INFINITI M35 2007 Factory Service Manual

TF-2Revision: 2007 April2007 M35/M45 Started .................................................................... 35
DIAGNOSTIC PROCEDURE .............................. 35
Vehicle Does Not Enter AWD Mode Even Though
AWD Warning Lamp Turned to OFF ....................... 36
DIAGNOSTIC PROCEDURE .............................. 36
While Driving, AWD Warning Lamp Flashes Rapidly
(When Flashing in Approx. 1 Minute and Then Turn-
ing OFF) ................................................................. 37
While Driving, AWD Warning Lamp Flashes Slowly
(When Continuing to Flash until Turning Ignition
Switch OFF) ............................................................ 37
DIAGNOSTIC PROCEDURE .............................. 37
AWD CONTROL UNIT .............................................. 39
Removal and Installation ........................................ 39
REMOVAL ........................................................... 39
INSTALLATION .................................................... 39
FRONT OIL SEAL ..................................................... 40
Removal and Installation ........................................ 40
REMOVAL ........................................................... 40
INSTALLATION .................................................... 40REAR OIL SEAL ....................................................... 41
Removal and Installation ......................................... 41
REMOVAL ............................................................ 41
INSTALLATION .................................................... 42
AIR BREATHER HOSE ............................................. 43
Removal and Installation ......................................... 43
TRANSFER ASSEMBLY ........................................... 44
Removal and Installation ......................................... 44
REMOVAL ............................................................ 44
INSTALLATION .................................................... 44
Disassembly and Assembly .................................... 45
COMPONENTS ................................................... 45
DISASSEMBLY .................................................... 46
INSPECTION ....................................................... 51
ASSEMBLY .......................................................... 52
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 59
General Specifications ............................................ 59

PRECAUTIONS
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Revision: 2007 April2007 M35/M45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
NDS000D3
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.

Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.

Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
PrecautionsNDS000D4

Before connecting or disconnecting the AWD control unit
harness connector, turn ignition switch “OFF” and discon-
nect battery ground cable. Because battery voltage is
applied to AWD control unit even if ignition switch is turned
“OFF”.

When connecting or disconnecting pin connectors into or
from AWD control unit, take care not to damage pin termi-
nals (bend or break).
When connecting pin connectors, make sure that there are
no bends or breaks on AWD control unit pin terminal.

Before replacing AWD control unit, perform AWD control
unit input/output signal inspection and make sure whether
AWD control unit functions properly or not. Refer to TF-20,
"AWD Control Unit Input/Output Signal Reference Values" .
SEF289H
SEF291H
SDIA1848E

TF-4
PRECAUTIONS
Revision: 2007 April2007 M35/M45
Service Notice or PrecautionsNDS000D5

Do not reuse transfer fluid, once it has been drained.

Check the fluid level or replace the fluid only with the vehicle parked on level ground.

During removal or installation, keep inside of transfer clear of dust or dirt.

Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern.
Fitting improper size and unusual wear tires applies excessive force to vehicle mechanism and can cause
longitudinal vibration.

Disassembly should be done in a clean work area, it is preferable to work in dustproof area.

Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
parts from becoming contaminated by dirt or other foreign matter.

All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.

Check 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.

Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.

Gaskets, seals and O-rings should be replaced any time when the transfer is disassembled.

In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, use it.

Observe the specified torque when assembling.

Clean and flush the parts sufficiently and blow-dry them.

Be careful not to damage sliding surfaces and mating surfaces.

Clean innerparts with lint-free cloth or towels. Do not use cotton work gloves and rags to prevent adhering
fibers.

PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsNDS000D6
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool nameDescription
ST27862000
(—)
Drift
a: 62.5 mm (2.461 in) dia.
b: 42 mm (1.65 in) dia.

Installing front oil seal
KV381054S0
(J-34286)
Puller

Removing rear oil seal
ST30720000
(J-25405)
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.

Installing rear oil seal

Installing mainshaft oil seal
KV40104830
(—)
Drift
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia.

Installing rear oil seal
KV38100300
(J-25523)
Drift
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.

Removing mainshaft bearing
ST33052000
(—)
Drift
a: 28 mm (1.10 in) dia.
b: 22 mm (0.87 in) dia.

Removing mainshaft assembly
ST30611000
(J-25742-1)
Drift bar
a: 350 mm (1.10 in)
b: 25 mm (1.10 in) dia.
c: M12 × 1.5P

Removing rear bearing
ZZA0194D
ZZA0601D
ZZA0811D
ZZA1003D
ZZA1046D
ZZA1000D
NT663

TF-6
PREPARATION
Revision: 2007 April2007 M35/M45
ST35321000
(—)
Drift
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
Removing rear bearing

Installing mainshaft assembly
ST31214000
(J-25269-B)
Drift
a: 34 mm (1.34 in) dia.
b: 25.5 mm (1.004 in) dia.

Removing front drive shaft front bearing

Removing front drive shaft rear bearing
KV38104010
(—)
Drift
a: 67 mm (2.64 in) dia.
b: 49 mm (1.93 in) dia.

Installing front drive shaft rear bearing

Installing rear bearing
ST33200000
(J-26082)
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.

Installing front drive shaft front bearing
ST30621000
(J-25742-5)
Drift
a: 80 mm (3.15 in) dia.
b: 59 mm (2.32 in) dia.

Installing mainshaft bearing Tool number
(Kent-Moore No.)
Tool nameDescription
ZZA1000D
ZZA0534D
ZZA1000D
ZZA1002D
ZZA1000D

PREPARATION
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Commercial Service ToolsNDS000D7
Tool nameDescription
Puller

Removing companion flange
Flange wrench

Removing and installing self-lock nut
Puller

Removing front drive shaft front bearing

Removing front drive shaft rear bearing
Power tool

Loosening bolts and nuts
NT077
NT771
ZZB0823D
PBIC0190E

TF-8
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: 2007 April2007 M35/M45
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartNDS000D8
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageTF-9TF-45TF-45TF-51TF-51TF-51
SUSPECTED PARTS
(Possible cause)
TRANSFER FLUID (Level low)
TRANSFER FLUID (Wrong)
TRANSFER FLUID (Level too high)
LIQUID GASKET (Damaged)
OIL SEAL (Worn or damaged)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
TRANSFER CASE (Damaged)
SymptomNoise 1 2 3 3 3
Transfer fluid leakage 4 1 2 2 3

TRANSFER FLUID
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TRANSFER FLUIDPFP:31001
ReplacementNDS000D9
DRAINING
1. Run the vehicle to warm up the transfer unit sufficiently.
2. Stop the engine, and remove the drain plug to drain the transfer
fluid.
CAUTION:
When draining fluid, protect exhaust tube flange with cover.
3. Apply sealant to drain plug. Install drain plug on transfer and
tighten to the specified torque. Refer to TF-45, "
COMPO-
NENTS" .

Use Genuine Silicone RTV or equivalent. Refer to GI-47,
"Recommended Chemical Products and Sealants" .
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
FILLING
1. Remove filler plug and add transfer fluid until fluid level reaches
the specified limit near filler plug mounting hole.
CAUTION:
Carefully fill the fluid. (Fill up for approx. 3 minutes.)
2. Leave the vehicle for 3 minutes, and check the fluid level again.
3. Set a new gasket onto filler plug and install it on transfer and
tighten to the specified torque. Refer to TF-45, "
COMPO-
NENTS" .
CAUTION:
Do not reuse gasket.
InspectionNDS000DA
FLUID LEAKAGE AND FLUID LEVEL
1. Check if fluid is leaking from transfer or around it.
2. Check fluid level from filler plug mounting hole as shown in the
figure.
CAUTION:
Never start engine while checking fluid level.
3. Before installing filler plug, set a new gasket. Install filler plug on
transfer and tighten to the specified torque. Refer to TF-45,
"COMPONENTS" .
CAUTION:
Do not reuse gasket.
SDIA2087E
Fluid capacity
: Approx. 1.25 (2-5/8 US pt, 2-1/4 lmp pt)
SDIA2028E
SDIA2028E

TF-10
AWD SYSTEM
Revision: 2007 April2007 M35/M45
AWD SYSTEMPFP:41650
Power Transfer DiagramNDS000DB
System DescriptionNDS000DC
DESCRIPTION

Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.

Makes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.

On roads which do not require AWD, it contributes to improved fuel economy by driving in conditions close
to rear-wheel drive.

Sensor inputs determine the vehicle's turning condition, and in response tight cornering/braking are con-
trolled by distributing optimum torque to front wheels.
NOTE:

When driving, if there is a large difference between front and rear wheel speed which continues for a long
time, fluid temperature of drive system parts becomes too high and AWD warning lamp flashes rapidly.
(When AWD warning lamp flashes, vehicle changes to rear-wheel drive conditions.) Also, optional distri-
bution of torque sometimes becomes rigid before lamp flashes rapidly, but it is not malfunction.

If AWD warning lamp is flashing rapidly, stop vehicle and allow it to idle for some time. Flashing will stop
and AWD system will be restored.

When driving, AWD warning lamp may flash slowly if there is a significant difference in diameter of the
tires. At this time, vehicle performance is not fully available and cautious driving is required. (Continues
until engine is turned OFF.)

If the warning lamp flashes slowly during driving but remains OFF after engine is restarted, the system is
normal. If it again flashes slowly after driving for some time, vehicle must be inspected.

When the difference of revolution speed between the front and rear wheel the shift occasionally changes
to direct 4-wheel driving conditions automatically. This is not malfunction.
SDIA1611E

AWD SYSTEM
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Revision: 2007 April2007 M35/M45
ELECTRIC CONTROLLED COUPLING
Operation Principle
1. AWD control unit supplies command current to electric controlled coupling (AWD solenoid).
2. Control clutch is engaged by electromagnet and torque is detected in control clutch.
3. The cam operates in response to control clutch torque and applies pressure to main clutch.
4. Main clutch transmits torque to front wheels according to pressing power.

Transmission torque to front wheels is determined according
to command current.
AWD CONTROL UNIT

Controls distribution of drive power between rear-wheel drive
(0:100) and AWD (50:50) conditions according to signals from
sensors.

Self-diagnosis can be done with CONSULT-II.
SDIA2270E
SDIA1844E
SDIA3133E