NISSAN NAVARA 2005 Repair Workshop Manual

RF-24
SUNROOF
3. Disconnect the harness connector from the sunroof motor
assembly.
4. Remove the mounting screws and the sunroof motor assembly.
Installation
1. Move the sunroof motor assembly laterally little by little so that
the gear is completely engaged into the wire on the sunroof unit
and the mounting surface becomes parallel. Then secure the
motor with bolts.
2. Connect the wire harness connector to the sunroof motor
assembly.
3. Install the roof console assembly. Refer toEI-40, "
Removal and Installation".
CAUTION:
lBefore installing the sunroof motor assembly, be sure to place the link and wire assembly in the
symmetrical and fully closed position.
lInitialization of the sunroof motor after installing the sunroof motor.
LIIA1673E
LIIA1674E

SUNROOF
RF-25
C
D
E
F
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MA
B
RF
DRAIN HOSES
1. Remove the headlining. Refer toEI-40, "Removal and Installation".
2. Visually check the drain hoses for proper connections, damage or deterioration.
3. Remove each drain hose and check visually for damage, cracks or deterioration.
4. Pour water through the drain hose to check for damage.
lIf any damage is found, replace the drain hose.
WEATHERSTRIP
Visually check weatherstrip for any damage, deterioration, or flattening.
lIn the case of leakage around glass lid, close glass lid and pour water around it to find the damaged or
gaped portion, remove glass lid assembly.
lIf any damage is found, replace glass lid assembly.
CAUTION:
Do not remove weatherstrip.
REAR DRAIN ASSEMBLY
Removal
1. Remove sunroof frame assembly. Refer toRF-22, "SUNROOF UNIT".
2. Remove sunshade assembly. Refer toRF-23, "
SUNSHADE".
3. Disconnect the rear drain pin from the sunroof link assembly.
4. Remove the rear drain assembly from the rear end of the sunroof frame.
Installation
Install in the reverse order of removal.
LIIA0272E

RF-26
SUNROOF
LINK AND WIRE ASSEMBLY
NOTE:
Before replacing any suspect part, carefully ensure it is the source of the noise being experienced.
1. Visually check to determine if a sufficient amount of petroleum jelly has been applied to the wire or rail
groove. If not, add petroleum jelly as required.
2. Check wire for any damage or deterioration. If any damage is found, remove rear guide, then replace
wire.

RFD-1
REAR FINAL DRIVE
D DRIVELINE/AXLE
CONTENTS
C
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M
SECTIONRFD
A
B
RFD
REAR FINAL DRIVE
WITH LIMITED SLIP DIFFERENTIAL
PRECAUTIONS .......................................................... 3
Limited Slip Differential (LSD) Performance Judge-
ment ......................................................................... 3
METHOD FOR TROUBLESHOOTING ................. 3
Service Notice or Precautions .................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 5
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 7
NVH Troubleshooting Chart ..................................... 7
DESCRIPTION ............................................................ 8
Cross-Sectional View ............................................... 8
DIFFERENTIAL GEAR OIL ........................................ 9
Changing Differential Gear Oil ................................. 9
DRAINING ............................................................. 9
FILLING ................................................................. 9
Checking Differential Gear Oil .................................. 9
OIL LEAKAGE AND OIL LEVEL ........................... 9
FRONT OIL SEAL .................................................... 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION .................................................... 11
CARRIER COVER .................................................... 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
REAR FINAL DRIVE ASSEMBLY ............................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
Disassembly and Assembly ................................... 15
COMPONENTS .................................................. 15
ASSEMBLY INSPECTION AND ADJUSTMENT... 16
DISASSEMBLY ................................................... 19
INSPECTION AFTER DISASSEMBLY ............... 22
SELECTION ADJUSTING WASHERS ............... 23
ASSEMBLY ......................................................... 24SERVICE DATA AND SPECIFICATIONS (SDS) ...... 31
General Specifications ............................................ 31
Inspection and Adjustment ..................................... 31
PRELOAD TORQUE ........................................... 31
BACKLASH ......................................................... 31
COMPANION FLANGE RUNOUT ....................... 31
SELECTIVE PARTS ............................................ 32
WITH ELECTRONIC LOCKING DIFFEREN-
TIAL
PRECAUTIONS ........................................................ 33
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” ................................................................. 33
Precautions for Differential Case Assembly and Dif-
ferential Lock Control Unit Replacement ................ 33
CHECK DIFF LOCK INDICATOR LAMP ............. 33
METHOD FOR ADJUSTMENT ........................... 34
Precautions ............................................................. 34
Service Notice or Precaution .................................. 35
Wiring Diagrams and Trouble Diagnosis ................ 35
PREPARATION ......................................................... 36
Special Service Tools ............................................. 36
Commercial Service Tools ...................................... 37
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 39
NVH Troubleshooting Chart ................................... 39
DIFFERENTIAL GEAR OIL ...................................... 40
Changing Differential Gear Oil ................................ 40
DRAINING ........................................................... 40
FILLING ............................................................... 40
Checking Differential Gear Oil ................................ 40
OIL LEAKAGE AND OIL LEVEL ......................... 40
DIFFERENTIAL LOCK SYSTEM .............................. 41
Cross-sectional View .............................................. 41
Differential Lock Operation ..................................... 42
System Description ................................................. 42
DIFFERENTIAL LOCK SOLENOID .................... 42
DIFFERENTIAL LOCK POSITION SWITCH ....... 42

RFD-2
DIFFERENTIAL LOCK CONTROL UNIT ............ 42
DIFFERENTIAL LOCK MODE SWITCH ............. 42
DIFF LOCK INDICATOR LAMP ........................... 42
System Diagram ..................................................... 43
COMPONENTS FUNCTION DESCRIPTION ...... 43
CAN Communication .............................................. 43
SYSTEM DESCRIPTION .................................... 43
TROUBLE DIAGNOSIS ............................................ 44
Fail-safe Function ................................................... 44
How to Perform Trouble Diagnosis ......................... 44
BASIC CONCEPT ............................................... 44
Location of Electrical Parts ..................................... 45
Wiring Diagram — DIFLOC — ................................ 46
Trouble Diagnosis Chart for Symptoms .................. 48
Differential Lock Control Unit Input/Output Signal
Reference Values ................................................... 48
DIFFERENTIAL LOCK CONTROL UNIT
INSPECTION TABLE .......................................... 48
CONSULT-II Function (DIFF LOCK) ....................... 50
FUNCTION .......................................................... 50
CONSULT-II SETTING PROCEDURE ................ 50
SELF-DIAG RESULTS MODE ............................. 51
DATA MONITOR MODE ...................................... 53
TROUBLE DIAGNOSIS FOR SYSTEM .................... 54
Power Supply Circuit For Differential Lock Control
Unit ......................................................................... 54
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 54
DIFFERENTIAL LOCK CONTROL UNIT TER-
MINALS AND REFERENCE VALUE ................... 54
DIAGNOSTIC PROCEDURE .............................. 55
Differential Lock Control Unit .................................. 56
DIAGNOSTIC PROCEDURE .............................. 56
Differential Lock Mode Switch ................................ 56
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 56
DIFFERENTIAL LOCK CONTROL UNIT TER-
MINALS AND REFERENCE VALUE ................... 56
DIAGNOSTIC PROCEDURE .............................. 57
COMPONENT INSPECTION .............................. 59
Differential Lock Position Switch ............................. 60
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 60
DIFFERENTIAL CONTROL UNIT TERMINALS
AND REFERENCE VALUE ................................. 60
DIAGNOSTIC PROCEDURE .............................. 61
COMPONENT INSPECTION .............................. 63
Differential Lock Solenoid Relay ............................. 63
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 63DIAGNOSTIC PROCEDURE ............................... 63
Differential Lock Solenoid ....................................... 64
CONSULT-II REFERENCE VALUE IN DATA
MONITOR MODE ................................................ 64
DIFFERENTIAL LOCK CONTROL UNIT TER-
MINALS AND REFERENCE VALUE ................... 64
DIAGNOSTIC PROCEDURE ............................... 65
COMPONENT INSPECTION ............................... 68
ABS System ............................................................ 68
DIAGNOSTIC PROCEDURE ............................... 68
CAN Communication Line ....................................... 69
DIAGNOSTIC PROCEDURE ............................... 69
TROUBLE DIAGNOSIS FOR SYMPTOMS .............. 70
DIFF LOCK Indicator Lamp Does Not Turn ON ...... 70
DIAGNOSTIC PROCEDURE ............................... 70
DIFF LOCK Indicator Lamp Does Not Change ....... 73
DIAGNOSTIC PROCEDURE ............................... 73
DIFF LOCK Indicator Lamp Sometimes Flashes .... 74
DIAGNOSTIC PROCEDURE ............................... 74
DIFFERENTIAL LOCK CONTROL UNIT .................. 76
Removal and Installation ......................................... 76
REMOVAL ............................................................ 76
INSTALLATION .................................................... 76
FRONT OIL SEAL ..................................................... 77
Removal and Installation ......................................... 77
REMOVAL ............................................................ 77
INSTALLATION .................................................... 78
CARRIER COVER ..................................................... 80
Removal and Installation ......................................... 80
REMOVAL ............................................................ 80
INSTALLATION .................................................... 80
REAR FINAL DRIVE ASSEMBLY ............................. 81
Removal and Installation ......................................... 81
REMOVAL ............................................................ 81
INSTALLATION .................................................... 81
Disassembly and Assembly .................................... 82
COMPONENTS ................................................... 82
ASSEMBLY INSPECTION AND ADJUSTMENT...83
DISASSEMBLY .................................................... 86
INSPECTION AFTER DISASSEMBLY ................ 90
SELECTION ADJUSTING WASHERS ................ 90
ASSEMBLY .......................................................... 91
SERVICE DATA AND SPECIFICATIONS (SDS) ....100
General Specifications ..........................................100
Inspection and Adjustment ....................................100
PRELOAD TORQUE .........................................100
BACKLASH ........................................................100
COMPANION FLANGE RUNOUT .....................100
SELECTIVE PARTS ..........................................101

PRECAUTIONS
RFD-3
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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K
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MA
B
RFD
[WITH LIMITED SLIP DIFFERENTIAL]PRECAUTIONSPFP:00001
Limited Slip Differential (LSD) Performance JudgementEDS003IG
lInspection is required when detecting any noise or malfunction while driving or turning. Improper condition
of oil or differential case assembly is suspected. Refer toRFD-3, "
METHOD FOR TROUBLESHOOTING"
.
METHOD FOR TROUBLESHOOTING
1. Check differential gear oil level and differential gear oil leakage. Refer toRFD-9, "Checking Differential
Gear Oil".
2. Changing differential gear oil. Refer toRFD-9, "
Changing Differential Gear Oil".
3. Start engine. Drive for 10 min.
4. Again changing differential gear oil. Refer toRFD-9, "
Changing Differential Gear Oil".
5. Start engine. Drive for 10 min. Check if any noise or improper oil condition is detected.
lIf OK, check differential gear oil level and differential gear oil leakage. Refer toRFD-9, "Checking Differ-
ential Gear Oil".
lIf NG, replace differential case assembly after checking each part of final drive. Refer toRFD-15, "Dis-
assembly and Assembly".
Service Notice or PrecautionsEDS0038Z
lCheck for the correct installation status prior to removal or disassembly. If matching marks are required,
be certain they do not interfere with the function of the parts when applied.
lOverhaul should be done in a clean work area, it is preferable to work in dust proof area.
lBefore disassembly completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
lCheck appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with new ones if necessary.
lGaskets, seals and O-rings should be replaced any time the unit is disassembled.
lIn principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
lClean and flush the parts sufficiently and blow-dry them.
lBe careful not to damage sliding surfaces and mating surfaces.
lWhen applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
lAlways use shop paper for cleaning the inside of components.
lAvoid using cotton gloves or shop rags to prevent entering of lint.
lDuring assembly, observe the specified tightening torque, and apply new differential gear oil, petroleum
jelly, or multi-purpose grease as specified.

RFD-4
[WITH LIMITED SLIP DIFFERENTIAL]
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEDS003H7
Tool number
Tool nameDescription
ST3127S000
Preload gauge set
1. GG91030000
Torque wrench
2. HT62940000 (1/2²)
Socket adapter
3. HT62900000 (3/8²)
Socket adapterInspecting pinion bearing preload and
total preload
KV40104000
Flange wrench
a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia.Removing and installing drive pinion
lock nut
KV381054S0
PullerRemoving front oil seal
KV10111100
Seal cutterRemoving carrier cover
KV38108800
Adjuster toolRemoving and installing side bearing
adjuster
ST30021000
PullerRemoving drive pinion rear bearing
inner race
NT124
NT659
ZZA0601D
S-NT046
WDIA0192E
ZZA0700D

PREPARATION
RFD-5
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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RFD
Commercial Service ToolsEDS003H8
ST30022000
Drift
a: 46 mm (1.81 in) dia.
b: 110 mm (4.33 in) dia.Installing drive pinion rear bearing outer
race
KV38100300
Drift
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32mm (1.26 in) dia.Installing side bearing inner race Tool number
Tool nameDescription
NT660
ZZA1046D
Tool nameDescription
Puller
lRemoving companion flange
lRemoving side bearing inner race
Drift
a: 96mm (3.77 in) dia.
b: 84 mm (3.30 in) dia.Installing front oil seal
Adapter
a: 43 mm (1.69 in) dia.Removing and installing side bearing
inner race
PullerRemoving side bearing inner race
Drift
a: 89 mm (3.50 in) dia.
b: 79 mm (3.11 in) dia.Installing drive pinion rear bearing outer
race
NT077
NT115
PDIA0893E
ZZB0823D
ZZA0811D

RFD-6
[WITH LIMITED SLIP DIFFERENTIAL]
PREPARATION
Drift
a: 67 mm (2.63 in) dia.Installing drive pinion front bearing outer
race
Installer
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.Installing drive pinion rear bearing inner
race Tool nameDescription
PDIA0893E
NT065

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
RFD-7
[WITH LIMITED SLIP DIFFERENTIAL]
C
E
F
G
H
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MA
B
RFD
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS00392
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
´: ApplicableReference page
RFD-22, "
INSPECTION AFTER DISASSEMBLY
"
RFD-16, "
Tooth Contact
"
RFD-22, "
INSPECTION AFTER DISASSEMBLY
"
RFD-17, "
Backlash
"
RFD-18, "
Companion Flange Runout
"
RFD-9, "
Checking Differential Gear Oil
"
PR-2, "
NVH Troubleshooting Chart
"
RAX-5, "
NVH Troubleshooting Chart
",RSU-3, "
NVH Troubleshooting Chart
"
WT-2, "
NVH Troubleshooting Chart
"
RAX-5, "
NVH Troubleshooting Chart
"
BR-5, "
NVH Troubleshooting Chart
"
PS-5, "
NVH Troubleshooting Chart
"
Possible cause and SUSPECTED PARTS
Gear tooth rough
Gear contact improper
Tooth surfaces worn
Backlash incorrect
Companion flange excessive runout
Gear oil improper
PROPELLER SHAFT
AXLE AND SUSPENSION
TIRES
ROAD WHEEL
AXLE SHAFT
BRAKES
STEERING
Symptom Noise´´´´´´´´´´´´´