMBLY
Drive Pinion Assembly A
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. B
Tool number : ST17130000 ( — )
CAUTION:
C
● At first, using a hammer, tap bearing outer race until it
becomes flush to gear carrier.
● Do not reuse pinion rear bearing outer race.
RFD
PDIA0056E

2. Press pinion front bearing outer race into gear carrier, using the E
drift.
Tool number : ST33230000 (J-25805-01)
F
CAUTION:
● At first, using a hammer, tap bearing outer race until it
becomes flush to gear carrier.
● Do not reuse pinion front bearing outer race. G

PDIA0067E H

3. Press pinion rear bearing inner race to drive pinion, using the
drift.
I
Tool number : ST23860000 ( — )
CAUTION:
Do not reuse pinion rear bearing inner race. J
4. After checking and adjusting the tooth contact and backlash of
the hypoid gear following the procedure below.
a. Apply gear oil to the drive pinon rear bearing, and assemble the K
drive pinion to the gear carrier.
CAUTION: PDIA0068E

Do not assemble a collapsible spacer. L

b. Apply gear oil to drive pinon front bearing, and assemble pinion
front bearing inner race to drive pinion. Using the drifts and
press stand, press pinion front bearing inner race to drive pinon M
as far as drive pinion nut can be tightened.
Tool number A: KV40100610 (J-26089)
B: ST38220000 ( — )
C: ST23860000 ( — )
CAUTION:
Do not reuse pinion front bearing inner race.
PDIA0057E
c. Temporarily tighten removed drive pinon nut to drive pinion.
NOTE:
Use removed drive pinon nut only for the preload measurement.

Revision: 2005 March RFD-25 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

d. Fit the drive pinon socket onto the drive pinion spline. Using the
pinon nut wrench, tighten drive pinon nut to the specified pre-
load torque.
Tool number A: KV38108400 ( — )
B: KV38108500 ( — )
C: ST3127S000 (J-25765-A)

Drive pinion bearing preload:

0.69 - 1.17 N·m (0.07 - 0.11 kg-m, 7 - 10 in-lb)
CAUTION:
Drive pinon nut is tightened with no collapsible spacer. Be
careful not to overtighten it. While measuring the preload,
tighten it by 5° to 10°.

PDIA0058E

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. Install differential case assembly to gear carrier.
Tool number : KV40100610 (J-26089)
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 PDIA0064E
pressure shall be 10 kN (1 ton, 1.1 US 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 RFD-18, "Tooth Contact" .
g. Check and adjust the backlash. Refer to RFD-20, "Backlash" .
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:
Do not drop drive pinion assembly.
j. Remove pinion front bearing inner race.

PDIA0445E

Revision: 2005 March RFD-26 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

5. Assemble collapsible spacer to drive pinion.

CAUTION: A
● Be careful of the mounting direction of collapsible
spacer.
● Do not reuse collapsible spacer. B

SDIA2525E

RFD
6. Apply gear oil to drive pinon front bearing, and assemble pinion
front bearing inner race to drive pinion. Using the drifts and
press stand, press the pinion front bearing inner race to drive
E
pinon as far as drive pinion nut can be tightened.
Tool number A: KV40100610 (J-26089)
B: ST38220000 ( — ) F
C: ST23860000 ( — )
CAUTION:
Do not reuse pinion front bearing inner race. G
PDIA0057E

7. Apply anti-corrosive oil to the thread and seat of drive pinion nut, and temporarily tighten drive pinion nut H
to drive pinion.
CAUTION:
Do not reuse drive pinion nut.
I
8. Fit drive pinon socket onto drive pinion spline. Using the pinon
nut wrench, adjust the drive pinion nut tightening torque and pin-
ion bearing preload torque.
J
Tool number A: KV38108400 ( — )
B: KV38108500 ( — )
C: ST3127S000 (J-25765-A) K

Drive pinion nut tightening torque:

98 - 431 N·m (10 - 43 kg-m, 73 - 317 ft-lb) L
Drive pinion bearing preload:
0.69 - 1.17 N·m (0.07 - 0.11 kg-m, 7 - 10 in-lb)
M
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. PDIA0058E

9. Install differential case assembly. Refer to RFD-28, "Differential Assembly" .

CAUTION:
Do not install rear cover.
10. Install dummy cover set, and check drive gear runout, tooth contact, and backlash. Refer to RFD-17,
"Drive Gear Runout" , RFD-18, "Tooth Contact" , RFD-20, "Backlash" .
11. Remove dummy cover set, then install rear cover, and side oil seal. Refer to RFD-28, "Differential Assem-
bly" .

Revision: 2005 March RFD-27 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

12. Check total preload torque. Refer to RFD-17, "Total Preload Torque" .
13. Install electric controlled coupling assembly. Refer to RFD-31, "Electric Controlled Coupling Assembly" .
14. Check companion flange runout. Refer to RFD-20, "Companion Flange Runout" .

Differential 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 gear and thrust washer into differential case.

SDIA0193J

3. 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.

SDIA0036J

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

SDIA0037J

5. Measure side gear end play following the procedure below, and select the appropriate side gear thrust
washers.
a. Place differential case straight up so that side gear to be mea-
sured comes upward.

PDIA0460E

Revision: 2005 March RFD-28 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

b. Using thickness gauges, measure the clearance between side

gear back and differential case at 3 different positions, while A
rotating side gear. Average the 3 readings, and then measure
the clearance. (Measure the clearance of the other side as well.)
Side gear back clearance specification: B
0.2 mm (0.008 in) or less.
(Each gear should rotate smoothly without excessive
resistance during differential motion.) C
CAUTION:
To prevent side gear from tilting, insert thickness gauges
with the same thickness from both sides. RFD
c. If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. Refer to RFD-34,
"Side Gear Thrust Washer" . E
When the back clearance is large:
Use a thicker thrust washer.
F
When the back clearance is small:
Use a thinner thrust washer.
CAUTION: G
Select a side gear thrust washer for right and left individu- SDIA0583E

ally.
6. Drive a lock pin into pinion mating shaft, using the pin punch. H
Tool number : ST23550000 ( — )
CAUTION:
Do not reuse lock pin. I

PDIA0062E K

7. Press side bearing inner races to differential case, using the

drift.
L
Tool number : KV40105020 ( — )
CAUTION:
Do not reuse side bearing inner race. M

PDIA0052E

8. Apply thread locking sealant into the thread hole of drive gear.
● Use Genuine Medium Strength Thread Locking Sealant or
equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL
PRODUCTS AND SEALANTS" .
CAUTION:
The drive gear back and threaded holes shall be cleaned
and decreased sufficiently.

SPD554

Revision: 2005 March RFD-29 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

9. Install drive gear to the differential case, and apply anti-corrosive

oil onto threads and seats on the mounting bolts, and then
tighten to the specified torque. Refer to RFD-16, "COMPO-
NENTS" .
10. Apply gear oil to side bearings, and 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, with side bearing outer race to differential case.
If side bearing adjusting shims have been already selected, use
them.
CAUTION: PDIA0466E

Do not reuse side bearing outer race.

11. Set the drifts to the right and left side bearing adjusting shims
individually. Compress differential case assembly and side bear-
ing to install gear carrier assembly to differential case assembly.
Tool number : KV40100610 (J-26089)
CAUTION:
● The drift shall be placed on the center of the adjusting
shims.
● The pressure shall be as low as possible to install differ-
ential assembly into gear carrier assembly. The maximum
pressure shall be 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). PDIA0064E

● If the adjusting shims are installed by tapping, the gear

carrier may be damaged. Avoid tapping.
12. Install dummy cover set, check and adjust drive gear runout, tooth contact, backlash, and total preload
torque. Refer to RFD-17, "Drive Gear Runout" , RFD-18, "Tooth Contact" , RFD-20, "Backlash" , RFD-17,
"Total Preload Torque" .
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).
● Use Genuine Silicone RTV or equivalent. Refer to GI-48,
"RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS" .
CAUTION:
Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces.

PDIA0447E

15. Set the drifts to the right and left side bearing adjusting shims
individually. Compress differential case assembly and side bear-
ing to install rear cover.
Tool number : KV40100610 (J-26089)
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,
1.1 US ton, 1.0 Imp ton). PDIA0065E

● 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. Refer to RFD-16, "COMPONENTS" .

Revision: 2005 March RFD-30 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

17. Using the drift, drive side oil seals until it becomes flush with the
case end. A
Tool number : KV38100200 (J-26233)
CAUTION:
● Do not reuse oil seal.
B
● When installing, do not incline oil seal.

● Apply multi-purpose grease onto oil seal lips, and gear

C
oil onto the circumference of oil seal.
18. Check total preload torque. Refer to RFD-17, "Total Preload
Torque" . PDIA0448E

RFD
Electric Controlled Coupling Assembly
1. Using the drift, install center oil seal as shown in the figure.
Tool number : ST35271000 (J-26091) E
CAUTION:
● Do not reuse the oil seal.

● When installing, do not incline oil seal. F

● Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
G

PDIA0464E
K

2. Install bearing shim and coupling front bearing to electric con-

trolled coupling, using the drift. L
Tool number : ST22360002 (J-25679-01)
CAUTION:
When assembling bearing shim, shim chamfer side should M
face electric controlled coupling side.
3. Connect AWD solenoid harness to electric controlled coupling.

PDIA0450E

Revision: 2005 March RFD-31 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

4. Install electric controlled coupling to drive pinion.

CAUTION:
● Align the pin on electric controlled coupling with the
groove of gear carrier.
● Be careful not to damage center oil seal.

5. Set AWD solenoid harness guide to gear carrier.

PDIA0463E

6. Using the drifts, drive front oil seal until it becomes flush with the
case end.
Tool number A: KV38100200 (J-26233)
B: ST27861000 ( — )
CAUTION:
● Do not reuse oil seal.
● When installing, do not incline oil seal.

● Apply multi-purpose grease onto oil seal lips, and gear

oil onto the circumference of oil seal.
PDIA0449E

7. Apply liquid gasket to mating surface of coupling cover. Overlap

both ends of the bead for at least 3 mm (0.12 in).
● Use Genuine Silicone RTV or equivalent. Refer to GI-48,
"RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS" .
CAUTION:
Remove old sealant adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces.

PDIA0451E

8. Install coupling cover to gear carrier with the arrow facing

upward, temporarily tighten reamer bolts to the positions shown
in the figure.
9. Tighten reamer bolts and coupling cover mounting bolts to the
specified torque. Refer to RFD-16, "COMPONENTS" .

SDIA0587E

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.

PDIA0455E

Revision: 2005 March RFD-32 2005 X-Trail

 REAR FINAL DRIVE ASSEMBLY

11. Install companion flange lock nut using a flange wrench, tighten
to the specified torque. Refer to RFD-16, "COMPONENTS" . A
CAUTION:
Do not reuse companion flange lock nut.
12. Check companion flange runout. Refer to RFD-20, "Companion B
Flange Runout" .
13. Install connector bracket, and tighten bolts to the specified
torque. Refer to RFD-16, "COMPONENTS" . C

PDIA0442E
RFD

Revision: 2005 March RFD-33 2005 X-Trail

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications ADS0016A

Applied model QR25DE

Final drive model R145
Gear ratio 2.466
Number of teeth (Drive gear/Drive pinion) 37/15
Oil capacity (Approx.) (US pt, lmp pt) 0.55 (1-1/8, 1)
Number of pinion gears 2
Drive pinion adjustment spacer type Collapsible

Inspection and Adjustment ADS0018F

DRIVE GEAR RUNOUT

Unit: mm (in)
Item Runout limit
Drive gear back face 0.05 (0.0020) or less

DIFFERENTIAL SIDE GEAR CLEARANCE

Unit: mm (in)
Item Specification
0.2 (0.008) or less.
Side gear backlash (Clearance between side gear and differential
(Each gear should rotate smoothly without excessive resistance
case)
during differential motion.)

PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
Item Specification
Pinion bearing (P1 ) 0.69 - 1.17 (0.07 - 0.11, 7 - 10)
Side bearing (P2 ) 0.64 - 0.98 (0.07 - 0.09, 6 - 8)
Side bearing to pinion bearing (Total preload)
1.33 - 2.15 (0.14 - 0.21, 12 - 19)
(Total preload = P1 + P2 )

BACKLASH
Unit: mm (in)
Item Specification
Drive gear to drive pinion gear 0.10 - 0.15 (0.0039 - 0.0059)

COMPANION FLANGE RUNOUT

Unit: mm (in)
Item Runout limit
Companion flange face 0.13 (0.0051) or less
Inner side of the companion flange 0.19 (0.0075) or less

SELECTIVE PARTS
Side Gear Thrust Washer
Unit: mm (in)
Thickness Part number* Thickness Part number*
0.74 (0.0291) 38424 4N200 0.83 (0.0327) 38424 4N203
0.77 (0.0303) 38424 4N201 0.86 (0.0339) 38424 4N204
0.80 (0.0315) 38424 4N202

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

Revision: 2005 March RFD-34 2005 X-Trail

 SERVICE DATA AND SPECIFICATIONS (SDS)

Drive Pinion Adjusting Shim

Unit: mm (in) A
Thickness Part number* Thickness Part number*
1.70 (0.0669) 38154 4N200 2.00 (0.0787) 38154 4N210
1.73 (0.0681) 38154 4N201 2.03 (0.0799) 38154 4N211 B
1.76 (0.0693) 38154 4N202 2.06 (0.0811) 38154 4N212
1.79 (0.0705) 38154 4N203 2.09 (0.0823) 38154 4N213
1.82 (0.0717) 38154 4N204 2.12 (0.0835) 38154 4N214
1.85 (0.0728) 38154 4N205 2.15 (0.0846) 38154 4N215 C
1.88 (0.0740) 38154 4N206 2.18 (0.0858) 38154 4N216
1.91 (0.0752) 38154 4N207 2.21 (0.0870) 38154 4N217
1.94 (0.0764) 38154 4N208 2.24 (0.0882) 38154 4N218
1.97 (0.0776) 38154 4N209 RFD

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

Side Bearing Adjusting Shim E

Unit: mm (in)
Thickness Part number* Thickness Part number*
1.85 (0.0728) 38453 4N200 2.05 (0.0807) 38453 4N204 F
1.90 (0.0748) 38453 4N201 2.10 (0.0827) 38453 4N205
1.95 (0.0768) 38453 4N202 2.15 (0.0854) 38453 4N206
2.00 (0.0787) 38453 4N203 2.20 (0.0866) 38453 4N207
G
*: Always check with the Parts Department for the latest parts information.

Revision: 2005 March RFD-35 2005 X-Trail

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision: 2005 March RFD-36 2005 X-Trail