Nissan Repair: 2004 nissan 350Z, rear axle assembly, rear control arm

Question
QUESTION: Making a right turn at a normal 15 or so mph the right rear axle pulled out of the differential and the car coasted to a stop.  After towing the car home a mechanic neighbor discovered rope and wire around the yoke which he removed and tapped the yoke which was not completely out of the differential back into place.  The car is now driveable, but I'm afraid this is going to happen again as I can't imagine how something on the yoke would cause this.  One dealer who looked at it could find nothing wrong. Another forwarded me a schematic and there is a c clip that he indicates could be broken but doesn't require disassembly of the rear plate on the differential to replace so it must be some sort of spring clip?  The one person I spoke with who sounded like he knew anything suggested that if the clip was broken it might get into the gears and cause more grief and that along with being left on the road again at 1AM in BFE is what worries me. Is this part on the schematic 38225+a something that should pull out with the axle intact or be able to snap back in without dissassembling the differential as I was told by one dealer service rep who suggested that parts of the clip might get into the gears and cause problems? I just don't understand how there could be enough lateral motion of the rear axle assembly to pull the thing beyond connection with the differential.  There must be something wrong with the rear control arm or whatever to permit this much lateral motion.

ANSWER: Clem,

I have a 2003 350Z and have never heard of this.  But, if the control arm is loose that could have allowed extension beyond the slip yoke's limits.  Now, way back when there was a service bulletin for the rear axle bearings.  And, if done improperly that could have caused the problem.  If the rope and wire were picked up from the road that could have caused it too.  I would be looking at a new axle or a used one to make sure the splines are not damaged and to keep it from moving again.  Another issue with the 350Z is the liquid filled differential mount.  But, I cannot imagine that allowing enough play to get the differential far away enough to have the axle come a part.  I would be looking into any play in the rear suspension, differential included and make sure it is corrected along with a remanufactured/used axle.  Lastly, there was another service bulletin that delt with the gas tank and fuel hoses that required the rear end to be dropped.  If this was done improperly that could cause the problem too.  Oh, make sure anyone working on the car does not nick or scratch the main driveshaft as it is composite.

---------- FOLLOW-UP ----------

QUESTION: WE agree there must be some slack in the control arm, and you mentioned possibly the differential itself.  One service rep suggested the c clip38225 might be broken and could cause trouble with the gears, but pulling the axle with it intact would verify its integrity.  I thought it would have to be inserted with the back off the differential.  I'm wondering what could be wrong with the axle itself to permit this problem?  Thanks again for the detailed answer--hope your 03 doesn't leave you in BFE at 1:30 AM like mine did.  

Answer
Clem,

I just reviewed the Rear Final Drive (RDF) PDF for the 350Z.  Amazing that the side is a press fit.  You are probably going to need to get another side flange since yours is not enough of an interference fit to stay in the differential.  That would be my guess.  If you wanted to make sure it did not come out you could use LockTite Blue on the splines before driving it back on.  If you send me an email I will send you the procedure in PDF for the side flange removal and installation.  I have never heard of what happened to you on a 350Z.  This is a first for me...  vonsudderth@yahoo.com