NISSAN TERRANO 2004 Service Repair Manual

10. Install oil pan.
a. Attach a magnet to oil pan.
b. Install new oil pan gasket on transmission case.
c. Install oil pan and bracket on transmission case.
IAlways replace oil pan bolts as they are self-sealing bolts.
I Before installing bolts, remove traces of sealant and oil
from mating surface and thread holes.
I Tighten four bolts in a criss-cross pattern to prevent dis-
location of gasket.
d. Tighten drain plug.
11. Install park/neutral position switch.
a. Check that manual shaft is in ª1º position.
b. Temporarily install park/neutral position switch on manual shaft.
c. Move manual shaft to ªNº.
d. Tighten bolts while inserting 4.0 mm (0.157 in) dia. pin vertically into locating holes in park/neutral position switch and manual
shaft.
12. Install torque converter.
a. Pour ATF into torque converter.
I Approximately 2 liters (1-3/4 Imp qt) of fluid are required for
a new torque converter.
I When reusing old torque converter, add the same amount
of fluid as was drained.
SAT011B
NAT291
NAT292
NAT290
SAT428DA
ASSEMBLY
Assembly (2) (Cont'd)
AT-198
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b. Install torque converter while aligning notches and oil pump.
c. Measure distance A to check that torque converter is in properposition.Distance ªAº: 26.0 mm (1.024 in) or more
SAT016B
SAT017B
ASSEMBLY
Assembly (2) (Cont'd)
AT-199
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A/T Fluid Cooler
REMOVAL AND INSTALLATION
1. Remove front radiator grill. Refer to BT section (ªBODY ENDº).
2. Disconnect fluid hoses from fluid cooler unit.
3. Remove fluid cooler unit.
4. Remove fluid cooler bracket.
5. Remove clips securing fluid hose (cooler unit to radiator) andloosen hose clamps, then remove the fluid hose.
6. Loosen clamps securing fluid hose (A/T assembly to fluid cooler), then remove the fluid hose.
7. Remove bolts securing fluid cooler tube bracket.
8. Remove fluid hose with bracket. Reverse the removal procedure to install the A/T fluid cooler
unit. Refer to the component drawing and specified tightening
torque.
Check A/T fluid level and refill if necessary. Refer to MA sec-
tion (ªCHASSIS AND BODY MAINTENANCEº).
NAT288
NAT289
A/T FLUID COOLER SYSTEM
AT-200
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General Specifications
Applied modelTD27ETi engine
Automatic transmission model RE4R01A
Transmission model code number 4GX07
Stall torque ratio 2.0 : 1
Transmission gear ratio 1st 2.785
2nd 1.545
Top 1.000
OD 0.694
Reverse 2.272
Recommended fluid Genuine Nissan ATF or equiva-
lent*1
Fluid capacity (Imp qt) 8.5 (7-1/2)
*1: Refer to MA section (ªFluids and Lubricantsº, ªRECOMMENDED FLUIDS AND LUBRICANTSº).
Specifications and Adjustment
SHIFT SCHEDULE
Vehicle speed when shifting gears
Throttle position Vehicle speed km/h (MPH)
D1, D2D2,D3D3,D4D4,D3D3,D2D2,D112,11
Full throttle 32-36
(20 - 23) 66-74
(41 - 46) 108 - 118
(68 - 74) 103 - 113
(64 - 71) 61-69
(38 - 43) 27-31
(17 - 19) 43-47
(27 - 29)
Half throttle 30-34
(19 - 21) 62-68
(39 - 43) 82-92
(51 - 58) 67-75
(42 - 47) 26-32
(16 - 20) 7-11
(4-7) 43-47
(27 - 29)
Vehicle speed when performing and
releasing lock-up
Throttle
position Overdrive con-
trol switch
[Shift position] Vehicle speed km/h (MPH)
Lock-up ªONº Lock-up
ªOFFº
Full throttle ON
[D
4] 121 - 129
(76 - 81) 116 - 124
(73 - 78)
OFF [D
3] 74-82
(46 - 51) 74-82
(46 - 51)
Half throttle ON
[D
4] 104 - 112
(65 - 70) 93 - 101
(58 - 63)
OFF [D
3] 74-82
(46 - 51) 74-82
(46 - 51)
STALL REVOLUTION
Stall revolution rpm2,450 - 2,700
LINE PRESSURE
Engine speed
rpm Line pressure kPa (bar, kg/cm2, psi)
D, 2 and 1 positions R position
Idle 422 - 461
(4.22 - 4.61, 4.3 - 4.7,61 - 67) 589 - 627
(5.89 - 6.27, 6.01 - 6.40,
85.4 - 90.9)
Stall 1,020 - 1,098
(10.20 - 10.98, 10.4 - 11.2,148 - 159) 1,422 - 1,500
(14.22 - 15.00, 14.5 - 15.3,206 - 218)
SERVICE DATA AND SPECIFICATIONS (SDS)
AT-201
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RETURN SPRINGSUnit: mm (in)
PartsItem
Part No. Free length Outer diameter
Control
valve Upper
bodyTorque converter relief valve
spring
q
131742-41X23
38.0 (1.496)9.0 (0.354)
Pressure regulator valve
spring q
231742-41X24
44.02 (1.7331) 14.0 (0.551)
Pressure modifier valve
spring q
331742-41X19
31.95 (1.2579) 6.8 (0.268)
Accumulator control valve
spring ÐÐÐÐ
Shuttle shift valve D spring q
431762-41X01
25.0 (0.984)7.0 (0.276)
4-2 sequence valve spring q
531756-41X00
29.1 (1.146)6.95 (0.2736)
Shift valve B spring q
631762-41X01
25.0 (0.984)7.0 (0.276)
4-2 relay valve spring q
731756-41X00
29.1 (1.146)6.95 (0.2736)
Shift valve A spring q
831762-41X01
25.0 (0.984)7.0 (0.276)
Overrun clutch control valve
spring q
931762-41X03
23.6 (0.929)7.0 (0.276)
Overrun clutch reducing
valve spring q
1031742-41X20
32.5 (1.280)7.0 (0.276)
Shuttle shift valve S spring q
1131762-41X04
51.0 (2.008)5.65 (0.2224)
Pilot valve spring q
1231742-41X13
25.7 (1.012)9.0 (0.354)
Torque converter clutch con-
trol valve spring q
1331742-41X22
18.5 (0.728)13.0 (0.512)
Lower
body Modifier accumulator
piston spring
q
131742-27X70
31.4 (1.236)9.8 (0.386)
1st reducing valve spring q
231756-41X05
25.4 (1.000)6.75 (0.2657)
3-2 timing valve spring q
331742-41X06
23.0 (0.906)6.7 (0.264)
Servo charger valve spring q
431742-41X06
23.0 (0.906)6.7 (0.264)
Reverse clutch 16 pcs 31521-41X02 (Assembly) 19.69 (0.7752) 11.6 (0.457)
High clutch 10 pcs 31521-41X03 (Assembly)24.2 (0.953)11.6 (0.457)
Forward clutch
(Overrun clutch) 20 pcs 32521-41X00 (Assembly) 35.77 (1.4083)
9.7 (0.382)
Low & reverse
brake 18 pcs 31655-41X00 (Assembly)
22.3 (0.878)11.2 (0.441)
Band servo Spring
q
A31605-41X05
45.6 (1.795)34.3 (1.350)
Spring q
B31605-41X00
53.8 (2.118)40.3 (1.587)
Spring q
C31605-41X01
29.7 (1.169)27.6 (1.087)
Accumulator Accumulator
q
A31605-41X02
43.0 (1.693)18.0 (0.709)
Accumulator q
B31605-41X10
66.0 (2.598)20.0 (0.787)
Accumulator q
C31605-41X09
45.0 (1.772)29.3 (1.154)
Accumulator q
D31605-41X06
58.4 (2.299)17.3 (0.681)
ACCUMULATOR O-RING
Accumulator Diameter mm (in)
qAqBqCqD
Small diameter end 29 (1.14) 32 (1.26) 45 (1.77) 29 (1.14)
Large diameter end 45 (1.77) 50 (1.97) 50 (1.97) 45 (1.77)
SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont'd)
AT-202
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CLUTCHES AND BRAKES
Code number4GX07
Reverse clutch
Number of drive plates 2
Number of driven plates 2
Thickness of
drive plate mm (in) Standard 1.90 - 2.05 (0.0748 - 0.0807)
Wear limit 1.80 (0.0709)
Clearance mm (in) Standard 0.5 - 0.8 (0.020 - 0.031)
Allowable limit 1.2 (0.047)
Thickness of retaining plate Thickness
mm (in) Part number
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220) 31537-42X02
31537-42X03
31537-42X04
31537-42X05
31537-42X06
High clutch
Number of drive plates 5
Number of driven plates 5
Thickness of
drive plate mm (in) Standard 1.52 - 1.67 (0.0598 - 0.0657)
Wear limit 1.40 (0.0551)
Clearance mm (in) Standard 1.8 - 2.2 (0.071 - 0.087)
Allowable limit 3.2 (0.126)
Thickness of retaining plate Thickness
mm (in) Part number
3.4 (0.134)
3.6 (0.142)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189) 31537-41X71
31537-41X61
31537-41X62
31537-41X63
31537-41X64
31537-41X65
31537-41X66
31537-41X67
Forward clutch
Number of drive plates 7
Number of driven plates 7
Thickness of
drive plate mm (in) Standard 1.52 - 1.67 (0.0598 - 0.0657)
Wear limit 1.40 (0.0551)
Clearance mm (in) Standard 0.35 - 0.75 (0.0138 - 0.0295)
Allowable limit 2.15 (0.0846)
Thickness of retaining plate Thickness
mm (in) Part number
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
5.4 (0.213)
5.6 (0.220) 31537-42X13
31537-42X14
31537-42X15
31537-4AX00
31537-4AX01
31537-4AX02
Code number 4GX07
Overrun clutch
Number of drive plates 3
Number of driven plates 5
Thickness of
drive plate mm (in) Standard 1.90 - 2.05 (0.0748 - 0.0807)
Wear limit 1.80 (0.0709)
Clearance mm (in) Standard 1.0 - 1.4 (0.039 - 0.055)
Allowable limit 2.0 (0.079)
Thickness of retaining plate Thickness
mm (in) Part number
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197) 31537-41X80
31537-41X81
31537-41X82
31537-41X83
31537-41X84
Low & reverse brake
Number of drive plates 7
Number of driven plates 7
Thickness of
drive plate mm (in) Standard 1.52 - 1.67 (0.0598 - 0.0657)
Wear limit 1.4 (0.055)
Clearance mm (in) Standard 0.8 - 1.1 (0.031 - 0.043)
Allowable limit 2.5 (0.098)
Thickness of retaining plate Thickness
mm (in) Part number
6.6 (0.260)
6.8 (0.268)
7.0 (0.276)
7.2 (0.283)
7.4 (0.291)
7.6 (0.299)
7.8 (0.307)
8.0 (0.315)
8.2 (0.323)
8.4 (0.331)
8.6 (0.339)
8.8 (0.346)
9.0 (0.354) 31667-41X17
31667-41X11
31667-41X12
31667-41X13
31667-41X14
31667-41X07
31667-41X08
31667-41X00
31667-41X01
31667-41X02
31667-41X03
31667-41X04
31667-41X05
Brake band
Anchor end bolt tightening
torque N×m (kg-m, in-lb) 4 - 6 (0.4 - 0.6, 35 - 52)
Number of returning revolution
for anchor end bolt 2.5
SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont'd)
AT-203
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OIL PUMP AND LOW ONE-WAY CLUTCH
Oil pump clearance mm (in)Cam ring Ð oil pump housingStandard 0.01 - 0.024 (0.0004 - 0.0009)
Rotor, vanes and control piston
Ð oil pump housing Standard 0.03 - 0.044 (0.0012 - 0.0017)
Seal ring clearance mm (in) Standard 0.10 - 0.25 (0.0039 - 0.0098)
Allowable limit 0.25 (0.0098)
TOTAL END PLAY
Total end play ªT1º0.25 - 0.55 mm
(0.0098 - 0.0217 in)
Thickness of oil pump
cover bearing race Thickness
mm (in) Part number
0.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.4 (0.055)
1.6 (0.063)
1.8 (0.071)
2.0 (0.079) 31435-41X01
31435-41X02
31435-41X03
31435-41X04
31435-41X05
31435-41X06
31435-41X07
REVERSE CLUTCH DRUM END PLAY
Reverse clutch drum
end play ªT
2º
0.55 - 0.90 mm
(0.0217 - 0.0354 in)
Thickness of oil pump
thrust washer Thickness
mm (in) Part number
0.9 (0.035)
1.1 (0.043)
1.3 (0.051)
1.5 (0.059)
1.7 (0.067)
1.9 (0.075) 31528-21X01
31528-21X02
31528-21X03
31528-21X04
31528-21X05
31528-21X06
REMOVAL AND INSTALLATION
Manual control linkage
Number of returning revolutions
for lock nut 2
Lock nut tightening torque N×m (kg-m, in-lb) 4.4 - 5.9
(0.45 - 0.60, 39.1 - 52.1)
Distance between end of converter
housing and torque converter mm (in)26.0 (1.024) or more
SERVICE DATA AND SPECIFICATIONS (SDS)
Specifications and Adjustment (Cont'd)
AT-204
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TRANSFER
SECTION
TF
CONTENTS
PREPARATION ................................................................2
ON-VEHICLE SERVICE ..................................................4
Replacing Oil Seal .......................................................4
REMOVAL AND INSTALLATION ....................................7
Removal .......................................................................7
Installation ....................................................................7
TRANSFER GEAR CONTROL .......................................8
MAJOR OVERHAUL .......................................................9
Case Components .......................................................9
Gear Components .....................................................10
Shift Control Components ......................................... 11
DISASSEMBLY ..............................................................12
REPAIR FOR COMPONENT PARTS ............................17Mainshaft ...................................................................17
Front Drive Shaft .......................................................19
Counter Gear .............................................................20
Main Gear ..................................................................21
Front Case .................................................................23
Front Case Cover ......................................................23
Bearing Retainer ........................................................23
Rear Case..................................................................24
Shift Control Components .........................................24
ASSEMBLY ....................................................................26
SERVICE DATA AND SPECIFICATIONS (SDS) ..........33
General Specifications ...............................................33
Inspection and Adjustment ........................................33
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SPECIAL SERVICE TOOLS
*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST38060002*
Flange wrench
Removing companion flange nut
Installing companion flange nut
ST30021000*
Puller
Removing counter gear front bearing
(Use with ST36710010)
ST30031000*
Puller
Removing counter gear rear bearing
(Use with ST36710010)
ST33290001*
Puller
Removing center case oil seal
Removing rear oil seal
ST33051001*
Puller
Removing companion flange
ST30720000*
Drift
Installing center case oil seal
Installing rear oil seal
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ST36710010*
DriftRemoving counter gear front bearing
(Use with ST30021000)
Removing counter gear rear bearing
(Use with ST30031000)
a: 34.5 mm (1.358 in) dia.
ST33061000*
DriftRemoving main gear bearing
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
PREPARATION
TF-2
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*: Special tool or commercial equivalent
Tool number
Tool nameDescription
ST30613000*
Drift
Installing main gear bearing
Installing cover oil seal
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
COMMERCIAL SERVICE TOOLS
Tool name Description
Puller
Removing front drive shaft front bearing
Removing front drive shaft rear bearing
Removing main gear bearing
Drift
Installing shift shaft oil seal
a: 26 mm (1.02 in) dia.
b: 20 mm (0.79 in) dia.
c: 150 mm (5.91 in)
DriftInstalling mainshaft rear bearing
a: 50 mm (1.97 in) dia.
b: 42 mm (1.65 in) dia.
c: 180 mm (7.09 in)
DriftInstalling L & H hub
a: 60 mm (2.36 in) dia.
b: 50 mm (1.97 in) dia.
c: 60 mm (2.36 in)
PREPARATION
TF-3
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