Garage411 : RearAxleS13

Nissan 240sx S13 Rear Axles - R200 and R200V: overhaul, removal, installation and more

Nissan 240sx S13



Nissan does not identify axles with a specific external identification marking. Axle ratio is determined by dividing the number of ring gear teeth by the number of drive pinion gear teeth.

AXLE RATIO SPECIFICATIONS


Axle assembly is a hypoid-type gear with integral carrier housing. Pinion bearing preload adjustment on R200 and R200V is made with a spacer and washer between the front and rear bearing races. Differential side bearing preload and pinion depth adjustment are made using washers. Driving power is transmitted to the wheels by spline type axle shafts with CV type joints. A limited slip differential is optional on SE models.


LUBRICATION



REMOVAL AND INSTALLATION


AXLE SHAFT

Removal
1. Raise and support vehicle. Remove rear wheels. Cover boots with shop towel to prevent damage. Remove side flange-to-differential bolts and separate axle shaft.
2. To remove axle shaft from outboard/wheel side, loosen wheel hub lock nut, but do not remove completely. Tap lock nut lightly with soft hammer to drive out axle shaft. Remove wheel hub lock nut.

Installation
1. Install axle shafts into wheel hub, and temporarily tighten wheel hub lock nut. Install axle shaft onto differential side flange.
2. Tighten wheel hub lock nut to specification. Replace differential fluid (if required). To complete installation, reverse removal procedure.

DRIVE SHAFT

Removal
Put match marks on pinion and drive shaft flanges for reassembly reference. Remove nuts and bolts holding drive shaft to differential. Remove bolts holding center bearing support to body. Remove drive shaft and insert plug in rear of transmission extension housing.

Installation
Align match marks made during removal. Install nuts and bolts finger-tight. Turn drive shaft until match marks are at 12 o'clock position. Carefully and evenly tighten nuts and bolts to specification.

PINION FLANGE AND OIL SEAL: REMOVAL AND INSTALLATION

1. Raise and support rear of vehicle. Drain differential. Disconnect drive shaft from pinion flange.
2. Remove pinion nut. Remove pinion flange with puller. Remove oil seal. To install, reverse removal procedure. Apply grease between seal lips before installation.

SIDE FLANGE AND OIL SEAL

Removal
Remove axle shaft. Pry side flange from differential case. Use screwdriver or similar tool to remove seal.

Installation
Use seal installer to drive in seal. Press side flange into differential case. Try to pull side flange out of differential by hand to ensure proper engagement of snap rings. To complete installation, reverse removal procedure.

DIFFERENTIAL ASSEMBLY

NOTE: Support suspension member on a stand to prevent damage to insulators.

Removal and Installation
1. Raise and support rear of vehicle. Drain gear oil. Disconnect drive shaft at pinion flange, and remove axle shafts.
2. Support differential on jack. Remove mounting bolts at suspension members. Remove nut on end of differential bracket. Lower assembly on jack and remove from vehicle. To install, reverse removal procedure. Refill gear oil.


OVERHAUL


DIFFERENTIAL ASSEMBLY

Disassembly
1. With differential assembly removed from vehicle, remove rear mounting member and cover plate. See Fig. 1 or Fig. 2 . Using an INCH-lb. torque wrench, check total differential preload. Total preload should be 12-15 INCH lbs. (1.4-1.7 N.m).

Fig. 1: Exploded View Of Differential Assembly (R200)
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Fig. 2: Exploded View Of Limited Slip Differential Assembly (R200V)
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2. Mount dial indicator on gear carrier gasket surface. Record ring gear to pinion backlash readings at several points around ring gear for use during reassembly. Backlash specification is:


3. Place dial indicator so that it contacts ring gear surface behind tooth face. Check ring gear runout. Runout limit is:


Check ring and pinion gear tooth contact pattern.
4. On R200, check clearance between side gear thrust washer and differential case. Clearance should be:


5. On all models, mark carrier, caps and bearing outer races for reinstallation in original position. Remove side bearing caps. Extract differential case from carrier. Do not mix right and left side bearings or races.
6. Remove pinion nut. Remove pinion flange with puller. Using a press, remove drive pinion (together with rear bearing inner race, bearing spacer and adjusting washer or collapsible spacer) from carrier. Remove pinion oil seal. Remove front bearing inner race. Remove side oil seal.
7. Remove pinion bearing outer races using a brass drift. Remove pinion rear bearing inner race and the drive pinion height adjusting washer.

NOTE: Keep left and right side bearings separate, as they are not interchangeable.

8. To disassemble differential case, use Side Bearing Puller (ST33051001) with Driver (ST33061000) and remove side bearings. Loosen ring gear bolts in diagonal pattern. To remove ring gear, tap with soft hammer evenly all around gear to prevent binding.

NOTE: Mark gears and thrust washers for installation in original positions.

9. On R200, drive out pinion mate shaft lock pin from ring gear side. On R200V, mark differential cases for reassembly reference. Remove screws and separate differential cases. On all models, remove pinion mate shaft, pinion gears, side gears and thrust washers.

Cleaning and Inspection
Thoroughly clean and inspect all parts for wear and damage. Check bearings for scratches, pitting and flaking. Check tapered roller bearings for rough rotation. Replace bearings as necessary.

Reassembly and Adjustments
1. For R200V, go to step 4). For R200, assemble pinion gears, side gears and thrust washers in original positions in differential case. Fit pinion mate shaft to differential case so it aligns with lock pin holes.

2. Measure side gear-to-thrust washer clearance. See Fig. 3 . Clearance should be:


Select thrust washer to obtain specified clearance.

Fig. 3: Measuring Side Gear-To-Thrust Washer Clearance (R200)
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3. Install pinion mate shaft lock pin and lock in place with punch. Apply gear oil to gear tooth surface and thrust surfaces. Ensure gears rotate smoothly. Go to step 9).

NOTE: On R200V, whenever side gears or pinion mate gears are replaced, replace thrust washers.

4. On R200V, clean and lubricate gears. Install previously removed thrust washer on right side gear. Select a thrust washer (for measurement purposes) and install on left side gear. Assemble gears and pinion mate shaft into differential case. Using 2 screws, temporarily tighten differential case.
5. Position differential assembly with right side gear upward. Insert 2 .0012" (.030 mm) feeler gauges 180 degrees apart, between right side gear and thrust washer. See Fig. 4 .

Fig. 4: Measuring For Side Bearing Thrust Washer Selection (R200V)
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6. Attempt to rotate right side gear. If right side gear cannot be rotated, replace left side gear thrust washer with a thinner one. If right side gear can be rotated, replace .0012" (.030 mm) feeler gauges with .0039" (.100 mm) thick feeler gauges.
7. Right side gear should rotate with thinner feeler gauges in place but not rotate with thicker feeler gauges in place. If right side gear rotates with thicker feeler gauges in place, replace left side gear thrust washer with a thicker one.
8. Repeat thrust washer selection procedure for left side gear. Change right side gear thrust washers when adjusting left side gear. Select thrust washers as necessary to ensure both side gears can rotate while thinner feeler gauges are in place and side gears are stationary with thicker feeler gauges in place. Tighten differential case bolts to specification.

NOTE: Tighten ring gear bolts diagonally, while tapping around bolt heads with hammer.

9. Apply Loctite to ring gear bolt threads. Install ring gear on differential case. Install bolts and new lock washers, and tighten to specification. See TORQUE SPECIFICATIONS .
10. Ensure parts are clean and lubricated with light oil or Dexron type automatic transmission fluid. Place differential case, with side bearings and races installed, into gear carrier.
11. Install side bearing spacer on ring gear side of gear carrier. See Fig. 5 . Using Side Bearing Spacer Drift (J-25267), install both original side bearing preload washers on the opposite side of the gear carrier from the spacer just installed.



Fig. 5: Installing Side Bearing Spacer
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12. Install side bearing caps in original locations. Tighten cap bolts to specification. Turn ring gear several times to seat bearings.
13. Attach Spring Gauge (J-8129) to ring gear bolt. It should require 7.7-8.8 lbs. (3.5-4.0 kg) of torque to turn ring gear and assembly. Use thicker or thinner washers to obtain correct reading.
14. After correct reading is obtained, remove differential case from gear carrier and save washers for use during final assembly.

NOTE: See manufacturer's Pinion Preload Washer/Shim Selector Kit (J-34309) for complete tool and component identification.

15. Ensure parts are clean and bearings are lubricated. Install front and rear pinion bearings onto Pinion Preload Washer/Shim Selector (J-34309).
16. Ensure that Front Pinion Bearing Seat (J-34309-3) is secured tightly against the Gauge Anvil (J-34309-2). Turn Front Pinion Bearing Pilot (J-34309-5) to secure bearing in its proper position.
17. Rear Pinion Bearing Pilot (J-34309-8) is used to center rear pinion bearing. Use Rear Pinion Bearing Locking Seat (J-34309-4) to secure bearing in tool assembly.
18. On R200V, place a .098" (2.49 mm) thick plain washer between Preload Washer/Shim Selector Components (J-34309-9 and J-34309-16). Components must be parallel with .098" (2.49 mm) clearance.
19. On all models, place assembled rear pinion bearing and preload washer selector into gear carrier. See Fig. 6 . Place assembled front pinion bearing and preload washer selector into gear carrier. Screw 2 tool and bearing assemblies together by hand.

Fig. 6: Installing Rear Pinion Bearing Height and Preload Washer Selector Assembly
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20. Ensure that Pinion Height Gauge Plate (J-34309-16) turns a full 360 degrees and go to next step.
21. Turn assembly several times to seat bearings. Using an INCH-lb. torque wrench at end of Gauge Anvil (J-34309-2), measure turning torque. Correct reading should be 8.7-11.3 INCH lbs. (1.0-1.3 N.m).
22. Place Pinion Height Adapter (J-34309-11 "R200A") onto gauge plate and hand tighten. Place pinion bearing spacer (small end first) over Gauge Anvil (J-34309-2). Seat small end of pinion bearing spacer squarely against Gauge Screw (J-34309-1). See Fig. 7 .

Fig. 7: Measuring For Drive Pinion Bearing Preload Washer Selection
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23. Place a standard .138" (3.51 mm) thick feeler gauge between pinion bearing spacer and gauge screw. With another set of feeler gauges, measure clearance between pinion bearing and gauge screw. See Fig.7.
24. This measurement is equal to the required drive pinion preload adjusting washer thickness. Select required bearing preload washer. Set selected pinion bearing preload adjustment washer aside for use during final assembly.

PINION BEARING PRELOAD ADJUSTMENT WASHERS


25. For all models, position Side Bearing Discs and Arbor (J25269-4) firmly into side bearing bores. Install side bearing caps, and tighten to specification.
26. Place a standard .12" (3.0 mm) thick feeler gauge between Pinion Height Adapter (J-34309-11). With another set of feeler gauges, measure between pinion height adapter and arbor. Measurement (including standard .12" (3.0 mm) gauge) is referred to as Standard Pinion Height measurement.
27. Record the Standard Pinion Height measurement. There is a plus (+) or minus (-) number painted on pinion gear. Add or subtract from Standard Pinion Height measurement as directed. Select pinion height adjustment washer that corresponds with this corrected figure from appropriate PINION HEIGHT ADJUSTMENT WASHERS.

CORRECTED PINION HEIGHT ADJUSTMENT


PINION HEIGHT ADJUSTMENT WASHERS


28. Remove Pinion Preload Washer/Shim Selector (J-34309) and pinion bearings assembly. Remove bearings from tool assembly for final assembly.
29. Press side bearing inner races onto differential case. Install selected drive pinion height adjustment washer on drive pinion shaft, and press pinion rear bearing race onto drive pinion shaft.
30. Pack bearings with multipurpose grease. Place pinion front bearing inner race in front of gear carrier. Assemble drive pinion and pinion bearing adjusting spacer and washer. Press into gear carrier until drive pinion just touches bearing.
31. Apply multipurpose grease to front pinion bearing seal lips and install in gear carrier using seal installer. Clean oil and grease from threaded portion of drive pinion.
32. Install pinion flange. Tighten drive pinion flange nut to specification.
33. Using an INCH-lb. torque wrench, check pinion bearing preload. Pinion preload should be:


Correct as necessary with thicker or thinner pinion bearing adjusting washer.
34. Install differential case assembly. Insert selected side bearing adjusting washers. Using Side Bearing Spacer Drift (J-25267), drive in side bearing spacer. Align side bearing cap match marks, and install caps. Tighten cap bolts to specification.
35. Apply multi-purpose grease to side bearing seal lips and install in gear carrier using seal installer. Mount
dial indicator and measure ring gear backlash. Backlash should be:


36. If backlash is too small, decrease thickness of left washer and increase thickness of right washer by same amount so total washer thickness remains same.

NOTE: If total washer thickness is altered, side bearing preload will be changed.

37. If backlash is too great, decrease thickness of right washer and increase thickness of left washer by same amount so total washer thickness remains same.
38. Turn drive pinion several times to seat bearings. Using INCH-lb. torque wrench on drive pinion nut, check total preload. Total preload should add 2.6 INCH lbs. to pinion bearing preload measurement made in step 33).
39. If total preload is too great, decrease thickness of left washer and right washer by same amount so both sides are reduced by same amount.
40. If total preload is too small, increase thickness of right washer and increase thickness of left washer by same amount so both sides are increased by same amount.

NOTE: If right side to left side washer relation is altered, ring gear-to-drive pinion backlash will be changed.

41. Recheck ring gear-to-drive pinion backlash as in step 35). Reposition dial indicator to contact ring gear behind tooth surface and measure ring gear runout. Runout limit is .002" (.05 mm).
42. If backlash varies excessively in different places, foreign material may be caught between ring gear and differential case. If backlash varies greatly when runout is within specification, replace hypoid gear set and/or differential case.
43. Check tooth contact pattern. Install rear cover and gasket. Tighten cover bolts to specification.


TORQUE SPECIFICATIONS





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Nissan 240sx S13

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