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Disassembly

1. With differential assembly removed from vehicle, remove rear mounting member and cover plate. See Figure 1 or Figure 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).
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:

• .0039-.0059"(.100-.150 mm).

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

• .002" (.05 mm)

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

• .004-.008" (.10-.20 mm).

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.

FYI: 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.

FYI: 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.
Clearance should be:

• .004-.008" (.10-.20 mm), Select thrust washer to obtain specified clearance.

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).

FYI: 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.
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.

FYI: 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.
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.
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.
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.

FYI: 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.
Place assembled front pinion bearing and preload washer selector into gear carrier. Screw 2 tool and bearing assemblies together by hand.
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).
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 image.
24. This measurement is equal to the required drive pinion preload adjusting washer thickness. Select required bearing preload washer from pinion bearing prelouad adjustment washers. Set selected pinion bearing preload adjustment washer aside for use during final assembly.

PINION BEARING PRELOAD ADJUSTMENT WASHERS

• .1496-.1504 inch (3.80-3.82mm)
  • Part No: 38125-61001
• .1504-.1512 inch (3.82-3.84mm)
  • Part No: 38126-61001
• .1512-.1520 inch (3.84-3.86mm)
  • Part No: 38127-61001
• .1520-.1528 inch (3.86-3.88mm)
  • Part No: 38128-61001
• .1528-.1535 inch (3.88-3.90mm)
  • Part No: 38129-61001
• .1535-.1543 inch (3.90-3.92mm)
  • Part No: 38130-61001
• .1543-.1551 inch (3.92-3.94mm)
  • Part No: 38131-61001
• .1551-.1559 inch (3.94-3.96mm)
  • Part No: 38132-61001
• .1559-.1567 inch (3.96-3.98mm)
  • Part No: 38133-61001
• .1567-.1575 inch (3.98-4.00mm)
  • Part No: 38134-61001
• .1575-.1583 inch (4.00-4.02mm)
  • Part No: 38135-61001
• .1583-.1591 inch (4.02-4.04mm)
  • Part No: 38136-61001
• .1591-.1598 inch (4.04-4.06mm)
  • Part No: 38137-61001
• .1598-.1606 inch (4.06-4.08mm)
  • Part No: 38138-61001
• .1606-.1614 inch (4.08-4.10mm)
  • Part No: 38139-61001

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.

To see the continuation with images check it out here: Garage411: Nissan 240SX Differential Overhaul S13: cleaning, inspection, adjustments and more