NISSAN NAVARA 2005 Repair Workshop Manual

EXHAUST SYSTEM
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Removal and InstallationEBS01E7B
CAUTION:
lBe sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance and shape.
lPerform the operation with the exhaust system fully cooled down because the system will be hot
just after engine stops.
lBe careful not to cut your hand on the insulator edge.
REMOVAL
Separate each connection as necessary.
CAUTION:
Do not disassemble main muffler at the portion “A” shown in the figure.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
lAlways replace exhaust gaskets and seal bearings with new ones when reassembling.
lIf insulator is badly deformed, repair or replace it. If deposits such as mud pile up on insulator,
remove them.
lWhen installing insulator avoid large gaps or interference between insulator and each exhaust
pipe.
lRemove deposits from the sealing surface of each connection. Connect them securely to avoid
gas leakage.
lTemporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehi-
cle side. Check each part for unusual interference, and then tighten them to the specified torque.
lWhen installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
lInstall tail tube to main muffler as follows.
Ta i l t u b e
Install tail tube (3) to main muffler (1) as shown in the figure.
CAUTION:
The emboss (B) of tail tube (3) shall be properly fitted to the slit
(A) of main muffler (1).
INSPECTION AFTER INSTALLATION
lWith the engine running, check exhaust tube joints for gas leakage and unusual noises.
lCheck to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.
2:Band
PBIC3362E

EX-4
EXHAUST SYSTEM

FAX-1
FRONT AXLE
D DRIVELINE/AXLE
CONTENTS
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SECTIONFA X
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FA X
FRONT AXLE
PRECAUTIONS .......................................................... 2
Precautions .............................................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
WHEEL HUB .............................................................. 5
On-Vehicle Inspection and Service .......................... 5
WHEEL BEARING INSPECTION ......................... 5
Removal and Installation .......................................... 5
REMOVAL ............................................................. 5
INSPECTION AFTER REMOVAL ......................... 6
INSTALLATION ..................................................... 6DRIVE SHAFT ............................................................. 7
Removal and Installation .......................................... 7
REMOVAL ............................................................. 7
INSPECTION AFTER REMOVAL ......................... 7
INSTALLATION ..................................................... 8
Disassembly and Assembly ...................................... 8
DISASSEMBLY ..................................................... 8
INSPECTION AFTER DISASSEMBLY .................. 9
ASSEMBLY ......................................................... 10
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 14
Wheel Bearing ........................................................ 14
Drive Shaft .............................................................. 14

FAX-2
PRECAUTIONS
PRECAUTIONS
PFP:00001
PrecautionsEDS003I3
Observe the following precautions when disassembling and servicing the wheel hub and drive shafts.
lPerform work in a location which is as dust-free as possible.
lBefore disassembling and servicing, clean the outside of parts.
lPrevention of the entry of foreign objects must be taken into account during disassembly of the compo-
nent parts.
lDisassembled parts must be carefully reassembled in the correct order. If work is interrupted, a clean
cover must be placed over parts.
lPaper shop cloths must be used. Fabric shop cloths must not be used because of the danger of lint adher-
ing to parts.
lDisassembled parts (except for rubber parts) should be cleaned with a suitable solvent which shall be
removed by blowing with air or wiping with paper shop cloths.

PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsEDS003I4
Commercial Service ToolsEDS003I5
Tool number
Tool nameDescription
ST29020001
Gear arm pullerRemoving ball joint for steering knuckle
a: 34 mm (1.34 in)
b: 6.5 mm (0.256 in)
c: 61.5 mm (2.421 in)
KV38105500
ProtectorInstalling drive shaft
a: 40 mm (1.57 in) dia
KV40107300
BootbandcrimpingtoolInstalling boot bands
NT694
ZZA0835D
ZZA1229D
Tool nameDescription
PullerRemoving drive shaft
NT077

FAX-4
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
PFP:00003
NVH Troubleshooting ChartEDS003I6
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
´: ApplicableReference page
FAX-14FAX-7FAX-5FAX-5FAX-7FAX-5
PR-2, "
NVH Troubleshooting Chart
"
FFD-6, "
NVH Troubleshooting Chart
"
FSU-5, "
NVH Troubleshooting Chart
"
WT-2, "
NVH Troubleshooting Chart
"
WT-2, "
NVH Troubleshooting Chart
"
BR-5, "
NVH Troubleshooting Chart
"
PS-5, "
NVH Troubleshooting Chart
"
Possible cause and SUSPECTED PARTS
Excessive joint angle
Joint sliding resistance
Imbalance
Improper installation, looseness
Parts interference
Wheel bearing damage
PROPELLER SHAFT
FRONT FINAL DRIVE
SUSPENSION
TIRES
ROAD WHEEL
BRAKES
STEERING
SymptomNoise´´ ´´ ´´´´´´´
Shake´ ´´´ ´ ´´´´´
Vibration´´´´´ ´ ´´ ´
Shimmy´ ´´ ´´´´´
Shudder´´´´ ´´´´´
Poor quality ride or
handling´´´ ´´´

WHEEL HUB
FAX-5
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FA X
WHEEL HUBPFP:43202
On-Vehicle Inspection and ServiceEDS003I7
Make sure the mounting conditions (looseness, backlash) of each component and component status (wear,
damage) are normal.
WHEEL BEARING INSPECTION
lMove wheel hub in the axial direction by hand. Make sure there
is no looseness of wheel bearing.
lRotate wheel hub and make sure there is no unusual noise or
other irregular conditions. If there are any irregular conditions,
replace wheel hub and bearing assembly.
Removal and InstallationEDS003I8
REMOVAL
1. Remove wheel.
2. Without disassembling the hydraulic lines, remove caliper torque member bolts. Then reposition brake
caliper aside with wire. Refer toBR-26, "
Removal and Installation of Brake Caliper Assembly".
CAUTION:
Do not press brake pedal while brake caliper is removed.Axial end play limit : 0.05 mm (0.002 in) or less
SMA571A
1. Disc rotor 2. Wheel hub and bearing assembly* 3. Wheel stud
4. Splash guard 5. Steering knuckle 6. Wheel sensor bracket
*: Do not disassemble
MDIB9011E

FAX-6
WHEEL HUB
3. Put alignment mark on disc rotor and wheel hub and bearing
assembly, then remove disc rotor.
— For 4WD models —
lRemove cotter pin, then remove lock nut from drive shaft. Refer toFA X - 7 , "Removal and Installation".
lRemove drive shaft from wheel hub and bearing assembly. Refer toFAX-5, "Removal and Installation".
4. Remove wheel sensor from wheel hub and bearing assembly. Refer toBRC-37, "
Removal and Installa-
tion".
lInspect the wheel sensor O-ring, replace the wheel sensor assembly if damaged.
lClean the wheel sensor hole and mounting surface with a suitable brake cleaner and clean lint-free
shop rag. Be careful that dirt and debris do not enter the axle bearing area.
lApply a coat of suitable grease to the wheel sensor O-ring and mounting hole.
CAUTION:
Do not pull on the ABS sensor harness.
5. Remove wheel hub and bearing assembly bolts.
6. Remove splash guard and wheel hub and bearing assembly from steering knuckle.
lCarefully remove wheel sensor and harness through hole in splash guard.
INSPECTION AFTER REMOVAL
Check for deformity, cracks and damage on each part and replace if necessary.
INSTALLATION
Installation is in the reverse order of removal.
lUse new bolts when installing the wheel hub and bearing assembly.
lWhen installing disc rotor on wheel hub and bearing assembly,
position the disc rotor according to alignment mark.
(When not using the alignment mark, refer toBR-26, "
Removal
and Installation of Brake Caliper Assembly".)
lWhen installing wheel and tire, refer toWT-5, "Rotation".
WDIA0044E
WDIA0044E

DRIVE SHAFT
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DRIVE SHAFTPFP:39100
Removal and InstallationEDS003I9
REMOVAL
1. Remove wheel.
2. Remove ABS sensor harness from mount on knuckle, then disconnect ABS sensor harness connector.
CAUTION:
Do not pull on ABS sensor harness.
3. Remove steering knuckle. Refer toFSU-16, "
Removal and Installation".
4. Using a slide hammer, remove the drive shaft from final drive.
CAUTION:
lWhen removing drive shaft from vehicle, be careful to
avoid interfering with brake hose, ABS wheel speed sen-
sor harness, and other parts.
lWhen removing drive shaft, do not apply an excessive
angle (22°or more) to drive shaft joint. Also be careful
not to excessively extend slide joint.
INSPECTION AFTER REMOVAL
lMove joint up, down, left, right, and in axial direction. Check for any rough movement or significant loose-
ness.
lCheck boot for cracks or other damage, and for grease leakage.
lIf damaged, disassemble drive shaft to verify damage, and
repair or replace as necessary.
1. Differential side oil seal 2. Drive shaft 3. Drive shaft nut
4. Cotter pin 5. Circlip
MDIB9012E
SFA092A
SFA108A

FAX-8
DRIVE SHAFT
INSTALLATION
Installation is in the reverse order of removal.
lWhen installing drive shaft onto front final drive, use Tool to pre-
vent damage to the oil seal while inserting drive shaft. Slide
drive shaft sliding joint and tap with a hammer to install securely.
CAUTION:
Be sure to check that circlip is securely fastened.
Never reuse the differential side oil seal.
Disassembly and AssemblyEDS003IA
DISASSEMBLY
Final Drive Side
1. Mount the drive shaft in a vise.
CAUTION:
When mounting the drive shaft in a vise, use copper or aluminum plates between the vise and the
drive shaft.
2. Remove boot bands and slide the boot back.
3. Put matching marks on housing and shaft before separating joint assembly.
CAUTION:
Use paint or similar substance for matching marks. Do not scratch the surfaces.Tool number : KV38105500
MDIB9015E
1. Circlip 2. Dust cover 3. Housing (slide joint)
4. Snap ring 5. Spider assembly 6. Boot band
7. Boot 8. Shaft 9. Joint sub-assembly*
*: Do not disassemble
MDIB9014E