REAR FINAL DRIVE

D DRIVELINE/AXLE

SECTION RFD
REAR FINAL DRIVE
B

RFD

E
CONTENTS
PREPARATION ........................................................... 2 ASSEMBLY (R200 2–PINION) ............................ 18 F
Special Service Tools ............................................... 2 DISASSEMBLY OF DIFFERENTIAL CASE
Commercial Service Tools ........................................ 4 ASSEMBLY(R200V) ............................................ 20
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION ...................................................... 21 G
TROUBLESHOOTING ................................................ 5 ADJUSTMENT OF DIFFERENTIAL CASE (R200
NVH Troubleshooting Chart ..................................... 5 2–PINION) ........................................................... 21
FRONT OIL SEAL ...................................................... 6 ADJUSTMENT OF DIFFERENTIAL CASE
H
Removal and Installation .......................................... 6 (R200V) ............................................................... 22
REMOVAL ............................................................. 6 SIDE BEARING PRELOAD ................................. 22
INSTALLATION ..................................................... 7 PINION GEAR HEIGHT ...................................... 24
SIDE OIL SEAL .......................................................... 8 TOOTH CONTACT .............................................. 27 I
Removal and Installation .......................................... 8 ASSEMBLY OF DIFFERENTIAL CASE ASSEM-
REMOVAL ............................................................. 8 BLY (R200 2–PINION) ......................................... 28
INSTALLATION ..................................................... 8 ASSEMBLY OF DIFFERENTIAL CASE ASSEM- J
REAR FINAL DRIVE ASSEMBLY ............................ 10 BLY (R200V) ........................................................ 29
Removal and Installation ........................................ 10 INSTALLATION OF DRIVE PINION ASSEMBLY... 30
REMOVAL ........................................................... 10 INSTALLATION OF DIFFERENTIAL CASE
K
INSTALLATION ....................................................11 ASSEMBLY ......................................................... 31
Components ........................................................... 12 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34
R200 2–PINION .................................................. 12 General Specifications ............................................ 34
R200V VISCOUS ................................................ 14 Ring Gear Runout ................................................... 34 L
Pre-Inspection ........................................................ 15 Side Gear Adjustment ............................................ 34
TOTAL PRELOAD ............................................... 15 AVAILABLE SIDE GEAR THRUST WASHERS... 34
RING GEAR TO DRIVE PINION BACKLASH ... 15 Drive Pinion Height Adjustment .............................. 35 M
RING GEAR RUNOUT ........................................ 15 AVAILABLE PINION HEIGHT ADJUSTING
TOOTH CONTACT .............................................. 15 WASHERS .......................................................... 35
Disassembly and Assembly ................................... 16 Drive Pinion Preload Adjustment ............................ 35
REMOVAL OF DIFFERENTIAL CASE ASSEM- Side Bearing Preload Adjustment ........................... 35
BLY ...................................................................... 16 SIDE BEARING ADJUSTING WASHERS .......... 35
REMOVAL OF DRIVE PINION ASSEMBLY ....... 17 Total Preload Adjustment ........................................ 35
DISASSEMBLY OF DIFFERENTIAL CASE

Revision; 2004 April RFD-1 2003 G35 Coupe

 PREPARATION

PREPARATION PFP:00002

Special Service Tools ADS000CD

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

Drift
ST30720000 (J25405)
Installing front oil seal
a : 77 mm (3.03 in) dia.
b : 55 mm (2.17 in) dia.

ZZA0811D

Drift
KV38100200 (J26233)
Installing final drive side oil seal
a : 65 mm (2.56 in) dia.
b : 49 mm (1.93 in) dia.

ZZA1143D

Protector
Installing final drive side flange
KV38107900 (J39352)

S-NT129

Attachment
KV38100800 (J25604-01)
Fixing unit assembly
a : 541 mm (21.30 in)
b : 200 mm (7.87 in)

SDIA0267E

Differential side bearing puller set

ST3306S001 ( – )
1. ST3305S001 ( – )
Removing and installing side bearing
2. ST33061000 (J8107–2)
a : 28.5 mm (1.122 in) dia.
b : 38 mm (1.50 in) dia.
NT072

Drift
ST30613000 (J25742-3) Installing pinion front and rear bearing outer
a : 72 mm (2.83 in) dia. race
b : 48 mm (1.89 in) dia.

ZZA0810D

Drift
KV38100300 (J25523)
a : 54 mm (2.13 in) dia. Installing side bearing
b : 46 mm (1.81 in) dia.
c : 32 mm (1.26 in) dia.
ZZA1046D

Revision; 2004 April RFD-2 2003 G35 Coupe

 PREPARATION

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

Drive pinion flange wrench B

KV40104000 ( – ) Removing and installing drive pinion lock
a : 85 mm (3.35 in) dia. nut
b : 65 mm (2.56 in) dia.
C
NT659

RFD

Sliding hammer
Removing side flange
ST36230000 (J25840-A)
E

ZZA0803D

Axle stand
Removing side flange
KV40104100 ( – ) G

ZZA0804D
H

Sliding hammer I
Removing differential case assembly
HT72400000 ( – )

S-NT125 J
Drive pinion rear inner race puller set
ST3090S000 ( – )
1. ST30031000 (J22912-01) Puller K
2. ST30901000 ( – ) Base
Equivalent tool (J26010-01)
Removing and installing drive pinion rear
a : 90 mm (3.54 in) dia.
bearing inner race
b : 80 mm (3.15 in) dia. L
c : 50 mm (1.97 in) dia.
d : 79 mm (3.11 in) dia.
S-NT640
e : 45 mm (1.77 in) dia.
f : 35 mm (1.38 in) dia. M

Drift Installing pinion rear bearing outer race

ST30611000 (J25742–1) (Use with ST30613000)

S-NT090

Preload gauge
ST3127S000 (see J25765-A)
1. GG91030000
Torque wrench (J25765) Measuring pinion bearing preload and total
2. HT62940000 ( – ) preload
Socket adapter (1/2″)
3. HT62900000 ( – )
Socket adapter (3/8″) NT124

Revision; 2004 April RFD-3 2003 G35 Coupe

 PREPARATION

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

Side bearing outer race puller

Removing oil seal
ST33290001 (J34286)

NT713

Differential shim selection (J34309) Adjusting bearing preload gear height

NT134

Commercial Service Tools ADS000CE

Tool name Description

Power tool Loosening bolts and nuts

PBIC0190E

Revision; 2004 April RFD-4 2003 G35 Coupe

 Symptom
×: Applicable
Reference page

Revision; 2004 April

DIFFERENTIAL
Possible cause and SUSPECTED PARTS

Noise
NVH Troubleshooting Chart

×
Rough gear tooth Refer to RFD-21, "INSPECTION" .

Improper gear contact Refer to RFD-27, "TOOTH CONTACT" .

RFD-5
×
Tooth surfaces worn Refer to RFD-21, "INSPECTION" .

Incorrect backlash Refer to RFD-15, "Pre-Inspection" .

×
×
Companion flange excessive runout —

×
Improper gear oil Refer to MA-18, "CHASSIS AND BODY MAINTENANCE" .

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 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.

2003 G35 Coupe

PFP:00003

ADS000CF

L
F

K
E
B
A

H
C

M
RFD
 FRONT OIL SEAL

FRONT OIL SEAL PFP:38189

Removal and Installation ADS000CG

REMOVAL
1. Remove the propeller shaft. Refer to PR-4, "REAR PROPELLER SHAFT" .
2. Put a mark on the end of the drive pinion corresponding to the B
position mark on the final drive companion flange.
CAUTION:
● For matching mark, use paint. Never damage drive pin-
ion.
● The mark on the final drive companion flange indicates
the maximum vertical runout position.

SDIA0270E

3. Using the drive pinion flange wrench, Remove drive pinion nut.
Tool number : KV40104000 ( – )

SDIA1142E

4. Using the puller, remove the companion flange.

SDIA1054E

5. Using the side bearing outer race puller, remove oil seal.
Tool number : ST33290001 (J34286)

SDIA0485E

Revision; 2004 April RFD-6 2003 G35 Coupe

 FRONT OIL SEAL

INSTALLATION
1. Apply multi-purpose grease to sealing lips of oil seal. Press front A
oil seal into carrier with tool.
Tool number : ST30720000 (J25405)
B
CAUTION:
● When installing the oil seal, be careful not to get it
inclined.
● Discard the old oil seal. Always replace with new one.
C

SDIA0493E
RFD

2. Align the matching mark of drive pinion with the matching mark
B of companion flange, then install the companion flange. E

SDIA0270E

H
3. Apply oil or grease on the screw part of drive pinion and the seating surface of drive pinion nut.
4. Install drive pinion nut with tool.
Tool number : KV40104000 ( – ) I

: 147 - 323N·m (15.0 - 32.0 kg-m, 109 - 238 ft-lb)

J
CAUTION:
The drive pinion nut is not reusable. Never reuse drive pinion nut.
5. Install propeller shaft. Refer to PR-4, "REAR PROPELLER SHAFT" .
K

Revision; 2004 April RFD-7 2003 G35 Coupe

 SIDE OIL SEAL

SIDE OIL SEAL PFP:33142

Removal and Installation ADS000CH

REMOVAL
1. Remove side flange with the following procedure for press-fitting.
a. Remove rear wheel sensor. Refer to BRC-64, "WHEEL SENSORS" .
b. Remove drive shaft and axle assembly. Refer to RAX-10, "REAR DRIVE SHAFT" and RAX-6, "WHEEL
HUB" .
c. Install axle stand to side flange.
Tool number A : KV40104100 ( – )
d. Using a sliding hammer, pull out the side flange.
Tool number B : ST36230000 (J25840–A)

SDIA1005E

Circular clip installation position

Model
Right side Left side
R200 Final drive side
R200V Final drive side Side flange side

2. Remove oil seal using a flat-bladed screwdriver.

SDIA0495E

INSTALLATION
NOTE:
Be sure to install the RH companion flange of the R200V, then install the LH companion flange. If LH compan-
ion flange is installed first, the RH companion flange comes out sometimes from the shock of installing the RH
companion flange.
1. Apply multi-purpose grease to sealing lips of oil seal.

2. Using the drift, press-fit oil seal so that its surface comes face to
face with the end surface of the case.
Tool number : KV38100200 (J26233)
CAUTION:
● When installing the oil seal be careful not to get it
inclined.
● Discard the old oil seal. Always replace with new one.

SDIA0496E

Revision; 2004 April RFD-8 2003 G35 Coupe

 SIDE OIL SEAL

3. Install the side flange with the following procedure.

a. Attach the protector to side oil seal. A

Tool number : KV38107900 (J39352)

b. After the side flange is inserted and the serrated part of side B
gear has engaged the serrated part of flange, remove the pro-
tector.
C

SDIA0822E

RFD
c. Put suitable drift on the center of side flange, then drive it until
sound changes.
NOTE: E
When installation is completed, driving sound of the side flange
turns into a sound which seems to affect the whole final drive.
4. Confirm that the dimension of the side flange installation (Mea-
F
surement A) in the illustration comes into the following.
Measurement A
: Approx. 326 - 328 mm (12.83 - 12.91 in) G
SDIA0276E
5. Install the drive shaft and axle assembly. Refer to RAX-6,
"WHEEL HUB" . and RAX-10, "REAR DRIVE SHAFT" .
H
6. Align the installing position of the wheel sensor. Refer to BRC-64, "WHEEL SENSORS" .

Revision; 2004 April RFD-9 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

REAR FINAL DRIVE ASSEMBLY PFP:38300

Removal and Installation ADS000CI

SDIA1041E

REMOVAL
1. Remove exhaust center tube with power tool. EX-3, "EXHAUST SYSTEM" .
2. Remove rear stabilizer bar with power tool. Refer to RSU-16, "STABILIZER BAR" .
3. Remove rear propeller shaft from the final drive. Refer to PR-5, "REMOVAL" .
4. Remove rear drive shaft from final drive. Then suspend it by
wire etc. Refer to RAX-10, "REAR DRIVE SHAFT" .
5. Remove breather hose from the final drive.
6. Remove wheel sensor. Refer to BRC-64, "WHEEL SENSORS" .
7. Place a transmission jack on the final drive.
CAUTION:
Do not place a transmission jack on the rear cover (alumi-
num case).
8. Remove the mounting bolts and nuts connecting to the suspen-
sion member, and remove the rear final drive. SDIA1094E

Revision; 2004 April RFD-10 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

INSTALLATION
Install in the reverse order of removal. A
CAUTION:
After installation, check the final drive oil level. Refer to MA-21, "Changing Differential Gear Oil" .
B

RFD

Revision; 2004 April RFD-11 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

Components ADS000CJ

R200 2–PINION

SDIA1023E

Revision; 2004 April RFD-12 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

1. Drive pinion nut 2. Companion flange 3. Front oil seal

4. Pinion front bearing 5. Pinion bearing adjusting spacer 6. Pinion rear bearing
A
(Collapsible spacer)
7. Pinion height adjusting washer 8. Drive pinion 9. Side oil seal
10. Ring gear 11. Pinion mate shaft 12. Look pin B
13. Pinion mate gear 14. Pinion mate thrust washer 15. Side gear
16. Side gear thrust washer 17. Differential case 18. Side bearing
19. Side bearing adjusting washer 20. Bearing cap 21. Rear cover C
22. Filler plug 23. Drain plug 24. Gear carrier
25. Circular clip 26. Gasket
RFD

Revision; 2004 April RFD-13 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

R200V VISCOUS

SDIA1022E

Revision; 2004 April RFD-14 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

1. Drive pinion nut 2. Companion flange 3. Front oil seal

4. Pinion front bearing 5. Pinion bearing adjusting spacer 6. Pinion rear bearing
A
(Collapsible spacer)
7. Pinion height adjusting washer 8. Drive pinion 9. Side oil seal
10. Ring gear 11. Pinion mate shaft 12. Pinion mate gear B
13. Pinion mate thrust washer 14. Side gear thrust washer 15. Side gear
16. Viscous coupling 17. Side gear thrust washer 18. Differential case B
19. Differential case A 20. Side bearing 21. Side bearing adjusting washer C
22. Bearing cap 23. Rear cover 24. Filler plug
25. Drain plug 26. Gear carrier 27. Circular clip
28. Gasket RFD

Pre-Inspection ADS000CK
E
Before disassembling final drive, drain off oil from final drive assembly and remove the rear cover. Then, per-
form the following inspection.
TOTAL PRELOAD F
1. Turn drive pinion in both directions several times to set bearing
rollers.
2. Check total preload with Tool. G
Tool number
: ST3127S000 (see J25765-A) H
Total preload
: 2.84 - 3.75 N·m (0.29 - 0.38 kg-m, 26 - 33 in-lb)
I
SPD884

RING GEAR TO DRIVE PINION BACKLASH

J
Check ring gear to drive pinion backlash with a dial indicator at sev-
eral points.
Ring gear backlash K
: 0.10 - 0.15 mm (0.0039 - 0.0059 in)

M
SPD513

RING GEAR RUNOUT

Check runout of ring gear with a dial indicator.
Runout limit : 0.05 mm (0.0020 in) less

SPD886

TOOTH CONTACT
Check tooth contact. Refer to RFD-27, "TOOTH CONTACT" .

Revision; 2004 April RFD-15 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

Disassembly and Assembly ADS000CL

REMOVAL OF DIFFERENTIAL CASE ASSEMBLY

1. Using two 45 mm (1.77 in) spacers, mount carrier on Tool.
Tool number : KV38100800 (J25604–01)

SPD888

2. For proper reinstallation, paint match marks on one side of the

bearing cap.
Bearing caps are line-board during manufacture. Replace them
in their proper positions.

SPD889

3. Remove bearing caps.

S-PD343

4. Lift differential case assembly out with Tool.

Tool number : HT72400000 (–)

S-PD344

Revision; 2004 April RFD-16 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

● Keep the side bearing outer races together with inner races.
Do not mix them up. A
Also, keep adjusting washers together with bearings.

SPD919

RFD
REMOVAL OF DRIVE PINION ASSEMBLY
1. Put match marks on companion flange and drive pinion with
paint. E
2. Loosen drive pinion nut with tool.
Tool number : KV40104000 (–)
F

SDIA1144E

H
3. Using the puller remove companion flange.

K
SDIA1132E

4. Take out drive pinion (together with rear bearing inner race,
bearing adjusting spacer). L
5. Remove front oil seal. Refer to RFD-6, "FRONT OIL SEAL"
6. Remove pinion front bearing inner race.
M
7. Remove side oil seal. Refer toRFD-8, "SIDE OIL SEAL"

SPD892

Revision; 2004 April RFD-17 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

8. Remove pinion bearing outer races with a brass drift.

SDIA0817E

9. Remove pinion rear bearing inner race and drive pinion height
adjusting washer with Tool.
Tool number: : ST30031000 (J22912-01)

S-PD179

DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200 2–PINION)

1. Remove side bearing inner races.
● To prevent damage to bearing, engage puller jaws in groove.

Tool number : A ST3305S001 (–)

: B ST33061000 (J8107-2)

SPD920

Revision; 2004 April RFD-18 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

● Be careful not to confuse left- and right-hand parts.

A

SPD022

RFD
2. Loosen ring gear bolts in a criss-cross fashion.
3. Tap ring gear off the differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding. E

G
SPD024

4. Drive out pinion mate shaft lock pin with punch from ring gear H
side.

SPD025
K

Revision; 2004 April RFD-19 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY(R200V)

1. Remove side bearing inner race.
● To prevent damage to bearing, engage puller jaws in groove.

Tool number : A ST3305S001 (–)

: B ST33061000 (J8107-2)

SDIA0818E

● Be careful not to confuse left- and right-hand parts.

SPD022

2. Loosen ring gear bolts in a criss-cross fashion.

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

SPD024

Revision; 2004 April RFD-20 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

4. Put match marks with paint

5. Loosen screws on differential cases A and B. A
6. Separate differential cases A and B.

SPD862

RFD
INSPECTION
Clean up the dissembled parts. Then, inspect the parts for wear and damage. If the parts are worn or dam-
aged, follow the measures below.
E
Content Measures
● If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or
replace as necessary.
Hypoid gear F
● If the gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with a
new gears.
● If found any chipped (by friction), pitted, worn, rusted, scratched mark, or unusual noise from the G
Bearing
Bearing, replace with a new bearing ASSY (as a new set).
● Replace with a new one if found any cracks or damage on the surface of the tooth.
Side gear thrust washer and
Pinion mate thrust washer ● Replace with a new one if found any worn or chipped mark on the contact sides of the thrust H
washer.
Side gear and Pinion mate
● Replace with a new one if found that it is chipped (by friction), damaged, or unusual worn.
thrust washer
I
Oil seal ● Oil seals must be replaced with a new one whenever disassembled.
Differential case ● Replace with a new one if found any wear or cracks on the contact sides of the Differential case.
● Replace with a new one if found any chipped marks (about 0.10mm, 0.0039in) or other damage on J
Companion flange
the contact sides of the Lips of the Companion flange.

ADJUSTMENT OF DIFFERENTIAL CASE (R200 2–PINION) K

Thrust Washer Selection
1. Install side gears, pinion mate gears, thrust washers into differ-
ential case. L

SPD552

2. Fit pinion mate shaft to differential case so that it meets lock pin
holes.

SPD553

Revision; 2004 April RFD-21 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

3. Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer.
Refer to RFD-34, "AVAILABLE SIDE GEAR THRUST WASHERS" .
Use two feeler gauges to prevent leaning of side gear as shown,
figure.
Clearance between side gear thrust washer and differ-
ential case
: 0.20 mm (0.0079 in) less

SPD828

ADJUSTMENT OF DIFFERENTIAL CASE (R200V)

Side gear Thrust Washer Selection
Whenever side gears or pinion mate gears are replaced, select suit-
able thrust washers as follows:
1. Clean side gears and pinion mate gears using white gasoline.
2. Before assembling gears, apply hypoid gear oil to frictional sur-
faces.
3. Install the previously removed thrust washer on right side gear.
On left side gear, install a suitable thrust washer.
Temporarily tighten differential cases using two screws.
4. Position differential assembly so that right side gear is on the
upper side. Place feeler gauge of 0.03 mm (0.0012 in) thickness SDIA1146E
between right side gear and thrust washer as shown.
Do not place feeler gauge at groove side of differential case.
5. Also place a 0.03 mm (0.0012 in) additional feeler gauge between right side gear and thrust washer so
that it is positioned diagonal to (180° apart from) the feeler gauge described previously.
6. Rotate right side gear with a suitable tool attached to splines. If hard to rotate, replace thrust washer on
left side gear with a thinner one.
7. Replace both 0.03 mm (0.0012 in) feeler gauges with 0.15 mm (0.0059 in) gauges. At this point, make
sure right side gear does not rotate. If it rotates, replace thrust washer on left side gear with a thicker one
to prevent rotation.
8. As explained in above example, select suitable thrust washers to ensure that:
a. Both side gears rotate. [0.03 mm (0.0012 in) feeler gauges are used in this case.]
b. Side gear is held stationary. [0.15 mm (0.0059 in) feeler gauges are used in this case.]

For quiet and reliable final drive operation, the following five adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear to pinion backlash.
5. Ring and pinion gear tooth contact pattern
SIDE BEARING PRELOAD
A selection of carrier side bearing adjusting washers is required for successful completion of this procedure.

Revision; 2004 April RFD-22 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

1. Make sure all parts are clean. Also, make sure the bearings are
well lubricated with gear oil. A
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.
B

SPD527

RFD
3. Insert left and right side bearing adjusting washer in place
between side bearings and carrier.
E

G
SPD924

4. Install the side bearing caps in their correct locations and torque H
the bearing cap retaining bolts.
: 88 - 98 N·m (9.0 - 9.9 kg-m, 65 - 72 ft.-
lb) I
5. Turn the carrier several times to seat the bearings.

SPD526
K
6. Measure the turning torque of the carrier at the ring gear retain-
ing bolts with a spring gauge, J-8129.
L
Specification
: 34.2 - 39.2 N (3.5 - 4 kg, 7.7 - 8.8 lb)
of pulling force at the ring gear bolt
M

SPD194A

7. If the turning torque is not within the specifications, correct the

torque as follows:
● If the turning torque is less than the specified range, install
washers of greater thickness.
● If the turning torque is greater than the specification, install
thinner washers.
● See the SDS section for washer dimensions and part num-
bers.
8. Record the total amount of washer thickness required for the
correct carrier side bearing preload. SPD772

Revision; 2004 April RFD-23 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

9. Remove the carrier from the final drive housing. Save the
selected washers for later use during the assembly of the final
drive unit.
Tool number : HT72400000 (–)

S-PD344

PINION GEAR HEIGHT

1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the pinion bearings into the differential shim selection
Tool, J34309.

SPD769

● Pinion front bearing; make sure the J34309-3 pinion front

bearing seat is secured tightly against the J34309-2 gauge
anvil. Then turn the pinion front bearing pilot, J34309-5, to
secure the bearing in its proper position.
● Rear pinion bearing; the pinion rear bearing pilot, J34309-8, is
used to center the pinion rear bearing only. The pinion rear
bearing locking seat, J34309-4, is used to lock the bearing to
the assembly.
● Installation of J34309-9 and J34309-16; place a suitable 2.5
mm (0.098 in) thick plain washer between J34309-9 and
J34309-16. Both surfaces of J34309-9 and J34309-16 must SPD197A

be parallel with a clearance of 2.5 mm (0.098 in).

3. Install the pinion rear bearing inner race into the final drive hous-
ing. Then place the pinion preload shim selector Tool, J34309-1,
gauge screw assembly.

SPD893

Revision; 2004 April RFD-24 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

4. Assemble the front pinion bearing inner race and the J34309-2
gauge anvil. Assemble them together with the J34309-1 gauge A
screw in the final drive housing. Make sure that the pinion height
gauge plate, J34309-16, will turn a full 360 degrees. Tighten the
two sections together by hand.
B

SPD199A

RFD
5. Turn the assembly several times to seat the bearings.

G
SPD770

6. Measure the turning torque at the end of the J34309-2 gauge H

anvil using torque wrench J-25765A.
Turning torque specification
: 1.0 - 1.3 N·m(0.11 - 0.13 kg-m, 9 - 11 in-lb) I

SPD234A
K
7. Place the J34309-11 “R200A” pinion height adapter onto the
gauge plate and tighten it by hand.
CAUTION: L
Make sure all machined surfaces are clean.

SPD208A

Revision; 2004 April RFD-25 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

Pinion Height Adjusting Washer Selection

1. Now, position the side bearing discs, J25269-4, and arbor firmly
into the side bearing bores. Install the bearing caps and tighten
the cap bolts to proper torque.

SPD211A

2. Select the correct standard pinion height adjusting washer thick-

ness. Select by using a standard gauge of 3 mm (0.12 in) and
your J34309-101 feeler gauge. Measure the distance between
the J34309-11 pinion height adapter including the standard
gauge and the arbor.

SPD204A

3. Write down your exact measurement (the value of feeler gauge).

SPD775

4. Correct the pinion height washer size by referring to the “pinion

head number”.

SPD542

There are two numbers painted on the drive pinion gear. The first one refers to the drive 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 standard for quietest
operation. Use the following chart to determine the correct pinion height washer.

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 REAR FINAL DRIVE ASSEMBLY

Pinion head height number Add or remove from the standard pinion height washer thickness measurement A
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in)
-3 Add 0.03 mm (0.0012 in) B
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
C
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in) RFD
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)

5. Select the correct pinion height washer as follows. Refer to RFD-35, "AVAILABLE PINION HEIGHT E
ADJUSTING WASHERS" .
6. Remove the J34309 pinion differential shim selection Tool from
the final drive housing. Then disassemble to retrieve the pinion F
bearings.

SPD205A

I
TOOTH CONTACT
Checking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pin-
ion.
Hypoid gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check J
gear tooth contact pattern to obtain the best contact for low noise and long life.

1. Thoroughly clean ring gear and drive pinion teeth. K

2. Lightly apply a mixture of powdered ferric oxide and oil or the
equivalent. Apply it to 3 or 4 teeth of ring gear drive side.
L

SPD357

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

SDIA0813E

Revision; 2004 April RFD-27 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

SDIA0821E

ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200 2–PINION)

1. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.

SPD030

2. Place differential case on ring gear.

3. Apply genuine medium strength locking sealant or equivalent.
Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS" to ring gear bolts, and install them.
● Tighten bolts in a criss-cross fashion.
● After tightening the bolt to the specified torque, turn the bolt 31
to 36 more degrees.

SPD554

4. Press-fit side bearing inner races on differential case with Tool.

Tool number : A KV38100300 (J25523)
: B ST33061000 (J8107-2)

SPD353

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 REAR FINAL DRIVE ASSEMBLY

ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200V)

1. Install differential cases A and B. A
: 3.8 - 5.8 N·m(0.39 - 0.59 kg-m, 34 - 51 in-lb)

RFD
SPD862

2. Place differential case on ring gear.

E
3. Apply genuine medium strength locking sealant or equivalent.
Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS" to ring gear bolts, and install them.
F
● Tighten bolts in a criss-cross fashion.
● After tightening the bolt to the specified torque, turn the bolt 31
to 36 more degrees.
G

SPD554
H

4. Press-fit side bearing inner races on differential case with Tool.

Tool number : A KV38100300 (J25523) I
: B ST33061000 (J8107-2)

SPD353

Revision; 2004 April RFD-29 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

INSTALLATION OF DRIVE PINION ASSEMBLY

1. Press-fit pinion front and rear bearing outer races with Tools.
Tool number : A Suitable tool
: B ST30611000 (J25742-1)
: C ST30613000 (J25742-3)

SPD992

2. Select pinion height adjusting washer. Refer to RFD-26, "Pinion Height Adjusting Washer Selection" .

3. Install selected pinion height adjusting washer in drive pinion.

Using press and Tool, press-fit pinion rear bearing inner race
into it.
Tool number : ST30901000 (–)

SPD377

4. Apply multi-purpose grease to pinion rear bearing inner race

and pinion front bearing inner race.

SDIA0826E

Revision; 2004 April RFD-30 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

5. Set drive pinion assembly (as shown in figure) in differential car-

rier and install drive pinion, with press and suitable tool. A
Stop when drive pinion touches bearing.

SPD896

RFD
6. Install front oil seal with Tool. Refer to RFD-6, "FRONT OIL SEAL" .

7. Install companion flange, and tighten pinion nut to minimum. E

Ascertain that threaded portion of drive pinion and drive pinion
nut are free from oil or grease.
Tool number : KV40104000 (–) F
CAUTION:
The drive pinion nut is not reusable. Never reuse drive pin-
ion nut. G

SDIA1145E H

8. Tighten the drive pinion nut by very small degrees until the spec-
ified preload in achieved, when checking the preload, turn drive I
pinion in both directions several times.
Tool number
: ST3127S000 (See J25765-A) J

Pinion bearing preload

: 2.65 - 3.23 N·m (0.27 - 0.32 kg-m, 24 - 28 in-lb) K

SPD884

L
● If pinion bearing preload is too small, tighten the drive pinion nut more.
● If pinion bearing preload is too great, replace pinion bearing adjusting spacer.
M
INSTALLATION OF DIFFERENTIAL CASE ASSEMBLY
1. Select side bearing adjusting washer. Refer to RFD-22, "SIDE
BEARING PRELOAD" .
2. Install differential case assembly with side bearing outer races
into gear carrier.

SPD919

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 REAR FINAL DRIVE ASSEMBLY

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

between side bearings and carrier.

SPD924

4. Align mark on bearing cap with that on gear carrier.

5. Install the side bearing cap.
: 88 - 98 N·m (9.0 - 9.9 kg-m, 65 - 72 fl-lb)

SPD889

6. Install side oil seal. Refer to RFD-8, "SIDE OIL SEAL" .

Tool number : KV38100200 (J26233)

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

at several point.
Ring gear backlash
: 0.10 - 0.15 mm (0.0039 - 0.0059 in) less

SPD513

● It backlash is too small, adjustment of washer thickness is required. Decrease thickness of left shim
and increase thickness of right by the same amount.
If backlash is too great, reverse the above procedure.
● Never change the total amount of washers as it will change the bearing preload.

8. Check total preload with Tool.

Tool number : ST3127S000 (See J25765-A)
When checking preload, turn drive pinion in both directions sev-
eral times to seat bearing rollers correctly.
Total preload
: 2.84 - 3.75 N·m (0.29 - 0.38 kg-m, 26 - 33 in-lb)

SPD884

● if preload is too great, remove the same amount of washer to each side.
● if preload is too small, add the same amount of washer to each side.

Revision; 2004 April RFD-32 2003 G35 Coupe

 REAR FINAL DRIVE ASSEMBLY

never add or remove a different number of washer for each side. Difference in number of washers will
change ring gear to drive pinion backlash. A
9. Recheck ring gear to drive pinion backlash. Increase or decrease in thickness of shims will cause change
to ring gear to pinion backlash.
● Check whether the backlash varies excessively in different places. Foreign matter may be caught B
between the ring gear and the differential case causing the trouble.
● The backlash can vary greatly even when the ring gear runout is within a specified range. In that case,
replace the hypoid gear set or differential case. C
10. Check runout of ring gear with a dial indicator.
Runout limit : 0.05 mm (0.0020 in) less
RFD
11. Check tooth contact.
Refer to RFD-27, "TOOTH CONTACT" .
E

F
SPD524

12. Install rear cover. Apply liquid sealant to rear cover side and G
install gear carrier.

SDIA0970E
J

Revision; 2004 April RFD-33 2003 G35 Coupe

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications ADS000CM

VQ35DE engine
Applied model
M/T A/T
Final drive model R200V (LSD) R200 (2-pinion)
Gear ratio 3.357
Number of teeth (Ring gear / drive pinion) 47 / 14
Oil capacity (Approx.) 1.4 liter (3 US pt, 2 - 1/2 Imp pt)

Ring Gear Runout ADS000CN

Unit: mm (in)
Type R200, R200V
Ring gear runout limit 0.05 (0.0020) less

Side Gear Adjustment ADS000CO

Unit: mm (in)
Type R200 R200V
Clearance limit between side gear and differential case mm (in) 0.20 (0.0079) less 0.15 (0.0059) less

AVAILABLE SIDE GEAR THRUST WASHERS

Unit: mm (in)
Type R200 R200V
Thickness Part number Thickness Part number
0.75 (0.0295) 38424 0C000 0.80 (0.0315) 38424 40F60
0.78 (0.0307) 38424 0C001 0.83 (0.0327) 38424 40F61
0.81 (0.0319) 38424 0C002 0.86 (0.0339) 38424 40F62
0.84 (0.0331) 38424 0C003 0.89 (0.0350) 38424 40F63
0.87 (0.0343) 38424 0C004 0.92 (0.0362) 38424 40F64
0.90 (0.0350) 38424 0C005 0.95 (0.0374) 38424 40F65
0.93 (0.0366) 38424 0C006 0.98 (0.0386) 38424 40F66
1.01 (0.0398) 38424 40F67
1.04 (0.0409) 38424 40F68
1.07 (0.0421) 38424 40F69
1.10 (0.0433) 38424 40F70
Thrust washer 1.13 (0.0445) 38424 40F71
1.16 (0.0457) 38424 40F72
1.19 (0.0469) 38424 40F73
1.22 (0.0480) 38424 40F74
1.25 (0.0492) 38424 40F75
1.28 (0.0504) 38424 40F76
1.31 (0.0516) 38424 40F77
1.34 (0.0528) 38424 40F78
1.37 (0.0539) 38424 40F79
1.40 (0.0551) 38424 40F80
1.43 (0.0563) 38424 40F81
1.46 (0.0575) 38424 40F82
1.49 (0.0587) 38424 40F83

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 SERVICE DATA AND SPECIFICATIONS (SDS)

Drive Pinion Height Adjustment ADS000CP

AVAILABLE PINION HEIGHT ADJUSTING WASHERS A

Unit: mm (in)
Type R200, R200V
Thickness Part number Thickness Part number B
3.05 (0.1201) 38154 0C000 3.35 (0.1319) 38154 0C010
3.08 (0.1213) 38154 0C001 3.38 (0.1331) 38154 0C011
C
3.11 (0.1224) 38154 0C002 3.41 (0.1343) 38154 0C012
3.14 (0.1236) 38154 0C003 3.44 (0.1354) 38154 0C013
Adjusting washer 3.17 (0.1248) 38154 0C004 3.47 (0.1366) 38154 0C014 RFD
3.20 (0.1260) 38154 0C005 3.50(0.1378) 38154 0C015
3.23 (0.1272) 38154 0C006
E
3.26 (0.1283) 38154 0C007
3.29 (0.1295) 38154 0C008
3.32 (0.1307) 38154 0C009 F
Drive Pinion Preload Adjustment ADS000CQ

Type R200, R200V G

Drive pinion preload 2.65 − 3.23 N·m (0.27 − 0.32 kg−m, 24 − 28 in lb)

Side Bearing Preload Adjustment ADS000CR

H
Type R200, R200V
Side bearing preload <Reference value> 0.20 − 0.52 N·m (0.02 − 0.05 kg−m, 2 − 4 in lb)
I
Torque by spring gauge 34.2 − 39.2 N (3.5 − 4 kg, 7.7 − 8.8 lb)

SIDE BEARING ADJUSTING WASHERS

Unit: mm (in) J
Type R200, R200V
Thickness Part number Thickness Part number
K
2.00 (0.0787) 38453 N3100 2.35 (0.0925) 38453 N3107
2.05 (0.0807) 38453 N3101 2.40 (0.0945) 38453 N3108
2.10 (0.0827) 38453 N3102 2.45 (0.0965) 38453 N3109 L
Adjusting washer
2.15 (0.0846) 38453 N3103 2.50 (0.0984) 38453 N3110
2.20 (0.0866) 38453 N3104 2.55 (0.1004) 38453 N3111
M
2.25 (0.0886) 38453 N3105 2.60 (0.1024) 38453 N3112
2.30 (0.0906) 38453 N3106 2.65 (0.1043) 38453 N3113

Total Preload Adjustment ADS000CS

Type R200, R200V

Total preload with oil seal 2.84 − 3.75 N·m (0.29 − 0.38 kg−m, 26 − 33 in lb)
Ring gear to drive pinion backlash 0.10 − 0.15 mm (0.0039 − 0.0059 in)

Revision; 2004 April RFD-35 2003 G35 Coupe

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision; 2004 April RFD-36 2003 G35 Coupe